AW Gear Meters EMO-1005 User Manual

TRANSMITTERS

FLOW

ELECTRONICS FOR

INSTRUMENTATION

EMO-1005

Flow Computer

Oppeerraattiioonn

O

Rev. 1a

Maannuuaall

M

8809 Industrial Drive, Franksville, WI 53126-9337

Tel: [phone] Fax: [phone]

E-Mail: [e-mail]

Web: http://www.awgearmeters.com

Table of Contents

Introduction 2

Using the EMO-1005 4

Unit Installation 5
Screen Manipulation 6
Display Mode Selection 6
Rate Display 7
Total Display 7
Simple Ratio Display 8
Peak Ratio Display 8
Status Display Mode 9

Programming the EMO-1005 10
Rate Scaling 12
Totalizer Scaling - KFT 13
Limits Programming 15
Rate Limit 16
Total Limit 16
Analog Gain - KFA 17
Offset Analog Out 18
Sample Amount 18
Cutoff Frequency 19
Analog In Gain 19

Channel Mode Selection 20
Monitor Mode 20
PID Operations 21
Transparent PI Controller 21
Limits in PID Operation 22
Initial Kick 23
Auto Hold 23
Manual Hold 23
Software Change 24
Gun-on PI Controller 25
Complex Ratio Mode 25
Closed Loop Control Mode 26

Linearizer 27
Using the Linearizer 27
Programming the Linearizer 28

Serial Port 29
Serial Port Programming 29

Hardware Hints 36
Back Panel Details 37

Troubleshooting 38

Warranty 40

Appendixes

Quick Reference Key Sequences A
Programmable Parameters B
Analog I/O Circuits C
Digital I/O Circuits D

Jumper Settings F
Power Supply-Jumpers & Fuses G
Panel Cutouts H
Dimensions I
PID Mode External Hookup J
Fiber Optic Flow Control System K
EMO-1005 w/built in PNAO L

Serial Port Connection Wiring 31

Back Panel Connections E

INTRODUCTION

The EMO-1005 is a multi channel indicating, computing and signal processing system, applicable in
single channel use and expandable to systems with as many as 250 independently operating channels.
All its functions can be programmed through the programming keyboard in the front panel or
optionally, by a host computer through a RS 422 (RS 232 option) serial port.

There are 5 selectable modes of operation (see page 19); the most popular are either MONITOR or
PID (closed loop). In any mode both instantaneous flow rate and batch totalizing can be displayed
simultaneously.

The main housing is equipped to hold four channel cards, the display board, the programming
keyboard, the communication port and the power supply.

The display is a 16 character, two line alphanumeric Super-Twist LCD with back-lighting for improved
readability in non-daylight situations.

Before installation read HARDWARE HINTS (page 38)

Each channel can be programmed with the following information:

- Rate scale and engineering units

- Totalizer scaling and engineering units

- Rate limit settings (four)

- Totalizer limit settings (four)

- Analog Output Gain

- Analog Output Offset

- Sample amount

- Cut-off frequency

- Analog Input Gain

- Monitor or PI mode

- Linearizer setting (10 points with linear interpolation between points)

Display of rate ratio between any two of the channels can also be programmed.

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Typical applications for the EMO-1005 unit:

- Rate and total indicator for flow meters, tachometers, parts counters, etc.

- Processing unit for batch operations.

- Closed loop controller for flow rate, speed, etc.

- In applications with non-linear transmitters
(frequency output not directly proportional w/flow or speed).

- Operations requiring limit outputs.

- Computing and display unit for:

Flow meters

Pressure transducers

Tachometers

Inductive pick-ups

Hall sensors

Temperature sensors

Encoders

Pulse generators

Etc.

The EMO-1005 is capable of displaying 28 different engineering units.
Example of some of these are:

* Impulses/Gallon * Ounces/Minute * Volt
* Impulses/Liter * Gallons/Minute * Ampere
* Impulses/Revolution * CC/Minute * RPM
* Revolutions/Minute * Pound/Minute * Hertz
* Centipoises * Feet/Minute * PSI

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USING THE EMO-1005

FLO

A+B

The keyboard has membrane type switches. There is no "click" heard or felt when pressing a key. The
press on the key must be very firm to activate the switch. This type of keyboard was selected to avoid
the likelihood of accidental programming.

Programming should in most cases be done once in a "lifetime" on the EMO-1005, so an
"user-friendly" keyboard is not really that necessary.

If frequent programming or changes in the programmed values or set-points is necessary, interfacing to
a PC through the serial port will make the programming task more "user-friendly".

7

A/B

4

1

0

TOT

5

5

A

2

DP

.

SPC

RAO

ENT KFA

9

6

B

3

CHA

LIM

KFR

The EMO-1005 Keyboard

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UNIT INITIALIZATION

When powering up the EMO-1005 unit, the following sequence will display system hardware and
software information.

LINE 1

LINE 2

Line one indicates the RAM memory is being tested. Line two indicates whether the RAM memory
battery back-up is installed and operational.

The next display screen appears as follows:

LINE1

LINE 2

where,
CH means channel
the channel number is indicated after the CH.
The letter after the "=" means:

M = Channel in question is in Monitoring Mode

P = Channel in question is in PID Mode
R = Channel in question is in Complex Ratio Mode
OFF = Channel is not installed or is not responding

After the "/", an "L" would indicate the Linearizer is active.
A blank would indicate the Linearizer to be OFF.
If the channel card is in the Gun-On Mode, Transparent Mode or Closed Loop Control (CLC)
Mode the channel will initialize as a P in the above screen.

The next screen is the operating screen with the channel information - actual rate/total values and
engineering units.

A sample of the screen if the unit receiving a frequency signal would appears as follows:

LINE 1

LINE 2

Ram Test .................

Ram and no Bat Ram and battery

or

Ram test .....................

CH1=M/L CH2=R/

CH3=P/ CH4=OFF

01:

01:

500.00 Hz

22245.0 Imp

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QUICK START

The EMO-1005 has several default values programmed in at the factory. This means you can hook it
up and test it out before any serious programming is necessary. The unit comes up in Monitor mode as
a default. The default rate scaling is 100 and the engineering units is Hertz (Hz). This means that a 100
Hz signal input on pin 4 will be displayed as 100 Hz on line 1. And the totalizer will display impulses
(Imp) on line 2. When a frequency is detected on either pin 3 or 4, the LED under the connector on the
back panel will start to blink at a steady rate.

SCREEN MANIPULATION

When the EMO-1005 is turned on it always returns to the last screen displayed before the unit was
turned off. The EMO-1005 screen is easy manipulated to show different information. To select a
different channel, press CHA and then the channel number, (1, 2,..) The channel will be displayed in
line 1. The former line 1 will scroll into the line 2 position. The information located in line 2 will scroll
off the display. It should be noted that the channel located in line 1 will be the channel which is
displayed when the status display mode is selected. Also, when line 1 is scrolled into line 2 it remains
in the current display mode and the new line 1 will also be in that mode unless otherwise changed.

NOTE: If the unit has 10 or more channels, channel selection is entered as: CHA and then channel
number, 01, 02.. 11 etc, and after channel number press ENT.

DISPLAY MODE SELECTION

There are four display modes on a standard EMO-1005: Rate, Total, Peak Rate and Simple Ratio.
The Rate Mode displays the current frequency coming into the EMO-1005. The Total Mode displays
the totalized amount of impulses received from the transducer or flowmeter. The Peak Rate will
display the highest rate reached during current readings. The Simple Ratio Mode displays the ratio
between channel 1 and the channel currently on line 1. To select a new display mode (Total/Rate or
Ratio) just press one of the TOT, FLO or RAO keys. This operation will change only line 1, not line

2. The display mode can be changed as many times as needed

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6

RATE

FLO

The rate will be displayed in the following form:

LINE 1

LINE 2

where,
01: is the channel number
XXXXX.XXX is the derived rate
zzzz is the selected engineering units
Sample engineering units: Hz, GPM, cc/m, li/m, etc.

The default unit is Hz.

To display the rate press the FLO key. The Rate Mode displays the current
incoming frequency for the channel selected on line 1. The displayed frequency
is initially displayed in Hz. But the display can be programmed to any of the 28
familiar engineering units. For further information see the Programming section,
page 11.

