Liquid Controls SP2850 User Manual

INSTALLATION & OPERATION

MANUAL

SP2850 (MS-649)

Temperature Compensated

2 Stage Batch Controller

DOC#: MN-2850

Sponsler, Inc.

Model SP2850-TC with MS649

Page 2

DOC#: MN-2850

INTRODUCTION

Description:

Featuring 8 digits of bright, .55”, alpha-numeric display, the unit can accept up to 10,000 pulses per second and a
direct 100 ohm platinum RTD or analog input. An 8 digit, floating decimal, “K” factor converts inputs to meaningful
count and rate data. The user, with the push of a button, can view the total of the batch, the rate of flow, Preset
value, temperature, or density. Two control outputs are provided for two-stage valve control.
A scaled pulse output is provided by an open-collector driver. Since the output frequency is user selectable at 10,
200, 2K or 20K Hz, the unit can transmit the count data to electromechanical or electronic counters as well as
computers, programmable controllers or other monitor equipment.
An analog output allows the user to select low and high settings to control strip recorders or other peripherals. A
16 Point Linearization variable K-factor option makes flow systems more accurate and often extends the usable
range by allowing the users to dial in different K-factors for different flow rates. It is recommended for flow meters
whose K-factors change with different rates of flow. From 3 to 16 points of frequency (0 to 10,000 Hz) and K-factors
greater than .0001 are programmed in at set up. The unit uses 8 digit floating math to interpolate between settings.
Rate per second, per minute or per hour programmability eliminates the need to calculate separate K-factors for
total or rate.

Features:

• Accepts 4-30V Inputs (pre-amp required)

• Takes a Direct 100 ohm Platinum RTD or Analog Signal For Compensation Input

• Display Mass or Corrected Volume, Rate,Temperature or Density

• Two Setpoints For Two-Stage Valve Control

• 10Khz Count Input Frequency

• K-Factor Programmable to 8 Places

• Temperature or Density Compensation Input

• Scaleable 4-20mA Output of Rate/Total

• 16 Point Linearization Selectable Programming

• NEMA 4X/IP65 Front Panel

• Two Way RS232/422 Communications Option (must be specified with unit order)

• Temperature/Density out of range input inhibit

SPECIFICATIONS:

DISPLAY: 8 digit, .55” High, 15 Segment, Red Orange, LED.
INPUT POWER:

A: 110 VAC +/- 15% or 15 to 27 VDC
B: 220 VAC +/- 15% or 15 to 27 VDC

CURRENT: Maximum 350mA DC or 8.8 VA at rated AC voltage.
OUTPUT POWER (On AC powered units only): +12 VDC at 100mA. Separate Isolated 12 VDC at 100mA to allow

+12 VDC or +24 VDC regulated +5% worst case.
MEMORY: EEPROM stores all program and count data for minimum of ten years if power is lost.
PULSE INPUT:

Standard) 4-30 VDC 30 K ohm impedance to GND, 10 Khz max. Input speed (min. On/off µ50 sec.)
Requires pulse amplifier.
Magnetic Pickup) 30mV to 30V P/P min., 2 Hz to 5 Khz Input Speed

COMPENSATION INPUT:

The compensation input can be hooked up directly to an RTD or an analog signal. The input types available
are : RTD, 4-20mA, 0-5V, or 0-10V. If the compensation input is not used, select `MANUAL’ input type and
enter the parameters at which the unit is operating.

Sponsler, Inc.

Model SP2850-TC with MS649

Page 3

DOC#: MN-2850

Speed (HZ)

10

200

2000

20000

Min. on/off (msec)

47.5

2.0

0.2

0.013

RESET: Front push button: `CLEAR’ resets displayed batch counter and control input.
Remote: 4 to 30 VDC positive edge resets batch counter and control output.
Impedance: 10K to ground (-DC)
Minimum pulse: 5 msec.
START: Front push button: `START’: When pressed, the unit displays, `STARTED’ and both relays energize.

The relays will remain energized until the preset values are reached or the `STOP’ is activated.
Remote: 4 to 30 VDC positive edge starts unit as described above.
Impedance: 10K to ground (-DC)
Minimum pulse: 5 msec.

