Advanced Wireless Solutions EMO-500 Automobile Parts User Manual

FLOW
TRANSMITTERS
ELECTRONICS FOR
INSTRUMENTATION
EMO-500
Operation Manual rev.4
8809 Industrial Drive, Franksville, WI 53126-9337
Tel: 262-884-9800
E-Mail: aw@awcompany.com
Fax: 262-884-9810
Web: www.awcompany.com
EMO 500 MANUAL TABLE OF CONTENTS
Table of Contents.......................................................................................................................... 2
Overview of Display Screens ....................................................................................................... 3
Introduction................................................................................................................................... 4
Special Features ............................................................................................................................ 5
Hardware Connections.................................................................................................................. 6
Hardware for External Resets and Controls ................................................................................. 7
External Resets and Controls........................................................................................................ 8
Quick Programming Options ........................................................................................................ 9
Programming the EMO 500 (F2)................................................................................................ 11
Ratio Programming (F3)....................................................................................................... 12
Limit Programming (F4)....................................................................................................... 13
Meters/Units Programming (F5)............................................................................................. 15
Global Programming (F6)...................................................................................................... 17
KFR.................................................................................................................................... 18
KFT.................................................................................................................................... 19
Units for Rate..................................................................................................................... 20
Sample Size ....................................................................................................................... 20
Gate Time .......................................................................................................................... 21
Analog Offset..................................................................................................................... 21
Analog Gain....................................................................................................................... 21
Analog Rule ....................................................................................................................... 23
Unit Number ...................................................................................................................... 23
Default Values Throughout the EMO 500.................................................................................. 24
Ratio Feedback Mode ................................................................................................................. 25
Serial Port Operations................................................................................................................. 26
Protocol Format ..................................................................................................................... 26
Checksum Calculation ........................................................................................................... 27
Address Information .............................................................................................................. 30
Limited Warranty........................................................................................................................ 33
Appendix
How to hookup external connections - Appendix A thru E
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Overview of Display Screens
The 0 through 9, and F1 keys display these screens except when programming.
0-KEY = = =>
RATIOA/B = 1.19
W=Y A=N I = 1.00
= = =>Current Ratio A/B
= = =>Warning, Alarm, Ideal Ratio
1-KEY = = =>
FLW A=139.3 CCM
FLW B=136.3 CCM
= = = > Flow A
= = = > Flow B
2-KEY = = =>
JOB A=10779. CC
JOB B=11703. CC
= = = > Job Total A
= = = > Job Total B
3-KEY = = =>
GR A=300912. CC
GR B=313391. CC
= = = > Grand Total A
= = = > Grand Total B
4-KEY = = =>
J A+B 614303. CC
G A+B 623476. CC
= = = > Job Total (A+B)
= = = > Grand Total (A+B)
5-KEY = = =>
= = = >Ratio Warning/Alarm Settings
ANo Ratio Mode@ when Limit
CURRENT RATIO LI
2 Rule is not on Ratio
WAR=005%ALA=010%
6-KEY = = =>
SD1: AO=0000
IN=11111OUT=0000
= = = >Analog Out, 0-4095 = 0-20mA
= = = >Inputs pins 1-5, Limits Out
7-KEY = = =>
SD2:FA=139FB=136
TA=10779TB=11793
= = = >Frequency A, B .....(Hz)
= = = >Total Impulses A, B
8-KEY = = =>
RATIO A/B=1.19
FL A+B 275.6 CCM
= = = >Current Ratio A/B
= = = >Flow Rate (A+B)
= = = >Limit Status
9-KEY = = =>
L1 L2 L3 L4
OFF OFF ON ON
F1-KEY ===>
T A-B= 24321. CC
F A-B=
15.4CCM
= = = >Total Differences
= = = >Flow Differences
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Introduction
The EMO-500 is a Two Component Ratio and Flow Computer. It is primarily designed
for use as a two component, ratio monitoring unit but can also be used as a Two Channel
Flow Rate Monitor and Totalizer. The EMO 500 has the added capability of current
(4-20mA) and voltage (0-5V) analog output signals. These outputs can be used as a
representation of a selectable range of functions or in a ratio linked, closed loop mode Ratio Feedback Mode.
The unit is powered by 110V AC but can be jumpered for 220V AC.
The back panel provides these features:
<
18V supply plus ground and input lines for two flow meters.
<
4 programmable relay switched limits which can be used for warnings, alarms, or
automatic shut-down control.
<
5 "Ready to Hardwire" function controls. #'s 1 through 4 allow for remote
operation of resets, display, and Quick Programming. # 5 will "enable" the main
programming menu.
<
RS-232 and RS-485 serial ports.
<
Analog outputs (4 - 20mA) and (0 - 5V).
Programming functions are shown in red on the keypad.
All of the default program variables can be changed to alternative values through
the keypad or by a host computer with an RS-232 serial port. There are security features
to prevent unintended programming changes - for more information review the pages on
Quick Programming and Full Programming. The Quick Programming functions
allocated to certain keys are indicated in red on the keypad. Keys F1 through F6 have
multiple functions and are also used for the main programming purposes. The alternative
function of each key when in Full Programming Mode is indicated by a banner on the
keypad immediately above these specific keys.
When programming is not enabled the F3/F4/F5 serve as Job Resets and keys 0 through9
are used to select from the 11 operating displays shown on page 1.