01:XXXXX.XXXzzzz

TOTAL

TOT

The totalized amount will be displayed in the following form:

LINE 1

LINE 2

where,
01: is the channel number
XXXXX.XXX is the derived totalized amount
zzzz is the selected engineering units
Sample engineering units: Imp, Gal, cc, REV, etc.

The default unit is Imp.

The Totalizer displayed on line one can be reset tozero by pressing the 0 (Zero) key on the
keyboard

To display the totalized amount press the TOT key. The Total Mode displays
the current totalized incoming frequency on the channel selected in line 1. The
totalized amount is initially displayed in impulses but the display can be
programmed to any of 14 engineering units. For further information see the
Programming section, page 12 .

01:XXXXX.XXXzzzz

.

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SIMPLE RATIO

RAO

The Simple Ratio is displayed in the following form:

LINE
LINE

where,
CH1 means channel 1
/ means divided by
CH means channel
xx is the channel number on line 1
ZZZ.ZZZ is the ratio of this division

There are two ratios available on the EMO-1005: the Simple Ratio and the
Complex Ratio. The Complex Ratio is a channel mode selection. This ratio
changes the inputs and outputs on the channel designated to be in the Complex
Ratio Mode. The Simple Ratio Mode however, does not affect anything on the
unit but the display screen. When the RAO key is pressed, the channel being
displayed on line 1 is changed to show a ratio of channel 1 divided by the
channel on line 1.

CH1/CHxx ZZZ.ZZZ

PEAK RATE

SPC

The Peak Rate Mode was added to give the user the ability to measure the
highest rate a transducer reaches. This is very useful in applications where the
rate is very inconsistent or unstable. By pressing the SPC key the unit will
measure the incoming frequency and display the rate on line 1. Remember, the
peak rate displayed will be that of the transducer plugged into the channel
located on line 1 of the operatin screen. The Peak Rate will be reset to Zero
when the Rate has been zero and starts again.

The peak rate will be displayed in the following form:

LINE 1
LINE 2

01/P XXXXX.XXzzz

where,
01 is the channel number
/P means Peak Rate Mode
XXXXX.XX is the derived peak rate
zzz is the selected engineering units

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STATUS DISPLAY MODE

Press the following key sequence:

CHA

The status display will be displayed in the following form:

LINE 1
LINE 2

where,
xx: is the channel selected in line 1
XXXX is the input rate (frequency) in Hz
P indicates the mode: P = PID R = Complex Ratio
M = Monitor T = Transparent
G = Gun-On C = Closed Loop Control

O indicates the Linearizer, O= Not active, L=Active
/ separator
YYYY is the totalizer lowest 4 digits in impulses
AO stands for Analog Output (1024 steps). 51.2 steps/mA.
zzzz is the current Analog Output value in decimal
(range is 0 - 1023)
AI stands for Analog Input (256 steps). 12.8 steps/mA.
yyy is the 8-bit analog converter value (000 - 255)
L stands for Limits, O = Limit On, I = Limit Off
OOIO
^.. Limit 1 Output (ON) (terminal 14)
^... Limit 2 Output (OFF) (terminal 13)

^.... Limit 3 Output (ON) (terminal 12)

^..... Limit 4 Output (ON) (terminal 11)

(Terminal 15 is common for Limits)

The numbers for Digital input or Analog input/output are unscaled numbers. Rate Scaling or gain

factors will have no effect on these numbers. By pressing the CHA key and then number 1, 2 or 3....

the status of other channels can be displayed. By doing this the status of the channel in line 1 of the
normal operating screen will be displayed on line 1. To go out of the Status display and back to the
normal operating display, press the ENT key. Check the status display first if there are any problems
with any inputs or outputs.

The Limits in the Status Display have no validity in PID mode.

->

DP

SDxx:XXXXPO/YYYY
AOzzzzAIyyyLOOIO

->

ENT

->

KFR

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PROGRAMMING THE EMO-1005

To enter the programming mode press the following key sequence:

CHA

Now the display will show:

LINE 1 PROGRAMMING
LINE 2 0 = NO 1 = YES

If this screen did not come up then try the key sequence once more (press
slowly and firmly on the keys). If you would like to program press the 1 key;
if not, press the 0 key. Pressing the 0 key returns the unit to the normal
operating mode. If a 1 was pushed the following screen will appear:

LINE 1 ENTER CHANNEL
LINE 2 NUMBER=??

Enter the channel number that should be programmed and press the ENT key.

NOTE: Channel 1 = 01, 2 = 02 ....

Any mistakes made during programming in the next steps must be edited while at that screen. After
leaving any display you must toggle through the remaining displays to return to the operating screen
display. Then enter the programming mode again and toggle through until you get to the screen where
you want to edit the entered value.

->

DP

->

ENT

->

KFA

Before entering any new data in any of the programmable parameters, zero out the old data first.
Then start to enter the new number. The numbers will be shifted to left as they are entered.

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In the following lines the menu questions are listed in the order they appear while in programming
mode:

Display 1

RATE SCALING ?

QUESTION: ANSWER:

0 or 1 ENTER

0 = NO and 1 = YES

Display 2

TOTALIZER SCALE?

0 or 1 ENTER

0 = NO and 1 = YES

Display 3

LIMITS? (none=0)

0, 1 or 2 ENTER

RATE=1 TOTAL=2

Display 4

ANALOG GAIN (KFA)
CURRENT=00000167

Enter new KFA
ENT alone is no change

(167 is default)

Display 5

OFFSET ANALOGOUT
CURRENT=00000205

Enter new number
ENT alone is no change
(205 is default)

Display 6

Display 7

Display 8

SAMPLE AMOUNT
CURRENT=00000008

Enter new number
ENT alone is no change (8 is default)

CUTOFF FREQ.
CURRENT=00000050

Enter new number
ENT alone is no change (50 is default)

ANALOG IN GAIN
CURRENT=00000000

Enter new number
ENT alone is no change (0 is default)

(Only used in PID Mode)

In the following sections, all of the previous displays will be explained in detail.

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RATE SCALING - KFR (Display 1)

By answering with a 0 the scaling will be skipped.
By answering with a 1 the following display appears:

CURRENT KFR/UNIT

XXXXXXXX.X YYYY

where,
XXXXXXX.X is the current rate scaling
YYYY is the selected engineering units

The EMO-1005 is programmed, at the factory, to calculate the incoming frequency in Hertz (Hz). In
order to make the EMO-1005 show a more convenient engineering unit, such as GPM, an appropriate
scaling factor must be applied. This factor is called the KFR and is calculated by applying the K-factor
of the transmitter that is being monitored. The K-factor is the number of impulses per engineering unit
and is published by the transmitter manufacturer or established by a calibration test. (AW-Company
provides a calibration test sheet with every flow meter).

For example a flowmeter could have a K-factor of 6304 imp/Gal or 329.22 imp/lit. A rpm pickup
could be 34.66 imp/rev.

In order to calculate the KFR multiplier for the EMO-1005 apply the following formula.

6000

KFR =
K-factor

where,

KFR is the number that should be entered in to the RATE SCALING display (Display1)
K-factor is the number published by the manufacturer as the average K-factor for the

transmitter.

100 is the constant if the time base is seconds.
6000 is the constant when the time base is minutes.
360000 is the constant when the time base is hours.

For example:

A flowmeter has the K-factor 2053.7 imp/Gal and the display should show Gallons/minute.

6000

KFR = = 2.921 GPM

2053.7

When entering the number into the EMO-1005 keep in mind that the maximum number is 65000
(regardless where the decimal point is.)

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Decimal Point Location

In order to change the scaling just enter the number, and change the decimal point location by pressing
the DP key. After having the desired number in the display press the ENT key once.

Engineering Units

Now by pressing the SPC key the unit display can be changed to one of the following engineering
units:

Hz, GPM, li/m, ci/m, cc/m, lb/m, lb/s, lb/h, gr/s, kg/m,
gr/m, mm/s, cm/m, in/m, ft/m, oz/m, Volt, mV, Amp, mA, PSI,
Bar, F, C, RPM, SSU, cSt, cPs.

