Omega Products FPM-9020A Installation Manual

OMEGA FPM-9020A Batch Controller Instructions

Batch

Option

flow

AC or DC

power

valve

FPM-9020A Terminals

CAUTION!

• Refer to this instruction manual for more details.

• Remove power to unit before wiring input and output connections.

• Follow instructions carefully to avoid personal injury.

Contents

1. Dial Selection

2. Power Connection

3. Compatible Sensor Wiring

4. Batch Contact Wiring

5. Remote Control Wiring

6. End of Batch/Counter Pulse Output Wiring

7. Option Contact Wiring Options

8. Current Output Wiring Options

9. FPM-9020A Operation Modes

10. Menu Functions

11. Parts and Accessories

12. Specifications

13. Quick Reference Menu Parameters

14. Maintenance

15. Troubleshooting

1. Dial Selection

The analog display shows percentage of batch complete 0 - 100%, or percentage of remaining batch 100 - 0% on the reversible dial face plate. Meter deflection is fixed from left to right. The instrument is shipped with the percentage of batch complete 0 - 100% scale shown. Reverse the face plate for either scale, as desired.

0 - 100

ALARM 1

Batch

ALARM 2

100

ALARM 1

Batch

ENTER

ALARM 2

100

3. Compatible Sensor Wiring

2. Power Connection

CAUTION! Never connect 115 VAC or 230 VAC to rear power terminals. High voltage AC will damage instrument and

void warranty.

FPM-9020A

Terminals

External power supply

12 - 24 VDC

= Double Insulated = DC or AC power

12-24 V

10 W

12 - 24 VAC

Technical Notes:

• Maximum 4-20 mA loop impedance (sec. 8A) is affected by the supply voltage.

• To reduce the possibility of noise interference, isolate AC power lines from signal lines.

4. Batch Contact Wiring

See section 9 for simple and advanced mode configuration options.

OMEGA Sensors:

Red Black Shld.

Freq. IN

Std. Sensor

Technical Notes:

• To reduce the possibility of noise interference, route sensor cable away from AC power lines.

Iso. Gnd

Sen. Pwr.

Open Collector Sensor

FPM-9020A Terminals

FP-5300 FP-5200 FP-6000

FP-5061 FP-5072 2536 FP-2541 Vortex*

• *Vortex sensor or system frequency output

Technical Notes:

• Maximum alarm contact ratings: 5 A @ 30 VDC, 5 A @ 125 VAC, or 3 A @ 250 VAC

• To reduce the possibility of noise interference, isolate AC power lines from signal lines.

5. Remote Control Wiring

6. End of Batch/Counter Pulse Output Wiring

Rear START, STOP, and RESUME (Rsm) terminals can provide remote

Momentary Switch Contacts

(customer supplied)

batch control from a distance using one of four methods:

• Mechanical switch closures (shown)

Start

Stop Resume

• End of batch pulse from a second FPM-9020A (sec. 6)

• End of batch contact closure from a second FPM-9020A (sec. 7C).

FPM-9020A

Terminals

Start

Stop

Remote

Rsm

RTN

• End of batch current pulse from a second FPM-9020A (sec. 8C).

Technical Notes:

• Use 4-conductor shielded cable for remote control lines up to 30 m (100 ft) max.

7. Option Contact Wiring Options

A. Two Stage Shutdown (advanced mode only, sec. 9.2)

FPM-9020A

Option

Batch

Terminals

See section 9 for simple and advanced mode configuration options.

A. External counter connection

5 - 30

VDC

Gnd

FPM-9020A Terminals

External Counter

10 kΩ

CNT/EOB

output

B. Daisy chaining two FPM-9020A

batch controllers together

CNT/EOB

output

Gnd

Start

Stop

Remote

Rsm

First FPM-9020A Second FPM-9020A

Technical Notes:

• Use 2-conductor shielded twisted-pair cable for output lines up to 30 m (100 ft.) max.

8. Current Output Wiring Options

A. Batch Completion (simple or advanced mode, sec. 9)

Fuse**

1/8A

4 - 20 mA

RTN

AC or DC

power

Bypass line

Main line

flow

Valve

to tank

Technical Notes:

• Maximum alarm contact ratings: 5 A @ 30 VDC, 5 A @ 125 VAC, or 3 A @ 250 VAC

• To reduce the possibility of noise interference, isolate AC power lines from signal lines.

B. Missing Signal Alarm (simple or advanced mode, sec. 9)

Overrun Alarm (advanced mode only, sec. 9.2)

FPM-9020A

Terminals

Alarm

device

Option

Batch

AC or DC

power

Current

output

FPM-9020A

Terminals

Technical Notes:

**1/8A fuse recommended (customer supplied) * 4-20 mA output is internally powered (non-isolated), maximum loop

impedance 350 Ω with a 12 V instrument supply voltage, 950 Ω with a 24 V instrument supply voltage.

To isolate output and prevent ground loop problems:

1. Use monitor device with isolated inputs, or

2. Use separate DC supply for FPM-9020A and monitor device, or

3. Power FPM-9020A with 12 - 24 VAC step down transformer

B. Valve Control (advanced mode only, sec. 9.2)

#5 ( + )

4 - 20 mA

#6 ( - )

Current

output

FPM-9020A

Terminals

4-20 mA electronic

actuated valve

Technical Notes:

• Maximum alarm contact ratings: 5 A @ 30 VDC, 5 A @ 125 VAC, or 3 A @ 250 VAC

• To reduce the possibility of noise interference, isolate AC power lines from signal lines.

Technical Notes:

• Output compatible with 4-20 mA electronic actuated valves.

• Max loop impedance: 350 Ω max with a 12 V instrument supply voltage, 950 Ω max with a 24 V instrument supply voltage

100%

Batch running...

4 mA

20 mA

Section 7 Continued...

Section 8 Continued...

C. End of Batch Pulse (advanced mode only, sec. 9.2)

Daisy chaining two FPM-9020A batch controllers together for a second batching stage.

C. End of Batch Pulse (advanced mode only, sec. 9.2) Daisy chaining two FPM-9020A batch controllers together for a second batching stage.

FPM-9020A

Batch

Option

First FPM-9020A

FPM-9020A

Technical Notes:

• Use 2-conductor shielded twisted-pair cable for contact lines up to 30 m (100 ft.) max.

Second

Terminals

Start

Stop

Remote

Rsm

RTN

Current

output

First FPM-9020A

FPM-9020A

Terminals

Rsm

RTN

Stop

Start

Remote

Second FPM-9020A

Technical Notes:

• Wiring MUST be connected exactly as shown.

• Use 2-conductor shielded twisted-pair cable for output lines up to 30 m (100 ft) max.

9. FPM-9020A Operation Modes

This section gives a detailed description of the FPM-9020A's simple and advanced operation modes (sec. 14) and how they affect the batch contact, End of batch/totalizer output, option contact, and current output.

9.1 Simple Operation Mode

• Batch Contact (sec. 4): In simple mode, the batch contact is dedicated for on/off control. It is energized at the start of a batch and

de-energized at the end of a batch. It also de-energizes when STOP is selected from the front keypad or initiated by a remote contact closure to the rear STOP terminals (sec. 5). A RESUME command can also be initiated by either method to complete the batch. The front panel batch indicator turns on when the batch contact is energized.

• Counter/End of Batch Pulse Output (sec. 6): In simple mode, the output is configured as a counter pulse output. The output emits a 130 millisecond pulse for each engineering (total) unit measured. The output is a open collector type which requires an external pull up resistor and power supply for external counter use (sec. 6).

• Option Contact - Missing Signal Alarm (sec. 7B): This function provides alarm capability if flow is not detected in 30 seconds after a batch cycle starts. If the flow sensor signal is missing, the option contact energizes and the front panel contact indicator turns on, signaling the missing sensor signal. The batch contact also de-energizes, closing the flow control valve and stopping the batch. The alarm condition will remain until the front panel ENTER key is pressed or a remote contact closure is made to the rear STOP terminal (sec. 5).

Batch started...

Sensor input option contact batch contact

• Current Output - Batch Completion (sec. 8A): This function is offered in the simple or advanced operation mode. The output is a linear increase from 4 mA at batch start to 20 mA at batch end.

9.2 Advanced Operation Mode

Overrun Comp: automatic manual

for valve closing time and eliminating batch overrun. Automatic overrun compensation counts sensor pulses during the batch cycle, and any excess pulses after the batch stops. The instrument calculates the estimated batch overrun based on the additional sensor pulses, then automatically reduces the next batch size for the next batch. During the next batch cycle, the batch contact de-energizes early, thus closing the flow control valve early and eliminating batch overrun.

• Batch Contact (sec. 4) The batch contact is dedicated for on/off control and is either manually or automatically compensated for batch overrun. Manual overrun compensation allows the operator to compensate for valve closure time in a batching system. The operator is prompted to enter a batch volume that de-energizes the batch contact early, compensating

• Counter/End of Batch Pulse Output (sec. 6): In advanced mode, the output can be configured as either a counter pulse output (sec. 9.1) or as an end of batch pulse output. When configured as an end of batch pulse, the output emits a 500 millisecond pulse at the completion of every batch. The output is a open collector type which requires an external pull up resistor and power supply for external counter use (sec. 6).

batch contact

Option contact

100%

500ms

Batch running...

Option Contact: Two Stage

•Option Contact - Two Stage Shutdown (sec. 7A): This function is designed to prevent over filling or to minimize water hammer. Both the batch and the option contact are

energized when the batch starts. The option contact then de-energizes at a programmed batch percentage, forcing flow through a smaller bypass line to reduce the fill rate. After the entire batch is measured, the batch contact de-energizes, completing the sequence. Front keypad and remote START, STOP, and RESUME inputs (sec. 5) also control the option contact. The front panel contact indicator turns on when the option contact is energized.

Batch running...

Option contact

batch contact

90%

100%

Option Contact: Overrun Alarm

• Option Contact - Overrun Alarm (sec. 7B): This function provides overrun alarm

capability for detecting a leaky or stuck valve. If the programmed batch overrun volume is

measured after the batch ends, the option contact is energized and the front panel contact indicator turns on, alarming the operator that the flow shut off valve is leaking or stuck open. To cancel alarm, press the ENTER key (or remote STOP switch) once. The overrun alarm will retrigger if the condition persists.

Option Contact: End of Batch

• Option Contact - End of Batch Pulse (sec. 7C): This function is designed to trigger an

external batch counter or second FPM-9020A Batch Controller at the end of a batch. The

option contact is energized for 500 milliseconds at the end of every batch cycle. An external power supply switched through the option contact's common (COM) and normally open (NO) terminal provides a pulse for triggering these devices.

Option Contact: Missing Signal

• Option Contact - Missing Signal Alarm (sec. 7B): The missing signal alarm represents a missing sensor signal after batch start-up. An adjustable time delay entry (in seconds) is offered which specifies how long the instrument will wait after batch start-up before initiating the missing signal alarm. See simple operation mode (sec. 9.1) for alarm operation details.

Option Contact: Off

Missing Signal Alarm: On

• Option Contact On/Off (sec. 10.4H): This function enables or disables the option contact and front panel option LED.

When the option contact is configured "Off", the option contact and front panel LED are disabled.

• Missing Signal Alarm On/Off (sec. 10.4H):

Missing signal alarm is always enabled (factory default sec. 9.1) even if the option contact is selected to be a different

function. This function is designed to completely disable the missing signal alarm, if desired. NOTE: If disabled, the batch contact is NOT affected and will NOT signal the operator or stop the running batch if there is a problem.

Batch running...

Option contact

batch contact

100%

Overrun

Current Output: Batch Completion

Current Output: Valve Control

• Current Output - Batch Completion (sec. 8A): In advanced mode, the current output functions identical to the simple operation mode. See the simple operation mode explanation above.

• Current Output - Valve Control (sec. 8B): This function is designed for use with 4-20 mA electronic actuated values for preventing overflow or minimizing water hammer. When a batch starts, the current output is held at 20 mA, forcing the actuated valve to the full open position. Near batch end, the output gradually ramps downward to slow the flowrate, then

drops to 4 mA closing the valve and ending the batch. Front keypad and remote START, STOP, and RESUME inputs also control the output (sec. 5). A STOP command any time during a batch sequence will force the output to 4 mA and close the valve. (Note: for optimum performance, the batch process should last at least 1 minute!)

Current Output: End of Batch

• Current Output - End of Batch (sec. 8C): This function is designed to trigger a second FPM-9020A batch controller's remote START input for a second batching stage. When the batch starts, the current output remains at 0 mA until the end of the batch, then jumps to 20

mA for 500 milliseconds. The 500 millisecond current pulse triggers the second FPM-9020A's remote START terminal to start the second batch stage.

Batch running...

valve

20 mA 4 mA

Batch running...

0 mA

100%

valve

100%

20 mA 500ms

+ 8 hidden pages

Omega Products FPM-9020A Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual