Kobold DOR Operating Manual

K03/1213

Manufactured and sold by:

Kobold Messring GmbH

Nordring 22-24

D-65719 Hofheim

Tel.: +49(0)6192-2990

Fax: +49(0)6192-23398

BI-DIRECTIONAL INSERTION FLOW TRANSDUCER

Model DOR

INSTRUCTION MANUAL

KOBOLD

LOCK

IMPORTANT INFORMATION

Thank you for purcha

sing a Kobold Insertion Flowmeter. It is important that you read this manual to gain a full understanding of the capability and operational aspects of the equipment you are about to install.

This information is provided only to assist in the installation of the product and does not diminish your obligation to read the manual.

1. Select a location that meets the requirements as illustrated on the guideline sheet (please see the data sheet/order codes). An ideal installation would provide for 25 diameters of straight pipe upstream from the meter and 10 diameters downstream.

You will also need to know the pipe internal diameter (NB) and pipe wall thickness

for calculation of the insertion depth. (refer page 5.) Non ideal installations may require in-situ calibration (refer to the factory for details).

2. After screwing the flowmeter in place ensure the flow alignment mark located

on the top positioning collar of the meter aligns with the flow in the pipe (refer page 5). This ensures the paddle is correctly aligned to the flow.

Note. the meter is bi-directional so a flow direction arrow is not provided.

3. Calculate and adjust the height of the flowmeter (refer page 5).

4. Electrical Installation depends on the model you have purchased. If the dualpulse is fitted or supplied with a receiving instrument such as a totaliser or rate totaliser please refer to the appropriate manual and page 10 of this manual. For pulse output meters, select the appropriate output and wire to your

receiving device. (refer pages 7 to 9).

5. Calculate the flowmeter K (scale) factor to suit the installation. For ideal

installations refer to page 11 or 12 or 13 of the flowmeter Manual. For non ideal installations the K-factor may be calculated by performing an in-situ calibration. Enter the appropriate K-factor into your receiving instrument.

page 1

CONTENTS PAGE

1.0 INTRODUCTION

1.1 Model number designation

1.2 Overview

1.3 Operating principal 3

1.4 Specifications 3

2.0 INSTALLATION

2.1 Meter location

2.2 Meter installation & orientation 4

2.3 Height adjustment 5

2.4 Flow direction orientation 5

2.5 Hot tap installations 6

3.0 ELECTRICAL CONNECTIONS

3.1 Standard outputs 7

3.2 Optional Reed switch output 7

3.3 Instrument cable installation requirements 8

3.4 Pulse output selection ( standard outputs ) 8

3.5 QP Quadrature pulse output option 9

3.6 Bi-directional flow using QP option 9

3.7 Connection to family instruments 10

4.0 K – FACTOR ( calibration factor for meter )

4.1 K-factors for common pipe ID sizes <575mm 11

4.2 K-factors for large pipe ID >460mm 11

4.3 Calculating K-factors ( metric units – litres or M3 ) 12

4.4 Calculating K-factors ( US gallons )

5.0 Declaration of Conformance

3

4

12

14

Page 2

1.1 Model no. designation

Please see the data sheet

1.2 Overview

Kobold insertion flow transducers provide a cost effective and simple means of measuring the flow of a wide range of low viscosity liquids. Installation is quick and inexpensive for pipe diameters ranging from 40mm to 900mm (1.5-36") and up to 2500mm (100") nominal bore for the Hot tap capable model DOR-52.

The flowmeter has a linear measuring range of 0.3~10.0 metres/sec. (1~33 ft/sec.). Minimum detectable flow velocity is 0.15 m/sec. (0.5 ft/sec.). When used in conjunction with the ZOD-Z3 flow rate totaliser NLC feature the linear flow range is extended down to 0.15 m/sec. (0.5 ft/sec.) with an improved linearity.

The flowmeter is constructed from 316 L (1.4404) stainless steel enabling use in many applications for metering water and low viscosity chemicals.

Two independent pulse outputs are standard & can directly input to a wide range of ancillary instruments, PLC’s and computers. Both pulse outputs have a high level of immunity to electrical interference. Options include a reed switch.

1.3 Operating principle

Flow passes through a pipe causing the rotor to spin. Magnets installed in the rotor pass by pulse sensors within the transducer body & inturn this produces frequency outputs proportional to flow rate.

page 3

1.4 Specifications

Velocity measuring range (linear): 0.3...10 m/s equates to approx.0.25...49,000 l/s in

Linearity: ±1.5% with well est. flow profile

Repeatability: ±1% of f. s. at factory conditions and optimal straight

Max pressure: 80 bar

Temperature range: -40…+100°C standard, see max.allowable medium

Material

Body: stainless steel 1.4404 (316L)

Rotor: PVDF or PEEK (depending on model)

Rotor shaft: stainless steel 1.4404 (316L)

Bearing: graphite/PTFE

Seals: FPM (standard): -15…+200°C

EPR (ethylene propylene rubber): -20…+120°C, for

PTFE encapsulated FPM: -20…+200°C

NBR (Nitril): -65…+125°C

Electronics

Output frequency at max. velocity: 220...240 Hz (hall effect and voltage output),

73...80 Hz (reed switch output)

Supply voltage: see electrical output specifications and electronics

Electronic features: see electronics comparison table in the data sheet

Wiring (standard): 5 core, screened cable, length 3 meters

Transmission distance: 1,000 meters maximum, without integrated electronics Cable entry (terminal box): M20x1.5 (standard), 1/2“ NPT adapter (optional)

Protection Class: IP68 (cable connection),

IP66/67 (all other electrical connections)

Straight piping requirement: Minimum: 10xd (upstream), 5xd (downstream) Optimal: 25xd (upstream), 10xd (downstream)

Weight: (approx., without electronics):

1.6 kg (DOR-4), 2.5 kg (DOR-5)

DN40 to DN2500 pipes; 0.15...10 m/s when using the linearisation function of electronic type Z3

runs

temperature table for other options and restrictions

ketones only

comparison table in the data sheet

page 4

page 5

2.0 INSTALLATION

2.1 Meter location

Choose an appropriate section of horizontal or vertical pipe as per the guidelines below. With vertical pipe installations the media should be pumped up through the pipe past the flow sensor so that any entrained air will pass freely.

The DOR flow sensor requires a fully developed turbulent flow profile to ensure maximum measurement accuracy and repeatability. This can be achieved by installing the DOR in a straight run of pipe. We recommend at least 10 but ideally 25 straight pipe diameters upstream & at least 5 but ideally 10 pipe diameters downstream of the flowmeter. Major obstructions such as pumps, valves or strainers will require longer straight runs before and after the flowmeter.

Major obstructions such as

pumps,valves,reducers or strainers

to be kept well outside the straight

run pipe sections

10 pipe dia. minimum

25 pipe dia. prefered

FLOW

5 pipe dia. min.

10 pipe dia. prefered

2.3 Height adjustment calculation

Calculate the adjustment height A for DOR-42 (or AA for the DOR-52) as follows: A ( for DOR-42 ) = 175mm ( 6.9") - ( B + C + D )

AA ( for DOR-52 ) = 420mm (16.5") - ( B + C + D )

Where :

B = Distance between the top of the pipe & the top of the hex adaptor. C = Pipe wall thickness D = Insertion depth ( pipe ID ÷ 8 )

ALIGNMENT SLOT TO

PARRALLEL PIPE

LOCK

Examples of insertion depth D : For 40mm pipe ID ( D= 5.0 mm )

For 50mm pipe ID ( D= 6.25 mm )

3 1

A (AA)

For 100mm pipe ID ( D= 12.5 mm ) For 400mm pipe ID ( D= 50.0 mm )

2

D

B

C

2.2 Meter installation & orientation

Cut a 40mm diameter hole (1.6") on either the 2, 10 or 12 o’clock positions of the pipe. If there is any likelihood of air entrainment in a horizontal pipe do not locate the flow transducer in the 12 o’clock position.

12 o’clock

2 o’clock

Other positions

around the pipe are

ptable

acce

Install a female threaded weld on fitting (threadolet) or service saddle. Wrap the threads of the flowmeter with PTFE tape or sealing compound & screw the unit into the installed fitting.

C

Turn the height adjustment nuts (1) as required so that the distance between the top of the

hex adaptor (2) and the top of the positioning collar (3) equals your calculated distance A (for DOR-42) or AA for model DOR-52. Retighten the height adjustment nuts (1).

2.4 Flow direction orientation

The unit is bi-directional however the paddle must be aligned with the direction of flow.

Using a 2mm hex key (Allen key), unlock the locking screw located on the positioning collar (3) then insert the hex key (as a lever) in the body rotating hole located above the collar, turn the body until the alignment slot is parallel with the direction of pipe. Retighten the locking screw.

page 6

2.5 Hot tap installation

( model DOR-52 )

Clean & lubricate screw threads before withdrawing the transducer body in order to avoid nut seizure

IMPORTANT

Before removing the DOR-52 from the installation first withdraw the transducer body to the maximum distance allowed by the three height adjusting threaded rods. This will enable the isolating valve to be fully closed without damaging the paddle.

If necessary extend valve port using a 2” nipple & socket combination to ensure the paddle is clear of the ball valve.

CAUTION : Hot tap installation should only be performed by qualified personal. Installation procedures should be in accordance with the safety rules, regulations and requirements applying to the territory in which the flow transducer is being installed.

2" ball or gate isolation valve.

(Allow min. 40mm I.D. to clear metering head)

2" Nipple

2" Weld-O-let ( threadolet )

FLOW

Hot tap clearance hole in pipe wall to be a minimum of 40mm diameter (1.6").

page 7

3.0 ELECTRICAL CONNECTIONS

( see page 9 for QP outputs )

3.1 Standard outpu

ts

Conductor color coding also applies to the Non-magnetic

sensor and high temperature output options

Height

adjustment

Body

KOBOLD

LOCK

Positioning

collar

Pull up resistor

required, they are

generally incorporated

in most receiving

instruments

SQUARE WAVE PULSE OUTPUT

Black ( -0v ground )

Red ( VDC supply )

White ( + Sig. output )

Hex adaptor

1.5” or 2” BSPT or NPT

Rotor

Terminal box option

terminal connections

b1

A1

A2

B2 B1

VOLTAGE PULSE

Screen

OUTPUT

Yellow ( + )

Green ( - )

3.2 Optional Reed switch output

The REED SWITCH output is classed as a “simple apparatus“ as defined in the CENELEC standard EN50020 & recognized ATEX directive. It can be connected to an approved I.S. secondary instrument with both being located in the hazardous area. The Reed Switch may also be connected through an approved I.S. barrier.

Note: The Reed switch produces 1/3

( eg. 1/3 the standard K-factor )

HAZARDOUS AREAS

the normal pulse output value

KOBOLD

LOCK

rd

Screen

To -0V

REED SWITCH

OUTPUT

Yellow

Green

page 8

3.3 Instrument cable installation requirements

Use twisted multi-core low capacitance shielded instrument cable (22 AWG ~ 7x 0.3 stranded) for electrical connection between the flow meter and the remote instrumentation. The screen should be earthed at the readout instrument end only to protect the transmitted signal from mutual inductive interference.

The cable should not be run in a common conduit or parallel with power and high inductive

load carrying cables as power surges may induce erroneous noise transients onto the transmitted pulse signal. Run the cable in separate conduit or with other low energy instrument cables .

3.4 Pulse output selection ( standard outputs )

The standard flowmeter has two independent pulse output signals that are linearly proportional to volumetric flow rate. Pulse transmission can be up to 1000 metres (3300 ft ).

An optional I.S. Reed Switch output is available (see page 7).

Voltage pulse (pulse wire) output

A self generating pulse output which produces a strong 1.5 volt voltage spike of approximately 10 micro/second duration with no dependence on rotor speed.

Screen

Yellow ( + )

Green ( - )

Square Wave Pulse (Hall sensor) ( also applies to non-magnetic & QP Hall outputs )

An NPN open collector transistor pulse output produced by a solid state Hall Effect device. This three wire device requires 5~24vdc and produces an NPN square wave output (20mA max. sink), pulse width is 2~75 mSec. The Hall output requires a pull up resistor, these are generally incorporated in most receiving instruments. For (QP) Quadrature pulse output refer details page 9.

(5-24vdc supply )

signal output

( -0v ground )

Screen

Red

White

Black

Page 9

3.5 Quadrature outputs

DOR series flow meters supplied with the QP option produce two NPN open collector pulse outputs from two Hall Effect sensors. The outputs are “ phase offset ” in their timing so that external electronics are able to differentiate. These outputs may be used to assure output signal integrity or to measure bi-directional flow.

Red ~ Vdc

Black ~ -0V

Screen

White ~ output 1

Blue ~ output 2

3.6 Bi-directional flow

The DOR flow transducer is capable of accurately measuring flow in both directions without modification. Meters fitted with the QP output option (quadrature pulse output) may be interfaced with the Pulse Discriminator Module (PD2). The PD2 accepts the Quadrature pulse inputs & from these will discriminate between forward & reverse flow. Two individual & proportional pulse outputs can then be sent to appropriate totalising registers or an Z3 add and subtract flow rate totaliser.

It is important to note that the Quadrature Pulse option has the same pulse resolution (pulses/unit volume) as a standard flowmeter for both forward & reverse outputs.

Flowmeter with QP outputs

Reg

X

Reg

X

5~24Vdc maximum

Output Signal 1

(forward flow)

Output Signal 2

(reverse flow)

Vdc

+

PD2 Pulse Discriminator

10

Sig.1

9

Sig.2

7 6

+Vdc

-0V

+8~24Vdc

Forward flow Sig.

Output signals

Reverse flow Sig.

-0V

5 4

2 1

Ground

-0V

page 10

)

3.7 Voltage Pulse Connection to family instruments

RATE TOTALISER

RUN ACCUM. TOTAL STOP BAT LOW

RESET

PROGRAM

ENTER

>

RATE

TOTAL

ACCUM

TOTAL

gal

^

Note: For other output styles see receiving instrument manual

Z3 & B1 SERIES

yellow

green

Screen

1

INSTRUMENTS

2

3

O

2

N

4

1

-0V (ground)

5

6

7

All flow DIP

switches in the

position

OFF

14

13

12

11

10

9

8

KOBOLD

LOCK

yellow

green

Z1 TOTALISER

ON

1 2 3

-

+

1 2 3

DIP switch 1 in the ON

position

( 2 Khz max.)

gnd

+Vdc

4 5 6

+∏

-gnd

Screen

The flowmeter cable should

not

be run with other high

energy cables ( clause 3.3 ).

Flow instruments or a

terminal box can be

directly mounted to the

flowmeter using ST4 (for

DOR-42) or ST5 (DOR-

52) mounting stem kits

FLOMEC

LOCK

page 11

4.0 K – FACTORS ( calibration factors for meter )

The K-factor (pulses / litre, gallon etc.) will vary in relation to the bore size of the pipe in which the flowmeter is installed.

The K-factors and formula shown are a result of factory testing using smooth bore piping under ideal conditions. Variations to the given K-factors may occur when using rough bore piping or inadequate flow conditioning on either side of the flow transducer (refer clause

2.1). In these instances on site calibration may be used to determine the K-factor.

4.1 Flow transducer K- factors for common pipe sizes

Pipe detail

NB ID (#40)

K-factors

Schedule 40 pipe - (#40

inches mm p / litre p / m3 p / USgal p / litre p / m3 p / USgal

1.5" 40.9 18.678 18678 70.695 21.524 21524 81.468 2" 52.6 11.238 11238 42.534 12.818 12818 48.517

2.5" 62.7 7.880 7880 29.824 8.899 8899 33.682 3" 78.0 5.062 5062 19.161 5.676 5676 21.485

3.5" 90.2 3.768 3768 14.263 4.200 4200 15.896 4" 102 2.912 2912 11.021 3.233 3233 12.237 5" 128 1.839 1839 6.959 2.025 2025 7.665 6" 154 1.268 1268 4.798 1.402 1402 5.307 8" 203 0.719 719.0 2.721 0.787 787.2 2.980

10" 255 0.450 450.3 1.705 0.496 495.9 1.877 12" 303 0.316 316.0 1.196 0.347 347.4 1.315 14" 333 0.261 260.5 0.986 0.286 285.7 1.081 16" 381 0.198 198.0 0.750 0.217 217.0 0.821 18" 429 0.156 155.8 0.590 0.171 170.6 0.646 20" 478 0.125 125.4 0.475 0.138 137.8 0.521 24" 575 0.087 86.64 0.328 0.095

For other pipe sizes below 610mm (24") not listed above, use the graphs and apply the formula on the following pages ( 12 & 13 ).