Note: This is merely a convenient display function.

The actual units are scaled thru the KFR factor.

Press Enter to exit the KFR scaling.

The default value for the KFR is 0000100.0 (Maximum= 65000) The default engineering unit is Hz
(Hertz).

We recommend removing the insignificant decimal numbers often produced by calculator
mathematics. These are mathematically redundant and may offer a misleading level of precision in the
display. We recommend using a maximum of 4 digits, irrespective of the decimal point position.

Example: 60.675 is no good; better: 60.6

2.3456 is no good; better: 2.345

TOTALIZER SCALING - KFT (Display 2)

By answering with a 0 the scaling will be skipped.
By answering with a 1 the following display appears:

CURRENT KFR/UNIT

XXXXXXXX. YYYY

where,
XXXXXXXX. is the current total scaling
YYYY is the selected engineering units

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In order to make the EMO-1005 display show the desired engineering units, the most important thing
to know is the K-factor of the transmitter that is being monitored. The K-factor is the relationship
between the amount of impulses and the engineering unit.

To change the scaling just enter the number, (zero the display first) and to change the decimal point
location press the DP key. After having the decimal point in the correct location press the ENT key
once. Now, by pressing the SPC key the unit display can be changed to one of the following
engineering units: Imp, Gal, lit, cin, cc, lbs, kg, gr, mm, cm, Inch, ft, Oz, Rev.

Press Enter to exit KFT programming.

The default value for the KFT is 00010000 (Maximum= 65000)
The default engineering unit is Imp (Impulses)

For example a flowmeter's K-factor could be 1998 imp/Gal or 123.22 imp/lit. A rpm pickup could be

55.0 imp/rev.

In order to calculate the KFT multiplier for the EMO-1005 apply the following formula.

10000

KFT =
K-factor

where,

KFT is the number that should be entered for TOTALIZER SCALING in display 2.
K-factor is the number published by the manufacturer as the average K-factor of the

transmitter. If this is published in imp/gal the totalizer can still be set in, say cc's, by
converting the K-factor to imp/cc.
10000 is a constant.

For example:

A flowmeter has the K-factor 10666.0 imp/Gal and the display should show gallons/minute.

10000

KFT = = 0.9376 Gal

10666.0 Gal

In the above example enter 9-3-7 (zero the display first, and don't enter the number 6) and then adjust
the decimal point by pressing DP until the point appears at the correct position. After pressing the ENT
key, the engineering unit may now be chosen by pressing the SPC key until the correct unit comes up.
Now, by pressing the ENT key the KFT number and engineering unit will be stored in memory.

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LIMITS PROGRAMMING (Display 3)

By answering with a 0 the scaling will be skipped

By answering with a 2 go to the next section

There are a total of 4 limits per channel. Each of the limits can be a totalizer or rate limit. If the limit
has been programmed for total and rate, the output will respond to the one that occurs first. This can
produce unexpected limit initiation therefore you should be careful to avoid this type of programming
duplication.

The limits are always programmed in:

- rate limit in Hertz 000000.00 Hz

- total limit in impulses 00000000. Imp.

In order to program the limits it is necessary to know the K-factor of the transmitter.

For example:

A flow meter has a K-factor of 8000 imp/Gal. Limit 1 should
turn on when ever the flow exceeds 3.22 GPM and limit 2
should turn on when ever the totalized flow has reached 2.50
Gallons.

8000 * 3.22 imp
LIMIT 1 = = 429.33 Hz
60 sec

LIMIT 2 = 2.50 * 8000 imp = 20000 imp

To check whether a limit is ON or OFF, go into the Status Display Mode for the channel in question.
(see page 8)

WARNING!! Never enter two different limits, Rate and Total, under the same limit number.

LIMITS? (none=0)
RATE=1 TOTAL=2

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RATE LIMIT

By answering with a 1 the following display appears:

RATE LIMIT NO ?

ENTER 1 ........4

Select the rate limit that needs to be changed. Do this by pressing a number 1...4 Now the display will
show the selected limit in the following fashion:

CURRENT RATE Y
LIMIT XXXXXX.XX

where,
Y indicates the limit number selected
XXXXXX.XX indicates the current rate limit in Hertz

To change the limit enter the right number and press ENT After entering the number the display
returns to the Limit Main Menu.

The default values for all rate limits is 000000.00
The maximum number is 999999.99
The decimal is fixed at 000000.00

TOTAL LIMIT

By answering with a 2 the following display appears:

TOTAL LIMIT NO ?

ENTER 1 ........4

Select the total limit that needs to changed. Do this by pressing a number 1...4 Now the display will
show the selected limit number (Y) and current rate in impulses. (XXXXXX.XX)

CURRENT TOTAL Y
LIMIT XXXXXX.XX

To change the limit enter the right number and press ENT. After entering the number the display
returns to the Limit Main Menu.

The default value for all total limits is 00000000.
The maximum is 99999999.
The total limit decimal point is fixed at 00000000.

NEVER ENTER RATE AND TOTAL LIMITS UNDER SAME NUMBER

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ANALOG GAIN - KFA (Display 4)

The Analog Gain (KFA) is the scaling between the frequency input and the analog output. This is only
valid in Monitor Mode -- in PID Mode, KFA controls the closed loop reaction time (P21).

This should not be confused with the KFR factor

ANALOG GAIN (KFA)
CURRENT=XXXXXXXX

The formula that describes the relation is as follows:

V * 33400 Imp/gal X GPM
KFA = f =
f 60 sec

where,

V is the desired Output Voltage at frequency f: If 5V - use the GPM realistically achievable by

your system to find f.

- 33400 is a constant

Once the right number is entered press ENT
The default value for KFA=00000167 (1000Hz = 5Volt)
The maximum KFA is 00065000

After the formula has been calculated and the correct number has been programmed in to the KFA, the
Analog Output can be seen by going into the Status Display Mode. The Status Display shows a number
from 0 to 1023 for the Analog Output. This number is the D/A converter input from the
microprocessor. When the EMO-1005 is set for a maximum of 5 Volt DC on the Analog Output (Pin

10) then each step of the converter is equal to:

One step = 5Volt/1024steps = 4.8828mV

Therefore, if 1 Volt is measured on the Analog Output then the Status Display should be showing a
count of 205 in the Analog Out (AO0205) position. (1 Volt = 205steps * 4.8828mV)

Frequency when Eng. Unit =Gallons

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OFFSET ANALOG OUT (Display 5)

OFFSET ANALOG OUT
CURRENT=XXXXXXXX

This display takes care of the Analog Offset adjustment. The full voltage span goes from 0 to 5V
(0-20mA). Some applications however require a base voltage of 1 Volt (4mA). This base voltage can
be programmed in the Offset Voltage. The EMO-1005 unit uses a 10 bit D/A converter for the Analog
Output, where 0 Volt relates to a count of 0000 and 5 Volt is 1023. The offset is a number between
000 and 255 (0V to approximately 1.24V). This offset should be adjusted in the field. The offset has a
connection with the gain Factor. In order to achieve the maximum span the following formula is
applied:

AV * ( 205 + ((205-Offset) / 4)))
Analog Out = AV -
256
where,
Analog Out is the offset voltage at zero frequency input
AV is the maximum Voltage (usually 5V)
The default value is 00000205 (4mA)

**** 1Volt = 205 steps * 4.8828mV/step
**** 4 mA = 205 steps * 19.5 μA/step

After having the right number press the ENT key

SAMPLE AMOUNT (Display 6)

SAMPLE AMOUNT
CURRENT=XXXXXXXX

The sample amount can be entered in this display. This sample amount is a digital filter used to make
the display rate steadier. The amount can be a number between 2 and 50. By increasing the number of
samples used to produce an output into the display, the display response slows and the numbers are
steadier and easier to read. The default value is 00000008. After having the right number press the

ENT key.

