Yokogawa 414 User Manual
BATCH CONTROLLERS
MODEL 414A
November 1995
CONTENTS
1. Introduction 3
1.1 Model Number Designation 4
2. Specification 5
3. Operation 7
3.1 Front Panel Operation 8
3.2 Batch Operations 11
3.2.1 Control Relay Outputs 13
3.2.2 Signal Timeout 14
3.2.3 End of Batch 15
3.2.4 Auto Restart 16
3.2.5 Automatic Overrun Compensation 17
3.3 Calculation of Rate and Total 18
3.3.1 Analog Input 18
3.3.2 The Cutoff Point 19
3.3.3 Filtering 20
3.4 Total Conversion 22
3.5 The Output Pulse and Flow Alarm 23
4. Options 25
4.1 The RS232/422/485 Interface Option 25
4.1.1 Hardware 25
4.1.2 Multipoint Communication 26
4.1.3 Communication Protocol 28
5. Calibration 30
5.1 Programming the Setup Parameters 32
5.2 Entering the Batch Parameters 34
5.3 Programming Options 36
5.4 Checking the Input Signal 38
6. Input Circuits 39
6.1 The Signal Input 39
6.2 Remote Switch Inputs 41
7. Installation 42
7.1 General 42
7.2 Wiring Designations for the Model 414A 44
8. Trouble Shooting 45
8.1 Error Codes 47
Index 48
Introduction 3
1. INTRODUCTION
The Model 414A Batch Controller accepts analog flow signals and automatically
controls the batching of fluids via a one or two stage control valve.
The instrument is extremely flexible and easy to operate, with a four key, front
panel operation that enables the batch quantity to be set, and batches to be
started or stopped.
The Batch Controller is a microprocessor based instrument which measures
4-20mA, 0-20mA, 1-5 Volt or 0-10 Volt signals from flowmeters and pressure
transducers. The instrument can be programmed to display directly in
engineering units and includes such features as linear or square law calculation,
integration and digital filtering.
The 4-20mA, 0-20mA, 1-5 Volt and 0-10 Volt input signals are isolated from the
supply rails and outputs, and may therefore float independently. This ensures
that the input will be compatible with all transmitters and can be used in current
loops which have more than one receiver.
The instrument is fully programmable, with all calculation constants set via the
front panel switches and stored in a non-volatile memory which will retain data
indefinitely. The user can program such parameters as span, zero, filtering
levels, display resolution and cutoff points.
This instrument conforms to the EMC-Directive of the Council of European
Communities 89/336/EEC and the following standards:
Generic Emission Standard EN 50081-1 Residential, Commercial & Light
Industry Environment.
Generic Emission Standard EN 50081-2 Industrial Environment.
Generic Immunity Standard EN 50082-1 Residential, Commercial & Light
Industry Environment.
Generic Immunity Standard EN 50082-2 Industrial Environment.
In order to comply with these standards, the wiring instructions in Section 8.1
must be followed.
4 Introduction
1.1 MODEL NUMBER DESIGNATION
The Model number of an instrument describes which input and output options
are installed and the AC mains voltage rating.
Model 414 A. 1 0 E B
B for Backlite
C for Conformal Coating
E for 220/240 VAC
A for 110/120 VAC
D for DC Power Only
Options
0 for no option
2 for RS232/422/485
Mounting
1 for panel mounting
2 for field mounting
3 for explosionproof
The Model Number of the instrument is displayed on first entering the
Calibration Mode (see Section 5).
Specification 5
2. SPECIFICATION
General
Display: 6 digit LCD. 0.7" (17.8mm) high digits.
Display Update Rate: 0.25 seconds.
Transducer Supply: 8-24VDC field adjustable.
50mA maximum.
Power Requirements: 11.5 to 28.5 volts DC.
130 mA typical current (no options).
AC Mains: Set internally to 95-135 VAC or
190-260 VAC.
Operating Temperature: 0 to 55°C standard.
Dimensions: 5.7" (144mm) wide x 2.8" (72mm) high x
7.0" (178mm) deep.
Cutout: 5.5" (139mm) wide x 2.6" (67mm) high.
Analog Input
Input: 4-20mA, 0-20mA, 1-5 Volt or 0-10 Volt.
The input circuit is floating and isolated from
the power supply and outputs.
Span: 0.1000 to 50000.0000.
Zone: 0.0000 to 50000.0000.
Accuracy: 0.075% of full scale.
Self-Calibrating: An internal reference is sampled every 10
minutes. Temp Co-efficient is 40ppm/C.
Aging is 20ppm/1000 hrs.
Integration: The rate is integrated with a timebase
selectable to be in days, hours, minutes or
seconds.
Cut-off: A cut-off point can be set below which the
rate is not integrated.
6 Specification
Relay Outputs
Maximum Switching Power: 1250VA.
Maximum Switching Voltage: 250VAC, 30VDC.
Maximum Switching Current: 5 Amps.
Pulse Output
Pulse Width: 10mSec (negative going pulse).
Maximum Duty Cycle: 49 pulses per second.
Output: An open collector transistor will sink
100mA.
Scaling: The pulse output is scaled and outputs one
pulse each time the accumulated total
increments.
Operation 7
3. OPERATION
The Model 414A Batch Controller uses a low power CMOS microprocessor to
perform all control functions and calculations.
The instrument is fully programmable with all operating parameters and
calculation constants user programmable. (See Section 5 entitled "Calibration"
for information on programming.) All parameters and constants are stored in a
non-volatile memory which retains data without battery backup for a minimum
of 10 years.
A block diagram of the instrument is shown below.
4-20mA
(0-20mA)
Signal
Common
0-10 V
1-5 V
Model 414A
110/220V
AC Main s
RS232/422
Option
Relays
RS232/422
Output
EOB
Control
Relay Outputs (2)
Pulse
Output
Flow Alarm
DC Input Power
DC Power Ground
DC Power Output to Sensors
8 Operation
3.1 FRONT PANEL OPERATION
The four key operation of the Batch Controller is straight forward.
SETTING THE BATCH QUANTITY
The Batch quantity is programmed as follows:
Switch Action Display Comments
Press BATCH SET Batch "Batch" is displayed for one second
followed by the batch quantity last
entered. The Batch Set LED lights.
"1" 2345 The most significant digit flashes
indicating that it can be changed.
Press "2" 2345 Pressing the DISPLAY key will
increment the digit. (The up arrow on
the Display key indicates to increment
digit.)
Press 2 "2" 345 Pressing the RUN key will change digit
and enables the next digit to be
incremented. (The right arrow on the
RUN key indicates to change digit.)
Press BATCH SET Set Once the desired number is entered,
press the BATCH SET key to return to
the Run mode. The Batch Set LED will
extinguish.
Once programmed, the Batch quantity will be retained in the non-volatile
memory and will not alter until changed by the user.
Operation 9
The Batch quantity can only be set while the instrument is in non-operational
state such as when the batch is complete, or if the batch process has been
interrupted. However, the Batch key can be pressed while in the run state and
the Batch quantity checked. All digits will flash to signal the quantity cannot be
changed.
STARTING A BATCH
To start the process the RUN key is pressed. The Run LED will light and the
instrument will begin to totalise from zero or, if programmed for the count down
mode, the display will decrement from the batch quantity.
The batcher has two output relays and these are energised and de-energised as
described in section 3.2.
STOPPING
The process can be stopped at any time by pressing the STOP switch. Once the
process has been interrupted in this way it can be continued by pressing the RUN
switch or the process can be aborted and the instrument reset by pressing the
STOP switch a second time.
When the process is interrupted, the STOP LED will flash to prompt the
operator to either restart or abort the batch.
RESETTING
The instrument can be programmed to reset in one of two ways.
At the end of a batch, the STOP key must be pressed to reset the Batch
Total. If the instrument is programmed to count down, the Batch
Total will then revert to the preset quantity. If it is programmed to
count up, the Batch Total will clear to zero.
If Auto Reset is programmed, the Batch Total will automatically reset
when the RUN key is pressed and then commence the next batch.
10 Operation
DISPLAYED INFORMATION
The display will normally show the Batch Total, which is the total count for the
current batch and is reset on each new batch.
The DISPLAY key can be used to display the following additional information:
Rate
On the first press of the DISPLAY key, the display shows RATE for
one second followed by the flowrate.
Accumulated Total
On the next press of the DISPLAY key, the display shows ACC for
one second followed by the actual total. The Accumulated Total
cannot be reset during normal operation.
LIMIT ON BATCH SIZE
To prevent accidental entry of large batch quantities, a maximum batch limit can
be programmed during calibration. The operator is then prevented from entering
a batch quantity which exceeds this value.
Operation 11
3.2 BATCH OPERATIONS
The Batch Control functions can be programmed, during Calibration, to operate
in one of two ways.
1. At the end of the batch, the STOP key must be pressed to reset the Batch
Total. (This must be done before another batch can be started.)
Run Stop Run
Count Down
Count Up
Relay 1
Relay 2
Start Time
End of
Batch
PAUSE
Presto p
Quantity
End of Batch
Batch
Quantity
Reached
Stop Run
12 Operation
2. If Automatic Reset is programmed, a new batch is commenced each time the
RUN key is pressed.
Batch
Quantity
Reached
Run
Auto Restart
Time
Run Stop Run
Count Down
Count Up
Relay 1
Relay 2
Start Time
End of
Batch
PAUSE
Presto p
Quantity
End of Batch
The Batch Controller can also be programmed, during Calibration, to either
count up from zero on each batch, or to count down from the preset batch
quantity.
Operation 13
3.2.1 Control Relay Outputs
The two output relays can be set up to control a single valve or a dual valve with
slow stop and/or slow start. Alternatively, the second relay can be used to
control a pump.
The relay operation is shown on the previous two pages.
A time delay between the Start and the time when relay 2 energises can be
programmed to provide a soft startup. The delay can range from 0 (no delay) to
79 minutes and 59 seconds.
A Prestop quantity (ie. the quantity to the end of the batch) can also be
programmed to provide a slowdown of flow at the end of the batch, thereby
enabling precise quantities to be batched.
The process can be stopped at any time by pressing the STOP key, whereby both
relays will immediately de-energise. The process can then be aborted and the
batcher reset by pressing the STOP key again, or the process continued by
pressing the RUN key.
If the process is continued and the instrument was previously in the slow start or
main control phases (ie. not the prestop phase), the timer will be reset and a slow
start will occur with a full time delay to ensure a correct start up. The totals will
not be reset and the batch quantity will remain unchanged.
14 Operation
3.2.2 Signal Timeout
The Signal Timeout period defines a time interval which is used to detect if the
flow has stopped. If there is no signal input for a time greater than the Signal
Timeout period, the flow is deemed to have stopped. A Signal Timeout period
has two functions:
To detect the loss of signal midway through a batch when the relays
are energised. In this case, the Batcher will enter a Flow Alarm
condition and de-energise the relays.
After the preset batch quantity has been reached and the relays
de-energised, some overrun of flow may occur due to slow valve
closure, etc. In this case, the Signal Timeout is used to determine
when the flow has ceased and thereby accurately determine the
amount of overrun.
The instrument enables the user to program a time interval of up to 99 seconds to
detect an absence of signal input. If the Signal Timeout is set to 0, this
function is disabled.
Flow Alarm
If the Signal Timeout is set at greater than 0, and loss of signal is detected
midway through a batch, a Flow Alarm signal is output on terminal 7. In
addition, both relays are de-energised. The Flow Alarm output and condition is
maintained until acknowledged by pressing the STOP switch. The alarm
condition is also signalled to the operator by the flashing STOP LED. Once
acknowledged, process can then be reset via the STOP switch or continued by
pressing the RUN key.
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