KEP SUPERtrol-ILE Operating Manual

SUPERtrol-I LE

FLOW COMPUTER

Version 4.X

http://www.kep.com

99572 10/13/04

KESSLER-ELLIS PRODUCTS

10 Industrial Way East

Eatontown, NJ 07724

800-631-2165 • 732-935-1320

Fax: 732-935-9344

Proprietary Notice

The information contained in this publication is derived in part from proprietary and patent data. This information has been prepared for the expressed purpose of assisting operating and maintenance personnel in the efficient use of the instrument described herein. Publication of this information does not convey any rights to use or reproduce it or to use for any purpose other than in connection with the installation, operation and maintenance of the equipment described herein.

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

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.

WARNING!

failure.

SAFETY INSTRUCTIONS

• 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 specified type and rating only:

Disconnect power supply before replacing fuse!

• The manufacturer assumes no liability for damage caused by incorrect use of the instrument or for modifications or changes

made to the instrument.

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

Symbols Used On Unit

Number Symbol Publication Description

IEC 417, No. 5031 Direct current

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.

1. DESCRIPTION

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

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

1.3 Specifications .............................................................................................................................. 2

2. INSTALLATION

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

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

3. APPLICATIONS

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

3.2 Batching ....................................................................................................................................... 8

4. WIRING

4.1 Typical Batcher Wiring ................................................................................................................. 9

4.2 Typical Rate/Total Wiring ............................................................................................................. 9

5. UNIT OPERATION

5.1 Front Panel Operation Concept for Run Mode .......................................................................... 10

5.2 General Operation ..................................................................................................................... 11

5.3 Ratemeter/Totalizer Operation ................................................................................................... 11

5.3.1 Password Protection for Rate/Total mode ................................................................ 11

5.3.2 Relay Operation in Rate/Total mode ........................................................................ 11

5.3.3 Pulse Output in Rate/Total mode ............................................................................. 11

5.3.4 Analog Output in Rate/Total mode ........................................................................... 11

5.3.5 RS-232 Serial Port Operation in Rate/Total mode .................................................. 12

5.3.6 RS-485 Serial Port Operation in Rate/Total mode .................................................. 12

5.4 Batcher Operation ..................................................................................................................... 13

5.4.1 Batcher Configuration .............................................................................................. 13

5.4.2 Password Protection for Batcher mode .................................................................... 14

5.4.3 Relay Operation in Batcher mode ............................................................................ 14

5.4.4 Pulse Output in Batcher mode ................................................................................ 14

5.3.5 Analog Output in Batcher mode .............................................................................. 14

5.4.6 RS-232 Serial Port Operation in Batcher mode ...................................................... 15

5.4.7 RS-485 Serial Port Operation in Batcher mode ...................................................... 15

CONTENTS

6. PROGRAMMING

6.1 Front Panel Operation Concept for Program Mode ................................................................... 16

6.2 EZ Setup .................................................................................................................................... 17

6.3 Setup Menus ............................................................................................................................. 18

6.4 Setup Sub-Menus ...................................................................................................................... 19

6.4.1 SELECT EZ SETUP ................................................................................................. 19

6.4.2 INSTRUMENT TYPE ............................................................................................... 19

6.4.3 SETUP INDICATORS (Total) ................................................................................... 21

6.4.4 SETUP INDICATORS (Rate) ................................................................................... 21

6.4.5 SETUP FLOW INPUT (Pulse - chA & chA=chB) ...................................................... 22

6.4.6 SETUP FLOW INPUT (Pulse - Quadrature, Qx1 or Qx2) ........................................ 23

6.4.7 SETUP PULSE OUTPUT ......................................................................................... 24

6.4.8 SETUP ANALOG OUTPUT ...................................................................................... 25

6.4.9 SETUP RELAYS ...................................................................................................... 25