WARNING:

SHOULD THIS VALUE BE CHANGED TO ZERO, THIS DISPLAY WILL READ ZERO

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18

CUTOFF FREQUENCY (Display 7)

CUTOFF FREQ.
CURRENT=XXXXXXXX

The cutoff frequency can be entered in this display. The cutoff frequency is used to remove a slowly
decreasing rate being displayed when the flow is shut off - this is a display function only and pulses are
not being counted. When actual flow stops, however, the unit will momentarily look for the next pulse
and for a very short period, the displayed flow rate will tail away to zero. To avoid this confusing an
operator, if the cutoff frequency is programmed, the display will drop to zero at frequencies below this.
The cutoff frequency is a number between 000 and 255. This number relates to a frequency between

0.00 and 2.55 Hz.

The totalizer is not affected by the Cutoff Frequency. The default value is 00000050
(corresponding to 0.5 Hz).

After having the right number press the ENT key.

ANALOG IN GAIN (Display 8)

ANALOG IN GAIN
CURRENT= XXXXXXXX

The Analog In Gain factor is used at the present time in the PI Mode as a relationship between Analog
Input signal from a PLC or PC, if used, and the set value.

The formula is as follows:

Freq. * 100
Analog In gain =
205

Freq. Is the actual frequency feedback from the flow meter (in Hz) at 20 mA analog input signal from
the PLC. This can be established for most systems by fully opening the fluid regulator and reading the
feedback frequency signal in status display mode.

WARNING: TO PID USERS: The default value is 00000000, however, if PID user has PLC
analog Input control - ZERO in Analog-In Gain will cause failure. We suggest a value in the
range 20-50. After having the right number, press the ENT key.

THE PROGRAMMING IS NOW OVER

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19

CHANNEL MODE SELECTION

Each channel card installed in an EMO-1005 is a separate microprocessor controlled system. Each
channel card has the option to designated as a Monitor, PI Controller, Closed Loop Controller
(CLC) or a Complex Ratio System. To change a channel card to a different mode press the following
key sequence:

CHA -> DP -> ENT -> LIM

When this is done the following screen will appear:

MODE: 1=MON 2=PID
3=GON 4=TRA 5=RA

The next five sections will explain what happens when these numbers are selected.

For standard PID operations, select Mode #4, TRANSPARENT - This replaces Mode #2 for all
uses.

MONITOR MODE (Select 1)

When a 1 is selected in the above screen, the channel card will be designated as a Monitor card. In the
standard monitor mode the EMO-1005 will read the incoming frequency, display the derived rate and
total on the display, and adjust the Analog Outputs and Limits accordingly.

Using the 2 line display, both Rate and Total or Rate from 2 different channels could be
monitored simultaneously - or any combinations of Rate, Total and Peak Rate.

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THE EMO-1005 PID OPERATIONS (Select 4)

When a 4 is selected in the previous screen, the channel card will be designated as a PI Controller with
the Transparent option.

The PI Controller with the Transparent option works the same as the standard PI - controller except that
the mode, when activated, takes the Analog Input and diverts it to the Analog Output. This feature
even overrides the HOLD signal. By doing this the EMO-1005 channel card becomes transparent.
This is used to override PID control mode during the flushing cycle. To do this the Limit 4 Output (pin

11) must be connected to +15V (pin 1) and the RESET (pin 9) must be connected to the Limit
Common (pin 15). This mode works well when testing the system components. As long as the Limit 4
is connected to +15V, the PI Controller will not start to regulate. (See Appendix J).

This is a very useful function for system evaluation and troubleshooting because PLC signal
commands can be routed directly through the unit to the other system components and the
response can still be evaluated via the EMO status display mode. For example the fluid regulator
limitations can be easily investigated in this manner.

The Transparent mode is used in applications where the rate (flow, rpm, speed, etc...) has to be
controlled and maintained. The PI-controller uses the frequency coming from the transmitter, as a
feedback signal, referred to as CURRENT RATE. The unit puts out an analog signal (4-20mA/0-5V)
to correct for the difference between SET VALUE and CURRENT RATE

SET-VALUE can be programmed via one of the following methods:

A. 4-20mA into Analog Input (Pin 5 & 6) (From PLC)
B. Programmed values (SET VALUE1/SET VALUE2) through the keyboard
entry. Programmed in Hz.
C. Set value can be entered through the RS-422 (RS-232) connection.

When using a channel as a PID controller it still works as a totalizer unit and rate indicator.

Some input pins and programmed values will have a different effect when the channel is used as
a PID controller.

(See Appendix J & Table Following)

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The limits in monitor mode have no validity in PID mode, the following table shows their revised
functions and programming locations.

MONITOR MODE CLOSED LOOP (PID)

Rate Limit 1 (Hz)
Rate Limit 2 (Hz)

Set Value 1 (Pg. 20)

Set Value 2 (Pg. 20)
Rate Limit 3 (Hz)
Rate Limit 4 (Hz)

Total Limit 1 (Impulses)
Total Limit 2 (Impulses)
Total Limit 3 (Impulses)
Total Limit 4 (Impulses)

Initial Kick (Pg. 22)

Integral Adder for I-Part (Pg.

21)

Initial Kick Threshold (Pg. 23)

Totalizer Reset (Pin 9) Auto Hold of last Analog Value

When operating in Monitor Mode, there are a total of 4 Limits available for use. Each one can be
programmed for both Rate and Total Values in separate locations. However, to avoid operator
confusion, it is recommended to maintain separation.

Use each Limit number for only one alarm condition.

The formula used in PID Mode to achieve a set value from a frequency input signal (CURRENT

VALUE) is as follows:

AnalogOut=AnalogOutOld+KFA* (SET VALUE-CURRENT VALUE) + I-part

where,

AnalogOutOld is the Analog Output value prior to the current calculation.
KFA is the gain factor
SET VALUE is a selected programmed value.
CURRENT VALUE is the last calculated rate value.
I-part is the programmed adder.

Integral Adder, I-Part

In most applications, an I-part is not necessary, but if the KFA is very low, an I-part = 1 could be used.
The above formula will be evaluated every rising edge of the input frequency. This feature makes the
EMO-1005 PI-unit react faster at higher frequencies and slower at lower frequencies.

KFA in Monitor mode is the gain factor for the Analog Output.

In the PI-mode KFA becomes the closed loop gain factor, and an increase in the KFA results in a
quicker reaction time and in a "stiffer" system. However, whenever the KFA has too big of a value, the
system tends to show unstable behavior (swinging).

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Initial Kick

The PI-controller will output the value in total limit 2 (P. 21) if there is a set value and nothing is being
received from the feedback loop. This is called the initial kick and is meant to >kick start= some fluid
regulators, which will resist an initial opening when starting from a zero flow condition. The initial
kick can be programmed from 0000 to 1023 (where 0000=omA and 1023=20mA). In units prior to
AUGUST 1987, the initial kick could be programmed only from 000 to 255.

Auto Hold

In PID mode, if the feedback signal is cut off abruptly, the software will maintain the last analog output
value. This is an advantage in an ON/OFF operation since the unit does not have to start regulating
again from zero when the signal is given to restart. An example of an ON/OFF system is a paint
spraying gun.

Manual Hold

There is an additional HOLD function for applications where ON-cycles are extremely short or where
during the flush cycle no control is desired. The HOLD signal is overriding in a sense that nothing is
able to change the Analog Output while HOLD is on. This function can be initiated with 15 V to pin
12, and pin 9 jumped to pin 15 (See Appendix J).

The EMO-1005 PI-mode is fairly uncritical. AW Company, however, recommends some prior
knowledge of Closed Loop System controlling before hooking us the PI-mode channel. The response
times are dependent upon the following things:

- Resolution of the transmitter

- Mechanical delays in the system
o (boosters and I/P converters or the hose/pipe length between components)

- Gain factors (KFA)

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EMO-1005 SOFTWARE CHANGE

A new programmable feature has been added to the EMO-1005 software.

It is a Programmable Threshold for the initial kick value used in PI and Closed Loop Mode. (See
Initial Kick, pg. 22). While most good fluid regulators are supposed to crack open at 4mA, there is
much inconsistency to be found. The earlier threshold value was fixed at 5.0 mA -this is now user
programmable. If nothing is programmed here (0000), a threshold default value of 5.0 mA (256) is
still used.

The location of the programmable value is in Total Limit #4.

The range is from 0000 to 1023 steps (Where 0000 = 0mA, and 1023 = 20mA, 51 steps = 1mA).