IMPORTANT----IMPORTANT----IMPORTANT----IMPORTANT
The higher flow side should be connected to
flow meter A as the Ratio calculation is A/B
IMPORTANT----IMPORTANT----IMPORTANT----IMPORTANT
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Special Features of the EMO-500
The EMO 500 is especially suited for use in dispensing systems with irregular flow
patterns. The unit employs a user programmable sampling size to govern how often the
ratio display is updated - the operator then has maximum control over the sampling period
and can easily adjust this to suit his own system parameters. The user is often more
interested in the ratio of components dispensed over a period of time, say in a batch,
rather than on an instantaneous basis.
Programming
<
There are 3 methods of programming the unit - two have lockout features to
prevent unauthorized access.
Full Programming Enable:
<
The full programming menu is accessible by placing a jumper between pin 5
(enable programming) and pin 6 (Common). The F2 key will page through the
menu of programming options - these options are indicated in red lettering on a
banner above the upper function keys.* See Programming the EMO 500 (Pg.8).
Quick Programming Feature:
<
Some variables only need to be installed once. With others, such as Gate Time or
Sample Time, the user may wish to experiment to find a preferred value. To make
this easier or make some selected variables permanently available, such selected
programming functions are accessible in the following way:
Simultaneously - Engage the 'Scroll Display' (jump pin #2 to #6) and press one key on the
upper line, F1 through key #1. Note -The variable is highlighted in red on the key. Press
Enter (F6) to exit. (Pg.17).
Serial Port Programming:
<
The EMO-500 is fully programmable through the serial port using RS-232 or
RS-485 type communication. Refer to the Serial Port Operations portion of this
manual for complete information.
Sample Size - # of impulses collected for the Ratio Calculation.
<
To determine the ratio - the total number of pulses from both flow meters are
separately counted until one of them reaches the programmed Sample Size. The
number of pulses from flow meter A is then divided by the number of pulses from
flow meter B. The governor will therefore be the meter with the slower pulse rate.
The Sample Size determines both the accuracy and response time of the ratio
calculation - reducing the sample size, increases the response time but decreases
the accuracy. A default value of 200 is factory installed. See P.
Gate Time - Time period over which Rate Calculations are made.
<
The gate time (in seconds) is the time period the microprocessor collects pulses to
perform rate calculations. A default value of 1.85 is factory installed. See P.15.
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Hardware Connections
Warning: The AC Power should
be wired just as labeled on the
three pin connector.
PIN 1-Ground
PIN 2-Line 110v.
PIN 3-Line Neutral
Grounding Considerations
The grounding is a most important consideration in an installation where
microprocessor technology is applied. The EMO-500 is a panel mounted unit and
therefore the casing is connected to the sub-panel. If the sub-panel is metal it should be
grounded. If the sub-panel is non-conductive - PIN 1 of the three pin connector on the
EMO-500 back panel must be grounded.
To insure a proper ground we recommend connecting PIN 1 of the three pin
connector to the panel's central ground point.
Signal and Shielding
The two flow meter pick-ups should be supplied with their respective 18v. supply
voltages and referenced to their respective grounds. This will insure that the input signals
from the flow meters are referenced to the ground connections on pins 2 and 5. Most
applications require some signal shielding. A solid aluminum wrap shielding will work
fine. The shield should be connected to pins 2 and 5 on the flow meter connector. DO
NOT connect the shielding at the flow transmitter.
IMPORTANT! NEVER CONNECT THE SHIELD TO GROUND AT BOTH ENDS!!
DOING SO CAN PRODUCE UNWANTED OSCILLATIONS IN THE SIGNAL WIRES.
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Hardware for External Resets and Controls
There are 5 inputs to the 15 pin connector to provide extra control capability without
having to go through the keyboard. To
activate the external resets and controls the
user should simply connect the respective
pin to the common 1 - 5 pin. Pins 1 - 4 are
edge triggered, therefore momentary
contact switches should be used to activate
them. Pin 5 (enable programming) is an
on/off function and single pole toggle
switch is recommended.
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External Resets and Controls
1. Reset All
This reset is the most powerful on the EMO 500.
When activated it will reset:
Ratio : A/B
Job Vol A, Job Vol B & Job Vol A+B
Warning & Alarm Limits
Limits 3 & 4
Grand Totals
Analog Outputs to start point
2. Scroll Display
When activated, this input will scroll the display through all of the 11 screens available. It
also allows access to the Quick Programming functions which are highlighted in red on
the upper keypad line. (See pg 8. for more details on Quick Programming).
3. Reset Job B - resets OFF-RATIO WARNING/ALARM (LIMIT 1 & 2).
When activated, this input will reset the Job B totalizer. This also resets the A/B RATIO
to the IDEAL setting, which simultaneously resets the WARNING & ALARM LIMITS.
4. Reset Job A - resets OFF-RATIO WARNING/ALARM (LIMIT 1 & 2).
When activated this input will reset the Job A total. This also resets the A/B RATIO to
the IDEAL setting, which simultaneously resets the WARNING & ALARM LIMITS.
Note: Simultaneously pressing and holding RESET JOB A and RESET JOB B on the
keyboard, or through the back-panel connections, implements a HOLD TOTAL
function.
5. Enable Full Programming.
When activated, this input enables the F2 through F6 keys to perform the programming
functions shown in red on the banner strip above the keypad.
NOTE: F3, F4, F5 will serve as Job Resets in the Job Totals screen when the
Enable Programming switch is off.
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The Quick Program Options
While many programming variables such as KFR or meter selection may only require a
"one time" setting - others may require some experimentation to find maximum efficiency
settings. It may also prove desirable to allow an operator in the field some limited ability
to make some quick adjustments. To accommodate these circumstances a method of
jumping directly into some limited programming functions has been made available. This
method is called "Quick Programming" The functions available are noted in red on the
top line of keys -F1-F6 Function Keys & 0-1 keys.