TEMPERATURE:

Storage: -40°F (-40°C) to +200°F (+93°C)

FACTORED OUTPUT: The unit gives one pulse out for each factored count. The open collector sinks 30 VDC
maximum to 1 volt at 100mA maximum. Output speed is user selectable (see table below). An internal buffer holds
up to 10,000 pulses for output at the selected frequency before `DATALOST’ flashes, indicating pulses are lost. If
factored rate exceeds 7 digits `RFF...’ flashes. These alarms indicate that speed has been exceeded.

CONTROL OUTPUTS: (Each of two outputs)

1. NPN Transistor Version: Open Collector sinks max. 250mA from 30 VDC when active. (When relay is used,
10 VDC is provided at transistor outputs through relay coil. If greater than 2mA is used, relay will remain
energized. Applying greater than 10 VDC may destroy unit. Transistor will sink 100mA in `ON’ state)

2. SPDT Relay Version: 10A 120/240 VAC or 28 VDC (Standard).
ANALOG OUTPUT:

Current Outputs:
with each update of the rate. Accuracy is +/- 100µA worst case. Compliance voltage must be 3 to 24 VDC, non
inductive. (The unit can provide the DC source as long as the drop across any device being driven does not exceed
21V)

referenced to pin 12 (ground). Accuracy is .1% @ 20°C (max. Drift .01% / °C).
SECURITY: This output is not available when using RTD input. The unit has a missing pulse detector. The user

selects the amount of time (1 to 99 sec.) that the unit will ‘wait’ for input pulses. If the unit doesn’t receive pulses
within the selected time, the unit will display ‘SECURITY’ and both relays drop out. (00 disables the security feature;
Entering the lockout code returns the unit to the run mode).

PRESETS: The user may enter two numbers to set up the batch counter, Preset and Prewarn. The Prewarn value
is the number of counts before the Preset value that the Prewarn relay will de-activate. For instance, a 100 gallon
batch with a valve to close and slow down flow 25 gallons before the end of the batch is desired, the preset is 100,
and the prewarn is 25. When the start is activated, the relays energize simultaneously to start flow. When the
counter reaches 75 (25 before 100) the prewarn relay drops out. When the counter reaches 100, the preset relay
drops out. The preset values can be viewed or changed via the menu (when stopped).

OPERATION USING EZ PRE: The EZ PRE (easy preset) programming option has been designed for users who
are changing the batch amount often. By choosing EZ PRE, the user has fewer buttons to push to change the
Preset. The EZ PRE features functions as follows:

Operating: -40°F (-40°C) to +158°F (+70°C)

A sinking driver generated a corresponding linear current through the external devices, updating

Voltage Outputs:

Security output:

Initially, the preset is set to zero upon entering EZ-PRE mode. A new batch PRESET will be entered after pressing
CLR. Once the unit is started, the relays engage and the unit begins to count. When the batch is complete the relays
drop out and the display flashes zero. To start another run, the user must enter a new value for the Preset by simply
keying in the new Preset value. The user may press CLR to clear the Preset to zero, however, the Preset must
comply with the PREWARN value before the unit will start. Pressing START will automatically reset the count and
start a new batch using the new Preset value.

When the voltage option is ordered, a controlled voltage output is located at terminal 3 and

When the unit is in ‘SECURITY’, a normally high (5V) at pin 8 goes low (< 0.4V).

Sponsler, Inc.

Model SP2850-TC with MS649

Page 4

DOC#: MN-2850

NOTE: Once the EZ PRE mode is entered, the internal LOCK is automatically turned on. The only way to get back
to the menu is to enter the lockout code. See page , `Locking and Unlocking the Unit’.
NOTE: If the STOP is activated before a batch is complete, pressing START will continue the batch from the point
where it was stopped. If a new preset is desired after activation of a STOP, the CLR button may be pressed to clear
out the remaining count and a new PRESET value can be entered.

