AW Gear Meters EMO-500 User Manual
EMO-500
TWO-COMPONENT RATIO MONITOR
OperaƟon & InstallaƟon Manual
Rev. 6
EMO-500
Operation and Programming Manual
Table of Contents
Safety Definitions and Information ............................................................................................................... 4
Unpacking ..................................................................................................................................................... 4
Quick Start Guide .......................................................................................................................................... 5
Connect to Flow Transmitters ................................................................................................................... 5
Connect Unit to Power .............................................................................................................................. 7
Overview of Display Screens ..................................................................................................................... 8
Product Description ...................................................................................................................................... 9
Features .................................................................................................................................................... 9
Principle of Operation ............................................................................................................................... 9
Technical Data ........................................................................................................................................... 9
Key Programming Features ....................................................................................................................... 9
Technical Information ............................................................................................................................... 9
Display Information................................................................................................................................. 10
Special Features ...................................................................................................................................... 10
Helpful Information For Using the EMO-500 .......................................................................................... 10
Sample Size ......................................................................................................................................... 10
Gate Time ............................................................................................................................................ 10
Serial Port Programming ..................................................................................................................... 10
Hardware Connections ............................................................................................................................... 11
Grounding Considerations ...................................................................................................................... 11
Signal and Shielding ................................................................................................................................ 11
External Resets and Controls (Hardware) ............................................................................................... 12
External Resets and Controls (Definitions) ............................................................................................. 13
Reset All .............................................................................................................................................. 13
Scroll Display ....................................................................................................................................... 13
Reset Job B - resets OFF-RATIO WARNING/ALARM (LIMIT 1 and 2) ................................................... 13
Reset Job A - resets OFF-RATIO WARNING/ALARM (LIMIT 1 and 2) .................................................. 13
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EMO-500
Operation and Programming Manual
Enable Full Programming .................................................................................................................... 13
Quick Programming .................................................................................................................................... 14
Activation ................................................................................................................................................ 14
Keys and Values ...................................................................................................................................... 16
F1 Ratio (Default Value = 1.00) ........................................................................................................... 16
F2 Gate Time (Default Value = 1.85) ................................................................................................... 16
F3 Warning (Default Value = 5%) ........................................................................................................ 16
F4 Alarm (Default Value = 10%) .......................................................................................................... 16
F5 DP (Decimal Point) ......................................................................................................................... 16
F6 Enter ............................................................................................................................................... 16
#0 Sample Size (Default = 200) ........................................................................................................... 16
#1 SG (Specific Gravity [Default = 1.0]) ............................................................................................... 16
Full Programming ........................................................................................................................................ 17
Enable ..................................................................................................................................................... 17
F1 ............................................................................................................................................................. 18
F2 ............................................................................................................................................................. 18
F3 ............................................................................................................................................................. 18
F4 ............................................................................................................................................................. 19
Off-Ration Warning and Alarm Settings ............................................................................................. 19
Adjust Limits 3 and 4 ........................................................................................................................... 20
F5 ............................................................................................................................................................. 22
F6 ............................................................................................................................................................. 24
Explanation of Global Variables .............................................................................................................. 24
1. KFR for A (Default 100.0) ............................................................................................................ 24
2. FT for A (Default 10000) .............................................................................................................. 25
3. KFR for B ...................................................................................................................................... 26
4. KFT for B ...................................................................................................................................... 26
5. Units for Rate. ............................................................................................................................. 26
6. Units for Total. ............................................................................................................................ 27
7. Sample Size (Default 200) ........................................................................................................... 27
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EMO-500
Operation and Programming Manual
8. Gate Time (Default 1.85 sec.) ..................................................................................................... 27
9. Analog Offset (Default 0000) ...................................................................................................... 28
10. Analog Gain (Default 10200) ................................................................................................... 28
11. Analog Rule (Default 06) ......................................................................................................... 29
12. Unit Number (Default 001) ..................................................................................................... 30
Default Values Throughout the EMO-500 .................................................................................................. 30
Ratio Programming ................................................................................................................................. 30
Limit Programming.................................................................................................................................. 30
Meters/Units Programming .................................................................................................................... 30
Global Variables ...................................................................................................................................... 30
Ratio Feedback Mode ................................................................................................................................. 31
Serial Port Operations ................................................................................................................................. 31
Protocol Format ...................................................................................................................................... 32
Checksum Calculation ............................................................................................................................. 33
Important Points for Serial Communication ........................................................................................... 34
Address Information ............................................................................................................................... 35
Appendixes .................................................................................................................................................. 39
Limited Warranty ........................................................................................................................................ 46
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EMO-500
Warning!
