Batch controller
Batching Master 110
Installation Guide
Revision 12
IBS BatchControl GmbH
Im Sträßchen 2–4 Tel.: ++49 2441 9199 801
53925 Kall Fax.: ++49 2441 9199 871
Germany Internet: www.ibs-batchcontrol.com
IG_BM110_120_EN 06.04.2016
Safety information
The Batching Master must only be installed by process electronics engineers or qual ified electricians who are authorised by the plant operator to carry out these tasks.
The instrument may only be operated by personnel who are authorised and trained
by the plant operator.
The Batching Master must only be connected as specified in the electrical data. The upper
part of the housing must not be opened, otherwise maintenance of the electrical data is not
ensured and the guarantee becomes null and void.
Validity of Installation and Operating Instructions
• These Installation and Operating Instructions apply to all Batching Master 110
models.
• Your IBS agent will be able to give you information about any improvements or
modifications.
• The manufacturer is not responsible for damage caused by incorrect or unauthorised
use. Conversions and changes to the instrument must not be made, otherwise the
certification and guarantee become invalid.
Operating safety
• The instruments are manufactured in our ISO 9001 certified factory. They comply with
the requirements laid down in this standard.
• The Batching Master 110 satisfies the requirements of protection class IP65.
• Danger may occur if the instrument is used incorrectly or in an unauthorised manner.
All the information in this manual must be rigorously observed.
Technical Developments
The manufacturer reserves the right to modify technical data without notice.
Repairs, dangerous chemicals
Only the IBS BatchControl GmbH is allowed to repair the instruments. Instruments sent to
IBS BatchControl GmbH for repair must always be accompanied by a note describing the
fault.
Warning!
The following procedures must be carried out before an instrument is sent in for repair:
• Remove all residues and deposits that may be present. Pay special attention to the
gasket grooves and crevices where residue may collect.
• If materials injurious to health are not completely removed to the highest levels of
safety, we cannot accept an instrument for repair.
• Costs of disposal of materials or of injury to personnel (acid burns, etc.) arising
because of defective cleaning of the equipment will be charged to the owner of the
equipment.
2
Contents
1 System Description........................................................................................................4
1.1 Type Codes.................................................................................................................4
1.2 Areas of Application....................................................................................................4
1.3 Block diagram.............................................................................................................5
2 Fitting and Installation....................................................................................................6
2.1 Fitting the Batching Master 110..................................................................................6
2.2 Protection class IP65..................................................................................................6
2.3 Temperature range.....................................................................................................6
2.4 Cable gland and PE....................................................................................................7
2.5 Terminal connection....................................................................................................8
2.5.1 Power supply 1 and 2.............................................................................................8
2.5.2 Pulse inputs............................................................................................................8
2.5.3 Analogue inputs......................................................................................................8
2.5.4 Analogue output......................................................................................................9
2.5.5 Digital inputs...........................................................................................................9
2.5.6 Digital outputs.......................................................................................................10
2.5.7 Digital input for an additional OFF contact...........................................................10
2.5.8 Digital output “OFF pressed”................................................................................10
2.5.9 RS485 interfaces..................................................................................................11
2.5.10 Potential equalisation...........................................................................................11
2.5.11 Switch for the enabling of the programming.........................................................11
3 Operating and display elements..................................................................................12
3.1 Display......................................................................................................................12
3.2 LEDs.........................................................................................................................12
3.3 Keyboard...................................................................................................................12
4 Operation.....................................................................................................................13
4.1 Switching on the Batching Masters...........................................................................13
4.2 Batching with the Batching Master...........................................................................14
4.3 Fault messages.........................................................................................................14
4.4 Programming............................................................................................................16
5 Terminal assignment...................................................................................................17
3
System Description
1 System Description
The microprocessor-controlled Batching Master 110 is a simple to use multi-function
batch controller used for the recording and controlling of flow quantities in batching
and filling processes.
1.1 Type Codes
The following types can be supplied:
Batching Master 110 Analogue inputs 1–3 not electrically isolated
Batching Master 110 –SB Analogue inputs 1–3 not electrically isolated,
Display with back-light
1.2 Areas of Application
• The maximum permissible ambient temperature is +60 °C.
• The minimum permissible ambient temperature is -20 °C.
The Batching Master controls batching and terminates this when the preselected
quantity is reached. An actuator (4–20 mA) and several contacts are controlled depending on the batching. Up to four control signals can be fed to the Batching
Master. A controller is available to control the flow rate or another physical quantity
(option).
There is a choice of current (4–20 mA) or contact input. The contact input permits the
connection of passive contacts or optical couplers. Selection of the input option is
carried out via the software.
The input can be linearised by the software.
The Batching Master can be easily set to the different measuring ranges.
The (active) digital inputs can be assigned various functions (e.g. preselection, start,
stop, etc.).
The (passive) digital outputs can be programmed to provide status signalling.
The Batching Master can be configured and controlled via a serial interface (Modbus)
with RS485.
Access to the various program levels can be protected by a numerical code.
The Batching Master 110 is supplied in a field housing (IP65) with external dimensions of 240 mm x 240 mm.
4
System Description
1.3 Block diagram
5
Fitting and Installation
2 Fitting and Installation
This information in this section is important and must be observed during fitting and
installation.
2.1 Fitting the Batching Master 110
The Batching Master 110 has external dimensions of 240 mm x 240 mm. There are
fixing straps on the rear for wall mounting. Cable entry is from below.
2.2 Protection class IP65
The Batching Master 110 conforms to protection class IP65. The following points
must be observed to guarantee the protection class.
• The housing seals must be fitted correctly and undamaged in the sealing
grooves. If necessary, the seals must be dried, cleaned or replaced.
• All housing screws and screwed covers must be correctly tightened.
• The cables used for the connections must have the specified external dia-
meter.
• Cable glands must be screwed up tight.
• Unused cable glands must be replaced by blanking plugs.
• The protective sleeve must not be removed from the cable gland.
2.3 Temperature range
The Batching Master 110 can be operated in the range –20°C to +60°C.
6
141,5 mm
255 mm
274 mm
240 mm
M20 M20 M20 M20 M20
260 mm
6,5 mm
240 mm
Fitting and Installation
2.4 Cable gland and PE
Only shielded cable may be used. The shield must be connected in the EMC gland.
The PE must be connected to the PE terminal on the side of the housing.
The glands are suitable for cable diameters from 7.5 to 13 mm.
The cable end must be stripped as shown in the drawing below.
The metal shield must be at least 30 mm long for M20 glands.
Insert the cable into the gland.
Push the cable and sleeve into the gland and cut off the projecting braid.
Tighten the nut.
Conformance with the EMC regulations can only be guaranteed if these measures
are observed.
7
Fitting and Installation
2.5 Terminal connection
The technical data must be observed at all times.
2.5.1 Power supply 1 and 2
The power supply 1 provides power for the electronics, the analogue output and the
digital inputs and outputs.
The power supply 2 provides power for the optional back light of the LCD.
Terminal 1 (+) Terminal 2 (-)
Terminal 3 (+) Terminal 4 (-)
Voltage U DC 18–30 V
Current I 330 mA
2.5.2 Pulse inputs
The Batching Master has connections for 2 pulse inputs. The second pulse input is
needed for evaluation purposes when using certified custody transfer instruments.
Namur contacts or passive electrically isolated contacts (opto coupler, relay contact)
may be connected.
Pulse input 1: Terminal 5 (+) Terminal 6 (-)
Pulse input 2: Terminal 7 (+) Terminal 8 (-)
Voltage U
max
DC 5.6 V
Current I
max
3 mA
The pulse input supplies a constant current of approx. 3 mA. The maximum voltage
that can be measured is approximately 5.6 V. Please note that terminals 6 and 8
must not be connected to ground and not to the same potential.
2.5.3 Analogue inputs
The Batching Master has 3 analogue inputs (4–20 mA).
The analogue inputs are not voltage-free, i.e. the minus is at instrument ground potential. The equipment connected must be able to drive a load of approx. 100Ω.
Current input 1: Terminal 9 (+) Terminal 10 (-)
Current input 2: Terminal 11 (+) Terminal 12 (-)
Current input 3: Terminal 13 (+) Terminal 14 (-)
Voltage U
max
DC 5 V
Current I
max
25 mA
8
Fitting and Installation
2.5.4 Analogue output
The Batching Master has an analogue output (4–20 mA) for the controlling of a valve.
The analogue output is not electrically isolated. The minus is at ground potential. The
maximum load that can be connected depends on the valve control module that supplies the Batching Master. A load of up to 1000Ω can be driven by 24V power supply.
Analogue output: Terminal 15 (+) Terminal 16 (GND)
The following values may occur:
Voltage U
max
U
in
Current I
max
25 mA
The current output is switched off when the OFF switch is operated.
2.5.5 Digital inputs
The Batching Master has five digital inputs. The digital inputs can be assigned a wide
range of functions via the software.
The digital inputs are active (approx. 100 µA/5V). Passive switches or optical
couplers can be connected.
Digital input 1: Terminal 19 (+) Terminal 20 (GND)
Digital input 2: Terminal 21 (+) Terminal 22 (GND)
Digital input 3: Terminal 23 (+) Terminal 24 (GND)
Digital input 4: Terminal 25 (+) Terminal 26 (GND)
Digital input 5: Terminal 27 (+) Terminal 28 (GND)
Voltage U
max
DC 6 V
Current I
max
0.2 mA
Supply circuits with the following maximum values can be
connected to each circuit:
Voltage U
i
DC 36 V
Current I
i
100 mA
If you want to use active signals you have to switch the 24V and 0V to the input. It is
not enough to switch only 24V to the input. Then the open contact is not identified.
After setting the input to 0V the controller identified this signal.
9
Fitting and Installation
2.5.6 Digital outputs
The Batching Master has five digital outputs. The digital outputs can be assigned a
wide range of functions via the software. Digital outputs 1 to 3 are switched off when
the OFF switch is operated. These contacts then open.
The control outputs are electrically isolated and passive. Please note the potential
direction of the outputs.
Digital output 1: Terminal 29 (+) Terminal 30 (-)
Digital output 2: Terminal 31 (+) Terminal 32 (-)
Digital output 3: Terminal 33 (+) Terminal 34 (-)
Digital output 4: Terminal 35 (+) Terminal 36 (-)
Digital output 5: Terminal 37 (+) Terminal 38 (-)
Supply circuits with the following maximum values can be
connected to each circuit:
Voltage U
max
DC 36 V
Current I
max
500 mA
2.5.7 Digital input for an additional OFF contact
An external passive OFF switch can be connected to these terminals. These terminals carries 5 V at 0.5 mA. If an external OFF switch is not connected, these terminals
must be linked. When the OFF switch is operated, a hardware action switches off digital outputs 1 to 3 and the current output, i.e. the current is less than 4 mA and di gital outputs 1 to 3 are open. The OFF switch at the front has the same function.
Active OFF: Terminal 17 (+) Terminal 18 (GND)
The following values may occur:
Voltage U
o
DC 6 V
Current I
o
1 mA
2.5.8 Digital output “OFF pressed”
A second normally-closed contact from the OFF switch in the front of the device is
connected directly to the terminals. This don't switch if only the external OFF input
(Terminal 17+ and 18-) is open.
Passive OFF switch: Terminal 45 Terminal 46
Supply circuits with the following maximum values can be
connected:
Voltage U
i
DC 36 V
Current I
i
500 mA
10
Fitting and Installation
2.5.9 RS485 interfaces
A higher level system can be connected to the interface. The protocol is Modbus
RTU or ASCII.
Interface 1: Terminal 39 (B) Terminal 40 (GND) Terminal 41 (A)
Interface 2: Terminal 42 (B) Terminal 43 (GND) Terminal 44 (A)
The first and the last device in the Modbus
system must be terminated. To terminate the
interface, please connect a 120Ω resistor
between A and B. We can terminate the interfaces with internal jumpers in our factory.
If the termination by an external 120Ω resistor
is not required, the housing must be opened.
There are two slots for two jumpers on the
controller board. These must be closed with
the jumpers for termination. The images represent the two existing interfaces. The first interface is not terminated, the second interface
is terminated.
2.5.10 Potential equalisation
The PE must be connected to the PE terminal on the side of the housing.
2.5.11 Switch for the enabling of the programming
For certified custody transfer instruments, there is a small switch near the connection
terminals. In the case of certified instruments, the switch is sealed by the Weights
and Measures Office and cannot be operated. This switch disable the programming
of menu 4 (install), 6 (linearisation), 7 (flow conversion) and 8 (factory).
11
Operating and display elements
3 Operating and display elements
3.1 Display
The LCD display has two lines of 16 characters each. The character height is approx.
10 mm. An LCD back-light is available in version –SB.
The upper LCD indicates the preselected quantity. The lower LCD indicates the cur rent quantity batched. The display can be changed to flow, totaliser or flow controller
(only if this is active) using the [#] key.
3.2 LEDs
The LEDs in function keys F1 to F3 can indicate various conditions. The RC LED in dicates that data can be read and also written by the interface.
3.3 Keyboard
The Batching Master has 24 short-stroke keys. In addition, there is an OFF switch in
the housing.
In these Operating Instructions, keys are shown in square brackets. For instance, if
the number 15 is to be entered, this is shown as [15]. The Set key is shown as [Set].
12
Operation
4 Operation
The upper line of the display indicates the preset quantity. In programming mode, the
function to be executed is displayed.
The lower line indicates the quantity batched. In programming mode, the value of the
function or setting is shown.
You can switch the lower display to flow indication with the [#] key. You can switch to
totaliser by pressing the key again. The totaliser indication is only possible when
batching is not taking place. The display resets itself after about 4 seconds.
If the flow controller is active, the flow setpoint is displayed in the upper display by
pressing the [#] key at the same time as the flow is being indicated in the lower dis play.
If a limiting controller is switched on, the lower display will show the controlled vari able rather than the flow when the [RC] key is pressed. The upper display shows the
reference variable. The controller display resets itself to the batched quantity after
about 4 seconds.
If the lower display indicates flow at the start of batching, it will switch automatically to
the batched quantity. The flow can then be displayed again by pressing the [#] key.
The display will not automatically revert to batched quantity.
The quantity is always shown with the appropriate unit in each case.
The RC key also contains a red LED to indicate that the remote control interface is
on.
Keys 1 to 3 contain additional indicator LEDs. Functions can be assigned to these
LEDs.
These LEDs can also be activated via the interface. Keys F1 to F3 can be interrogated via the interface.
4.1 Switching on the Batching Masters
The instrument carries out a self-test as soon as it is connected to the power supply.
The instrument number and software version are displayed. All data stored in the
FRAM (ferro-electric non-volatile RAM, a non-volatile data memory) is then read.
The most recent preselected and batched quantities are displayed. The instrument
waits for an input.
13
Operation
4.2 Batching with the Batching Master
You must press the [Reset] key before the first batching process. The last preselec tion is reset.
Enter the preselected quantity using the numeric keys [1 to 9]. A decimal point will be
displayed in a fixed position.
The preselection value must be confirmed with [Set]. The last quantity batched is set
to 0.
The Batching Master is now ready to start batching.
Press the [Start] key to start batching. The digital shutoff steps switch on, the current
output runs up to 20 mA. Active batching is indicated on the display (B appears at the
bottom left). You can interrupt the batching with [Stop] or OFF at any time.
Batching interrupted with Stop can be continued immediately with [Start]. If batching
is stopped as the result of an OFF, the fault message must first be reset with [Reset].
You can then continue batching with [Start].
A new batching process can be started immediately with [Set] [Start] if the preselected quantity does not need to be changed.
After stopping, batching can be terminated with RESET.
After a supply break down you can take up the batch with [Start] again.
4.3 Fault messages
The Batching Master can detect various faults. Batching is interrupted immediately.
The fault is reset by pressing the RESET key (see Holding Register 5 and 6).
Lower Display Upper Display Fault No. Fault Type
FRAM Error in
1
Memory error
ERR S.-Break NK1
alternating with batched
quantity (app. 1 sec intervals)
Preselected
quantity
2
NAMUR contact 1
sensor break
ERR S.-Break NK2
altern. with batched quantity
Preselected
quantity
4
NAMUR contact 2
sensor break
ERR S.-Break mA1
altern. with batched quantity
Preselected
quantity
8
Analogue input 1
sensor break
ERR S.-Break mA2
altern. with batched quantity
Preselected
quantity
16
Analogue input 2
sensor break
ERR S.-Break mA3
altern. with batched quantity
Preselected
quantity
32
Analogue input 3
sensor break
ERR M.-range mA1
altern. with batched quantity
Preselected
quantity
64
Analogue input 1
measurement range
violation
14
Operation
Lower Display Upper Display Fault No. Fault Type
ERR M.-range mA2
altern. with batched quantity
Preselected
quantity
128
Analogue input 2
measurement range
violation
ERR M.-range mA3
altern. with batched quantity
Preselected
quantity
256
Analogue input 3
measurement range
violation
ERR MIN. FLOW
altern. with batched quantity
Preselected
quantity
1024
Flow-rate lower than
permitted minimum
ERR sensor
altern. with batched quantity
Preselected
quantity
2048
External fault message
(e.g. mass
measurement fault)
not enabled 1
altern. with batched quantity
Preselected
quantity
4096
1 not enabled
not enabled 2
altern. with batched quantity
Preselected
quantity
8192
2 not enabled
ERR Over batched
altern. with batched quantity
Preselected
quantity
16384
Over-batching
ERR OFF
altern. with batched quantity
Preselected
quantity
32768
OFF
ERR Printer
altern. with batched quantity
Preselected
quantity
65536
Printer fault
131072
Preselection too small
262144
Preselection too large
524288
Pulse faulty (in case of
double pulse)
1048476
B confirmation not
present
2097152
Printer ERR.
Communication error
4194304
Printer Busy
8388608
Printer ERR. Paper
OUT
Faults 1 and 32768 are monitored continuously. Faults 2 to 8192 are monitored
following start. Fault 65536 is monitored before starting and after stopping batching.
Fault 16384 is monitored after stopping batching.
15
Operation
4.4 Programming
To enter the programming level, press the Menu key. The Batching Master displays
the current software version and the instrument number. A checksum has to be generated to check the certification data.
If a sub-menu is selected, you can access the next level using the key. A code is
requested if one has been entered. The code request is by-passed if the programming enable switch is on. For certified instruments, the certification data can only be
changed by switching on the programming enable switch (install, calibration and
characteristic level).
Programming is only implemented when the “Quit programming” menu level is cor rectly terminated. The programming level is quit via a selection menu by pressing the
key to exit all levels. The “Save” prompt appears. You can change from “Yes” to
“No” using the keys. The setting is then confirmed by pressing the or Set key.
All data are saved. The batch controller in now in batching mode again. Programming
cannot take place during batching (except for the controller function).
If the Batching Master detects invalid data in FRAM, a fault message is issued. A
COLD-START can be initiated by pressing the RC key when switching on. A prompt
appears asking whether all data is to be deleted (factory) or whether just the settings
(basic settings) are to be reset (software options, characteristic and instrument number). The factory reset cannot be accessed by the user.
Cold-Start Upper Display Lower Display
The LCD indicates Cold Start after
switching on. Entries are made using
the key. The upper display flashes.
You can change between the levels with
the arrow keys and confirm with the
or SET keys. When the setting has
been confirmed, the associated code is
requested. The setting is only deleted if
the code is entered correctly.
Settings: Basic setting
Factory setting
Display basic setting at first
Cold-Start
Factory setting
Basic setting Code
Install code request
Each key pressed
is shown as a field.
Factory Code
Factory code request
Each key pressed
is shown as a field.
16
Terminal assignment
5 Terminal assignment
Terminal Function Remark Page
1 Power supply 1 + 8
2 Power supply 1 -
3 Power supply 2 + not usesd 8
4 Power supply 2 - not used
5 Pulse input 1 + 8
6 Pulse input 1 -
7 Pulse input 2 + 8
8 Pulse input 2 -
9 4/20 mA analoge input 1+ 8
10 4/20 mA analoge input 1-
11 4/20 mA analoge input 2+ 8
12 4/20 mA analoge input 2-
13 4/20 mA analoge input 3+ 8
14 4/20 mA analoge input 3-
15 4/20 mA analoge output + 9
16 4/20 mA analoge output +
17 Digital input for an ext. OFF contact + 10
18 Digital input for an ext. OFF contact +
19 Digital input 1 + 9
20 Digital input 1 -
21 Digital input 2 + 9
22 Digital input 2 -
23 Digital input 3 + 9
24 Digital input 3 -
25 Digital input 4 + 9
26 Digital input 4 -
27 Digital input 5 + 9
28 Digital input 5 -
29 Digital output 1 + 10
30 Digital output 1 -
31 Digital output 2 + 10
32 Digital output 2 -
17
Terminal assignment
Terminal Function Remark Page
33 Digital output 3 + 10
34
Digital output 3 -
35
Digital output 4 + 10
36
Digital output 4 -
37
Digital output 5 + 10
38
Digital output 5 -
39
Interface RS485 1 B +
11
40
Interface RS485 1 GND
41
Interface RS485 1 A -
42
Interface RS485 2 B +
11
43
Interface RS485 2 GND
44
Interface RS485 2 A -
45
Digital output „OFF pressed“ only for Batching Master 110
46
Digital output „OFF pressed“ only for Batching Master 110
18
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