OPERATION USING STD PRE:The STD PRE (standard preset) programming option has been used in the past in
our batching units. When the STD PRE option is selected, the unit operates as follows:

The Preset and Prewarn values are entered by entering the programming menu and selecting Preset and
Prewarn. After these values are entered, the user can reset the counter (front panel or remote) and start
the batcher. When started both relays energize, and the counter begins to count. When the batch is
complete the relays drop out and the unit displays the amount that was batched (0 if set to preset mode).
To run a batch of the same amount, the user must reset the counter and press start. To run a batch of a
different value, the user must enter the programming menu and enter the new Preset and Prewarn values.
The counter must be reset before the new batch is started.

K-FACTOR: A user selectable K-Factor is used to convert the input pulses into engineering units. The value to
enter is the number of pulses per unit volume.

16-POINT LINEARIZATION: The 16 point K-Factor selection allows the user to program in from 3 to 16 different
frequency points (inputs per second) and different K-Factor dividers from 0.0001 to 999999999 for each of these
frequencies.

The 16 point unit determines the incoming frequency and calculates a K-Factor line slope from the two
closest data points that had been entered. The `specific K-Factor’ is then proportionally interpolated using
8-position floating math. This K-Factor is applied to all inputs until the next frequency calculation, usually 1
second later. If a `0’ frequency is entered into `point 1’ the ‘point 1’ K-Factor will be applied to all inputs
received before the first frequency calculation.

The rate can be displayed in 3 ways: `SECONDS_’, `MINUTES_’, `HOURS_’. If `SECONDS_’ is selected
the unit displays the `base’ rate calculated from the incoming frequency and the ‘specific K-Factor’. If
‘MINUTES_’ is selected, the rate displayed is 60 times the ‘base’ rate. If ‘HOURS_’ is selected, the rate
displayed is 3600 times the ‘base’ rate.

COUNTER: The total counter has 8 digits. In the set-up mode choose ‘RO’ (reset to zero) for adding operation or
`SP’ (set to preset) for subtracting operation..

COUNT INHIBIT: A user selectable temperature or density range which can be used to inhibit counting outside a
given range.

RATEMETER: Accurate to 5 1/2 digits (+/-1 display digit). The rate meter can be programmed to accept almost any
number of pulses per unit of measurement, perform a weighted averaging function to stabilize fluctuating displays
and autorange up to 6 digits of significant information. The unit will update each second. The 2 to 24 second
`WINDOW’, selected at set-up, is the maximum time the unit will wait for sufficient input pulses to make an accurate
calculation before it displays zero. The rate meter with a K-Factor of 1 displays the rate of pulses per second.
Simply dial in the proper K-Factor to display in minutes, hours or other units of measurement. Press the `C’ button
to display the rate, total, temperature, preset or density.

LOCKOUT: Unauthorized front panel changes can be prevented by entering a user selected 4 digit code.
OUTCARD: RS232 or RS422 serial two way communication options are available. Up to 15 units can be linked

together and addressed separately to transmit unit status or accept new set points in the standard ASCII format.
Baud rates of 300, 600, 1200, 2400, or 9600 as well as choice of odd, even, space or mark parity can be selected
by keypad control.

Sponsler, Inc.

Model SP2850-TC with MS649

Page 5

DOC#: MN-2850

OPERATION: Through the 16 key, NEMA 4X/IP 65 front panel, the operator enters all the necessary operating
parameters. First the user enters all of the count and rate information (i.e. K-Factors, Decimal Location, etc.), as
well as the lockout configuration and available options. Next the compensation parameters are entered. These
parameters consist of:

COMP IN (input type): RTD, 4-20mA, 0-5V, 0-10V or MANUAL (when an input other than RTD is selected,

the user selects whether to compensate for Density or Temperature and enters the low and high values.)
FLUID (fluid parameters): reference density, reference temperature, and coefficient of expansion.
FLOW EQ (flow equations): Corrected volume or Mass.

After these operating parameters are entered, the operator enters the Prewarn (slow down) and Preset (batch size)
values. With the push of the `START’ button (or remote start) the unit will energize the relays which open the valves
and begins flow. The flow will continue until the final preset is reached. The operation can be halted at any time by
activating the `STOP’ (front panel or remote).

Sponsler, Inc.

Model SP2850-TC with MS649

Page 6

DOC#: MN-2850

INSTALLATION

Receipt of Equipment:

When the equipment is received, the outside packing case should be checked for damage incurred during
shipment. If the packing case is damaged, the local carrier should be notified at once regarding his liability. A
report should be submitted to the distributor. Carefully remove the equipment from the packing case and inspect for
damage or missing parts.

Return Shipment:

Do not return assembly or part without a Return Material Authorization (RMA). The RMA is obtained by calling your
local authorized distributor.

Mounting:

The controller should be located in an area with a clean, dry atmosphere which is relatively free of shock and
vibration. The SP2850-TC is installed in a 7.365” (18mm) wide by 2.495” (63.4mm) high panel cutout. (See
mounting Dimensions) To mount the controller, proceed as follows:

a. Prepare the panel opening.
b. Slip the gasket (provided) over the rear case and slide it forward until it engages the inner surface of the front

bezel.
c. Slide the unit into the panel opening and slide it forward until the panel engages the inner surface of the gasket
at the
front bezel.
d. Install the screws (provided) in the mounting brackets and insert into the mounting holes on top, bottom and
sides of
case.
e. Tighten the screws firmly to attach the bezel to the panel. 3 in. Lb. Of torque must be applied and the bezel
must be
parallel to the panel to maintain NEMA 4 rating.

NOTE: To seal to NEMA 4X specs., supplied gasket must be used and panel cannot flex more than .010”. All 4
clamps must be tightened a min. Of 3 in. Lb. Torque. If panel flex occurs, seal unit with RTV type sealer.

Sponsler, Inc.

Model SP2850-TC with MS649

Page 7

DOC#: MN-2850

PRESET

PREWARN

WIRING

AC/DC Connections:

NOTE: Connect power only after other connections are finished. Do not touch the live AC power terminals. The

unit has been designed with an isolated AC input, therefore polarity is not a concern for the AC power. The chassis
is plastic, therefore earth ground is not used. For DC operation, connect +DC to terminal 14 and -DC to terminal 12.

Although the unit is designed to be immune from line or RF interference, the unit is controlled by a microprocessor
and an electrically ‘noisy’ environment could cause operating problems. The input power lines should not be
common to power lines or motors, pumps, contactors, etc.

Four sources of noise can occur:

1) AC power line noise- If the unit cannot be connected to an electrically clean power source, an inductive load
suppressing device (MOV as GE#V130LA1 or Resistor, Capacitor as Paktron # .2uf/220 ohm @400V) can be
installed. Although locating the suppressor across the AC supply at the unit should help, best results are obtained
by connecting the suppressor across the leads of the ‘load’ at the device causing the spikes.

2) Input line noise- The noise is carried on the input and DC ground lines. Make sure the input wires are not run
into the unit in a bundle with power input lines. We recommend using shielded cable. Connect the shield to DC
ground of the unit and ‘earth’ at one point in the circuit preferably at the DC ground terminal of the unit.

3) Output lines- The unit has two open collector outputs and two relay outputs. When these outputs are used to
run external relays or solenoids, spikes can be generated upon activation. This noise can spread through the
instrument causing operating problems. If the source is a DC operated device, a general purpose diode (IN4004)
placed across the solenoid prevents electrical noise spikes. Connect the cathode (banded side) to the more
positive side of the coil. If the source is an AC operated device, use a Resistor, Capacitor or MOV across the coil.

4) DC output supply- Noise can be generated on the DC output supply if it is used to drive inductive loads or if the
current draw exceeds 100mA. Insure that all inductive loads have a diode (such as IN4004) across the coil and that
the current does not exceed 100mA.

WIRING CONNECTIONS

Terminal Connections:

1 - REMOTE START
2 - SCALED OUTPUT (OPEN COLLECTOR)
3 - ANALOG OUTPUT
4 - INPUT A (PULSE)
5 - RESET INPUT
6 - REMOTE STOP
7 - RTD EXCITATION +
8 - RTD SENSE + (OPT SECURITY OUT)
9 - RTD SENSE - / VOLTAGE INPUT +
10- RTD EXCITATION - / CURRENT I NPUT +
11- GROUND (-DC)
12- GROUND (-DC)
13- 12 VOLTS OUT
14- DC POWER I N
15- ISOLATED -12 VOLTS OUT
16- ISOLATED +12 VOLTS OUT
17- AC INPUT
18- AC INPUT
19- PREWARN TRANSISTOR
20- PRESET TRANSISTOR

1 - N.O.
2 - N.C.
3 - COMMON

4 - N.O.
5 - N.C.
6 – COMMON

Sponsler, Inc.

Model SP2850-TC with MS649

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DOC#: MN-2850

Typical Wiring:

Pulse Input/RTD Input/Current Output

Pulse Input/Analog Input/Voltage Output

Sponsler, Inc.

Model SP2850-TC with MS649

Page 9

DOC#: MN-2850

TYPICAL WIRING: SP714 & SP717

ANALOG OUTPUTS

The output on external pin 3 is a 4-20mA, 0-5 VDC, or 0-10 VDC output corresponding to the selected rate
readings. When the output is 4-20mA, a sinking driver generates a linear current across the recorder, PLC,
computer or external meter. When the output is a voltage, the unit generates a positive voltage with respect to
ground (pin 12). In the program set-up mode the user is prompted to `SET LOW’ (4mA rate or 0V rate) and ‘SET
HIGH’ (20mA rate or 5V; 10V rate).
The unit can supply the 24 VDC to power the current loop. Connect Pin 15 to Pin 13. Pin 16 is now +24 VDC with
respect to Pin 12. With Pin 15 connected to Pin 13, connect Pin 16 to the +DC side of the external device and
connect Pin 3 to -DC side of the external device.

CURRENT OUT VOLTAGE OUT

Sponsler, Inc.

Model SP2850-TC with MS649

Page 10

DOC#: MN-2850

DEFINITION OF MENU PROMPTS

MENU- This prompt is displayed when the programming menu is entered.
PRESET- This sets the value at which the preset A will drop out (R0, reset to 0 mode). In the ‘SP’ (set to preset

mode) the unit will reset to this Preset value and count down to 0.
PREWARN- This value is the amount before the preset value that the Prewarn relay will drop out. For example: the

Prewarn relay is to drop out 10 counts before the Preset and the Preset is 1234, then set the Prewarn at 10
(not 1224). NOTE: If the Prewarn is larger than the Preset, the warning ‘PREWRONG’ will be displayed.

PRE TYP- (PRESET TYPE): This section of the menu allows the user to choose between ‘EZ PRE’ (easy preset) or
‘STD PRE’ (standard preset).

EZ PRE- (EASY PRESET): See ‘OPERATION USING EZ PRE’ pg.
STD PRE- (STANDARD PRESET): See ‘OPERATION USING STD PRE’ pg.
INHKEY(INHIBIT): Disables front panel START, STOP, MENU, ENT keys.
ENAKEY (ENABLE): Enables front panel START, STOP, MENU, ENT keys.
16 POINT- This section of the menu allows the user to select 16 point variable K-Factor data or linear K-Factor

programming.
16PT- (16 POINT); Enter this section to enter the 16 point setup procedure.
LN- (LINEAR); Enter this section to set up a linear K-Factor.
K-FACTOR- This is a scaling factor that converts the input into engineering units. Example: To total in gallons when

the meter is putting out 100 pulses per gallon, enter 100 for K-Factor.
TEST- When ‘TEST’ is selected, point data can be entered exactly as in selected time entries. However, when the

unit ‘runs’ in Test mode, K-Factor is always 1. ‘Rate’ (R) displays frequency (inputs per second). ‘Counter’ displays
1 count per each unit.

HOURS- When `hours’ is selected, the ratemeter will display units per hour.
MINUTES- When `minutes’ is selected, the ratemeter will display units per minute.

SECONDS- When `seconds’ is selected, the ratemeter will display units per second.
POINT ##- This prompt appears before each of the 16 points to be entered. To exit the 16 point set-up press `CLR’

then `ENTER’.
F#######- This prompt indicates the Frequency for each of the 16 points.
K#######- This prompt indicates the K-Factor for each of the 16 points.
COUNT- This section of the menu is used to set up the counter information.
R0- (RESET TO ZERO): When `R0’ is selected, the counter will reset to 0 (count up) when reset.
SP- (SET TO PRESET); When `SP’ is selected, the unit will reset to preset (count down) when reset.