F1 ..........................................................................................................................Ideal Ratio
F2 .......................................................................................................................... Gate Time
F3 ............................................................................................................... Ratio Warning %
F4 ................................................................................................................... Ratio Alarm %
F5 .................................................................................................................... Decimal Point
F6 ...................................................................................................................................Enter
0 ......................................................................................................................... Sample Size
1 ...................................................................................................................Specific Gravity
To activate a Quick Programming Option.
Connect the Scroll Line Input (Pin 2) and the Common 1 - 5 (Pin 6) of the 15 Pin
connector on the back panel of the EMO 500 -a momentary contact switch is
recommended. While this connection is made, simultaneously push any one of the keys
shown above. NOTE: This will not work if full programming is enabled.
*NOTE
See Appendix D for a circuit drawing.
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F1 Ratio
Default Value = 1.00
This function is the address of the IDEAL RATIO which represents the desired ratio
of FLOW A/FLOW B. The default is 1.00 which represents a 1 to 1 ratio.
F2 Gate Time
Default Value = 1.85
The GATE TIME is the period of time, in seconds, during which the flow rate
calculation is made. The accuracy and response time of the flow rate display is therefore
dependent upon this value. To achieve a 1% accuracy, the slowest pulse rate should
deliver at least 100 pulses.
F3 Warning
Default Value = 5%
The WARNING variable is available to set as a % deviation from the Ideal Ratio. The
ratio calculation is triggered by the first meter to deliver the number of pulses
programmed under the SAMPLE AMOUNT variable. The calculation compares the
measured ratio to the Ideal Ratio and if the difference in % terms exceeds the
programmed value, the warning is activated.
F4 Alarm
Default Value = 10%
The ALARM variable is similar to the warning function.
F5 DP
Decimal Point
This key is used to locate the decimal point when
programming.
F6 Enter
Locks in programmed values.
#0 Sample Size
Default = 200
To determine the ratio the total number of pulses from both flowmeters are separately
counted until the fastest one reaches the programmed SAMPLE SIZE. The number of
pulses produced by flowmeter A is then divided by flowmeter B, and the result
determines the ratio calculation. The accuracy and response time of the ratio calculation
are therefore dependent upon the SAMPLE SIZE. The flowmeter with the lowest pulse
rate should produce 100 pulses before the ratio calculation is updated to achieve a "1%
accuracy. The display screen #7 is an useful guide for this purpose.
#1 SG
Default = 1.0
Specific gravity values may be entered for each metered flow should quick corrections
be required in this value.
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Programming the EMO 500
As a security precaution, access to the full programming section is only possible when pin
5 is "enabled". This can be accomplished by connecting pin 5, on the 15 pin connector, to
the pin 6 Common (See Appendix D). Next, after first hitting F2, each function key, F1
through F6, will then allow access to the programming menu indicated immediately
above it on the red banner strip (The banner strip is labeled 'PROGRAMMING' as
indicated below).
ESCAPE
ACCESS
RATIO
LIMITS
METERS
GLOBALS
PROGRAMMING
IMPORTANT ACCESS IS DENIED TO F3, F4 & F5 UNTIL F2 IS PRESSED FIRST.
THIS IS A SECURITY MEASURE TO PREVENT UNINTENTIONAL PROGRAMMING
CHANGES
Reminder Note: The other programming functions, indicated in red, on the F1 - F6 and 0
- 1 keys are activated by the Quick Programming Options which are reviewed on page 8.
(Quick Programming is provided for immediate access to a few limited programming
functions only).
AFTER JUMPERING PIN 5 TO PIN 6 - THE ACCESS SEQUENCE IS AS FOLLOWS:
MAIN MENU
F2
OPTIONS
F3
RATIO PRG.
F4
LIMIT PRG.
F5
METER/UNIT PRG.
F6
GLOBALS
PRG.
Enable Prog. --> F2
-->
-->
-->
-->
F3
F4
F5
F6
...
...
...
...
(Access to Ratio Prog)
(Access to Limit Prog)
(Access to Meter/Units)
(Access to Global Prog)
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The F1 key serves as an ESCAPE key to leave the programming functions and return to
the last screen displayed.
The F2 key will page the user through the programming options shown above AND IS
REQUIRED TO ALLOW FURTHER ACCESS.
The F3 key will call up Ratio Programming.
<
Enter the Ideal Ratio. This number represents the desired Ratio of Flow Amount
A to Flow Amount B. The default is 1.00,
meaning a 1 to 1 ratio.
<
Enter the Ratio Warning. This number
represents the percentage of error between the
actual measured ratio and the desired ideal ratio.
The default is 5%. Therefore, if the actual and
measured ratio differ by more than 5%, the
Limit 1 relay will close.
<
Enter the Ratio Alarm. This number works the
same as Ratio Warning except that after the
warning, the EMO 500 will wait for one more
sample amount before closing the Limit 2 Relay
if the ratio error is greater than the programmed
percentage. The default is 10%.
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The F4 key will call up Limit Programming.
OFF-RATIO WARNING & ALARM SETTINGS
Since the EMO 500 is primarily a Ratio Monitor, Limits 1 and 2 are factory set to be
triggered by an off-ratio condition.
Default values are set at Limit 1 = Warning 5% and Limit 2 = Alarm 10%.