In the software prior to these changes, the Initial Kick (programmed in Total Limit #2) was activated
providing the following 3 system conditions were met:

1. A flow set point had been initiated.

2. Analog output was below 5.0 mA (256 steps).

3. Actual flow was zero.

Conditions 1 & 3 remain unchanged - #2 is now programmable

Example:

The Initial Kick (in Total Limit #2) is set to 615 (12 mA).
The Threshold (in Total Limit #4) is set to 358 ( 7 mA).

The current Analog output is at 5.5 mA (281 steps), but the actual flow is at zero. The valve has not
opened. The Analog Output is BELOW the Threshold and now the Initial Kick will take effect. The
Analog Output will go immediately to the Initial Kick value. In Total Limit #2 - 12 mA (615 steps).

The new version for Channel 1 software is 2.0 and for Channel 2 and over it is 1.4. This is determined
by removing the channel card, the software version is indicated on the EPROM chip. See Appendix F
for location.

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24

GUN-ON PI CONTROLLER (Select 3)

When a 3 is selected in the previous screen, the channel card will be designated as a PI Controller with
the Gun-On option. The only difference between this and the standard PI Controller is the Gun-On
feature which makes the Analog Output increase until the EMO-1005 starts to see a feedback
frequency. When the EMO-1005 is in this mode, the initial kick has no affect on the Analog Output. In
order to turn on the Gun-On feature, the Limit 4 (Pin 11) must be connected to pin 1 (+15V) and the
RESET (pin 9) must be jumped to the Limit common (pin 15). When the EMO-1005 sees a set signal
but no frequency return it immediately starts to increase the Analog Output until a feedback frequency
is recognized.

COMPLEX RATIO MODE (Select 5)

This is a monitoring function - not closed loop control of ratio delivery.

This ratio mode applies to channel one only; it takes the rate of channel 1 and divides it with the rate of
channel 2. The channel 1 outputs are affected by the ratio calculations as shown below:

KFA * KFR Ch1 * RATE Ch1

Analog Out =
KFR Ch2 * Rate Ch2

Complex Ratio mode has no effect on the display (Simple Ratio does - pg. 7). In this mode, however,
the outputs are also modified. In Complex Ratio mode, the values programmed in the dour totalizer
limits will be compared to the Analog Output numeric value.

The limits will be turned ON if the Analog Output value is larger than the programmed totalizer value -

- this can provide a ratio alarm indication.

The Analog Output is a number between 0000 - 1023, where 0000 equals 0 Volt and 1023 equals 5
Volts. If channel 2 is not inserted or the rate of channel 2 is zero, then the output of channel 1 is 5 volts
(1023 steps). If the Analog Offset is programmed, then the regular offset rules apply.

Example: A two component flow measurement system is needed and flow 1 is two times the flow 2.
Also, a limit alarm is needed for a 5% high and a 5% low measurement. Then channel 1 of the EMO­1005 would be programmed as a Complex Ratio Monitor. The flow 1 frequency would be connected
to the channel 1 frequency input and the flow 2 would be connected to channel 2 frequency input. By
using the ratio analog out formula, the KFA (Analog Output) can be set to give a 2.00 VDC (2V = 410
steps) output when the ratio is correct. Then, by wetting totalizer limit 1 to 431 steps (2V +5%) and
totalizer limit 2 to 390 steps (2V -5%), the two limits will give a signal when this margin has been
exceeded.

** CAUTION ** Never program the channel 1 card to be a Complex Ratio Monitor unless the
channel 2 card is installed. If this is done the EMO-1005 unit will lock up.

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CLOSED LOOP CONTROL MODE (CLC)

The CLC mode has been adapted to the EMO-1005 for extremely slow closed loop applications. In
some applications (fluid) where the distance between the I/P converter and the regulator is more than
40 feet and the pneumatic system is not quick enough in response, the standard PI loop will not do the
job. The CLC mode has one major difference to the standard PI mode in that the corrections are done
by a percentage to the error rather than proportionally.

For example:

If a set value (Analog In) is calling for a flow rate of 20 liquid ounces but the feedback frequency is
only 18.2 liq.oz. when sending out 10mA's, then the CLC would correct the Analog Output as
follows:
Set Value - Current Value
New Analog Out=Old Analog Out + * A
Set Value
where,
A is the highest value of the Analog Output. (Usually 5VDC)

After making the corrections, the CLC waits until the mellow frequency (average) catches up with the
actual frequency. After the catch-up has been achieved, within the death band limits, the CLC is then
ready for a new round of calculations.

There are a great many applications which show a lag time before any reaction in the system can be
seen. To take care of this problem, a programmable lag time factor has been added to the CLC mode.
In the CLC mode, a change at the Analog Input will immediately cause a change in the Analog
Output. Again, the change on the output is based on a percentage.

CLC Parameters

Totalizer Limit # 1 = Lag time (0100 - 0255)
Sample amount = Average (005 -040)
Cutoff = Death band (100=1Hz...255=2.55Hz)
Analog In Gain = Scales Analog Input

The initial kick is used to start a system regulating. See the section "THE EMO-1005 PID
OPERATIONS", page 20, for more information about the initial kick.

The Cutoff is used to stop the unwanted hunting of the CLC mode. When Cutoff is set, the number in
the Cutoff is translated into a frequency. The number in the Cutoff is the margin where the EMO-1005
will stop regulating and will hold a steady Analog Output.

By increasing the Sample amount, the Lag time reaction becomes slower.

By increasing the Death band the unwanted hunting will be avoided.

Totalizer Limit # 2 = Initial kick (205=4mA...1023=20mA)

** CAUTION ** Changing from one mode to another changes some of the inputs to outputs therefore,
please make sure which mode the channel card is in before hooking up external signals.

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26

THE EMO-1005 LINEARIZER

Some systems have un-linear transducers for the rate or frequency. To solve this problem the
EMO-1005 was developed with a ten point Linearizer that can be programmed with an error of +/-

12.7%.

USING THE LINEARIZER

The Emo-1005 Linearizer can be used with any of the channel mode selections listed. This means that
the unit can linearize the feedback frequency of a PID controlled system or correct for error of one
component in a two component ratio system. When the unit is turned on, the initialization process
designates whether the Linearizer is ON or OFF. If the Linearizer was previously being used then it
will be functional when the unit is again turned on. The un-linearized frequency input can be viewed in
the Status Display Mode. The Linearizer feature is used mainly in connection with "un-linear"
transmitters. There are plenty of transmitters around that show a variation in the K-factor with varying
rates. In order to use the Linearizer effectively the transmitter manufacture or supplier should supply a
calibration sheet that would look as follows (this is just an example):

FREQUENCY RATE K-factor ERROR
Hz GPM Imp/Gal %

10 .26 2037.7 -5.2
100 2.60 2157.7 +0.5
500 13.00 2100.0 -2.5

If the percentage of error is not shown it can be calculated using the average K-factor.

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PROGRAMMING THE LINEARIZER

To enter the Linearizer mode press the following key sequence:

Now the display shows:

By pressing the 1 key the Linearizer will be cleared. This means all error values are set to +12.7% and
all frequency points are set to zero.

By pressing the 2 key the Linearizer will be activated.
By pressing the 3 key the Linearizer will de deactivated.

Regardless of the key pressed the following display will come up:

If the 0 key is pressed the Linearizer selection done above will go into effect and the unit returns to the
regular operating screen.

If the 1 key is pressed the unit enters a 10-point programming routine. When the 10-point programming
routine is entered there is no short cut, which means, all of the errors and points have to be reviewed
and entered.

The following display will appear:

where,
xx is the current point 01 through 10
yy.y is the error -12.7% to +12.7% at point xx
zzzzz.zz is the frequency at which the error xx occurs.

There are 10 points to be programmed. The first thing to be entered is the percentage of error. To
change the sign use the DP key. After the correct percentage of error is put in the unit and the correct
sign is selected (+ or -) then press the ENT key. On the second line is the frequency at which the above
error occurs. Enter new frequency and press the ENT key. All ten points will show up, but only
program the points that are necessary. Leave all unused points at zero Hz.

