Cameron Nuflo Mc-iii EXP User Manual
NUFLO
TM
MC-III™ EXP
Flow Analyzer
User Manual
Manual No. 9A-50165003, Rev. 02
NuFlo and MC-III are trademarks of Cameron.
Modbus is a registered trademark of the Modbus Organization, Inc.
Windows is a registered trademark of Microsoft Corporation.
Acrobat Reader is a registered trademark of Adobe Systems Incorporated.
© 2008 Cameron International Corporation (“Cameron”). All information contained in this publication is
condential and proprietary property of Cameron. Any reproduction or use of these instructions, drawings,
or photographs without the express written permission of an ofcer of Cameron is forbidden.
All Rights Reserved.
Printed in the United States of America.
Manual No. 9A-50165003, Rev. 02
September 2008
MC-III™ EXP Flow Analyzer Table of Contents
Contents
Section 1—Introduction ................................................................................................................................... 1
Operation ............................................................................................................................................................ 1
Key Product Features ........................................................................................................................................ 3
LCD Display ................................................................................................................................................. 4
Keypad ......................................................................................................................................................... 4
Interface Software ........................................................................................................................................ 6
Power Supply ............................................................................................................................................... 6
Multipoint Linearization ................................................................................................................................ 6
Gas Volume Correction ................................................................................................................................ 6
Input Options ................................................................................................................................................ 6
Output Options ............................................................................................................................................. 6
Flow Log Archival ........................................................................................................................................ 7
Event Log Archival ...................................................................................................................................... 7
Password-Protected Security ....................................................................................................................... 7
Optional Features ............................................................................................................................................... 7
Explosion-Proof Reset/Control Switch ......................................................................................................... 7
Explosion-Proof Communications Adapter .................................................................................................. 7
RS-485 IS Barrier ......................................................................................................................................... 8
Commonly Used Functions ................................................................................................................................ 8
Reading Totals ............................................................................................................................................. 8
Saving Totals to Memory .............................................................................................................................. 8
Resetting the Total ....................................................................................................................................... 8
Viewing Daily and Hourly Logs .................................................................................................................... 9
Saving and Uploading Conguration Files ................................................................................................... 9
Exporting Log Data ...................................................................................................................................... 9
Saving Log Data in a Report ........................................................................................................................ 9
Section 2—Installation ....................................................................................................................................11
Preparation ........................................................................................................................................................11
Connection to the Flowmeter.............................................................................................................................11
Instrument Dimensions ..................................................................................................................................... 12
Field Wiring Connections.................................................................................................................................. 13
Power Supply Wiring ........................................................................................................................................ 14
Internal Power Supply ................................................................................................................................ 14
External Power Supply .............................................................................................................................. 14
Input Wiring ...................................................................................................................................................... 15
Turbine Flowmeter (TFM) Input ................................................................................................................. 15
Pulse Input ................................................................................................................................................. 15
Remote Reset Input ................................................................................................................................... 16
Output Wiring.................................................................................................................................................... 17
Pulse Output ............................................................................................................................................. 17
Analog (4-20 mA) Rate Output ................................................................................................................. 17
Flowmeter Frequency Output .................................................................................................................... 18
RS-485 Output ........................................................................................................................................... 19
Section 3—Conguration and Operation via Keypad ................................................................................. 23
Entering a Calibration Factor ........................................................................................................................... 24
Entering a Calculated Divisor ........................................................................................................................... 25
Setting Input Type and Sensitivity .................................................................................................................... 26
Conguring the Total Display ............................................................................................................................ 27
i
Table of Contents MC-III™ EXP Flow Analyzer
Conguring the Rate Display ............................................................................................................................ 28
Conguring the 4-20 mA Rate Output .............................................................................................................. 29
Conguring the Pulse Output ........................................................................................................................... 32
Entering the Slave Address .............................................................................................................................. 33
Entering the Baud Rate .................................................................................................................................... 33
Section 4—Conguration and Operation via Software ............................................................................... 35
Installing the Software ...................................................................................................................................... 35
Accessing Help ................................................................................................................................................. 35
Connecting to the Software .............................................................................................................................. 36
Automating Functions on Software Startup ............................................................................................... 37
Changing Autorun Settings ........................................................................................................................ 38
Express Connect Option ............................................................................................................................ 38
Changing the Communications Port .......................................................................................................... 39
Software Connection in Multi-Device Network ........................................................................................... 39
Setting Log Download Preferences .................................................................................................................. 41
Conguring the MC-III EXP .............................................................................................................................. 42
Conguration Wizard ................................................................................................................................. 44
MC-III Main Screen .................................................................................................................................... 46
Buttons and Tools....................................................................................................................................... 47
Conguration Submenus (See Scroll Bar on MC-III Main Screen) ........................................................... 48
Conguration Submenus (cont’d) .............................................................................................................. 49
System Setup ................................................................................................................................................... 50
Time/Date Synchronization ....................................................................................................................... 50
Contract Hour ............................................................................................................................................. 50
LCD Contrast Adjustment .......................................................................................................................... 50
Security Setup ............................................................................................................................................ 51
Firmware Version Number ......................................................................................................................... 51
Serial Number ............................................................................................................................................ 51
Communications Port ....................................................................................................................................... 51
Slave Address ............................................................................................................................................ 51
Baud Rate ................................................................................................................................................. 52
Bus Delay ................................................................................................................................................... 53
Bus Timeout ............................................................................................................................................... 53
Software Communication Options ............................................................................................................. 53
Wellsite Information .......................................................................................................................................... 53
Turbine Input .................................................................................................................................................... 54
Volume Display .......................................................................................................................................... 54
Rate Display ............................................................................................................................................... 54
Input Type and Sensitivity Conguration .................................................................................................... 55
Cut-Off Thresholds ..................................................................................................................................... 55
Calculation Period ...................................................................................................................................... 55
K-Factor Entry .................................................................................................................................................. 56
K-Factor Units ............................................................................................................................................ 56
K-Factor Type............................................................................................................................................. 56