6.4.10 SETUP CONTROL INPUTS (RATE/TOTAL) ......................................................... 27

6.4.11 SETUP CONTROL INPUTS (BATCH) .................................................................... 27

6.4.12 SETUP REALTIME CLOCK (Time) ........................................................................ 28

6.4.13 SETUP REALTIME CLOCK (Date) ........................................................................ 28

6.4.14 SERIAL USAGE ..................................................................................................... 29

6.4.15 SET DATALOG/PRINT (Configure) ........................................................................ 30

6.4.16 SET DATALOG/PRINT (Select_list) ....................................................................... 31

6.4.17 ADMINISTRATIVE SETUP ..................................................................................... 31

6.4.18 SETUP NETWORK CARD ..................................................................................... 32

CONTENTS

7. PRINCIPLE OF OPERATION

7.1 General ...................................................................................................................................... 33

7.2 Flow Equations .......................................................................................................................... 33

7.3 Linearization Table ..................................................................................................................... 34

8. TEST, SERVICE and MAINTENANCE

8.1 Test Menus ................................................................................................................................ 35

8.2 Test Sub-Menus ......................................................................................................................... 36

8.3 Internal Fuse Replacement ....................................................................................................... 40

7.6.1 Linearization Table General Information ................................................................... 34

7.6.2 Linearization Table for Pulse Inputs ......................................................................... 34

7.6.3 Linearization Table Interpolation ............................................................................... 34

8.2.1 Audit Trail ................................................................................................................. 36

8.2.2 Error History .............................................................................................................36

8.2.3 Print System Setup .................................................................................................. 36

8.2.4 Keypad test .............................................................................................................. 37

8.2.5 Display test ............................................................................................................... 37

8.2.6 Calibrate 0mA out ..................................................................................................... 37

8.2.7 Calibrate 20mA out ................................................................................................... 37

8.2.8 Pulse input test ......................................................................................................... 38

8.2.9 Analog out test ......................................................................................................... 38

8.2.10 Excitation out test ................................................................................................... 39

8.2.11 Pulse out test .......................................................................................................... 39

8.2.12 Relay test ..............................................................................................................39

8.2.13 Control input test .................................................................................................... 39

8.2.14 Data logger utility ................................................................................................... 39

9. RS-232 SERIAL PORT

9.1 RS-232 Serial Port Description .................................................................................................. 41

9.2 Instrument Setup by PC Over Serial Port .................................................................................. 41

9.3 Operation of Serial Communication Port with Printers .............................................................. 41

9.4 SUPERtrol-I LE RS-232 Port Pinout .......................................................................................... 41

10. RS-485 SERIAL PORT

10.1 RS-485 Serial Port Description ................................................................................................ 42

10.2 General .................................................................................................................................... 42

10.3 Operation of Serial Communication Port with PC .................................................................... 42

10.4 SUPERtrol-I LE RS-485 Port Pinout ........................................................................................ 42

11. FLOW COMPUTER SETUP SOFTWARE

11.1 System Requirements .............................................................................................................. 43

11.2 Cable and Wiring Requirements ..............................................................................................43

11.3 Installation for Windows™3.1 or 3.11 ...................................................................................... 43

11.4 Using the Flow Computer Setup Software ............................................................................... 43

11.5 File Tab .................................................................................................................................... 44

11.6 Setup Tab ................................................................................................................................. 44

11.7 View Tab .................................................................................................................................. 45

11.8 Misc. Tab .................................................................................................................................. 45

12. GLOSSARY OF TERMS

12 Glossary Of Terms ...................................................................................................................... 46

13. DIAGNOSIS AND TROUBLESHOOTING

13.1 Response of SUPERtrol-I LE on Error or Alarm: ..................................................................... 50

13.2 Diagnosis Flow Chart and Troubleshooting ............................................................................. 51

13.3 Error & Warning Messages:..................................................................................................... 52

13.3.1 Sensor/Process Alarms .......................................................................................... 52

13.3.2 Self Test Alarms ...................................................................................................... 52

APPENDIX A

Setup Menu Flowchart ..................................................................................................................... 52

SUPERtrol-I LE Flow Computer

1. Description

1.1 Unit Description:

The SUPERtrol-I LE Flow Computer satisfies the rate, total and batching instrument requirements for a variety of pulse producing flowmeter types in liquid applications. Multiple flow 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 LE permits a wide measure of versatility 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 configuring the instrument. Consider the following illustrative examples.