The Linearizer uses linear interpolation between points, which means a straight line between two error
points.

** IMPORTANT ** The channel that will be linearized is the one on the display line 1 !!!!!

CHA

->

DP

LINEARIZER !!!
1=CL 2=AC 3=DEAC

LINEARIZER PROG?
0 = NO AND 1 = YES

ERRxx=00000yy.y%
POIxx=zzzzz.zzHz

->

ENT

->

DP

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THE EMO-1005 SERIAL PORT

The standard EMO-1005 has a RS-422 serial port. AW-Company decided to use the RS-422 as a
standard because of higher noise immunity and better acceptance in industrial applications.

General characteristics for the EMO-1005 serial port.

Signals: RS-422 Standard with the following components
Receiver: SN75157
Transmitter:SN74159 (tri-state output)
Receiver has no pull-ups or pull-downs
Transmitter in tri-state when no action
Baud Rate: Programmable, 2400, 4800 or 9600 baud
Stop bits: 1 Stop bit
Start bits: 1 Start bit
Data bits: 8 Data bits
Parity: No Parity
Echo: Supports Echo Mode (Receive ---> transmit)
Module Offset: Supports large scale systems with offset
Protocol: OPTOMUX-like protocol format

The serial port is used in conjunction with a host computer.

SERIAL PORT PROGRAMMING

To enter serial port programming press the following key sequence:

The display will show:

By pressing 1,2 or 3 the indicated baud rate can be programmed and the display will automatically go
to the next step

Echo mode should be selected in the trouble shooting session. In Echo mode the EMO-1005 transmits
exactly the same string it receives. The next step is:

CHA -> DP

BAUD RATE: 9600=1
4800=2 2400=3

.

ECHO ON=1 OFF=0
PRESS 1 or 0

ACTIVATE SERIAL
1=ON 0=OFF

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-> ENT -> 1

29

After pressing 1 or 0 the EMO-1005 unit goes into the Receiver/Transmitter display mode and the
beginning usually looks as follows:

RXXXXXXXXXXXXXXX
TXXXXXXXXXXXXXXX

If left in this mode the serial communication can be viewed. The Receiver is on the upper line and the
Transmitter on the lower line.

If the text ORFE is right after the R it means that the unit has an over run/framing error. This error
usually occurs when there is nothing hooked up to the serial port or when the baud rate is not right.

In order to leave the above display mode just press the ENT key. Now the display will show:

CUR OFFSET 000
NEW OFFSET 000

At this point a new offset can be entered ( a number 000 to 256). The offset is necessary if there is
more than one rack mounted unit involved. The channel address is calculated in the following way:

Send Address = Channel Number + Module Offset

Example: If you have two four channel units, unit one will have offset=0, channel # 1 - 4. Unit two
will have offset=4, channel 5 - 10 (Send address Ch(5)=Ch(1) + offset(4)

By pressing the ENT key the unit goes back into display mode.

IMPORTANT!! If you are using only ONE EMO-1005 do NOT enter anything in the OFFSET.
If you do - your serial communication will not work.

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SERIAL PORT CONNECTION WIRING

The serial port connection is established through the 9 pin D-sub connector on the back panel of the
unit.
The pin termination is as follows:

PIN 1 - No connection
PIN 2 - RX TTL level (EMO receiving)
PIN 3 - TX Inverted RS-422 (EMO transmitting)
PIN 4 - RX Inverted RS-422 (EMO receiving)
PIN 5 - GND for shielding
PIN 6 - TX TTL level (EMO transmitting)
PIN 7 - TX RS-422 (EMO transmitting)
PIN 8 - RX RS-422 (EMO receiving)
PIN 9 - GND signal

PROTOCOL FORMAT

The EMO-1005 protocol format follows OPTOMUX by the OPTO-22 company.

The EMO-1005 is treated as a smart front end and the host communication is always initiated by
the host computer.

The following are basic commands and answers.

Reading a channel with the host computer:

>03K0F3403XXcr

^.............. start of text always the > sign

^^............ channel address number (00 through FF)

^........... read command is K (J is write)

^^^^......address that should be read 0000-FFFF

^^..... how many bytes to be read 00 through 0D

^^...checksum for the string 03K0F3403
^.. carriage return (decimal 13)

Answer back from the channel would look like this:

A03FF89XXcr

^.............. every answer back starts with an A

^^............ low byte (at address 0F34)

^^.......... next byte (at address 0F35)

^^........next byte (at address 0F36)

^^......checksum for the string 03FF89

^^....carriage return

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Writing with the host computer:

>01J03340F6587XXcr

^....................... start of text always > sign

^^.................... channel number that should be written to

^................... J = writing into channel (K = read)

^^^^........... address to write to

^^......... byte written to 0334

^^...... byte written to 0335

^^... byte written to 0336
^^.. checksum for string 01J03340F6558
^^. carriage return

If write operation was successful the channel answers with an: Acr

The following error messages have been implemented in the EMO-1005 protocol:

N01cr - Undefined command (something else than K/J)
N02cr - Checksum error
N03cr - Non printable ASCII character

There is a booklet published by OPTO 22 on the protocol format.

CHECKSUM CALCULATION

Calculating the previous string variable for the read command:

>03K0F3403XXcr

^^^^^^^^^...... these characters have to be put into the calculation.

Add the values for the ASCII Decimal variables as follows:

HEX 0 + 3 +K + 0 + F + 3 + 4 + 0 + 3
ASCII 48 + 51 + 75 + 48 + 70 + 51 + 52 + 48 + 51 = 494

To calculate the final checksum, convert the decimal number 494 into HEX (494=1EEh) and take the
last two characters (EE) for the checksum.

The final string would look like this:

>03K0F3403EEcr

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These are the ASCII characters needed when working with the EMO-1005

ASCII Decimal ASCII Decimal
0 48 A 65
1 49 B 66
2 50 C 67
3 51 D 68
4 52 E 69
5 53 F 70
6 54
7 55 J 74
8 56 K 75
9 57

BASIC PROGRAM FOR TESTING THE SERIAL PORT.

The BASIC program below will help test the communication port with a IBM PC compatible
computer. The program can be used in connection with BASIC, BASICA, GWBASIC or any other
reasonably standard PC BASIC.

10 REM *** EMO-1005 Serial port test program --------------

20 REM

30 OPEN "COM1:9600,N,8,1,RS,CS,DS,CD" AS #1

40 REM 9600 baud/no parity/8 data bits/1 stop bit/no hand shakes

50 INPUT "Enter string to send ",T$

60 REM for example 01K006304. This will read Totalizer channel 1

70 REM the > sign and carriage return is added later in the

80 REM program.

90 REM the next 4 lines calculates the checksum

100 FOR X=1 to LEN(T$)

110 NUM=NUM+ASC(MID$(T$,X,1))

120 NEXT X

130 CHK$=HEX$(NUM-(FIX(NUM/256)*256))

140 REM CHK$ carries the checksum as a string

150 REM now send the message

160 PRINT#1,;">";T$;CHK$;CHR$(13)

170 REM and print the message on screen

180 PRINT "Sent : ";">";T$;CHK$;CHR$(13)

190 PRINT "Waiting for replay........"

200 LINE INPUT#1,X$

210 PRINT "Received : ";X$;CHR$(13)

220 CLOSE #1

230 END

Before running the program make sure all hardware aspects are OK and the EMO-1005 is hooked up
correctly.

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33

IMPORTANT ADDRESSES

r

g

t

(

)

q

)

g

q

)

q

)

g

,

,

play

y

p

y

(

)

(

)

(

)

(

)

(

)

(

)

(

)

(

)

g

g

,

(

)

,

r

,

r

,

WARNING --- IMPORTANT --- WARNING --- IMPORTANT --- WARNING
The communication port does not discriminate any addresses. This means that any address can be
written to as well read from. Certain addresses will change the operation of the EMO-1005
drastically. Caution is recommended. Double check your programming.

The bytes are always arranged such that the low byte is first and then the more significant byte.

Example: the Totalizer is at 0063 0064 0065 0066 LSB MSB

Address
In HEX

0053
0055
0063
0067
006A
006B
006F
0074
0075

0076
0077
0078
007B
007E
0081
0084
0088
008C
0090
0094
009B
009D
009E
00A1
009E
00A1

......