4.2 K-factors for large pipes 460mm ID (18") and above use:

Pulses per litre = 28647 ÷ pipe ID² (mm) Pulses per M³ = 28647000 ÷ pipe ID² (mm) Pulses per US gallon = 168.14 ÷ pipe ID² (inches) Pulses per Imp. gallon = 201.94 ÷ pipe ID² (inches)

( standard K-factors for voltage & square wave outputs )

Schedule 80 pipe - (#80

95.39 0.361

NOTE : K-factors for Reed Switch output option are 1/3 the standard factors of voltage

pulse output.

page 12

4.3 Calculating K-factors ( litres or m³ )

25

24.5

24

(A)

23.5

Pipe ID 450mm & above (A) = 22.5

23

See

example a

22.5

22

40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400 420 440 460

pipe ID (mm)

Calculate K-factor ( pulses / litre ) using the above graph and the metric constant of 1273.2 as follows :

Pulses / litre = 1273.2 x (A) from graph pipe ID² (mm)

Example ‘a’ :

K-factor for 100mm pipe: 1) from graph 100mm ID (A) = 24.0

2) pulses/litre. = 1273.2 x 24.0

10000 = 3.056 p/litre

K-factor for m³ : multiply by 1000 eg. K = 3056 p/m³ K-factor for megalitres : multiply by 1000000 eg. K = 3056000 p/megalitre

NOTE : K-factors for Reed Switch output option are 1/3 the standard factors of voltage

pulse output.

page 13

4.4 Calculating K-factors ( US gallons )

7.6

7.5

7.4

7.3

7.2

(A)

7.1

Pipe ID 19.5 ” & above (A) = 6.86

7.0

6.9

6.8

12345678 91011 12 13 14 15 16 17 18 19 20

pipe ID

(inches)

Calculate K-factor ( pulses / gallon ) using the above graph and the volumetric constant of 24.51 as follows :

Pulses / US gal. = 24.51 x (A) from graph pipe ID² (inches)

Example ‘b’ :

K-factor for 10" pipe: 1) from graph 10" ID (A) = 7.01

2) pulses/gal. = 24.51 x 7.01 100 = 1.718 p/gal

NOTE :

K-factors for Reed Switch output option are 1/3 the standard factors of voltage pulse output.

page 14

5.0 Declaration of Conformance

We, KOBOLD Messring GmbH, Hofheim-Ts, Germany, declare under our sole responsibility that the product:

Bi-Directional Insertion Flow Transducer Model: DOR

to which this declaration relates is in conformity with the standards noted below:

97/23 EC Pressure Equipment Directive Pressure Accessory – Insertion Flowmeter – No CE Marking

Article 3, Paragraph 3; Diagram 9, Piping, Group II Liquids Article 3, Paragraph 3; Diagram 8, Piping, Group I Liquids – with the following restrictions

Connection Nominal Size Maximum Pressure Rating

For Group I Liquids

1.5“ (40 mm) 2” (50 mm)

2002/96/EC Waste Electrical & Electronic Equipment (WEEE) 2002/95/EC Restriction of Hazardous Substances (RoHS)

Also the following EEC guidelines are fulfilled: 2004/108/EC EMC Directive – Electromagnetic Compatibility Directive When fitted with an optional Reed Switch ONLY pulse outp ut, which is classified as a simple apparatus, and

when installed in accordance with Hazardous Area standards by a competent professional the product also complies with:

EN 60079-11: 2011 – Section 5.7

Equipment protected by Intrinsic Safety – Simple Apparatus

EN 13463-1: 2009

Non electrical equipment for use in potentially explosive atmospheres

When fitted with an integral EX-ia certified instrument such as the ZOD-Z3 or ZOD-Z1, in combination with a Reed Switch only output, the product also complies with:

94/9/EC

ATEX Directive

50 bar 40 bar

Certificate about acknowledgement of quality assurance production

Certificate number: BVS 12 ATEX ZQS/E110 Certification body: DEKRA EXAM GmbH, notified body No 0158

SIRA 06 ATEX M348 – Only when equipped with integral ZOD-Z3 or ZOD-Z1 options

Issued by Sira Certification – United Kingdom

EN 13980:2002

Potentially Explosive Atmospheres – Application of Quality Systems

94/9/EC Articles IV and VII

ATEX Directive

Hofheim, 12. Nov. 2013 H. Peters M. Wenzel General Manager Proxy Holder

page 15

11. Declaration of Conformance

We, KOBOLD Messring GmbH, Hofheim-Ts, Germany, declare under our sole responsibility that the product:

Batch Controller Model: ZOD-B1K

to which this declaration relates is in conformity with the standards noted below:

EN 60529, DIN VDE 0470-1 1992-11

I.P. Ingress Protection Classifications

EN 61326-1: 2006-10

Electrical equipment for control, instrumentation technology and laboratory use – EMC requirements (Industrial area)

EN 61010-1: 2002-08

Safety requirements for electrical equipment for measurement, control, and laboratory use 2008/35/EC Waste Electrical & Electronic Equipment (WEEE)

Also the following EWG guidelines are fulfilled:

2004/108EC EMC Directive 2006/95 EC Low Voltage Directive

Universal Mount Series

BATCH CONTROLLER Model ZOD-B1K

I N S T R U C T I O N M A N U A L

Hofheim, 8. Nov. 2010 H. Peters M. Wenzel General Manager Proxy Holder

Manufactured and sold by: Kobold Messring GmbH

Nordring 22-24

D-65719 Hofheim

Tel.: +49(0)6192-2990

Fax: +49(0)6192-23398

K01/1110

Software versions

01.09.04 V 3.0

11.02.08 V 3.1

Replacement Battery:

Supplied battery

P/No. ERS-ZOD-1312007

3.6V x 2.4Ah AA

Lithium Thionyl Chloride

-

non - rechargeable cell

+

Suitable batteries also available from :

R S Components

Stock No. 596-602

Farnell Components

Order code 206-532

Table of contents 1

1. INTRODUCTION

1.1 Model number designation 2

1.2 Specifications 3

1.3 Overview 4

1.4 LCD displays 4

2. OPERATION

2.1 Batch Set 5

2.2 Batch RUN 5

2.3 Batch STOP 5

2.4 Batch Total 5

2.5 Accumulative total 5

2.6 Total Number of Batches ( TNB ) 5

2.7 Keypad function matrix 5

3. INSTALLATION

3.1 Mounting - integral mount - wall mount 6

- pipe mount – panel mount 7

3.2 Flowmeter connections - unpowered sensors 8

- powered sensors 9

3.3 Wiring connections - external powering 10

- remote switches 10

- wiring requirements 10

- single stage control 10

- two stage control 11

- relay control logic 11

- status & relay connections 16 & 17

4. PROGRAM PARAMETERS

4.1 PIN number protection 12

4.2 Resetting accumulative total 12

4.3 Engineering units 12

4.4 K-factor (scale factor) 12

4.5 Decimal points 12

4.6 Count direction 12

4.7 Start delay & Pre-stop 12

4.8 Automatic overrun compensation ( AOC ) 13

4.9 Missing pulse detection - no flow alarm output 13

4.10 Batch limiting 13

4.11 Controller network ID number 13

5. PROGRAMMING FLOW CHART 14

6. BATCH OPERATING PROCEDURE 15

7. SECONDARY I/O

7.1 Batch status output 16

7.2 No flow alarm output 16

7.3 Run inhibit input 16

7.4 Solid state output logics ( NPN selection ) 17

7.5 Solid state output logics ( PNP selection ) 17

8. BATCH CONTROLLER NETWORKING 18 & 19

9. REFERENCE INFORMATION

9.1 Program detail record 20

9.2 Error messages 20

9.3 Back up PIN number 20

10. ALPHABETICAL INDEX 21

2 Introduction

1.1 Model number designation

Order Details (E

Model Housing Type

ZOD-B1 KM¹⁾ = integral mount

xample: ZOD-B1KS1F300)

KS = universal mount

(standard)

PP = panel mount (IP20)

¹⁾order only when retrofitting a pulse meter ²⁾only possible with ZOD-B1PP...

Electrical connection/ Cable gland

=

1

3 x cable entry M20

2 = 3 x cable entry 1/2" NPT

0²⁾ = screw terminal

Supply Voltage Options

F3 = 8…24 VDC,

Battery

F1²⁾ = 110 VAC, 8…24 VDC 0 = without

R = 2 x Relay

F0²⁾ = 220 VA 8…24 VDC

C,

(for ZODB1K)

Mechanical protection

0 =

without

S²⁾ = silicone bezel boot

1.2 Specifications

Display : 8 digit alpha numeric LCD characters 9mm

Functions : Batch total, Accumulated total & Total number of batches (TNB).

Configuration : Flow chart entry of data with scrolling English text prompts. User

Signal Input : Universal pulse/frequency input compatible with Reed switch,

Power requirement : Regulated 12~24Vdc x 50mA (add switched current).

Battery : 3.6Vdc lithium battery annunciates a power loss & preserves

Control outputs : Two independent NPN open collectors, 1A dc resistive load max.

Introduction 3

( 0.35 ”) high with

second line sub script text. 8 digits totalising, 3 programmable decimal points, 5 digits for Total number of batches.

selectable 4 digit PIN number set-up protection. Programmable decimal points and K-factors. All programmed data and batch status are E

2

PROM protected in the event of a power failure.

Hall effect, Namur proximity detectors, Pulse wire, voltage,

current & Coil (15mV P-P min). Max. input frequency 10Khz.

batch settings & progress at time of power loss.

May be link configured for PNP to drive compatible logic circuits.

Part No.

1522001 stainless steel wall mount kit

1522002 stainless steel 2" pipe mount kit

1522011 DOM series cooling fin kit for flowmeters with integral instruments

1522005 DOR & Turbine stem adaptor - metric ( M16 to M20 )

1522006 DOR & Turbine stem adaptor - USA ( M16 to 1/2" NPT )

1323006 DOR-42 stem ( 100mm effective height, threaded M16 male )

1323011 DOR-52 stem ( 350mm effective height, threaded M16 male )

1412063

ACCESSORIES FOR ABOVE SERIES: Model: ERS-ZOD-...

Relay contol output board with two SPCO relays

Alarm / pulse output : NPN-PNP solid state alarm or non-scaleable pulse output @

terminal 7, ( 5000hz max.), 1A maximum drive capability.

Batch status output : NPN open collector, 0.1A dc resistive load max.

(page 16).

K-factor range : Eg. Pulses/litre, gallon, lb etc. Programmable range is 0.001~

9999999.999 with a floating decimal point during K-factor entry.

Engineering units : Selectable Ltr, gal, m3, kgs, lbs (maximum 8 digits of batch).

Count direction : Count UP or count DOWN selectable at program level.

Automatic overrun : AOC enabled-disabled selection at programming level (

page 13).

compensation

Batch limiting : Batch size limits can be set at programming level

(page 13).

Run inhibit input : Run key can be inhibited from an external source (page 16).

Network I/O : A two wire loop system can link up to 9 individual batch

controllers with one common flowmeter to provide an economical multi source/dispense interlocked batching system (page 18) .

Physical : A) IP66 / 67 high impact glass reinforced Polyamide enclosure.

B) 3 x M20 or ½” NPT female conduit entries. C) 125mm diameter (5”) x 61mm deep (2.5”) x 400g (0.9lb). D) Temperature range from -20ºC to +80ºC ( -4ºF to +176ºF).

4 Introduction

A

p

A

1.3 Overview

The ZOD-B1 is a dc powered high speed batch controller specifically designed for liquid batching using a flowmeter with a pulse or frequency output.

ZOD-B1 is push button programmable with PIN protection and an internal battery is provided allowing pre-programming without applying power. The large LCD provides batch quantity in selected engineering units, batch status and has scrolling English prompts to make programming easy.

Two independent output relays, the second with programmable start delay and pre-stop, enable pump and valve control or 2 stage flow phasing at the start and end of each batch. Precise batching is aided by Automatic Overrun Compensation which, when enabled, automatically manages variations in system time lags which could otherwise lead to discrepancies in dispensed quantity.

Safety features includes for an alarm output and automatic cessation of batching if no flow input is detected and programmable batch limiting protects against setting an oversize batch quantity. Scrolling messages on the LCD annunciate any alarm fault conditions.

Control features include batch count up or down, remote operational switch interface, run inhibit interlock and batch status output. The ZOD-B1 is capable of networking with up to 9 batch controllers using one common flowmeter.

Operation 5

2. OPERATION

2.1 Batch set : Pressing the Batch set key allows the user to enter a batch value by using the arrowed keys to select the appropriate digits and change their value. Pressing Batch set again enters & confirms that the new batch value has been entered.

2.2 Run : Press RESET then RUN to start the batch. If there are no interruptions the batch controller will automatically stop the batch once the batch value has been reached.

2.3 Stop : Pressing the STOP key at any time during the batch will cause the batcher to go into a “PAUSED ” state and the output relays will be turned off. At this point the user can resume batching by pressing the RUN key or abort the batch by pressing the RESET key.

2.4 Batch Total : The batch value is displayed in all normal operational modes.

2.5 Accumulative Total : Accumulative total can be reset in the program mode.

The accumulative total is displayed momentarily by pressing the ACCUM TOTAL key.

2.6 TNB display ( Total number of batches ) : ZOD-B1 will accumulate the total number of individual completed batches. Reset of TNB is simultaneous with the resetting of the Accumulative total in program mode. To view the TNB value simultaneously press & hold the two top right hand keys ( Prog. & Accum Tot).

Environments The ZOD-B1 is designed to suit harsh indoor and outdoor industrial environments & conforms to EMC directives. The housing is weatherproof to IP66/67 (Nema 4X) standards, UV resistant, robust glass re-enforced plastic with stainless steel screws & FKM O-ring seals.

ZOD-B1 can be mounted on a variety of flowmeters or as a stand alone instrument for wall, surface, pipe or panel mount. Various mounting kits are available.

1.4 LCD displays

RUN ACCUM. TOTAL STOP BAT LOW HIGH RATE

Ltr gal m3 lbs kgs

Ltr

Full LCD display test feature illuminates all display segments and script text displays for 5 seconds when entering the program mode.

Up to 8 digits of Batch quantity programmable for up to 3 decimal places. English prompts

RUN LOW HIGH

clearly show the status of the batch.

n 5 digit TNB display shows the Total

number of batches dispensed since last reset

TOTAL

gal

ACCUM. TOTAL

( reset of TNB and Accumulative Total is only

ossible whilst in the program mode ).

The 8 digit

ccumulative Total display can be

programmed for up to 3 decimal places. Reset is only possible when in the program mode which can be PIN protected for security.

2.7 Keypad functions :

KEY FUNCTION IN OPERATING MODE FUNCTION IN PROGRAM MODE

BATCH SET

RUN

RESET

ACCUM

TOTAL

PROGRAM

1) Enters & Exits the batch set mode.

2) May be pressed during batching to show batch pre-set value, this action will not

interfere with the batch process.

Selects the digit to be Increments the selected digit Indexed ( digit will flash ) ( selected digit will be flashing )

1) Starts a batch

2) Resumes a batch if paused

Pauses a batch during batching

1. Resets the batch to the last pre-set value.

2. Resets individual digits to zero when in the BATCH SET

mode

.

1) Displays Unit ID number followed by the

Accumulative Total as the key is held.

2) Displays total number of batches ( press

Accum. Total & Prog. keys at the same time)

Pressing PROGRAM & ACCUM TOTAL keys

displays the Total Number of Batches ( TNB )

No function

Pressing PROG & STOP keys for 5 sec.

gives entry to the program mode

No function

1) Pressing PROGRAM & STOP keys for 5 seconds gives entry to the program mode.

2) Steps you through the program ladder.

3) Holding for 3 secs. fast tracks to end prog.

6 Installation

3.1 Mounting

RATE TOTALISER

RUN ACCUM. TOTAL STOP BAT LOW HIGH

RESET

RUN ACCUM. TOTAL STOP BAT LOW HIGH

RUN

BATCH

ACCUM

TOTAL

PROG

STOP

RESET

gal

PROGRAM

ACCUM

TOTAL

ENTER

RATE

TOTAL

Wall mount using optional

bracket set

gal

Integral meter

mounts

Surface mount footprint

(use 4 screws supplied )

( P/No. AWM )

RUN ACCUM. TOTAL STOP BAT LOW HIGH

RUN

BATCH

ACCUM

TOTAL

PROG

STOP

RESET

96 mm ( 3.8 ” )

gal

42.6 mm ( 1.67 ” )

18 mm ( 0.7 ” )

Installation 7

3.1 Mounting

RUN ACCUM. TOTAL STOP BAT LOW HIGH

RUN

BATCH

PROG

STOP

RESET

ACCUM

TOTAL

gal

* Vertical pipe mount

* order Pipe mount kit P/No. APM

comprising two brackets,

screws and worm drive clamps.

Panel mount

* Horizontal pipe mount

Conduit entries have an integral

moulded seal, to remove break

seal out using suitable lever

( eg. screwdriver or rod )

Cut a 106.5mm (4.2 ”)

diameter hole in panel

8 Installation

t

_

t

_

t

3.2 Flowmeter connections ( un powered sensors )

Flow input switch functions

3

O

2

N

1 3

Flow

O

2

Input

N

1

Switch 1 : ON engages 0.01µf capacitor to suppress reed switch bounce

Switch 2 : ON engages 1 meg Ω pull up resister

Switch 3 : ON engages 820Ω pull down resister

Factory set network default settings, do not change

1. Reed switch ( 200hz max.)

Flow DIP switches 1 & 2 are on

Ground screen at -0V (5)

3

1

O

2

N

2

1 3

3

O

2

N

4

1

-0V (ground)

5

+8~24Vdc in

6

Pulse output

7

Factory set, do not change

Network loop

Flow

Input A

Relay 2 (high)

Relay 1 (low)

Batch status

Not used

Inhibit inpu

-0V (ground)

14

13

12

11

10

9

8

2. Voltage Pulse ( & pulse wires )

1.1 ~ 30 Vdc

+

_

N

S

All flow DIP swithes off

Ground screen at -0V (5)

3

1

O

2

N

2

1

3

O

2

N

4

1

-0V (ground)

5

+8~24Vdc in

6

Pulse output

7

Factory set, do not change

Network loop

Flow

Input A

Relay 2 (high)

Relay 1 (low)

Batch status

Not used

Inhibit inpu

-0V (ground)

14

13

12

11

10

9

8

3. Coil ( Turbine & paddle style flowmeters )

All flow DIP switches off (position switch 1

if unit is effected by line noise)

ON

use twisted pairs

3

1

O

2

N

2

1 3

3

O

2

N

4

1

5

-0V (ground)

+8~24Vdc in

6

Pulse output

7

Factory set, do not change

Network loop

Flow

Input A

Relay 2 (high)

Relay 1 (low)

Batch status

Not used

Inhibit inpu

-0V (ground)

14

13

12

11

10

9

8

Installation 9

3.2 Flowmeter connections ( powered sensors )

4. Hall Effect ( open collector )

Hall effect

+ Signal out

- 0V ground

Vdc supply

Flow input DIP SW2 is on

+

Reg. Vdc

3

1

O

2

N

2

1

3

O

2

N

4

1

-0V (ground)

5

+8~24Vdc in

6

Pulse output

7

Factory set, do not change

Network loop

Flow

Input A

Relay 2 (high)

Relay 1 (low)

Batch status

Inhibit inpu

-0V (ground)

5. Namur ( inductive proximity switch )

intrinsically safe NAMUR proximities

NAMUR

Inductive Proximity

NOTE : Limit supply to 8.5Vdc through an approved barrier for

-

+

Flow input DIP SW3 is on

+

Reg. Vdc

3

1

O

2

N

2

1 3

3

O

2

N

4

1

-0V (ground)

5

+8~24Vdc in

6

Pulse output

7

Factory set, do not change

Network loop

Flow

Input A

Relay 2 (high)

Relay 1 (low)

Batch status

Inhibit inpu

-0V (ground)

6. Current modulated pulse

( 4mA to 20mA pulse amplitude )

Coil with pre-amp

current modulated

NOTE : Position a 100Ω, ¼W

Resistor across terminals 3 & 5

Flow input DIP switches off

-

B A

+

Reg.Vdc

3

1

O

2

N

2

1

3

O

2

N

4

1

-0V (ground)

5

+8~24Vdc in

6

Pulse output

7

Factory set, do not change

Network loop

Flow

Input A

Relay 2 (high)

Relay 1 (low)

-0V (ground)

Batch status

Inhibit inpu

Not used

14

13

12

11

10

9

8

14

13

12

11

10

9

8

14

13

12

11

10

9

8

10 Installation

_

w

_

w

_

V

w

3.3 Wiring connections

Powering & Remote switches

+

Reg.Vdc

1

2

3

4

-0V (ground)

5

+8~24Vdc in

6

No flow alarm

7

( remote keys )

Network loop

Flow Input

Relay 2 high

Relay 1 lo

Batch status

not used

Run inhibit

-0V (ground)

Remote keys

15 16 17 18 19

use momentary contact

14

13

12

11

10

9

8

remote switches only

STOP

TOTAL

SET

RUN

15 16 17 18 19

Wiring requirements : Use multi-core screened twisted pair instrument cable (0.25~0.5mm

electrical connection between the ZOD-B1 and any flowmeter or remote switch input. The screen needs to be grounded at -0V (terminal 8), this is to protect the transmitted signal from mutual inductive interference.

Instrument cabling should not be run in a common conduit or parallel with power or high inductive load cables. Power surges & power line frequencies may induce erroneous noise transients onto the signal. Run instrument cables in a separate conduit or with other instrument cables.

2

) for

Single Stage Control

( use relay 1 or 2, relay 2 has pre-stop programming capability )

+

Reg.Vdc

Network

1

2

3

4

5

6

7

Flow

Input

-0V (ground)

+8~24Vdc in

No flow alarm

Relay 2 high

Relay 1 lo

Batch status

not used

Run inhibit

-0V (ground)

14

13

12

11

10

9

8

IMPORTANT

Fix 1N4004 electrical surge suppression diode supplied

across solenoid valve coil

( band to + side )

Flow

meter

Flow

+

1N4004

Installation 11

Two Stage Control

( using relays 1 & 2 )

+

Reg.Vdc

Network

1

2

3

4

-0V (ground)

5

+8~24Vdc in

6

No flow alarm

7

Flow Input

Relay 2 high

Relay 1 lo

Batch status

not used

Run inhibit

-0V (ground)

14

13

12

11

10

9

8

+

1N4004

1

_

1N4004

V2

Flow

meter

Flow

+

See notation on 1N4004 diode. When the solenoid valve coil is de-energized

it generates its own voltage sending a “surge spike” through the circuit.

Depending on the coil size and the number of amp turns it contains, this

generated voltage can be very high. Installing the diode will suppress this

“spike” and protect sensitive components of the electronic instrument.

IMPORTANT

Relay Control Logic

Batch

complete

Relay 1 LOW FLOW

ENERGISED

Relay 2 HIGH FLOW

Start delay

Batch & network

status ( NPN ) output

ENERGISED

Batch & network status (end of batch)

(occurs 1~4 seconds after relay 1 is off)

ENERGISED

ENERGISED ENERGISED

OFF

Pre-stop

1~4 sec.

OFF

12 Programming

4. PROGRAM PARAMETERS

4.1 PIN No. Program Protection

Any user defined PIN number other than 0000 will engage the program protection feature, failure to input the correct PIN number will deny the ability to change any of the program parameters but will allow the user to step through and view the existing program parameters.

Only one PIN number may be set but this can be changed at any time after gaining access through PIN entry. A second back up PIN number is installed at the factory should the programmed PIN be lost or forgotten. ( refer bottom of page 19 for the back up PIN No. )

4.2 Resetting Accumulated Total & Total Number of Batches ( TNB )

Resetting the Accumulated Total & Total Number of Batches (TNB) is done at “RESET ACCUMULATIVE TOTALS ” in the program mode. Both Accumulated Total & TNB are reset if you select YES

at this program level.

4.3 Engineering Units ( refer clause 1.4 )

Select from available Engineering units to right of the display. No engineering units denote NIL set allowing the user to set up the instrument with other units of measure which are not available on the ZOD-B1 LCD display.

4.4 K-factor ( scale factor )

Enter K-factor starting with the most significant number, up to 7 prime numbers & 3 decimal numbers can be entered. Trailing decimal numbers move into view as digits to the right are progressively selected, any significant digits which may move from view remain functional.

4.5 Decimal Points

Up to three decimals points can be selected for Batch Total or Accumulative Total.

4.6 Count Direction

B1 can be programmed to count DOWN from a preset quantity or UP from zero. Overruns in the count down mode will show with a minus sign in front of the overrun value.

4.7 Start Delay & Pre-Stop Relay 2 can be programmed to turn on a time period after the run signal is given then turn off again a preset number of litres, gallons etc. before the end of the batch. These operational features provide greater control over the dynamics of the batching process through soft start and/or soft stop or phasing of the control valves and/or pump control.

The Start Delay can be set from 0 seconds ( no delay ) to 999 seconds. The pre-stop range is 0 (no pre-stop) to 999 units of measure ( litres or gallons etc.).

Programming 13

4.8 Automatic Overrun Compensation ( AOC )

Most batching applications will have an inherent end of batch overrun due mainly to the response time of the process valve. Overrun can be compensated by closing the valve slightly before the batch value is reached so that the exact batch value is achieved by the time that the system comes to rest.

ZOD-B1 has an Automatic Overrun Compensation feature which when enabled will assess the degree of overrun on previous batches and automatically alters the close timing of the process valve so that the exact batch value is reached. This feature should not be enabled on batch processes which are subject to erratic or inconsistent flow conditions.

4.9 Missing Pulse Detection

When a value other than 00 seconds is set at Time Out ( T / OUT ) in the program mode, ZOD-B1 will monitor for loss of flowmeter input signal at all times when either of the control relays 1 & 2 are energised. If no pulses are received within the time out period ( 0~99 sec. ) the controller will de-energise both control relays and scroll a “NO INPUT” message across the LCD display, at the same time it will turn on the “no flow alarm” output at terminal 7, (see

page 17 for flow alarm connection detail).

At “NO INPUT ” the user must acknowledge the alarm condition by pressing the STOP key once, the operator then has the option of continuing the batch by pressing the RUN key or aborting the batch by pressing the RESET key which will return the controller to the original batch set value.

4.10 Batch Limit

To avoid entering excessive batch quantities, a maximum batch limit can be set at the program level. ZOD-B1 will not accept a batch value which exceeds the batch limit, on rejecting an excessive batch value the controller will scroll the message “BATCH VALUE EXCEEDS BATCH LIMIT” and default to the batch limit on entry (batch set).

4.11 Controller networking ID number Each controller can be given a networking ID number in the range of 1~9. Allocating an ID number other than 0 is only necessary when a number of controllers are to be networked together for interlocking purposes

( see page 18 for Controller Networking ). Setting the ID

number to zero inhibits this function.

Note : The instrument defaults out of the program mode if no program entries are made after 4 minutes.

14 Programming

5. PROGRAMMING FLOW CHART

press Prog. key

to step through

program levels

ENG UNIT Ltr gal m3 Ibs kgs (none)

DPt TOTAL 0 0.0 0.00 0.000 DPt ACCUM TOTAL 0 0.0 0.00 0.000

V3.1 HOLD 3 2 1

TESTING DISPLAY 88888888

PROGRAM MODE ENTERED

if PIN protected

PROG

CHANGE PIN No. Y / N

NU PIN Y ~ N

YES NO

PIN _ _ _ _

RESET ACCUM TOTALS Y / N

RESET Y ~ N

SET ENGINEERING UNITS

ENTER NUMBER PULSES PER

Ltr m3 kg gal Ib (unit)

K 0000.001 ~ 999999.999

SET DECIMAL POINTS

SET COUNT DIRECTION

COUNT DN ~ UP

START DELAY - RELAY 2

DELAY 000 ~ 999 seconds

PRE STOP VALUE - RELAY 2

PRE 000 ~ 999

AUTOMATIC OVERRUN COMPENSATION

A/COMP Y ~ N

ENTER PIN PIN _ _ _ _

continued

PROG

hold Program & Stop

keys for 5 secs to enter the program

PIN No. is entered

INVALID PIN VIEW

EXISTING PROGRAM

DETAILS ONLY

K-factor (scale factor) is the number of

pulses per unit volume or unit mass

eg: 20.465 pulses / litre, gallon, kg etc.

SET MISSING PULSE TIME OUT

T / OUT 00 ~ 99 seconds

SET BATCH LIMIT

NETWORK OPERATION

N / WORK Y ~ N

YES

SET UNIT ID No.

ID No. X

STOP

if incorrect

XXXXXXXX

See page 13.

END Y ~ N

NO

YES

NO

Exit program

mode

Operating 15

6. BATCH OPERATING PROCEDURE

TO REPEAT

BATCH

B A T C H E N D

BATCH SET

ENTER BATCH

QTY. XXXXXXXX

BATCH SET

RUN

TO

PAUSE

TO CHANGE

TO ABORT

TO RESUME

BATCH

RESET

STOP

RUN

16 Secondary I/O

0

(

)

(

)

0

7. SECONDARY I/O

7.1 Batch Status Output

A solid state NPN output signal is switched on at terminal 12 when a batch is started, the signal remains on until the batch cycle is completely finished or the batch is stopped and aborted using the STOP & RESET keys.

The output is used to notify other control equipment when ZOD-B1 is in operation or is paused (by pressing STOP) or inhibited through an input at terminal 9 (RUN inhibit), the signal remains on under all three conditions. The signal can also be used to inhibit (lock out) other equipment whilst the controller is in use.

1

No flow alarm

(refer 7.4 & 7.5)

Network

2

3

Flow input

4

5

-0V (ground) +8~24Vdc in

6

7

Alarm output

High flow-relay 2

Low flow-relay 1

Batch status

Run Inhibit

-0V (ground)

14

13

12

11

10

Remote keys

15 16 17 18 19

Batch status

(refer 7.4)

9

8

Run inhibit

input

( closed = inhibit RUN )

7.2 Alarm Output

An NPN/PNP selectable solid state output signal (terminal 7) is activated when the missing pulse detection feature detects a no flow condition (refer 4.9). NPN/PNP selection is to be in accordance with the connection options on the following page (17).

7.3 Run Inhibit Input

The RUN inhibit feature enables ZOD-B1 to interlock with other devices within the system or process when ZOD-B1 is in use.

When a contact is made across the Run inhibit input at terminal 9, a batch cannot be started and at the same time an “ENGAGED “ prompt will show on the LCD display. If the inhibit contact is made whilst a batch is running the batch will be paused. When the run function is inhibited it is still possible to enter a new batch quantity or review the accumulated totals but it will not allow the operator to RUN or re-start the batch until the inhibit input is released.

An example of this feature in practice is where a batch should not be allowed to RUN whilst a valve at another location is open.

Solid state output logics 17

7.4 Current Sinking outputs ( NPN )

Current sinking derives its name from the fact that it “sinks current from a load”. When activated the current flows from the load into the appropriate output ( terminals 7, 12, 13 & 14 ). NPN is the factory default configuration for the outputs. Refer to pages 10 & 11 for wiring control outputs.

Driving a logic input The output voltage pulse is typically the internal voltage of the load. The load would normally have an internal pull up resistor on its input as shown.

Driving a coil - - - - - - - The NPN style of output is to be used when driving a coil. The coil load is obtained by dividing the coil voltage by coil impediance ( Ω ), is expressed in amps & is not to exceed 100mA at terminals 7 & 12 or 1A at terminals 13 & 14. The coil voltage is connected across & must match the ZOD-B1 supply voltage & the appropriate output ( terminals 7, 12, 13 & 14 ).

- +

SPO (no flow alarm)

REP repeater pulse

7A

1

2

3

4

-0V (ground)

5

+8~24Vdc in

6

Alarm output

7

7B

0 0 0

PNPNPN

High flow relay 2

Low flow relay 1

Set jumper

7.5 Current Sourcing outputs ( PNP )

Current sourcing gets its name from the fact that it “sources current to a load”. When activated the current flows from the output (7,13 & 14) into the load. When wired as below the output voltage pulse is the supply voltage of the load. The load would normally have an internal pull down resistor on its input as shown.

0 0

13

Batch status

NPN

-0V (ground)

to NPN

0 0

14

13

0

PNP

0

14

13

12

11

10

9

8

0

PNP

0

NPN

Set jumper(s)

NPN

to NPN

coil

For solenoid valve coils fix a 1N4004 electrical surge

suppression diode across the coil (refer page 10)

Set jumper(s)

to PNP

IMPORTANT

OR

logic

+

input

load

_

- +

1

2

3

4

5

-0V (ground)

+8~24Vdc in

6

Alarm output

7

0 0 07B

PNP

NPN

High flow relay 2

Low flow relay 1

PNP

-0V (ground)

Set jumper

to PNP

14

13

12

11

10

+

logic input

_

load

9

8

Do not tie 0 volts of the

logic input to 0 volts of

the ZOD-B1 when wired

in PNP configuration

18 Networking

V1V

8. CONTROLLER NETWORKING

ZOD-B1 has a unique networking feature which allows up to 9 individual batch controllers to be networked together with each being connected to one common flowmeter (see opposite).

Typical applications are where one liquid is being dispensed to a number of individual outlets or a number of different liquids are to be batched via one common flowmeter. In either application each batch controller is wired to the same flowmeter but controls its own process control valve.

Networking takes place when any one controller is started, at this point the flowmeter input (count) is restricted to the controller in use, all other controllers will not count and their start function will be inhibited and an “ENGAGED” will scroll across the LCD display showing the ID number of the controller in use.

Batch entries can be made whilst individual batch controllers are inhibited (locked out) but they cannot be started until the controller in operation has completed its batch cycle.

For the network feature to work the network DIP switches must be set as shown & each batch controller MUST be programmed with an individual ID number other than 0 (zero).

Network loop wiring

1

O N

2

3

4

-0V (ground)

5

+8~24Vdc in

6

Alarm output

7

ZOD-B1 1

3

Network

2

DIP switch

settings

1

Flow

input DIP

switches

High relay 2

Low relay 1

Batch status

Run inhibit

-0V (ground)

14

13

12

11

10

9

8

1

O N

2

3

4

-0V (ground)

5

+8~24Vdc in

6

Alarm output

7

ZOD-B1 3

3

Network

2

DIP switch

settings

1

Flow input DIP

switches

High relay 2

Low relay 1

Batch status

Run inhibit

-0V (ground)

14

13

12

11

10

9

8

1

O N

2

3

4

-0V (ground)

5

+8~24Vdc in

6

Alarm output

7

ZOD-B1 2

3

Network

2

DIP switch

settings

1

Flow

input DIP

switches

High relay 2

Low relay 1

Batch status

Run inhibit

-0V (ground)

14

13

12

11

10

9

3

Network

1

O

2

DIP switch

N

2

3

4

-0V (ground)

5

6

Alarm output

7

settings

1

Flow input DIP

switches

+8~24Vdc in

ZOD-B1 4

High relay 2

Low relay 1

Batch status

Run inhibit

-0V (ground)

14

13

12

11

10

9

88

Flowmeter

ZOD-B1 1

Networking (continued) 19

Multi point batching

ZOD-B1 1

V1

Mix tank 1

ZOD-B1 2 ZOD-B1 3

network

loop

Valve

V2 V3 V4

Mix tank 2 Mix tank 3 Mix tank 4

Multi product batching

Product 2

V2 V3

Valves

Flowmeter

Product 3 Product 4

Product 1

ZOD-B1 2 ZOD-B1 3

network

loop

ZOD-B1 4

4

Reference information 20

9. REFERENCE INFORMATION

9.1 Program detail

User selected PIN No.

K-factor (scale factor)

Decimal for batch total

Decimal for Accum. total

Count direction

Start delay on relay 2

Pre-stop value on relay 2

Automatic overrun comp.

Missing pulse time-out

Batch limit

Unit ID number ( 1~9 )

9.2 Error messages: ZOD-B1 has a series of error messages which are scrolled across the LCD display when ever an error condition exists.

NO POWER

No power indicates that the instrument is on battery power only and needs to be supplied with an external power source in order to operate.

NO INPUT

No input (missing pulse detection) indicates that no pulses were received at the controller input within the time out period at any stage of the batch cycle. ( see clause 4.9 )

BATCH VALUE EXCEEDS

BATCH LIMIT

The new batch value will not be accepted because it exceeds the maximum batch limit value. ( see clause 4.10 )

PRE-STOP EXCEEDS

BATCH VALUE

The new batch value will not be accepted as it is less than the pre-stop value ( clause 4.7)

WAIT

This message will show if the RUN button is pressed whilst the controller is in the process of assessing the degree of overrun from the previous batch when AOC is enabled.

9.3.1 Back up PIN number ( see clause 4.1 )

Cut from manual for increased security

Your back up 4 digit PIN number is 0502

Pencil your program details here

Engineering units

K =

000. 00.0 0.00 .000

count DOWN count UP

seconds

AOC yes no

seconds

( 0 = inhibit network function)

10. ALPHABETICAL INDEX

Accumulative total

A

Alarm output

Automatic Overrun Comp. 13

B

Batch RUN

Batch SET

Batch STOP

Batch total

Batch limit

Batch operating procedure

Batch status

Back up PIN number

Battery

C

Controller ID number

Controller networking 18,

Count direction

Decimal points 12

D

Engineering units 3,

E

End of batch

Error messages

External DC powering

F

Flow alarm output

Flowmeter connections 8,

ID numbering

I

Inhibit input

Keypad functions

K

K-factor (scale factor) 12,

(batch status)

11, 16 & 17

16

5

13

15

16

20

4

12

20

18

13

16

14

5

13

19

12

10

Index 21

5

LCD display 4

L

Model number designation 2

M

Missing pulse detection

Mounting options 6,

Networking 18,

N

Operation 5

O

13

7

19

Overrun compensation 13

Overview

PIN number protection

P

Pre-stop

4

12

Programming 12, 13

Program detail record 20

Programming flow chart

14

Relay control logic

R

Remote operating keys

Resetting totals

Run inhibit input

Scale factor (K-factor) 12,

S

Single stage control

Specifications

Start delay

11 10 12

16

14

10

12

3

9

Total Number of Batches

T

Two stage control

Wiring connections 10,

5

W

Wiring requirements

5

11

10

K01/1010

Manufactured and sold by:

ZOD-Z1 BATTERY TOTALISER

I N S T R U C T I O N M A N U A L

Kobold Messring GmbH

Nordring 22-24

D-65719 Hofheim

Tel.: +49(0)6192-2990

Fax: +49(0)6192-23398

Universal Mount Series

prog

y

To review software version No’s press &

hold

ram ke

Replacement Batteries:

Factory supplied batteries :

Non I.S. battery

P/No. 1312007

3.6V x 2.4Ah AA

Lithium Thionyl Chloride

-

non - rechargeable cell

+

Suitable non I.S. batteries also available from :

R S Components

Stock No. 596-602

Farnell Components

Order code 206-532

TABLE OF CONTENTS

1. INTRODUCTION

1.1 Model number designation 2

1.2 Specifications 3

1.3 Overview 4

1.4 LCD displays 4

2. OPERATION

2.1 Resettable total 5

2.2 Accumulative total 5

2.3 Keypad function matrix 5

2.4 Battery replacement 5

2.5 Processor reset button 5

3. INSTALLATION

3.1 Mounting - integral meter mounting 6

- panel mounting 6

- wall / surface mounting 7

- pipe mounting 7

3.2 Flowmeter connections - un-powered sensors 8

- powered sensors 9

3.3 Wiring connections - Terminal designation 10

- Interface board layout 10

- Wiring practice 10

- PNP pulse output 11

4. PROGRAM PARAMETERS

4.1 PIN number protection 12

4.2 Resetting accumulative total 12

4.3 Engineering units 12

4.4 K-factor (scale factor) 12

4.5 Pulse output 12

5. PROGRAMMING FLOW CHART 13

5.1 Program detail record 14

6. TROUBLESHOOTING 14

7. Declaration of Conformance 16

8. ALPHABETICAL INDEX 17

- NPN pulse output 11

Page 1

2 Introduction

Introduction 3

1.2 Specifications

1. INTRODUCTION

Model Housing Type Electrical connection/

ZOD-Z1...

*order only when retrofitting a pulse meter

KS = universal mount

(standard)

KM* = integral mount

Cable gland

0 = cable gland supplied

(suits 3...6 mm Ø cables)

Supply Voltage Options Mechanical

F3= 8...24 VDC, battery 0= without 0= without

protection

Display : 5 digit resettable LCD totaliser 7.5mm ( 0.3”) high with second

line 8 digit accumulative total display & text 3.6mm ( 0.15”) high.

3 programmable decimal points with both display lines.

Signal Inputs : Universal pulse-frequency input compatible with Reed switch,

Hall effect, Coil-sine (20mV P-P min.), Voltage or current pulse &

Namur proximity detectors. Maximum input frequency is 5Khz for

coils, 2.5Khz for Hall effect & current pulse inputs, 2Khz for voltage pulse devices & 500Hz for a Namur proximity sensor.

Powering : 3.6Vdc Ultra Lithium battery or I.S. battery pack supplied, life

expectancy can be up to 7~10 years. Battery life reduces when

connected with a coil input from turbine flowmeters. The ZOD-Z1

may also be externally powered from a regulated 8~24Vdc supply (see page 14 for special instructions regarding ghosting).

Pulse output : Scaleable or non-scaleable NPN-PNP selectable field effect output

Transistor. Non scaleable pulse is particularly suitable for preamplifying pick-off coil inputs from turbine meters ( 5Khz. Max.).

The scaleable pulse output has a fixed pulse width of 60ms and therefore has a frequency limit of 8hz . Both pulse outputs have a 50mA maximum drive capability.

Physical : A)

IP66/67 high impact, glass reinforced Polyamide enclosure. B) Self drill cable gland entry at base & rear of the enclosure. C) Overall 85mm diameter x 45mm deep x 175g (0.4lb). D) Operating temperature -20ºC ~ +80ºC ( -4ºF ~ +176ºF).

Configuration

Functions : Accumulated & Resettable totals, pre-amplifier pulse output & a

scaleable pulse output. Low battery indication.

Configuration : Flow chart entry of data with English text prompts.

User selectable 4 digit PIN number program protection. Programmable engineering units, decimal points and K-factors. All programmed data protected with the battery.

K-factor range : Entered as pulses / litre, gallon, lb etc. Programmable range is

0.001~9,999,999.999 with a floating decimal point during K-factor

(scale factor) entry.

Pulse output range : Entered as engineering units/pulse. Range is 0.1~9999.9

units/pulse.

Engineering units : Selectable Ltr, Gal, m3, kgs, lbs, MLtr & Mgal or no units of display.

4 Introduction

1.3 Overview

The ZOD-Z1 series i

nstruments are specifically designed for computing & displaying totals from flowmeters with pulse or frequency outputs. They are battery powered or can be powered by an external 8~24Vdc regulated or I.S. certified supply.

The instrument will display Resettable Total and an Accumulated Total in engineering units as programmed by the user. Simple PIN protected flow chart programming with English prompts guide you through the programming routine greatly reducing the need to refer to the manual.

Special Features Standard

: PIN Protection. Amplified non-scaled repeater or scaleable pulse output.

: NPN/PNP selectable pulse output.

Optional : Display backlighting (needs external dc power for this option to illuminate).

: Intrinsic Safety Certification to IECex scheme and ATEX directive.

Environments The ZOD-Z1 series is designed to suit harsh indoor and outdoor industrial and marine environments. The robust housing is weatherproof to IP676 / IP67 standards, UV resistant, glass reinforced Polyamide with stainless steel screws & FKM O-ring seals.

Installation Specifically engineered to be directly mounted on a variety of flowmeters, wall, surface or pipe mounted in the field or control room. Various mounting kits are available. The instrument is self powered using one 3.6Vdc lithium battery or I.S. battery pack, the pulse output option requires 8~24Vdc.

Operation 5

2. OPERATION

2.1 Resettable Total

Pressing the RESET key will cause the large 5 digit total to reset to zero. The reset function is possible at any time during counting.

2.2 Accumulative Total

There are 8 digits in the accumulative total display, these can only be reset in the program mode or can be protected by enabling the PIN protection feature at the front end of program mode.

2.3 Keypad functions

KEY FUNCTION IN OPERATING MODE FUNCTION IN PROGRAM MODE

Resets the 8 digit accumulative

total display to zero. Resets internal K-factor

1. Each press steps you through each level of

2. Holding for 3 seconds fast tracks to the END

Selects the digit to

will be “flashing ” indicating that it can be

(scale factor) to zero

the program chart.

of the program from any program level.

be set, the selected digit

incremented.

Increments the selected

that it is pressed.

digit each time

PROGRAM

ENTER

Resets the 5 digit resettable

total display to zero.

1. Pressing the Program & Reset keys for 5 seconds enters you into the program mode

2. Displays model & software revision No.

No function

.

1.4 LCD display

The 8 digit Accumulative Total display can be programmed for up to 3 decimal places. Reset is only possible when in the program mode which can be PIN protected for security.

Full LCD display test feature illuminates all characters and script text displays for 5 seconds when entering the program mode.

The 5 digit Total display is front panel resettable and can be programmed for up to 3 decimal places.

Engineering units are selected during the initial programming routine.

Battery condition indicator shows only when battery is low, battery life can last up to 7~10 years.

2.4 Battery replacement

The instrument draws very little power and will run for many years* without the need to replace the battery. A battery condition indicator on the LCD display will appear when the battery is low, if the low battery is not replaced the programmed detail & totals will be lost.

When changing the battery a small capacitor within the instrument will maintain the programmed detail & totals in memory for up to 10 seconds providing sufficient time for the battery change to take place. Changing the battery whilst flow is taking place could cause loss of the programmed detail. It is advisable to record program details prior to battery change.

* The battery can last 7~10 years depending on application & environment.

2.5 Processor reset button

Should the instrument be corrupted by an electrical hit the processor can be reset by pressing the black re-boot button located above the red DIP switch block on the input interface board (refer page 10). This procedure does not effect totals or programmed data.

6

3. INSTALLATION

3.1 Mounting

Integral meter mounting

Panel mounting

Cut a 75mm ( 3”) dia. hole in

panel. Existing O-ring seals

against panel face

If using the cable gland supplied carefully bottom or rear of housing as shown

on housing footprint detail on page 7

drill a 12.5mm (½”) hole at

Installation 7

Surface mount footprint

42.6mm

( 1.67 ” )

If using the cable gland

supplied carefully

12.5mm (½”) hole at

the underside or from

the inside rear of

housing

Use only the 4

special length

self tapping

screws supplied

drill a

Cable diameter range is 2.9~6.4mm (⅛~¼”)

80 mm ( 3.15 ” )

Wall - surface mount using optional bracket kit ( P/No. AWM )

18 mm ( 0.7 ” )

42.6 mm ( 1.7 ” )

Pipe mounting ( P/No. APM )

APM adaptor pipe

mount kit is suitable

for vertical or

horizontal pipes

8 Installation

p

A

3.2 Flowmeter connections ( un-powered sensors )

Reed switch input

DIP switches

ON

1 & 3 (de-bounce)

in the ON

1 2 3

+

gnd

-

( 40 hz max.)

1 2 3

position

+Vdc

4 5 6

+∏

-gnd

Note: DIP switch 3 is to be

OFF

for reed switch input

frequencies greater than 40 hz.

Ground screen at 3

Coil input from

turbines or paddle

ON

DIP switch 1 in the ON ( 5 Khz max.)

1 2 3

position

+∏

gnd

-

+ 1 2 3

+Vdc

-gnd

4 5 6

twisted pair

Voltage pulse

input (pulse

ON

1 2 3

gnd

-

+ 1 2 3

Ground screen

wire)

DIP switch 1 in the ON

position

( 2 Khz max.)

+∏

+Vdc

4 5 6

at 3

-gnd

Screen grounded at

amphenol shroud or

terminal box and

terminal 3 at ZOD-Z1

yellow

green

N

S

Installation 9

3.2 Flowmeter connections ( powered sensors )

NOTE : Voltage not to exceed 13.4 Vdc

through an approved barrier if when using an intrinsically safe NAMUR proximity in a

hazardous area ( EEx Ia 11C ). Typically

these proximity’s are limited to 8.2 Vdc

NAMUR

Inductive Proximity

-

+

Ground screen at 3

Namur proximity

ON

DIP switch 2 in the ON

( 250 hz max.)

1 2 3

gnd

-

+

input

position

+Vdc

4 5 6 1 2 3

+

+∏

-gnd

8~24Vdc

external

-

power

NOTE: For an input >800hz position a ¼

Hall effect

watt resistor across

terminals 1 & 4,

12Vdc: 1Meg 24Vdc: 2Meg Ω

Ω

+ ∏

-0V gnd

+Vdc

Ground screen at 3

Hall effect input

( NPN open collector )

ON

DIP switch 1 in the ON

1 2 3

gnd

-

+

+Vdc

position

+∏

4 5 61 2 3

+

-gnd

8~24Vdc

-

external

power

NOTE: Position a 100 ohm,

¼ watt resistor across

terminals 1 & 3 as shown

Modulated current

pulse input (4~20mA)

ON

1 2 3

+ 1 2 3

ll DIP switches to be in the OFF position

gnd

-

+Vdc

4 5 6

+∏

-gnd

Coil with pre-amp current modulated

-

B A

+

Ground screen at 3

+

8~24Vdc

-

external

ower

10 Installation

r

(

)

p

r

(

)

( 50

)

(

)

3.3 Wiring connections

Terminal designation

1 + I/P Flow input pulse signal

2 - Vref. Flow input ( coils & voltage type inputs )

3 gnd GND Flow input ( pulse type inputs )

4 +Vdc +Vdc External power , +8~24Vdc (see P14)

5 + ∏ O/P Output pulse ( J1 & J3 selectable )

6 -gnd GND External power

Interface board layout

Processor

reset button

Input DIP switches

1 = 1MΩ pull up resistor 2 = 820Ω pull down resistor 3 = 0.01µf de-bounce & noise capacitor

( limits max. input freq. to 40hz)

SW5

ON

1 2 3

SW6

+

gnd

-

NPN

PNP

+Vdc

J1

0 0 0

+∏

4 5 61 2 3

I/P Vref O/P

J3

0 0

0 0 0

-gnd

J2

F/O P/O

Battery jumper

0

battery engaged

0

battery isolated

0

Output jumpers

J1 NPN-PNP selection J3 Output pulse selection:

F/O non-scaled frequency P/O scaleable pulse

Wiring practice

Use multi-core screened twisted pair instrument cable ( 0.5mm between the instrument and any remote flowmeter or receiving instrument. The screen needs to be earthed to the signal ground or the receiving instrument, this is to protect the transmitted signal from mutual inductive interference. Do not

Instrument cabling is not be run in a common conduit or parallel with power and high inductive load carrying cables, power surges & power line frequencies may induce erroneous noise transients onto the signal. Run instrument cables in a dedicated low energy, low voltage conduit.

earth the screen at both ends of the cable.

2

) for electrical connection

Installation 11

3.3 Wiring connections - pulse outputs

Current Sinking outputs ( NPN )

Current sinking derives its name from the fact that it “sinks current from a load”. The current flows from the load into the appropriate output (terminal 5).

Driving a logic input The output voltage pulse is typically the internal voltage of the load. The load would normally have an internal pull up resistor on its input.

Driving a coil - - - - - - - The NPN style of output is to be used when driving a coil. The coil load is obtained by dividing the coil voltage by coil impediance ( Ω ), is expressed in amps & is not to exceed

0.1A. The coil voltage is connected across, & must match, the ZOD-Z1 supply voltage & the output (5).

J1

NPN

PNP

1 2 3

0 0 0

+∏

+Vdc

4 5 6

J3

0

F/O

0

P/O

0

scaleable

pulse output

-gnd

8hz max.

coil

-

+

8~24Vdc external powe

NPN output pulse

( 50mA max.)

Current Sourcing outputs ( PNP )

Current sourcing gets its name from the fact that it “sources current to a load”. The current flows from the output (terminal 5) into the load. When wired as below the output voltage pulse is the supply voltage of the load. The load would normally have an internal pull down resistor on its input.

+

logic input

load

_

1 2 3

PNP output pulse

mA max.

NPN

PNP

J1

0 0 0

+∏

+Vdc

4 5 6

+

J3

0 0 0

F/O P/O

-gnd

-

external

scaleable

pulse output

8~24Vdc

NPN

PNP

8hz max.

owe

J1

0 0 0

J1 in the

NPN position

J3

non-scaled freq.

0 0

pulse output

0

( 5Khz max.)

+

(load)

J1 in the PNP

position

J3

non-scaled freq.

0 0

pulse output

0

( 5Khz max.)

logic input

_

12 Programming

O

OG

T

f

4. PROGRAM PARAMETERS

4.1 PIN No. Program Protection

The option exists to protect the programmed detail & Accum. Total with a user selected four digit PIN No. ( 0000 represents no PIN protection ). If activated the user must input the correct PIN No., failure to do so will deny access to change any of the program parameters or reset the Accumulative Total but will allow the user to step through and view the program details.

Only one PIN number may be set but this can be changed at any time after gaining access through PIN entry. A second back up PIN number is installed at the factory should the programmed PIN be lost or forgotten. ( refer page 14 for the back up PIN No. )

4.2 Resetting Accumulated Total

Resetting the accumulated total can only be done within the program mode.

4.3 Engineering Units ( refer clause 1.4 )

Select from available Eng. units to right of the display. The ZOD-Z1 can display in engineering units not available on the LCD display by programming to “no eng. units” and a suitable Kfactor.

4.4 K-factor (scale factor)

Enter K-factor starting with the most significant number, up to 8 prime numbers & 3 decimal numbers can be entered. Trailing decimal numbers move into view as digits to the right are progressively selected, any significant digits which may move from view remain functional.

4.5 Pulse output

The pulse output is NPN-PNP link selectable via jumper J1. It is also selected at jumper J3 to act as a non-scaled pre-amplified pulse output or scaleable pulse output, maximum load is 50mA.

Non-scaled pulse output:

The un-scaled repeater pulse output represents one pulse out for each input pulse from the primary measuring element (flowmeter). This output acts as an input signal pre-amplifier particularly suitable for pick-up coil inputs up to 5Khz. The duty cycle of the output adopts the duty cycle of the input. The ZOD-Z1 needs to be externally powered for this feature to operate (see page 11).

Scaleable pulse output : The fully scaleable pulse output is programmable as the number of litres / gallons etc. per output pulse Eg. 0.1 litres/pulse, 10 litres/pulse, 100 gallons/pulse. Range is 0.1 ~ 9999.9 Eng. unit/pulse. The ZOD-Z1 needs to be externally powered for this feature to operate ( p11 ).

The scaleable pulse output is suitable only for remote integration due to the spasmodic nature of its output frequency, it is limited to 8hz. Should the potential incidence of this output exceed 8hz it can continue to count after flow has stopped until such time as the processor buffer has completed integration. Most scaleable pulse output requirements are low frequency due to down scaling and therefore not effected by the buffer count effect.

Programming 13

5. PROGRAMMING FLOW CHART

hold Program & Reset

keys for 5 seconds to

enter the program mode

Note: The ZOD-Z1 will

default out of the

program mode if no

entries are made

N

RESE

press Program key to advance

through each program level. Use

PR

arrowed keys to enter parameters

if PIN

protected

if incorrect

PIN No. is entered

view program

details only

K-factor (scale factor) is the

number of pulses per unit

volume or unit mass eg:

20.465 pulses/litre, gal, kg etc.

Important: record program details overlea

14 Programming flow chart

5.1 Program detail record If not powered for more than 10 seconds the programmed detail & Accumulated Total will

be lost from the processor memory, it is advisable to record your programmed detail below. Specific instructions on changing the battery without loss of program detail are given at clause 2.4, page 5.

User selected PIN No.

K-factor (scale factor)

Decimal for reset total

Decimal for Accum. total

Output pulse value

Pencil your program details here

Engineering units

K =

0 0.0 0.00 0.000

0000

litres

1.000

0.0

0001.0

Factory default settings

6. TROUBLESHOOTING

# No display.

Check position of the battery jumper J2 ( see interface board layout page 10 ) & check battery contact connections. Replace battery.

# Display ghosting under external power.

The LCD display will “ghost” when the instrument is powered from an external 24Vdc power supply, this is corrected by including two ¼ watt resistors (1.2K & 3.3K) on the input power source as shown below.

24Vdc

external

power

ON

1 2 3

-

+ 1 2 3

+

-

ZOD-Z1

gnd

+Vdc

+∏

-gnd

4 5 6

Troubleshooting 15

# Display shows model number at all times.

example

The instrument has not been fully programmed after power up, enter the program mode & enter program parameters, be sure to exit the program mode before the 4 minute no data entry time out or the instrument will revert back to model number display.

# Display ghosting under external power.

The LCD display will “ghost” when the instrument is powered from an external 24Vdc power supply, this is corrected by including two ¼ watt resistors (1.2K & 3.3K) on the input power source as shown below.

# Scaleable pulse output counts on after flow has stopped.

The scaled pulse output has exceeded its output limit of 8Hz. Allow the memory buffer to catch up or increase the pulse value - number of litres etc. per pulse, (clause 4.5, p12.)

# Display shows random characters.

The instrument may have taken an electrical “hit”, press the processor reset button (p10).

Cut from manual for increased security

Your back up 4 digit PIN number is 0220

.

16 Declaration of Conformance

7. Declaration of Conformance

We, KOBOLD Messring GmbH, Hofheim-Ts, Germany, declare under our sole responsibility that the product:

Battery Totaliser Model: ZOD-Z1

to which this declaration relates is in conformity with the standards noted below:

Optional for Equipment intended for use in Potentially Explosive Atmospheres: ATEX Directive 94/9/EC

EN 50014: 1997 + Amds. 1 & 2 Intrinsically Safe Electronics (I.S.) – Optional

EN 50020: 2002 Intrinsically Safe Electronics (I.S.) – Optional

EN 60529, DIN VDE 0470-1 1992-11

I.P. Ingress Protection Classifications

EN 61326-1: 2006-10

Electrical equipment for control, instrumentation technology and laboratory use – EMC requirements (Industrial area)

EN 61010-1: 2002-08

Safety requirements for electrical equipment for measurement, control, and laboratory use –

2008/35/EC Waste Electrical & Electronic Equipment (WEEE)

Also the following EEC guidelines are fulfilled:

2004/108EC EMC Directive 2006/95 EC Low Voltage Directive

Hofheim, 18. Oct. 2010 H. Peters M. Wenzel General Manager Proxy

Holder

Index 17

8. ALPHABETICAL INDEX

Accumulative total 5

A

Battery condition indicator

B

Battery replacement

Battery jumper

DC power ( powering )

D

Decimal points

Displays

Engineering units

E

External DC powering

Flowmeter connections 8,

F

Input signal

I

Interface board

Installation 6 ~

Keypad functions

K

K-factor (scale factor) 12,

LCD display

L

Model number designation

M

Mounting options 6,

NPN pulse output 3,

N

Operation

4 5

10

3

12

4

12

3,

3

9

8,

9

10

11

5

14

4

2

7

O

Overview & Options

PIN number protection

P

PNP pulse output 3, Processor reset button

Programming 12,

Program detail record

Pulse output 3,

R

Resettable total

Resetting accumulative total 5, 12

Resetting the processor 5

Scale factor (K-factor)

S

Scaleable pulse output

Specifications

Terminal designation

T

Terminal layout 10

Troubleshooting 14,

Wiring connections 8 ~ 11

W

Wiring practice

11

12

11

13

14

11

12

10

15

10

5

4

5

3

Universal Mount Series

ZOD-Z3 FLOW RATE TOTALISER

I N S T R U C T I O N M A N U A L

Non I.S. battery

KOBOLD P/No. 1312007

Suitable non I.S. batteries also available from :

R S Components

Stock No. 596-602

Press & hold Program key to show

instrument model & software version

Replacement Batteries:

KOBOLD supplied batteries :

Lithium Thionyl Chloride

-

non - rechargeable cell

Software version

16.12.04 V 3.2

27.04.07 V 3.3

PROG

I.S. battery

Kobold P/No. 1412028

Warning : KOBOLD

Intrinsically safe battery

assembly only is approved

for ZOD-Z3 mounted in a

hazardous area.

Farnell Components

Order code 206-532

3.6V x 2.4Ah AA

+

TABLE OF CONTENTS

1. INTRODUCTION

1.1 Model number designation 2

1.2 Specifications 3

1.3 Overview 4

1.4 LCD displays 4

2. OPERATION

2.1 Accumulative total display 5

2.2 Resettable total display 5

2.3 Rate display 5

2.4 Low frequency cut-off 5

2.5 Inhibit total function 5

2.6 Keypad function matrix 6

3. INSTALLATION

3.1 Mounting - wall / surface mount 6

- pipe mount 7

- panel mount 7

3.2 Flowmeter connections - unpowered sensors 8

- powered sensors 9

3.3 Wiring connections - external powering 10

- 4~20mA loop powering 10

- wiring requirements 10

- pulse outputs 11

- alarm outputs 11

- remote switches 18

4. PROGRAM PARAMETERS

4.1 PIN number program protection 12

4.2 Resetting accumulative total 12

4.3 Engineering units 12

4.4 K-factor (flow input scale factor) 12

4.5 Rate conversion factor 12

4.6 Rate dampening ( see response graph page 19 ) 12 & 19

4.7 Low frequency cut-off ( refer clause 2.4 page 5 ) 5

4.8 Pulse outputs ( scaleable or non-scaleable ) 12

4.9 Non linearity correction ( NLC) Linearisation 12

4.10 Presetting battery power levels 13

5. ADDITIONAL PROGRAM PARAMETERS

5.2 Flow alarms 13

5.4 Dual flow inputs 13 & 20

5.1 Analog output 13

5.3 Flow alarm deadband 13

6. PROGRAMMING

Program levels 8~13 15

6.2 Program levels 14~24 16

6.3 Program detail record 17

6.1 Program levels 1~7 14

7. TERMINAL LAYOUT, SELECTION LINKS & REMOTE SWITCHES

8. DECLARATION OF CONFORMANCE 21

9. ALPHABETICAL INDEX

18

22

Introduction 2

y

1.1 Model number designation

Electrical connection/

Model Housing Type protection

KS = universal mount

ZODZ3…

bezel boot

¹⁾order only when retrofitting a pulse meter ²⁾only possible with ZOD-Z3PP...

³⁾

only possible with ZOD-Z3K... Options "R " and "E " cannot be com bined

(standard)

KM¹⁾ = integral mount

PP = panel mount

(IP20)

Part No.

ACCESSORIES FOR ABOVE SERIES

Cable gland Supply Voltage Options Mechanical

1 = 3 x cable entry

M20

2 = 3 x cable entry 1/2" NPT

0²⁾ = screw terminal

F3 = 8…24 VDC,

Batter

F1²⁾ = 110 VAC, 8…24 VDC F0²⁾ = 220 VAC, 8…24 VDC

0 = without 0 = without

R³⁾ = 2 x Relay

(for ZOD-Z3K)

S²⁾ =

E³⁾ = EExia IIB T4

silicone

ERS-ZOD-1522001 stainless steel wall mount kit

ERS-ZOD-1522002 stainless steel 2" pipe mount kit

ERS-ZOD-1522011 DRT series cooling fin kit for flowmeters with integral instruments

ERS-ZOD-1522005 DOR & Turbine stem adaptor - metric ( M16 to M20 )

ERS-ZOD-1522006 DOR & Turbine stem adaptor - USA ( M16 to 1/2" NPT )

ERS-ZOD-1323006 DOR-42 stem ( 100mm effective height, threaded M16 male )

ERS-ZOD1323011

ERS-ZOD-1322071 3/4" BSPF fixed stem for Turbine flowmeters ( 3/4" BSPF to M16 )

ERS-ZOD-

132822101

ERS-ZOD-1334001 DC switch mode DIN mount power supply - 100~240Vac input

ERS-ZOD-1412063 Relay contol output board with two SPCO relays

DOR-52 stem ( 350mm effective height, threaded M16 male )

1" NPTF universal swivel stem for Turbine flowmeters ( 3/4" BSPF to M16 )

3 Introduction

1.2 Specifications

Display : 8 digit alpha numeric LCD characters 9mm ( 0.35 ”) high with second line sub script text,

8 digits totalising, 5 digits rate. Programmable 0~3 decimal places for all displays.

Signal Input : Universal pulse/frequency input compatible with Reed switch, Hall effect, Namur proximity

detectors, Pulse wire, voltage, current & Coil (15mV P-P min). Max. input frequency 10Khz.

Minimum input frequency for rate display is 0.1hz with low frequency cut off feature enabled,

0.3hz when disabled & 0.7hz if the non-linearity feature is enabled. Totals have no minimum.

Battery power : Battery life expectancy can be up to 5~10 years when programmed with the unique

“Ultra Power Save” sleep cycle. Battery life reduces when connected with a coil input from turbine flowmeters. Rate display defaults to total display 4 minutes after pressing the rate key in order to conserve battery power.

(reverse polarity protected)

External power : Regulated 8~24Vdc x 150mA or 4~20mA loop powered.

Memory : All programmed & accumulated data is stored permanently in non-volatile memory.

Pulse output : NPN-PNP transistor, scaleable (50hz max.) or non-scaleable ( 5000hz max.), 1A maximum

drive capability.

Analog output : Two wire loop powered, 12~28Vdc into 100~900Ω loop load, accuracy +/-0.25% FS, key

entry programming of Zero & Span.

Alarm outputs: Two NPN-PNP selectable FET (transistors) programmable low & high flow alarm with

adjustable deadband (reset differential). Maximum drive 100mA resistive load. 24Vdc max.

Physical : A)

IP66 / 67 high impact glass reinforced Polyamide enclosure.

B) 3 x M20 or ½” NPT female conduit entries. C) 125mm diameter (5”) x 61mm deep (2.5”) x 400g (0.9lb). D) Temperature range from -20ºC to +80ºC ( -4ºF to +176ºF).

Configuring : PIN protected data entry with scrolling English text prompts.

K-factor range : Eg. Pulses/litre, gallon, lb etc. Programmable range is 0.001~ 9999999.999 with a floating

decimal point during K-factor entry.

Engineering units : Selectable Ltr, gal, m3, kgs, lbs (total). /sec,min,hr or day (rate).

Rate conversion : Enables the rate to be displayed in different engineering units to that of the totals

eg: totals in barrels (oil) & rate in US gallons.

Battery modes : Ultra power save, standby or continuous display selectable.

Dual Input option :Programmable for computations of A+B, A-B, or A÷B (ratio).

Introduction 4

1.3 Overview

The ZOD-Z3 is specifically designed for computing, displaying and transmitting totals and flowrate from flowmeters with pulse or frequency outputs.

The instrument will display Flow Rate, Resettable Total and an Accumulated Total in engineering units as programmed by the user. Simple flow chart programming with scrolling English prompts guide you through the programming routine greatly reducing the need to refer to the instruction manual. All user program data is retained if the battery is removed.

Environments The ZOD-Z3 is weatherproof to IP66/67 (Nema 4X) standards, UV resistant glass reinforced Polyamide with stainless screws & FKM O-ring seals.The instrument suits harsh indoor and outdoor environments & conforms to EMC directive 89/336/EEC Electro Magnetic Compatibility.

Features 10 point Linearisation, PIN Protection, NPN/PNP selectable autoranging pulse outputs (scaled or un-scaled), Low frequency cut-off, Battery conservation mode, 4~20mA output, High / Low flow alarms with adjustable deadbands, Dual inputs. Optional I.S. certification to ATEX directive, for conforming standards refer to I.S. supplement.

Conforming standards include:

EN 61326 ( immunity in industrial locations )

EN 62326 ( emissions in industrial locations ) EN 60529 ( degrees of protection [ IP ] )

Installation Specifically engineered to be directly mounted on a variety of flowmeters, wall or surface mounted, pipe or panel mounted. Various mounting kits are available. The instrument can be self powered or may be powered by an external dc supply or two wire loop powered.

1.4 LCD displays

RUN ACCUM. TOTAL STOP BAT LOW HIGH RATE

Ltr gal m3 lbs kgs

Ltr

Full LCD display test feature illuminates all display segments and script text displays for 5 seconds when entering the program mode.

Rate display has flashing SEC, MIN, HR or DAY followed by up to 5 digits of rate programmable for up to 3 “floating”

RATE

decimal places.

TOTAL

ACCUM. TOTAL

lbs

gal

The 8 digit Total display is push button or remote resettable and can be programmed for up to 3 decimal places.

The 8 digit Accumulative Total display can be programmed for up to 3 decimal places. Reset is only possible when in the program mode which can be PIN protected for security.

5 Operation

2. OPERATION

2.1 Accumulative Total

Accumulative total can be reset at L2 in the program mode. The accumulative total can be displayed momentarily or continuously through use of the front panel ACCUM TOTAL key.

Momentary display

: Accumulative total is displayed only whilst the key is held pressed.

Latching display

: To have the accum. total display latch when key is pressed simply press & hold the ACCUM TOTAL key for 10 seconds, the display will then latch each time the key is pressed. Holding the accumulative total key again for 10 seconds will revert this key function back to a momentary action.

2.2 Resettable Total ( also see page 18 for remote reset feature )

The display toggles between Rate & Total when the RATE-TOTAL key is pressed.

Pressing the RESET key whilst displaying total will cause the total to reset to zero.

2.3 Rate display

When rate is displayed the leading three alpha characters on the left of the display “flash ” the time base for rate eg. rate /SEC

. rate /MIN. rate /HR. or rate /DAY. Decimal points float to provide good resolution & rangeability.

Ltr /

SEC

( litres / second )

RATE

Ltr

The minimum input frequency for rate display is 0.3hz reducing to 0.1hz If the low frequency cut-off is set to 0.1Hz (see below) & 0.7Hz with NLC enabled.

2.4 Low frequency cut-off

The low frequency cut-off is most commonly set to 0.0Hz (disabled) other than to:

1) To display rate for input frequencies below 0.3hz, for example setting the cut-off at 0.1Hz the rate will continue to display for input frequencies as low as 0.1Hz (one pulse every 10 seconds), such conditions often apply to flowmeters with low resolution pulse outputs (low frequency) or flowmeters with a high operational turndown (maximum to minimum flow rate).

2) Inhibit the integration & registration of “apparent flow” which at times may be encountered on mobile installations where the movement of the vehicle or dead heading a pulsating pump may cause spurious flow signals which are not attributed to actual flow.

3) Inhibit the integration & registration of flow at input frequencies below what is considered the minimum accurate flow rate of the primary flow element (flowmeter).

Caution: If the low frequency cut-off is set to any value other than 0.0Hz then the integration of rate and total will cease at frequencies on or below the set value (HERTZ).

2.5 Inhibit total (see wiring schematic page 18) With the remote “inhibit total” switch closed the ZOD-Z3 with display flow rate but at the same time will inhibit the resettable & accumulative totalising functions.

2.6 Keypad function matrix

Operation 6

KEY FUNCTION IN OPERATING MODE FUNCTION IN PROGRAM MODE

ACCUM

TOTAL

Displays Accumulative Total when pressed.

( refer clause 2.1 for options )

No function

RATE

TOTAL

RESET

PROGRAM

ENTER

Toggles between Rate & resettable

Total displays.

Resets the resettable total display to zero

when it is being displayed.

1) Pressing the Prog. & Rate/Total keys for 5

seconds enters you into the program mode

2) Displays model & software revision No.

No function

1) Each press steps you through each

.

2) Holding for 3 seconds fast tracks to the end

Selects the digit to be set, the selected digit

will be “flashing ” indicating that it can be

level of the program chart.

of the program from any program level.

Increments the selected digit each time

that it is pressed.

No function

incremented.

3. INSTALLATION

3.1 Remote Mounting

RATE TOTALIS ER

RUN ACCUM. TOTAL STOP BAT LOW HIGH

RESET

PROGRAM

ENTER

RATE

TOTAL

gal

ACCUM

TOTAL

Wall mount using optional

bracket set

Surface mount footprint

(use 4 screws supplied )

(ERS-ZO D-1522001)

96 mm ( 3.8 ” )

42.6 mm ( 1.67 ” )

18 mm ( 0.7 ” )

7 Installation

3.1 Remote Mounting

(continued)

RATE TOTALISER

gal

RUN ACCUM. TOTAL STOP BAT LOW HIGH

RESET

PROGRAM

ENTER

RATE

TOTAL

ACCUM

TOTAL

* Vertical pipe mount

* order Pipe mount kit P/No.

152202

screws and worm drive clamps.

comprising two brackets,

ERS-ZO D-

Panel mount

* Horizontal

pipe mount

Conduit entries have an integral

moulded seal, to remove break

seal out using suitable lever

( eg. screwdriver or rod )

Cut a 106.5mm (4.2 ”)

diameter hole in panel

Installation 8

t

w

3.2 Flowmeter connections - unpowered sensors

( for I.S. installations refer to I.S. supplement )

O N

Flow input A & B switch functions

3

Flow

2

Input B

1 3

Flow

2

Input A

1

Terminals 1, 2 & 5 replicate terminals 3, 4 & 5 for dual flow inputs

Switch 1 : ON engages 0.01µf capacitor to suppress reed switch bounce

Switch 2 : ON engages 1 meg Ω pull up resister

Switch 3 : ON engages 820Ω pull down resister

1. Reed switch ( 200hz max.)

DIP switch 1 & 2 are on

1

2

Ground screen at -0V (5)

3

4

-0V (ground)

5

+8~24Vdc in

6

Pulse output

7

O N

3

Flow

2

Input B

1

3

Flow

2

Input A

1

High flow alarm

Low flow alarm

+4~20mA outpu

-4~20mA output

not used

-0V (ground)

2. Voltage Pulse ( & pulse wires )

3

1.1 ~ 30 Vdc

N

+

-

S

All DIP swithes off

Ground screen at -0V (5)

1

O N

2

3

O N

4

-0V (ground)

5

+8~24Vdc in

6

Pulse output

7

Flow

2

Input B

1 3

Flow

2

Input A

1

High flow alarm

Low flow alarm

+4~20mA outpu

-4~20mA output

not used

-0V (ground)

3. Coil ( Turbine & paddle style flowmeters – minimum 15mV p-p )

All DIP switches off (position switch 1

ON

if unit is effected by line noise)

use twisted pairs

1

2

3

4

-0V (ground)

5

+8~24Vdc in

6

Pulse output

7

O

N

O

N

3

Flo

2

Input B

1 3

Flow

2

Input A

1

High flow alarm

Low flow alarm

+4~20mA outpu

-4~20mA outpu

not used

-0V (ground)

14

13

12

11

10

9

8

14

13

12

11

10

9

8

14

13

12

11

10

9

8

9 Installation

_

t

_

t

_

3.2 Flowmeter connections - powered sensors

( for I.S. installations refer to I.S. supplement )

4. Hall effect ( 5~24Vdc open collector )

Hall effect

+ Signal out

- 0V ground

Vdc supply

Ground screen

at terminal 5

+

Reg. Vdc

DIP SW2 (pull up) is on

3

1

O

2

N

2

3

4

-0V (ground)

5

+8~24Vdc in

6

Pulse output

7

O N

1 3

2 1

5. Namur ( inductive proximity switch )

NOTE : Limit supply to 8.5Vdc

through an approved barrier for

intrinsically safe NAMUR proximities

NAMUR

Inductive Proximity

-

+

Ground screen

at terminal 5

+

Reg. Vdc

DIP SW3 (pull down) is on

3

1

O

2

N

2

3

4

-0V (ground)

5

+8~24Vdc in

6

Pulse output

7

O

N

1 3

2 1

6. Current modulated pulse ( 4mA to 20mA pulse amplitude )

Resistor across terminals 3 & 5

Coil with pre-amp

current modulated

NOTE : Position a 100Ω, ¼W

Ground screen

-

B A

at terminal 5

+

Reg.Vdc

DIP switches off

3

1

O

2

N

2

3

4

-0V (ground)

5

+8~24Vdc in

6

Pulse output

7

O

N

1 3

2 1

Flow

Input B

Flow

Input A

Flow

Input B

Flow

Input A

Flow

Input B

Flow

Input A

High flow alarm

Low flow alarm

+4~20mA outpu

-4~20mA output

not used

-0V (ground)

High flow alarm

Low flow alarm

+4~20mA outpu

-4~20mA output

not used

-0V (ground)

High flow alarm

Low flow alarm

+4~20mA output

-4~20mA output

not used

-0V (ground)

14

13

12

11

10

9

8

14

13

12

11

10

9

8

14

13

12

11

10

9

8

Installation 10

_

t

_

+

t

w

_

+

t

3.3 Wiring connections

( for I.S. installations refer to I.S. supplement )

External DC powering

8~24Vdc

regulated supply

+

– required for powered flow sensors, flow alarms or pulse outputs & dual flow inputs.

1

2

3

4

-0V (ground)

5

+8~24Vdc in

6

Pulse output

7

Flow

Input B

Flow

Input A

High flow alarm

Low flow alarm

+4~20mA outpu

-4~20mA outpu

not used

-0V (ground)

14

13

12

11

10

9

8

CAUTION :

Avoid using low cost

digital switch mode

power packs

Powering via 4~20mA loop

( Negative referenced )

Hall

effect

Shows powering of a Hall Effect

device using the loop power

+ Signal out

- Negative

Vdc supply

Optional wiring

source if required.

1

2

3

4

-0V (ground)

5

+8~24Vdc in

6

Pulse output

7

O N

O

N

3

Flo

2

Input B

1 3

Flow

2

Input A

1

High flow alarm

Low flow alarm

+4~20mA outpu

-4~20mA outpu

not used

-0V (ground)

14

13

12

11

10

9

8

regulated 12~28 Vdc

+

Load

Loop load specification : R = (V –10) / 0.02

where : V = loop voltage, R = max. load Ω

Powering via 4~20mA loop

( Positive referenced )

Optional wiring

When wired in this manner the one loop power supply (limited to 24Vdc) may be used to also power active flow sensors, scaled pulse & alarm outputs at terminals 7, 13 & 14 & / or multiple RT’s if required.

1

2

3

4

-0V (ground)

5

+8~24Vdc in

6

Pulse output

7

Flow

Input B

Flow

Input A

High flow alarm

Low flow alarm

+4~20mA outpu

-4~20mA outpu

not used

-0V (ground)

14

13

12

11

10

9

8

+

Load

regulated 12~28V

Wiring requirements : Use multi-core screened twisted pair instrument cable ( 0.25 – 0.5mm

flowmeter or receiving instrument. The screen needs to be earthed to the signal ground of the receiving instrument only to protect the transmitted signal from mutual inductive interference.

Instrument cabling should not be run in a common conduit or parallel with power and high inductive load carrying cables, power surges & power line frequencies may induce erroneous noise transients onto the signal. Run instrument cables in a separate conduit or with other instrument cables.