K-Factor Backup ........................................................................................................................................ 57
Gas Volume Correction (Supercompressibility Calculation) ...................................................................... 58
4-20 mA Output ................................................................................................................................................ 60
Enabling 4-20 mA Output .......................................................................................................................... 62
4-20 mA Output Testing.............................................................................................................................. 62
Pulse Output ..................................................................................................................................................... 63
Conguring Pulse Output ........................................................................................................................... 64
Pulse Output Testing .................................................................................................................................. 65
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MC-III™ EXP Flow Analyzer Table of Contents
Saving and Uploading Conguration Files ....................................................................................................... 66
Saving a Conguration File ........................................................................................................................ 66
Uploading a Conguration File ................................................................................................................... 67
Advanced Access ............................................................................................................................................ 69
Section 5—Flow Logs and Event Logs ........................................................................................................ 71
Auto-Save Log Formats.................................................................................................................................... 71
Log Directory and Filenames............................................................................................................................ 72
Flow Archive ..................................................................................................................................................... 72
Downloading Flow Logs ............................................................................................................................. 73
Viewing Trend Charts ................................................................................................................................. 75
Printing/Saving a Report ............................................................................................................................ 75
Viewing a Saved Report............................................................................................................................. 77
Exporting Flow Logs ................................................................................................................................. 79
Event Archive.................................................................................................................................................... 80
Downloading Event Logs ........................................................................................................................... 81
Printing/Saving a Report ............................................................................................................................ 82
Exporting Event Logs ................................................................................................................................ 82
Section 6 - MC-III EXP Maintenance .............................................................................................................. 85
Lithium Battery Replacement ........................................................................................................................... 85
Alkaline Battery Replacement .......................................................................................................................... 87
Circuit Assembly Replacement ......................................................................................................................... 89
Keypad Replacement ....................................................................................................................................... 91
Firmware Update .............................................................................................................................................. 92
Spare Parts List ................................................................................................................................................ 93
Optional Parts List ............................................................................................................................................ 93
Appendix A—MC-III EXP Hardware Options ...............................................................................................A-1
Explosion-Proof Reset/Control Switch.............................................................................................................A-1
Explosion-Proof Communications Adapter ......................................................................................................A-3
Appendix B—Software Program Options ...................................................................................................B-1
General Options ..............................................................................................................................................B-1
Autorun Options...............................................................................................................................................B-2
Communications Options ................................................................................................................................B-3
Express Connect Option ...........................................................................................................................B-4
Auto-Negotiate Option ..............................................................................................................................B-4
Enable Auto-Negotiated Baud Rate Option ..............................................................................................B-4
Request-to-Send (RTS) Line Option ......................................................................................................... B-4
Enable Modbus Address Support for Firmware Versions 1.06 through 1.08 ............................................B-4
Timing Parameters ....................................................................................................................................B-4
Downloading Options ......................................................................................................................................B-5
Advanced Options ........................................................................................................................................... B-6
Clear EEPROM ......................................................................................................................................... B-6
Automatic Data Logging ............................................................................................................................B-6
Appendix C—Lithium Battery Information ..................................................................................................C-1
Lithium Battery Disposal .................................................................................................................................C-1
Transportation Information ..............................................................................................................................C-1
Material Safety Data Sheet..............................................................................................................................C-1
iii
Table of Contents MC-III™ EXP Flow Analyzer
Appendix D—Communications Protocol ....................................................................................................D-1
Introduction ......................................................................................................................................................D-1
Supported Commands.....................................................................................................................................D-1
Data Types ......................................................................................................................................................D-1
Registers ........................................................................................................................................................D-2
System Conguration ................................................................................................................................D-3
Product Code (register 1000) ....................................................................................................................D-4
Firmware/Register Table Version Numbers (registers 1001, 1002) ..........................................................D-4
Manufacture Date/Sales Date (registers 1003, 1004) ...............................................................................D-4
Slave Address (register 1009) ...................................................................................................................D-4
Baud Rate (register 1010) .........................................................................................................................D-4
Real Time ..................................................................................................................................................D-5
Input Conguration ....................................................................................................................................D-5
Output Conguration .................................................................................................................................D-8
Holding Registers (16-bit Mode) ...............................................................................................................D-9
Base Units/Congured Units ................................................................................................................... D-11
Conversion Factors ................................................................................................................................. D-11
Polling Registers ..................................................................................................................................... D-11
Pointer/Daily/Event Pointer (registers 17001 through 17006) .................................................................D-11
Real Date (registers 17007, 17008) ........................................................................................................ D-11
Real Time (registers 17009, 17010) ........................................................................................................D-12
Totals ......................................................................................................................................................D-12
Pulse Output Pulses (register 17077) .....................................................................................................D-12
Analog Output Current (register 17079) ..................................................................................................D-12
Calculated K-Factor (register 17081) ......................................................................................................D-12
Holding Registers (32-bit Mode) .............................................................................................................D-12
Control Register ......................................................................................................................................D-14
Wellsite Parameters ................................................................................................................................D-15
Log Data .................................................................................................................................................D-15
Enron Registers ......................................................................................................................................D-16
Enron Hourly/Daily Record Format .........................................................................................................D-16
Enron Event Record Format ...................................................................................................................D-16
Reset Status ...........................................................................................................................................D-17
Log Capacity ...........................................................................................................................................D-17
iv
MC-III™ EXP Flow Analyzer Section 1
Section 1—Introduction
The NuFlo™ MC-III™ EXP Flow Analyzer (Figure 1.1) packs a full spectrum of gas and liquid measurement
functionality, high-speed performance, and log archive and retrieval capabilities in an easy-to-use, explosionproof totalizer. Commonly used operations can be accessed from the six-button keypad on the front of the
instrument or from the dynamic interface software, allowing you to calibrate and congure the unit quickly
and easily.
Operation
The MC-III EXP calculates and displays
instantaneous ow rates and accumulated totals
based on a turbine owmeter input signal. The
MC-III’s microprocessor circuitry counts the
pulses generated by a companion owmeter,
converts that data into volume and rate values
in accordance with calibration settings, and
displays the totalized data on a two-line liquid
crystal display (LCD). The eight-digit top readout
indicates total ow volume; the six-digit bottom
readout indicates ow rate.
With the press of a single key, totals are saved to
nonvolatile memory, minimizing the risk of data
loss even if a power outage occurs.
Up to 384 daily logs, 768 hourly logs, and 345
event logs can be archived and accessed quickly
on demand.
Offering a variety of user-congurable display
options, input and output options, RS-485
Modbus® compatibility, ow logging, and turbine
owmeter linearization, the MC-III EXP is one
of the most versatile totalizers on the market. For
specications, see Table 1.1, page 2.
An optional explosion-proof reset switch further
expands the unit’s versatility, making it possible
to reset the total and view daily ow logs without
opening the enclosure.
Figure 1.1—MC-III EXP ow analyzer
1
Section 1 MC-III™ EXP Flow Analyzer
Table 1.1—MC-III EXP Specications
Enclosure CSA-approved for US and Canada
Class I, Div. 1, Groups B, C, D (explosion-proof)
Type 4 enclosure
T6 temperature class
System Power Internal power supply
3.6 VDC, D-size lithium battery (2-year typical life)
•
alkaline battery pack containing 3 C-size industrial-grade batteries
•
External power supply (6 to 30 VDC) with internal battery backup (reverse
polarity protected)
Loop-powered (4-20 mA) with internal battery backup
(reverse polarity protected)
Loop power: 8 to 30 VDC
Load resistance: 1100 ohms @ 30 VDC; 200 ohms @ 12 VDC
Operating Temperature Lithium-Powered: -40°C to 70°C (-40°F to 158°F)
Alkaline-Powered: -18°C to 55°C (0°F to 130°F)
LCD contrast is reduced below -20°C (-4°F)
LCD Display 8-digit Total (volume) display (7-segment characters)
6-digit Rate display (11-segment characters for easy-to-read prompts)
0.3” character height
Adjustable contrast and update period
User-selectable units of measurement (Total):
Preprogrammed units: BBL, GAL, LIT, M3, CF, SCF, any unit x 1000
•
User-dened units
•
User-selectable units of measurement (Rate):
Preprogrammed units: BBL, GAL, LIT, M3, CF, SCF (per DAY, HR,
•
MIN, SEC), any unit x 1000 (per DAY, HR, MIN, SEC)
User-dened units
•
Keypad 6-key membrane switch
Communications/
Archive Retrieval
Logging 384 daily logs
Inputs Turbine Meter Input
RS-485 Modbus® communications with transfer speeds up to 115.2K (allows
full download in less than 1 minute)
768 hourly logs
345 event logs
Congurable sensitivity adjustment via front panel
Sensitivity adjustment range: 20 mV P-P to 40 mV P-P
Frequency range: 0 to 3500 Hz
Remote Reset Input
Optically-isolated input
3.0 to 30 VDC
Pulse duration > 3 seconds to reset
Explosion-Proof Reset Switch (option)
Press and hold > 3 seconds, then release to reset total
Press and hold < 1 second, then release to view daily log data
2
MC-III™ EXP Flow Analyzer Section 1
Table 1.1—MC-III EXP Specications
Inputs (cont’d) Pulse Input
Optically-isolated input
3.0 to 30 VDC
Outputs Analog Output
4-20 mA, loop-powered (two-wire)
16-bit resolution
Accuracy: 0.1% of full scale @ 25°C, 50 PPM/°C temperature drift
Loop power: 8.0 to 30 VDC
Zero and full-scale engineering values congurable from front panel
RS-485 Communications
Baud rates: 300, 600, 1200, 2400, 4800, 9600, 19200, 38400, 57600 and up
to 115.2K
Volumetric Pulse Output
Solid-state relay
Output rating: 60 mA max. @ 50 VDC, on-state drop = 1.4 VDC @ 50 mA,
0.25 VDC @ 10 mA
Congurable pulse width (duration): 10 to 60,000 ms
Amp & Square (Flowmeter Frequency) Output
Open-drain transistor output of turbine meter input signal
Output rating: 50 mA @ 30 VDC, on-state drop = 0.3 VDC @ 50 mA,
0.1 VDC @ 10 mA
(Analog output and amp & square outputs cannot be used simultaneously.)
Modbus
Enron Modbus
System Requirements Operating System - Windows 2000 or later (Windows XP recommended)
®
®
RTU mode Modbus® supports 16-bit and 32-bit holding registers. For more
information, see Appendix D.
Flow log parameters (time stamp, period total, period run time, and supply
voltage) and download method are Enron-compatible.
Computer/Processor - 1 GHz or faster Pentium-compatible CPU
Memory - 128 MB of RAM
Hard Disk Space - 21 MB for program les, 30 MB for Adobe Reader,
adequate space for data les
Drive - CD-ROM for install
Display - 800 x 600 (SVGA), 16-bit (thousands of colors) color display or
greater
Browser - Internet Explorer 4 or later
Internet Connection - for web links, tech support
Communications Port - physical or virtual RS-232 compatible serial port
Key Product Features
This section presents an overview of key features of the MC-III EXP. Many of these features are discussed in
more detail in Sections 3 and 4 (conguration procedures) and Section 5 (ow log archival).
Key features discussed here include:
LCD display
•
keypad
•
interface software
•
3
Section 1 MC-III™ EXP Flow Analyzer
power supply
•
calibration options
•
input options
•
output options
•
ow log archival
•
password-protected security
•
explosion-proof reset switch (option)
•
RS-485 IS barrier (option)
•
LCD Display
The liquid crystal display (Figure 1.2, page 5) provides a simultaneous indication of accumulated total (top
readout) and ow rate (bottom readout). The eight-digit total display uses 7-segment characters to form
numbers and letters, which results in a combination of uppercase and lowercase letters. The six-digit ow rate
display uses 11-segment characters to form numbers and letters for improved readability. When the keypad
is used to calibrate the MC-III EXP, the name of the menu option selected appears in the lower (rate) display,
and settings are entered in the top (total) display.
Flow volume can be measured in barrels, gallons, liters, cubic meters, cubic feet, standard cubic feet or other
user-dened units. A multiplication factor is also available for indicating ow volume in terms of 1,000 units.
The unit of measure for the Total readout and the decimal point position are selected by the operator during
calibration. If a user-dened unit is used, none of the preprogrammed volume units will be visible on the
display during operation.
Flow rate can be measured in a wide variety of preprogrammed units, or other user-dened units. The ow
rate unit of measure is selected in two steps: (1) a volume unit is chosen and (2) a time-base unit (per day, per
hour, per minute, or per second) is chosen. Users can choose any combination of preprogrammed volume and
time units in establishing the ow rate engineering unit (for example, gallons per hour, gallons per day, or
gallons per minute). Also, the volume unit used for the ow rate can be different from the volume unit used to
read Total volume. The unit of measure for the Rate readout and the decimal point position are selected by the
operator during calibration.