00C2
00C5

Number
of Bytes

2
2
4
3
1
3
3
1
1

1
1
3
3
3
3
4
4
4
4
2
2
1
3
1
3
1
.
3
1

Description

Transparent Analog Registe
Analo
Totalizer
Fre
Analo
Peak Fre
Fre
Analo
Mode selector: 01=Mon
04=Trans
Dis
Sam
Flow Limit 1
Flow Limit 2
Flow Limit 3
Flow Limit 4
Total Limit 1
Total Limit 2
Total Limit 3
Total Limit 4
Analo
Analo
Linearizer Activator
Point 1 Linearizer
Point 1 error
Point 2 Linearize
Point 2 error

.........................................................................

Point 10 Linearize
Point 10 error

Outpu

In impulses

uency Instant (In 0.00 Hz

Input, 00=0V, FF=5V

uency (In 0.00 Hz

uency Mellow (In 0.00 Hz

Output Offset

02=PID, 03=Gun-On

05= Ratio

Cut Off Frequenc

le amount for Mellow Frequenc

In 0.00 Hz
In 0.00 Hz
In 0.00 Hz
In 0.00 Hz
in impulses
in impulses
in impulses

in impulses
Output Gain
Input Gain

FF=active

In 0.00 Hz

E3h=-10%, 7Fh=0%, 1Bh=+10%

E3h=-10%, 7Fh=0%, 1Bh=+10%

E3h=-10%, 7Fh=0%, 1Bh=+10%

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These addresses are located in every channel..

Example:
>03K006304XXcr Reads channel 03 totalizer
>01K006304XXcr Reads channel 01 totalizer

The next information is battery backed in Channel 01 even though it concerns channel 01 through FF.

Below is a table where to find this information located in the Channel 1 memory.

in HEX

Ch1 Ch2

Address for

Ch3 Ch4

Ch5 .............. Description

0552 05D2 0652 06D2 0752 ............ Display KFT factor, 2 bytes

0554 05D4 0654 06D4 0754 ............ Display decimal p., 1 byte

0555 05D5 0655 06D5 0755 ............ Display KFR factor, 2 bytes

0557 05D7 0657 06D7 0757 ............ Display decimal p., 1 byte

0558 05D8 0658 06D8 0758 ............ Eng. Units Total 1 byte

0559 05D9 0659 06D9 0759 ............ Eng. Units Flow 1 byte

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35

HARDWARE HINTS

The EMO-1005 internally has 1-5 microprocessors therefore, it is very important to pay attention to
proper signal wiring and shielding.

The standard EMO-1005 is delivered with two frequency inputs. Pin 4 of any channel card is an
opto-coupler input where 5-30Volts turn on the opto-coupler. This input is used mainly for the ZHM
series flowmeters distributed by the AW Company. The frequency return from a ZHM meter can be
directly connected to this input. Pin 3 is an adjustable threshold input. This input has the ability to be
adjusted to three different sensitivity levels. The highest level is 3.25Volts. This is used for signals that
have a amplitude swing from 3.5-50Volts maximum. This means that the incoming wave form must
have an amplitude of at least 3.25V (3.5V is better). If the signal source is less that 3.5V the threshold
has to be adjusted lower. The next lower threshold is 1.7V. The lowest threshold is mainly used for
inductive pick-ups. This threshold is set at 50mV. Refer to drawing EMO10904, Appendix F, for the
location of the sensitivity adjustment jumpers. The frequency input signal should always be referenced
to the ground connection (pin 2). Most applications require signal shielding. A solid aluminum wrap
shielding will work fine. The shield should be connected to pin 2 on the respective channel terminal.

Do NOT connect the shielding at the transmitter.

IMPORTANT! NEVER CONNECT THE SHIELD TO GROUND IN BOTH ENDS !
THAT COULD PRODUCE UNWANTED OSCILLATIONS IN THE SIGNAL WIRES!

GROUNDING CONSIDERATIONS

The grounding is the most important consideration in an installation where microprocessor technology
is applied. The EMO-1005 is a panel mounted unit and therefore the casing is connected to the
sub-panel. If the sub-panel is metal this should be grounded. This way the EMO-1005 housing is
grounded. If the sub-panel is non-conductive the rear panel terminal block for power supply, pin 1, can
be used for grounding.

In case of strong EMI (ElectroMagnetic Interference) it is recommended to use an EMI filter in the
110V/60Hz (220V/50- 60Hz) supply line. These filters can be purchased at any local electronic parts
supplier.

A few important hints:

- Always establish a solid ground in the installation.

- Place the EMO-1005 as close as possible to the central ground.

- Never pull the signal lines close to High-Voltage wires.

- Use shielding on all signal wires.

- Never plug an EMO-1005 in the same outlet with motor controls or lighting
circuits. A separate 110V line is recommended.

SIGNALS AND SHIELDING

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36

BACK PANEL DETAILS

Before hooking up the EMO-1005 it would be advisable to read this complete section.

The EMO-1005 consists of a POWER SUPPLY CARD and at least one CHANNEL CARD. The
regular EMO-1005 could be equipped to hold 4 CHANNEL CARDS. In the expanded chassis model
the case can hold as many as 14 Channel cards. The 5" units holds up to 4 channels, the 10" unit up to
12 channels, and the 15" unit up to 14 (15) channels. Looking from the rear into the unit the cards are
arranged as on drawing EMO10903, Appendix E. The EMO-1005 is a CMOS based computer. This
means the unit will draw very little power from the 110VAC line. A separate 20 Amp. line is
recommended for the unit although the power consumption will be less than 2 Amps.

The location next to the power supply card can only have the Channel 1 card installed.
The other locations are for channel 2 and up. Any of these channel card can be in any of these locations
and still work properly. But, it is advisable that channel 2 is next to channel 1 and so on. Doing this
will keep the channel numbers in order. If there is a question about the channel number designation of a
card, pull the card out of the chassis and read the label on top of the EPROM IC chip located on the
card (see drawing EMO10904, Appendix F, for location)

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37

EMO-1005 TROUBLESHOOTING

t

pply

p

pply

play

g

g

g

y p

g

p

g

q

g

Symptom

No display at all.

No dis

is ne

Analo

Analo

Zero reading on rate or total. LED on
channel card is blinking.

Zero reading on display. LED on channel
card is NOT blinking.

No frequency input reading on pin 4.
LED on channel card is NOT blinking.

No frequency input reading on pin 3
LED on channel card is NOT blinking.

Zero reading of both Rate and Total.

Wrong reading of Rate or Totalizer.

No Analog Input reading.

No Analog Output signal.

None of the Limit outputs are working

at all & Analog Output

ative

4-20 mA Output very High

5 V Output very High

The Power-supply card has live 110 VAC on the card.

Disconnect the power cord before opening the EMO-1005.

CAUTION!!!

Possible Cause

No 110 VAC power to uni

Blown main fuse in

three LED=s on su

+12 VDC/+5VDC supply fuse blown LED

D1 and D3 off

-12 VDC supply fuse blown, LED D2 OFF Check fuse F3

-12 VDC supply fuse blown, LED D2 OFF Check fuse F3

KFR or KFT set to Zero
KFR and KFT must NOT be Zero

Fault

Fre

Frequency amplitude too low
Try pin 3 input.

Sensitivity adjustment wrong.

Sample amount set to Zero
KFR set to Zero

KFR or KFT programmed wrong

Faulty wiring or sensor KFA set to Zero

Faulty wiring/receiver

Common connection on pin 15 missing/bad Check wiring

ick-up, wiring wron

uency amplitude too low

ower supply All

card OFF

Correction

Check 110 VAC Su

Check fuse F1

Check fuse F2

Correct KFR and KFT
Default KFR=100,
KFT=10000

Check

Wire from pickup is too lon

Pin 4 amplitude must be at
least 4.5 V p-p

Check jumper J10-J12 on
channel card.