For example: If the RATIO WARNING is programmed at +/- 10%, then the LIMIT 1
contact will close when this event occurs. LIMIT 2 will be similarly activated by the
value programmed in the RATIO ALARM. Note - Press key #5 to review the current
ratio alarm settings and key #9 to review the limit status. Off-ratio alarms can be reset
easily by pressing either F3 (Reset A) or F4 (Reset B).
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As mentioned previously, Limits 1 & 2 are preset for ratio alarms and are very easily
adjusted for different ratio settings via the Quick Programming.
Limits 3 & 4 can be used to warn of other monitored parameters such as flow rates or
totalized fluid volumes. These settings can be adjusted as follows.
There are three parts to the full Limit Programming section and each part should be done
in order. They are:
1. Limit 3 Rule & value
2. Limit 4 Rule & value
3. Limit 2 Rule and or value
This procedure is also shown pictorially on the previous page.
First you must enter the "Limit 3 Rule". This means the user must select the function
wanted to trigger the Limit 3 relay. The options are:
- Job Total for A
- Flow A
- Job Total for B
- Flow B
- Job Total for A+B - Flow A+B
Page through the options above by pressing F4, enter using F6.
The numeric value at which the Limit 3 Relay will trip should now be entered. This
number will work with the Limit 3 Rule selected above.
NOTE: The display will flash "DP Location Will Match KFT/KFR".
This means that the number entered for the Limit trip point will automatically take the
same decimal point location as the Total Scaling Factor (KFT) for Total Limits or Rate
Scaling Factor (KFR)for Flow Rate Limits.
Type in the Limit 3 value desired and enter with F6
The limit 3 number must be entered to proceed to Limit 4
The Limit 4 Rule and Number entry is exactly the same as above.
The limit 4 number must be entered to proceed to Limit 2
Next the Limit 2 Rule can be entered.
<
If the user selects Ratio A/B the Limits 1 and 2 will operate on the ratio
percentage of error under F3 Ratio Programming. Therefore, if Ratio A/B is
selected - limit programming is complete. The unit will exit to the last display in
memory before entering the programming mode.
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For example - Limit 1 & 2 can be programmed for Warning & Alarm settings on Flow A
while Limit 3 & 4 could be allocated to Warning & Alarm for Flow B or Flow A+B and
Total B respectively. Therefore Limits 3 and 4 can be selected independently but 1 & 2
cannot be separated.
Therefore, if Ratio A/B is selected under the Limit 2 rule, the limit programming is
complete. The unit will exit to the last display in memory before entering the
programming mode.
Other options are as follows: Page using F4 and Enter, F6.
- Ratio A/B
- Job Total for A
- Job Total for B
- Job Total for A+B
- Flow A
- Flow B
- Flow A+B
NOTE: If the user selects any function other than Ratio A/B for the Limit 2 Rule,
the EMO 500 will still monitor the ratio of flow A/B, but no Warning or Alarm will
trip when flow is out of the programmed error percentages. This will be indicated in
display 5 as " NO RATIO MODE FOR LIMITS 1 & 2 ".
The F5 key will call up Meters/Units Programming
<
In this program section the user can select from 9 Flow Meters and 3 Engineering
Units. The EMO 500 will automatically enter the Rate Scaling Factors (KFR) and
Total Scaling Factors (KFT) for each of the selections below.
Flow Meters and their approximate K-factors
- ZHM01..160000 PPG - ZHM03...6600 PPG
- HPM-15..32000 PPG
- ZHM02/1.32000 PPG - ZHM04...1800 PPG
- HPM-20..16000 PPG
- ZHM02...16000 PPG
- HPM-30...6600 PPG
- ZHM05....500 PPG
When in the Meters/Units Program, scroll through the Meters until the selection
desired appears on the display. Then enter with the F6 key. The unit will then ask the
user to select the Engineering Units in the same manner.
Engineering Units
- CC & CCPM
- GAL & GPM
- OZ & OZM
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The EMO 500 will flash "Direct Selection, Meter A or B" then the display will read
"F2=A, F3=B, F4=A&B". This is where the user can choose the input the selected Flow
Meter and Engineering Unit will be set. The display will the read "More Selections?,
F2=Yes, F3=No". If both Flow Meters are programmed select F3, if not F2 will start the
Meters/Units Program section again.
NOTE: The Engineering Units for A and B should be the same.
NOTE: The (KFR) and (KFT) values in the Meters/Units Programming are only
approximations because the K-factors of the above flow meters are only
approximations. The user should calculate the (KFR) and (KFT) using the
calibrated K-factor whenever possible. This will be covered in the Global
Programming section.
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F6 key will call up Global Programming.
Global Default Values
1. KFR for A
-----------
100.0
2. KFT for A
-----------
10000
3. KFR for B
-----------
100.0
4. KFT for B
-----------
10000
5. Units for Rate
-----------
12 Hz
6. Units for Total
-----------
08 Impulses
7. Sample Size
-----------
200 Impulses
8. Gate Time
-----------
1.85seconds
9. Analog Offset
-----------
0000
10. Analog Gain
-----------
10200
11. Analog Rule
-----------
06 Ratio
12. Unit Number
-----------
01
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EXPLANATIONS OF THE GLOBAL VARIABLES
1. KFR for A.....Default 100.0
In order to make the EMO 500 display the correct rate in an engineering unit such as
GPM, a scaling factor must be calculated. This Rate Scaling Factor is called the KFR.
The KFR is calculated using the K-factor of the flow transmitter being monitored. The
K-factor is the number of impulses per engineering unit established by a calibration
test.
For example: A flow meter could have a K-factor of 6304 imp/Gal. In order to calculate
the KFR multiplier for the EMO 500 apply the following formula:
6000
KFR=
K-factor
100 is the constant for seconds
6000 is the constant for minutes
360000 is the constant for hours
This KFR is the number that should be entered in the Globals Programming section. The
K-factor is the number published by the manufacturer as the average K-factor for the
transmitter.
For Example: A flow meter has the K-factor 2053.7 imp/GAL and the display should
show Gallons/minute.
6000
KFR=
= 2.921 GPM
2053.7
The number 2921 would be entered as the respective KFR and the DP (decimal point)
key would move the DP to the number 2.921.
NOTE: We recommend removing the insignificant decimal numbers often produced
by calculator mathematics. These present a misleading level of precision in the display.
We recommend using a maximum of 4 digits regardless of the decimal point
position.
Example:
for 60.675 enter 60.67
for 2.3456 enter 2.346
NOTE: The largest number that can be entered as a KFR is 65000 ignoring the
decimal point position. Therefore 7.3456 will fail to be accepted as too large. A
message will alert the user if this should occur.
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2. KFT for A ................................................................................................Default 10000
In order to make the EMO 500 display the correct Totalized Value in Engineering
Units, again the most important thing to know is the K-factor of the flow meter. The
K-factor is the relationship between the amount of the impulses and the engineering units.
In order to calculate the KFT for the EMO 500 apply the following formula.
10000
KFT =
K-factor
The KFT is the number that should be entered in the Globals Programming section. The
K-factor is the number published by the manufacturer as the average K-factor of the flow
meter. If this is published in imp/Gal the totalizer can still be set in, say cc's , by
converting the K-factor to imp/cc. 10000 is a constant.
For example: A flow meter has a K-factor of 106666.0 imp/Gal and the display
should show gallons/minute.
10000
KFT=
= .9376 Gal
10666.0
The number 9376 would be entered as the KFT and then the DP (decimal point) key
would move the DP to 0.937. (See note below).
NOTE: We recommend removing the insignificant decimal numbers often produced
by calculator mathematics. These are mathematically redundant and offer a misleading
level of precision in the display. We recommend using a maximum of 4 digits regardless
of the decimal point.
Example:
for 60.675, enter 60.6
for 2.34543 enter 2.345
NOTE:
<
The largest number that can be entered as a KFT is 65000. Refer to KFR note
above.
3. KFR for B The operations are the same as KFR for A.
4. KFT for B The operations are the same as KFT for A.
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5. Units for Rate.
This variable will display the Engineering Units required for the flow rate display. This
is strictly a display and does not perform the actual conversion of raw counted impulses.
Those calculations are handled by the KFR. Enter the two digit number for the desired
Units for Rate.
00 - cc/min
01 - liter/min
02 - gallon/min
03 - ounce/min
04 - RPM
05 - gram/min
06 - gram/sec
07 - lb/min
08 - Kg/min
09 - Kg/sec
10 - lb/sec
11 - lb/Hr
12 - Hz (Impulses/sec)
6. Enter Units for Total.
This variable will determine the Engineering Units for Total displayed after the
totalizer value. It is also a display function only and doesn't perform the actual
conversion of total impulses to the correct value. Those calculations are handled by the
KFT.
Enter the two digit number for the desired Units for Total.
00 - cc
01 - liter
02 - gallon
03 - ounce
04 - revolution
05 - gram
06 - lb
07 - kg
08 - Impulses
7. Sample Size..................................................................................................Default 200
To determine the ratio the total number of pulses from both flow meters are separately
counted until one of them reaches the programmed Sample Size. The number of pulses
from flow meter A is then divided by the number of pulses received from flow meter B.
The accuracy and response time of the ratio calculation are therefore dependent on
the Sample Size.
To determine a reasonable number to program for Sample Size the main factor will be
the flow meter with the lowest pulse rate should produce at least 100 pulses before the
Ratio calculation. If 100 pulses are counted on the slowest moving totalizer then the
accuracy of the ratio calculation should be about " 1 %.
NOTE:
The pulses being counted are straight from the flow meter,
not scaled engineering unit values.
The display screen #7 (Status Disp. 2) is a useful guide in this selection. The lower line
shows the incoming raw pulse count. If the Sample Amount is say 1000, the ratio display
will update each time the fastest total increments by 1000. Also by this method, the
slower pulse count can be observed. The default value is 200
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8. Gate Time ........................................................................................... Default 1.85 sec.
The gate time (in seconds) is the amount of time pulses are accepted before flow rate
calculations are performed. The accuracy and response time of the flow rate display are
dependent on the gate time. To achieve a 1% flow rate accuracy, the lowest pulse rate
should produce 100 pulses before the rate calculation is performed. In display #7 (Status
Display 2) the lower line indicates incoming flow meter impulses, an estimate of the time
elapsed for 100 pulses, to be accumulated by the slowest meter, will give a good
approximation of the minimum recommended gate time.
Another method would be to change the default Gate Time value by trial and error
until the best results for the system and user are achieved.
9. Analog Offset.............................................................................................Default 0000
The Analog Output Offset will be a number from 0000-4095 that will become the
bottom end of the 0 - 5 volt & 4 - 20 mAmp analog outputs.
For example:
0000 for 0 to
20mAmps and 0 to 5v.
819
for 4 to
20mAmps and 1 to 5v.
1638 for 8 to
20mAmps and 2 to 5v.
2457 for 12 to
20mAmps and 3 to 5v.
10. Analog Gain............................................................................................Default 10200
The analog gain factor integrates the controller output signal range and speed with the
rest of the system capabilities. If the gain factor is correct the full range of the analog
output signal can be used to cover the operating range of the equipment in which it is
installed.
The formula used to determine the analog output is as follows:
(Variable Value) * Gain
Analog Output=
512
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The Analog Output arrived at above should be a number from 0000-4095 which
drives a D/A converter for a 4 - 20 mAmp and a 0 - 5 volt output on Pins 7 and 8 of the 9
Pin connector. Therefore the gain factor can be estimated by re-arranging the analog
output equation as follows:
GAIN = (512)(Analog Out)
Variable Value
If the desired max output of the system is achieved at 5V or 20 mAmp - this is equivalent
to an Analog Out value of 4095 and the above equation would read:
GAIN =
(512)(4095)
Variable Value
The "Variable Value" is the true flow rate or volume capability of the system
measured at the analog value discussed above and will therefore depend upon the
ANALOG RULE selected. The Analog Rule is discussed further on the next page.
NOTE: The value entered ignores the decimal point position.
For Example:
In Ratio Mode (06)
If Ideal Ratio = 5.00...........................................................................Variable Value = 500
If Ideal Ratio = 10.00.........................................................................Variable Value = 1000
In Flow Mode (00-02)
If Flow Rate = 80.0 cc/m ..................................................................Variable Value = 800
" " " = 200.0 cc/m ......................................................................Variable Value = 2000
" " " = 5.25 GPM .......................................................................Variable Value = 525
In Flow Mode (03-05)
If Total Flow = 10.00 Gal .................................................................Variable Value = 1000
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11. Analog Rule
Default 06
The analog rule allows the user to set the analog output to follow any of the variables
listed below. The variable is selected by entering its number as the Analog Rule.
These are:
00 01 02 03 04 05 -
Flow A
Flow B
Flow A+B
Total A
Total B
Total A+B
06 - Ratio
07 - Ratio Feedback Mode
08 - Ratio w/Reset
09 - Ratio Feedback w/Reset
10 - A - B Job Total
11 - A - B Flow Rate
NOTE: These variables will be used in the computations as numbers in Engineering
Units.(ccpm,gals,ozs.etc.) This means that the Decimal Points, if any, will be dropped
from the numbers.
For instance: 113.7ccpm will be 1137 for computations.
12. Unit Number................................................................................................Default 001
This Variable is used for Serial Communication with a host computer. It will identify
each EMO 500 unit if there is more than one on the communication line. For example Unit #1 would be designated 01 & unit #2, 02 ....etc.
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DEFAULT VALUES THROUGHOUT THE EMO 500
Ratio Programming
Ideal Ratio.................................................................................................................. 1.00
Ratio Warning..............................................................................................................5%
Ratio Alarm ...............................................................................................................10%
Limit Programming
Limit Rule 3................................................................................................... Job Total A
value.......................................................................................................................... 3000
Limit Rule 4................................................................................................... Job Total A
value.......................................................................................................................... 4000
Meters/Units Programming
Meter.............................................................................................................................Hz
Units...............................................................................................................IMPULSES
Global Variables
KFR for A ................................................................................................................ 100.0
KFT for A ............................................................................................................... 10000
KFR for B ................................................................................................................ 100.0
KFT for B ............................................................................................................... 10000
Units Rate .................................................................................................................... .12
Units Total .................................................................................................................... 08
Sample Size ................................................................................................................ 200
Gate Time .................................................................................................................. 1.85
Analog Offset............................................................................................................ 0000
Analog Gain............................................................................................................ 10200
Analog Rule .................................................................................................................. 06
Unit Number ................................................................................................................. 01
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EMO 500 - RATIO FEEDBACK MODE
The EMO 500 also features a Ratio Feedback Mode of operation in which the Ideal
Ratio and the Actual Measured Ratio are compared and a 4-20 mA signal will be
generated to control one of the Flow Rates. This will maintain the programmed Ideal
Ratio over a wide range of flow rates.
The formula used to determine the correct analog output is as follows:
Analog Output = Half Range + (Ideal Ratio-Actual Ratio) * Gain
The Half Range refers to the middle point of the Analog Output. If the output varies
from 0 to 20mAmp. the half point will be 10mAmp.. If the Analog Offset is set to give
an output of 4 to 20mAmp. the Half Point will be 12mAmp.
To use the Ratio Feedback Mode the user should enter 07 as the Analog Rule (See P.18).
NOTE: The Ratio Feedback Mode w/Reset works in exactly the same manner
excepting that the analog output will go to the start point (mid-point) on Reset All input.
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Serial Port Operations
The EMO 500 has RS-232 and RS-485 serial port connections standard on the back panel
9 Pin connector. The user can connect this port to a host computer and then Read or
Write to any memory location in the EMO 500. The RS-232 Pins on the 9 Pin connector
are:
Pin 3......TX transmit
Pin 2......RX receive
Pin 5......Ground
The RS-485 connections are:
Pin 6 ..... RX
Pin 7 ..... TX
Pin 8 ..... RX*
Pin 9 ..... TX*
WARNING --- IMPORTANT --- WARNING --- IMPORTANT
The communication port does not discriminate any addresses. This means that any
address can be written to as well as read from. Writing to certain addresses will change
the operation of the EMO 500 drastically. Caution is a must when programming
through a host computer. Double Check Addresses and Variables Before Writing to
the EMO 500 !!
Note: The communication through the serial port will not work if the EMO-500 is in
programming mode
Protocol Format
The EMO 500 uses a protocol format follows OPTOMUX by the OPTO 22 Company.
The format for reading from the EMO 500 is as follows:
>01K0F3404XXcr
^................start of string must use the > sign
^^.............unit number (under global variables)
^.............read command K (use J to write)
^^^^......address to read from
^^......number of bytes to read
^^....checksum for the string 01K0F3404
......carriage return (ASCII 13) ends the string
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The answer received back from the EMO 500 will look like this:
A03E36712XXcr
^...............all answers start with A
^^............low byte (at address 0F34)
^^..........next byte(at address 0F35)
^^........next byte(at address 0F36)
^^......high byte(at address 0F37)
^^....checksum
......carriage return ends the string
The protocol format for writing to the EMO 500 is as follows:
>01J03340F3587XXcr
^.....................start of string must use the > sign
^^..................unit number
^..................write command J (use K to read)
^^^^...........address to write into
^^...........byte written to 0334
^^.........byte written to 0335
^^.......byte written to 0336
^^.....checksum
.....carriage return
If the operation was successful the EMO 500 answers with: Acr.
The following error messages have been implemented in the EMO 500 protocol.
NO1cr - Undefined command (something other than K/J)
NO2cr - Checksum error
NO3cr - Non printable ASCII character
There is a booklet published by OPTO 22 on the protocol format.
Checksum Calculation
The calculation for the string variables in the read command would be as follows:
>01K0F3404XXcr
^^^^^^^^^.......these characters are used in the calculation.
Add the values for the ASCII Decimal variables.
HEX
ASCII
0 + 1 + K + 0 + F + 3 + 4 + 0 + 4
48 + 49 + 75 + 48 + 70 + 51 + 52 + 48 + 52 = 493
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To calculate the final checksum, convert the decimal number 493 into HEX (493=1EDh)
and take the last two characters (ED) for the checksum.
The final string would look like this:
>01K0F3404EDcr
Important points for serial communication
1. Serial communication will be disabled if the EMO-500 is in programming mode.
2. All characters in the communication string should be in CAPITALS.
Example: >K= is ASCII 75 and will be recognized by the EMO-500, but >k= is ASCII 107
and will not be recognized.
3. All numbers in the communication string are represented in hexadecimal format.
3. You should not try to read or write more than 12 bytes at a time due to limitations of the
EMO-500's serial buffers.
4. The least significant byte of a number is stored at the lower address.
5. The >>= in the transmit string and the >A= in the reply string are not used in the checksum
calculation.
The ASCII characters needed for checksum calculations are:
ASCII
0
1
2
3
4
5
6
7
8
9
Decimal
48
49
50
51
52
53
54
55
56
57
ASCII
Decimal
A
B
C
D
E
F
65
66
67
68
69
70
J
K
74
75
WARNING --- IMPORTANT --- WARNING --- IMPORTANT --- WARNING
The communication port does not discriminate any addresses. This means that any address
can be written to as well as read from. Writing to certain addresses will change the operation
of the EMO 500 drastically. Caution is a must !!! Double Check Addresses and Variables
Before Writing to the EMO 500.
WARNING --- IMPORTANT --- WARNING --- IMPORTANT --- WARNING
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The bytes are always arranged such that the low byte is first and the more
significant bytes follow. In the EMO-500, the least significant byte (LSB) is at the lower
address.
For example: If the data from the totalizer was read as
90D58901 the LSB is 90 and the MSB is 01.
The arrangement of these four bytes in the EMO-500 memory would be:
Address = 05A0H
05A1H
05A2H
05A3H
Vaule = 90H
D5H
89H
01H
And the totalizer value should be interpreted as:
0189D590H = 25,810,320 (in decimal)
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ADDRESS INFORMATION
IMPORTANT
When writing to the EMO 500 there are always two locations to be changed for a
permanent entry into the memory. This is because there are locations for data running
currently in the RAM and there are locations for data that will be battery backed. If the
information has been written to the running locations alone it will be lost when the
EMO 500 is turned off.
Below is a QBASIC program that will allow the user to communicate with the
EMO 500 by initiating serial port #1 and prompting for read and write strings. The
strings must use the OPTO 22 protocol format described on page 18.
DEFINT A-Z
'* Serial Communication Test Program for OPTOMUX Code
'* For use with AW Company's EMO Series Flow Computers
'* Open serial port #1 to 9600 baud
OPEN "COM1:9600,N,8,1,RS,CS,DS,CD" FOR RANDOM AS #1
'* set up loop for transmitting several strings
CLS
DO
PRINT "Enter String to send. (Press ENTER alone to END)"
INPUT "Transmitting String: >", Transm$
IF LEN(Transm$) = 0 THEN END
'* Calculate Chksum
Chk = 0
FOR Char = 1 TO LEN(Transm$)
Chk = Chk + ASC(MID$(Transm$, Char, 1))
NEXT
Chk$ = HEX$(Chk)
'* Must be 2 characters, 1 byte
IF LEN(Chk$) < 2 THEN Chk$ = "0" + Chk$
'* Add the recognition character plus checksum
'* use only the last byte of checksum
Transm$ = ">" + Transm$ + RIGHT$(Chk$, 2)
'* Send it to the EMO
PRINT #1, ; Transm$; CHR$(13);
'* Read what the EMO sending back
LINE INPUT #1, Receive$
PRINT "Received: "; Receive$
PRINT
LOOP
WARNING --- IMPORTANT --- WARNING --- IMPORTANT --- WARNING
The communication port does not discriminate any addresses. This means that any address can be
written to as well as read from. Writing to certain addresses will change the operation of the EMO 500
drastically. Caution is a must !!! Double Check Addresses and Variables Before Writing to the EMO
500.
WARNING
--- IMPORTANT --- WARNING --- IMPORTANT --- WARNING
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Running
Address in
HEX
Back-up
Address in
HEX
Bytes Description
05F5
061A
0637
05FF
061C
0639
05F7
061E
063B
0601
0620
063D
050A
050C
050E
0510
060B
0604
0605
*0614 (4)
0618
0622
059D
05AA
05B9
0606
*053D
0626
0516
051A
051E
05B5
*05A0
*05A6
05EF
*052E
*0533
0504
05A4
0402
0404
0412
040A
040C
0414
0406
0408
0416
040E
0410
0418
042D
042F
0422
0424
042C
0429
042A
042
0420
041E
0437
0433
0431
041A
041C
042C
read only
read only
read only
read only
read only
read only
read only
read only
read only
read only
read only
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
1
4
4
4
4
4
4
4
4
4
4
2
Default Value
KFR A
KFR A Decimal Pt.
KFR A Eng. Units
KFT A
KFT A Decimal Pt.
KFT A Eng. Units
KFR B
KFR B Decimal Pt.
KFR B Eng. Units
KFT B
KFT B Decimal Pt.
KFT B Eng. Units
Limit 1 Value
Limit 2 Value
Limit 3 Value
Limit 4 Value
Limit 1 & 2 Rule
Limit 3 Rule
Limit 4 Rule
Ideal Ratio
Ratio Alarm
Ratio Warning
Analog Rule
Analog Gain
Analog Offset
Sample Size
Gate Time
Unit Number
Flow A
Flow B
Flow A & B
Ratio A/B
Job Total A (SD2)
Job Total B (SD2)
Job Total A + B
Grand Total A
Grand Total B
Grand Total A & B
Analog Out
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1000
01
00
10000
00
00
1000
01
00
10000
00
00
1000
2000
3000
4000
06
00
00
100
10
05
06
102000
0000
200
1.85
001
xxxx
xxxx
xxxx
xxxx
xxxxxxxx
xxxxxxxx
xxxxxxxx
xxxxxxxx
xxxxxxxx
xxxxxxxx
xxx
31
* These special variables indicated on the next page function in this manner.
* Ideal Ratio- The largest number that can be written into the Ideal Ratio without an
overflow is 640. Variable at address 0426h is 3 bytes, at 0614h is 4 bytes.
* Job Total A (SD2)- This variable will show twice the amount read from the Job A
display. This is because the number is actually a raw count from the freq. input. The
number read will match the totals seen in the Status Display 2 screen.
* Job Total B (SD2)- Same as above.
* Grand Total A- This variable will not be stored into the backup memory until the Job
Volume A has been reset. Therefore the location will read zero until the count is stored
away with the Reset Job A.
* Grand Total B- Same as above.
* Gate Time-This variable is a converted number because the keypad entry is made in
seconds and a constant must be applied for computations. Therefore after reading the
Gate Time the number read must be converted to decimal then divided by 5388 for an
answer in seconds.
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LIMITED WARRANTY
AW-Company warrants the EMO-500 Flow Computer to be in good working order for a
period of 1 (one) year from the date of purchase from AW-Company or an Authorized
AW-Company distributor. Should the EMO-500 fail to be good working order at any
time during this 1 year warranty period, AW-Company will, at its option, repair or
replace the EMO-500 at no additional change expect as set forth below. Repair parts and
replacement products will be furnished on an exchange basis and will be reconditioned or
new. All replaced parts and products become the property of AW-Company. This limited
warranty does not include service to repair damage to the EMO-500 resulting from
accident, disaster, abuse, or a Non-AW-Company modification to the EMO-500.
Limited Warranty service may be obtained by delivering the EMO-500 during the 1 year
warranty period to AW-Company and provide proof of purchase date. If this product is
delivered by mail, you agree to insure the EMO-500 or assume the risk of loss or damage
in transit, to prepay shipping charges to warranty location and use the original shipping
container or equivalent.
For further information contact:
AW-Company
8809 Industrial Drive, Franksville, WI 53126
Phone: (262) 884-9800
Fax: (262) 884-9810
ALL EXPRESS AND IMPLIED WARRANTIES FOR THIS PRODUCT
INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS
FOR A PARTICULAR PURPOSE, ARE LIMITED IN DURATION TO A PERIOD
OF 1 (ONE) YEAR FROM DATE OF PURCHASE, AND NO WARRANTIES,
WHETHER EXPRESS OR IMPLIED, WILL APPLY AFTER THIS PERIOD.
SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN
IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATIONS MAY NOT
APPLY TO YOU.
IF THIS PRODUCT IS NOT IN GOOD WORKING ORDER AS WARRANTED
ABOVE, YOUR SOLE REMEDY SHALL BE REPAIR OR REPLACEMENT AS
PROVIDED ABOVE. IN NO EVENT WILL AW COMPANY BE LIABLE TO
YOU FOR ANY DAMAGES, INCLUDING ANY LOST PROFITS, LOST
SAVINGS OR INCIDENTAL OR CONSEQUENTIAL DAMAGE ARISING OUT
OF THE USE OR INABILITY TO USE SUCH PRODUCT, EVEN IF AW
COMPANY HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH
DAMAGES, OR FOR ANY CLAIM BY ANY OTHER PARTY.
THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY
ALSO HAVE OTHER RIGHTS WHICH MAY VARY FROM STATE TO STATE.
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