Caution
Notice
Caution
Operation and Programming Manual
Safety Definitions and Information
Do not attempt to install or use your AW Gear Meters product until you have read the safety
instructions in this section. Save this manual and keep it in an easily accessible place.
Warning means that failure to follow this safety statement may result in extensive product damage,
serious personal injury, or death.
Caution means that failure to follow this safety statement may result in minor or moderate personal
injury, property or equipment damage.
Notice is a statement that informs about installation, operation, maintenance, performance issues, or
general tips that are important but do not create a hazard or safety concern.
Unpacking
Separate the EMO-500 from packaging materials and check for any visual signs of damage. If you
determine there has been damage caused by shipping, file a claim with the shipping company. If the
flow monitor appears to have been improperly assembled or does not operate properly, return it for
replacement or repair (see Limited Warranty information at the end of this manual).
Before connecting, programming, or operating the EMO-500, read this manual.
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EMO-500
Caution
Notice
Notice
Operation and Programming Manual
Quick Start Guide
As with any precision-engineered device, always operate the EMO-500 in accordance with the
manufacturer’s instructions.
Connect to Flow Transmitters
You will connect three wires from each of the two sensors to the back of the EMO-500 (see samples next
page):
Insert the two red wires (electrical power) to the two +18 volt terminals
Insert the two white (signal) wires to the input terminals
Insert the two black (ground) wires to the ground terminals
Use a screwdriver to secure.
Color of wires may vary.
Connect the higher flow side to flow meter A as the Ratio calculation is A/B.
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EMO-500
Operation and Programming Manual
Figure 1: Sample pickup connections
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EMO-500
Warning!
Operation and Programming Manual
Connect Unit to Power
Before connecting to power source, connect ground, neutral and live wires to terminals on back of the
EMO-500 (see diagram below). See shielding information on page 11.
Connect wires to back of unit before applying power and wire the unit only as described on label on back
of unit.
Figure 2: Connections to power
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EMO-500
0-KEY = = =>
RATIOA/B = 1.19
W=Y A=N I = 1.00
= = => Current Ratio A/B
= = => Warning, Alarm, Ideal Ratio
1-KEY = = =>
FLW A=139.3 CCM
FLW B=136.3 CCM
= = = > Flow A
= = = > Flow B
2-KEY = = =>
JOB A=10779. CC
JOB B=11703. CC
= = = > Job Total A
= = = > Job Total B
3-KEY = = =>
GR A=300912. CC
GR B=313391. CC
= = = > Grand Total A
= = = > Grand Total B
4-KEY = = =>
J A+B 614303. CC
G A+B 623476. CC
= = = > Job Total (A+B)
= = = > Grand Total (A+B)
5-KEY = = =>
CURRENT RATIO LI
WAR=005% ALA=010%
= = = > Ratio Warning/Alarm Settings *
6-KEY = = =>
SD1: AO=0000
IN=11111OUT=0000
= = = > Analog Out, 0-4095 = 0-20mA
= = = > Inputs pins 1-5, Limits Out
7-KEY = = =>
SD2:FA=139FB=136
TA=10779TB=11793
= = = > Frequency A, B .....(Hz)
= = = > Total Impulses A, B
8-KEY = = =>
RATIO A/B=1.19
FL A+B 275.6 CCM
= = = > Current Ratio A/B
= = = > Flow Rate (A+B)
9-KEY = = =>
L1 L2 L3 L4
OFF OFF ON ON
= = = > Limit Status
F1-KEY ===>
T A-B= 24321. CC
F A-B= 15.4CCM
= = = > Total Differences
= = = > Flow Differences
*
Operation and Programming Manual
Overview of Display Screens
The 0 through 9, and F1 keys display these screens except when programming.