Set Sample amount to more
than Zero (Default=8)

Check formula for KFT or
KFT
Check programmed value

Check Status display, if NOT
OK, check sensor/wiring.
Check with mA meter on pin

5. If NO reading, check
wiring/sensor.

Check wiring/receiver. Check
with Volt meter between pin
6 and pin 7. Over 12 VDC =
Output OK, but open current
loop (1-5 VDC = 4-20 mA)

ickup, Check wirin

Lost configuration Data
Display ΑRam and no Bat≅ at power-up

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RAM battery dead

Return to AW-Company for
repair

38

One of the Limits output is not working

Random number comes up when a
number is entered in programming mode.

Serial communication does not work.

External Wiring Wrong
Faulty Opto-coupler

The number entered is too large.

If only ONE EMO-1005 is used and an
offset value has been programmed.

Serial communication is turned off.

Echo turned ON, Baud rate wrong

If Status display is OK
Check external wiring

If Status display and
wiring is OK, return to
AW Company

Check programming
section for maximum
allowable number.

Offset must be set to Zero
when only one EMO-1005
is used.

Check Serial Port
Programming.

Three easy steps to check a system with an EMO-1005, a pickup and wiring in between.

1. With a paper clip, touch between pin 2 to pin 4 (or pin 3, if used) via the 15 pin connector
on the back of the EMO-1005, wiggle the clip and see if there are any pulses registered on the display.
If so, the EMO-1005 is working fine, go to step 2. If no pulses are registered, please call AW company
for technical assistance or return authorization.

2. Disconnect the pickup from its Amphenol connector, and use the paper clip between the A and C
holes on the connector. If wiring is OK, pulses should be registered on the EMO-1005 display. Go to
step 3. If no pulses, check the wiring from the connector to the EMO-1005.

3. Unscrew the pickup, and replace the connector. With a screw driver or any other ferrous
material move it in front of the pickup sensor, no more than 1/8" from the sensor. If pulses are
registered on the EMO-1005, check if the flowmeter is turning and if the pickup is screwed all the way
into the flowmeter. If no pulses are registered on the EMO-1005, the pickup is probably defective.

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LIMITED WARRANTY

AW Company warrants the EMO-1005 flow computer to be in good working order for a period of 1
(one) year from the date of purchase from AW Company or an authorized AW Company distributor.
Should the EMO-1005 fail to be in good working order at any time during this 1 year warranty period,
AW Company will, at its option, repair or replace the EMO-1005, at no additional charge except as set
forth below. Repair parts and replacement products will be furnished on an exchange basis and will be
reconditioned or new. All replaced parts and products become the property of AW Company. This
limited warranty does not include service to repair damage to the EMO-1005 resulting from accident,
disaster, abuse, or a Non-AW Company modification to the EMO-1005.

Limited warranty service may be obtained by delivering the EMO-1005 during the 1 year warranty
period to AW Company and proof of purchase date. If this product is delivered by mail, you agree to
insure the EMO-1005 or assume the risk of loss or damage in transit, to prepay shipping charges to the
warranty location and to use the original shipping container or equivalent.

Contact:
AW Company Phone: [phone]

8809 Industrial Dr. Fax: [phone]
Franksville, WI 53126

For further information.

ALL EXPRESS AND IMPLIED WARRANTIES FOR THIS PRODUCT INCLUDING THE
WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE
LIMITED IN DURATION TO A PERIOD OF 1 (ONE) YEAR FROM THE DATE OF PURCHASE,
AND NO WARRANTIES, WHETHER EXPRESS OR IMPLIED, WILL APPLY AFTER THIS
PERIOD. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED
WARRANTY LASTS, SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU.

IF THIS PRODUCT IS NOT IN GOOD WORKING ORDER AS WARRANTED ABOVE, YOUR
SOLE REMEDY SHALL BE REPAIR OR REPLACEMENT AS PROVIDED ABOVE. IN NO
EVENT WILL AW COMPANY BE LIABLE TO YOU FOR ANY DAMAGES, INCLUDING ANY
LOST PROFITS, LOST SAVINGS OR INCIDENTAL OR CONSEQUENTIAL DAMAGE ARISING
OUT OF THE USE OR INABILITY TO USE SUCH PRODUCT, EVEN IF AW COMPANY HAS
BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES, OR FOR ANY CLAIM BY ANY
OTHER PARTY.

THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE
OTHER RIGHTS WHICH MAY VARY FROM STATE TO STATE.

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40

QUICK REFERENCE KEY SEQUENCES

STATUS DISPLAY MODE

CHA -> DP -> ENT -> KFR

PROGRAMMING

CHANNEL MODE SELECTION

PROGRAMMING THE LINEARIZER

CHA -> 01, 02, etc = Channel Number

CHA -> DP -> ENT ->

SPC = Engineering Units

DP = Decimal Point

CHA

->

DP

->

ENT

CHA -> DP -> ENT -> DP

->

KF
A

LIM

SERIAL PORT PROGRAMMING

CHA -> DP -> ENT -> 1

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APPENDIX A

41

PROGRAMMABLE PARAMETERS

PARAMETER DEFAULT YOUR PROGRAMMED VALUE

RATE SCALING (KFR)

TOTALIZER SCALING

RATE LIMIT 1

RATE LIMIT 2

RATE LIMIT 3

RATE LIMIT 4

TOTAL LIMIT 1

TOTAL LIMIT 2

TOTAL LIMIT 3

TOTAL LIMIT 4

ANALOG GAIN (KFA)

OFFSET ANALOG OUT

SAMPLE AMOUNT

CUTOFF FREQUENCY

ANALOG IN GAIN

LINEARIZER ERR. POINT 01

LINEARIZER POI. POINT 01

LINEARIZER ERR. POINT 02

LINEARIZER POI. POINT 02

LINEARIZER ERR. POINT 03

LINEARIZER POI. POINT 03

LINEARIZER ERR. POINT 04

LINEARIZER POI. POINT 04

LINEARIZER ERR. POINT 05

LINEARIZER POI. POINT 05

LINEARIZER ERR. POINT 06

LINEARIZER POI. POINT 06

LINEARIZER ERR. POINT 07

LINEARIZER POI. POINT 07

LINEARIZER ERR. POINT 08

LINEARIZER POI. POINT 08

LINEARIZER ERR. POINT 09

LINEARIZER POI. POINT 09

LINEARIZER ERR. POINT 10

LINEARIZER POI. POINT 10

SERIAL PORT BAUD RATE

SERIAL PORT ECHO

SERIAL PORT ON/OFF

ADDRESS OFFSET

0000100.0

00010000

00000000

00000000

00000000

00000000

00000000

00000000

00000000

00000000

00000167

00000205

00000008

00000050

00000000

0000012.7

00000000

0000012.7

00000000

0000012.7

00000000

0000012.7

00000000

0000012.7

00000000

0000012.7

00000000

0000012.7

00000000

0000012.7

00000000

0000012.7

00000000

0000012.7

00000000

9600

OFF

OFF

000

APPENDIX B

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APPENDIX L: EMO-1005 WITH BUILT-IN PNAO

When the EMO-1005 is modified to have a built-in PNAO module, the following items need to be taken into consideration.

The PNAO modification allows the EMO-1005 to receive quadrature input flow-meter signals and provide a ± 5 volt output depending on flow
direction. The voltage output is scaled using the KFA. When calculating the KFA, assume +5 volts for maximum forward flow over a flow
range of 0-5 volts. When flow is reversed, the same KFA value is used to determine the zero to negative 5 volt scaling.

Pins 3 and 4 of the EMO-1005 receive the two frequency inputs, with pin 4 referred to as frequency A and pin 3 referred to as frequency B. If
the PNAO output is opposite of what is desired, simply switch the connections to pins 3 and 4 on the EMO-1005.

The PNAO modifications do not affect the flow rate or totalization calculations of the EMO-1005. The flow rate displayed has no direction
associated with it. For example, if the system is running 5 gpm in the reverse direction, the EMO-1005 will display 5 gpm, not -5 gpm.
Furthermore, totals counted from flow in the reverse direction are added, not subtracted, to the various totalizers such as the current total and
grand total.

It is recommended that the milli-amp output not be used on an EMO-1005 that has a built-in PNAO. This is because the modifications made
for the PNAO alter the milli-amp circuitry somewhat.

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