2

) for electrical connection between the ZOD-Z3 and any remote

11 Installation

(

)

0

(

)

Pulse & Alarm Outputs

Current Sinking outputs ( NPN )

Current sinking derives its name from the fact that it “sinks current from a load”. When activated the current flows from the load into the appropriate output (7,13 & 14).

Driving a logic input The output voltage pulse is typically the internal voltage of the load. The load would normally have an internal pull up resistor on its input as shown.

Driving a coil - - - - - - - The NPN style of output is to be used when diving a coil. The coil load is obtained by dividing the coil voltage by coil impediance ( Ω ), is expressed in amps & is not to exceed 0.1A. The coil voltage is connected across & must match the ZOD-Z3 supply voltage & the output (7,13 & 14).

0

13

0

14

PNP

0

NPN

0

Set jumper(s)

to NPN

+

logic input

load

14

13

12

11

10

OR

coil

_

9

8

- +

SPO scaled pulse

REP repeater pulse

7A

1

2

3

4

-0V (ground)

5

+8~24Vdc in

6

Pulse output

7

High flow alarm

Low flow alarm

NPN

-0V (ground)

7B

0 0 0

NPN

PNP

Set jumper

to NPN

Current Sourcing outputs ( PNP )

Current sourcing gets its name from the fact that it “sources current to a load”. When activated the current flows from the output (7,13 & 14) into the load. When wired as below the output voltage pulse is the supply voltage of the load. The load would normally have an internal pull down resistor on its input as shown.

7A

SPO scaled pulse

REP repeater pulse

13

0

0 0

14

PNP

0

NPN

Set jumper(s)

to PNP

- +

1

2

3

4

-0V (ground)

5

+8~24Vdc in

6

Pulse output

7

7B

0 0 0

PNP

NPN

High flow alarm

Low flow alarm

PNP

14

13

12

11

_

10

9

-0V (ground)

Set jumper

to PNP

8

Do not tie 0 volts of the

logic input to 0 volts of

the RT when wired in

PNP configuration

+

logic input

load

Programming 12

4. PROGRAM PARAMETERS

Note: The ZOD-Z3 defaults out of the program mode if no programming entries are made after 4 minutes.

4.1 PIN No. Program Protection

Any user defined PIN number other than 0000 will engage the program protection feature, failure to input the correct PIN number will deny the ability to change any of the program parameters but will allow the user to step through and view the existing program parameters.

Only one PIN number may be set but this can be changed at any time after gaining access through PIN entry. A second back up PIN number is installed at the factory should the programmed PIN be lost or forgotten. ( refer bottom of page 17 for the back up PIN No. )

4.2 Resetting Accumulated Total

Resetting the accumulated total can only be done at level 2 (L2) in the program mode.

4.3 Engineering Units ( refer clause 1.4 )

Select from available Engineering units to right of the display. For other engineering units set display to show no engineering units & program a suitable K-factor.

4.4 K-factor (scale factor)

Enter K-factor starting with the most significant number, up to 7 whole numbers & 3 decimal numbers can be entered. Trailing decimal numbers move into view as digits to the right are progressively selected, any significant digits which may move from view remain functional.

4.5 Rate conversion factor

A rate conversion feature is available & is explained at level 6 in the program chart (page 14). When enabled the analog output under rate conversion needs to be programmed in relation to the “TOTAL” engineering units.

4.6 Rate dampening

Dampening is available to smooth out fluctuating flow input signals in order to provide a stable rate analog

response graph on page 19 ).

4.7 Low frequency cut-off This feature is explained in clause 2.4 ( page 5 ).

4.8 Pulse Outputs ( for this feature the ZOD-Z3 must be externally powered as per page 10 ) The pulse output

is link selectable as a scaleable pulse or non-scaled repeater pulse & NPN (current sinking) or PNP (current sourcing) style pulse capable of switching up to 1 amp. Pulse scaling, when selected, is set as the number of litres

/ gallons etc. per output pulse Eg. 0.1 litres/pulse, 10 litres/pulse, 100 gallons/pulse. Range is 0.1 - 9999.9 Eng.unit/pulse. The totalising display visually slows to two updates/sec. if the scaled pulse output is selected. The pulse width (pulse duration 1:1) automatically adjusts to the output frequency defaulting to a maximum pulse width of 300 milliseconds at frequencies below 1.66hz. To calculate pulse width at higher frequencies use: 1000 ÷ (hz x 2) = pulse width in milliseconds.

4.9 Non Linearity Correction ( NLC ) - Linearisation Linearisation enables the instrument to correct for known inaccuracies in a flowmeter thereby improving the overall accuracy and in many cases increasing the effective flow range (turndown) of the flowmeter. Refer to program level L12, page 15 for setting NLC points. NLC can be used without external power however, battery life is reduced according to usage.

output. Most input signal are reasonably stable and need only a low setting value of 40 to 70 ( see

display &

13 Programming

4.10 Presetting battery power levels

When the instrument is operated under battery power only a special “Power Mode” program option will appear at level 13 within the programming routine. A choice of three battery power modes enable maximisation of the battery life according to operational requirements:

Ultra Power Save:

Typically selected if reading the register infrequently. The display scrolls a Prompt “PRESS ANY KEY”, when a key is pressed display wakes up for 4 minutes then returns to sleep mode* greatly extending the battery life.

Standby :

Display becomes active whenever a key is pressed or product flows through the flowmeter. Display returns to sleep mode* after 4 minutes of no flow input or key actions, prompt then returns to “PRESS ANY KEY”.

Continuous:

Display is active at all times resulting in reduced battery life. Display

reverts from Rate to Total after 4 minutes to reduce battery draw.

* In sleep mode

(and programming mode) flow is always continually totalised.

When the battery voltage is low a battery low indicator will appear on the display.

5. ADDITIONAL PROGRAM PARAMETERS

5.1 Analog Output ( loop powered )

The loop powered 4~20mA output can be spanned anywhere within the flow meter range. Testing the current loop is available during programming when 4mA will output at programming level L15 and 20mA will output at level L16 (page 16). ). Note. If using the Rate Conversion Factor (RCF) the span for 20mA must be set in relation to the total units, not the rate units.

5.2 Flow Alarms ( The ZOD-Z3 must be externally powered as per page 10 ) Two flow alarm FET (transistor) outputs may be programmed for Low & High flow alarms.

5.3 Flow Alarm Deadband Alarms are NPN/PNP link selectable. An adjustable deadband (reset differential) provides a trip buffer zone about the set point in order to overcome alarm “chattering” when the flow rate is fluctuating close to the alarm set point. Deadband is entered as % of each set point value (refer to page 16 for an example).

5.4 Dual Flow Inputs

When externally powered at terminals 5 & 6 the ZOD-Z3 accepts inputs from two sources (input A & input B), a separate scaling factor is entered for the second flow input, the instrument is then programmed for one of the dual input functions of A+B

A+B

Both inputs are added and displayed as one for Rate & Totals.

A-B

Input B is subtracted from input A & the difference is displayed for both Rate & Totals.

A÷B

Totalises A & B separately & Rate is a function of A÷B to give instantaneous ratio.

Note : - When using A & B inputs the functions of Scaled Pulse output, Alarm set points and the Analog output are relevant to resultant computation between A & B. - The analog output of function A÷B can be used as an input for ratio control.

(see also page 20 for complete description)

, A-B or A÷B (ratio).

Programming 14

r

6. PROGRAMMING

6.1 Program levels 1~7

V3.2 HOLD 3 2 1

TESTING DISPLAY 88888888

PROGRAM MODE ENTERED

press Prog. key

to step through

program levels

PROG

if PIN protected

ENTER PIN

PIN * * * *

L1 CHANGE PIN No. Y / N

NU PIN Y - N

YES

PIN * * * *

NO

L2 RESET ACCUM TOTAL Y / N

RESET Y - N

L3 SET ENGINEERING UNITS

ENG UNIT Ltr gal m3 Ibs kgs (none)

L4 ENTER NUMBER PULSES PER

Ltr m3 kg gal Ib (unit of measure)

0000000.001 ~ 9999999.999

L5 SET DECIMAL POINTS

DPt TOTAL 0 0.0 0.00 0.000 DPt ACCUM TOTAL 0 0.0 0.00 0.000 DPt RATE 0 0.0 0.00 0.000

L6 RATE CONVERSION Y / N

RATECON Y - N

NO

L7 SET TIME BASE FOR RATE

Ltr gal etc / SEC MIN HR or DAY

Saves & exits program

NO

YES

PROG

hold Program & Rate

keys for 5 secs to

enter the program

K-factor (scale factor) is the number of

YES

END

- N

Y

pulses per unit volume or unit mass

eg: 20.465 pulses / litre, gallon, kg etc.

WARNING on rate conversion factor (RCF)

This feature need only be programmed when the total & rate engineering units are to be different. eg: m3

The conversion factor is the number needed to convert to the required rate unit, some examples are:

Total unit Rate unit Conversion facto

Cubic metres

US Barrels

Imp. gallons

PIN No. is entered

INVALID PIN VIEW

EXISTING PROGRAM

R 0000.001 ~ 9999.999

RATE

if incorrect

DETAILS ONLY

for total and litres for rate

Litres /

USgal /

Litres /

continued

program return

1000.000

42.000

4.546

15 Programming

6.1 Program levels 8 ~ 13

L8 SET RATE DAMPENING

DAMP 00 ~ 99 RATE

L9 SET LOW FREQUENCY CUT-OFF

HERTZ 0.0 ~ 9.9

L10 OUTPUT PULSE REQUIRED Y / N

L11 ENTER No. OF gal - litres etc

PER OUTPUT PULSE

PULSE Y - N

YES

OP XXXX . X

NO

Low frequency cut-off

The low frequency cut-off is generally set to

0.0Hz (disabled) for most applications other

than those described at clause 2.4 on page 5

L12 NON LINEAR CORRECTION

0F 0000.0 (set output freq. at point 0)

000000.000 ( set K-factor at point 0 )

1F 0000.0 (set output freq. at point 1)

000000.000 ( set K-factor at point 1 )

9F 0000.0 (set output freq. at point 9)

000000.000 ( set K-factor at point 9 )

NLC Y - N

YES

10 points from 0F up to 9F

NO

Non-linear correction (NLC)

( overrides K-factor set at L4 )

1) Any number up to 10 frequency points of nonlinearity can be programmed with point 0F being

the pulse output frequency at the lowest flow rate.

2) If any frequency point is set to zero Hz then all remaining NLC points up to point 9F will

automatically assume the last entered NLC

K-factor and the program will advance to the

next level. This feature simplifies programming

when not all points of correction are used.

3) Linear interpolation is used between frequency

points, except above the last entered frequency

where the last entered NLC K-factor is applied.

L13 CHANGE POWER MODE Y / N

CHANGE Y - N (applicable under battery only)

YES

NO

1) ULTRA POWER SAVE

2) STANDBY

3) CONTINUOUS

( refer clause 4.10 )

continued

program return

6.2 Program levels 14~24

L14 ANALOG OUTPUT REQUIRED Y / N

4 ~ 20mA Y - N

YES

NO

L15 ENTER FLOW RATE AT 4mA

XXXXX.XXX LOW

PROG

TIP: holding the prog. key for 3 sec’s

fast tracks to the END of the program

L16 ENTER FLOW RATE AT 20mA

XXXXX.XXX HIGH

L17 ALARM OUTPUTS REQUIRED Y / N

ALARMS Y - N

Alarm outputs

YES

L18 ENTER FLOW RATE LOW ALARM

XXXXX.XXX LOW

L19 ENTER LOW ALARM DEADBAND %

BAND XX % LOW

L20 ENTER FLOW RATE HIGH ALARM

XXXXX.XXX HIGH

L21 ENTER HIGH ALARM DEADBAND %

BAND XX % HIGH

NO

1) Low flow alarm occurs when the flow falls below the set point, High flow alarm occurs when the flow goes above the set point.

2) Deadband (Reset Differential), provides a buffer zone about the alarm set point in order to avoid alarm output “chattering ” on & off when the flow rate is hovering about an alarm set point.

The % deadband applies above the Low point and below the High is set as a percentage of each set point.

Eg: 5% deadband at a low alarm set point of 100 L/hr will cause a low alarm when the flow drops to 100 L/hr, the alarm will not switch off until the flow increases above 105 L/hr.

L22 DUAL INPUTS REQUIRED Y / N

DUAL Y - N

YES

L23 ENTER NUMBER PULSES PER

Ltr m3 kg gal lb (unit) FOR INPUT B

00000.001 - 9999999.9

NO

L24 SET DUAL INPUT FUNCTION

A + B A - B A ÷B

program return

Programming 16

set

set point. Deadband

17 Programming

g

6.4 Program detail record

User selected PIN No.

L1

Pencil your program details here

Engineering units

L3

K-factor (scale factor)

L4

Decimal for reset Total

L5

Decimal for Accum. total

Decimal for Rate

K =

0 0.0 0.00 0.000

L6

L7

L8

L10

Rate dampenin

Units / Sec Min Hr Day

Hertz = L9 Low frequency cut-off

RCF= yes noRate conversion factor

L11 pulse value = yes noPulse output

L12 Non linear correction

- frequency 0

- frequency 1

yes no

0F Hz K-factor =

1F Hz K-factor =

- frequency 2

- frequency 3

- frequency 4

- frequency 5

- frequency 6

2F Hz K-factor =

3F Hz K-factor =

4F Hz K-factor =

5F Hz K-factor =

6F Hz K-factor =

L13

L14

L15

L16

- frequency 7

- frequency 8

- frequency 9

Power mode

Analog output

- zero set point

- span set point

7F Hz K-factor =

8F Hz K-factor =

9F Hz K-factor =

Ultra save Standby Continuous

yes no

4mA @

20mA @

L17

L18

L19

L20

L21

Alarm outputs

- low set point

- low deadband

- high set point

- high deadband

yes no

@

percentage

%

@

percentage

%

L22

L23

L24

Dual flow inputs

- K-factor for B input

- dual input function

yes no

=

A+B A-B A÷B

Your back up 4 digit PIN number is 1820

Terminal designation 18

prog

y

7. TERMINAL DESIGNATION

Terminals 1, 2 & 5 replicate

terminals 3, 4 & 5 for dual

flow inputs

Terminal

1

2

3

4

5 -

6 +8~24Vdc in

7 Pulse output

Terminal layout - links & remote switch inputs

LINK 7A select SPO or REP pulse output

( see clause 4.8 )

SPO (scaled pulse)

REP (repeater pulse)

7A

Inhibit total

switch

( clause 2.5 )

LINK 7B

Select NPN or PNP style pulse output

7B

NPN

1

2

3

4

5

6

7

0 0 0

PNP

ON

1 2 3

SWITCH 3 : ON engages 820Ω pull down resister

SWITCH

SWITCH 1 : ON engages 0.01µf capacitor to

suppress reed switch bounce

2 : ON engages 1 meg Ω pull up resister

Flow

input B

Flow

input A

0V (ground)

+4~20mA output 12

-4~20mA output 11

B

Flow input

conditioning DIP

switches

A

batter

High flow alarm 14

Low flow alarm 13

not used 10

-0V (ground) 8

SER.

13

0 0 0

REMOTE KEYS

Terminal

not used 9

LINKS 13 & 14

14

0 0 0

PNP NPN

select NPN or PNP style alarm outputs

14

13

12

11

10

9

8

use momentary action switches

reset

ram

accum. total

rate / total

19 Rate dampening

50

45

40

35

30

25

20

15

RESPO NSE TIME (seconds)

10

5

0

5 10152025303540 455055606570 758085 9095

ZOD-Z3 DAMPENING VALUE

RT DAMPENING VALUE

Response curve to 90% of actual

Response curve

to 99% of actual

flow rate

Rate dampening value verses time to reach new reading ( for an instantaneous change in actual flow rate ).

Dual flow inputs 20

Dual flow inputs

When externally powered at terminals 5 & 6 the ZOD-Z3 provides a dual flow input feature which can be configured for one of three available functions of A+B

, A-B or A÷B (ratio).

The dual flow inputs are referred to as “INPUT A” at terminals 3 & 4 and ”INPUT B” at terminals 1 & 2.

Function A+B

Both inputs are added together and displayed as one for Rate, Resettable & Accumulative Totals.

Displays Rate : The total of A+B flow rates displayed as one rate. Reset Total : The total of A+B totals displayed as one total. Accum. Total : The total of A+B accum.totals displayed as one total.

Outputs Alarms : Alarms are taken relative to the displayed rate. Analog Output : 4~20mA output is proportional to the displayed rate.

Scaled Pulse : Scaled pulse value is relative to the totalised values.

Function A-B

Input B is subtracted from input A, the resultant is displayed as one for Rate, Resettable & Accumulative Totals.

Displays Rate : The difference of A-B flow rates displayed as one rate Reset Total : The difference of A-B totals displayed as one total. Accum. Total : The difference of A-B accum.tot. displayed as one total.

Outputs Alarms : Alarms are taken relative to the displayed rate. Analog Output : 4~20mA output is proportional to the displayed rate.

Scaled Pulse : Scaled pulse value is relative to the totalised values.

Function A÷B

Input A is divided by input B, the resultant is displayed as an instantaneous Ratio, Resettable & Accumulative Totals are independently displayed for both A & B inputs.

Displays Rate : The resultant Ratio between A÷B flow rates displayed as an instantaneous

Ratio. Reset Total input A : The total of input A. Reset Total input B : The total of input B. Accum. Total input A : The Accumulative total of input A. Accum. Total input B : The Accumulative total of input B.

Outputs * Alarms : Alarms are taken relative to the displayed ratio. * Analog Output : 4~20mA output is proportional to the displayed ratio.

Scaled Pulse : The scaled pulse output relates to input A .

• Note: The alarm and analog outputs for the A÷B function are set in the initial stages of programming in

relation to rate units eg: setting the analog output range to 4mA = 00.000 litres/min and 20mA = 10.000 litres/min, the analog output will be proportional to the ratio rate display of 0.000~10.000 ( eg. 4mA @

0.000 and 20mA @ 10.000 ). The same set up analogy applies to the alarm settings.

Declaration of Conformance 21

7. Declaration of Conformance

We, KOBOLD Messring GmbH, Hofheim-Ts, Germany, declare under our sole responsibility that the product:

Flow Rate Totaliser Model: ZOD-Z3K

to which this declaration relates is in conformity with the standards noted below:

Optional for Equipment intended for use in Potentially Explosive Atmospheres: ATEX Directive 94/9/EC

EN 50014: 1997 + Amds. 1 & 2 Intrinsically Safe Electronics (I.S.) – Optional

EN 50020: 2002 Intrinsically Safe Electronics (I.S.) – Optional

EN 60529, DIN VDE 0470-1 1992-11

I.P. Ingress Protection Classifications

EN 61326-1: 2006-10

Electrical equipment for control, instrumentation technology and laboratory use – EMC requirements (Industrial area)

EN 61010-1: 2002-08

Safety requirements for electrical equipment for measurement, control, and laboratory use –

2008/35/EC Waste Electrical & Electronic Equipment (WEEE)

Also the following EEC guidelines are fulfilled:

2004/108EC EMC Directive 2006/95 EC Low Voltage Directive

Hofheim, 18. Oct. 2010 H. Peters M. Wenzel General Manager Proxy

Holder

8. ALPHABETICAL INDEX

Accumulative total

A

Alarm deadband

Alarm outputs 11,

Analog output

Battery power levels

B

DC power

D

Decimal point

Displays

Dual flow inputs 13,

Engineering units

E

External DC powering

Flowmeter connections

F

Flow rate 5,

Inhibit totals 5,

I

Installation 6 ~

Input signals

Keypad functions

K

K-factor (scale factor) 12,

LCD displays

L

Loop powering

Link selectors (for outputs)

Low frequency cut-off

13

4,

8,

13

10

14

20

12

10

12

18

11

14

10

18

22 Index

12,

12

18

12

13

~16

17

12

14

19

14

18

12

18

10

11

5

4

5

3

5

4

9

6

4

5

Non linear correction

N

Operation

O

Output selector links

Overview

PIN number protection

P

Presetting battery power levels

Programming 14

Program detail record

Pulse outputs 11,

Rate conversion factor 12,

R

Rate dampening

Rate display

Rate time base 4,

Remote switch inputs

Resettable total

Resetting accumulative total

Scale factor (K-factor)

S

Scaled pulse output 11,

Specifications

Terminal designation

T

Terminal layout 18

Wiring of analog output

W

Wiring of flowmeter inputs 8, 9 Wiring of pulse outputs

Model number designation

M

Mounting options 6,

2

7

Wiring to external supplies

Wiring requirements

10

Manufactured and sold by:

Kobold Messring GmbH

Nordring 22-24

D-65719 Hofheim

Tel.: +49(0)6192-2990

Fax: +49(0)6192-23398

E-Mail: info.de@kobold.com

Internet: www.kobold.com

Version: K02/1010

22 Declaration of Conformance

9. Declaration of Conformance

We, KOBOLD Messring GmbH, Hofheim-Ts, Germany, declare under our sole responsibility that the product:

Flow Rate Totaliser Model: ZOD-Z5

to which this declaration relates is in conformity with the standards noted below:

Optional for Equipment intended for use in Potentially Explosive Atmospheres: ATEX Directive 94/9/EC

EN 50014: 1997 + Amds. 1 & 2 Intrinsically Safe Electronics (I.S.) – Optional

EN 50020: 2002 Intrinsically Safe Electronics (I.S.) – Optional

EN 60529, DIN VDE 0470-1 1992-11

I.P. Ingress Protection Classifications

EN 61326-1: 2006-10

Electrical equipment for control, instrumentation technology and laboratory use – EMC requirements (Industrial area)

EN 61010-1: 2002-08

Safety requirements for electrical equipment for measurement, control, and laboratory use –

2008/35/EC Waste Electrical & Electronic Equipment (WEEE)

Also the following EEC guidelines are fulfilled:

2004/108EC EMC Directive 2006/95 EC Low Voltage Directive

Hofheim, 17. Sep. 2010 H. Peters M. Wenzel General Manager Proxy Holder

K01/1110

Universal Mount Series

Z5 FLOW RATE TOTALISER

with backlighting & flow alarms

I N S T R U C T I O N M A N U A L

2

R S Components

Stock No. 596-602

Press & hold Program key to show

Replacement Batteries:

battery

P/No. 1312007

Suitable batteries also available from :

Lithium Thionyl Chloride

-

non - rechargeable cell

Software issue

PROG

instrument software version

Farnell Components

Order code 206-532

3.6V x 2.4Ah AA

+

3

TABLE OF CONTENTS

1. INTRODUCTION

1.1 Order Details 4

1.2 Specifications 5

1.3 Overview 6

1.4 LCD displays 6

2. OPERATION

2.1 Accumulative total display 7

2.2 Resettable total display 7

2.3 Rate display 7

2.4 Keypad function matrix 7

3. INSTALLATION

3.1 Remote mounting - Surface mount footprint 8

- wall / surface mount 8

- panel mount 8

- pipe mount 9

- facia protector option 9

3.2 Flowmeter connections - unpowered sensors 10

- powered sensors 11

3.3 Wiring connections - external powering 12

- remote reset 12

- wiring requirements 12

- scaled pulse output 13

4. PROGRAM PARAMETERS

4.1 PIN number program protection 14

4.2 Resetting accumulative total 14

4.3 Engineering units 14

4.4 K-factor (flow input scale factor) 14

4.6 Rate response 14

4.7 Low frequency cut-off ( refer clause 2.4 page 5 ) 14

5. PROGRAMMING

5.1 Programming ladder chart 15

5.2 Program detail record 16

7. PANEL MOUNT DRILL TEMPLATE 18

8. Supplement 20

9. Declaration of Conformance 22

4 Introduction

1.1 Order Details

Model Housing Type Electrical connection/

ZOD-Z5...

*order only when retrofitting a pulse meter

KS = universal mount

(standard)

KM* = integral mount

Cable gland

2 = 3 x cable gland entry 1/2” NPT 3 = 3 x cable gland entry M16

Supply Voltage Options Mechanical

F3 = 8...24 VDC,

battery

0 = without R = 2xRelays

protection 0= without P = display

protection plate

Introduction 5

1.2 Specifications

Display : Large backlit 6 digit numeric display with LCD characters 17mm ( 0.67 ”) high, second line

of 8 digits x 7mm high totalising plus 5 digits of rate indication. Programmable 0~3 decimal places for all displays.

Signal Input : Universal pulse/frequency input compatible with Reed switch, Hall effect, Namur proximity detectors, voltage, current & Coil (15mV P-P min). Max. input frequency 5Khz.

Minimum input frequency for rate display is 0.1hz with low frequency cut off feature enabled, totals have no minimum input frequency when low frequency cut off is set to zero.

Battery power : The unit draws about 70ụA under battery, life expectancy is generally 3 years. Battery life

reduces when rate is more often displayed & there is no external power connected.. Rate display defaults to total display 1 minute after pressing the rate key in order to conserve battery power.

(reverse polarity protected)

Battery condition is continuously monitored internally, the instrument runs on 3.6Vdc, the battery icon illuminates when the battery output falls below 3.1Vdc, at this point the instrument will continue to operate for a short period but the battery should be change as soon as possible, batteries are readily available from all major electronic component suppliers (see page 2 for details).

External power : Regulated 8~24Vdc x 50mA minimum.

Memory : All programmed & accumulated data is stored permanently in non-volatile memory.

Pulse output : NPN transistor, scaleable, 5Khz max. 100mA maximum drive capability.

Physical : A) IP66 / 67 aluminum alloy with 0.3% magnesium (6% is maximum for mine sites).

B) 3 x M16 x 1.5 female conduit entries. C) 114mm (4.5”) wide x 96mm (3.8”) high x 62mm deep (2.5”) x 480g (1lb). D) Temperature range from -20ºC to +80ºC ( -4ºF to +176ºF).

Configuring : PIN protected data entry.

K-factor range : ( scale factor ) Eg. Pulses/litre, gallon, lb etc. Programmable range is 0.001~ 99,999.999 with a floating decimal point during K-factor entry.

Engineering units : Selectable Ltr, gal, m3, kgs, lbs (total). /sec, /min, /hr or /day (rate).

6 Introduction

r

A

Operation 7

1.3 Overview

The instrument will display Flow Rate, Resettable Total and an Accumulated Total in engineering units as programmed by the user. Simple flow chart programming prompts you through the programming set up greatly reducing the need to refer to the instruction manual. All user program data is retained if the battery is removed.

Environments The instrument is weatherproof to IP66/67 (Nema 4X) standards, constructed in ADC12 aluminum alloy with stainless screws & FKM O-ring seals.The instrument suits harsh indoor and outdoor environments & conforms to EMC directive 89/336/EEC Electro Magnetic Compatibility.

Features PIN Protection, NPN scaleable pulse output, Low frequency cut-off, display priority & large backlit digital display

(backlighting enabled under external DC power only).

Installation

Specifically engineered to be directly mounted on a variety of flowmeters, wall or surface mounted, pipe or panel mounted. Various mounting kits are available. The instrument can be self powered or may be powered by an external dc supply or two wire loop powered.

1.4 LCD displays

Full LCD display test feature illuminates all

ACCUM.

TOTAL

►

/min /hr

Ltr gal m3 lbs kgs

display segments and script text displays for 5 seconds when entering the program mode.

Resetable Total

This large 6 digit display can

be programmed for up to 3 decimal places.

ccumulative Total The 8 digit display can be programmed for up to 3 decimal places. Reset is only possible when in the program mode which can be PIN protected for security.

Ltr

Rate display

Rate is displayed with a flashing time base of either SEC, /min, /hr or dAy followed by up to 5 digits of rate, these are programmable for up to 3 “floating” decimal

/min

places.

Time bases of units /SEC & units /dAy are displayed to the left of the digital display whilst units /min & /hr are to the right of the rate digits as shown.

gal

Backlighting The LCD backlight feature will only work from an external dc power source in the range of 8~24Vdc.

2. OPERATION

2.1 Accumulative Total

Accumulative total can be reset in the program mode. The accumulative total is displayed by pressing the ACCUM TOTAL key.

2.2 Resettable Total

The resettable total display remains visible at all times & may be reset at any time by pressing the reset button for 1~2 seconds.

2.3 Rate display The second line display toggles between Rate & Accumulative Total as the appropriate keys are pressed. The instrument will default out of the rate mode after 1 minute when under battery power, this is to conserve the battery as the unit draws more current when it needs to calculate rate. Under external power the instrument will remain on Rate or Accumulative Total as they are selected.

When rate is displayed the leading three alpha characters on the left of the display “flash ” the time base for rate eg. rate /SEC resolution & rangeability.

The minimum input frequency for rate display is 0.25hz reducing to 0.1hz If the low frequency cut-off is set to

0.1Hz ( see clause 4.7 ).

2.4 Keypad function matrix

. rate /dAy. & rate /min. or rate /hr to the left of the rate digits. Decimal points float to provide good

Lt

Ltr / SEC

( litres / second )

KEY FUNCTION IN OPERATING MODE FUNCTION IN PROGRAM MODE

ACCUM TOTAL

PROGRAM

ENTER

RATE

Displays Accumulative T

when pressed.

No function

Resets the resettable total display to zero when pressed for 1~2 seconds.

1) Pressing the Prog. & Reset keys for 5

seconds enters you into the program mode

2) Displays model & software revision No.

Displays flow rate when pressed

otal

No function

Increments the sele

Resets the accumulative total

ess steps you through each

Each pr

.

Selects the digit t

will be “flashing ” indicating that it can be

level of the program.

cted digit each time

that it is pressed.

display to zero.

o be set, the selected digit

incremented.

8 Installation

A

/hr

A

r

/hr

3. INSTALLATION

3.1 Remote Mounting

Surface mount footprint

use 4 x M3 screws

Wall mount bracket

Optional, P/No. AWM )

Panel mount options

supplied

Cut a 71mm x 83mm

(2.8 x 3.3 ”) opening in panel.

Drill 4 holes to take

M4 screws on a

68.0 x 89.6mm pitch ( 2.68” x 3.53” )

See panel mount template page 18

6.5 x 19mm slots

RATE TOTALISER

ACCUM.

►

TOTAL

RATE

PROGRAM

ENTER

96 mm ( 3.8 ” )

Lt gal m3 lbs kgs

/min

CCUM

TOTAL

ce

Mount using 4 x M4 nuts

& washers, tap panel or use rear case as shown

3 x M16 conduit entries

@ 30mm pitch

42.6 mm ( 1.67 ” )

Installation 9

3.1 Remote Mounting

(continued)

* Pipe mount

* order Pipe mount kit P/No. APM

comprising two brackets,

screws and worm drive clamps.

CCUM.

TOTAL

RATE TOTALISER

►

RATE

PROGRAM

ENTER

/min

ACCUM TOTAL

Ltr gal m3 lbs kgs

ce

* Horizontal

pipe mount

Optional facia protector, 3mm clear

polycarbonate plate with access port

for keys. Order P/No. 1306061.

10 Installation

_

t

_

t

_

t

ppr

3.2 Flowmeter connections - unpowered sensors

DIP switch functions :

Flow Input

ON

Switch 3 : ON engages 820Ω pull down resister

3

Switch 2 : ON engages 1 meg Ω pull up resister

2

1

Switch 1 : ON engages 0.01µf capacitor to su

ess reed switch bounce

1. Reed switch

DIP switch 1 & 2 are on

Ground screen at -0V (5)

1

-0V (ground)

Remote reset

2

3

4

-0V (ground)

5

+8~24Vdc in

6

Pulse output

7

Flow

O

2

N

1

Input

High flow alarm

Low flow alarm

+4~20mA outpu

-4~20mA outpu

not used

-0V (ground)

2. Voltage Pulse

1.1 ~ 30 Vdc

1

All DIP swithes off

+

-

N

S

Ground screen at -0V (5)

-0V (ground)

Remote reset

2

3

4

-0V (ground)

5

+8~24Vdc in

6

Pulse output

7

Flow

O

2

N

1

Input

High flow alarm

Low flow alarm

+4~20mA outpu

-4~20mA outpu

not used

-0V (ground)

3. Coil ( Turbine & paddle style flowmeters – minimum 15mV p-p )

All DIP switches off (position switch 1

if unit is effected by line noise)

ON

use twisted pairs

1

-0V (ground)

Remote reset

2

3

4

-0V (ground)

5

+8~24Vdc in

6

Pulse output

7

Flow

O

2

N

1

Input

High flow alarm

Low flow alarm

+4~20mA outpu

-4~20mA outpu

not used

-0V (ground)

14

13

12

11

10

14

13

12

11

10

14

13

12

11

10

Installation 11

3.2 Flowmeter connections - powered sensors

4. Hall effect ( 5~24Vdc open collector )

Hall effect

+ Signal out

- 0V ground

Vdc supply

Ground screen

at terminal 5

+

Reg. Vdc

DIP SW2 (pull up) is on

1

-0V (ground)

Remote reset

2

3

4

-0V (ground)

5

+8~24Vdc in

6

Pulse output

7

Flow

O

2

Input

N

1

High flow alarm

Low flow alarm

+4~20mA outpu

-4~20mA outpu

not used

-0V (ground)

14

13

12

11

10

9

8

9

8

5. Namur ( inductive proximity switch )

intrinsically safe NAMUR proximities

NAMUR

Inductive Proximity

NOTE : Limit supply to 8.5Vdc through an approved barrier for

-

+

Ground screen

at terminal 5

+

Reg. Vdc

DIP SW3 (pull down) is on

-0V (ground)

1

Remote reset

2

3

4

-0V (ground)

5

+8~24Vdc in

6

Pulse output

7

Flow

O

2

N

1

Input

High flow alarm

Low flow alarm

+4~20mA outpu

-4~20mA output

not used

-0V (ground)

14

13

12

11

10

9

8

9

8

6. Current modulated pulse ( 4mA to 20mA pulse amplitude )

Coil with pre-amp

current modulated

9

8

NOTE : Position a 100Ω, ¼W

Resistor across terminals 3 & 5

Ground screen

-

B A

+

at terminal 5

+

Reg.Vdc

DIP switches off

-0V (ground)

1

Remote reset

2

3

4

-0V (ground)

5

+8~24Vdc in

6

Pulse output

7

Flow

O

2

Input

N

1

High flow alarm

Low flow alarm

+4~20mA outpu

-4~20mA output

not used

-0V (ground)

14

13

12

11

10

9

8

12 Installation

_

t

(

)

3.3 Wiring connections

External DC powering

– required for powered flow sensors, display backlighting or pulse outputs.

Note :

backlighting feature to turn on, if this is not desirable at all times then install a

CAUTION :

Avoid using low cost digital

switch mode power packs

8~24Vdc

regulated supply

+

Powering the instrument from an external DC source will cause the

power isolation switch in series with the DC power source as shown.

1

-0V (ground)

Remote reset

2

3

4

5

-0V (ground)

6

+8~24Vdc in

7

Pulse output

Flow

Input

High flow alarm

Low flow alarm

+4~20mA outpu

-4~20mA outpu

not used

-0V (ground)

14

13

12

11

10

9

8

Remote reset

Terminals 1 & 2 cater for the connection of a remote reset switch, this will reset the 6 digit resettable totaliser display but does not effect the 8 digit Accumulative totaliser. The remote switch needs to have a momentary contact action only.

Remote reset switch

Remote reset switch is to have a

momentary action – normally open.

-0V (ground)

1

Remote reset

2

3

4

-0V (ground)

5

+8~24Vdc in

6

Pulse output

7

Wiring requirements : Use multi-core screened twisted pair instrument cable ( 0.25 – 0.5mm2 ) for electrical connection between the RT and any remote flowmeter or receiving instrument. The screen needs to be earthed to the signal ground of the receiving instrument only to protect the transmitted signal from mutual inductive interference.

Instrument cabling should not be run in a common conduit or parallel with power and high inductive load carrying cables, power surges & power line frequencies may induce erroneous noise transients onto the signal. Run instrument cables in a separate conduit or with other instrument cables.

Installation 13

3.3 Wiring connections (continued)

Pulse & Alarm Output (for this feature the instrument must be externally powered as per page 12 )

The scaled pulse output is in the form of an NPN (current sinking) style pulse capable of switching up to 100mA. Current sinking derives its name from the fact that it “sinks current from a load”. When activated the current flows from the load into the appropriate output (terminals 7, 13 & 14).

Pulse scaling is set as the number of litres / gallons etc. per output pulse Eg. 0.1 litres/pulse, 10 litres/pulse, 100 gallons/pulse. Range is 0.1 - 9999.9 Eng.unit/pulse.

The pulse width (pulse duration) of the output pulse automatically mirrors the cyclic width of the incoming pulse, for example 5Hz input frequency would produce a scaled pulse output with a duration ≤200ms, for 100Hz input the output pulse duration would be ≤10ms.

- +

Driving a logic input The output voltage pulse is typically the internal voltage of the load. The load would normally have an internal pull up resistor on its input as shown.

Driving a coil - - - - - - - The coil load is obtained by dividing the coil voltage by coil impediance ( Ω ), is expressed in amps & is not to exceed 0.1A. The coil voltage is connected across & must match the RT supply voltage & the output (7,13 & 14).

1

2

3

4

-0V (ground)

5

+8~24Vdc

6

Pulse out

7

Low flow alarm

High flow alarm

10

11

12

13

14

8

9

logic

+

input

load

OR

coil

_

14 Programming

4. PROGRAM PARAMETERS

Note: The instrument defaults out of the program mode if no programming entries are made after 4 minutes.

4.1 PIN No. Program Protection

Any user defined PIN number other than 0000 will engage the program protection feature, failure to input the correct PIN number will deny the ability to change any of the program parameters but will allow the user to step through and view the existing program parameters.

Only one PIN number may be set but this can be changed at any time after gaining access through PIN entry. A second back up PIN number is installed at the factory should the programmed PIN be lost or forgotten. ( refer bottom of page 16 for the back up PIN No. )

4.2 Resetting Accumulated Total

Resetting the accumulated total can only be done in the program mode.

4.3 Engineering Units

Select from available Engineering units to right of the display (refer clause 1.4), for other engineering units set display to show no engineering units & program a suitable K-factor.

4.4 K-factor (scale factor)

Enter K-factor at S-Fact, up to 5 whole numbers & 3 decimal numbers can be entered using the arrowed keys.

4.6 Rate response

Adjustable response (rate dampening) is available to smooth out fluctuating flow input signals in order to provide a stable rate response number (ranged 001~999) represents the number of pulse intervals (duration between each pulse) that the processor averages and displays the rate as calculated.

As a general rule it would be best to apply a response number which is a multiple of the number of pulses a meter produces for each cycle of its primary measuring element, for example a rotating element may produce 4 pulses per revolution so 004, 008, 012 or 016 would be ideal response settings whereas a turbine meters with high resolution pulse outputs would require response settings like 050, 100, 200 or in some cases involving high frequency pulse outputs eg. 500hz, the response number would be set to say 999.

4.7 Low frequency cut-off The low frequency cut-off is most commonly set to 0.0Hz (disabled) other than to:

1) To display rate for input frequencies below 0.25hz, for example setting the cut-off at 0.1Hz the rate will continue to display for input frequencies as low as 0.1Hz (one pulse every 10 seconds), such conditions often apply to flowmeters with low frequency pulse outputs.

2) Inhibit the integration & registration of “apparent flow” which at times may be encountered on mobile installations where the movement of the vehicle or dead heading a pulsating pump may cause spurious flow signals which are not attributed to actual flow.

3) Inhibit the integration & registration of flow at input frequencies below what is considered the minimum accurate flow rate of the primary flow element (flowmeter).

Caution: If the low frequency cut-off is set to any value other than 0.0Hz then the integration of rate and total will cease at frequencies on or below the set frequency value.

display. Most input signal are reasonably stable and need only a low setting value of 001 to 004. The

Programming

4.8 Display priority The large digits at the top of the display can be programmed to show either flow rate or resettable total. When flow rate is selected at the top display the rate key can be used to cycle between rate, reset total & accumulate total, in this mode the instrument will default from rate to reset & accumulative totals after 1 minute, external power must be applied if required to display rate at top display continuously.

4.9.1 Flow Alarms ( The RT must be externally powered as per page 12 ) Two flow alarm FET (transistor) outputs may be programmed for Low & High flow alarms. An optional plug in alarm board is available having dual SPDT 5 amp electro-mechanical contacts.

4.9.2 Flow Alarm Deadband An adjustable deadband (reset differential) provides a trip buffer zone about the set point in order to overcome alarm “chattering” when the flow rate is fluctuating close to the alarm set point. Deadband is entered as % of each set point value (refer to page 17 for an example).

15

Programming 16

t

E

t

F

E

A

X

g

w

5.1

ISSUE 1.0

HoLd

5 4 3 2 1

RATE

PROGRAM

ENTER

ACCUM

TOTAL

press Prog. key

to step through

program levels

PROG

ProG

ccESSED

if PIN protected

****

Pin no.

RESET

hold Program & Reset keys for

5 secs to access program mode

****

NuPin

if incorrect

PIN No. is entered

ACCUM TOTAL►XXXXXXXX

Ltr gal m3 Ibs kgs (none)

rESEt

Enguni

Error

rEAdonLY

Read only

00000.001 ~ 99999.999

S -FAc

S-factor (K- factor) is the number of pulses / unit volume or unit mass eg: 20.465 pulses / litre, gallon, kg etc.

0 0.0 0.00 0.000

dEc to

0 0.0 0.00 0.000

dEc Accu

PEr SEC, /min, /hr, dAy.

rAtE

0 0.0 0.00 0.000

dEc rAt

001 ~ 999

rESPonS

Response to change in rate (see rate dampening 4.6)

0.0 ~ 50

cut oF

Low frequency cut-off is generally set to 0.0Hz (disabled) for most applications other than those described at clause 2.4 .

PuLSE

Out 0001.0

The scaleable pulse output is set as the number of litres,

gallons etc per output pulse, see clause 4.8.

totAL rAtE

toP diSP

Assign resettable total or rate to the large LCD top display (see display priority 4.8)

Return to top

of program

Continued over

page

Return to top

of program

Programming 17

XXXX

Lo -FLo

XX%

L d-bANd

XXXXXX

HI -FLo

X%

H d-bANd

NO

YES No

ENd Pro

YES

Saves settings & exits program

Optional alarm outputs

1) Low flow alarm (Lo-Flo) occurs when the flo falls below the set point, High flow alarm (Hi.Flo) occurs when the flow goes above the set point.

2) Deadband (d-bANd) or Reset Differential, provides a buffer zone about the alarm set point in order to avoid alarm output “chattering ” on & off when the flow rate is hovering on or about an alarm set point.

The % deadband applies above the Low below the High percentage of each set point.

Eg: 5% deadband at a low alarm set point of 100 L/hr will cause a low alarm when the flow drops to 100 L/hr, the alarm will not switch off until the flow increases above 105 L/hr.

set point. Deadband is set as a

set point and

5.2 Program detail record

User selected PIN No.

Engineering units

K-factor (scale factor)

Decimal for reset Total 0 0.0 0.00 0.000

Decimal for Accum. total

Decimal for Rate

Low flow alarm

Pencil your program details here

K =

0 0.0 0.00 0.000

Units / Sec Min Hr Day

Rate response

Hertz = Low frequency cut-off

1 pulse = Scaled pulse output

Set at : Deadband %

Set at : Deadband % High flow alarm

Your back up 4 digit PIN number is 1820

18 Index

(

)

(

)

(

)

(

)

(

)

g

8. ALPHABETICAL INDEX

Accumulative total 7

A

Battery

B

Backlighting the LCD display

DC power

D

Decimal point

Displays

Display priority

Engineering units

E

External DC powering

Flow alarms

F

Flowmeter connections 10,

Flow rate 6,

Installation

I

Input signals 10,

Keypad functions

K

K-factor (scale factor) 14,

LCD displays

L

Low frequency cut-off 14,

Model number designation

M

Mounting options 8,

Operation

O

Overview

2,

5,

15,

8 ~

12

15

20

15

12

17

11

15

13

11

15

Panel mount template 19

PIN number protection 14,

P

Programming 14,

5

6

7

6

4

9

7

6

Program detail record

Pulse output

Rate response

R

Rate display 7, 15

Rate time base 7,

Remote reset input

Resettable total

Resetting accumulative total

Scale factor (K-factor) 14,

S

Scaled pulse output

Specifications

W

Wiring of flowmeter inputs 10,

Wiring of pulse output 13

Wiring to external power

Wiring requirements

14,

16

15

16

13

15

12

15

13

11

12

7

12

71mm high x 83mm wide

Drill & tap 4 x M4 holes where indicated.

Tapping drills : 3.4mm, 1/8” or #30 drill.

Clearance drills : 4.7mm, 3/16” or #13 drill.

5

Edge rule for panel cut out & hole positionin

89.6 mm

3.53”

PANNEL CUT OUT :

( 2.8” x 3.3” )

Tapping :

Clearance drills :

89.6 mm

3.53”

83.0 mm

3.3”

71.0 mm

2.8”

68.0 mm

2.68”

68.0 mm

2.68” )

20 Supplement

8. Instruction manual supplement

ELECTRONICS ZOD-Z3, ZOD-Z5 & ZOD-B1 WITH

OPTIONAL RELAY OUTPUT BOARD

1. Overview

The Relay Control Output boards are an option for the flow rate totalisers and batch controller; they have two electro-mechanical SPCO relays instead of the solid state outputs of either instrument. The relays will switch higher loads (5 amps max.) to that of the solid state relays and provide electrical isolation between the switched output and the instruments circuitry. This option cannot be used in Intrinsically Safe environs.

Once plugged into the 16 pin socket (ZOD-Z3 & ZOD-B1) or 20 pin socket (ZOD-Z5), the solid state outputs at terminals 13 & 14 then cannot be used, the installer must make his control terminations at the relay board terminals marked NO (normally open), C (common) & NC (normally closed), DC & AC voltages may be switched at these terminals (generally the active is switched).

2. Installing relay board

First check (and set if necessary) the positions of the flow input DIP switches adjacent terminals 1~4 on the instrument PC board (see pages 9~10 in the relevant instrument instruction manual for setting options).

As the relay control output board requires external DC power (12~24Vdc at terminals 5 & 6) the instrument battery is no longer required. With no external power applied remove the battery to enable the relay board to be plugged into place using the battery cradle as the retaining mechanism, apply slight pressure to the board as you spread the battery cradle clips to embrace the relay PC board. The assembly is now ready to be wired.

3. Operation

The relay board has a voltage dropping circuit which limits the relay coil drive voltage to 12Vdc irrespective of the external supply to the instrument. When the external supply exceeds 12Vdc the largest component of this circuit will become hot to touch, this is a normal condition as the circuit dissipates the excess input voltage.

Relay

terminals

for

Relay control output board with two SPCO relays shown with a ZOD-Z3,

Check DIP switch

settings

Remove

N/O contacts are rated to 5A & the N/C contacts 3A max..

Terminals for relays

Relay board held by

battery cradle clips

Supplement 21

Relay board plugs into

16 & 20 pin sockets

FI-420 Universal pulse

processor board

I N S T R U C T I O N M A N U A L S U P P L E M E N T

IMFI420-0212

Meter K-factor *

Flow rate **

F/I converter

divider ³***(divisor)

Flow alarm

Program set points

2816

30 litres / hr

( 282 or 2816 )

23.47 hz

102.7

600 litres / hr

( 103 )

17.12 hz

52.44

220 LPM

( 52 or 524 )

192 hz

14.31

220 LPM

( 143 )

52.47 hz

4.412

1550 LPM

( 44 or 441 )

110 hz

Programming examples :

( * ) Flowmeter K-factor from calibration report or established tests.

( ** ) Flow rate for 20mA full scale output (no decimal position above 99.9 hz).

( *** ) Minimum divisor depends on acceptable error levels by the user.

Specifications

Programming On board programming via three tactile push buttons. Display 4 digit, seven segment LCD with 4 levels of contrast adjustment. Input frequency ( Hall Effect & Coil ) 1.0 ~ 9999 Hz. (frequencies below 1hz are not registered). ( Reed Switch ) 1.0 ~ 80.0 Hz. (frequencies below 1hz are not registered). Input sensor types Reed switch, Hall Effect, pulse wire or reluctance coil (turbine meter). Milliamp outputs 1) Analog 4 ~ 20mA, (600Ω maximum drive capability @ 28Vdc).

2) Modulated between 4 and 20mA (divided pulse & flow switch). Pulse repeater output Isolated NPN square wave, 30Vdc x 100mA maximum load. Maximum loop powered voltage 28Vdc – absolute maximum (reverse polarity protected). Accuracy +/- 0.3% of span. Response Programmable 1~9 seconds. Full scale limit 20mA internally limited (over range defaults to 0mA).

Temperature range -10ºC ~ +80ºC.

Processor 8 bit processing via 256 step Pulse Width Modulation Resolution 62uA.(frequencies above 99.99 Hz are processed as whole numbers). Program protection All programmed & accumulated data is stored in non-volatile memory.

Overview The FI-420 is a non volatile field programmable pulse converter which may be set to function as either a frequency to current converter (F/I), a pulse divider or a single point flow rate alarm device for high or low flow rate detection. The instrument also has an NPN pulse output which mirrors input pulse frequency, this two wire signal may be used for remote totalisation and/or rate indication.

The instrument is specifically designed to fit within the terminal housing of any of the propriety flowmeters or may be adapted to other styles of meters including Turbine and Insertion Paddle wheel flowmeters.

In all three functions, the output signal remains as a milliamp signal as follows:

Function 1 = frequency to current ( F/I ), 4 ~ 20mA proportional to flow rate, spanned as desired. Function 2 = frequency divider, divider range 1~9999, output is 4mA (pulse low) and 20ma (pulse high), 25hz max. Function 3 = frequency (flow rate) alarm, output is 4mA (no alarm condition) and 20ma (flow rate alarm condition).

Calibration

The philosophy behind the processor board rests on the origin of the flow input signal being expressed in terms of frequency rather than K-factor (scale factor) however, in order to derive the relevant frequency the user must work from the flowmeters known K-factor, these are in most cases available from the respective flowmeters calibration sheet or given as a nominal with some inferential style flowmeters such as insertion paddle wheel meters.

Some programming examples for each function are shown below.

Introduction 1

2 Configuration

Function in run mode

Displays set function

PROGRAM

Touch key matrix

Function in program mode

Adjusts LCD contrast

Shows set point, divide factor or resets total

Press & hold to enter program

Selects digit to be set

Changes value of selected digit

4 ~ 20mA

FI- 420

VR1

RESET

SELECT

►

PROGRAM

+

-

+

-

Pulse Out

20mA

SPAN

NPN

GND

mA

+

NOTE : Include a 250Ω load

resistor in circuit to protect

output from overload.

+

24Vdc supply

-

LCD contrast has 4

settings (0~3) Press 00

for best contrast.

- 4 to +20mA

FI- 420

VR1

RESET

SELECT

►

PROGRAM

+

-

+

-

Pulse Out

20mA

SPAN

NPN

GND

Input configurations

The processor board is produced in two configurations, the most common is supplied fitted with a loop powered Hall Effect pick up, this model is typically supplied with positive displacement flowmeters. The second configuration board does not have a Hall Effect device but has the facility to accept either a reed switch, coil or pulse wire input via hard wire solder pad connection. Unless otherwise requested at time of order placement the unit is preprogrammed at the factory to produce 20mA at the maximum flow rate of the associated flowmeter.

Function configuration

Frequency to current ( F/I ) Produces 4 ~ 20mA analog output proportional to flow rate. Programming requires the setting of a decimal point for frequency resolution eg. 1.000hz, 10.00hz, 100hz or 1000hz followed by the full scale frequency to produce 20mA output then finally a response time in seconds. The response time is used to smooth out fluctuating flow rate in order to provide a stable current output. Most input signals are reasonably stable and only need a low setting value of 1 to 3 seconds (9 sec. is maximum), these are step changes to the analog output signal, for example a response setting of 2 seconds would cause the processor to update the output every 2 seconds. The final setting covers the number of poles (NOP) of magnetic flux associated with the primary measuring elements, for example an Oval PD flowmeter may typically have 1, 2 or 4 magnetic poles per revolution, a Turbine flowmeter may have from 5 to 20 turbine blades, this feature compensates for any inherent cyclic variations in the flux density field of each pole which could otherwise produce an unstable output. Setting the NOP (or multiples of the NOP for even better stability) enables the processor to average the input readings thereby maximizing accuracy and repeatability of the output.

The span adjustment (20mA) is preset at the factory and should have no need to be adjusted there after.

In run mode the LCD defaults to display the flowmeter input frequency which is used during calibration.

Frequency (flow rate) alarm Output is current modulated between 4mA (no alarm condition) and 20ma (flow rate alarm condition) when the input frequency reaches the alarm set point frequency. Programming requires the setting

of a decimal point for frequency resolution eg. 5.243hz, 52.43hz, 524hz or 5243hz followed by the input frequency at which the flow alarm is to change status, next the deadband is set as a percentage of the frequency switch point. Deadband provides a variable trip buffer zone about the set point in order to overcome alarm “chattering” when the flow is fluctuating close to the set point. Deadband is expressed as 0~9% of the set point (hz). The final setting covers the number of poles (NOP) of magnetic flux associated with the primary measuring elements, for example an Oval PD flowmeter may typically have 1, 2 or 4 magnetic poles per revolution, a Turbine flowmeter may have from 5 to 20 turbine blades, this feature compensates for any inherent cyclic variations in the flux density field of each pole which could otherwise produce an unstable output. Setting the NOP (or multiples of the NOP for even better stability) enables the processor to average the input readings thereby maximizing accuracy and repeatability.

In run mode the LCD defaults to display the flowmeter input frequency which is used during alarm set point checks.

Frequency divider A limited divider range of 1~9999 suits most smaller capacity flowmeters having a high resolution pulse output generally in excess of 100 pulses per litre, gallon etc. often in situations where the output is used for totalising. Other applications can include dosing control signals or general output frequency reduction. Programming simply requires the setting of the appropriate divisor number (between 0001 & 9999). The divided pulse output is limited to 25hz. The output is current modulated between 4mA and 20mA.

In run mode the LCD defaults to function as an output totaliser & may be reset at any time.

Operation 3

Touch key operation

The 3 touch keys need to be operated slowly with deliberate action as the processor cyclic routine is some what slow & at times may miss a sharp key action, this is not to be interpreted as an intermittent fault.

Testing output with a multimeter

Wire in accordance with the diagram shown. Test output in proportion to frequency input for the 16mA span (4~20mA = 16mA span, 20mA being full scale [FS] range), for example, if 100hz were to produce 20mA then 50hz should produce 12mA, 25hz should produce 8mA & 10hz 5.6mA.

4 Analog output

Hz.

Run mode : display defaults to input frequency (Hz). Digits flash when in alarm condition. Press to show Hz set point.

Run mode : display defaults

to input frequency (Hz).

Press to show Hz for 20mA.

▲

Programming chart

Press & hold PROGRAM

key for 3 seconds to

enter program mode.

PROGRAM

ENTER

F/I converter

►

Divider

►

Flow switch

►

Position

decimal point

►

Position

decimal point

►

Select

divider factor

Select

response (sec)

Select %

deadband (0~9)

Press key to select function

Total

Run mode : display defaults

to a totaliser (divided value).

Press to reset totaliser.

Select number

of poles ( 1~32 )

Select number

of poles ( 1~32 )

Number of excitation poles (NOP)

for each revolution of the primary

measuring elements (see page 2).

Select flow

Switch point (Hz)

Select full

scale frequency (Hz)

PROGRAM

loop wiring + repeater pulse output

+ -

-

+

Loop

Load

+

24Vdc supply

-

Repeater pulse output

The NPN pulse output is isolated from the loop powered circuit and will support up to 30Vdc and drive to 100mA.

4 ~ 20mA

FI- 420

VR1

RESET

SELECT

►

PROGRAM

+

-

+

-

Pulse Out

20mA

SPAN

GND

NPN

loop wiring

4 ~ 20mA

FI- 420

VR1

RESET

SELECT

►

PROGRAM

+

-

+

-

Pulse Out

20mA

SPAN

NPN

GND

+ -

-

+

Loop

Load

+

24Vdc supply

-

The loop powered milliamp output is generally analog (4 to 20mA) or may be programmed in field for status switching between 4 & 20mA for either divided pulse or flow switch output.

Use of a good quality DC power supply is recommended. Avoid using low cost digital switch mode power packs.

Electrical connections Twisted pair low capacitance shielded instrument cable 7 x 0.3mm (0.5mm²) should be used for electrical connection between the flowmeter and remote instrumentation (Belden® number 9363 or similar). The cable drain or screen should be terminated on a DC COMMON or a specifically assigned shield termination at the readout instrument end only in order to protect the transmitted signal from mutual inductive interference. IMPORTANT, tape off & isolate the shield at the flowmeter end of the cable.

The cable should not be run in a common conduit or parallel with power and high inductive load carrying cables as power surges may induce erroneous noise transients onto the transmitted pulse signal or cause damage to the electronics. Run the cable in a separate conduit or with low energy instrument cables only.

Programming 5

Kobold DOR Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual