KEP SUPERtrol-I Operating Manual

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Page 1

SUPERtrol-I

Flow Computer

99534 04/28/10

KESSLER-ELLIS PRODUCTS

10 Industrial Way East

Eatontown, NJ 07724

800-631-2165 • 732-935-1320

Fax: 732-935-9344

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WARNING!

!!!

Power, input and output (I/O) wiring must be in accordance with Class I, Division 2 wiring methods Article 501-4 (b) or the National Electrical Code, NFPA 70 for installations in the U.S., or as specied in Section 18-1J2 of the Canadian Electrical Code for installations within Canada and in accordance with the authority having juristiction.

1. This equipment is suitable for use in Class I, Division 2, Groups A, B, C, and D or

Non-Hazardous Locations Only.

2. WARNING - EXPLOSION HAZARD - Substituition of components may impair suit-

ability for Class I, Division 2.

3. WARNING - EXPLOSION HAZARD - Do not disconnect equipment unless power

has been switched off or the area is known to be Non-Hazardous.

WARNING!

This instrument contains electronic components that are susceptible to damage by static electricity. Proper handling* procedures must be observed during the removal, installation, or handling of internal circuit boards or devices.

*Handling Procedure

1. Power to unit must be removed.

2. Personnel must be grounded, via wrist strap or other safe, suitable means, before any printed circuit board or other internal device is installed, removed or adjusted.

3. Printed circuit boards must be transported in a conductive bag or other conductive container. Boards must not be removed from protective enclosure until the immediate time of installation. Removed boards must be placed immediately in protective container for transport, storage, or return to factory.

Comments

This instrument is not unique in its content of ESD (electrostatic discharge) sensitive components. Most modern electronic designs contain components that utilize metal oxide technology (NMOS, CMOS, etc.). Experience has proven that even small amounts of static electricity can damage or destroy these devices. Damaged components, even though

they appear to function properly, may exhibit early failure.

SAFETY INSTRUCTIONS

The following instructions must be observed.

• This instrument was designed and is checked in accordance with regulations in force EN 60950 (“Safety of information technology equipment, including electrical business equipment”).

A hazardous situation may occur if this instrument is not used for its intended purpose or is used incorrectly.

Please note operating instructions provided in this manual.

• The instrument must be installed, operated and maintained by personnel who have been properly trained. Personnel must read and understand this manual prior to installation and operation of the instrument.

• This instrument is internally fused. Replace the internal fuse with the following specied type and rating only:

Input Power Recommended Fuse

115 VAC 160 mA slow blow fuse 230 VAC 80 mA slow blow fuse 12-24 VDC 800 mA slow blow fuse

Disconnect power supply before replacing fuse!

• The manufacturer assumes no liability for damage caused by incorrect use of the instrument or for modications or changes made to the instrument.

Symbols Used On Unit

Number Symbol Publication Description

1 IEC 417, No. 5031 Direct current 2 IEC 417, No. 5172 Equipment protected throughout by DOUBLE

INSULATION or REINFORCED INSULATION (equivalent to Class II of IEC 536–see annex H)

ISO 3864, No. B.3.1 Caution (refer to accompanying documents)

Technical Improvements

• The manufacturer reserves the right to modify technical data without prior notice.

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SUPERtrol-I Flow Computer

CONTENTS

1. DESCRIPTION

1.1 Unit Description ...............................................................................................1

1.2 Unit Features ...................................................................................................1

1.3 Specications ...................................................................................................2

2. INSTALLATION

2.1 General Mounting Hints ...................................................................................6

2.2 Mounting Diagrams ..........................................................................................6

3. APPLICATIONS

3.1 Liquid Volume ..................................................................................................7

3.2 Corrected Liquid Volume .................................................................................8

3.3 Liquid Mass ......................................................................................................9

3.4 Batching .........................................................................................................10

4. WIRING

4.1 Typical Batcher Wiring ................................................................................... 11

4.2 Typical Rate/Total Wiring ............................................................................... 11

4.3 Wiring In Hazardous Areas ............................................................................12

5. UNIT OPERATION

5.1 Front Panel Operation Concept for Run Mode ..............................................13

5.2 General Operation .........................................................................................14

5.3 Ratemeter/Totalizer Operation .......................................................................14

5.3.1 Password Protection for Rate/Total mode .......................................14

5.3.2 Relay Operation in Rate/Total mode ...............................................14

5.3.3 Pulse Output in Rate/Total mode ....................................................14

5.3.4 Analog Output in Rate/Total mode ..................................................14

5.3.5 RS-232 Serial Port Operation in Rate/Total mode ......................... 15

5.3.6 RS-485 Serial Port Operation in Rate/Total mode ......................... 15

5.4 Batcher Operation ..........................................................................................16

5.4.1 Batcher Conguration .....................................................................16

5.4.2 Password Protection for Batcher mode ..........................................17

5.4.3 Relay Operation in Batcher mode ...................................................17

5.4.4 Pulse Output in Batcher mode .......................................................17

5.4.5 Analog Output in Batcher mode ......................................................17

5.4.6 RS-232 Serial Port Operation in Batcher mode .............................18

5.4.7 RS-485 Serial Port Operation in Batcher mode .............................18

6. PROGRAMMING

6.1 Front Panel Operation Concept for Program Mode .......................................19

6.2 EZ Setup .......................................................................................................20

6.3 Setup Menus ..................................................................................................21

6.4 Setup Sub-Menus ..........................................................................................22

6.4.1 SELECT EZ SETUP ......................................................................22

6.4.2 INSTRUMENT TYPE ......................................................................22

6.4.3 SELECT FLOW EQUATION ..........................................................23

6.4.4 SETUP INDICATORS (Total) ..........................................................23

6.4.5 SETUP INDICATORS (Density) ......................................................23

6.4.6 SETUP INDICATORS (Rate) ..........................................................24

6.4.7 SETUP INDICATORS (Temperature) ..............................................24

6.4.8 SETUP FLOW INPUT (Pulse - Ain & PS (A=B)) .............................25

6.4.9 SETUP FLOW INPUT (Pulse - Quadrature, Qx1 or Qx2) ...............26

6.4.10 SETUP FLOW INPUT (Analog) ....................................................27

6.4.11 SETUP AUX INPUT .....................................................................28

6.4.12 SET FLUID PROPERTIES ..........................................................29

6.4.13 SETUP PULSE OUTPUT .............................................................29

6.4.14 SETUP ANALOG OUTPUT ..........................................................30

6.4.15 SETUP RELAYS ..........................................................................30

6.4.16 SETUP CONTROL INPUTS(RATE/TOTAL) ................................ 32

6.4.17 SETUP CONTROL INPUTS(BATCH) ...........................................32

6.4.18 SETUP REALTIME CLOCK(Time) ................................................33

6.4.19 SETUP REALTIME CLOCK(Date) ................................................33

6.4.20 SERIAL USAGE ............................................................................34

6.4.21 SET DATALOG/PRINT(Congure) ................................................35

6.4.22 SET DATALOG/PRINT (Select_list) ..............................................36

6.4.23 ADMINISTRATIVE SETUP ..........................................................36

6.4.24 SETUP NETWORK CARD ..........................................................37

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SUPERtrol-I Flow Computer

CONTENTS

7. PRINCIPLE OF OPERATION

7.1 General ..........................................................................................................38

7.2 Orice Flowmeter Considerations ..................................................................38

7.3 Flow Equations ..............................................................................................38

7.4 Calculating the Expansion Factor ..................................................................41

7.5 Computation of Viscosity Coef. A and B ........................................................42

7.6 Linearization Table .........................................................................................43

7.6.1 Linearization Table General Information .........................................43

7.6.2 Linearization Table for Pulse Inputs ................................................43

7.6.3 Linearization Table for Analog Inputs ..............................................43

7.6.4 Linearization Table Interpolation .....................................................43

8. TEST, SERVICE and MAINTENANCE

8.1 Test Menus ....................................................................................................44

8.2 Test Sub-Menus .............................................................................................45

8.2.1 Audit Trail ........................................................................................45

8.2.2 Error History ....................................................................................45

8.2.3 Print System Setup .........................................................................45

8.2.4 Keypad test .....................................................................................46

8.2.5 Display test .....................................................................................46

8.2.6 Calibrate CH1 0mA .........................................................................47

8.2.7 Calibrate CH1 20mA .......................................................................47

8.2.8 Calibrate CH2 0mA .........................................................................48

8.2.9 Calibrate CH2 20mA .......................................................................48

8.2.10 Calibrate CH1 0V ..........................................................................49

8.2.11 Calibrate CH1 10V ........................................................................49

8.2.12 Calibrate CH2 0V ..........................................................................50

8.2.13 Calibrate CH2 10V ........................................................................50

8.2.14 Calibrate 100 ohm RTD ................................................................50

8.2.15 Calibrate 4mA Out .........................................................................51

8.2.16 Calibrate 20mA Out ......................................................................51

8.2.17 Analog In Test ...............................................................................51

8.2.18 Pulse input test .............................................................................52

8.2.19 Analog out test ..............................................................................52

8.2.20 Excitation out test ..........................................................................52

8.2.21 Pulse out test ................................................................................53

8.2.22 Relay test .....................................................................................53

8.2.23 Control input test ...........................................................................53

8.2.24 Battery Voltage test .......................................................................54

8.2.25 Data logger utility .........................................................................54

8.3 Internal Fuse Replacement ............................................................................55

9. RS-232 SERIAL PORT

9.1 RS-232 Serial Port Description ......................................................................56

9.2 Instrument Setup by PC Over Serial Port .....................................................56

9.3 Operation of Serial Communication Port with Printers ..................................56

9.4 Flow Computer RS-232 Port Pinout ..............................................................56

10. RS-485 SERIAL PORT

10.1 RS-485 Serial Port Description ....................................................................57

10.2 General .......................................................................................................57

10.3 Operation of Serial Communication Port with PC ........................................57

10.4 Flow Computer RS-485 Port Pinout ............................................................57

11. FLOW COMPUTER SETUP SOFTWARE

11.1 System Requirements ..................................................................................58

11.2 Cable and Wiring Requirements .................................................................. 58

11.3 Installation for Windows™3.1 or 3.11 ..........................................................58

11.4 Using the Flow Computer Setup Software ...................................................59

11.5 File Tab ........................................................................................................59

11.6 Setup Tab .....................................................................................................59

11.7 View Tab .......................................................................................................60

11.8 Misc. Tab ......................................................................................................60

12. GLOSSARY OF TERMS

12 Glossary Of Terms ..........................................................................................61

13. DIAGNOSIS AND TROUBLESHOOTING

13.1 Response of Flow Computer on Error or Alarm: ..........................................65

13.2 Diagnosis Flow Chart and Troubleshooting ................................................. 66

13.3 Error & Warning Messages: .........................................................................67

13.3.1 Sensor/Process Alarms .................................................................67

13.3.2 Self Test Alarms ............................................................................68

APPENDIX A

Setup Menus ........................................................................................................69

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Unit Description 1. Description

1.1 Unit Description:

The SUPERtrol-I Flow Computer satises the instrument requirements for a variety of owmeter types in liquid applications. Multiple ow equations and instrument functions are available in a single unit with many advanced features.

The alphanumeric display shows measured and calculated parameters in easy to understand format. Single key direct access to measurements and display scrolling is supported.

The versatility of the SUPERtrol-I permits a wide range of measurements within the instrument package. The various hardware inputs and outputs can be “soft” assigned to meet a variety of common application needs. The user “soft selects” the usage of each input/output while conguring the instrument. Consider the following illustrative examples.

SUPERtrol-I Flow Computer

Unit Features

The isolated analog output can be chosen to follow volume ow, corrected volume ow, mass ow, temperature, or density by means of a menu selection. Most hardware features are assignable by this method.

The user can assign the standard RS-232 Serial Port for data logging, transaction printing, or for connection to a modem for remote meter reading.

1.2 Unit Features:

The SUPERtrol-I Flow Computer offers the following features:

• EZ-Preset or Standard Preset

• Custody Transfer with Audit Trail

• Multiple Instrument Functions

• Menu Selectable Hardware & Software Features

• Two Line LCD or VFD Display

• Isolated Outputs Standard

• Versatile RS-232 Port Standard

• DIN Enclosure with Two Piece Connector

• Optional Networking Cards

• Advanced Batching Features

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1.3 Specications:

SUPERtrol-I Flow Computer

Specications:

Environmental

Indoor Use Altitude up to 2000m Operating Temperature: 0°C to +50°C (-20°C to 55°C optional) Storage Temperature: -40°C to +85 C Maximum Relative Humidity : 80% for

temperatures

up to 31°C decreasing linearly to 50% RH at 40°C Mains supply voltage uctuations not to exceed ±10% of the nominal voltage Tr an s i e n t o v e r vo l t ag e a c c or d i n g to INSTALLATION CATEGORY II (see UL 3101-1 Annex J) POLLUTION DEGREE 2 in accordance with IEC 664 (see 3.7.3) Materials: UL, CSA, VDE approved UL= UL Class 1 Division 2

Approvals: CE Approved Light Industrial, UL File #: E192404 / CUL

Display

Type: 2 lines of 20 characters Types: Backlit LCD or VFD ordering options Character Size: 0.3" nominal User selectable label descriptors and units of

measure

Keypad

Keypad Type: Membrane Keypad Keypad Rating: Sealed to Nema 4 Number of keys: 16

Enclosure

Size: See Dimensions Seal: NEMA4X Materials: Aluminum

Power Input

The factory equipped power option is internally fused. An internal line to line lter capacitor is provided for added transient suppression. Order Option 1: 110VAC: 85 to 127 Vrms, 50/60Hz Order Option 2: 220VAC: 170 to 276 Vrms, 50/60Hz Order Option 3: 12VDC: 10.5 to 14 VDC Order Option 4: 24VDC: 18 to 24 VDC

Flow Inputs:

Analog Input:

Ranges Voltage: 0-10 VDC, 0-5 VDC, 1-5 VDC Current: 4-20 mA, 0-20 mA Basic Measurement Resolution: 16 bit Update Rate: 5 updates/sec minimum Automatic Fault detection: Signal over/underrange, Current Loop Broken Calibration: Self Calibration and Auto-zero Continuously Extended calibration: Learns Zero and Full Scale of each range using special test mode. Fault Protection: Fast Transient: 500 V Protection (Capacitive Clamp) Reverse Polarity: No ill effects Over-Voltage Limit: 50 VDC Over voltage protection Over-Current Protection: Internally current limited Protected to 24 VDC.

Pulse Inputs:

Number of Flow Inputs: one Congurations supported: single input with or without quadrature (menu selectable) Input Impedance: 10 KΩ nominal Pullup Resistance: 10 KΩ to 5 VDC (menu selectable) Pull Down Resistance: 10 KΩ to common Trigger Level: (menu selectable) High Level Input Logic On: 3 to 30 VDC Logic Off: 0 to 1 VDC Low Level Input (mag pickup) Selectable sensitivity: 10 mV & 100 mV Minimum Count Speed: User selectable Maximum Count Speed: Selectable: 0 to 20kHz Overvoltage Protection: 50 VDC Fast Transient: Protected to 500 VDC (Capacitive Clamp)

Compensation Input

The compensation input is menu selectable for temperature, density or not used.

Operation: Ratiometric Accuracy: 0.01% FS Thermal Drift: Less than 100 ppm/C Basic Measurement Resolution: 16 bit Update Rate: 1 update/sec minimum Automatic Fault detection: Signal Over-range/under-range Current Loop Broken RTD short RTD open Fault mode to user dened default settings

Transient Protection: 500 V (Capacitive Clamp) Reverse Polarity: No ill effects Over-Voltage Limit (Voltage Input): 50 VDC

Available Input Ranges Voltage: 0-10 VDC, 0-5 VDC, 1-5 VDC Current: 4-20 mA, 0-20 mA Resistance: 100 Ohms DIN RTD

100 Ohm DIN RTD (DIN 42-760, BS 1904): Three Wire Lead Compensation Internal RTD linearization learns ice point resistance 1 mA Excitation current with reverse polarity protection Temperature Resolution: 0.01 C

Control Inputs

Switch Inputs are menu selectable for Start, Stop, Reset, Lock, Inhibit, Alarm Acknowledge, Print or Not Used. Control Input Specications Input Scan Rate: 10 scans per second Logic 1: 4 - 30 VDC Logic 0: 0 - 0.8 VDC Transient Suppression: 500 V fast transient (Capacitive Clamp) Input Impedance: 100 KΩ Control Activation: Positive Edge or Pos. Level based on product denition

Excitation Voltage

110/220 VAC Powered Units Menu Selectable: 5, 12 or 24 VDC @ 100mA 24 VDC Powered Units Menu Selectable: 5 or 12 VDC @ 100mA 12 VDC Powered Units 5 VDC @ 100mA

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SUPERtrol-I Flow Computer

Relay Outputs

The relay outputs are menu assignable to (Individually for each relay) Low Rate Alarm, Hi Rate Alarm, Prewarn Alarm, Preset Alarm or General purpose warning (security).

Number of relays: 2 (4 optional) Contact Style: Form C contacts Contact Ratings: 2400 VAC Max., 3 Amps Max. Fast Transient Threshold: 1000 V

Serial Communication

The serial port can be used for printing, datalogging, modem connection and communication with a computer. RS-232: Device ID: 01-99 Baud Rates: 300, 600, 1200, 2400, 4800, 9600,

19200 Parity: None, Odd, Even Handshaking: None, Software, Hardware Print Setup: Configurable print list and formatting RS-485: Device ID: 01-247 Baud Rates: 1200, 2400, 4800, 9600, 19200 Parity: None, Odd, Even Protocol: Modbus RTU (Half Duplex)

Analog Output

The analog output is menu assignable to correspond to the Uncompensated Volume Rate, Corrected Volume Rate, Mass Rate, Temperature, Density, Volume Total, Corrected Volume Total or Mass Total. Type: Isolated Current Sourcing (AC power options) Isolated I/P/C: 500 V Available Ranges: 4-20 mA, 0-20 mA Resolution: 12 bit Accuracy: 0.05% FS at 20 Degrees C Update Rate: 1 update/sec minimum Temperature Drift: Less than 200 ppm/C Maximum Load: 1000 ohms (at nominal line voltage) Compliance Effect: Less than .05% Span 60 Hz rejection: 40 dB minimum EMI: No effect at 3 V/M Calibration: Operator assisted Learn Mode Averaging: User entry of DSP Averaging constant to cause an smooth control action.

Isolated Pulse output

The isolated pulse output is menu assignable to Uncompensated Volume Total, Compensated Volume Total or Mass Total. Isolation I/O/P: 500 V Pulse Output Form: Open Collector Maximum On Current: 125 mA Maximum Off Voltage: 30 VDC Saturation Voltage: 1.0 VDC Maximum Off Current: 0.1 mA Pulse Duration: User selectable Pulse output buffer: 8 bit Fault Protection Reverse polarity: Shunt Diode Transient Protection: 500 VDC (Capacitive Clamp)

Operating Mode

The Flow Computer can be thought of as making a series of measurements of ow, temperature/density sensors and then performing calculations to arrive at a result(s) which is then updated periodically on the display. The analog output, the pulse output, and the alarm relays are also updated. The cycle then repeats itself.

Step 1: Update the measurements of input

signalsRaw Input Measurements are made at each input using equations based on input signal type selected. The system notes the “out of range” input signal as an alarm condition.

Step 2: Compute the Flowing Fluid Parameters-

The temperature, viscosity, and density equations are computed as needed based on the ow equation and input usage selected by the user.

Step 3 : Compute the Volumetric Flow-

Uncompensated ow is the term given to the ow in volume units. The value is computed based on the owmeter input type selected and augmented by any performance enhancing linearization that has been specied by the user.

Step 4: Compute the Corrected Volume Flow at Reference Conditions-

In the case of a corrected liquid volume ow calculation, the corrected volume ow is computed as required by the selected compensation equation.

Step 5 : Compute the Mass Flow-

All required information is now available to compute the mass ow rate as volume ow times density.

Step 6: Check Flow Alarms-

The ow alarm functions have been assigned to one of the above ow rates during the setup of the instrument. A comparison is now made by comparing the current ow rates against the specied hi and low limits.

Step 7: Compute the Analog Output-

This designated ow rate value is now used to compute the analog output.

Step 8: Compute the Flow Totals by Summation-

A ow total increment is computed for each ow rate. This increment is computed by multiplying the respective ow rate by a time base scaler and then summing. The totalizer format also includes provisions for total rollover.

Step 9: Total Preset Comparisons-

The total associated with a preset function is then compared against the corresponding preset value and any required control actions taken.

Step 10: Pulse Output Service-

The pulse output is next updated by scaling the total increment which has just been determined by the pulse output scaler and summing it to any residual pulse output amount.

Step 11: Update Display and Printer Output-

The instrument nally runs a task to update the various table entries associated with the front panel display and serial outputs.

Page 8

SUPERtrol-I Flow Computer

Setup Mode

The setup mode is password protected by means of a numeric lock out code established by the user. In addition, a secret, manufacturers numeric unlock entry sequence is available.

The system also provides a minimum implementation of an “audit trail” which tracks signicant setup changes to the unit. This feature is increasingly being found of benet to users or simply required by Weights and Measurement Ofcials in systems used in commerce, trade, or “custody transfer” applications.

A software program is available which runs on a PC using a RS-232 Serial for connection to the Flow Computer. Illustrative examples may be down loaded in this manner.

The setup mode has numerous subgrouping of parameters needed for ow calculations. There is a well conceived hierarchy to the setup parameter list. Selections made at the beginning of the setup affect offerings further down in the lists.

In the setup mode, the ow computer activates the correct setup variables based on the instrument conguration, the ow equation, and the hardware selections made for the compensation transmitter type, the flow transmitter type, and meter enhancements (linearization) options selected. All required setup parameters are enabled. All setup parameters not required are suppressed.

A help line prompt is provided for each entry. In addition a help message is available which may be accessed by depressing the “HELP” key.

In the setup mode selections, several parameters are required to be input by the operator since these parameters are blank when the unit is received. The user will be prompted for these necessary values for his application.

Also note that in the setup mode are parameter selections which have preassigned industry standard values. The unit will assume these values unless they are modied by the user.

Most of the process input variables have available a “default” or emergency value which must be entered. These are the values that the unit assumes when a malfunction is determined to have occurred on the corresponding input.

It is possible to enter in a nominal constant value for temperature or density, or analog ow inputs by placing the desired nominal value into both the lo and hi values. This is also a convenience when performing bench top tests without simulators.

Maintenance Mode:

The Maintenance Mode of the Flow Computer is the Test and Calibration Mode for the device. This mode provides a number of specialized utilities required for factory calibration, instrument checkout on startup, and periodic calibration documentation.

A password is required to gain access to this specialized mode of operation. Normally quality, calibration, and maintenance personnel will nd this mode of operation very useful. It is also useful for factory testing.

Many of these tests may be used during start-up of a new system. Inputs signals may be read, and output signals may be exercised to verify the electrical interconnects before the entire system is put on line.

The following action items may be performed in the Maintenance Mode:

Print Calibration/Maintenance Report Examine Audit Trail Perform Keypad Checkout Perform Display Checkout Perform Pulse Input Checkout Perform Pulse Output Checkout Perform Control Input Checkout Perform Relay Output Checkout Perform Analog Input Checkout Perform Analog Output Checkout Calibrate Analog Inputs using the Learn Feature Calibrate Analog Output using the Learn Feature Battery Check

Note that a calibration of the analog input/output will advance the audit trail counters since it effects the accuracy of the system.

RS-232 Serial Port

The Flow Computer has a general purpose RS-232 Port which may be used for any one of the following purposes:

Transaction Printing Data Logging Internal Datalog Dumps Remote Metering by Modem (optional) Computer Communication Link Conguration by Computer Print System Setup Print Calibration/Malfunction History Remote Control

Instrument Setup by PC’s over Serial Port

A Diskette program is provided with the Flow Computer that enables the user to rapidly congure the Flow Computer using an Personnel Computer. Included on the diskette are common instrument applications which may be used as a starting point for your application. This permits the user to have an excellent starting point and helps speed the user through the instrument setup.

Page 9

SUPERtrol-I Flow Computer

Operation of Serial Communication Port with Printers

Flow Computer’s RS-232 channel supports a number of operating modes. One of these modes is intended to support operation with a printer in metering applications requiring transaction printing, data logging and/or printing of calibration and maintenance reports.

For transaction printing, the user denes the items to be included in the printed document. The user can also select what initiates the transaction print generated as part of the setup of the instrument. The transaction document may be initiated via a front panel key depression, a remote contact closure, or upon completion of a batch.

In data logging, the user denes the items to be included in each data log as a print list. The user can also select when or how often he wishes a data log to be made. This is done during the setup of the instrument as either a time of day or as a time interval between logging.

The system setup and maintenance report lists all the instrument setup parameters and usage for the current instrument conguration. In addition, the Audit trail information is presented along with a status report listing any observed malfunctions which have not been corrected.

Operation of Serial Port with Modems (optional)

The Flow Computer RS-232 channel supports a number of operating modes. One of these modes is intended to support operation with a modem in remote metering applications.

An external modem is intentionally being used with the Flow Computer. This permits use with the variety of modem standards worldwide while avoiding the specialized approvals required for equipment that is deemed to fall under the category of telecommunication equipment.

In the modem mode, the Flow Computer is assumed to be operating in a remote metering role. The Flow Computer will support key items in the Hayes Compatible “AT” Command Set. In this role, the Flow Computer will have the following special abilities:

0. Monitor the modem status as a task of the

system

1. Instruct the modem to answer an incoming call

ATA

2. Respond to the calling modem at a compatible

baud rate and protocol

3. Perform error checking in conjunction with the

modem

4. Monitor the status of the carrier

5. Terminate the telephone connection in event the

connection is lost.

The user initiates the printing of this report at a designated point in the menu by pressing the print key on the front panel.

In addition, the Flow Computer will be capable of initiating a call to a designed telephone number in the event of a metering malfunction.

Page 10

6.15

2. Installation

SUPERtrol-I Flow Computer

General Mounting Hints

Mounting Procedure

2.1 General Mounting Hints:

The SUPERtrol-I Flow Computer should be located in an area with a clean, dry atmosphere which is relatively free of shock and vibration. The unit is installed in a 5.43” (138mm) wide by 2.68” (68mm) high panel cutout. (see Mounting Dimensions) To mount the Flow Computer, proceed as follows:

a. Prepare the panel opening. b. Slide the unit through the panel cutout until the it touches the panel. c. Install the screws (provided) in the mounting bracket and slip the bracket

over the rear of the case until it snaps in place.

d. Tighten the screws rmly to attach the bezel to the panel. 3 in. lb. of

torque must be applied and the bezel must be parallel to the panel.

Termination Connectors:

Minimum Wire Gauge: 22 AWG Maximum Wire Gauge: 14 AWG Voltage/current limits are limited by unit specications.

Permanently Connected Equipment:

UL 3101-1, Section 6.12.2.1 species that:

• A switch or circuit breaker shall be included in the building installation;

• It shall be in close proximity to the equipment and within easy reach of the OPERATOR;

• It shall be marked as the disconnecting device for the equipment.

Ensure that the switch or circuit breaker chosen is suitable for the power requirements of the unit.

2.2 Mounting Diagrams:

Standard Mounting Bezel Kit Mounting

SUPERtrol-I

Mounting Bracket

Dimensions

3.43 (87)

RATE TOTAL

START

GRAND6SCROLL7PRE 28DENS

STOP

5.67 (144)

GPM

147.43 GAL

267395.749

TEMP4PRE 13RATE2TOTAL

TIME

–

6.18 Dotted Line Shows Optional Bezel Kit

CLEAR•MENU

HELP

2.83 (72)

ENTER

0.28 (7.2)

0.4 (10)

(156)

0.5

(13)

SUPERtrol-I

Bezel Adaptor

Gasket

Mounting Bracket

5.43

(138)

Panel

Cutout

2.68 (68)

Dimensions are in inches (mm)

Page 11

3. Applications

STOP

START

–

CLEAR•MENU

ENTER

HELP

PRE 1

RATE

TOTAL

GRAND6SCROLL7PRE 28F2

Flowmeter

SUPERtrol-I Flow Computer

Liquid Volume

3.1 Liquid Volume

Measurements:

A owmeter measures the actual volume in a liquid line. A temperature sensor can also be installed to correct for liquid thermal expansion (see

3.2 Corrected Volume).

Calculations:

• For Flowmeters with Pulse Outputs, Volume ow is calculated using the owmeter frequency output and the user entered K-Factor.

• For Flowmeters with Analog Transmitters, Volume ow is calculated using the measured owmeter signal and the user entered scale settings.

Output Results:

• Display Results

Flow Rate, Resettable Total, Non-Resettable Total

• Analog Output

Rate or Total

• Pulse Output

Total

• Relay Outputs

Rate or Total Alarms

Liquid Volume Illustration

Applications:

The Flow Computer can monitor actual volume ow and total of any liquid. Flow alarms are provided via relays and datalogging is available via analog (4-20mA) and serial outputs.

Calculations

Pulse Input; Average K-Factor

input frequency * time scale factor Volume Flow = K-Factor

Analog Input; Linear

Volume Flow = % input * Full Scale Flow

Page 12

SUPERtrol-I Flow Computer

STOP

START

–

TIME

CLEAR•MENU

ENTER

HELP

TEMP

PRE 1

RATE

TOTAL

GRAND6SCROLL7PRE 28DENS

Flowmeter Temperature Transmitter

Corrected Liquid Volume

3.2 Corrected Liquid Volume

Measurements:

A owmeter measures the actual volume in a liquid line. A temperature sensor is installed to correct for liquid thermal expansion.

Calculations:

• Corrected Volume is calculated using the ow and temperature inputs as well as the thermal expansion coefcient stored in the ow computer. Use the "SET FLUID PROPERTIES" submenu to dene reference temperature and density values for standard conditions.

Output Results:

• Display Results

Flow Rate, Resettable Total, Non-Resettable Total, Temperature,

Density

• Analog Output

Rate, Total, Temperature or Density

• Pulse Output

Total

• Relay Outputs

Rate , Total or Temperature Alarms

Corrected Liquid Volume Illustration

Applications:

Monitoring corrected volume ow and total of any liquid. Flow alarms are provided via relays and datalogging is available via analog (4-20mA) and serial outputs.

Calculations

Volume Flow

As calculated in section 3.1

Corrected Volume Flow (Temp. Transmitter)

Corrected Volume Flow = vol. ow * (1 - Therm.Exp.Coef. *(Tf-Tref))

Page 13

SUPERtrol-I Flow Computer

STOP

START

–

TIME

CLEAR•MENU

ENTER

HELP

TEMP

PRE 1

RATE

TOTAL

GRAND6SCROLL7PRE 28DENS

Orifice Plate

with DP Transmitter

Temp./Dens.

Transmitter

STOP

START

–

TIME

CLEAR•MENU

ENTER

HELP

TEMP

PRE 1

RATE

TOTAL

GRAND6SCROLL7PRE 28DENS

Flowmeter Temp./Dens.

Transmitter

Liquid Mass

3.3 Liquid Mass

Measurements:

Actual volume is measured by the flow element (DP transmitter, Flowmeter). Temperature is measured by the temperature transmitter. A density transmitter can be used for direct density measurements.

Calculations:

• The density and mass ow are calculated using the reference density and the thermal expansion coefcient of the liquid (see "SET FLUID PROPERTIES" submenu)

Output Results:

• Display Results

Flow Rate, Resettable Total, Non-Resettable Total, Temperature,

Density

• Analog Output

Rate, Total, Temperature or Density

• Pulse Output

Total

• Relay Outputs

Rate, Total or Temperature Alarms

Liquid Mass Illustration

Applications:

Monitoring mass ow and total of any liquid. Flow alarms are provided via relays and datalogging is available via analog (4-20mA) and serial outputs.

Calculations

Volume Flow

As calculated in section 3.1

Mass Flow

Mass Flow = volume ow * density

Page 14

SUPERtrol-I Flow Computer

STOP

START

–

CLEAR•MENU

ENTER

HELP

PRE 1

RATE

TOTAL

GRAND6SCROLL7PRE 28F2

Flowmeter Temperature Transmitter

(Optional)

Solenoid Valve

Batching

3.4 Batching

Measurements:

A owmeter measures the actual volume in a liquid line. A temperature sensor can also be installed to correct for liquid thermal expansion (see

3.2 Corrected Volume).

Calculations:

• For Flowmeters with Pulse Outputs, Volume ow is calculated using the owmeter frequency output and the user entered K-Factor.

• For Flowmeters with Analog Transmitters, Volume ow is calculated using the measured owmeter signal and the user entered scale settings.

• Corrected Volume is calculated using the ow and temperature inputs as well as the thermal expansion coefcient stored in the ow computer.

Output Results:

• Display Results

Flow Rate, Batch Total, Non-Resettable Total, Temperature,

Density

• Analog Output

Rate, Total, Temperature or Density

• Pulse Output

Total

• Relay Outputs

Batch Total, Rate, or Temperature Alarms

Batching Illustration

Applications:

Batching and monitoring ow and total of any liquid. Batching is accomplished via relays and datalogging is available via analog (4-20mA) and serial outputs.

Calculations

Volume Flow

As calculated in section 3.1

Corrected Volume Flow (Temp. Transmitter)

Corrected Vol. Flow = volume ow * (1 - Therm.Exp.Coef. *(Tf-Tref))

Page 15

4 WIRING

Optional Wiring for

(+) V

SUPERtrol-I Flow Computer

Batcher Wiring

Flow Sensor with Preamp

FLOW SENSOR

(+) V Signal

Com.

4.1 Typical Batcher Wiring:

Signal

1 2

FLOW SENSOR

MOV recommended

TURBINE

Remote Counter

115 VAC

115 VAC SOLENOID VALVE

Common

123456

DC OUTPUT

PULSE IN 1

PULSE IN 2

COMMON

---------

RTD EXCIT +

RTD SENS RTD SENS -

StartStop

8 9

CNTR IN 1

CNTR IN 2

CNTR IN 3

COMMON 13 PULSE OUTPUT + 14

PULSE OUTPUT 15

ANALOG OUTPUT + 16

ANALOG OUTPUT -

17 NC 18 COM 19 20 21 22

COM

RLY1

RLY2

Vin + Iin +

Vin +

Iin +

25 NC 26 27 28 29 30

FLOW

COMP

SEE USER MANUAL

4-20 mA

COM RLY3 NO

NC COM RLY4 NO

Rate / Total Wiring

115 VAC

4.2 Typical Rate/Total Wiring:

Signal

Common

FLOW SENSOR

100 Ohm DIN RTD

123456

STRIP CHART

RECORDER

Remote Counter

Alarm Relay 1

Alarm Relay 2

AC LINE

AC LINE24

DC OUTPUT 2

PULSE IN 1 3

PULSE IN 2 4

COMMON 5

---------

RTD EXCIT + 7

RTD SENS

RTD SENS -

8 9

CNTR IN 1 10

CNTR IN 2 11

CNTR IN 3 12

COMMON 13 PULSE OUTPUT + 14

PULSE OUTPUT 15

ANALOG OUTPUT + 16

ANALOG OUTPUT -

17 NC

{ {

18 COM 19 20 21 22

COM

RLY1

RLY2

DC + DC -

Vin + Iin +

Vin +

Iin +

25 NC 26 27 28 29 30

POWER IN

FLOW

COMP

SEE USER MANUAL

4-20 mA

COM RLY3 NO

NC COM RLY4 NO

115 VAC

AC LINE

AC LINE24

DC + DC -

POWER IN

Page 16

SUPERtrol-I Flow Computer

1 2 3 4

4-20

Q/∆P

–

2 1

3 4

28V

Diode

24V Out

4-20mA In Common

4-20mA Flow

Transmitter

4-20

–

1 2

4 3

28V

Diode

24V Out

4-20mA Press.