The daily index (Day) display is a two-digit number for selecting a daily archive log for viewing. The number
shown here represents the number of days that have passed since the log was saved. For example, an entry of
01 would yield yesterday’s log. An entry of 05 would yield the log generated 5 days ago. Up to 99 consecutive
daily logs can be viewed using the keypad. In addition, up to 384 daily logs, 768 hourly logs, and 345 event
logs can be viewed through the interface software.
The LCD contrast can be adjusted with the interface software (see Section 4).
Keypad
The six-button keypad allows users to perform a basic conguration of the instrument. Figure 1.3, page
5, summarizes the functions that can be accessed with each button. Most parameters can be congured in
seconds by selecting one of the three menu keys (K-Factor, Output, or Display), navigating settings with the
arrow buttons, and saving the selections with the Enter key.
Section 3 contains procedures for conguring the MC-III EXP using the keypad. Icons of the six buttons
provide a pictorial reference to help guide users through each step of conguration.
4
MC-III™ EXP Flow Analyzer Section 1
00000000
000000
M
3
BBL
GAL
LIT
M
3
BBL
GAL
LIT
/SEC
/MIN
/HR
/DAY
CF
CF
X1000
X1000
STANDARD
00
Day
Total
Rate
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Calibrate instrument
Set flowmeter input sensitivity
Select pulse input
Enable/disable/set up 4-20 mA output
pulse output
Enter slave address
Enter baud rate
Enable/disable/set up
Set engineering units for Total readout
Set engineering units for Rate readout
Set decimal placement for both readouts
During calibration, navigates
between submenus and scrolls
through menu selections
During operation, accesses
daily volume archive
During calibration, incrementally
changes digits and decimal point
position, on/off settings
During operation, tests temperature
and system voltage
During calibration, saves
calibration settings
During operation, saves
Total to nonvolatile memory
Note: To zero the Total
readout, press the LOG (left
arrow) and SAVE (ENTER)
keys simultaneously.
Important: Some conguration parameters are accessible only through the interface software. See
Section 4 for instructions on conguring the instrument using the software.
Figure 1.2—LCD display showing location of the Total, Rate, and daily index (Day) displays. Only the units of
measurement selected for displaying total and rate will be visible during normal operation.
Figure 1.3—MC-III EXP keypad functions
5
Section 1 MC-III™ EXP Flow Analyzer
Interface Software
Developed within the familiar Windows environment, the MC-III interface software is an intuitive and
easy-to-use application that provides access to all controls for setting up and operating the instrument. The
interface tailors the controls to the user’s needs, providing three options for conguring the instrument:
a “Conguration Wizard,” which steps through the most common conguration tasks
•
individual conguration menus for accessing specic settings
•
an advanced menu that gives host programmers access to Modbus® registers
•
For instructions on installing the interface software and entering conguration parameters via the interface
software, see Section 4.
Power Supply
The MC-III EXP is shipped with either a lithium battery or an alkaline battery pack. Alternately, the MC-III
EXP may be powered by an external power source; in this case, the lithium battery or alkaline battery pack
provides a backup power supply, signicantly extending battery service life. Low-power microprocessor
technology enables the MC-III EXP to operate approximately 2 years on a single lithium battery.
Wiring diagrams for connecting an external power supply are provided in Section 2.
Multipoint Linearization
The MC-III interface software supports up to 12 calibration points in addition to single-point calibration based
on the K-factor provided with the turbine owmeter. See K-Factor Type, page 56, for more information.
Gas Volume Correction
Gas turbine meters are calibrated in actual cubic feet (ACF), and measure gas in actual cubic feet. In some
applications, a user may benet from referencing gas measurements back to standard conditions by measuring
in terms of standard cubic feet (SCF). The MC-III EXP makes this process quick and easy, by using xed
average values for the owing gas temperature and owing gas pressure. See Gas Volume Correction, page
58, for more information.
Input Options
The owmeter signal can be obtained from a magnetic pickup or a pre-amplier device. The sensitivity of
the owmeter input may be adjusted with the instrument keypad or the interface software. See Section 2 for
wiring diagrams. See Sections 3 and 4 for conguration procedures.
Output Options
The MC-III EXP standard circuitry provides:
a scaled pulse output representing an increment in volume for each pulse
•
a loop-powered 4-20 mA output representing the ow rate
•
a owmeter frequency output for use with remote equipment to derive ow rate and volume
•
an RS-485 output for communication with interface software or other telemetry equipment
•
When the 4-20 mA rate output feature is used, the MC-III EXP is powered by the current loop, and the lithium
battery or alkaline battery pack is used as a backup supply.
The pulse output and 4-20 mA output features should be turned off when not required for reduced current
consumption. See Section 2 for wiring diagrams. See Sections 3 and 4 for conguration procedures.
6
MC-III™ EXP Flow Analyzer Section 1
Flow Log Archival
The MC-III EXP saves up to 384 daily logs and 768 hourly logs in nonvolatile memory. By connecting with
the interface software, users can download the logs for viewing and/or printing in tabular format or in a trend
chart.
Users can also export daily and hourly logs to a spreadsheet. For more information, see Section 5.
Event Log Archival
The MC-III EXP saves up to 345 user event logs. Event logs are generated to track user changes such as K-
Factor changes, input setting changes, power-on reset and “watch-dog” reset, ow cut-off and frequency cut-
off.
By connecting with the interface software, users can download the logs for viewing and/or printing in tabular
format. In addition to showing old and new values, each event log is time-stamped, and includes the register
associated with the change. For more information, see Section 5.
Password-Protected Security
A keypad security access code prevents unauthorized personnel from altering the calibration or accumulated
volume data in the instrument. The security feature may be disabled if this protection is not required.
Password-protected security access is enabled using the interface software. When this feature is enabled,
the user will be prompted for a password when attempting to enter any menu from the keypad. For more
information, see Security Setup, page 51.
Optional Features
Explosion-Proof Reset/Control Switch
An optional external reset/control switch can be mounted in either of the conduit openings near the top of
the MC-III EXP enclosure, allowing the user to zero the total and view daily logs instantaneously without
opening the enclosure or accessing the interface software. When the switch assembly is ordered with an MCIII EXP, it is factory installed. When ordered separately, the switch assembly is easily installed using the
instructions provided in this manual. For installation and wiring instructions, see Appendix A.
Zeroing the Total. To reset the total with an explosion-proof switch, press and hold the switch for 3 seconds,
then release it.
Important: When resetting the total with the explosion-proof reset switch, do not release the switch
prematurely. Releasing the switch too quickly (before 3 seconds have passed) will
activate the daily log view function and WILL NOT reset the volume to zero.
Viewing Daily Logs. To view daily logs with the explosion-proof switch, press the switch for 1 second
and release it. Subsequent press-and-release actions increment the daily index, allowing the user to select
a specic daily total. Additionally, when the log viewing function times out, the accumulated total is
automatically saved to memory.
Saving the Total. When the daily log display times out, the MC-III EXP will automatically save the
accumulated total.
Explosion-Proof Communications Adapter
An explosion-proof communications adapter provides an RS-485 connection for connecting a laptop or PC
to the instrument without removing the instrument cover. When the adapter is ordered with an MC-III EXP,
7
Section 1 MC-III™ EXP Flow Analyzer
it is factory installed. It may be relocated to either conduit opening in the instrument housing. When ordered
separately, the adapter is easily installed using the instructions provided in this manual. For installation and
wiring instructions, see Appendix A.
RS-485 IS Barrier
The MC-III EXP’s RS-485 output is approved for intrinsically safe installations. An intrinsically safe barrier
assembly with a conduit seal enables the RS-485 output to be used as an intrinsically safe output. In such
installations, only the turbine owmeter input may be used. See Figure 2.15 (page 21) for an IS barrier
assembly wiring diagram.
Commonly Used Functions
While the functions of the MC-III EXP are too numerous to mention, some of the most commonly used
functions are detailed in this section. They include:
reading the rate and accumulated total
•
saving totals to memory
•
resetting the total
•
viewing daily and hourly logs
•
saving and uploading conguration les
•
exporting log data to spreadsheet
•
saving log data in a report
•
Reading Totals
Current totals can be viewed from the LCD on the front of the MC-III EXP or from the interface software
(MC-III Main screen). The software calculates the ow total and updates the LCD display every 4 seconds, by
default. The user can adjust the calculation period with the interface software. See Calculation Period, page
55, for more information.
Saving Totals to Memory
Hourly and daily totals are automatically saved to nonvolatile memory. A user may also save an accumulated
total at any time by opening the enclosure and pressing ENTER (SAVE) on the keypad. In the event of a
power failure, the last saved total will be displayed on the LCD when power is restored. See also Explosion-
Proof Reset/Control Switch, page 7.
Note: Always save the accumulated total before replacing batteries.
Resetting the Total
Totals can be reset to zero using the keypad, the interface software, an explosion-proof switch mounted in the
top of the enclosure (if equipped), or a pulse from an external device.
To reset the total with the keypad, press LEFT ARROW (LOG) and ENTER (SAVE) keys simultaneously.
•
To reset the total with the interface software, double-click the NuFlo MC-III icon on the computer desk-
•
top and wait for the software to connect to the instrument; then select MC-III Main from the Device
Autorun Options screen, and click on the “Reset Flow Total” button in the lower right corner of the Main
screen.
8
MC-III™ EXP Flow Analyzer Section 1
To reset the total with an explosion-proof switch, press and hold the switch for 3 seconds, then release it.
•
See also Explosion-Proof Reset/Control Switch, page 7.
To reset the total with an external pulse generator located in safe area, congure the pulse to be active for
•
3 seconds. See also Remote Reset Input, page 16.
Viewing Daily and Hourly Logs
Each day, as the user-dened contract hour passes, a daily ow total is saved to nonvolatile memory. Hourly
logs are also automatically saved. A total of 384 daily logs and 768 hourly logs are accessible for viewing and
exporting using the interface software. See Section 5 for details.
Up to 99 daily ow log totals can be viewed from the LCD. Hourly ow log totals are accessible only through
the interface software.
To view daily ow totals from the LCD, perform the following steps:
Press the LEFT ARROW (LOG) key on the keypad. The words “Daily Volume Archive” will scroll across
1.
the bottom of the LCD and the day index will display “01.” The daily ow total recorded at the last contract hour will appear at the top of the LCD.
The index number represents the number of days previous to the current date. For example, yesterday’s
totals are read by entering an index of “01”; totals from two days previous are read by entering “02.”
2.
Press UP ARROW (TEST) to increment the index (01, 02, 03...); press LEFT ARROW (LOG) to decre
ment the index (01, 99, 98...).
3.
Press Enter (Save) to exit the Daily Volume Archive menu. (After 2 minutes of inactivity, the Daily Vol
ume Archive menu will timeout and the total readout will be restored automatically.)
The optional explosion-proof reset switch also allows users to view daily log totals. For more information, see
Explosion-Proof Reset/Control Switch, page 7.
-
-
Saving and Uploading Conguration Files
The MC-III interface software allows users to save an unlimited number of conguration les to their
computer. In the event that a conguration setting gets changed unintentionally or a user simply wants to
restore the settings he used previously, the user can upload the conguration le and resume operation within
minutes. The upload function also allows a conguration le to be loaded quickly into multiple devices. The
default directory for saving conguration les is C:\NuFlo log data\MC-III. However, the user can specify a
different location, if desired.
For complete information, see Saving and Uploading Conguration Files, page 66.
Exporting Log Data
Flow logs and event logs can be directly exported to an .xls or .csv le. For complete information, see
Exporting Flow Logs, page 79, and Exporting Event Logs, page 82. The default directory for exported logs is
C:\NuFlo log data\MC-III. However, the user can specify a different location, if desired.
Saving Log Data in a Report
Flow logs can be saved in a report format that can be loaded back into the software for viewing or printing at
a later time. For complete information, see Printing/Saving a Report, page 75. The default directory for log
reports is C:\NuFlo log data\MC-III\<WELL NAME>. However, the user can specify a different location.
9
Section 1 MC-III™ EXP Flow Analyzer
10
MC-III™ EXP Flow Analyzer Section 2
Pipe plugs
Explosion-proof
enclosure
3/4-in. to 1-in.
pipe adapter
1-in. pipe union
Cable
assembly
Magnetic pickup
Turbine flowmeter
Section 2—Installation
The MC-III™ EXP is fully assembled at the time of
shipment and ready for mounting to a owmeter. The
MC-III EXP is shipped with ¾” recessed pipe plugs
installed facing right and left, and the pipe union facing
downward (Figure 2.1). If the device is equipped with an
explosion-proof reset switch, only one plug is required. The
switch may be installed in the right or left conduit opening.
Warning: To prevent ignition of hazardous
atmospheres, do not remove the cover
while circuits are alive. Under normal
Preparation
Before attempting to install the MC-III EXP, make sure the
owmeter and magnetic pickup are installed as follows:
conditions, the MC-III EXP poses no
hazard when opened in a safe area.
Install the turbine owmeter in the ow line.
1.
Lightly grease the threads on both ends of the magnetic
2.
pickup, taking care to keep grease off of the connector
contacts. If the connector is plastic, apply grease only to
the end that threads into the meter.
3.
Install the magnetic pickup in the owmeter.
4.
After the owmeter and magnetic pickup are installed
in the ow line, mount the MC-III EXP ow analyzer
as described below.
Connection to the Flowmeter
To install the MC-III EXP on a turbine owmeter, perform
the following steps:
Position the MC-III EXP above the owmeter.
1.
Plug the MC-III EXP cable connector into the magnetic
2.
pickup and hand-tighten the knurled nut on the connector.
3.
Screw the MC-III EXP onto the owmeter threads sur
rounding the magnetic pickup with the display facing
the desired direction.
4.
Tighten all sections of the pipe union.
Figure 2.1—Connection of MC-III EXP to a
-
owmeter
Caution: Do not use Teon® tape on
threads of the union, adapter, or
pipe plugs. Use of Teon® tape
will void the explosion-proof
rating of the instrument.
11
Section 2 MC-III™ EXP Flow Analyzer
5.71 (145)
6.73
(171.1)
1.75
(44.5)
5.00 (127)
Instrument Dimensions
The MC-III EXP may include either of two enclosure styles. The standard enclosure shown on the cover of
this manual and in Figure 2.2 features mounting holes on either side of the display window, allowing it to be
mounted to a at bulkhead.
The alternate enclosure (Figure 2.3) does not have the bulkhead mounting holes on the sides, and a bright red
ring frames the display window. The alternate enclosure is slightly taller than the standard enclosure.
Figure 2.2—Mount dimensions in inches (millimeters) with standard enclosure
Figure 2.3—Mount dimensions in inches (millimeters) with alternate enclosure
12
MC-III™ EXP Flow Analyzer Section 2
Field Wiring Connections
Warning: To prevent ignition of hazardous atmospheres, do not remove the cover while circuits are
alive. Under normal conditions, the MC-III EXP poses no hazard when opened in a safe
area.
To wire the MC-III EXP for operation, complete the following eld connections:
Unscrew the cover of the enclosure counter-clockwise until it separates from the main body of the enclo
1.
sure.
2.
Using a small standard blade screwdriver, remove the two #4-40 × 7/8” screws located to the right and
left side of the display.
3.
Lift the display/keypad assembly from the enclosure, making sure the circuit assembly does not contact
the enclosure.
4.
Connect the lithium battery or alkaline battery pack to the J1 connector on the circuit assembly.
5.
Connect wiring for external power, if appropriate. See
6.
Connect the owmeter or pulse input wiring to terminal block TB1. See
7.
Connect wiring for the remote reset input to terminal block TB1, if appropriate.
page 16.
8.
Connect wiring for output signals, if appropriate.
9.
Place the circuit assembly over the standoffs and fasten with the two #4-40 × 7/8” screws, ensuring that
all connector wiring is inside the enclosure and in no position where it may be damaged when the enclosure cover is replaced.
10.
Recalibrate the MC-III EXP (if necessary).
11.
If external and internal power supplies were removed, reset the clock to ensure that the time stamps in the
log data are accurate. The clock is reset using the MC-III interface software. See Time/Date Synchroniza-
tion, page 50.
Figure 2.4, page 14.
Figures 2.5 and 2.6, page 15.
See Figures 2.7 and 2.8,
See Figures 2.9 through 2.14, pages 17 through 20.
-
12.
Replace the enclosure cover by threading it onto the enclosure in a clockwise direction.
13
Section 2 MC-III™ EXP Flow Analyzer
T
B
3
TB1
PULSE
INPUT
RESET
INPUT
TFM
A&S
GND
EXT POWER
TB2
RS485
SLAVE
4-20
OUT
PULSE
OUT
6
-
3
0
V
D
C
PO WE R
SU PP LY
6 to 3 0
VD C
J1
J2
RESET
SWITCH
BATTERY
Power Supply Wiring
Internal Power Supply
The MC-III EXP is shipped with either of two internal power supplies:
a 3.6-V lithium battery or
•
a shrink-wrapped alkaline battery pack containing three C-size industrial-grade batteries
•
Low-power microprocessor technology enables the MC-III EXP analyzer to operate approximately 2 years on
a single lithium battery. The lithium battery is strongly recommended for use in extreme temperatures (below
-20°C).
Users can power the instrument from an external power supply or a 4-20 mA current loop, and use the lithium
or alkaline battery as a backup power supply. The use of an alternate power source extends battery life and
helps ensure that timekeeping and volume accumulation will not be interrupted during a power failure.
Caution: If the MC-III EXP is installed in a hazardous location, all eld wiring must conform to wir-
ing methods for explosion-proof installations as dened in the National Electric Code for
installations within the United States or as specied in the Canadian Electric Code for
installations within Canada. State and local wiring ordinances may also apply.
External Power Supply
The MC-III EXP can be connected to a remote power supply by a two-conductor cable (Figure 2.4). The
power supply and cable must be capable of supplying 6 to 30 VDC @ 10 mA. This capability is available
only if the 4-20 mA rate output is not used.
Caution: When using the amp & square output with the external power supply, make sure the
power supplies for both features share a common negative (-) terminal or that they are
totally isolated from each other, since both share a common negative (-) connection.
Figure 2.4—External power supply wiring
14
MC-III™ EXP Flow Analyzer Section 2
6
-
3
0
V
D
C
TB1
PULSE
INPUT
RESET
INPUT
TFM
A&S
GND
T
B
3
EXT POWER
TU RB INE
M AG NE TI C PIC KU P
V
M AX
= 3.9 V
J1
J2
RESET
SWITCH
BATTERY
A
B
T
B
3
TB1
PULSE
INPUT
RESET
INPUT
TFM
A&S
GND
EXT POWER
6
-
3
0
V
D
C
J1
J2
RESET
SWITCH
BATTERY
PU LS E IN PU T
3 T O 3 0 VD C
Input Wiring
Turbine Flowmeter (TFM) Input
The TFM input provides the turbine owmeter input signal generated by a magnetic pickup, enabling the MCIII to calculate and display instantaneous ow rates and accumulated totals.
Figure 2.5—Flowmeter input wiring
Pulse Input
The pulse input provides an optically isolated input in systems where a preamplier is inserted between the
sensor and the MC-III EXP.
Figure 2.6—Pulse input wiring
15
Section 2 MC-III™ EXP Flow Analyzer
TB1
PULSE
INPUT
RESET
INPUT
TFM
A&S
GND
T
B
3
EXT POWER
6
-
3
0
V
D
C
J1
J2
RESET
SWITCH
BATTERY
PO WE R SU PP LY
3 to 3 0 V DC
TB1
PULSE
INPUT
RESET
INPUT
TFM
A&S
GND
T
B
3
EXT POWER
6
-
3
0
V
D
C
J1
J2
RESET
SWITCH
BATTERY
R E SE T PU LS E
3 T O 3 0 VD C
Remote Reset Input
The remote reset input allows the operator to reset the accumulated volume on the MC-III EXP to zero
without opening the enclosure. This input is optically isolated. The input is shown connected in two ways,
with a power supply and switch in a remote location (Figure 2.7), and with a pulse generator in a remote
location (Figure 2.8). The remote reset input can also be controlled with an optional explosion-proof switch
mounted in the top of the enclosure. See Appendix A for installation and wiring instructions.
The reset input, reset pulse, or local reset switch must be active for 3 seconds to clear the total. (The
explosion-proof switch can also be used to view daily logs and to save the accumulated volume to memory
without opening the enclosure. See Explosion-Proof Reset/Control Switch, page 7, for more information.)
Figure 2.7—Reset input wiring (when power supply and reset switch are in a safe area)
Figure 2.8—Reset pulse input wiring (when pulse generator is in a safe area)
16
MC-III™ EXP Flow Analyzer Section 2
TB1
PULSE
INPUT
RESET
INPUT
TFM
A&S
GND
T
B
3
EXT POWER
TB2
RS485
SLAVE
4-20
OUT
PULSE
OUT
6
-
3
0
V
D
C
J1
J2
RESET
SWITCH
BATTERY
Le av e th is
en d o f s hie ld
di sco nn ect ed .
PO W ER S UP PL Y
5 to 50 VD C
*
R e s is tor may b e i n c lu de d in puls e re a d o u t
devic e . S iz e t h e re sis tor to lim it th e cu rre nt
to 60 m A .
*
PU LS E RE AD OU T
D EV ICE
Output Wiring
The MC-III EXP supports four outputs: pulse output, 4 to 20 mA output, owmeter frequency (amp & square)
output, and RS-485 output. Wiring diagrams for each feature are provided below.
Pulse Output
The pulse output is a solid-state relay. Each pulse represents a user-dened volume. Because the circuit is
isolated, it can be used in conjunction with any other feature on the MC-III EXP. A two-conductor cable from
the MC-III EXP to the remote location is required (Figure 2.9). The maximum current rating of the pulse
output circuit is 60 mA at 50 VDC.
For information on conguring the pulse output with the keypad, see page 32. For information on conguring
the pulse output with the interface software, see page 64.
Figure 2.9—Pulse output wiring
Analog (4-20 mA) Rate Output
The 4-20 mA rate output provides a linear current output that represents ow rate. This output requires a twoconductor cable connected to an 8 to 30 VDC power supply (voltage required is dependent on loop resistance)
and a current readout device located in the remote location. The 4-20 mA rate output current loop also powers
the MC-III EXP. The internal battery (lithium or alkaline) provides a power supply backup to maintain
timekeeping accuracy and to continue accumulating volume in the event that the 4-20 mA current loop fails.
Figure 2.10, page 18, shows the minimum required voltage to power the instrument for a given loop
resistance. In addition, the mathematical relationship between loop voltage and load resistance is given. For
example, if a power supply voltage of 24 volts is available to power the current loop, the maximum load
resistance would be 800 ohms.
Caution: The 4-20 mA rate output and the owmeter frequency output circuits are not isolated
For information on conguring the 4-20 mA rate output with the keypad, see page 29. For information on
conguring the 4-20 mA rate output with the interface software, see page 60.
from each other and cannot be used simultaneously. When the 4-20 mA output option is
used, do not connect external power to TB3.
17
Section 2 MC-III™ EXP Flow Analyzer
TB1
PULSE
INPUT
RESET
INPUT
TFM
A&S
GND
T
B
3
EXT POWER
TB2
RS485
SLAVE
4-20
OUT
PULSE
OUT
6
-
3
0
V
D
C
J1
J2
RESET
SWITCH
BATTERY
PO W ER S UP PL Y
8 to 3 0 VD C
LO AD
R e s is tor m ay b e
in c lu de d i n r eadout
devi c e .
4-2 0 m A a nd
flow m eter fr equency
(a mp & s quare )
ca nn ot be u se d
si m ult aneously .
*
*
LOOP SUPPLY VOLTAGE (VDC)
LOAD RESISTANCE (OHMS)
OPERATING
REGION
Figure 2.10—4-20 mA rate output wiring
Flowmeter Frequency Output
The owmeter frequency (amp & square) output provides an open drain transistor output at the turbine meter
frequency, which may be used to provide ow rate and/or total information to peripheral equipment. The
output requires a two-conductor cable from the MC-III EXP to the remote frequency readout device requiring
50 mA or less and a 5 to 30 VDC power supply (Figure 2.11, page 19).
Caution: The owmeter frequency output and 4-20 mA rate output are not isolated from each other
and cannot be used simultaneously.
Caution: When using the owmeter frequency output and powering the device from an
The owmeter frequency output terminals on the MC-III EXP circuit assembly are labeled A & S to represent
“amp & square” output.
18
external power supply, make sure both power supplies share a common negative (-)
terminal or are totally isolated from each other.
MC-III™ EXP Flow Analyzer Section 2
TB1
PULSE
INPUT
RESET
INPUT
TFM
A&S
GND
T
B
3
EXT POWER
TB2
RS485
SLAVE
4-20
OUT
PULSE
OUT
6
-
3
0
V
D
C
J1
J2
RESET
SWITCH
BATTERY
Le av e th is
en d o f s hie ld
di sco nn ect ed .
PO WE R SU PP LY
5 to 30 VD C
FR E QU EN CY
R EA DO UT D EV ICE
*
R e s isto r m ay b e i n c lu de d in freque n c y
re ad o u t d evic e. S ize th e re sis tor to lim it
th e c urr e nt to 5 0 m A.
4-2 0 m A and f lo wm ete r fre qu e n c y
(a mp & s qu a re ) c anno t b e u sed
sim ulta ne o u s ly.
*
B
A
TB1
PULSE
INPUT
RESET
INPUT
TFM
A&S
GND
T
B
3
EXT POWER
TB2
RS485
SLAVE
4-20
OUT
PULSE
OUT
6
-
3
0
V
D
C
R S -48 5
C o mm un ica tio ns
J1
J2
RESET
SWITCH
BATTERY
Figure 2.11—Flowmeter frequency (amp & square) output wiring
RS-485 Output
The RS-485 output is required for communication with the interface software. Wiring diagrams are provided
for a permanent connection (Figure 2.12), as well as for temporary laptop connections using an RS-485 to RS232 converter (Figures 2.13 and 2.14, page 20).
Additionally, the RS-485 output is approved for intrinsically safe installations. An intrinsically safe
installation requires an intrinsically safe barrier assembly with a conduit seal (Figure 2.15, page 21). In such
installations, only the turbine owmeter input may be used.
Figure 2.12—RS-485 output (permanent connection)
19
Section 2 MC-III™ EXP Flow Analyzer
TB1
PULSE
INPUT
RESET
INPUT
TFM
A&S
GND
T
B
3
EXT POWER
TB2
RS485
SLAVE
4-20
OUT
PULSE
OUT
6
-
3
0
V
D
C
J1
J2
RESET
SWITCH
BATTERY
TD (B )
TD (A )
G ND
R S -23 2
9 - P IN
C O NN EC T O R
Pa rt No .
9A -1 012 83 11 6
TX +
TX -
TB1
PULSE
INPUT
RESET
INPUT
TFM
A&S
GND
T
B
3
EXT POWER
TB2
RS485
SLAVE
4-20
OUT
PULSE
OUT
6
-
3
0
V
D
C
J1
J2
RESET
SWITCH
BATTERY
B
A
G ND
R S -23 2
25 - P IN
C O NN EC T O R
Pa rt No .
9A -1 000 25 19 5
TX +
TX -
Figure 2.13—RS-485 output (connection to laptop with 9-pin converter)
Figure 2.14—RS-485 output (connection to laptop with 25-pin converter)
20
MC-III™ EXP Flow Analyzer Section 2
Figure 2.15—Intrinsically safe RS-485 connection, based on control drawing 9A-50053010
21
Section 2 MC-III™ EXP Flow Analyzer
22
MC-III™ EXP Flow Analyzer Section 3
Section 3—Conguration and Operation via Keypad
Calibration of the MC-III™ EXP is a simple matter of entering necessary parameters into the instrument.
The process for calibrating the MC-III EXP depends on how the instrument will be used. The keypad can
be used to calibrate the MC-III EXP for liquid or gas measurement using preprogrammed units, or for liquid
measurement using a calculated divisor. When preprogrammed units are used, the MC-III EXP automatically
calculates the divisor for volume calculation and the rate multiplier for ow rate calculation, making
calibration quick and easy.
Important: For compensated gas measurement, or gas or liquid measurement requiring multipoint
(2- to 12-point) linearization, calibration must be performed with the software user interface (see Section 4).
Because the keypad is protected beneath the lid of the instrument, the enclosure must be opened to access the
keypad. For this reason, it is important to calibrate the instrument before installing it in a hazardous area.
Warning: To prevent ignition of hazardous atmospheres, do not remove the cover while circuits are
alive. Under normal conditions, the MC-III EXP poses no hazard when opened in a safe
area.
The following parameters can be congured using the six-button keypad on the front of the instrument:
calibration factor and unit
•
units of measurement for Total and Rate displays
•
decimal position for Total and Rate displays
•
input type and sensitivity level
•
4-20 mA output
•
pulse output scale factor
•
slave address
•
baud rate
•
23
Section 3 MC-III™ EXP Flow Analyzer
K-FACTOR
MENU
00000000
M
3
BBL
GAL
LIT
CF
CF
X1000
X1000
TEST
LOG
00000000
M
3
BBL
GAL
LIT
CF
CF
X1000
X1000
.
TEST
LOG
TEST
00000000
M
3
BBL
GAL
LIT
CF
CF
X1000
X1000
LOG
SAVE
ENTER
Entering a Calibration Factor
When the volume is to be expressed in barrels (BBL), gallons (GAL), liters (LIT), cubic meters (M3), or cubic
feet (CF), and the ow rate is to be expressed in barrels, gallons, liters, cubic meters or cubic feet per day, per
hour, per minute, or per second, the MC-III EXP calculates the divisor automatically; only the turbine meter
calibration factor is required.
When the volume is to be expressed in a unit other than the preprogrammed units listed above, a calculated
divisor must be entered at the K-Factor prompt. See Entering a Calculated Divisor, page 25.
To Enter a Calibration Factor:
Enter the K-Factor menu. Press K-FACTOR MENU.
Select the unit of measure associated
with the calibration factor (typically,
Press UP ARROW until the correct
unit is displayed.
pulses per gallon).
Enter the decimal point position for
the calibration factor.
Press LEFT ARROW to select the
decimal point.
Press UP ARROW to change the
position of the decimal point.
Press LEFT ARROW to save the
decimal point position and proceed
with entering a calibration factor.
Enter the calibration factor, starting
with the last digit and entering digits
Press UP ARROW until the last digit
of the calibration factor is displayed.
right to left.
Press LEFT ARROW to select the
next digit to the left.
Repeat using UP and LEFT arrows to
enter all remaining digits.
Press ENTER.
The Input Sensitivity menu will appear following the entry of the calibration factor. See Setting Input Type
and Sensitivity, page 26, for the input sensitivity conguration procedure.
24
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