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
OPERATING THE FRONT PANEL
Press to "reset"
in operating
mode.Press to
"enter" in
programming
mode.
Start Here
PRGM
4
Press to
view or
change
preset B.
3
21
Press to alternately
view A rate, A total
or A grand total.
Press to
enter
lock code for
panel lock.
65
RST
ENTER
LOCK PRE A PRE B VIEW PRGM
Press to
view or
change
preset A.
PROGRAMMING FLOWCHART
Press this key to step through menu choices.
PRGM
RST
ENTER
Press this key to enter displayed value
Press to cycle
through PROGRAM
choices. Press to
toggle between
choices in program
mode.
FACToR
ENTER
DP F A
ENTER
#####
ENTER
DP F B
ENTER
#####
ENTER
RUN MODE
PRGM
CouNT
ENTER
RST
0
ENTER
DPLoC
Hi
CPS
RUN MODE
PRGM
ENTER
PRGM
ENTER
PRGM
SET
PR
Lo
CPS
RATE
ENTER
sec
min
PRGM
hour
day
ENTER
NoR ##
ENTER
FiguR#
ENTER
cut ##
ENTER
RUN MODE
PRGM
LoC
ENTER
LC
PRGM
PRg
ENTER
CoDE
#####
RUN MODE
ENTER
A
ToT
RELAY
ENTER
PRGM
PRGM
LC
ENTER ENTER
ALL
A ##.#
ENTER
B
PRGM
ToT
ENTER ENTER
B ##.#
RUN MODE
A
RATE
B
RATE
ENTER
7
The following is a list of abbreviations as they appear on the display and front panel of the unit.
ABBREVIATION DESCRIPTION
FACTOR
DP F A
DP F B
COUNT
RST 0
SET PR
DP LOC
HI CPS
LO CPS
RATE
SCALING FACTOR - Enter the 5 digit dividing scale factor (K-Factor) for the total input (Input A).
DECIMAL POINT FOR FACTOR A (K-Factor) - Enter location of decimal point for Scaling Factor A by press-
ing the button under the digit where the decimal is desired.
DECIMAL POINT FOR FACTOR B (offset) - Enter location of decimal point for the Offset Scaling Factor by
pressing the button under the digit where the decimal is desired.
PORTION OF MENU FOR SETTING COUNTER VARIABLES
RESET TO 0 - Counter will reset to 0. The totalizer will count up from 0.
SET TO PRESET - Counter will reset to preset A. The totalizer will count down from preset A. The grand
totalizer will count up .
DECIMAL POINT LOCATION - Enter desired location of decimal by pushing the button under the digit where
the decimal is desired. Changing the decimal will change the decimal location in the totalizer and grand
totalizer, but not the rate display.
HIGH COUNTS PER SECOND - This sets the unit for high count speeds (0-9.99KHz)
LOW COUNTS PER SECOND – This sets the unit for contact debounce filtering (0-40Hz)
PORTION OF MENU FOR SETTING RATE VARIABLES
sec
min
hour
day
NOR##
FIGUR ##
cut
LOC
RATE PER SECOND - The display will read in rate per second.
RATE PER MINUTE - The display will read in rate per minute.
RATE PER HOUR - The display will read in rate per hour.
RATE PER DAY- The display will read in rate per day.
NORMALIZING FACTOR - Normalizes (averages) the data being received. Higher settings provide more
normalizing (averaging) for a more stable display. Derived from the equation:
(Old Data x "NOR" + New Data)
("NOR" + 1)
SIGNIFICANT FIGURE - This sets the amount (1-5) of meaningful figures the unit will display. (RATE DIS
PLAY ONLY). FOR EXAMPLE: If "2" is set as the figure, a rate of 273.45 will be displayed as 270.
CUTOFF FREQUENCY - Enter the minimum usable frequency for the input device. Any input pulses below
this frequency are blocked, the rate reads "0" and totalization stops.
LOCK - This portion of the menu allows you to:
1) lock the program (presets are still accessible)
2) lock all (presets and program are locked).
8
LC PRG
LOCK PROGRAM - This will lock the program and allow the presets to be changed when the unit is in the
lock mode.
LC ALL
CODE
RELAY
A TOT
A RATE
A##.#
B TOT
B RATE
B##.#
LOCK ALL - This will lock the program and the presets when the unit is in the locked mode. The presets can
be viewed, but not changed.
LOCK CODE - This message (code) will flash on display for approximately 3 seconds. It will be followed by a
5 digit number (xxxxx). The number you enter here will be the code to lock and unlock the unit.
RELAY - This portion of the menu allows you to set your relay operation variables.
RELAY A FOR TOTALIZER - When this is selected relay A will activate when the total (Total A) has reached
Preset A.
RELAY A FOR RATE - When this is selected relay A will activate when the Rate of input A equals or exceeds
preset A.
RELAY A DURATION - This prompt will appear when "A TOT" is selected. It is the duration which the
relay will remain energized (00.1 to 99.9 sec). If 00.0 is selected, the relay will latch until reset. When the
duration is not at 00.0, the total will autorecycle.
RELAY B FOR TOTALIZER - When this is selected relay B will activate when the grand total (Total B) has
reached preset B.
RELAY B FOR RATE - When this is selected relay B will activate when the rate equals or exceeds preset B.
The relay will drop out when the rate falls below preset B.
RELAY B DURATION - This prompt will appear when "B TOT" is selected. It is the duration which
relay B will remain energized (00.1 to 99.9 sec). If 00.0 is selected, the relay will latch until reset. When the
duration is not at 00.0, the grand total will autorecycle. The autorecycle mode for the grand total may be used
to create a relay pulse output.
1- COMMON
2- N.O.(N.C./NPN)
3- COMMON
4- N.O.(N.C./NPN)
5- RATE / TOTAL INPUT
6- INHIBIT TOTAL INPUT
7- 12VDC OUT/+DC IN
8- -DC (GROUND)
9- RESET INPUT
10- NOT USED
11- A.C. INPUT
12- A.C. INPUT
A
B
SWITCH
RELAYS
ON
13- V+
14- I SINK
OFF
RUN
4-20mA
RATE
RUN
1 2 3 4
WIRING TERMINATIONS
ANALOG
OUTPUT
Analog Out Setup SwitchesSerial Port
13 14
ON
CAL.
0-20mA
TOTAL
SET
9
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4
ON
REAR VIEW
CALCULATING SCALE FACTORS
There are two separate scale factors, assciciated with pelton wheel flowmeters. The factor ranges from
0.0001 to 99999. Because the "units per second", "minute", "hour" or "day" are field programmable
from the keypad, scale factor calculations for the ratemeter are easy.
The A Factor is used for the linearized number of pulses per desired unit of measure.
The B Factor is used for the offset frequency (in Hz).
10
PROGRAMMING
STEP
1
SETTING
SCALING
FACTORS
PRESS
PRGM
ENTER
ENTER
ENTER
DISPLAY
factor
dp f a
#####
dp f b
REMARKS
This section of the menu is used to set up
the scaling factors for rate and total.
This sets the decimal for the primary
scaling factor (Factor A). Press the arrow key under the digit where the decimal is desired. To clear the decimal,
press the arrow key furthest to the right
(PRGM) .
This is the primary scaling factor (Factor
A) for input A. To change, press the
arrow key under the digit(s) to change.
Press ENTER to enter the displayed
value.
This sets the decimal for the offset scaling factor (Factor B). Press the arrow key
under the digit where the decimal is
desired. To clear the decimal, press the
arrow key furthest to the right (PRGM) .
ENTER
#####
This is the offset scaling factor (Factor B)
for the rate and totalizer. To change,
press the arrow key under the digit(s) to
change. Press ENTER to enter the displayed value.
11
PRESS DISPLAY REMARKS
STEP
2
SETTING
THE
COUNTER
PRGM
PRGM
ENTER
ENTER
ENTER
factor
count
rst 0
or
set pr
dp loc
hi cps
or
lo cps
This section of the menu sets up the
counter information.
Press the PRGM key to choose RST 0
(reset to 0, count up) or SET PR (set to
preset, count down), press the ENTER
key to enter the displayed choice.