Transmitter

4-20mA In

Common

4 5 6 7 8

1 2 3 4 5 6

7 8 9 10 11 12 13 14 15 16 17

Common

RTD Excite (+) RTD Sense (+) RTD Sense (–)

3-Wire RTD

4.3 Wiring In Hazardous Areas:

Examples using MLT787S+ Barrier (MTL4755ac for RTD)

Flow Input

Temperature Input (4-20mA Transmitter)

Flow Input

Hazardous Area Safe Area

Temperature Input (4-20mA Transmitter)

Hazardous Area Safe Area

Temperature Input (RTD)

Hazardous Area Safe Area

Page 17

SUPERtrol-I Flow Computer

5. UNIT OPERATION

5.1 Front Panel Operation Concept for Run Mode

The Flow Computer is fully programmable through the front panel. Please review the following usage summary before attempting to use the instrument.

START

STOP

TOTAL

GRAND6SCROLL7PRE 2

RATE

PRE 1

TEMP

DENS

TIME

CLEAR

HELP

–

•

ENTER

HELP

On-line help is provided to assist the operator in using this product. The help is available during RUN and SETUP modes simply by pressing the HELP key. The HELP key is used to enter decimals when entering numeric values.

FUNCTION KEYS

In the RUN mode, several keys have a special, direct access feature, to display an item of interest (i.e. RATE, TOTAL, PRE 1, etc.). Press the key to view your choice. Press the SCROLL key to return to scrolling display.

CLEARING TOTALIZER

To clear the total, you must press the TOTAL Function Key 3 times. You will be asked to verify this action. The operator will be prompted to enter password if the unit is locked. NOTE: In the Batcher Mode, simply press the CLEAR key to reset the total (the batcher must be stopped or nished

batching). It is not necessary to press the TOTAL Function Key rst.

CLEARING GRAND TOTAL

To clear the grand total, you must press the GRAND Function Key 3 times. You will be asked to verify this action. The supervisor will be prompted to enter the supervisor password if the unit is locked.

PRESET KEYS USING EZ PRESET

In the RUN mode, PRE 1 & PRE 2 keys are used to view and/or change the preset setpoints. To view the Presets, simply press the desired Preset key. Press Enter then press the Clear key for direct editing of the preset setpoints.

PRESET KEYS

In the RUN mode, PRE 1 & PRE 2 keys are used to view and/or change the preset setpoints. To view the Presets, simply press the desired Preset key. Rapidly press the Preset keys 3 times, then press the Clear key for direct editing of the preset setpoints. Press Enter or Start to complete the Preset entry.

SCROLL

Rapidly press the Scroll key three times to setup a display list. Press the CLEAR key to remove old scroll list. Press the function key for the item you wish to add Use the ∆ ∇ keys to assign the line.

The PRINT key is used to print on demand. When the PRINT key is pressed, a user dened list of data (TOTAL, RATE, PRE 1, etc.) is sent to the RS-232 port. A timed message of "PRINTING" will be displayed to acknowledge the print request.

SPECIAL BATCHING KEYS

The START and STOP keys are used only when batching to start and stop batches. The CLEAR key will clear the total without rst pressing the TOTAL key (unit must be stopped). All other keys work the same in both Rate/Total mode and Batch mode. The Start and Stop keys operation are set by the control input settings. The Start options are: START or RESET/START. The Stop options are: STOP or STOP/RESET.

MENU KEY

The MENU key is used to enter the Setup and Test modes. Press the MENU key to enter the Setup and Test modes. (See section 6 for Setup mode, section 8 for Test mode). The MENU key is used as "escape" in Setup and Test Programming. Pressing the MENU key wile programming in the Sub-Menu groups will backup the display to that Sub-Menu group heading. Pressing the MENU key while viewing the Sub-Menu groups will backup the display to the Top Level Menu.

ACKNOWLEDGING ALARMS

Most alarm messages are self-clearing. Press the ENTER key to acknowledge and clear alarms.

NOTE: Some keys and functions are password protected. Enter the password to gain access. The passwords are

factory set as follows: Operator = 0 Supervisor = 2000

Page 18

SUPERtrol-I Flow Computer

General Operation

Rate/Total Operation

Password Protection

(Rate/Total mode)

5.2 General Operation

The unit can display: Rate, Total, Grand Total, Temperature, Density, Presets and Time of Day. The Temperature and/or Density can be displayed even if you are using the Volumetric Flow Equation (a Temperature or Density sensor must be installed). The unit can perform Mass or Corrected Volume equations using a temperature or density sensor (these equations can be computed without Temp/ Dens sensors by using user dened default values). The unit can be programmed to perform Ratemeter/Totalizer or Batching functions (see section 6.3, SELECT INSTRUMENT Submenu).

5.3 Ratemeter/Totalizer Operation

The Ratemeter/Totalizer mode is used primarily to monitor owrate and accumulated total. The relays can be used to trigger ow, total, temperature or density alarms.

5.3.1 Password Protection for Rate/Total mode

After an Operator and/or Supervisor Password is entered in the setup mode (see section 6.3, SETUP PASSWORD submenu), the unit will be locked. The unit will prompt the user for the password when trying to perform the following functions:

Clear Total

Clear Grand Total Enter Menu Edit Preset 1 (PRE 1 Key) Edit Preset 2 (PRE 2 Key)

Relay Operation

(Rate/Total mode)

Pulse Output

(Rate/Total mode)

The Supervisor password should be reserved for supervisors. The Supervisor password will allow access to restricted areas of the Setup and Test menus.

5.3.2 Relay Operation in Rate/Total mode

Up to four relays are available (two standard) for alarm outputs. The relays can be assigned to trip according to rate, total, temperature, density readings or general system alarms. The relays can be programmed for low or high alarms. Preset 1 (RLY1) and Preset 2 (RLY2) are easily accessible by pressing the PRE 1 or PRE 2 key on the front panel. Preset 3 and Preset 4 are accessible only through the setup menu.

5.3.3 Pulse Output in Rate/Total mode

The isolated pulse output (open collector) is menu assignable to Volume Total, Corrected Volume Total or Mass Total. The pulse output duration can be set for 10mS (50 Hz max) or 100mS (5 Hz max). A pulse output scale factor (pulse value) can be set to scale the pulse output. The pulse output is ideal for connecting to remote totalizers or other devices such as a PLC. See section 1.3 for electrical specications.

Analog Output

(Rate/Total mode)

5.3.4 Analog Output in Rate/Total mode

The analog output is menu assignable to correspond to the Volume Rate, Corrected Volume Rate, Mass Rate, Temperature, Density, Volume Total, Corrected Volume Total or Mass Total. The analog output is ideal for "trend" tracking using strip chart recorders or other devices.

Page 19

SUPERtrol-I Flow Computer

RS-232 Serial Port

(Rate/Total mode)

5.3.5 RS-232 Serial Port Operation in Rate/Total mode

The RS-232 serial port can be used for programming (using the Setup Disk) or for communicating to printers and computers in the Operating Mode (Run Mode).

PC Communications:

The Setup Disk also allows the user to query the unit for operating status such as Flow Rate, Flow Total, Temperature, Density, Presets, etc.

Operation of RS-232 Serial Port with Printers:

Transaction Printing For transaction printing, the user denes the items to be included in the printed document (see section 6.3.20 SET DATA OUTPUT, Select_list). The transaction document can be initiated by pressing the PRINT key or by a remote contact closure.

Data Logging In data logging, the user denes the items to be included in each data log (see section 6.3.20 SET PRINTER OUTPUT, Select_list). The user can also select when (time of day) or how often (print interval) the data log is to be made (see section 6.3.19 SET PRINTER OUTPUT, Congure).

System Setup and Maintenance Report The system setup and maintenance report lists all of the instrument setup parameters and usage for the current instrument conguration. The audit trail information and a status report is also printed. This report is initiated in the Test menu (see section 8.2.3 PRINT SYSTEM SETUP).

RS-485 Serial Port

(Rate/Total mode)

5.3.6 RS-485 Serial Port (optional)

RS-485 Port Description:

The optional RS-485 card utilizes Modbus RTU protocol to access a variety of process parameters and totalizers. The Relays can be controlled via Modbus. In addition, action routines can be executed. For further information, contact factory and request RS-485 Protocol manual.

Operation of Serial Communication Port with PC

The ow computer's RS-485 channel supports a number of Modbus RTU commands. Modbus RTU drivers are available from third party sources for a variety of Man Machine Interface software for IBM compatible PC's.

The user reads and writes information from/to the RS-485 using the Modbus RTU commands. The Flow Computer then responds to these information and command requests.

Process variables and totalizers are read in register pairs in oating point format. Time and date are read as a series of integer register values. Alarms are individually read as coils. Action routines are initiated by writing to coils.

Page 20

SUPERtrol-I Flow Computer

5.4 Batcher Operation

The Batcher mode is used primarily to control batches. The main difference between the Batch mode and Rate/Total mode is the relay operation. The Batch mode allows the operator to "START" the unit via the front panel or remote input. Once started, the relays (RLY1 & RLY2) will energize and send power to a ow control device (i.e. solenoid valve or pump). The ow sensor will send a signal to the unit and total accumulation will begin. When the Prewarn value (PRE 2) is reached, Relay 2 will drop out (this is ideal for ow slow down). When the Batch amount (PRE 1) is reached, Relay 1 will drop out and the Batch is complete.

Several messages will be displayed during normal batch operation (i.e. Batch Fill, Batch Stopped). The keypad is disabled for the duration of these timed messages (approx. 2 sec).

Batcher Conguration

5.4.1 Batcher Conguration.

When the unit is programmed for batch mode, several batch operation choices are available. These choices include: Up or Down Counting, Maximum Batch Preset, Batch Overrun Compensation, Auto Batch Restart, Time Delay, Flow Signal Timeout, Maximum Drain Time, Slow Start Quantity, Start or Reset/Start, and Stop or Stop/Reset.

Standard Preset or EZ Preset

Use Standard Preset for applications in which the batch amount does not change frequently. Use EZ Preset in applications in which the batch amounts change frequently. The EZ Preset mode was designed to enter presets with minimum key strokes.

Batch Count Mode

The Batch Count Mode allows the user to choose whether the unit will batch up to a preset value or batch down from a preset value to zero.

Maximum Batch Preset

The Maximum Batch Preset allows the user to program the Maximum Batch value allowed to be entered by the operator. If an operator should try to program a batch higher then this value, the unit will not allow the value to be entered and will prompt the user with an error message saying that the Maximum Batch Preset has been exceeded.

Batch Overrun

The Batch Overrun is used for batch applications that have slow responding valves and a consistent batching owrate. When the Batch Overrun is set, the unit will compensate for batch overruns by computing an averaged overrun value from the last four batches. This average is used to internally adjust the batch setpoint to minimize overrun.

Flow Signal Timeout

The Flow Signal Timeout allows the user to enter a timeout of 0 to 99 seconds. If a batch is “Filling” and zero ow persists for more than the user entered time then the batch will be aborted. This prevents over ows due to faulty ow sensors and/or wiring.

Maximum Drain Time

The unit declares that a batch is “done” when the ow rate equals “0”. A ow rate may be present long after the Preset Relay de-energizes due to slow reacting valves or leaky valves. The Maximum Drain Time allows the user to enter an amount of time (0 to 99 seconds) to wait before declaring “Batch Done”. After the Preset Batch quantity is reached, the unit will declare “Batch Done” when the ow rate is “0” or the Maximum Drain Time has expired. The batch data will then be available for printing and datalogging.

Page 21

SUPERtrol-I Flow Computer

Slow Start Quantity

The Slow Start Quantity is a function that allows an amount to be entered for a Slow Start up. This function requires two stage valve control. RLY 1 (slow ow) will energize for Slow Start and RLY 2 (fast ow) will energize after the Slow Start Quantity has been delivered. This helps reduce turbulence when lling an empty container.

START, RESET/START and STOP, STOP/RESET

When conguring the control inputs, Control Input1 can be set for START or RESET/START. When set for START, the unit will start batching when a signal is applied to Control Input1 or the front panel Start key is pressed. A separate Reset signal must be used to clear the previous batch total. When set for RESET/ START, the unit will automatically reset then start when a signal is applied to Control Input1 or the front panel Start key is pressed (provided that the pervious batch was completed). If a previous batch was stopped during a batch cycle, the unit will Start from where it was stopped. Control Input 2 can be set for STOP or STOP/RESET. When set for STOP, the unit will stop batching when a signal is applied to Control Input 2 or the front panel Stop key is pressed. A separate Reset signal must be used to clear the batch total. When set for STOP/RESET, a running batch will stop when a signal is applied to Control Input 2 or the front panel Stop key is pressed. If the unit is Stopped or after a completed batch, the unit will reset when a signal is applied to Control Input 2 or the front panel Stop key is pressed. NOTE: Applying a voltage level to Control Input 2 will inhibit all Start inputs in

either mode.

Password Protection

(Batch mode)

Relay Operation

(Batch mode)

5.4.2 Password Protection for Batcher Mode

Clear Grand Total Enter Menu

The Supervisor password should be reserved for supervisors. The Supervisor password will allow access to restricted areas of the Setup and Test menus.

The passwords are factory set as follows: Operator = 0 Supervisor = 2000

5.4.3 Relay Operation in Batcher mode

Up to four relays are available (two standard) for alarm outputs. Preset 1 (RLY1) is reserved for batch amount, Preset 2 (RLY2) is reserved for prewarn. (see section

5.4 Batcher Operation for Relay 1 & Relay 2 functions) Preset 1 (RLY1) and Preset 2 (RLY2) are easily accessible by pressing the PRE 1 or PRE 2 key on the front panel. Preset 3 and Preset 4 are accessible only through the setup menu. Relays 3 and 4 can be assigned to trip according to rate, total, temperature, overrun or alarm. When Rate is selected the relays can be programmed for low or high alarms.

Pulse Output

(Batch mode)

Analog Output

(Batch mode)

5.4.4 Pulse Output in Batcher mode

5.4.5 Analog Output in Batcher mode

Page 22

SUPERtrol-I Flow Computer

RS-232 Serial Port

(Batch mode)

5.4.6 RS-232 Serial Port Operation in Batcher mode

The RS-232 serial port can be used for programming (using the Setup Disk) or for communicating to printers and computers in the Operating Mode (Run Mode).

PC Communications:

The Setup Disk also allows the user to query the unit for operating status such as Flow Rate, Flow Total, Temperature, Density, Presets, etc.

Operation of RS-232 Serial Port with Printers:

RS-485 Serial Port

(Batch mode)

5.4.7 RS-485 Serial Port (optional)

RS-485 Port Description:

The optional RS-485 card utilizes Modbus RTU protocol to access a variety of process parameters and totalizers. Batches/Relays can be controlled remotely via Modbus. In addition, action routines can be executed. For further information, contact factory and request RS-485 Protocol manual.

Operation of Serial Communication Port with PC

The user reads and writes information from/to the RS-485 using the Modbus RTU commands. The Flow Computer then responds to these information and command requests.

Page 23

SUPERtrol-I Flow Computer

6. PROGRAMMING

6.1 Front Panel Operation Concept for Program Mode

The Flow Computer is fully programmable through the front panel. Please review the following usage summary before attempting to use the instrument.

How To Make Mode Changes

How To Navigate Through Sub-Menu Groups

START

STOP

TOTAL

GRAND6SCROLL7PRE 2

RATE

PRE 1

TEMP

DENS

TIME

CLEAR

HELP

•

–

ENTER

Setup Mode:

MODE CHANGES

Pressing the MENU key will offer selections of RUN, SETUP, TEST. RUN is the normal operating mode for the instrument. SETUP offers various sub-menus used for instrument setup. TEST offers various sub-menus for Test, Calibration and System Start-up.

Submenu GROUP NAVIGATION

Use the UP and DOWN arrow keys to navigate up and down through the Sub-Menu groups when in the SETUP or TEST mode. Press the ENTER key to enter a desired setup or test Sub-Menu group.

How To Select Program Choices

How To Enter Numeric Values

How To Enter Text Characters

SELECTION OF ITEM

During setup, the unit will often offer multiple choices for a given topic. The topic prompt appears on the top line of the display. The choices are shown on the lower line of the display.

To select an item, press the key beneath the desired choice. The selected choice will blink. Press the ENTER key to accept the selected choice.

NUMERIC ENTRY

The keys labeled "0 - 9", "–", ".", CLEAR and ENTER are used to enter numerical values. A leading 0 will assume that you intend to enter a minus "–" sign. Press the CLEAR key to clear the existing value and to enable editing.