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 LE Flow Computer offers the following features:

• Compatible with Pulse Producing Flowmeters

• Multiple Instrument Functions; Rate, Total, Batching

• Menu Selectable Hardware & Software Features

• Two Line LCD Display

• Automatic Batch Overrun Compensation

• Isolated Pulse Output Standard

• Isolated Analog Output Standard

• Versatile RS-232 Port Standard

• Linearization Capability Standard

• DIN Enclosure with Two Piece Connectors

• EZ Setup Feature

• Advanced Batching Features

SUPERtrol-I LE Flow Computer

1.3 Specifications:

Specifications: 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 Main supply voltage fluctuations not to exceed ±10% of the nominal voltage Transient overvoltage according 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

Approvals: CE Compliant Light Industrial,

UL File #: E192404, C/UL

Display

Type: 2 lines of 20 characters Types: Backlit LCD 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 Depth behind panel: 6.5" including mating connector Type: DIN Materials: Plastic, UL94V-0, Flame retardant Bezel: Textured per matt finish Equipment Labels: Model, safety, and user wiring

Flow Inputs:

Pulse Inputs:

Number of Flow Inputs: one Configurations 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 down to 1 pulse in 99 sec. Maximum Count Speed: Selectable: 0 to 20kHz Overvoltage Protection: 50 VDC Fast Transient: Protected to 500 VDC

(Capacitive Clamp)

Control Inputs

Switch Inputs are menu selectable for Start, Stop, Reset, Lock, Inhibit, Alarm Acknowledge, Print or Not Used. Control Input Specifications

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 definition

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

Power Input

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

SUPERtrol-I LE 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, General purpose warning (security), overrun or not used.

Number of relays: 2 (4 optional) Contact Style: Form C contacts Contact Ratings: 250 VAC @ 5 amps

30 VDC @ 5 amps

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: 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 Rate or Total. Type: Isolated Current Sourcing 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 Calibration: Operator assisted Learn Mode Averaging: User entry of DSP Averaging constant

to cause an smooth control action.

Isolated Pulse output

The isolated pulse is assigned to Volume Total.

Isolation I/O/P: 500 V Pulse Output Form: Isolated Photomos Relay 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: 10mSec, 100mSec Pulse output buffer: 8 bit Fault Protection

Reverse polarity: Shunt Diode Transient Protection: 500 VDC

(Capacitive Clamp)

SUPERtrol-I LE Flow Computer

Operating Mode

The Flow Computer can be thought of as making a measurement of flow and then performing calculations which are then updated periodically on the display as rate and total. The pulse output, analog output and the alarm relays are also updated. The cycle then repeats itself.

Step 1:Update the measurements of input signals-

Raw Input Measurements are made at each input.

Step 2 : Compute the Volumetric Flow-

Uncompensated flow is the term given to the flow in volume units. The value is computed based on the flowmeter input type selected and augmented by any performance enhancing linearization that has been specified by the user.

Step 3: Check Flow Alarms-

The flow alarm functions have been assigned to flow rate during the setup of the instrument. A comparison is now made by comparing the current flow rates against the specified hi and low limits.

Step 4: Compute the Flow Totals by Summation-

A flow total increment is computed for each flow rate. This increment is computed by dividing the pulses by the K-Factor and then summing. The totalizer format also includes provisions for total rollover.

Step 5: 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 6: 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 7: Compute the Analog Output-

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

Step 8: Update Display and Printer Output-

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

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 significant setup changes to the unit. This feature is increasingly being found of benefit to users or simply required by Weights and Measurement Officials in systems used in commerce, trade, or “custody transfer” applications.