This sets the decimal location for the
totalizer and grand totalizer Press the
arrow key under the desired digit location. To clear the decimal, press the
arrow key furthest to the right. Press
the ENTER key to enter the displayed
location.
Press the PRGM key to choose HIGH
CPS (0-9.99KHz) or LOW CPS (040Hz). Press the ENTER key to enter
the displayed choice.
12
STEP
3
SETTING
THE RATE
PRGM
PRGM
REMARKSPRESS DISPLAY
factor
count
PRGM
ENTER
ENTER
ENTER
ENTER
rate
Sec
min
hour
day
nor #.#
figur #
cut ##
This section of the menu is used to set up
the rate information.
Press the PRGM key to choose SEC (rate
per second), MIN(RPM), HOUR (RPH) or
DAY (rate per day). Press ENTER to enter
displayed choice.
This sets the normalizing (averaging) factor. Press the arrow keys under the desired digits to change. Press ENTER to
enter displayed value.
This sets the minimum number of significant figures to be displayed. Press the arrow key under the digit to change. Press
ENTER to enter displayed value.
This sets the cutoff frequency 00-99 Hz.
Any input frequency below this value will
inhibit the totalizer and ratemeter reading.
Press the arrow keys under the desired
digits to change. Press ENTER to enter
displayed value.
13
PRESS
DISPLAY REMARKS
STEP
4
SETTING
LOCK
PRGM
PRGM
PRGM
PRGM
ENTER
ENTER
factor
count
rate
loc
LC PrG
or
LC ALL
CoDE
Flashes
followed by:
#####
This section of the menu is used to set up
the lockout type and code.
LC PRG = Locks program but presets and
reset are accessible.
LC ALL= Locks entire keypad.
Press the PRGM button to toggle between
choices; Press ENTER to enter displayed
choice.
After CODE flashes the display will show the
existing lock code. To change the code press
the key under each digit to be changed. Press
ENTER to enter displayed value.
SETTING
THE
LOCK
STATUS
LOCK
ENTER
CoDE
Flashes
followed by:
0
LoC
or
uN LoC
Key in the lock code (see programming step
4) by pressing the keys under the digits to be
changed. Press the ENTER key to enter the
displayed code.
After the code is entered the unit will display
LOC (unit is locked) or UN LOC (unit is unlocked). This message will be displayed for
approximately 3 seconds before the unit returns to the run mode.
14
DISPLAYPRESS
REMARKS
STEP
5
SETTING
THE
RELAYS
THIS SELECTION
WILL ONLY APPEAR
IF "A RATE" IS
CHOSEN
PRGM
PRGM
PRGM
PRGM
PRGM
ENTER
ENTER
ENTER
factor
count
rate
loc
relay
a tot
or
a rate
A ##.#
b tot
or
b rate
This section sets up the relay information.
Press the PRGM key to choose A TOT (A
assigned to total A) or A RATE (A assigned
to rate). Press enter when the desired choice
is displayed.
This is the duration (.1 to 99.9 sec) that relay
A will remain energized. If 00.0 is selected,
the relay will latch until reset
Press the PRGM key to choose B TOT (B
assigned to grand total B) or B RATE (B
assigned to rate). Press enter when the desired choice is displayed.
THIS SELECTION
WILL ONLY APPEAR
IF "B RATE" IS
CHOSEN
SETTING
THE
PRESETS
ENTER
PRE A
PRE B
b ##.#
PRE A
Followed by
last PRE A
entered
PRE B
Followed by
last PRE A
entered
This is the duration (.1 to 99.9 sec) that relay
B will remain energized. If 00.0 is selected,
the relay will latch until reset
PRE A = Preset A; The set point at which
output A will trigger. If the displayed value is
not the desired preset, press the key(s) under
the digit to be changed.
PRE B = Preset B; The set point at which
output B will trigger. If the displayed value is
not the desired preset, press the key(s) under
the digit to be changed.
15
OUTPUT WIRING
The following diagrams detail the connection of the relay and analog output options. Each relay consist of a form A contact
(Normally Open). NPN transistor or Normally Closed contacts are available with solder jumpers (see Jumper Options).
ANALOG OUTPUT
The analog output can be selected to output 4-20 mA or 0-20 mA and can be selected to track the rate or total.
Pin 13 supplies 12 to 18V to power the current loop. Pin 14 supplies the current sinking driver. When connecting
a strip chart recorder, make connections as follows:
ALARMS
STRIP CHART
ANALOG
OFF
RUN
RATE
RUN
OUTPUT
ON
CAL.
0-20mA
TOTAL
SET
RECORDER
TURBINE FLOWMETER
+
-
PULSE OUTPUT
+12V
GND
1- COMMON
2- N.O.(N.C./NPN)
3- COMMON
4- N.O.(N.C./NPN)
5- RATE / TOTAL INPUT
6- INHIBIT TOTAL INPUT
7- 12VDC OUT/+DC IN
8- -DC (GROUND)
9- RESET INPUT
10- NOT USED
11- A.C. INPUT
12- A.C. INPUT
A
B
SWITCH
RELAYS
ON
13- V+
14- I SINK
4-20mA
1 2 3 4
APPLICATION HINT: A 0-5 V output can be created by choosing 0-20 mA and using a 250Ω resistor.
The relays can be used to trigger alarms which warn the operator that the total or rate has exceeded a set
amount. The outputs are programmable to be assigned for rate or total. When assigned to the total, the relays
can have a user selectable on time (duration) or can be latched until reset.
LIGHT
BELL
TURBINE FLOWMETER
W/ MAG. PICKUP
1- COMMON
2- N.O.(N.C./NPN)
3- COMMON
4- N.O.(N.C./NPN)
5- RATE / TOTAL INPUT
6- INHIBIT TOTAL INPUT
7- 12VDC OUT/+DC IN
8- -DC (GROUND)
9- RESET INPUT
10- NOT USED
11- A.C. INPUT
12- A.C. INPUT
16
RELAYS
A
B
SWITCH
ON
13- V+
14- I SINK
OFF
RUN
4-20mA
RATE
RUN
1 2 3 4
OUTPUT
ON
CAL.
0-20mA
TOTAL
SET
ANALOG
ANALOG OUTPUT OPTION
Description:
An optional 4-20mA (0-20mA) output has been added to 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.
Connections: (see FIG. 1)
PIN13 supplies the 12 to 18 VDC to power the current loop.
PIN14 is the control sink driver
Accuracy:
± 0.25% FS
Compliance Voltage:
3 to 30 VDC
Setup:
The optional analog output feature uses 4 dip switches on the back
for setup. These switches are used as follows:
SW1 - View or change "set low" and/or "set high" values
SW2 - Select output for rate or total
SW3 - Select 4-20mA or 0-20mA
SW4 - Calibrate the unit.
After the regular parameters shown in the programming flowchart
have been set, locate the 4 switches on the back of the unit. (see
FIG. 1)
Switch Settings:
SWITCH 1: Enter Analog Low & High (normally off)
Switch 1 is used to load in the low (4mA or 0mA) and/or the high
(20mA) output settings. With power on, set switch 1 ON (up).
SWITCH 4: Calibrate (normally off)
Switch 4 is used for calibration. Calibration is done at the factory
and should not be needed (see SWITCH 1 to enter high and low
values). If recalibration is desired, a calibrated 20mA ammeter
with 1uA resolution is needed. Attach the "+" lead of the meter to
pin 13 and the "-" lead to pin 14. Set switch 4 ON (up). The unit
will output approximately 20.000mA and a decimal will light in the
third position. Read the output using the ammeter. Press PRE A.
If the display is the same as the ammeter reading, press ENTER.
If not, press buttons A through E to step to ammeter reading and
ENTER. (Disregard display which now shows the last count reading with decimal point in third position) Return switch 4 to OFF
(down) position.
RS232 & RS422 Operation:
When the unit is suppled with RS232 or RS422, the analog output
"low" and "high" settings can be accessed and changed through
the serial port. The codes are as follows:
AL Unit will display (transmit) analog out "low" value.
AL(S)XXXXX Unit will load analog out "low" with entered
number. (S) = space
AH Unit will display (transmit) analog out "high" value.
AH(S)XXXXX Unit will load analog out "high" with entered
number. (S) = space
FIG. 1
Analog Out Setup SwitchesSerial Port
13 14
1 2 3 4
ON
LOW SETTING is viewed or changed by pressing PRE A. If the
displayed value is correct, press ENTER. If not, press buttons A
through E to step to the desired value and press ENTER. (disregard the display which will show the last count reading).
HIGH SETTING is viewed or changed by pressing PRE B. If the
displayed value is correct, press ENTER. If not, press buttons A
through E to step to desired value and press ENTER.
Return switch 1 to OFF (down) position, PRE A and PRE B buttons
now function to view or change relay trip values.
SWITCH 2: Select Total or Rate
SW2 OFF (down): Analog output follows rate
SW2 ON (up): Analog output follows total
SWITCH 3: Select 4-20mA or 0-20mA
SW3 OFF (down): Selects 4-20mA output range
SW3 ON (up): Selects 0-20mA output range
1 2 3 4 5 6 7 8 9 10 11 12
Typical Wiring:
STRIP CHART
RECORDER
TURBINE FLOWMETER
REAR VIEW
+
-
PULSE OUTPUT
+12V
GND
1- COMMON
2- N.O.(N.C./NPN)
3- COMMON
4- N.O.(N.C./NPN)
5- A INPUT
6- INHIBIT TOTAL INPUT
7- 12VDC OUT/+DC IN
8- -DC (GROUND)
9- RESET INPUT
10- NOT USED
11- A.C. INPUT
12- A.C. INPUT
RELAYS
A
B
SWITCH
ON
1234
13- V+
14- I SINK
OFF
RUN
4-20mA
RATE
RUN
ON
CAL.
0-20mA
TOTAL
SET
ANALOG
OUTPUT
17
INTERF ACE CARD RS 232/422 OPERATION
RS 232/422 SET-UP:
All serial communication mode changes must be done
through serial communications. Mode changes cannot be
done through the front panel. To initialize the unit, place a
jumper between pin 7(+12V )[bottom board] and pin 1(init) [DB
-9 connector] on initial power up. The unit defaults to: 300
baud rate,"MARK" parity and device number 01. To enter the
program mode you must set your terminal for 300 baud rate
and "MARK" parity. Next, type D1(s), (s)= space bar. The
unit will echo back "DEVICE #1:". Now type EP (enter
program) and a carriage return (enter). The unit will echo back
"PROGRAM SETTING". You are now in the programming
mode.
SETUP PROCEDURE:
The following sections consist of the communications setup
options as they appear in the menu. (If you wish to exit the
program mode, at any time you can hit the "escape key" (Hex
Code: 1B) and the unit will save the changes made but not
effect the remaining data values.) When each section of the
setup menu is displayed, the current data will appear in the <
> signs. If you wish to change the data, type in the number
of the desired choice and press return (enter). If you wish to
keep the current data, simply press return.
DEVICE NUMBER:
Each unit in the multidrop installation must be assigned it's
own device number (1 to 99). Zero is reserved for a dedicated
hook-up to only one terminal, and it's transmit output line
remains in an "on" active state. The device number is entered
in the program mode. The unit will prompt you:
DEVICE# <XX>?
If XX is the desired device number press return (enter), if not
enter the desired number after the question mark and press
return (enter).
BAUD RATE:
The baud rate is the speed at which data is transmitted,
expressed in bits per second. Baud rates of 300, 600, 1200,
2400, 4800 or 9600 are available. When in the baud rate
section of the menu, the unit will list :
BAUD RATES:
1:300 2:600 3:1200
4:2400 5:4800 6:9600
then prompt you:
BAUD RATE <300>?
Press return (enter) if this is the desired baud rate or enter the
assigned number of one of the six possible baud rates. If an
invalid baud rate is entered the unit will prompt you to choose
another baud rate. This will occur until a valid baud rate is
entered or escape is pressed.
PARITY:
Parity is a bit of information that is inserted before the stop bit
and is used to help check if the data transmission is correct.
When setting the parity you may select "ODD" (parity bit is
logic 0 if total number of logic 1's in the first seven data bits is
odd), "EVEN" (parity bit is logic 0 if total number of logic 1's in
the first seven data bits is even), "MARK" (parity bit is always
logic 1 - High / Mark) or "SPACE" (parity bit is always logic 0
- Low / Space). If a "MARK" parity is chosen, it will appear that
two stop bits are used. Use the "MARK" parity with terminals
using parity "OFF" or "NONE". These terminals ignore the
parity. The unit does not check the parity but does transmit the
parity chosen. When setting the parity, the unit will print:
PARITIES:
MARK-0 SPACE-1 EVEN-2 ODD-3
Then the unit will prompt you:
PARITY<MARK>?
If this is the desired parity press return (enter), if it isn't enter
the number of the desired parity then press return (enter).
STROBE LIST:
The serial interface card is also equipped with a strobe line.
When the strobe line is triggered, a chosen set of data will be
transmitted to be displayed or printed. The selections for the
display list are entered in the program mode. Enter "1" to add
selections to the list and enter "0" to delete selections from the
list. The seven available items for the strobe display list are:
(1) Preset A, (2) Preset B, (3) K-Factor A, (4) K-Factor B, (5)
Rate of A, (6) Count A, (7) Count B. When setting the strobe
list the unit will print :
ENTER STROBE LIST:
DO NOT DISPLAY-0 DISPLAY-1
The unit will prompt you:
PRESET A<DISPLAY>?
PRESET B<DISPLAY>?
K-FACTOR A<DISPLAY>?
K-FACTOR B<DISPLAY>?
RATE<DISPLAY>?
COUNT A<DISPLAY>?
COUNT B<DISPLAY>?
If the above choices are entered, when the strobe line is
triggered (3-30V positive pulse) the unit will transmit:
DEVICE# 1:
PA XXXXX
PB XXXXX
KA XXXXX
KB XXXXX
DR XXXXXX
DA XXXXXX
DB XXXXXX
(SEE COMMANDS BELOW FOR DESCRIPTION OF COMMAND CODES).
Each time the strobe line gets triggered the unit will transmit
this data unless the program mode is entered and the strobe
list altered.
After these four items have been entered they will remain
unaltered unless the program mode is entered again and the
values changed. The unit is now set and must be addressed
by it's device number to come on line again.
18
SERIAL INPUT COMMANDS:
To get a unit on line you must address it by it's device number.
This is done by typing DXX(S), XX= device number. The unit
comes on line and echoes back DEVICE# XX. Insure that
"DEVICE# XX:" is received before requests are sent. The unit
is now ready to receive a command or string of commands
separated by a space. A carriage return (enter) will enter the
commands and processing of requests begins. The carriage
return (Hex Code "D") puts the unit "off line" after data is
processed.
COMMANDS:
EP...........Unit will enter program mode.
DA..........Unit will display (transmit) Total A.
DB..........Unit will display (transmit) Total B (grand total).
DR..........Unit will display (transmit) rate A.
KA..........Unit will display K-factor A.
†*KA(S)XXXXX....Unit will load K-factor A
with entered number.
KB..........Unit will display K-factor B
†*KB(S)XXXXX....Unit will load K-factor B
with entered number.
PA...........Unit will display Preset A.
†PA(S)XXXXX....Unit will load Preset A with
entered number.
PB...........Unit will display Preset B
†PB(S)XXXXX....Unit will load Preset B with
entered number.
RA..........Total A will reset
†*RA(S)XXXXXX...Unit will set Total A to
entered number.
RB..........Total B (grand total)will reset.
†*RB(S)XXXXXX...Unit will reset Total B (grand total) to
entered number.
*THE UNIT WILL RECOGNIZE A DECIMAL IF ONE IS
PLACED IN ANY OF THESE DATA VALUES.
†THE UNIT WILL ONLY RECOGNIZE THE LAST FIVE
DIGITS ENTERED (SIX DIGITS FOR RA & RB).
The following is an example of requests and responses:
Transmit from terminal Receive from unit
(s)=Space
D5(s) [Unit #5 Activated] DEVICE# 5:
PA(s)12345(s)PA PA 12345 PA
KA(s)1576(s)KA KA 1576 KA
KB(s)6751(s)KB KB 6751 KB
RA(s)RB[RETURN] RA RB
(UNIT PRESETS AND A & B K-FACTORS ARE SET AND
BOTH TOTALIZERS ARE RESET)
12345
1576
6751
SERIAL INTERFACE OPERATION:
Data is received and transmitted over standard EIA RS232 or
RS422 levels. Each ten bit character is made up of a start bit,
seven bit ASCII code, a parity bit and a stop bit. Device
number, baud rate, parity and strobe list are entered in the
program setup mode and will remain in memory even if power
is lost.
The input impedance of RS232 is 3KΩ to 7KΩ worst case. The
terminal addressing the unit must be capable of driving all
loads in the loop. The input impedance of RS422 is much
higher and there should be no problem driving as many as 99
units. The transmit line remains in a high impedance "off"
state until addressed. Only one unit is to be on line at a time!!!
More than one unit on line could damage the unit or corrupt the
transmitted data.
When the unit is active (on line) it will operate in a full duplex,
echo back mode, so that data sent from the terminal will be
transmitted back for verification. When the unit is "on line",
use the proper serial transmit commands to request data or
set a new value. Up to 80 characters of data can be linked
together and transmitted to the unit in a string as long as there
is a space between the commands. If an error is made, a
correction can be made by back spacing and retyping correct
data before the return (enter) is sent. Once a return (enter) is
sent, the unit begins processing the data and will transmit the
requested data on a non-priority basis over the data transmit
line. A keypad entry or incoming data will halt the data
communication cycle. Therefore, there should be a pause
after data is requested to insure that all data has been
transmitted before making another request or addressing
another unit. If the unit is not busy, it should not take longer
than 300 msec to process each request. To find the cycle time
to process and transmit a request, calculate the bit transmit
time by using this formula: [(1÷ baud rate) x (80) + .005] x
number of requests made. This time will be extended if the
unit must service the front keypad. If transmission has not
started within two seconds after data is requested, it can be
assumed that there is a problem. The unit transmits a carriage
return and line feed after each data value. Any new communication must be started with DXX(S) (device number and
space).
RS232/RS422 - IBM-PC INTERFACE:
The following program is for IBM basic to set up RS232/RS422
on serial port (#1) at 300 baud. Run this program after
connecting the serial interface connections.
10 SCREEN 0,0:WIDTH 80
20 CLS:CLOSE
30 OPEN "COM1:300,n,7,1,CS,DS,CD" AS #1
40 ON ERROR GOTO 110
50 B$=INKEY$
60 IF B$< >"" THEN PRINT #1,B$;
70 IF EOF (1) THEN 50
80 A$=INPUT$ (LOC(1),#1)
90 PRINT A$;
100 GOTO 50
110 RESUME
19
RS232 / RS422 WIRING
234
5
678
9
RS 232
COMPUTER HOOKUP:
RS 232: When connecting the unit to a computer with RS 232
communication, only three connections are needed. These
connections are: Receive data, Transmit data and Ground.
The connections should be made as follows:
DP -9 CONNECTOR COMPUTER
Transmit data (pin 2) Receive data
Receive data (pin 3) Transmit data
Ground (pin 5) Ground
RS 422: When connecting the unit to a computer with RS 422,
five connections are needed. These connections are: Receive data A (+), Receive data B (-), Transmit data A (+),
Transmit data B (-) and Ground. The connections should be
made as follows:
DP -9 CONNECTOR COMPUTER
Transmit data A(+) (pin 2 Receive data A(+)
Transmit data B(-) (pin 7) Receive data B(-)
Receive data A(+) (pin 3) Transmit data A(+)
Receive data B(-) (pin 8) Transmit data B(-)
Ground (pin 5) Ground
RST
B C
D E
A
ENTER LOCK PRE A PRE B VIEW PRGM
RST
B C
D E
A
ENTER LOCK PRE A PRE B VIEW PRGM
RS 232
1. INITIALIZE
2. TRANSMIT
3. RECEIVE
4. N/C
5. GROUND
6. STROBE
7. N/C
8. N/C
9. N/C
RECEIVE PIN (3)
TRANSMIT PIN (2)
GROUND PIN (5)
RS 422
RECEIVE A (+) PIN (3)
RECEIVE B (-) PIN (8)
TRANSMIT A (+) PIN (2)
TRANSMIT B (-) PIN (7)
GROUND PIN (5)
1
RS 422
1. INITIALIZE
2. TRANSMIT A (+)
3. RECEIVE A (+)
4. N/C
5. GROUND
6. STROBE
7. TRANSMIT B (-)
8. RECEIVE B (-)
9. N/C
RS 232
STROBE PIN (6)
PRINTER HOOKUP:
When connecting the unit to a printer, you must first program
the desired baud rate, parity and strobe list with a computer.
RST
B C
A
ENTER LOCK PRE A PRE B VIEW PRGM
After the unit is programmed it can be connected to the printer.
Connect the transmit line(s) of the unit to the receive line(s) of
the printer and be sure that both devices have common
grounds. When the strobe line is triggered the unit will transmit
the selected strobe list which you had previously programmed.
RST
B C
A
ENTER LOCK PRE A PRE B VIEW PRGM
20
+12V PIN (7)
(BOTTOM BOARD)
TRANSMIT PIN (2)
D E
GROUND PIN (5)
STROBE PIN (6)
+12V PIN (7)
(BOTTOM BOARD)
TRANSMIT A (+) PIN (2)
D E
TRANSMIT B (-) PIN (7)
GROUND PIN (5)
RS 422
TROUBLESHOOTING GUIDE
PROBLEM SOLUTIONSPOSSIBLE CAUSES
Power is applied to unit but the display
does not light.
Unit works, but occasionally the display
freezes or skips counts.
Input signal is connected but the unit
does not totalize or display rate.
Rate is displaying: r FFFFF.
1. AC or DC power wiring is incorrect.
1. Line noise is affecting the processor
due to a current spike or surge.
1. Input wiring is incorrect.
2. Scale factors are incorrect.
3. Transmitting device is defective.
4. Wrong debounce filtering selected.
5. Minitrol is defective.
6. Cutoff frequency set too high.
1. The unit is trying to display a
number which it can't (too large).
2. Line noise affected unit on power
up.
1. Recheck power wiring
1. Use a different power supply or
install a surge suppressor.
1. Recheck input wiring.
2. Recheck scale factors and factor
calculations.
3. Replace transmitting device.
4. Recheck debounce filtering selection
"hi cps" or "lo cps".
5. To confirm set Factor A at "1" &
Factor B at "0", Cut to "0" Connect a
wire to pin #7 and touch it to pin # 5
(input A). Each time pin #5 is touched
Total A should count once. If not,
call factory for RMA.
6. Recheck cutoff frequency setting
1. Check scaling factor, if it is correct,
lower the number of significant
figures.
2. Reprogram the unit and be sure to
enter a decimal (enter one and re
move it if a decimal is not desired).
Relays are not activating properly.
Totalizer resets before reaching
999999.
1. Wrong relay duration.
2. Relay set for wrong activation
i.e. total instead of rate.
1. Relay duration is set at a value other
than 00.0. This causes the total
to auto-reset at the preset.
1. Recheck programmed relay duration.
2. Recheck programmed relay
activation mode.
1. If relay outputs are not being used,
set the relays for rate.
2. Set the relay durations to 00.0.
21
NOTE TO OUR CUSTOMER
KEP is dedicated to providing complete customer service and customer satisfaction. If you
have any comments or criticisms about how to improve this manual, please make a note
of the problem/improvement and notify us. We are always open to new ideas and
improvements. So please let us know your ideas and comments.
Call us toll free: 800-631-2165
WARRANTY
This product is warranted against defects in materials and workmanship for a period of two
(2) years from the date of shipment to Buyer.
The Warranty is limited to repair or replacement of the defective unit at the option of the
manufacturer. This warranty is void if the product has been altered, misused, dismantled, or
otherwise abused.
ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, ARE EXCLUDED, INCLUDING
BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE.
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