TEXT CHARACTER ENTRY

Some setup items (i.e. Descriptors, Units Label) require the user to enter text characters. Press CLEAR to enable editing. The UP and DOWN arrow keys are used to scroll through the available character sets for each individual character. Press the ENTER key to accept the character and advance to the next character.

Page 24

SUPERtrol-I Flow Computer

6.2 EZ Setup

The EZ Setup routine is a quick and easy way to congure the unit for the most commonly used instrument functions. This setup assumes that you are measuring Volumetric Flow using a high level, DC Pulsing ow sensor. Entering the EZ Setup mode automatically sets many features. This may cause any previously programmed information to be lost or reset. For a complete customized conguration, see sections 6.3 and 6.4.

Menus Display Notes

6.2.1 TOP LEVEL SETUP MENU

6.2.2 EZ Setup Submenu Groups

SELECT OPERATE STATE Run Setup Test

ENTER

SELECT EZ SETUP

ENTER

ARE YOU SURE? No Yes

ENTER

INSTRUMENT TYPE Rate/Tot Batch

ENTER

RATE TIME BASE Sec Min Hour Day

ENTER

RATE DEC PLACES

ENTER

Select Setup to enter the instrument setup routine.

Press ENTER to begin EZ Setup routine.

Conrm that you want to run EZ Setup. Caution: Any previous program settings may be lost or reset.

Instrument Type.

Select the appropriate rate time base.

Enter the desired rate decimal location. 0-3 decimal places allowed.

TOTAL VOLUME UNITS

ENTER

TOTAL DEC PLACES

ENTER

K_FACTOR TYPE Avg LinTbl UVC

ENTER

AVERAGE KA-FACTOR ####### P/gal

LINEAR TABLE KA Fre01:######## Hz

ENTER

LINEAR TABLE KA

Through

16 Points

KA--01:##########

ENTER

gal

Enter the desired totalizer units label.

Enter the desired totalizer decimal location. 0-3 decimal places allowed.

Enter the desired K-Factor Type.

If Average selected, Enter the desired Average K-Factor.

If LinTbl or UVC selected, Enter the desired frequency/ K-Factor pair for each point in the Linearization Table. Enter a frequency of 0 for any point other than Fre01 to exit Linearization Table setup.

FS ANALOG OUT 20mA #######gal/m

ENTER

RATE 00.0 gal/m TOTAL 0 gal

Enter the desired full scale setting for the analog output.

Return to Run Mode

Page 25

SUPERtrol-I Flow Computer

START

6.3 Setup Menus

Menus Display Notes

6.3.1 Top Level Setup Menu

6.3.2 Submenu Groups

START

SELECT OPERATE STATE Run Setup Test

ENTER

SELECT EZ SETUP

STOP

START

INSTRUMENT TYPE

STOP

START

SELECT FLOW EQUATION

STOP

START

SETUP INDICATORS

STOP

START

SETUP FLOW INPUT

STOP

START

Select Setup to enter the instrument setup routine.

Refer to Page 20 for Details.

Refer to Page 22 for Details.

Refer to Pages 22 for Details.

Refer to Page 23 & 24 for Details.

Refer to Page 25, 26 & 27 for Details.

SETUP AUX INPUT

STOP

START

SET FLUID PROPERTIES

STOP

START

SETUP PULSE OUTPUT

STOP

START

SETUP ANALOG OUTPUT

STOP

START

SETUP RELAYS

STOP

START

SETUP CONTROL INPUTS

STOP

START

Refer to Pages 28 for Details.

Refer to Page 29 for Details.

Refer to Pages 29 for Details.

Refer to Page 30 for Details.

Refer to Page 30 & 31 for Details.

Refer to Page 32 for Details.

STOP

SETUP REALTIME CLOCK

STOP

START

SERIAL USAGE

STOP

START

SETUP DATALOG/PRINT

STOP

START

ADMINISTRATIVE SETUP

STOP

START

SETUP NETWORK CARD

Refer to Page 33 for Details.

Refer to Page 34 for Details.

Refer to Pages 35 & 36 for Details.

Refer to Page 36 for Details.

Refer to Page 37 for Details.

Page 26

6.4.1

START

SELECT EZ SETUP

6.4 Setup Sub-Menus

SELECT EZ SETUP

STOP

START

Advance To

INSTRUMENT TYPE

SUPERtrol-I Flow Computer

NotesDisplaySub-menus

Refer to page 20 for EZ Setup routine.

Press the DOWN (stop) key to advance to Instrument Type. Press the UP (start) key to advance to Administrative Setup.

6.4.2 INSTRUMENT TYPE

Rate/Tot

Batch

INSTRUMENT TYPE

ENTER

INSTRUMENT TYPE Rate/Tot Batch

STOP

ENTER

START

Advance To

SELECT FLOW EQUATION

INSTRUMENT TYPE

ENTER

INSTRUMENT TYPE Rate/Tot Batch

STOP

ENTER

START

SELECT PRESET TYPE Standard EZ Preset

STOP

ENTER

START

BATCH COUNT MODE Up Down

STOP

ENTER

START

MAXIMUM BATCH PRESET

1000.0 gal

STOP

ENTER

START

BATCH OVERRUN COMP Off On

ENTER

Press ENTER to enter Instrument Type submenus.

Press ENTER when Rate/Total is ashing to congure the instrument as a Ratemeter/ Totalizer.

If Rate/Tot selected, advance to Select Flow Equation.

Press ENTER to enter Instrument Type submenus.

Press ENTER when Batch is ashing to congure the instrument as a Batcher.

Select Standard or EZ Preset

Select UP to Reset to 0 and count up to preset. Select DOWN to reset to Preset and count down to 0.

Enter the maximum allowable Batch Preset. The operator will not be able to enter a batch preset larger than this value.

Select ON to set the unit to operate using a Batch Overrun Compensation routine. Select OFF to inhibit Batch Overrun Compensation routine. (See Section 5.4)

FLOW SIGNAL TIMEOUT 10

ENTER

MAXIMUM DRAIN TIME 10

ENTER

SLOW START QUANTITY 10

ENTER

Advance To

SELECT FLOW EQUATION

Enter a timeout of 0 to 99 seconds. If a batch is “Filling” and zero ow persists for more than this time, the batch will be aborted.

Enter time (0-99 sec.) for Max. Drain Time. After batch quantity is reached, “Batch Done” is declared when the ow rate is “0” or the Maximum Drain Time has expired.

Enter a quantity for a Slow Start up. RLY 2 (slow ow) will energize for Slow Start and RLY 1 (fast ow) will energize after the Slow Start Quantity has been delivered.

Page 27

SUPERtrol-I Flow Computer

Sub-menus

6.4.3 SELECT FLOW EQUATION

6.4.4 SETUP INDICATORS

(Total)

Display

SELECT FLOW EQUATION

ENTER

SELECT FLOW EQUATION Volume Mass Cor/Vol

ENTER

Advance To

SETUP INDICATORS (To-

tal)

SETUP INDICATORS

ENTER

SETUP INDICATORS Total Dens Rate Temp

Notes

Press ENTER to enter Select Flow Equation submenus.

Press ENTER when desired ow equation is ashing.

Press ENTER to begin setup of the Indicators

Press ENTER when Total is ashing to congure the Totalizer Indicators

6.4.5 SETUP INDICATORS

(Density)

ENTER

TOTAL DESCRIPTOR

TOTAL

ENTER

TOTAL VOLUME UNITS gal

ENTER

TOTAL DEC PLACES

ENTER

Advance To

SETUP INDICATORS

(Density)

SETUP INDICATORS Total Dens Rate Temp

ENTER

Enter the desired Total Descriptor

Enter the desired Volume Units Label for the Totalizer.

Select the desired Total Decimal Place.

0-3 decimal places allowed.

Press ENTER when Dens is ashing to congure the Density Indicators.

DENSITY DESCRIPTOR

DENS

ENTER

DENSITY MASS UNITS

lbs

ENTER

DENSITY DEC PLACES

ENTER

Advance To

SETUP INDICATORS

(Rate)

Enter the desired Density Descriptor.

Enter the desired Mass Units Label for Density.

Select the desired Density Decimal Place.

0-3 decimal places allowed.

Page 28

SUPERtrol-I Flow Computer

Sub-menus Display Notes

6.4.6 SETUP INDICATORS

(Rate)

SETUP INDICATORS Total Dens Rate Temp

ENTER

RATE TIME BASE Sec Min Hour Day

ENTER

RATE DESCRIPTOR

RATE

ENTER

RATE DEC PLACES

ENTER

RATE AVG FILTER

ENTER

Press ENTER when Rate is ashing to congure the Ratemeter Indicators

Select the desired Rate Time Base.

Enter the desired Descriptor for the Ratemeter.

Select the desired Rate Decimal Place.

0-3 decimal places allowed.

Enter desired Rate Averaging Filter.

6.4.7 SETUP INDICATORS

(Temperature)

QUICK UPDATE %

ENTER

Advance To

SETUP INDICATORS

(Temperature)

SETUP INDICATORS Total Dens Rate Temp

ENTER

TEMP DESCRIPTOR

TEMP

ENTER

Enter desired Percent of Change for Quick Update. If the current owrate deviates by

an amount greater than the percentage value entered, the Rate Averaging is inhibited. (See Page 57 for more details.)

Press ENTER when Temp is ashing to congure the Temperature Indicators.

Enter the desired Temperature Descriptor.

TEMPERATURE SCALE Deg_C Deg_F

ENTER

TEMP DEC PLACES

ENTER

Advance To

SETUP FLOW INPUT

Enter the desired Temperature Scale.

Select the desired Temperature Decimal Place. 0-3 decimal places allowed.

Page 29

SUPERtrol-I Flow Computer

Sub-menus Display Notes

6.4.8 SETUP FLOW INPUT

(Pulse - Ain & PS (A=B))

NOTE:

Ain = Single Pulse PS(A=B) = Pulse Security Qx1 = Quadrature Qx2 = Quadrature x 2

SETUP FLOW INPUT

ENTER

EXCITATION VOLTAGE 5v 12v 24v

ENTER

FLOW INPUT TYPE Pulse Analog

ENTER

PULSE INPUT TYPE Ain PS(A=B) Qx1 Qx2

ENTER

PULSE TRIGGER LEVEL 10mV 100mV 2.5V

ENTER

Press ENTER to begin setup of Flow Input.

Select the desired Excitation Voltage.

Press ENTER when Pulse is ashing to congure the ow input for Pulse signals.

Enter the desired Pulse type. See side note.

Select the desired Input Pulse Trigger Level.

Through

16 Points

LOW PASS FILTER 40Hz 3KHz 20KHz

ENTER

INPUT TERMINATION Pullup Pulldown None

ENTER

MAX WINDOW (1-99)

ENTER

K_FACTOR TYPE Avg LinTbl UVC

ENTER

AVERAGE KA-FACTOR

####### P/gal

LINEAR TABLE KA Fre01:######## Hz

ENTER

LINEAR TABLE KA KA--01:####### P/gal

ENTER

Select the desired Low Pass Filter. (Max. Count Speed).

Select the proper input termination.

Enter the desired Maximum Sample Window Time (1-99 sec).

Enter the desired K-Factor Type.

If Avg selected, Enter the desired Average K-Factor.

If LinTbl selected, Enter the desired frequency/ K-Factor pair for each point in the Linearization Table. NOTE: Enter 0 for Fre value of any point

(other than Fre01) to exit the routine and use the values entered up to that point.

LOW FLOW RATE ALARM

####### gal/m

ENTER

HIGH FLOW RATE ALARM

####### gal/m

Advance To

SETUP AUX INPUTS

Enter the desired volumetric Low Rate Alarm. This will trigger an alarm message if alarm conditions occur. The relays are not affected.

Enter the desired volumetric High Rate Alarm. This will trigger an alarm message if alarm conditions occur. The relays are not affected.

Page 30

SUPERtrol-I Flow Computer

Submenus Display Notes

6.4.9 SETUP FLOW INPUT

(Pulse - Quadrature, Qx1 or Qx2)

NOTE:

Ain = Single Pulse PS(A=B) = Pulse Security Qx1 = Quadrature Qx2 = Quadrature x 2

SETUP FLOW INPUT

ENTER

EXCITATION VOLTAGE 5v 12v 24v

ENTER

FLOW INPUT TYPE Pulse Analog

ENTER

PULSE INPUT TYPE Ain PS(A=B) Qx1 Qx2

ENTER

PULSE TRIGGER LEVEL 10mV 100mV 2.5V

ENTER

LOW PASS FILTER 40Hz 3KHz 20KHz

ENTER

INPUT TERMINATION Pullup Pulldown None

ENTER

Press ENTER to begin setup of Flow Input.

Select the desired Excitation Voltage.

Press ENTER when Pulse is ashing to congure the ow input for Pulse signals.

Enter the desired Pulse type. See side note.

Select the desired Input Pulse Trigger Level.

Select the desired Low Pass Filter. (Max. Count Speed).

Select the proper input termination.

MAX WINDOW (1-99)

ENTER

K_FACTOR TYPE Avg LinTbl UVC

ENTER

AVERAGE KA-FACTOR

####### P/gal

AVERAGE KB-FACTOR

####### P/gal

LINEAR TABLE KA Fre01:######## Hz

ENTER

LINEAR TABLE KA

Through

16 Points

KA--01:####### P/gal

ENTER

LINEAR TABLE KB Fre01:######## Hz

ENTER

LINEAR TABLE KB

Through

16 Points

KA--01:####### P/gal

ENTER

Enter the desired Maximum Sample Window Time (1-99 sec).

Enter the desired K-Factor Type.

If Avg selected, Enter the desired Average K-Factor (KA for channel A).

Enter the desired Average K-Factor (KB for channel B).

If LinTbl selected, Enter the desired frequency/ K-Factor pair for each point in the Linearization Table. (channel A) NOTE: Enter 0 for Fre value of any point

(other than Fre01) to exit the routine and use the values entered up to that

point. Enter the desired frequency/ K-Factor pair for each point in the Linearization Table. (channel B) NOTE: Enter 0 for Fre value of any point

(other than Fre01) to exit the routine

and use the values entered up to that

point.

LOW FLOW RATE ALARM

####### gal/m

ENTER

HIGH FLOW RATE ALARM

####### gal/m

ENTER

Advance To

SETUP AUX INPUTS

Enter the desired volumetric Low Rate Alarm. This will trigger an alarm message if alarm conditions occur. The relays are not affected.

Enter the desired volumetric High Rate Alarm. This will trigger an alarm message if alarm conditions occur. The relays are not affected.

Page 31

SUPERtrol-I Flow Computer

Sub-menus Display Notes

6.4.10 SETUP FLOW INPUT

(Analog)

SETUP FLOW INPUTS

ENTER

EXCITATION VOLTAGE 5v 12v 24v

ENTER

FLOW INPUT TYPE Pulse Analog

ENTER

ANALOG SIGNAL TYPE Voltage Current

ENTER

ANALOG VOLTAGE RANGE 0-10V 0-5V 1-5V

ANALOG CURRENT RANGE 4-20mA 0-20mA

ENTER

Press ENTER to begin setup of the Flow Input.

Select the desired Excitation Voltage.

Press ENTER when Analog is ashing to congure the ow input for Analog signals .

Choose Analog Signal Type.

If Voltage selected, Choose desired Voltage Range.

If Current selected, Choose desired Current Range.

Through

16 Points

LINEARIZATION TYPE Linear Sqrt LinTbl

ENTER

LINEAR TABLE KA APR01:######## gal/m

ENTER

LINEAR TABLE KA CFr01:########

ENTER

FLOW LOW SCALE

####### gal/m

ENTER

FLOW FULL SCALE

####### gal/m

ENTER

LOW FLOW CUTOFF

####### gal/m

Select the desired Linearization Type.

If LinTbl selected, Enter the desired Apparent Input Flow (APR) / Correction Factor (CFr) pair for each point in the Linearization Table. NOTE: Enter 0 for APR value of any point

(other than APR01) to exit the routine and use the values entered up to that

point. Enter the low owrate corresponding to the low analog signal.

Enter the High owrate corresponding to the High analog signal.

Enter the desired Low Flow Cutoff.

ENTER

LOW FLOW RATE ALARM

####### gal/m

ENTER

HIGH FLOW RATE ALARM

####### gal/m

ENTER

Advance To

SETUP AUX INPUT

Enter the desired volumetric Low Rate Alarm. This will trigger an alarm message if alarm conditions occur. The relays are not affected.

Enter the desired volumetric High Rate Alarm. This will trigger an alarm message if alarm conditions occur. The relays are not affected.

Page 32

SUPERtrol-I Flow Computer

Sub-menus Display Notes

6.4.11 SETUP AUX INPUT

NOTE:

When Density (Dens) is selected, The menu prompts will be very

similar to the Tem-

perature prompts. The menus will prompt the user for density values and density units.

SETUP AUX INPUT

ENTER

AUX INPUT TYPE None Dens Temp

ENTER

AUX SIGNAL TYPE Voltage Current RTD

ENTER

INPUT SIGNAL RANGE 0-10V 0-5V 1-5V

INPUT SIGNAL RANGE 4-20mA 0-20mA

ENTER

AUX LOW SCALE ###### F

ENTER

AUX FULL SCALE ###### F

ENTER

AUX DEFAULT ###### F

ENTER

AUX LOW ALARM ###### F

ENTER

AUX HIGH ALARM ###### F

ENTER

DENS EXTRACT METHOD Therm_Coef API_2540

ENTER

Press ENTER to begin setup of the Auxiliary Input.

Select Temperature to set the Auxiliary Input for Temperature inputs.

Choose Temperature Signal Type. Advance to "Aux Default", if RTD selected.

If Voltage selected, Choose desired Voltage Range. Skip if RTD.

