Milltronics COMPUFLO III Instruction Manual

COMPUFLO III

FLOWMETER

INTEGRATOR

Instruction Manual

PL-368

March 1993

33453680
PRR 1.1

TABLE OF CONTENTS

TITLE PAGE #

Gener al Inf ormation

About the CompuF lo III 1 – 1
About th is Manual

General 1 – 2
Conventions 1 – 2

Specifications

CompuFlo III 2 – 1
Options 2 – 2

Installation

CompuFlo III 3 – 1
Interconnection 3 – 1

Hazardous Locations 3 – 1

Start Up

Hardware Set Up 4 – 1
Pre Start Up Checks 4 – 3
Initial Start Up 4 – 3

Programming

Calibration

General 5 – 1
Keypad 5 – 1
Parameter Entry 5 – 2

Direct Parame ter Access 5 – 2
Automat ic Parameter Access 5 – 2
Altering Parameter Values 5 – 3
Last Parameter Recall 5 – 3

Parameter Reset 5 – 3
Programming Sequence 5 – 3
Quick Start Procedure 5 – 3

General 6 – 1
Initial Calibration References 6 – 1
Zero 6 – 2
Span 6 – 2
Calibration Accuracy 6 – 2
Calibration Alternatives 6 – 3

Auto Zero 6 – 3

Lockout Mode 6 – 3

On-Line Span Calibration 6 – 3

Alternate Test References 6 – 4

ECAL Calibration 6 – 4

PL-368 i

Parameters

General 7 – 1
Parameters 7 – 1

Programming Chart 8 – 1

Operation

Initial Operation 9 – 1
Normal Operation

Start Up 9 – 2
Zero Calibration Check 9 – 2
Span Calibration Check 9 – 2
Reset Total 9 – 2
Run 9 – 2

Communication

General 10 – 1

Remote Com munication 10 – 2
Host Communication 10 – 2
Serial Printer Communication 10 – 2

Protocol 10 – 3

Data Field Descriptions 10 – 3
Message Requests 10 – 4
Message Responses 10 – 4

Appendices

Figures

Alphabetical Par ameter Listing 11 – 1
Maintenance and Spare Parts 11 – 2
Error Messages 11 – 3
Trouble Shooting 11 – 4
Quick Start 11 – 5

Start U p 11 – 5
Calibration 11 – 6
Operation 11 – 7
Performance Enhancement 11 – 7

FIG. 1 Outline and Mounting 12 – 1
FIG. 2 Layout 12 – 2
FIG .3 CompuFlo III / Flowmeter Interconnection 12 – 3
FIG. 4 Po wer, Auto Zero, & Rate Output Wiring 12 – 4
FIG. 5 Relay Wiring 12 – 5
FIG. 6 Communication Wiring 12 – 6

PL-368 ii

GENERAL INFORMATION

ABOUT THE COMPUFLO

The Milltro nics CompuFlo III is a
microprocessor based integrator designed
specifically for b u lk dry solids in-line
weighing applications.

The CompuFlo III integrates a signal
proportional to material flowrate (such as
from a Milltronics flowmeter) over time to
provide material totalization.

The Com puFlo III provides:
» Rate and Total displays

» an analog mA output proportional to rate
» a relay contact f or remote total izer or PLC operation
» 2 alarm/ control relays based on rate and/or On-line Calibration
» 2 communication ports for computer , PLC, or serial printer c onnection

The CompuFlo I II has three modes of operation;
program, calib rate and run.

MULTI SPAN NO: 1R2:RATE HI R1:SPEED LO

1263957

TOTAL

T

150%100%50%0%-50%

The operator programs the CompuFlo III via the
keypad to provide displays and outputs in the
desired units of measure. The Comp uFlo III
displays the name, range of acceptable values,
(and additional information/instruction) of the
parameter (programming feature) accessed.

In the calibrate mode, the system Zero (no flow) and Span (100% flowrate) calibration is established. A test
reference (test weight) is used to simulate the force of material impacting the flowmeter sensing plate during
the Span calibration. A mater ial test is normally performed to verify the calibration accuracy. If necessary, the
material test results may be used to correct any deviation in calibration accuracy.

Calibration accuracy may be checked at any time. The results of th is check are automatically compared to the
system calibration and the deviation is displayed. The operator may choose to continue operation with the
previous calibration or the results of the calibration check.

All programming and calibration information is stored in non-volatile memor y. If desired, the security
parameter may be set to ensur e the CompuFlo III programming and calibration is not inadvertent ly altered in
the run mode.

The run mode is the normal operating mode, providing dynamic measurement displays, analog mA output,
and a variety of other features.

PL-368 1 – 1

ABOUT THIS MANUAL

GENERAL

This instruction manual conta ins informat ion essential to successful CompuFlo III operation.
SPECIFICATIONS, includes CompuFlo III environmental, phys ical, and operational characteristics.
INSTALLATION, indicates the typical mounting and interconnection procedure.
START UP, prepares the Compu Flo III for programming.
PROGRAM MING, details activities required to ta ilor t he CompuFlo III to the par ticular application.
CALIBRATION, includes the CompuFlo III input signal to output feature corr elation procedure.
PARAMETERS, describes the function, factory setting, and range of possible settings,

of each parameter.
PROGRAM MING CH A RT, provides a space to record programmed parameter values for futur e reference.
OPERATION, describes initial and normal CompuFlo III operation.
COMMUNICATION, provides CompuFlo III serial communication information.
APPENDICES, contains Quick Start , Alphabetical Parameter L ist, Maintenance and Spare Parts,

Error Messages and Trouble Shooting information.
FIGURES, includes a complete set of installation and interconnection drawings.

CONVENTIONS

Throughout this instruction manual the following symbols and presentation practices have been utilized:
[1234567ABCDEFG] alpha numeric characters enclosed within these brackets repr esents information

displayed by the CompuFlo III display.

[T/h] units of measure were arbitrarily chosen from the imperial set. The actual units

displayed or other wise applicable will be dependent upon o perator programming.

indicates the following CompuFlo III keypad button is to be pressed.

"RUN" or alpha numeric characters enclosed within quotation marks or this symbol

ENTER

represent a key on the CompuFlo III keypad.

Italics

are used to identify the defined word(s) or phrase within a definition statement.

Informat ion of a hig her order of importance, is indented from

both left and right margins and in bold print.

PL-368 1 – 2

■

SPECIFICATIONS

COMPUFLO III

Power: » 100/115/200/230 V AC ±10%, jumper

selectable, 50/60 Hz, 65 VA

Fuse: » FU 1 » 3/ 4 Amp MDL SLO-BLO or equivalent

» FU 2 » 1/ 4 Amp MDL SLO-BLO or equivalent

Operating » -20 to 50°C (-5 to 122°F)
Temperature:

Accuracy: » 0.1% of span, typical
Resolution: » 0.02% of span, typical
Inputs: » Load cell: » -20 to +45 mV DC per load cell

» 2 load cells max.
» LVDT: » 0 to 0.75 Vrms, 3 kHz
» Multispan: » 4 contact inputs for up to 8 spans
» Keypad: » 20 key sealed membrane with tactile feedback
» On-Line: » 4-20 mA proportional to weight

(Calibration)
» Auto Zero » contact input for enable
» Printer: » contact input for print request

Outputs: » Load cell: » 10 V DC, 250 mA max.

(excitation)
» LVDT: » 2.0 Vrms, 3 kHz, 50 mArms max.

(excitat ion)
» Analog: » 4-20 mA,(0-25 mA scaleable), isolated, proportional to rate
» 0.1% resolution

» 750 Ω max. load
» Remote » SPST sealed relay

Totalizer:

» 1 form "A" contact rated 2A at 250 V AC, 100 VA max.

» 25 msec. minimum contact closure duration

» 15 closur es per second max

PL-368 2 – 1

» Alarm: » 2 multipurpose relays for Rate or On-line Calibration

assignment

» 1 Form "C" SPDT contact per relay, rated 5A at 230 V AC

» Communication: » 1 relay, 4PDT used for communication loop dropout,

rated 1A at 230 V AC

» Display: » illuminated 256 x 128 dot matr ix

Communication: » 2 serial ports

» RS232C and ± 20 mA current loop

Enclosure: » NEMA 4 style, steel construction with polycarbonate window

» 330 mm W x 406 mm H x 102 mm D

(13" W x 16" H x 4" D)

Shipping Weight: » 11.0 Kg (24.3 lbs), no opti o n s

OPTIONS

Cable: » Single load cell, 150m (500 ft) max. 20 AWG, 4 wire shielded,

Belden 8404 or equivalent

» Single load cell, 300m (1 000 ft) max. 20 AWG, 6 wire shielded,

Belden 8426 or equivalent

» Dual load cell, 150 m (500 ft) max. 20 AWG, 6 wire shielded,

Belden 8426 or equivalent

» Dual load cell, 300 m (1000 ft) max. 20 AWG, 8 wire shielded,

Belden 8418 or equivalent

» LVDT, 150 m (500 ft) max. 20 AWG, 4 wire shielded,

Belden 8404 or equivalent
Barrier Strips: » For hazardous location flowmeters
Enclosure Heater: » Recommended for operating temperatur es below -10 ° C

(14°F) or excessive humidity
Relay: » Food Grade remote totalizer relay
CVCC: » For bipolar current loop/RS-232C conversion
BIC-II: » For 6 port bipolar current loop/RS-232C or RS-422 conversion.

PL-368 2 – 2

■

INSTALLATION

CompuFlo III

The CompuFlo III should be mounted in an area that is within the specified temper ature range, and that is
suitable for NEMA 4 style enclosures. The front cover should be accessible for keypad operation, display
viewing, and have sufficient room to swing open.

It is advisable to keep the CompuFlo III away from high voltage or current runs, contact ors, S CR control
drives and RF interference.

For proper totalizer relay operation, the CompuFlo III must be mounted within 30° from vertical.
Do not mount the CompuFlo III in direct sunl ight without the use of a sun shield.

INTERCONNECTION

Remov e the enclosure bottom plate prior t o drilling or punching cable/conduit entrance(s ), to ensure metal
filings do not come in contact with the CompuFlo III electronics.

Load cell or LVDT, rate output, On-Line Calibration input, communication, and low voltage contact wiring may
be run in a common conduit separated from power and high voltage contact wiring. Refer to Figures.

The power ground (TB1-50) is internally connected to SHLD connections (TB1-13,26, TB2-5), and to the
mother board bottom mounting lugs. COM connections (TB1-15,29,32,36,37, a nd TB2-8) are connected to
power ground via jumper J2 (below TB1, between the mounting lugs). If the COM connections must be
isolated from power ground, remove J2.

Refer to FIGURES
All wiring must be perf ormed in accordance with all governing regulations.

HAZARDOUS LOCATIONS

The CompuFlo III cannot be mounted in an area classed as hazardous. Where the associated flowmeter is
mounted in a hazardous area, barrier strips must be used to isola te the CompuFlo III from the hazardous area
for intrinsic safety. Encapsulated LVDT transducing elements are also available. Contact Milltronics or your
local representative for hazardous application information.

PL-368 3 – 1

■

START UP

HARDWARE SET UP

UNIT I.D.

The CompuFlo III identification code factory setting is 00,
as set by SW1 contacts 1 - 4.

When more than one CompuFlo III is connected to a
host computer or PLC, the identification code of each
CompuFlo III must be set to a differ ent value.

UNIT SW 1

I. D. 1 2 3 4

00 O O O O
01 C O O O
02 O C O O
03 C C O O
04 O O C O
05 C O C O
06 O C C O
07 C C C O

SW1

UNIT I. D. #

1248

METRIC

0000

IMPERIAL

UNIT SW 1

I. D. 1 2 3 4

08 O O O C
09 C O O C
10 O C O C
11 C C O C
12 O O C C
13 C O C C
14 O C C C
15 C C C C

LOCKOUT

MAIN
TOTAL
RESET

TEST

NORMAL

O = switch contact open C = switch contact closed

UNITS OF MEASURE

Two sets of Units are available; Imperial and Metric. Leave SW1 contact 5 (SW1-5) in the open position
for Imperial, or closed for Metric units. R efer to PARAMETERS / P0 - RATE UNITS for the Rate Unit
options available.

SW1-5 must be set to the desired position b ef ore i nitial pro grammi ng is performed.
To alter the Units of Measure of a programmed CompuFlo III, set SW1-5 as desired,

then perform a Reset. Refer to Parameters / P99 Reset.

LOCKOUT

Leave SW1 contact 6 (SW1-6) in the open position for normal applications. Close SW1-6 for Lockout Mode
operation, after all programming and calibration is complete. Refer to Calibration / Calibration Alternatives.

TOTALIZER RESET

Leave SW1 contact 7 (SW1-7) in the open position for normal operation. When this contact is closed, the
Main Total Display cannot be reset.

TEST MODE

Leave SW1 contact 8 (SW1-8) in the open position for normal operation. The closed position is reserved for
Milltronics service personnel.

PL-368 4 – 1

ALTERNATE

TB2 BAUD

000

4

X

4

2

PRINTER

REMOTE

TERMINAL

SERIAL

TEST /

ADJUST

SW2

3

0

1

X

ENGLISH

SPARE

PORT 2 BAUD RATE

The CompuFlo III TB2 com munication port baud rate is independent of the PORT 1 baud rate, and is set by
SW2 contacts 1 and 2. Set the baud as required by the device connected. The factory setting is 300 baud.

Baud SW2

Rat e 1 2

300 O O

O = switch contact open

1200 C O
2400 O C

C = switch contact closed

9600 C C

NORMAL

LANGUAGE

Leave SW2 contact 3 (SW2-3) in the open position for English, or closed for alternate language, CompuFlo III
displays.

REMOTE DISPLAY

Leave SW2 contact 6 (SW2-6) open for normal operation. If a remote mounted terminal is used, SW2-6 of the
remote terminal (only) must be closed.

PORT 2 COMMUNICATION MODE

Leave SW2 contact 7 (SW2-7) open for normal operation, or closed if a serial printer is connected to PORT 2.

TEST/ADJUST MODE

Leave SW2 contact 8 (SW2-8) in the ope n position for normal operation. In th e closed position, a test menu is
displayed.

When the keypad test is selected, a pictorial representat ion of the keypad is displayed. As each keypad
button is depressed, the display indicates successful operation.

When the display contrast adjustment is selected, pressing "4" increases, and pressing "8" decreases the
display contrast.

PL-368 4 – 2

PRE START UP CHECKS

After the Compu Flo III has been properly installed and interconnected, the following checks should be
performed prior to connecting power:

»all cable connections are correct and secure.
»the proper voltage has been selected (J1 on the mother board).
»SW1 and SW2 have been set as required.
»the POWER switch is in the OFF position.

Connect power to TB1 -51,52 and ground to TB1-50 of the CompuFlo III. Ensure all connections are secure.

Do not operate the CompuFlo III with the

ground (earth) wire disconnected.

INITIAL START UP

Se t the Co mpuFl o III POWER switch to the ON position. The CompuFlo III will enter the following
initialization routine:

COMPUSCALE/FLO III (REV DATE) (EPROM 2 REV)
TEST : (MESSAGES)

PL-368 4 – 3

When the display initializa tion routine is complete, the display revert s to the last operati ng mode accessed. If
the CompuFlo III is not programmed, the paramet er entry display is accessed.

The CompuFlo III display is divided into the following fields:

MULTISPAN

FEATURE

ECAL

VALUE

RELAY

CALIB
CYCLE

UNITS

AUX 1

AUX 2

-50%

150%100%RAT E0%

RATE BAR
GRAPH

FIELD DESCRIPTION

MULTISPAN current span calibration selected. If Multispan 0 is selected, the field is blank.
RELAY current relay status (run mode). If re lays are not used, or in non-alarm, the field is blank.
FEATURE para meter number (parameter entry), calibration type (calibrate mod e), Rate or Total (run mod e)
ECAL indicates ECAL (simulated rate signal) is on. If ECAL is off, the field is blank.
CYCLE full cycles remaining before calibration completion (calibrate mode).
CALIB calibrate mode indicator. When displayed, tota lizers are on HOLD (unless otherwise specified).
VALUE the current va lue associated with the featur e selected.
UNITS the units of measure associated with the value displayed
AUX 1 parameter name (parameter entry), auxiliary message (cali b rate mode), not used (run mode).
AUX 2 parameter value range (paramet er entry) , addit ional information or error message (any mode).
BAR GRA PH represents current rate, displayed as percent of span (run mode).

PL-368 4 – 4

■

PROGRAMMING

GENERAL

Information specific to a particular application is entered into the Com puFlo III memory, via the keypad, prior
to the calibration procedure.

KEYPAD

Button Operation Function

–

0

9

parameter entry numeric entries

4

8

RUN

PAR

ZERO

SPAN

ALT

DISP

RESET
TOTAL

parameter entry increase: analog mA output (P17 and P18 only), ECAL value (P22 only)

parameter entry decrease: analog mA output (P17 and P18 only), ECAL value (P22 only)

parameter entry decimal point

parameter entry negative entry or display prev ious parameter

any mode enter the run mode, return to previously selected display

any mode access parameter for entry or viewing

any mode access zero calibration, view current zero count

any mode access span calibration, view current span count

any mode enter the run mode, select rate or total display

any mode reset displayed totalizer value to zero (refer to Start Up\Hardware

Set Up\Total izer Reset)

CLEAR

parameter entry clear entry
calibrate mode abort calibration

ENTER

parameter entry display parameter value, or store altered parameter value,

or display next parameter
calibrate mode activate zero or span calibration, or accept calibration results
any mode with total displayed, switch to alternate total (ma in or sub)

PL-368 5 – 1

PARAMETER ENTRY

Application information must be entered into the appropriate CompuFlo III memory locations . These locations
are identified by a Paramet er Number (P#). The information entered is referred to as a Parameter Value
(Value ). To enter informat ion, the operator accesses the desired parameter number, v iews the parameter
value displayed, and then accepts or alters the current parameter value.

Common Parameter Entry Display Fields

FEATURE

VALUE

UNITS

AUX 1

AUX 2

-50%

150%100%RATE0%

RATE BAR
GRAPH

DIRECT PARAMETER ACCESS

To directly access any parameter, followed by the parameter number.

PAR

Only valid parameter numbers will be accepted. Refer to PARAMETERS for the list of valid parameter
numbers.

eg. [PARAMETER ] is displayed in the F EAT URE field, if PARAMETER 0 is desired
[PARAMETER 0 ] is displayed in the F EAT UR E field,

PAR

0

[RATE UNITS ] is displayed in the AUX 1 field.

To view the current paramet er value and auxiliary messages for the displayed parameter,

ENTER

[PARAMETER 0 ] is displayed in the FEAT UR E field
[ 1 ] is displayed in the VAL UE field (unless previously altered)
[RATE UNITS ] is displayed in the AUX 1 field

[1:T/h;2: LT/h;3: lb/ h;4: lb/m in ] is displayed in the AUX 2 field (with SW1-5 open)

AUTOMATIC PARAMETER ACCESS

Upon accessing any parameter value, pressing "ENTER" will autom atically access the next parameter in the
programming sequence. Pressing "-" will automat ically access the previous parameter.

eg. with the VA LUE field of PARA METER 0 displayed...

ENTER

[PARAMETER 1 ] is displayed in the FEAT UR E field
[ 0.0000 ] is displayed in the VAL UE field (unless previously altered)
[RATE ] is displayed in the AUX 1 field
[ENTER VALUE ] is displayed in the AUX 2 field

all fields associated with PARAMETER 0 are displayed

PL-368 5 – 2

ALTERING PARAMETER VALUES

Once the desired parameter number is accessed, the parameter value may be accept ed or altered as
required.

eg. if the VALUE f ield of PARAMETER 0 is 1 (T/h), however 2 (LT/h) is desired

2

ENTER

[ 2 ] is displayed in the VALUE fi eld
the new value (2) is now stored in memory

LAST PARAMETER RECALL

From the Calibrate or Run mode, the last parameter accessed in the Program mode, may be recalled.

the last parameter accessed is displayed.

ENTER

PAR

PARAMETER RESET

To reset all parameters to factory settings, refer to PARAMETE RS/P99 M aster Reset.

PROGRAMMING SEQUENCE

Typically, the CompuFlo III is programmed as follows:

a) Referring to PARAMETERS, copy the selected parameter v alues to the spaces provided on
the PROGRAMMING CHART fold out.

b) Perform a MASTER RESET (P99).
c) Access each parameter ( in sequence from P 0) and enter the parameter values

from the PROG RAMM ING CHA RT.
d) Perform a Zero and Span calibration (refer to CALIBRATION)
e) Perform Span Adjust (P8) or Factoring (P9) procedures, as req uired.

Remember to copy any parameter value alterations onto

the PROGRAMMING CHART for future refer ence.

QUICK START PROCEDURE

The Quick Start Procedure describes the minimum star t up, programming, and calibration requirements of the
CompuFlo III, to obta in successful RUN mode operation for most applications.

If desired, refer to APPENDICES /Quick Start. Parameters which are not included in the procedure may be
program med after the RU N mode is entered.

■

PL-368 5 – 3