A Worksheet is provided to assist the user in setting up the instrument. An Easy Setup (EZ Setup) feature is offered in the setup menu. The EZ Setup routine is a quick and easy way to configure the unit for the most commonly used instrument functions.

The setup mode has numerous subgrouping of parameters needed for flow 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 flow computer activates the correct setup variables based on the instrument configuration, the flow equation, and the hardware selections, 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.

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 modified by the user.

SUPERtrol-I LE Flow Computer

Maintenance (Test) Mode:

The Maintenance Mode of the SUPERtrol-I LE provides a number of specialized utilities required for instrument checkout on start-up, setup documentation and data logger access.

A password is required to gain access to this specialized mode of operation. Quality and maintenance personnel will find 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 Setup Report Examine Audit Trail Examine Error History Perform Keypad Checkout Perform Display Checkout Perform Pulse Input Checkout Perform Pulse Output Checkout Perform Control Input Checkout Perform Relay Output Checkout

Perform Analog Output Checkout Calibrate Analog Output using the Learn Feature

Perform Excitation Output Test Examine or Dump Data Logger

Operation of Serial Communication Port with Printers

SUPERtrol-I LE'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 maintenance reports.

For transaction printing, the user defines 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, upon completion of a batch, time of day or at a timed interval.

In data logging, the user defines 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 configuration. In addition, the Audit trail information is presented along with 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 requested key on the front panel.

RS-232 Serial Port

The SUPERtrol-I LE has a general purpose RS232 Port which may be used for any one of the following purposes:

Transaction Printing Data Logging Remote Metering by Modem (optional) Computer Communication Link Configuration by Computer Print System Setup Print Malfunction History

Operation of Serial Port with Modems (optional)

The SUPERtrol-I LE 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 SUPERtrol-I LE. 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 SUPERtrol-I LE is assumed to be operating in a remote metering role. In addition, the SUPERtrol-I LE will be capable of initiating a call to a designed telephone number in the event of a metering malfunction.

SUPERtrol-I LE Flow Computer

2. Installation

2.1 General Mounting Hints:

The SUPERtrol-I LE 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 firmly 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 specifications.

Permanently Connected Equipment: UL 3101-1, Section 6.12.2.1 specifies 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.

NOTE: 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

IMPORTANT!

To provide protection type IP65/NEMA 4X, the unit must be mounted with the bezel adaptor and the gasket (supplied with the mounting kit). The bezel must be glued to the unit with silicon. (see Instructions supplied with the mounting kit)

Dimensions

RATE

START

STOP

TOTAL

GRAND6SCROLL7PRE 2

3.43 (87)

Mounting Bracket

5.67 (144)

GPM

147.43 GAL

267395.749

PRE 13RATE2TOTAL

CLEAR•MENU

HELP

TIME

–

6.18 Dotted Line Shows Optional Bezel Kit

SUPERtrol-I LE

0.28 (7.2)

2.83 (72)

ENTER

0.4 (10)

Dimensions are in inches (mm)

6.15

(156)

SUPERtrol-I LE

Bezel Adaptor

Mounting Bracket

0.5

(13)

Panel

Cutout

Gasket

5.43

(138)

2.68 (68)

SUPERtrol-I LE Flow Computer

3. Applications

3.1 Liquid Volume

Measurements:

A flowmeter measures the actual volume in a liquid line.

Calculations:

• For Flowmeters with Pulse Outputs, Volume flow is calculated using the flowmeter frequency output and the user entered K-Factor or Linearization Table.

Output Results:

• Display Results

Flow Rate, Resettable Total, Non-Resettable Total

• Pulse Output

Total

• Analog Output

Rate or Total

• Relay Outputs

Rate or Total Alarms

Applications:

The Flow Computer can monitor actual volume flow and total of any liquid. Flow alarms are provided via relays and datalogging is available via serial outputs.

Liquid Volume Illustration

PRE 1

RATE

TOTAL

START

GRAND6SCROLL7PRE 28F2

STOP

Flowmeter

CLEAR•MENU

HELP

–

ENTER

Calculations

Pulse Input; Average K-Factor or Linearization Table

input frequency * time scale factor

Volume Flow =

K-Factor

SUPERtrol-I LE Flow Computer

3.2 Batching

Measurements:

A flowmeter measures the actual volume in a liquid line.

Calculations:

• For Flowmeters with Pulse Outputs, Volume flow is calculated using the flowmeter frequency output and the user entered K-Factor or Linearization Table.

Output Results:

• Display Results

Flow Rate, Batch Total, Non-Resettable Total

• Pulse Output

Total

• Analog Output

Rate or Total

• Relay Outputs

Batch Total, Rate, or Alarms

Applications:

Batching and monitoring flow and total of any liquid. Batching is accomplished via relays and datalogging is available via serial outputs.

Batching Illustration

PRE 1

RATE

TOTAL

START

GRAND6SCROLL7PRE 2

STOP

–

CLEAR•MENU

HELP

ENTER

Calculations

Flowmeter Solenoid Valve

Pulse Input; Average K-Factor or Linearization Table

input frequency * time scale factor

Volume Flow =

K-Factor

4 WIRING

SUPERtrol-I LE Flow Computer

4.1 Typical Batcher Wiring:

FLOW METER

with Pre Amp

MOV recommended

(+) V Signal

Common

StartStop

123456

Remote Electronic Counter

115 VAC

115 VAC SOLENOID VALVE

115 VAC

DC OUTPUT

PULSE IN 1

PULSE IN 2

COMMON

NOT USED

NOT USED NOT USED

8 9

CNTR IN 1

CNTR IN 2

CNTR IN 3

COMMON 13 PULSE OUTPUT + 14

PULSE OUTPUT – 15

ANALOG OUT + 16

ANALOG OUT –

17 NC 18 COM

COM

AC LINE

AC LINE24

RLY1

RLY2

25 NC 26 27 28 29 30

DC + DC -

FLOW

SEE USER MANUAL

COM RLY3 NO NC COM RLY4 NO

POWER IN

4.2 Typical Rate/Total Wiring:

FLOW SENSOR

with magnetic pickup

Remote Electronic Counter

Signal

Common

123456

Alarm Relay 1

Alarm Relay 2

115 VAC

DC OUTPUT

PULSE IN 1

PULSE IN 2

COMMON

NOT USED

NOT USED NOT USED

CNTR IN 1

CNTR IN 2

CNTR IN 3

COMMON

12 13 PULSE OUTPUT + 14

PULSE OUTPUT -

ANALOG OUT +

ANALOG OUT –

17 NC

{ {

18 COM 19 20 21 22

RLY1 NO NC COM

RLY2 NO

AC LINE AC LINE24

25 NC 26 27 28 29 30

DC + DC -

FLOW

SEE USER MANUAL

COM RLY3 NO NC COM RLY4 NO

POWER IN

SUPERtrol-I LE Flow Computer

5. UNIT OPERATION

5.1 Front Panel Operation Concept for Run Mode

The SUPERtrol-I LE is fully programmable through

PRE 1

RATE

the front panel. Please review the following usage summary before attempting to use the instrument.

TOTAL

START

GRAND6SCROLL7PRE 2

STOP

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 quickly to select the total. Once the total is selected, press the CLEAR key to reset the total. 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 finished

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

–

CLEAR•MENU

HELP

ENTER

CLEARING GRAND TOTAL

To clear the grand total, you must press the GRAND Function Key 3 times quickly to select the grand total. Once the grand total is selected, press the CLEAR key to reset the grand total. The operator will be prompted to enter password if the unit is locked.

PRESET KEYS

In the RUN mode, PRE 1, PRE 2, F1 and F2 keys are used to view and/or change the preset setpoints. To view the Presets, simply press the desired Preset key once. Rapidly press the Preset keys 3 times, then press the Clear key for direct editing of the preset setpoints.

SCROLL

Rapidly press the Scroll key 3 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. Press the ENTER key to save scroll list.

The PRINT key is used to print on demand. When the PRINT key is pressed, a user defined list of data (TOTAL, RATE, PRE 1, etc.) is sent to the RS232 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 first 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. The user will be prompted to enter a password if the unit is locked. (See section 6 for Setup mode, section 8 for Test mode). The MENU key is also used as "escape" in Setup and Test Programming. Pressing the MENU key while 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

TIME/DATE

The TIME key is reserved for displaying Time and Date. To View the Time or Date, press the TIME key once.

SUPERtrol-I LE Flow Computer

5.2 General Operation

The unit can display: Rate, Total, Grand Total, Presets and Time of Day. The unit can be programmed to perform Ratemeter/Totalizer or Batching functions.

5.3 Ratemeter/Totalizer Operation

The Ratemeter/Totalizer mode is used primarily to monitor flowrate and accumulated total. The relays can be used to trigger on flow rate, total, or 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) Edit Preset 3 (4 Key) Edit Preset 4 (9 Key)

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 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 by pressing the 4 or 9 keys.

5.3.3 Pulse Output in Rate/Total mode

The isolated pulse output (open collector) is assigned to Volume 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 specifications.

5.3.4 Analog Output in Rate/Total mode

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

SUPERtrol-I LE Flow Computer

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, Presets, etc.

Operation of RS-232 Serial Port with Printers:

Transaction Printing For transaction printing, the user defines 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 defines 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, Configure).

System Setup and Maintenance Report The system setup and maintenance report lists all of the instrument setup parameters and usage for the current instrument configuration. 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).

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 flow 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 SUPERtrol-I LE then responds to these information and command requests.

Process variables and totalizers are read in register pairs in floating 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.

SUPERtrol-I LE 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 a contact to a flow control device (i.e. solenoid valve or pump). The flow sensor will send a signal to the unit and total accumulation will begin. Just before the end of batch, when the Prewarn value (PRE 2) is reached, Relay 2 will drop out (this is ideal for flow slow down). When the final 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).

5.4.1 Batcher Configuration.

When the unit is programmed for batch mode, several batch operation choices are available. These choices include: EZ Preset, 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.

EZ Preset

A selectable mode of batching where user can press "PRE 1", then "ENTER" then the quantity to be batched, then "START" for a quick enter-start sequence.

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 permitted Maximum Batch Preset size has been exceeded.

Batch Overrun

The Batch Overrun is used for batch applications that have slow responding valves and a consistent batching flowrate. 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. The maximum drain time must be set greater than the slowest valve response time for proper operation of this feature.

Auto Batch Restart

The Auto Batch Restart function allows the user to set an amount of time to automatically restart a batch after the completion of a batch. This time can be set from 1 to 99 seconds.

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 flow persists for more than the user entered time then the batch will be aborted. This prevents over flows due to faulty flow sensors and/or wiring.

Maximum Drain Time

The unit declares that a batch is “done” when the flow rate equals “0”. A flow 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 flow rate is “0” or the Maximum Drain Time has expired. The batch data will then be available for printing and datalogging.

Slow Start Quantity

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

SUPERtrol-I LE Flow Computer

START, RESET/START and STOP, STOP/RESET

When configuring 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 Input 1 or the front panel Start key is pressed. A separate Reset signal or CLEAR key depression 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 or CLEAR key depression 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 and override all Start inputs in either mode.

5.4.2 Password Protection for Batcher Mode

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

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

NOTE: A password of "0" should not be used since it will leave the unit unlocked and open to accidental

changes.

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 by pressing the 4 or 9 keys. Relays 3 and 4 can be assigned to trip according to rate, total, overrun or alarm. When Rate is selected the relays can be programmed for low or high alarms. When N.A (not assigned) is selected, the relays may be tripped via serial commands. Alternately, Preset 2, 3 or 4 may be used to enter alternate information and can be printed in the print list for transaction history.

5.4.4 Pulse Output in Batcher mode

5.4.5 Analog Output in Batcher mode

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

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KEP SUPERtrol-ILE Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual