KEP MINItrol-PW Operating Manual
MINItrol-PW SERIES
MODELS:
MRT-PW
INSTALLATION & OPERATING INSTRUCTIONS
http://www.kep.com
99551 05/06/02
KESSLER-ELLIS PRODUCTS
10 Industrial Way East
Eatontown, NJ 07724
800-631-2165 • 732-935-1320
Fax 732-935-9344
TABLE OF CONTENTS
SPECIFICATIONS ..................................................................................................1
DECODING PART NUMBER..................................................................................2
HOW TO MOUNT THE UNIT..................................................................................3
WIRING GUIDE LINES ...........................................................................................4
WHAT CAN YOU VIEW ..........................................................................................6
OUTPUT JUMPER SELECTIONS..........................................................................6
MILLIVOLT INPUT OPTION JUMPER SELECTIONS............................................6
OPERATING FRONT PANEL.................................................................................7
PROGRAMMING FLOW CHART ...........................................................................7
PROGRAM CODES & DESCRIPTIONS ................................................................8
WIRING TERMINATIONS.......................................................................................9
CALCULATING SCALE FACTOR ..........................................................................10
SETUP PROGRAMMING PROCEDURE ...............................................................11
SETTING SCALING FACTOR ................................................................................11
SETTING THE COUNTER......................................................................................12
SETTING THE RATE..............................................................................................13
SETTING THE LOCK CODE & LOCKING THE UNIT ............................................14
SETTING THE RELAYS & PRESETS ....................................................................15
OUTPUT WIRING ...................................................................................................16
ANALOG OUTPUT OPTION...................................................................................17
RS232/RS422 SERIAL COMMUNICATIONS.........................................................18
TROUBLESHOOTING GUIDE................................................................................21
WARRANTY
DESCRIPTION & SPECIFICATIONS
DESCRIPTION:
The Minitrol-PW is a single input counter/ratemeter intended for
use with low flow paddle or pelton wheel turbine flowmeters. Two
scale factors are used to describe the flowmeter calibration characteristics. The two 5 AMP preset relay outputs can be programmed
by the user to apply to the "A" total counter or the "A" ratemeter.
The user can view the rate, total and grand total.
SPECIFICATIONS:
DISPLAY
6 digit, 0.55" High LED
INPUT POWER:
110 VAC ± 15% or 12 to 15 VDC
220 VAC ± 15% or 12 to 15 VDC
24 VAC ± 15% or 12 to 15 VDC
CURRENT:
250 mA DC max. or 6.5 VA AC
OUTPUT POWER (AC powered units only)
+12 VDC @ 50 mA, unregulated -10 + 50%
TEMPERATURE:
Operating:
+32°F (0°C) to +130 F (+54°C)
Storage:
-40 F (-40°C) to +200°F (93°C)
MEMORY
EEPROM stores data for 10 years if power is lost.
INPUTS:
3: High Impedance DC pulse input 4-30 VDC (high), Open or 0-
1 VDC (low),10 KΩ imp. 10 kHz max. speed.
3M: Mag. Input, Rate/total input only, accepts 30mV input (50 V
max. P/P) signals 10 KΩ imp. 5 kHz max. (Inhibit input, 430V)
NOTE: The Mag. input has filtering as follows: up to 300Hz
@30mV, 5KHz @ .25V to 50V max.
INHIBIT TOTAL INPUT
Terminal 6: 4-30 VDC level will inhibit totalization
RESET:
Front Panel: Resets displayed value and control output
Remote: 4-30 VDC, negative edge resets Totalizer
(Total A) and control output
NOTE: The remote reset will not reset Grand Total (Total B)
K FACTOR/SCALING
The K-Factor is used to convert the input pulses to engineering
units. The two 5 digit scale factors, with decimal keyed into any
position, allow easy direct entry of any scaling factor from 0.0001 to
99999. Factor A is used to enter the linearized K-Factor and Factor
B is used to enter the offset frequency.
LOW FLOW CUTOFF:
A low flow cutoff is provided to inhibit operation in low flow out of
range regions.
CONTROL OUTPUTS:
Relays:
The relays may be assigned to rate or total.
2 each N.O. Relay; 5 Amps120/240 VAC or 28 VDC. (N.C. relay
contacts and NPN transistor output available with solder jumpers. Transistor output is internally pulled up to 10 VDC through
relay coil, sinks from 10 VDC to .5 V @ 100 mA)
Analog Output:
An optional 4-20mA (0-20mA) output is available for the Minitrol
series. The output can be programmed to track rate or total.
This feature is available by adding suffix A to the part number.
Connections are via a 2 terminal pluggable screw connector.
Programming is accomplished by using the front panel in conjunction with rear dip switches.
Accuracy: ± 0.25% FS worst case.
Compliance Voltage: 3 to 30 VDC non inductive.
RS232/RS422 SERIAL INTERFACE
If the serial interface option is supplied, up to 99 units can be linked
together. (The terminal addressing the unit must be capable of
driving all loads in the loop.) Unit status and new set points can be
communicated by serial communication. Mode changes, however,
must always be made on the front panel. Data is transmitted at
selected baud rates using standard seven bit ASCII characters and
parity with two additional bits of “Start” and “Stop” to make up the
standard ten bit character.
Data is received and transmitted over standard EIA RS232 or
RS422 levels. Each 10 bit character is made up of a start bit, 7 bit
ASCII code, parity bit and stop bit. Unit number, baud rate and
parity are entered in the “Program Setting” set up mode and remain
in memory even if power is off.
Note that the input impedance of RS232 is 3K or 7K Ohm worst
case. The terminal addressing the unit must be capable of driving
all loads in the loop. RS422 input impedance is much higher and
there is usually no problem driving 25 units. Unit serial transmit line
remains in a high impedance “OFF” state until addressed.
1
SPECIFICATIONS
(continued)
DECODING PART NUMBER
PRESETS
Two control outputs are provided. To set relay values, press
“menu” button until “Relay” appears on the display, the A and B
outputs can be assigned to the rate alarm (high/low), or for total (A)
or grand total (B). A 5 digit value can be entered for both presets
and the decimal point location is the same as the counter. The
outputs can be set to energize from 0.1 to 99.9 seconds or latch
(0.0). If a value other than 0.0 is entered, the totalizers will auto
reset at the preset. This may be used to create a relay pulse output
instead of grand total.
LOCKOUT
Unauthorized front panel changes can be prevented by entering a
user selected 5 digit code, in the “LOC” , . mode. The front panel
can be completely locked out or the presets can remain accessible.
RATEMETER
Accurate to 4 1/2 digits (±1 display digit). The rate meter can be
programmed to accept almost any number of pulses per unit of
measurement and auto-range up to 5 digits of significant information. The display can be programmed to read in units per Second
(
sec
), Minute (
COUNTER
The two 6-digit totalizers can count at 10kHz speed. They share a
5-digit dividing scale factor. The totalizer performs as follows:
min
), Hour (
hour
), or Day (
day
).
MINItrol-PW (MRTPW)
Example: MRTPW A 3 1 A
Series:
MRTPW= 6 digits, totalizer / ratemeter
with presets and scaling.
Operating Voltage:
A= 110 VAC ± 15% or 12 to 15 VDC
B= 220 VAC ± 15% or 12 to 15 VDC
C= 24 VAC ± 15% or 12 to 15 VDC
Count Inputs:
3 = Standard, 4-30 VDC simultaneous inputs.
3M = Mag. Input A, rate/total input only, 30mV input
(Inhibit input, 4-30V)
Options (Multiple Options Available)
1= RS232 Communications
2= RS422 Communications
A= Analog Output (4-20/0-20 mA)
If Freq. In > Cutoff
Total increment = Freq. Offset • ∆ Time + Pulses In
K Factor A K Factor A
Rate = Freqin + Freq offset • time base
K Factor A
Time base: Sec =1, Min = 60, Hour = 3600, Day = 86400
If Freq. In < Cutoff
Total Increment = 0
Rate = 0
Total B (grand total) increments with Total A.
THEORY OF OPERATION
Low flow, Pelton Wheel turbine flowmeters have a transfer characteristic which can best be represented by the following equation for
frequencies above the minimum usable flowrate for the device:
frequency = K
Where: K
This transfer characteristic applies with the meter manufacturers
published range. Below some minimum flow meter output frequency , the flow rate should be considered as 0 and the totalization
inhibited. This is called the "cutoff" frequency.
and offset frequency are scaling constants de-
linearized
termined during flow sensor calibration.
• GPM – Offset Frequency
linearized
60
2
HOW TO MOUNT THE UNIT
The unit is designed to be mounted with a gasket providing a water tight seal. Two mounting brackets are provided to
secure the unit to the panel. A panel less than .1" may distort if the clamps are screwed too tightly.
Slide the body of the unit through the rubber gasket. Insert the unit into the panel. As shown in "FIG. A", slide the brackets
up the groove to press against the back of the panel. Insert screws into rear of brackets and tighten them evenly and
alternately. Do not over tighten! A normal level of torque is required. Maximum torque should be 3" pounds.
This product is designed to be panel mounted and is NEMA 4 rated if proper mounting procedures are followed and the
required and supplied hardware is correctly used.
If the panel in which the unit is mounted is less than 0.125" thick, the possibility exists that there will be some flexing.
Should this flexing occur, the resulting deformation of the panel could cause a loss of the water tight seal. In case this
should occur, the use of silicone or other sealant would be recommended.
This product is designed to the NEMA 4 rated. However, the fact that we are unable to control either the location in which
the device is installed or the actual installation itself requires that the company's liability shall extend only to the repair or
replacement of a defective product.
We are prepared to offer additional assistance in those special situations where normal mounting methods do not seem to
satisfy the customers needs. This assistance may be obtained by calling the factory and asking for Application Engineering.
DIMENSIONS
3.925
(99.7)
FIG. A
4.437
(112.7)
2.625
(66.68)
0.587
(14.91)
BEZEL
GASKET
4.245
(107.8)
CUSTOMER PANEL
Panel Thickness 0.062" (1.5)
to 0.187" (4.7) max.
3.622
(92)
1.772
(45)
3
WIRING GUIDELINES
The rear terminal contains 12 screw terminals for connecting #14 to #28 gauge wire.
The unit is controlled by a microprocessor and, therefore, an electrically "noisy" environment could cause operating
problems. The input power line should not be common to power lines for motors, pumps, contactors, etc.
The unit is designed to be immune from line or transient voltage interference. In some environments voltage spikes of over
1000 volts can occur. When common to a power line driving motors voltage fluctuations can be extreme and rapid. Lines
driving DC or AC solenoids, relays, or actuators can also cause problems.
Four sources of noise can occur:
1) AC power line noise - If the unit cannot be connected to a clean power source, an inductive load suppressing device
(MOV as GE # V130LA1 or Resistor Capacitor as Paktron # .2 uf/220 ohm @ 400V) can be installed. Although locating
the suppressor across the AC supply at the unit should help, best results are obtained by connecting the suppressor
across the leads of the "load" at the device causing the spike.
2) Input line noise -The noise is carried on the input and D.C. ground lines. Make sure the input wires are never run into
the unit in a bundle with power input lines. Also, keep these input lines isolated from inductive lines from devices
drawing heavy loads. If there is a possibility of electrical noise, we recommend using shielded cable, with the shield
being hooked to the D.C. ground terminal on the instrument, and to "earth" at one point in the circuit, preferably at the
D.C. ground terminal of the unit.
3) Output lines - The unit has two relay outputs. When these outputs are used to run external relays or solenoids, spikes
can be generated upon activation. This noise can spread through the instrument causing operating problems. If the
source is a D.C. operated device, a general purpose diode (IN4004) placed across the solenoid prevents electrical
noise spikes. Connect the cathode (banded side) to the more positive side of the coil. If the source is an A.C. operated
device, use a MOV or Resistor Capacitor across the coil.
4) 12 VDC output supply - Noise can be generated on the 12 VDC output supply if it is used to drive inductive loads or if
the current draw exceeds 50 mA. Insure that all inductive loads have a diode (such as IN4004) across the coil and that
the current does not exceed 50 mA.
TOTALIZER INHIBIT INPUT
In many applications it is sometimes necessary to inhibit totalization while certain operations are being performed. A high
logic level on this input inhibits totalization while the rate indication is still active. This feature is useful during meter proving
and may be used with liquid phase detectors.
4
CONNECTING AC / DC POWER
NOTE: Connect power only after other connections are finished. Do not touch the live AC power terminals! The unit has
been designed with an isolated AC input. Thus, polarity is not a concern for the AC input. The chassis is plastic, therefore
earth ground is not used. For D.C. operation, connect + 12V to pin 7 and - D.C. to pin 8.
CONNECTING SENSOR INPUTS
These diagrams show how to hook a typical input sensor to the unit. The unit supplies an unregulated 12 Volt (50mA)
output to power these sensors (Pin 7).
A valid pulse is one which makes a transition from the off-state (0 to 1V) to the on-state (4 to 30V): a positive going edge.
The input impedance is 10K Ohms to ground. The unit can be programmed from the front panel for slow switch closure
inputs up to 40Hz (select "Lo CPS"), or solid state switches (select "hi CPS") up to 9.99KHz. No rear terminal jumpers are
required. Use PNP (sourcing) type pulsers.
TYPICAL SENSOR HOOKUP
High Level Pulse Low Level Pulse (Mag Pickup)
Flowmeter
RELAYS
A
B
1 COMMON
2 N.O. (N.C./NPN)
3 COMMON
OUTPUT
POWER
GROUND
4 N.O. (N.C./NPN)
5 A INPUT
6INHIBIT TOTAL INPUT
7 12 V OUTPUT/ + DC INPUT
8 - DC (GROUND)
9 RESET INPUT
10 NOT USED
11 AC INPUT
12 AC INPUT
*
* PULLUP RESISTOR REQUIRED FOR
OPEN COLLECTOR OUTPUTS
4.7KΩ TYPICAL
Flowmeter
with Mag. Pickup
RELAYS
A
B
1 COMMON
2 N.O. (N.C./NPN)
3 COMMON
SIGNAL
GROUND
4 N.O. (N.C./NPN)
5 A INPUT
6INHIBIT TOTAL INPUT
7 12 V OUTPUT/ + DC INPUT
8 - DC (GROUND)
9 RESET INPUT
10 NOT USED
11 AC INPUT
12 AC INPUT
5
WHA T CAN YOU VIEW?
Pressing VIEW shows:
A) The total of input A. If "reset to 0" is selected A counts up, if "set to preset" is selected A will count down.
B) The rate of input A.
C)* The grand total of input A (B Total) which always count up.
NOTE:
* All decimal points are inverted when "B total" (grand total) is being displayed.
OUTPUT JUMPER SELECTIONS
FUNCTION
"A" RELAY
N.C. OUTPUT
"B" RELAY
N.C. OUTPUT
"A" PRESET
*
TRANSISTOR (NPN)
*
"B" PRESET
TRANSISTOR (NPN)
BOTTOM VIEW AT TERMINAL
L
20192
12 11 10 9 8 7 6 5 4 3 2 1
MODIFICATION
CUT JUMPER
AT "A" "B" TO "2"
CUT JUMPER
AT "D" "E" TO "4"
CUT JUMPER
AT "A" "C" TO "2"
CUT JUMPER
AT "D" "F" TO "4"
FC
AB
H
G
DE
4
2
MILLIVOLT INPUT OPTION
JUMPER SELECTIONS
J3
U1
P1
U6
C2
REV
20229
J6
J5
B
U3
J2
J1
J4
C3
CR5
C8R7R5
C7
R1
R10R6C6
R8
U5
R2
R9
U4
C4
C5
C1
C9
CR6
CR3
U2
CR2
R3
CR4
CR1
R4
If the unit has the millivolt input bd.# 20229, The A inputs can be
solder jumper programmed to accept either a low millivolt or 4-30 V
input. The B input should always be set for 4-30 V. Each unit
shipped is programmed according to part number. If solder jumpers are made, the part number should be modified to reflect the
changes made
C=CLOSE, O=OPEN
* The unit must be removed from the case to access jumpers C & F, all
other jumpers can be accessed by removing the plastic extender.
NOTE: All three pads at jumpers 2 and 4 are connected.
4-30V INPUT Millivolt INPUT
Input A J1-O, J2-C, J3-O J1-C, J2-O, J3-C
InputB J4-O, J5-C, J6-O
6
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