If Current selected, Choose desired Current Range. Skip if RTD.

Enter the low temperature scale corresponding to the low temperature signal. Skip if RTD.

Enter the high temperature scale corresponding to the high temperature signal. Skip if RTD.

Enter the Default Temperature. The unit will use this value if the temperature input fails.

Enter the Low setpoint for the Temperature Alarm.

Enter the High setpoint for the Temperature Alarm.

Choose the Density Extraction method to be used.

Advance To

SET FLUID PROPERTIES

Page 33

SUPERtrol-I Flow Computer

Sub-menus Display Notes

6.4.12 SET FLUID PROPERTIES

SET FLUID PROPERTIES

ENTER

REF. DENSITY ###### lbs/g

ENTER

REF. TEMPERATURE ###### F

ENTER

EXPAN. FACTOR [xe-6] ########

ENTER

CALIBRATION DENSITY ########

ENTER

Press ENTER at this prompt to Set Fluid Properties.

Enter the Reference Density. This is used in the calculation of density when you have a temp transmitter and used for corrected ow calculation if you have a density transmitter.

Enter the Reference Temperature.

Enter the proper Expansion Factor. (If Temp Compensated for Mass or Corrected Volume) See Section 7.4, Calculating the Expansion Factor.

Enter the Calibration Density. This is used in calculation of ow for analog inputs using SQRT.

VISCOSITY COEF. A

0.000

ENTER

VISCOSITY COEF. B

0.000

ENTER

BASE DENSITY H2O@4C ###### lbs/g

ENTER

Advance To

SETUP PULSE OUTPUT

Enter the Viscosity A Coefcient. See section

7.5, Computation of Viscosity Coef. A and B.

Enter the Viscosity B Coefcient. See section

7.5, Computation of Viscosity Coef. A and B.

Enter the Base Density H2O@4C. This is used in the centistoke calculation for UVC.

6.4.13 SETUP PULSE OUTPUT

SETUP PULSE OUTPUT

ENTER

PULSE OUTPUT USAGE Off Vol CVol/Mass

ENTER

PULSE WIDTH 10mS 100mS

ENTER

PULSE VALUE ####### gal/P

ENTER

Advance To

SETUP ANALOG OUTPUT

Press ENTER at this prompt to setup the Pulse Output.

Select the desired Pulse Output Usage.

Select the desired Pulse Width for the Pulse Output.

Enter the desired Pulse Value for the Pulse Output (Units per Pulse).

Page 34

SUPERtrol-I Flow Computer

Sub-menus Display Notes

6.4.14 SETUP ANALOG OUTPUT

SETUP ANALOG OUTPUT

ENTER

ANALOG OUTPUT USAGE Rate Total Temp Dens

ENTER

ANALOG OUT FLOW TYPE Vol CVol/Mass

ENTER

ANALOG OUTPUT RANGE 4-20mA 0-20mA

ENTER

LS ANALOG OUTPUT

####### gal/m

ENTER

Press ENTER when Analog is ashing to setup the Analog Output.

Select the desired Analog Output Usage.

Only if Rate selected & Flow EQ. = Mass, Cor/Vol Select the desired Analog Output Flow.

Select the desired current range for the Analog Output.

Enter desired Analog Output Low Scale Value. NOTE: Units label will correspond with output

usage type selected.

6.4.15 SETUP RELAYS (Relay 1 & Relay 2)

NOTE:

In Batch mode,

Relay 1 is reserved for Preset,

Relay 2 is reserved

for Prewarn.

FS ANALOG OUT 20mA

####### gal/m

ENTER

ANALOG OUT DAMPING

0.0

ENTER

Advance To

SETUP RELAYS

SETUP RELAYS Rly1 Rly2 Rly3 Rly4

ENTER

RELAY 1 USAGE RATE TOTAL NA

ENTER

RELAY 1 DELAY sec 0

ENTER

RELAY 1 MODE LO_ALARM HI_ALARM

ENTER

RELAY 1 DURATION

#####

Enter desired Analog Output Full Scale Value.

Enter the desired Analog Output Damping Constant.

Select the desired Relay for setup. (Relays 3 & 4 Optional)

If Relay 1 or Relay 2 Selected, Select Rate, Total or NA.

If Rate selected, enter desired relay activation delay value.

Select the desired Relay Activation. Low: Relay activates when reading is below

setpoint.

High: Relay activates when reading is above

setpoint.

If Total Selected, Enter desired Relay Duration.

ENTER

RELAY 1 SETPOINT

####### gal

ENTER

RELAY 1 HYSTERESIS

##### gal/m

ENTER

Advance To

SETUP RELAYS 3, 4

Enter the desired Setpoint. The Setpoint can be edited in run mode using the PRE 1 key (PRE 2 key for Relay 2).

If Rate, selected, Enter desired Relay Hysteresis.

Page 35

SUPERtrol-I Flow Computer

Sub-menus Display Notes

6.4.15 (Continued) SETUP RELAYS (Relay 3 & Relay 4)

NOTE:

Settings for Relays 3

& 4 may be entered even if relays are not supplied. The settings will still trigger display alarms.

SETUP RELAYS Rly1 Rly2 Rly3 Rly4

ENTER

RELAY 3 USAGE Rate Tot Aux Ovrn NA

RELAY 4 USAGE Rate Tot Aux Alrm NA

ENTER

RELAY 3 DELAY sec 0

ENTER

RELAY 3 MODE LO_ALARM HI_ALARM

ENTER

RELAY 3 DURATION

#####

ENTER

RELAY 3 SETPOINT

####### gal

ENTER

RELAY 3 HYSTERESIS

##### gal/m

ENTER

Select the desired Relay for setup. (Relays 3 & 4 Optional)

If Relay 3 Selected, Choose Rate, Total, Aux, Ovrn or NA.

If Relay 4 Selected, Choose Rate, Total, Aux, Alrm or NA.

If Rate / Aux selected, enter desired relay activation delay value.

Select the desired Relay Activation for Rate/Aux. Low: Relay activates when reading is below

setpoint.

High: Relay activates when reading is above

setpoint.

If Total Selected, Enter desired Relay Duration.

Enter the desired Setpoint.

If Rate, selected, Enter desired Relay Hysteresis.

Advance To

SETUP CONTROL INPUTS

RELAY NOTES & CONSIDERATIONS

1. Relay activation is based on the computed readings not the displayed value. Therefore the display damping factor will not affect the relay response time. The RELAY DELAY feature allows the user to enter a time delay for relay activation. This feature is very useful in applications where short over/ under range conditions are not considered alarm conditions.

2. When INSTRUMENT TYPE is set to batcher, Relay 1 is reserved for PRESET and Relay 2 is reserved for PREWARN.

3. Setting the relays to NA (Not Assigned), will allow the relay activation to be controlled via the RS232 Serial and/or RS-485 Modbus ports.

4. Relay 3 and Relay 4 settings may be used to trigger display alarm conditions even if the relays are not supplied.

Page 36

SUPERtrol-I Flow Computer

Sub-menus Display Notes

6.4.16 SETUP CONTROL INPUTS

(RATE/TOTAL)

SETUP CONTROL INPUTS

ENTER

SETUP CONTROL INPUTS Input1 Input2 Input3

ENTER

CONTROL INPUT1 USAGE INHIBIT_TOTAL NA

CONTROL INPUT2 USAGE RESET_TOTAL NA

CONTROL INPUT3 USAGE Prn Ack KeyLk NA

ENTER

Advance To

SETUP REALTIME CLOCK

Press Enter to begin setup of the Control Inputs.

Select the desired Control Input for setup.

If Control Input 1 Selected, Select Inhibit Total or NA (Not Assigned).

If Control Input 2 Selected, Select Reset Total or NA (Not Assigned).

If Control Input 3 Selected, Select Prn (Print), Ack (acknowledge), KeyLk (Keylock) or NA (Not Assigned). ACK will acknowledge and clear alarms and warning messages. Note: Alarms may reassert themselves if alarm conditions are still present.

6.4.17 SETUP CONTROL INPUTS

(BATCH)

SETUP CONTROL INPUTS Input1 Input2 Input3

ENTER

CONTROL INPUT1 USAGE Start Rst/Start NA

CONTROL INPUT2 USAGE Stop Stop/Rst NA

CONTROL INPUT3 USAGE Rst Prn KeyLk Ack NA

ENTER

Advance To

SETUP REALTIME CLOCK

Select the desired Control Input for setup.

If Control Input 1 Selected, Select Start ,Reset/Start, NA (Not Assigned).

If Control Input 2 Selected, Select Stop, Stop/Reset, NA (Not Assigned).

Page 37

SUPERtrol-I Flow Computer

Sub-menus Display Notes

6.4.18 SETUP REALTIME CLOCK

(Time)

SETUP REALTIME CLOCK

ENTER

SETUP REALTIME CLOCK Time Date

ENTER

CLOCK TYPE 24HR 12HR

ENTER

SELECT CLOCK AM/PM AM PM

ENTER

TIME OF DAY HH:MM:SS ##:##:##

ENTER

Press Enter to begin setup of the Realtime Clock.

Select Time to set the time.

Select 24Hr or 12Hr clock

If 12Hr Clock, Enter AM or PM

Enter time of day.

6.4.19 SETUP REALTIME CLOCK

(Date)

Advance To

SETUP REALTIME CLOCK

(Date)

SETUP REALTIME CLOCK Time Date

ENTER

DATE: MONTH,DAY,YEAR ##/##/####

ENTER

Advance To

SERIAL USAGE

Select Date to enter the date.

Enter the date. (Month, Day, Last two digits of Year)

Page 38

SUPERtrol-I Flow Computer

Sub-menus Display Notes

6.4.20 SERIAL USAGE

SERIAL USAGE

ENTER

SERIAL HARDWARE RS232 RS485

ENTER

DEVICE ID ##

ENTER

BAUD RATE 300 600 1200 <more>

BAUD RATE 2400 4800 9600 19200

ENTER

PARITY None Odd Even

Press Enter to begin setup of the Serial Port.

Select Serial Hardware type for standard port. (See SETUP NETWORK CARD for RS485 Modbus option)

Select the Device ID.

Select the desired Baud Rate.

(If <more> selected)

Select the desired Parity.

ENTER

HANDSHAKING None Softwre Hardwre

ENTER

DEVICE LINE FEED <CR> <CR+LF>

ENTER

MODEM OPTIONS No Yes

ENTER

MODEM INIT MASTER No Yes

ENTER

MODEM AUTO ANSWER No Yes

ENTER

Set the Handshake.

Choose end of line termination. Only choose <CR> if your external device automatically assigns a line feed for every <CR> carriage return.

Select "Yes" if the serial port will be used to control a modem.

Select "Yes" to have the unit engage in a conguration conversation with the modem on power up .

Select the desired Modem Auto Answer mode.

CALL OUT DAY OF WEEK Friday

ENTER

CALL OUT TIME ##:##:##

ENTER

CALL ON ERROR/ALARM No Yes

ENTER

Continued on Next Page

Enter the day of week to perform Call Out transmission.

Enter the time of day to perform Call Out transmission.

Select "Yes" to have the unit perform a Call Out transmission upon error/alarm condition.

Page 39

SUPERtrol-I Flow Computer

Sub-menus Display Notes

6.4.20 SERIAL USAGE (continued)

6.4.21 SETUP DATALOG/PRINT

(Congure)

CALL OUT PHONE # 0

ENTER

NUMBER OF REDIALS 0

ENTER

HANGUP IF 2MIN INACT No Yes

ENTER

Advance To

SETUP DATALOG/PRINT

ENTER

Enter the Call Out Phone Number to be dialed for "Call Out Time" or "Print On Error/Alarm".

Enter the number of redials to be performed on call out time if busy or no answer. (error/ alarm tries until connected)

Select "Yes" to perform hangup if there is inactivity for more than 2 minutes.

Press Enter to setup the Datalog/Print information.

SETUP DATALOG/PRINT Conﬁg Select_list

ENTER

OUTPUT FORMAT Printer Term Dbase

ENTER

PAGE LENGTH [66 max] 66

ENTER

TOP MARGIN [60 max] 3

ENTER

DATALOG PRINT ONLY No Yes

ENTER

PRINT TIME HH:MM:SS 00:00:00

Select Cong to congure the Datalog/Print information.

Select the type of Output Format.

Enter the desired Page Length. If Printer selected above.

Enter the desired Top Margin. If Printer selected above.

Select Yes to record events to the datalogger only. Events will not be sent to the serial port.

Enter Print Time, printer will print at this time every day. Enter 00:00:00 to inhibit print time.

ENTER

PRINT INTERVAL 00:00:00

ENTER

ENABLE PRINT KEY NO YES

ENTER

PRINT END OF BATCH NO YES

ENTER

Advance To

SETUP DATALOG/PRINT

(Select_list)

Enter Print Interval, Enter 00:00:00 to inhibit print interval..

Select YES to enable Print Key. Select NO to disable Print Key

Batch mode only. Select Yes to print at end of batch.

Page 40

SUPERtrol-I Flow Computer

START

Sub-menus Display Notes

6.4.22 SETUP DATALOG/PRINT

(Select_list)

STOP

START

List Items:

TOTAL RATE

PRE1

TEMP GRAND PRE2 DENS TIME

SET DATALOG/PRINT

ENTER

SET DATALOG/PRINT Conﬁg Select_list

PRINT LIST ITEMS TOTAL YES

PRINT LIST ITEMS RATE YES

PRINT LIST ITEMS PRE 1 YES

ENTER

PRINT LIST ITEMS DataLog size =001489

ENTER

Press enter to begin Setup Datalog/Print routine.

Press enter when Select_list is selected to setup print list.

Use Up and Down arrow keys to view list status. Press the Corresponding function key to the items that you wish to add or remove from the list. Items marked with Yes will be added to the list, items marked with No will be removed from the list.

The Select Print List Information display shows the current possible Datalog size.

6.4.23 ADMINISTRATIVE SETUP

Advance To

ADMINISTRATIVE SETUP

ENTER

TAG NUMBER

FT####

ENTER

OPERATOR PASSWORD

*****

ENTER

SUPERVISOR PASSWORD

*****

ENTER

SOFTWARE VERSION

vxx.xx

Press Enter to begin Administrative Setup.

Enter Tag Number

Enter Operator Password. (Factory Set to 0)

Enter Supervisor Password. (Factory Set to 2000)

This display is used to show the software version of the installed software.

ENTER

PRODUCT ORDER CODE xxxxxxxxxxxx

ENTER

UNIT SERIAL NUMBER 00000

ENTER

SENSOR SERIAL NUMBER 00000

ENTER

Advance To

SETUP NETWORK CARD

This display is used to show the product order code (model number).

This display is used to show the unit's serial number.

This display is used to show the sensor's serial number.

Page 41

SUPERtrol-I Flow Computer

6.4.24 SETUP NETWORK CARD (optional)

SETUP NETWORK CARD

ENTER

SELECT NTW PROTOCOL ModbusRTU

ENTER

NETWORK DEVICE ID 1

ENTER

BAUD RATE 2400 4800 9600 19200

ENTER

PARITY None Odd Even

ENTER

Press Enter to setup Network Card

Select desired Network Protocol.

Enter the device address on network (00-

255).

Select the desired Baud Rate.

Select the desired Parity.

Advance To

SELECT EZ SETUP?

Page 42

7. Principle Of Operation

SUPERtrol-I Flow Computer

General Operation

Orice Flowmeter

Considerations

7.1 General:

The Flow Computer uses several internal calculations to compute the compensated ow based on specic data input. Several computations are performed to arrive at the uncompensated ow, temperature, density and viscosity. This information is then used to compute the Corrected Volume Flow or Mass Flow.

7.2 Orice Flowmeter Considerations:

Head class owmeters are supplied by the manufacturers with a 4-20 mA output span which is already in ow units. The Flow Computer permits the user to enter this owmeter information directly. However, closely associated with this information is the density that was assumed during owmeter calibration. This information must also be input if the user is to obtain maximum accuracy.

It is assumed that the user has the printout from a standardized orice sizing program for the particular device he will be using. Such standardized printouts list all the necessary information which the user will then be prompted for.

Several specialized ow equations are listed that are not intended for the standard unit but to be offered to appropriate OEMs or as special order items. These are designated by a “†”.

Flow Equations

Note concerning Fluid Information

The user will be prompted for Fluid Information during the setup of the instrument. The Factory will be preparing application information for several common uid types.

7.3 Flow Equations:

Input Flow Computation:

Linear or External SQRT

Input Flow = [% input span * (ow FS - ow low scale)]+ ow low scale

Orice

Input Flow = [(√% input span) * ( ow FS - ow low scale)] + ow low scale

Input Flow Computation:

General Case

Tf = [% input span * (temp FS - Temp low scale)] + temp low scale

RTD Case

Tf = f(measured input resistance)

Input Density Computation:

Temperature Transmitter density = reference density * (1 - Therm.Exp.Coef. * (Tf-Tref))

Density Transmitter

density = [% input span * (density FS - density low scale)] + density low scale

Page 43

7.3 Flow Equations: (Continued)

( )

centistokes = cP/(kg/l)

SUPERtrol-I Flow Computer

Flow Equations

Input Viscosity Computation:

A exp

† centistokes =

Where:

Uncompensated Flow Computation:

Pulse Input; Average K-Factor

input frequency * time scale factor Volume Flow = K-Factor

Pulse Input; Linear Table

input frequency * time scale factor Volume Flow = K-Factor (Hz)

Pulse Input; UVC

input frequency * time scale factor † Volume Flow = K-Factor (Hz/cstk)

(Deg F + 459.67)

Absolute Density

Analog Input; Linear

Volume Flow = input ow

Analog Input; Linear Table Volume Flow = input ow * correction factor (input ow)

Analog Input; Orice or External SQRT

√(calibrated density) Volume Flow = input ow * √(density)

Analog Input; Orice Linear Table or External SQRT Linear Table

√(calibrated density) † Volume Flow = CF(rn) * input ow * √(density)

Corrected Volume Flow Computation:

Temperature Transmitter

Standard Volume Flow = volume ow * (1 - Therm.Exp.Coef. *(Tf-Tref))

Density Transmitter

density Standard Volume Flow = volume ow * reference density

Mass Flow Computation:

Mass Flow = volume ow * density

† These special ow equations are not available in the standard unit. They are to be

offered to OEMs or as special order items.

Page 44

Flow Equations

SUPERtrol-I Flow Computer

7.3 Flow Equations: (Continued)

The above information was obtained from "Flow Measurement Engineering Handbook, 3rd Edition" by Richard W Miller.

Page 45

7.4 Calculating the Expansion Factor

1 - (Spec.Grav.2 / Ref.Spec.Grav.)

Temp.2 - Ref.Temp

√

[ ]

x 1,000,000C =

1 - (Dens.2 / Ref.Dens.)

Temp.2 - Ref.Temp

√

[ ]

x 1,000,000C =

SUPERtrol-I Flow Computer

Calculating Expansion Factor

The liquid density is a function of the owing temperature for many uids. This unit solves an equation which represents this physical property of the uid. The information which the unit uses to describe the uid is entered by the user in the following variables: Reference Temperature, Reference Density, Expansion Factor. This information is available for many uids in one or more of the following forms: Fluid Specic Gravity vs. Temp. Table Specic Gravity vs. Temp. Graph Fluid Density vs. Temp. Table Fluid Density vs. Temp. Graph Begin by obtaining one of the uid properties for the uid you are using from available manufacturers information or Engineering Handbooks. In some cases this information is listed on the Material Safety Data Sheet for the uid. Two temperature-specic gravity pairs will be required to compute the temperature coefcient. The reference temperature is simply chosen by the user. Common reference temperatures are 60° F or 15° C. However, for cryogenic uids, the normal boiling point may also be used. In some cases the uid data may list properties at 100° F, this temperature may also be used as the reference temperature. The reference temperature should be chosen so that it is in the application temperature range. i.e. application temperature range -10 to 120° F, reference temperature of 60° F chosen. Enter the reference temperature you have chosen at this point. The reference specic gravity corresponds to the uid SPECIFIC GRAVITY at the reference temperature chosen. You may convert the uid density information to specic gravity if it is in units other than specic gravity. Use EQ1.

Expansion Factor Equations

EQ1. Spec.Grav. = Density of Fluid / Density of Water

Given the reference temperature, reference specic gravity, a second temp. and a second Spec.Grav., the Expansion Factor (C Factor) can be computed as follows:

EQ2. Used for Liquid Mass and Corrected Volume Equations

Given the reference temperature, reference density, a second temp. and a second density, the Expansion Factor (C Factor) can be computed as follows:

EQ3. Used for Liquid Mass and Corrected Volume Equations

Page 46

7.5 Computation of Viscosity Coef. A and B

SUPERtrol-I Flow Computer

Computation of Viscosity Coef. A & B

The ow computer solves an equation which computes the viscosity as a function of temperature. Two parameters must be entered for this calculation to be performed. These are the setup parameters Viscosity Coef. A and Viscosity Coef. B. A table listing these values for common uids is available from THE FACTORY.

Alternately, if your intended uid is not listed, the Viscosity Coef. A and B can be derived from two known temperature/viscosity pairs. Begin by obtaining this information for you intended uid. Convert these known points to units of Degrees F and centipoise (cP)

The information is now in a suitable form to compute the Viscosity Coef. A and Viscosity Coef. B using the following equation based on the uid state.

For a liquid, A and B are computed as follows:

(T1 + 459.67) • (T2 + 459.67) • ln [ cP1/cP2] B = —————————————————————— (T2 + 459.67) - (T1 + 459.67)

cP1 A = ——————————— exp [ B / ( T1 + 459.67) ]

cP • Density of Water at 4°C NOTE: cS = —————————————— Density of Liquid

Page 47

7.6 Linearization Table

KAKA KN KB

Y H X

Input

K factor

SUPERtrol-I Flow Computer

Linearization Table General Information

Linearization Table

(Pulse Inputs)

7.6.1 Linearization Table General Information

The Linearization Table is used when the ow input device gives a nonlinear input signal. The unit uses up to 16 different points, as entered by the operator, to form a curve for linearizing the input signal.

Notes:

1) A minimum of three points must be set up.

2) If "0" is entered for the frequency of any point other than point 1, the Flow Computer assumes there are no more points above the points that preceded them. The display will advance to the next setup prompt. Extrapolation is taken from the last two nonzero points.

3) If the input frequency is above the highest or below the lowest frequency programmed, the unit will use the last known point for the K factor in computing the resulting actual ow.

4) Frequencies or apparent ows should be entered in ascending order.

7.6.2 Linearization Table for Pulse Inputs

The linearization table for pulse inputs programming is quite simple when values of frequency and ow are known. The Flow Computer asks for 16 different frequencies (Freq) and 16 corresponding K factors (K). It then uses this data to determine what the actual ow is for any given input frequency. Usually the necessary data is provided with the owmeter.

Linearization Table

(Analog Inputs)

Linearization Table Interpolation

7.6.3 Linearization Table for Analog Inputs

The Linearization Table for Analog inputs programming is similar to the Pulse input setup. The Flow Computer asks for 16 different ow rates (apparent ow) and 16 corresponding Correction Factors. It then uses this data to determine what the Actual ow is for any given apparent input signal. Again, a minimum of three points must be set up.

Correction factor = Actual Flow Apparent Input Flow

The same rules that applied for the Digital setup apply for the Analog setup as well. The Flow Computer prompts you for the Apparent input signal (APR) and a correction factor CFr) to multiply it by to yield true actual ow.

7.6.4 Linearization Table Interpolation

The Linearization Table routine uses the entered data to determine the K factor for any given input frequency or input ow signal. This is done by taking the closest data points above and below the input signal, then using those points to extrapolate the K factor (correction factor), then calculating the uncompensated ow from the data. Below are the formulas.

Parameters: Determine closest point above input signal signal = X, K factor (correction factor) = KA

Determine closest point below input signal signal = Y, K factor (correction factor) = KB

Let input signal = H, unknown K factor (correction factor) = KN

To nd KN use this formula:

Page 48

8. Test, Service and Maintenance

START

8.1 Test Menus

SUPERtrol-I Flow Computer

Menus Display

8.1.1 TOP LEVEL TEST MENUS

START

SELECT OPERATE STATE Run Setup Test

ENTER

Audit Trail

STOP

START

Error history

STOP

START

Print System Setup

STOP

START

Keypad Test

STOP

START

Display test

Notes

Select Test to enter the instrument test & calibration routine.

NOTE: Supervisor (Service) password

required to gain access to this mode.

Refer to Page 40 for Details.

Refer to Page 41 Details.

Refer to Page 41 for Details.

STOP

START

Calibrate

STOP

START

Analog In Test

STOP

START

Pulse input test

STOP

START

Analog out test

STOP

START

Excitation out test

STOP

START

Pulse out test

Refer to Pages 42 - 46 for Details.

Refer to Page 46 Details.

Refer to Page 47 for Details.

Refer to Page 48 for Details.

STOP

START

Relay Test

STOP

START

Control inputs test

STOP

START

Battery Voltage Test

STOP

START

Data logger utility

Refer to Page 48 for Details.

Refer to Page 49 for Details.

Page 49

8.2 Test Sub-Menus

SUPERtrol-I Flow Computer

Display NotesSub-menus

8.2.1 Audit Trail Submenu Group

8.2.2 Error History Submenu Group

Audit Trail

ENTER

Audit Trail nnnnn hh:mm:ss mm/dd/yy

Audit Trail

Error history

ENTER

Error history Flow rate alarm low

Press Enter to view the audit trail information.

The audit trail is viewed in this format: nnnnn= number of critical menu changes, hh:mm:ss; mm/dd/yy = time and date of last change.

Press Menu to get back to audit trail top-level menu.

Press Enter to view error history.

NOTE: Press Print Key to print Error History. Printout will include time/date of each errors rst occurrence.

Press Up/Down arrow keys to scroll through error message history. Press CLEAR to clear entire error log.

8.2.3 Print System Setup Submenu Group

Error history

Print System Setup

ENTER

Print System Setup Press ENTER to print

ENTER

Print System Setup —— Printing ——-

Print System Setup

Press Menu to get back to error history top=level menu.

Press enter key to enter print system setup submenu

Press enter to begin printing the system setup.

This message will display as the data transmission takes place.

Press Menu to get back to print system setup top-level menu.

Page 50

SUPERtrol-I Flow Computer

Sub-menus Display Notes

8.2.4 Keypad test Submenu Group

8.2.5 Display test Submenu Group

Keypad test

ENTER

Keypad test Key pressed—> ENTER

Keypad test

Display test

ENTER

00000000000000000000 00000000000000000000

Press Enter to enter keypad test

Press the various keys and the display will show the key that was pressed. Press Menu to exit the test

Press Menu to get back to Keypad test toplevel menu.

Press Enter to enter display test.

Upon pressing enter the each digit on the display will scroll 0-9 then A-Z. Press menu to exit the test.

Display test

Press Menu to get back to Display test toplevel menu.

Page 51

SUPERtrol-I Flow Computer

START

ALL UNITS ARE CALIBRATED AT THE FACTORY PRIOR TO SHIPMENT CAUTION:

This unit must be calibrated using precision and calibrated equipment.

Equipment needed is as follows: Frequency Generator, Digital Multimeter, Precision Current/Voltage Source, Oscilloscope, Frequency Counter.

Sub-menus Display Notes

Calibration Submenu Group

8.2.6 Calibrate CH1 0mA Submenu Group

8.2.7 Calibrate CH1 20mA Submenu Group

Calibrate

ENTER

Calibrate ch1 0mA Iin=TB1-3 GND=TB1-4

ENTER

Calibrate ch1 0mA CALIBRATING ——

Calibrate ch1 0mA *** DONE ***

Calibrate ch1 0mA Iin=TB1-3 GND=TB1-4

STOP

Calibrate ch1 20mA Iin=TB1-3 GND=TB1-4

ENTER

Press Enter to begin the calibration routine. (Please note the caution above)

Connect Current Source (+) TB1-3, (-) TB1-4. Input 0mA and press Enter.

This message is displayed during calibration.

This message is displayed when the 0mA calibration is nished.

The display will automatically return to the Calibrate CH1 0mA submenu. Press the Down arrow key to advance to the CH1 20mA calibration.

Connect Current Source (+) TB1-3, (-) TB1-4. Input 20mA and press Enter.

Calibrate ch1 20mA 0 CALIBRATING ——

Calibrate ch1 20mA *** DONE ***

Calibrate ch1 20mA Iin=TB1-3 GND=TB1-4

STOP

Advance to

Calibrate ch2 0mA

This message is displayed during calibration.

This message is displayed when the 20mA calibration is nished.

The display will automatically return to the Calibrate CH1 20mA submenu. Press the Down arrow key to advance to the CH2 0mA calibration.

Page 52

SUPERtrol-I Flow Computer

START

Sub-menus Display Notes

8.2.8 Calibrate CH2 0mA Submenu Group

8.2.9 Calibrate CH2 20mA Submenu Group

Calibrate ch2 0mA Iin=TB1-8 GND=TB1-4

ENTER

Calibrate ch2 0mA 0 CALIBRATING ——

Calibrate ch2 0mA *** DONE ***

Calibrate ch2 0mA Iin=TB1-8 GND=TB1-4

STOP

Calibrate ch2 20mA Iin=TB1-8 GND=TB1-4

ENTER

To Calibrate: Connect Current Source (+) TB1-8, (-) TB1-4. Input 0mA and press Enter.

This message is displayed during calibration.

This message is displayed when the 0mA calibration is nished.

The display will automatically return to the Calibrate CH2 0mA submenu. Press the Down arrow key to advance to the CH2 20mA calibration.

To Calibrate: Connect Current Source (+) TB1-8, (-) TB1-4. Input 20mA and press Enter.

Calibrate ch2 20mA 0 CALIBRATING ——

Calibrate ch2 20mA *** DONE ***

Calibrate ch2 20mA Iin=TB1-8 GND=TB1-4

STOP

Advance to

Calibrate ch1 0V

This message is displayed during calibration.

This message is displayed when the 20mA calibration is nished.

The display will automatically return to the Calibrate CH2 20mA submenu. Press the Down arrow key to advance to the CH1 0V calibration.

Page 53

SUPERtrol-I Flow Computer

START

Sub-menus Display Notes

8.2.10 Calibrate CH1 0V Submenu Group

8.2.11 Calibrate CH1 10V Submenu Group

Calibrate ch1 0V Vin=TB1-2 GND=TB1-4

ENTER

Calibrate ch1 0V 0 CALIBRATING ——

Calibrate ch1 0V *** DONE ***

Calibrate ch1 0V Iin=TB1-2 GND=TB1-4

STOP

Calibrate ch1 10V Iin=TB1-2 GND=TB1-4

ENTER

To Calibrate: Connect Voltage Source (+) TB1-2, (-) TB1-4. Input 0V and press Enter.

This message is displayed during calibration.

This message is displayed when the 0V calibration is nished.

The display will automatically return to the Calibrate CH1 0V submenu. Press the Down arrow key to advance to the CH1 10V calibration.

To Calibrate: Connect Voltage Source (+) TB1-2, (-) TB1-4. Input 10V and press Enter.

Calibrate ch1 10V 0 CALIBRATING ——

Calibrate ch1 10V *** DONE ***

Calibrate ch1 10V Iin=TB1-2 GND=TB1-4

STOP

Advance to

Calibrate ch2 0V

This message is displayed during calibration.

This message is displayed when the 10V calibration is nished.

The display will automatically return to the Calibrate CH1 10V submenu. Press the Down arrow key to advance to the CH2 0V calibration.

Page 54

SUPERtrol-I Flow Computer

START

Sub-menus Display Notes

8.2.12 Calibrate CH2 0V Submenu Group

8.2.13 Calibrate CH2 10V Submenu Group

Calibrate ch2 0V Vin=TB1-5 GND=TB1-4

ENTER

Calibrate ch2 0V 0 CALIBRATING ——

Calibrate ch2 0V *** DONE ***

Calibrate ch2 0V Iin=TB1-5 GND=TB1-4

STOP

Calibrate ch2 10V Iin=TB1-5 GND=TB1-4

ENTER

To Calibrate: Connect Voltage Source (+) TB1-5, (-) TB1-4. Input 0V and press Enter.

This message is displayed during calibration.

This message is displayed when the 0V calibration is nished.

The display will automatically return to the Calibrate CH2 0V top-level menu. Press the Down arrow key to advance to the CH2 10V calibration.

To Calibrate: Connect Voltage Source (+) TB1-5, (-) TB1-4. Input 10V and press Enter.

8.2.14 Calibrate 100 ohm RTD Submenu Group

Calibrate ch2 10V 0 CALIBRATING ——

Calibrate ch2 10V *** DONE ***

Calibrate ch2 10V Iin=TB1-5 GND=TB1-4

STOP

Advance to

Calibrate 100ohm RTD

Calibrate 100ohm RTD JMP TB1-6,7 100R=7,8

ENTER

Calibrate 100ohm RTD 0 CALIBRATING ——

This message is displayed during calibration.

This message is displayed when the 10V calibration is nished.

The display will automatically return to the Calibrate CH2 10V top-level menu. Press the Down arrow key to advance to the 100 ohm RTD calibration.

To Calibrate: Connect a jumper wire between TB1-6 and TB1-7, Place a 100 ohm 0.1% resistor between TB1-7 and TB1-8. Press enter to calibrate.

This message is displayed during calibration.

Calibrate 100ohm RTD *** DONE ***

Calibrate 100ohm RTD JMP TB1-6,7 100R=7,8

STOP

Advance to

Calibrate 4mA out

This message is displayed when the RTD calibration is nished.

The display will automatically return to the Calibrate 100 ohm RTD top-level menu. Press the Down arrow key to advance to the 4mA out calibration.

Page 55

SUPERtrol-I Flow Computer

START

Sub-menus Display Notes

8.2.15 Calibrate 4mA Out Submenu Group

8.2.16 Calibrate 20mA Out Submenu Group

Calibrate 0mA out + TB1-15 - TB1-16

ENTER

Calibrate 0mA out Enter mA: 0.00000

ENTER

Calibrate 0mA out + TB1-15 - TB1-16

STOP

Calibrate 20mA out + TB1-15 - TB1-16

ENTER

Calibrate 20mA out Enter mA: 20.00000

ENTER

Calibrate 20mA out + TB1-15 - TB1-16

Calibrate

Connect ammeter to (+) TB1-15, (-) TB1-16. Press enter.

To trim 0mA output: Press CLEAR to enable editing and enter a small negative number (i.e.

-0.100) to force a display reading, then clear and enter small quantity measured on your meter.

The display will return to Calibrate 0mA out. Press the down arrow key to advance to Cal. 20mA out or repeat above if necessary.

Connect ammeter to (+) TB1-15, (-) TB1-16. Press enter.

To trim 20mA output: Press CLEAR to enable editing and enter the current reading that is on the ammeter display. Press enter.

The display will automatically return to the Calibrate 20mA out submenu. Calibration is complete.

Press the Menu key to go back to Calibrate top-level menu.

8.2.17 Analog In Test Submenu Group

Analog In Test

ENTER

Analog In Test Volts T2:00.000 T5:00.000

STOP

Analog In Test mA T3:00.000 T8:00.000

STOP

Analog In Test OHMS RTD 00.000

Analog In Test

Press enter to test the analog inputs.

To check voltage input accuracy: Use TB1-4 as Reference Ground, input 0-10 Volts to TB1-2 and/or TB1-5. Display should show voltage being input. Use voltage meter to verify input.

To check current input accuracy: Use TB1-4 as Reference Ground, input 0-20mA to TB1-3 and/or TB1-8. Display should show current being input. Use ammeter to verify input.

To check RTD input accuracy: Connect a jumper wire between TB1-6 and TB1-7, Place a 100 ohm 0.1% resistor between TB1-7 and TB1-8. Display should show 100 ohms ±0.1%.

Press Menu key to return to Analog In Test

Page 56

SUPERtrol-I Flow Computer

START

Sub-menus Display Notes

8.2.18 Pulse input test Submenu Group

2.5V 10mV

100mV

40Hz 3KHz

20kHz

STOP

START

Pulse input test

ENTER

Pulse input test Trigger level 2.5V

ENTER

Pulse input test count speed 3kHz

ENTER

Pulse input test F1: 0 F2: 0

Pulse input test

top-level menu.

Press Enter key to test the pulse input.

Use the Up/Down arrow keys to select the appropriate trigger level.

Use the Up/Down arrow keys to select the appropriate frequency range.

To check Pulse input accuracy: Use TB1-4 as reference ground, input a frequency on TB1-2. The display should show frequency being input. Use a frequency counter to verify input.

Press Menu key to return to Pulse input test top-level menu.

8.2.19 Analog out test Submenu Group

8.2.20 Excitation out test Submenu Group

Analog out test

ENTER

Analog out test *0 4 10 15 20 mA

Analog out test

Excitation out test

ENTER

Excitation out test *5v 12v 24v

Press Enter to test the analog output.

To simulate analog output: Connect an ammeter to (+) TB1-15, (-) TB1-16. Press the key under the desired setting to move the asterisk (*). The unit should output the selected current.

Press Menu key to return to Analog out test top-level menu.

Press Enter to test the excitation output.

To test the excitation output: Connect a voltmeter to (+) TB1-1, (-) TB1-4. Press the key under the desired setting to move the asterisk (*). The unit should output the selected voltage.

Excitation out test

Press Menu key to return to Excitation out test top-level menu.

Page 57

SUPERtrol-I Flow Computer

Sub-menus Display Notes

8.2.21 Pulse out test Submenu Group

8.2.22 Relay test Submenu Group

Pulse out test

ENTER

Pulse out test *0Hz 1Hz 10Hz 20Hz

Pulse out test

Relay Test

ENTER

Rly1 Rly2 Rly3 Rly4 Off Off Off Off

Press Enter key to test the pulse output.

To simulate a frequency on the pulse output: Connect a frequency counter to (+)TB1-13, (-)TB1-14. Press the key under the desired setting to move the asterisk (*). The unit should output the selected frequency.

Press Menu key to return to Pulse out test top-level menu.

Press Enter to test the relays.

To manually control the relay outputs: Press the key under the desired relay to toggle the relays On/Off. Use an ohmmeter to check the relay contacts.

8.2.23 Control input test Submenu Group

Relay Test

Control inputs test

ENTER

TB1-9 TB1-10 TB1-11 Off Off Off

Control inputs test

Press Menu key to return to Relay Test toplevel menu.

Press Enter to test the control inputs.

To check the control inputs: Use TB1-12 as reference, input a DC signal to TB1-9, TB110 and/or TB1-11, The Display will show ON when input is active, OFF when inactive.

Press Menu key to return to control input test top-level menu.

Page 58

SUPERtrol-I Flow Computer

START

Sub-menus Display Notes

8.2.24 Battery Voltage test Submenu Group

8.2.25 Data logger utility Submenu Group

Battery Voltage Test

ENTER

Battery Voltage Test

3.312 Volts

Battery Voltage Test

Data logger utility

ENTER

Data logger utility Log 10 958 Max

STOP

Press Enter key to view the battery voltage.

The display will show the battery voltage. Replace battery at 2.5 VDC or below.

Press Menu key to return to battery voltage test top-level menu.

Press Enter to use data logger utility.

The displays shows the number of Data Logs. Press the Down arrow key to advance to PRT (print) or CLR (clear).

Data logger utility Log 00001 PRT CLR

Data logger utility

Press PRINT key to output data logger logs to printer, Press CLEAR key to clear the data logger contents.

Press Menu key to return to Data logger utility top-level menu.

Page 59

SUPERtrol-I Flow Computer

Screws (4 places)

FUSE

8.3 Internal Fuse Replacement

Instructions:

1. Make sure you follow proper E.S.D. Precautions. All persons performing this replacement must follow proper grounding procedures.

2. Turn the power to the unit off.

3. Disconnect the two piece connector rear terminal block, leaving all connections in place.

4. Remove the unit from the panel.

5. Remove the four machine screws (see g. 1) which hold the two sections of the case together.

6. The rear section of the case should detach from the rest of the case. It may be necessary two cut the wiring label along the joint where the two sections connect. With the rear section of the case removed the fuse will be exposed (located near the rear terminal, AC connection).

7. Locate the Fuse F1 (see g. 2) and unplug the fuse from its socket.

8. Insert the new fuse into the socket. Insure that the pins are fully inserted and straight.

9. Reassemble the case and install the four machine screws which join the two sections of the case.

10. Reinstall the unit into the panel.

11. Reconnect the rear terminal block.

12. Turn the unit back on.

Fuse Specications:

110 VAC Power: 160mA/250V, TD Wickman 19372-030-k or equivalent 220 VAC Power: 80mA/250V, TD Wickman 19372-026-k or equivalent 12/24 VDC Power: 800mA/250V, TD Wickman 19374-046-k or equivalent

g. 1

g. 2

fuse

Page 60

9. RS-232 Serial Port

9.1 RS-232 Port Description:

The Flow Computer has a general purpose RS-232 Port which may be used for any one of the following purposes:

Transaction Printing Data Logging Remote Metering by Modem (optional) Computer Communication Link Conguration by Computer Print System Setup Print Calibration/Malfunction History

9.2 Instrument Setup by PC’s over Serial Port

A Diskette program is provided with the Flow Computer that enables the user to rapidly congure the Flow Computer using a Personal Computer. Included on the diskette are common instrument applications which may be used as a starting point for your application. This permits the user to have an excellent starting point and helps speed the user through the instrument setup.

SUPERtrol-I Flow Computer

9.3 Operation of Serial Communication Port with Printers

The system setup and maintenance report list all the instrument setup parameters and usage for the current instrument conguration. In addition, the Audit trail information is presented as well as a status report listing any observed malfunctions which have not been corrected.

The user initiates the printing of this report at a designated point in the menu by pressing the print key on the front panel.

The user may specify a “next calibration date” for periodic maintenance. The unit will automatically remind the user that calibration is scheduled during instrument power up and in some printed documents after that date.

9.4 Flow Computer RS-232 Port Pinout

12345

6789

1 Handshake Line 2 Transmit 3 Receive 4 Do Not Use 5 Ground 6 Do Not Use 8 Do Not Use 9 Do Not Use

RS-232 RS-485

12345

6789

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

12345

6789

23 24

Page 61

10. RS-485 Serial Port (optional)

10.1 RS-485 Port Description:

The Flow Computer has a an optional general purpose RS-485 Port which may be used for any one of the following purposes:

Accessing Process Parameters Rate, Temperatures, Density, Setpoints, Month, Day, Year, Hour, Min-

utes, Seconds, etc. Accessing System Alarms System, Process, Self Test, Service Test Errors Accessing Totalizers Totalizer and Grand Totalizer Executing Various Action Routines Reset Alarms, Reset Totalizers, Print Transaction, Reset Error History,

Start, Stop, Clear

SUPERtrol-I Flow Computer

10.2 General

The optional RS-485 card utilizes Modbus RTU protocol to access a variety of process parameters and totalizers. In addition, action routines can be executed. For further information, contact factory and request RS-485 Protocol manual for Flow Computer.

10.3 Operation of Serial Communication Port with PC

The ow computer's RS-485 channel supports a number of Modbus RTU commands. Refer to port pinout (below) for wiring details. Modbus RTU drivers are available from third party sources for a variety of Man Machine Interface software for IBM compatible PC's.

The user reads and writes information from/to the RS-485 using the Modbus RTU commands. The Flow Computer then responds to these information and command requests.

10.4 Flow Computer RS-485 Port Pinout

12345

6789

1 Ground 2 Ground 3 Ground 4 TX/RX (+) 5 TX/RX (-) 6 Do Not Use 7 Terminating Resistor (180 Ω) 8 TX/RX (+) 9 TX/RX (-)

RS-232 RS-485

12345

6789

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

12345

6789

23 24

Page 62

11. Flow Computer Setup Software

The Flow Computer setup program provides for conguring, monitoring and controlling a Flow Computer unit.

Sample applications are stored in disk les. The setup program calls these Templates. You can store the setup from the program’s memory to either the Flow Computer (Downloading the le) or to a disk le (Saving the le) for later usage. Similarly you can load the setup in program memory from either a disk le (Opening a le) or from the Flow Computer unit (Uploading a le).

The program can monitor outputs from the unit while it is running. The program can reset alarms and totalizers. For assistance there are mini-helps at the bottom of each screen in the program.

There is also context sensitive help available for each screen accessible by pressing the F1 key.

11.1 System Requirements:

SUPERtrol-I Flow Computer

IBM PC or compatible with 386 or higher class microprocessor 4 MB RAM 3 MB free disk space VGA or higher color monitor at 640 x 480 Microsoft® Windows™ 3.1 or 3.11 or Windows 95™ Communication Port - RS-232 RS-232 Cable

11.2 Cable and Wiring Requirements:

The serial communication port on your PC is either a 25 pin or 9 pin connector. No cabling is supplied with the setup software. A cable must be purchased separately or made by the user. It is recommended to purchase a modem cable which matches the available communication port on you PC and a 9 pin male connection for the Flow Computer serial port.

11.3 Installation for Windows™ 3.1 or 3.11

The Setup Software includes an installation program which copies the software to your hard drive.

Insert Setup Disk 1 in a oppy drive. In the Program Manager, click File, and then select Run. NOTE: For Windows 95™ Click the Start button, select Run and proceed

as follows:

Type the oppy drive letter followed by a colon (:) and a backslash (\), and the word setup. For Example:

a:\setup Follow the instructions on your screen.

Page 63

11.4 Using the Flow Computer Setup Software

The setup software window consists of several menu “Tabs”. Each tab is organized into groups containing various conguration and/or monitoring functions. To view the tab windows, simply click on the tab. The previous tab window will be hidden as the new tab window is brought to the foreground.

11.5 File Tab

The File Tab has three sections. Any of the options on this tab can also be accessed from the File submenu.

The Template Section provides for opening and saving templates. The Save and Save As buttons provide the standard Windows functionality for dealing with les.

The Load button is used to open existing templates. There are two additional menu items available only from the File menu: Create new

le and Templates. The Create new le, option allows for creating custom templates using the existing

template in memory as the starting point. Assign a new name for this template. The template will be saved under this new name.

SUPERtrol-I Flow Computer

The Template option will bring up a list of predened templates that can be loaded

into the program. These predened templates are useful as a starting point when dening custom templates.

A typical scenario using the setup program would be the following:

• Open up a predened template from the supplied list

• Choose ‘Save As’ to save this to a new le name

• Proceed to customize the template by making any changes that are needed

• Save the template to disk (if you want to reuse this template)

• Download the template to an attached unit. The Communications with Flow Computer Section allows the user to upload a

template le from the unit, download the program’s current template to the unit or Compare the program’s current template with the unit.

The Print (report) Section allows the user to:

1. Congure the current Windows printer through the Select Printer option.

2. Print a Maintenance Report through the PC's printer using the Print

Maintenance option.

3. Print the current template through the PC's printer using Print Setup option.

11.6 Setup Tab

The Setup tab is where majority of the Flow Computer instrument setup modications are done. The Setup tab is divided into ve sections.

System Section: Parameters, Display, Indicators Input Section: Flow, Fluid, Compensations, Control Inputs Output Section: Pulse, Currents

Relay Section: Relays Other Settings Section: Administration, Communication, Printing NOTE: Many setup items are enabled or disabled depending on previous setup

selections, It is important to work your way through the above list in the order shown. Be sure to verify your selections when you are through programming to insure that no settings were changed automatically.

Page 64

11.7 View Tab

SUPERtrol-I Flow Computer

The View Tab screen allows for viewing selected group items on the PC in a similar format as shown on the unit display. Data from the following groups can be viewed in the List of Values section:

Process Parameters (i.e. rate, temperature) Totalizers (i.e. total, grand total)

The setup software assumes the current setup has been uploaded from the ow computer into the PC. It is important that the setup program and the Flow Computer unit are using the same setup information at all times or the data will be inconsistent. It is best to upload or download the setup before using this feature.

To start the viewer, rst check the boxes of items to view and then click the start button. The data will appear in the appropriate sections and will be continuously updated. The refresh rate is dependent on the number of items that are being viewed and the baud rate of the connection. Data in the List of Values section can be collapsed by clicking on the ‘minus’ sign in front of the group title. The data can be expanded by clicking on the ‘plus’ sign in front of the group title. If a group is collapsed and data in the group changes on refresh, the group will automatically expand. Changing the view items requires stopping the current viewing, checking the new selections and then restarting the viewer.

11.8 Misc. Tab

If communication errors occur while reading data from the Flow Computer device, the word ‘Error’ will appear in place of the actual value. If the connection to the Flow Computer is lost, the viewer will time out with a message saying the device is not responding.

The viewer will attempt to communicate with the Flow Computer device matching the device ID set in the communications screen. If you are having trouble establishing communication, compare settings for the PC and the ow computer. Also verify the connections between the PC and ow computer.

This tab has three sections: Tools, Actions and Options. The tools section contains various system administration activities such as creating/

modifying the initial sign-on screen or calibration, service test etc. Create Sign-on, Create Print Header, Calibration, Service Test

The Actions section is used to send commands to the unit. Reset Totalizers, Reset Alarms

The Options section has the following selections: Linearization, PC Communication Additional capabilities may be provided in the future. NOTE: Future options appear as disabled buttons on the screen.

Page 65

SUPERtrol-I Flow Computer

12. Glossary Of Terms

Acknowledge & Clear Alarms

Acknowledge is used to clear alarm relays and remove any visual alarm messages from the display. In

the run mode, press the ENTER key or activate CONTROL INPUT 3 (if set for ACK) to momentarily clear alarms and alarm messages. Alarms will reassert themselves if alarm conditions are still present.

Analog Output

The analog signal (4-20mA) that is generated by the Flow Computer. It can correspond to the Rate,

Total, Temperature or Density. This output is used primarily for transmission of process information to remote systems.

Audit Trail

The audit trail is used to track the number of changes made to the units setup program.

Batch Count Mode

Batch Count Mode species the user preference for count direction. The "Up" selection begins with

a value of "0" and counts up until the batch size is reached. The "Down" selection begins with a value equal to the desired batch size and counts down to "0".

Batch Overrun

The Flow Computer offers a batch overrun compensation routine. If batch overrun occurs due to slow

valve response time, the unit will compensate for the overrun amount on the next batch. This feature can be disabled if desired.

Batcher

An instrument which controls the dispensing of desired batch amounts. Liquid batching systems are

usually comprised of a batch controller (batcher), owmeter and control valve. The batcher opens and closes the valve through the use of relays and measures the amounts of liquid being dispensed via the owmeter.

Baud Rate

The speed of serial communication transmissions, expressed in bits per second.

C-Factor (Fluid Expansion Factor) A parameter in a ow equation which is used to describe the relationship between density or volume and

temperature changes.

Corrected Volume Flow

The equivalently volume at a reference temperature condition which involves the measurement of liquid

volume ow using a ow sensor and temperature sensor to compensate for thermal expansion.

Custody Transfer

Weights and Measure metering codes often specify several requirements for instruments and

mechanisms to prevent and track changes in the setup of an instrument which may be used in the commercial sale of goods. The Flow Computer tracks changes via the Audit Trail.

Data Logger

The capturing of information for later use and the mechanism for specifying the conditions where a

capture should be made.

DC Output / Excitation Voltage

An on-board DC power supply used to power peripheral sensors. The Flow Computer offers excitation

voltages of 5VDC, 12VDC or 24VDC when powered by AC voltage.

Default Value

The value to be used by the instrument if a sensor failure or out of ranch signal is detected.

Expansion Factor

See C-Factor

EZ Preset

The EZ Preset mode was designed for users who frequently change the batch amount.

Flow Alarm

A visual indication that the volumetric owrate is above or below the ow alarm setpoint specied by

the user.

Flow Signal Timeout

Page 66

SUPERtrol-I Flow Computer

12. Glossary Of Terms (Continued)

Flow Equation

A ow control expression or algorithm describing a mathematical equation to be solved by a ow

computer in the desired application.

Follow, Alarm

Alarm relays which are non latching and whose output state is based solely on the comparison of the

current process value and the alarm setpoint (trip point).

Function Key

A key on a push-button panel or keyboard (whose function is described by the key label) used to

perform an instrument function or special routine.

Handshake

A means of controlling the information ow between two pieces of equipment to prevent the sending

device from transmitting information at a rate faster than what can be accepted by the receiver.

Hysteresis

The relay hysteresis is a "dead band" setting which allows the relay to remain energized for a given

amount below the setpoint. This is used to prevent relay chatter when the process value is near the setpoint value.

Example: If the Preset is set at 100, and the hysteresis is set at 10, the relay will energize when the rate,

temp or dens. reaches 100, the relay will remain energized until the reading falls below 90.

Input Termination

Input signal lines on digital inputs often require pullup or pulldown resistor congurations to operate

properly with different sensor congurations. The Flow Computer contains such resistors and may be enabled via the setup menu.

Inhibit Totalizer

"Inhibit Total" is a Control Input 1 setting that is used to stop the totalization. If enabled, a voltage level

on control input 1 will inhibit the total as long as the voltage is present. This feature is useful during meter proving and in applications that provide a sensor to signal the ow computer when uid is present.

K-Factor

A scaling factor derived from the pulses produced by a owmeter output, expressed in pulses per unit

(i.e. pulses/gallon)

LCD

Abbreviation for: Liquid Crystal Display

Limit Setpoint

An alarm trip point setting which species the value or magnitude of a process parameter necessary to

activate an alarm indicator or control relay.

Linear Flowmeter

A ow measurement device whose output is proportional to ow.

Linearization

The mathematical correction of a nonlinear device. The Flow Computer uses a linearization Table

which is made up of input/output values and makes interpolations of the table to arrive at a "linearized" measurement.

LinTbl

Abbreviation for Linearization Table.

Low Flow Cutoff

A value set at which any ow measurements read below this value will be ignored.

Low Pass Filter

A low pass lter passes low input frequencies while blocking high frequencies. In the Flow Computer,

this is the maximum input count speed to be encountered in an application. It is expressed in counts per second (Hz).

Mass Flow

Mass Flow is inferred by the volumetric ow and density (or implied density) of a uid.

Page 67

SUPERtrol-I Flow Computer

12. Glossary Of Terms (Continued)

Maximum Batch Preset

Maximum Drain Time

Max Window

The max. window time sets the maximum sample time (1 to 99 sec) for the ratemeter.

Modem Init Master

The "Modem Init Master" menu allows the user to select whether the unit will engage in a conguration

conversation with the modem on power up or impart no setup information to the modem and use it "as is". For most users it is recommended to choose "yes" for "Modem Init Master".

Orice Plate Flowmeter

A class of ow measurement devices where the measured signal (differential pressure) has a square law

relationship to ow.

Parity

A method for detecting errors in transmissions of serial communications data.

Preset

A set point used to trigger the relay outputs of the Flow Computer.

Print Interval

The print interval allows the Flow Computer to transmit information to the serial port at selectable time

intervals.

Private Code

An operator password code which authorizes changes to the setup of the instrument but blocks access to

the Service/Calibration/Test mode. The private code also blocks the clearing of the Grand Total.

Process Parameters

Any sensor information which has been scaled to engineering units including Flow, Temperature and

Density.

Pulldown (Input Termination) The termination of an input at which the input is pulled down to ground through a resistor. Inputs that

are terminated by this method need to be driven high with a positive voltage pulse.

Pullup (Input Termination) The termination of an input at which the input is pulled up to a positive voltage through a resistor.

Inputs that are terminated by this method need to be pulled low with a sinking current or contact to ground .

Pulse Output

The pulse output of the Flow Computer is available for remote accumulation of the total or sent to

peripheral devices, such as a PLC. The output can be scaled using the Pulse Output Scaling Constant.

Quad

Abbreviation for Quadrature. Quadrature signals are used for direction control. Two owmeter signals

are output with a 90° phase shift. The counter counts UP when channel A precedes channel B, and counts DOWN when Channel A lags Channel B.

Quick Setup

A utility that provides for rapid conguration of an instrument. The Flow Computer quick setup provides

the following:

1) Prompts the user for only critical information.

2) Automatically sets specications to common uses. After following the Quick Setup procedure, the unit will be operational to perform the basic

measurement. The setup can be further customized using the setup menus.

Page 68

SUPERtrol-I Flow Computer

12. Glossary Of Terms (Continued)

Quick Update %

This feature is used to disable the rate averaging lter when a signicant change in the ow rate occurs.

The user can enter the percent of change needed to be detected to disable the averaging feature. This is especially useful during start-up and shutdown of ow.

Rate Averaging Filter

The rate averaging lter is used to stabilize uctuating rate displays. Higher settings provide more

averaging for a more stable display. Derived from the equation:

(OLD DATA x "Avg. Filter" + NEW DATA) ("Avg. Filter" + 1)

Ratemeter

Any device used to display the speed of a process. The ratemeter in the Flow Computer displays ow

rate.

Ref. Dens.

Abbreviation for Reference Density. This is the uid density at reference temperature.

Ref. Temp.

Abbreviation for Reference Temperature. This represents the base or reference condition to which

corrected ow will be computed.

Reset/Start Control Input

In a batching system, a single operator activation of the START key or Control Input 1 will reset the

total then start the batch process.

Single_Pulse

The Single_Pulse setting is used for owmeters with single pulse outputs.

Slow Start Quantity

Sqrt

Abbreviation for Square Root Extraction. Used for ow elements using differential pressure

measurements.

Standard Preset

The Standard Preset mode should be used in applications where the batch amount does not change often.

Stop/Reset Control Input

In a batching system, a single operator activation of the STOP key or Control Input 2 will stop the batch

process then reset the total.

Time Constant

A damping factor for an averaging lter for the analog output. (see also Rate Averaging Filter)

Totalizer

Any device which accumulates and displays a total count.

UVC

Abbreviation for Universal Viscosity Curve. A presentation of the combined owrate/viscosity

calibration for a turbine owmeter.

VFD

Abbreviation for Vacuum Fluorescent Display

Visc Coef

Abbreviation for Viscosity Coefcient. One or more coefcients in an equation used to describe the

viscosity as a function of temperature for a uid.

Volume Flow

The measurement of volumetric ow.

Page 69

13. Diagnosis and Troubleshooting

13.1 Response of Flow Computer on Error or Alarm:

Error and warning indications which occur during operation are indicated in the RUN mode alternately with the measured values. The Flow Computer has three types of error:

TYPE OF ERROR DESCRIPTION

Sensor/Process Alarms Erro r s de t e cted due to

SUPERtrol-I Flow Computer

sensor failure or process alarm conditions

Self Test Errors

Errors detected during self test.

System Alarms Errors detected due to system

failure

Some alarms are self clearing. Other alarms require the user to acknowledge and clear the alarm. Press the ENTER button to acknowledged and clear alarms. Alarms may reassert themselves if the alarm condition is still present.

NOTE: A historical error alarm log is available in the "Test Mode".

The following descriptions suggest possible causes and corrective actions for each alarm message.

Page 70

13.2 Diagnosis Flow Chart and Troubleshooting

Is there an input power supply voltage across Terminals 23 and 24?

Yes

Check the connections according to the circuit diagrams.

Check junction box fuses.

Is the Display Backlight Visible?

Yes

Check/Replace internal fuse. If fuse is OK, Factory Service Required.

Is there a black bar across the display?

Yes

Does the display alternate between blank and sign on message?

Yes

Does the display show an error message?

Yes

See section 12.3 for cause and remedy.

No system or process errors present.

Are the Display Characters Visible?

Yes

The display may not be visible with ambient temperatures below -10 °C Allow the instrument to warm up. Contact factory if necessary

Check line voltage. If voltage is OK, Factory Service Required.

All instruments undergo various stages of quality control during production. The last of these stages is a complete calibration carried out on state-of-the-art calibration rigs.

A summary of possible causes is given below to help you identify faults.

SUPERtrol-I Flow Computer

Page 71

13.3 Error & Warning Messages:

SUPERtrol-I Flow Computer

13.3.1 Sensor/Process Alarms

Error/Warning Message

TOTALIZER ROLLOVER

AUX INPUT TOO LOW

RTD OUT OF RANGE

RATE OVERFLOW ERROR

PULSE OUT OVERFLOW

Cause

Displayed when totalizer

rolls over

4-20 mA Input current at aux input smaller than 3.5 mA:

• Faulty Wiring

• Transmitter not set to "4-20 mA"

• Transmitter defective

Input current at RTD input too low:

• Faulty wiring

• RTD defective

Pulse counter overowed. The totalizer may have lost counts.

Calculated pulse frequency too large:

• Pulse width setting too long

• Larger pulse scaler needed

Remedy

Acknowledge Rollover, Remedy not required

• Check wiring

• Check function of sensor

• Check wiring

• Check function of RTD sensor

• Report error to factory

• Check application conditions

• Check wiring

• Adjust pulse value

• Adjust pulse width

• Check process conditions

FLOW RATE ALARM LOW FLOW RATE ALARM HIGH

TEMP ALARM LOW TEMP ALARM HIGH

DENSITY ALARM LOW DENSITY ALARM HIGH

BATCH OVERRUN ALARM

MODEM NOT PRESENT

Limit value exceeded.

Batch size exceeded by more than set limit.

The setup expects modem usage and a modem is not responding.

• Check application if necessary

• Check limit value

• Adjust the limit value if required

• Check valves in system for proper operation and/or leaks

• Check limit value

• Adjust the limit value if required

• Check setup for proper baud rate, parity, etc.

• Check modem connection and cycle power to Flow

Computer

• Replace modem

SOFTWARE ERROR RESET

EXTENDED PFI LOCKUP

Watchdog Error. Transient likely

Unit was operated with an input power level lower than safe operating range for an extended period of time.

• Cycle power to

Flow Computer

• Check data in unit. Totalizer may have inaccuracies

• Investigate brownout cause.

Page 72

13.3 Error & Warning Messages: (Continued)

SUPERtrol-I Flow Computer

13.3.2 Self Test Alarms

Error/Warning Message

FLOW INPUT TOO HIGH

AUX INPUT TOO HIGH

FLOW INPUT TOO LOW

Cause

Analog input signal of the ow input exceeded by more than 3%:

• Sensor overranged

• Incorrect full scale setting of owmeter

• Function error in transmitter or faulty wiring

Analog input signal of the auxiliary input exceeded by more than 3%:

• Sensor overranged

• Incorrect full scale setting of transmitter

• Function error in transmitter or faulty wiring

Analog input signal of the ow input fell below the low scale range by more than 3% of full scale value:

• Flowmeter not set to 4-20 mA

• Function error in transmitter or faulty wiring

Remedy

• Check analog signal range

• Check the application conditions

• Check wiring

• Check analog signal range

• Check the application conditions

• Check wiring

• Check calibration of owmeter

• Check function of owmeter

BATTERY LOW WARNING

A to D NOT CONVERTING

TIME CLOCK ERROR

CAL CHECKSUM ERROR

SETUP CHECKSUM ERROR

Battery voltage too low

Fault in analog/digital converter

The correct time/date is no longer shown

Calibration constants have been corrupted

The units setup has been corrupted

• Replace Battery

• Consult Factory for service information

• Unit may self correct, Press ENTER to acknowledge & clear alarm

• If error reasserts, factory service is required

• Re-enter time and date.

• If error occurs again contact factory

• Report error to factory

Page 73

APPENDIX A

TEMPERATURE

PLACES

DECIMAL

SCALE

HIGH FLOW

RATE ALARM

SUPERtrol-I Flow Computer

IF 2MIN.

HANGUP

INACTIVE

SETUP MENUS

QUANTITY

SLOW START

TIME

MAX. DRAIN

TIMEOUT

FLOW SIGNAL

COMP.

BATCH

OVERRUN

TEMP

DESCRIPTOR

QUICK

UPDATE %

RATE

FILTER

AVERAGE

PLACES

RATE DECIMAL

RATE

DESCRIPTOR

BASE

RATE TIME

PLACES

DENSITY

DECIMAL

MASS UNITS

DENSITY

DESCRIPTOR

LOW FLOW

RATE ALARM

TABLE B

CHANGE

TABLE A

CHANGE

AVERAGE

KB-FACTOR

AVERAGE

KA-FACTOR

TYPE

MAX WINDOW K-FACTOR

INPUT

TERMINATION

FILTER

LOW PASS

HIGH FLOW

RATE ALARM

LOW FLOW

RATE ALARM

CUTOFF

LOW FLOW

TABLE A

CHANGE

SCALE

FLOW HIGH

SCALE

FLOW LOW

TYPE

LINEARIZATION

DENS

METHOD

EXTRACT

ALARM

AUX HIGH

ALARM

AUX LOW

AUX. DEFAULTAUX LOW

SCALE

AUX FULL

These functions will only appear with

appropriate settings in other functions.

DAMPING

FULL SCALE

RELAY

HYSTERESIS

RELAY

SETPOINT

RELAY MODE

H2O DENSITY

VISCOSITY

AT 4DEGC

COEF. B

COEF. A

ANALOG OUT

REDIALS

NUMBER OF

PHONE

NUMBER

CALL OUT

ITEMS

ALARM

ERROR/

CALL ON

CALL OUT

MODEM AUTO

MODEM

ENTER DATESELECT

TIME

DAY OF WEEK

ANSWER

CONTROL

FEED

PRINT LIST

IF PRINT

CLEAR TOTAL

BATCH

PRINT END OF

KEY

ENABLE PRINT

INTERVAL

PRINT TIME

ONLY

DATALOG

SERIAL

SENSOR

NUMBER

UNIT

SERIAL

NUMBER

PRODUCT

ORDER CODE

PRESET

MAX. BATCH

MODE

BATCH COUNT

SELECT

PRESET TYPE

TYPE

INSTRUMENT

SELECT

EZ SETUP

INSTRUMENT

START HERE

EQUATION

SELECT FLOW

TYPE

EQUATION

SELECT FLOW

PLACES

TOTAL DECIMAL

UNITS

VOLUME

TOTAL

DESCRIPTOR

SETUP

INDICATORS

SETUP INDICATORS

TYPE

PULSE

TRIGGER

VOLTAGE/

CURRENT

TYPE

ANALOG

INPUT TYPE

PULSE INPUT

TYPE

FLOW

INPUT

VOLTAGE

EXCITATION

SETUP FLOW INPUT

RANGE

VOLTAGE/

AUX SIGNAL

AUX INPUT

CURRENT

SCALE

RANGE

TYPE

DENSITY

CALIBRATION

FACTOR

EXPANSION

TEMPERATURE

REF. DENSITY REF.

SET FLUID

PROPERTIES

SETUP AUX INPUT

PULSE WIDTH PULSE VALUE

USAGE

PULSE OUPUT

OUTPUT

SETUP PULSE

LOW SCALE

ANALOG OUT

RANGE

OUTPUT

ANALOG

FLOW TYPE

ANALOG OUT

ANALOG

OUPUT USAGE

OUTPUT

SETUP ANALOG

RELAY

DURATION

RELAY

DELAY

RELAY USAGE

SETUP

RELAYS

SETUP RELAYS

1, 2, 3, 4

CONTROL

SETUP

CONTROL

SETUP CONTROL

INPUT 3

INPUT 2

INPUT 1

USAGE

1, 2, 3

INPUTS

TIME OF DAY

CLOCK AM/PM

CLOCK TYPE

TIME CLOCK

SETUP REAL

CLOCK

SETUP REAL TIME

DEVICE ID BAUD RATE PARITY HANDSHAKE DEVICE LINE

SERIAL

HARDWARE

SERIAL USAGE

SOFTWARE

FORMAT

DATALOG/

SUPERVISOR

TAG NUMBER

OPERATOR

PAGE LENGTH TOP MARGIN

OUTPUT

SETUP

DATALOG/PRINT

ADMINISTRATIVE

VERSION

PASSWORD

SETUP

BAUD RATE PARITY

DEVICE ID

NETWORK

SELECT

NETWORK

PROTOCOL

CARD

SETUP NETWORK

Page 74

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.

SUPERtrol-I Flow Computer

DECODING PART NUMBER

Example ST1 L 1 A 0 P TU

Series: ST1= Supertrol-1 Display Type: L= LCD V= VFD Input Type: 1= 110 VAC 2= 220 VAC 3= 12 VDC (10 to 14 VDC) 4= 24 VDC (14 to 28 VDC) Relays: A= 2 SPDT Relays B= 4 SPDT Relays

Network Card: 0= None (STD) 2= RS485/Modbus Mounting: P= Panel Mount *N= NEMA 4 Wall Mount *W= NEMA 12/13 Wall Mount w/ Clear Cover *E= Explosion Proof (No Button Access) *X= Explosion Proof (with Button Access)

Options: ET= Extended Tempertaure

-4°F to 131°F (-20°C to 55°C) IM = IM-2400 Internal Modem IM-56K = 56K Internal Secure Modem M = Modem Power Option

TB= RS485 Terminal Block for Panel Mount Enclosure Accessories:

KEPS-KEP1-32 KEP RS232 for SUPERtrol 1, SUPERtrol 1LE,

 SUPERtrol2andLEVELtrol2•32BitDDEServer

KEPS-MBS32 Supports RS485 for ST1, ST1LE, ST2, LT2, MRT, DRT & MB2 (Modbus RTU) Modem Available, see MPP-56KN, MPP-2400 and MPP-2400N

Serial printer available, see P1000, P295 Ethernet Port Server available, see IEPS RS-422/485 to RS-232 Communication Adaptor available, see CA285

RS232 Extender Cable: P/N=13220-<length in inches> Remote metering and data collection software available, (TROLlink)

RoHS Compliant planned

Kessler-Ellis Products

10 Industrial Way East

Eatontown, NJ 07724

Toll Free: 800-631-2165

Phone: (732) 935-1320

Fax: (732) 935-9344

http://www.kep.com