A no Ratio Mode when Limit 2 Rule is not on Ratio
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EMO-500
Operation and Programming Manual
Product Description
For use in steady or pulsing streams, the EMO-500’s primary purpose is to monitor the flow rates of two
flow meters, measuring flow rates, comparing totals, and verifying the ratio of flow A to flow B. You can
also wire an alarm to the EMO-500 so it can alert you to fluctuations from normal.
The unit comes from the factory with default values already programmed. However, if programming
parameters require change, you can input data from the front keypad; you can also do this from a
computer.
You can “Quick Program” the EMO-500, or take advantage of the Full Programming option. Program
keys are in red on the unit’s keyboard (some keys have a dual function). You can also program the EMO-
500 through the unit’s serial port. As a security measure, you can block access to programming when in
the Full and Serial Port programming modes.
Features
Seven different totalizers for record keeping and reports
Nine programmable units of measure
Net consumption display
“Ready-to-Hardwire” function controls allow for remote resets, operation of displays, and
Quick/Full Programming
Four programmable relay switched limits for warnings, alarms, or automatic shut-down control
RS-232 and RS-485 serial ports
Analog outputs (4 - 20mA) and (0 - 5V)
Principle of Operation
After you connect two flow meters to the unit and power it up, the EMO-500 can begin monitoring flow,
totals, and ratios. Monitor data on-screen; fine tune and adjust programming parameters as needed.
Technical Data
Key Programming Features
Ideal Ratio: user-defined, compared to actual ratio
Gate Time: time-before-the-flow rate display updates
Sample Size: number of pulses counted before ratio updates
Limits: Ratio, Flow Rate and Total
Units of Measure: liter, cc, gal, oz, gr, kg, lb, rpm, Hz
Technical Information
Power Supply: input = 110 or 220 VAC; consumption = 4 watts
Communication: type = RS-232 and RS-485; protocol type similar to OPTO 323
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EMO-500
Operation and Programming Manual
Environmental: storage = -40°C to 85°C; operating = 0°C to 50°C; humidity = 10 to 90%, non-
condensing
Limits: 10 amp, 110 V dry contact relays
Display Information
Ratio (ideal): Flow Rate A, Job Total A, Grand total A
Ratio (actual): Flow Rate B, Job Total B, Grand Total B
Limit Settings: Flow Rate A+B, Job Total A+B, Grand Total A+B
Limit Status: Flow Rate A-B, Job Total A-B
Special Features
The EMO-500 is geared toward applications where the main interest is the ratio of components
dispensed over a period of time, for example in a batch, rather than monitoring on an instantaneous
basis. The unit is especially suited for use in dispensing systems with irregular flow patterns. The EMO500 features a programmable sampling size, which governs how often the ratio display updates and
provides maximum control over the sampling period. The EMO-500 is easy to adjust to suit system
parameters.
Helpful Information For Using the EMO-500
Sample Size
This is the number of impulses collected for the ratio calculation. To determine the ratio, the EMO-500
separately counts the total number of pulses from both flowmeters until the fastest one reaches the
SAMPLE SIZE. The EMO-500 divides the number of pulses flowmeter A produces by flowmeter B’s
pulses, and the result is the ratio. The accuracy and response time of the ratio calculation is therefore
dependent upon the SAMPLE SIZE. The flowmeter with the lowest pulse rate should produce 100 pulses
before the ratio calculation updates to achieve a 1% accuracy. Default value is 200. The display screen
#7 is a useful guide for this purpose.
Gate Time
This is the time period over which the EMO-500 makes Rate Calculations. The gate time (in seconds) is
the time period during which the microprocessor collects pulses to perform rate calculations. Default
value is 1.85.
Serial Port Programming
You can program the EMO-500 through the serial port using RS-232- or RS-485-type communication.
Refer to the Serial Port Operations on page 31 for complete information.
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EMO-500
Warning!
Operation and Programming Manual
Hardware Connections
Before connecting to power source, connect ground, neutral and live wires to terminals on back of the
EMO-500: PIN 1= ground, PIN 2 = line 110 or 220 V, and PIN 3 = line neutral (see Figure 3).
Wire the AC power only as labeled on the three pin connector.
Figure 3: Connections to power
Grounding Considerations
The grounding is a most important consideration in an installation where microprocessor technology is
applied. The EMO-500 is a panel-mounted unit where the casing connects to a sub-panel. If the
sub-panel is metal, it should be grounded. If the sub-panel is made of non-conductive material, PIN 1 of
the three-pin connector on the EMO-500 back panel must be grounded. To insure a proper ground, the
factory recommends connecting PIN 1 of the three-pin connector to the panel's central ground point.
Signal and Shielding
The two flow meter pickups should be supplied with their respective 18-volt supply voltages and
referenced to their respective grounds. This insures the input signals from the flow meters are
referenced to the ground connections on pins 2 and 5. Most applications require some signal shielding;
a solid-aluminum wrap shielding works well. Connect the shield to pins 2 and 5 on the flow meter
connector. DO NOT connect the shielding at the flow transmitter.
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EMO-500
Figure 4: Connecting five inputs to common
Caution
Figure 5: Pin 1-4 and Pin 5 connections
Operation and Programming Manual
Never connect the shield to ground at both ends. Doing so can produce unwanted oscillations in the
signal wires.
External Resets and Controls (Hardware)
Five inputs to the 15-pin connector help provide extra control without having to go through the
keyboard. To activate the external resets and controls, connect the respective pin to the “Common for 1
– 5” pin. See Figure 4.
Pins 1 - 4 are edge-triggered; use
momentary contact switches to activate
them. Pin 5 (enable programming) is an
on/off function; use a single-pole toggle
switch for it. See Figure 5.
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EMO-500
Notice
Notice
Operation and Programming Manual
External Resets and Controls (Definitions)
Reset All
This reset is the most powerful on the EMO-500. It resets:
Ratio A/B
Job Vol A, Job Vol B and Job Vol A+B
Warning and Alarm Limits
Limits 3 and 4
Grand Totals
Analog Outputs to start point
Scroll Display
This input scrolls through all of the 11 screens available. It also allows access to the Quick Programming
functions, which are highlighted in red on the upper keypad line. (See page 14 for more details on Quick
Programming).
Reset Job B - resets OFF-RATIO WARNING/ALARM (LIMIT 1 and 2)
This input resets the Job B totalizer. It also resets the A/B RATIO to the IDEAL setting, which
simultaneously resets the WARNING and ALARM LIMITS.
Reset Job A - resets OFF-RATIO WARNING/ALARM (LIMIT 1 and 2)
This resets the Job A total. It also resets the A/B RATIO to the IDEAL setting, which simultaneously resets
the WARNING and ALARM LIMITS.
Simultaneously pressing and holding RESET JOB A and RESET JOB B on the keyboard, or through the
back-panel connections, actuates HOLD TOTAL.
Enable Full Programming
Enables the F2 through F6 keys to perform the programming functions shown in red on the banner strip
above the keypad.
F3, F4, and F5 serve as Job Resets in the Job Totals screen when the Enable Programming switch is OFF.
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EMO-500
Figure 6: Quick Programming Display Screens
†
Notice
Operation and Programming Manual
Quick Programming
Many programming variables such as KFR† or meter selection only require a "one time" setting; other
variables require some experimentation to find maximum efficiency settings. It is also desirable to allow
field personnel the limited ability to make some quick adjustments.
To accommodate these circumstances the EMO-500’s "Quick Programming" option allows you to jump
directly into some limited programming functions. These functions are noted in red on the keypad on
the top line of function keys F1 through F6, and the 0 and 1 keys (also see Figure 6). The keys and their
functions are:
F1 = Ideal Ratio
F2= Gate Time
F3 = Ratio Warning %
F4 = Ratio Alarm %
F5 = Decimal Point
F6 = Enter
0 = Sample Size
1 = Specific Gravity
Activation
To activate Quick Programming, connect the Scroll Line Input (Pin 2) and the “Common 1 – 5” (Pin 6) of
the 15-Pin connector on the back panel of the EMO-500 with a momentary contact switch. With this
connection established, push any one of the above keys.
This does not work if full programming is enabled.
A rate scaling factor.
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