BATCH CONTROLLER MODEL 430D

BATCH CONTROLLER MODEL 430D
BATCH CONTROLLER
MODEL 430D
430D-M-V3
September 2013
430D-M-V3
CONTENTS
1. Introduction
1.1 Model Number Designation
3
4
2. Specification
5
3. Operation
7
3.1 Front Panel Operation
3.1.1 Batch Configuration
3.1.2 Rate Totaliser Configuration
8
8
3.2 Batch Operations
3.2.1 Control Relay Outputs
3.2.2 Signal Timeout
3.2.3 End of Batch
3.2.4 Auto Restart
3.2.5 Automatic Overrun Compensation
3.3 Calculation of Rate and Total
3.3.1 Frequency Input
3.3.2 Filtering
3.4 Total Conversion
3.5 The Output Pulse and Flow Alarm
13
15
16
17
18
19
20
20
21
23
24
12
4. Options
4.1 The RS232/422/485 Interface Option
4.1.1 Hardware
4.1.2 Multi-point Communication
4.1.3 Communication Protocol
4.2 Relay Output Option (Rate Totaliser Only)
430D-M-V3
26
26
26
27
29
31
5. Calibration
32
5.1 Programming the Setup Parameters
34
5.2 Entering the Batch Parameters
5.3 Programming Options
5.4 Checking the Input Signal
6. Input Circuits
6.1 Input Circuit
6.2 Remote Switches
7. Installation
7.1 General
7.2 Wiring Designations for the Model 430D
7.3 Ex 410 Enclosure Dimensions
8. Trouble Shooting
8.1 Error Codes
Index
430D-M-V3
36
38
41
42
42
47
48
48
50
51
52
54
55
Introduction
3
1. INTRODUCTION
The Model 430D Batch Controller accepts pulse or frequency 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 four front
panel operational keys that allow batches to be started, paused, stopped
and reset, and a full twelve key numeric keypad for data entry such as
batch quantity and calibration parameters.
The Model 430D will accept most frequency and pulse signals, including
mV outputs from turbine flowmeters, and 2 wire proximity switch output.
It also enables all four of the front panel operational keys to be remotely
connected via the rear terminal strip. The instrument also has a scaled
pulse output for driving remote counters, together with a flow alarm
output.
The Model 430D can also be configured as a rate totaliser via calibration. In
this mode the instrument will totalise and perform a rate calculation on an
incoming pulse or frequency flow signal. In this mode, the instrument will
display Rate, a Resettable Total and an Accumulated Total.
The instrument is fully programmable, with all calculation constants set via
the front panel switches and stored permanently in non-volatile memory.
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.
430D-M-V3
4
Introduction
1.1 MODEL NUMBER DESIGNATION
The Model Number describes the options installed and the type of
Model 430 D. 1 0 EC
C for Conformal Coating
Type of Power
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
The Model Number of the instrument is displayed on first entering
the Calibration Mode (see Section 5).
430D-M-V3
Specification
5
2. SPECIFICATION
General
Display:
Display Update Rate:
Transducer Supply:
Power Requirements:
Operating Temperature:
Dimensions:
Cutout:
0.4" (10.2mm) high 6 digit green LED.
0.25s.
8-24V dc field adjustable.
50mA maximum.
14 to 28.5 V dc.
450mA typical current (no options).
ac Mains: Set internally to 95 - 135 VAC or
190 - 260 VAC.
0 to 55°C standard.
5.7" (144mm) wide x 2.8" (72mm) high x
7.0" (178mm) deep.
5.5" (139mm) wide x 2.6" (67mm) high.
Frequency Input
Frequency Range:
Input Circuits:
Scaling Range:
Minimum:
0.25Hz on Rate.
0Hz on Total.
Maximum:
10KHz.
See sections 6.1 and 6.2.
0.1000 to 50,000.
Relay Outputs
Maximum Switching Power: 1250VA.
Maximum Switching Voltage: 250Vac, 30Vdc.
Maximum Switching Current: 5A.
430D-M-V3
6
Specification
Pulse Output
Pulse Width:
Maximum Duty Cycle:
Scaling:
430D-M-V3
10mSec (negative going pulse).
49 pulses per second.
The pulse output is scaled and outputs
one pulse each time the accumulated
total increments.
Operation
7
3. OPERATION
The Model 430D 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 back-up for a
minimum of 10 years.
A block diagram of the instrument is shown below.
Pulse Input
RS232/422
Option
Signal
Common
RS232/422
Output
End of Batch (EOB)
Relays
Model 430D
Control
Relay Outputs (2)
Pulse
Output
Flow Alarm
dc Input Power
110/220V
ac Mains
430D-M-V3
dc Power Ground
dc Power Output to Sensors
8
Operation
3.1 FRONT PANEL OPERATION
3.1.1 Batch Configuration
The keypad operation of the Batch Controller is straight forward.
SETTING THE BATCH QUANTITY
The batch quantity is programmed as follows:
As an example, if the current batch quantity is 420.5 and we wish to change
the batch quantity to 130.4 the new value would be programmed as follows.
Key
Display
Press Batch Set
Batch
420.5
Press 1
."1"
The first digit is pressed. The display is
cleared and only the first digit and
the decimal point (if programmed)
are displayed.
Press 3
1."3"
Successive digits are entered from
the right and shifted across the
display to the left.
Press 0
13."0"
Press 4
130."4"
430D-M-V3
Comments
"batch" is displayed for one second
followed by the batch quantity
last entered.
The STOP LED
lights and the display will flash
indicating that the unit is in the
Batch Set mode.
Operation
Press Batch Set
Set
9
Once the desired number is
entered, press the Batch Set key
to enter the number and return
to the Run mode.
When the Batch Set key is pressed
"SET" is displayed for one second and
the display is restored to its
previous state. The entered
quantity will be stored in memory.
If, during editing, an incorrect entry is made, the Clear key can be pressed
to clear the last number entered as follows:
130."1"
The display shows 130.1 instead of
130.4.
Press Clear
13.0
The last entered digit, ie "1", is
cleared and all remaining digits are
shifted to the right 1 position.
Press 4
130."4"
Now the correct number is entered.
Successive presses of the Clear button will clear the left most digit. When
the last remaining number is cleared, the previous value will be restored as
the batch quantity and displayed as follows:
130.4
The display shows 130.4 as the
new batch quantity to be
programmed.
Press Clear
13.0
The last entered digit, ie "4", is
cleared and all remaining digits are
shifted to the right 1 position.
Press Clear
1.3
Press Clear
.1
430D-M-V3
10
Operation
Press Clear
420.5
The last remaining digit is cleared and
the previous value is restored
and displayed.
Once programmed, the Batch quantity will be retained in the
non-volatile memory and will not alter until changed by the user.
The Batch quantity can only be set while the instrument is in a
non-operational state such as when the batch is complete, or if the batch
process has been interrupted. However, the Batch Set key can be pressed
while in the Run mode and the Batch quantity checked. All digits will flash
to signal the quantity cannot be changed. Once the Batch Set key has been
released, the display will return to its previous state.
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 Batch Controller 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 by pressing the STOP switch a
second time.
When the process is interrupted, the PAUSE LED will flash to prompt
the operator to either restart or abort the batch. When the process is
aborted, the STOP LED will light.
430D-M-V3
Operation
11
RESETTING
The instrument can be programmed to reset in one of two ways.
At the end of a batch, the Reset key m u s t 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.
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.
Additional infomation can be displayed as follows:
Rate
Pressing the Rate key will light the Rate LED, save the previous status of
the LEDs and display the rate. Pressing the Rate key a second time will
revert the display back to the batch total and restore the LED status to
its previous state. In this way the Rate key can be used to toggle the
display between the rate and the batch total.
If a batch is in progress when the Rate is displayed, the display will
automatically revert back to the Batch Total when the batch is
completed or if the batch is aborted by pressing the STOP key. Any
automatic change of state or any key press which changes the current
state of the instrument will restore the display back to the Batch Total.
The current state of the instrument can be Run, Pause, Stop, or Reset.
430D-M-V3
12
Operation
Accumulated Total
Pressing and holding the Accum (also zero) key on the numeric
keypad will display the Accumulated Total whenever the instrument
is not in the data entry mode. As soon as the key is released the
display will be restored to its previous state, ie. Rate or Batch Total.
The Accumulated Total cannot be reset during normal operation.
LIMIT ON BATCH SIZE
To prevent erroneous entry of large batch quantities, a maximum batch limit
can be programmed during calibration. The operator is then unable to enter
a batch quantity which exceeds this value.
3.1.2 Rate Totaliser Configuration
When the Model 430D is set-up as a Rate Totaliser (see Section 5 entitled
" Calibration"), the RUN, STOP and Batch Set keys are made redundant, ie.
They perform no operation when pressed.
The display will normally show the Rate or ResettableTotal, as determined by
the status of the Rate LED.
The Rate key is used to toggle the display between the Rate and the
Resettable Total. The Rate LED will light when the Rate is displayed and will
be off when the Resettable Total is displayed.
As with the Batch configuration, pressing and holding the Accum (also zero) key
on the numeric keypad will display the Accumulated Total whenever the
instrument is not in the data entry mode.As soon as the key is released, the
display and Rate LED will be restored to its previous state. The Accumulated
Total cannot be reset during normal operation.
430D-M-V3
Operation
13
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 Reset key must be pressed to reset the
Batch
Batch
Quantity
Reached
PAUSE
Ru n
Stop Run
Count Down
Count Up
Relay 1
Relay 2
Start Time
Prestop
Quantity
End of
Batch
End of Batch
430D-M-V3
Stop
Ru n
14
Operation
2.
If Automatic Reset is programmed, a new batch is commenced
each time the RUN key is pressed.
Batch
Quantity
Reached
PAUSE
Ru n
Stop Run
Run
Count Down
Count Up
Relay 1
Relay 2
Start Time
Prestop
Quantity
End of
Batch
Auto Restart
Time
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
430D-M-V3
Operation
15
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 when relay 2 energises can be programmed
to provide a soft start-up. The delay can range from 0 (no delay) to 79 minutes
and 59 seconds.
A Pre-stop 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 Batch Controller reset by pressing the Reset key, 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.
430D-M-V3
16
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 Batch Controller 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, for example. In this case, the Signal Timeout is used to
determine when the flow has ceased and thereby accurately determine
the amount of overrun.
It is recommended that Signal Timeout periods are kept fairly short, but long
enough such that the period is significantly longer than the time period between
successive input pulses from the flowmeter at the minimum flowrate.
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 condition exits and both relays
are de-energised. The Flow Alarm condition is maintained until acknowledged
by pressing the STOP key. The alarm condition is also signalled to the operator
by the Pause LED flashing. Once acknowledged, the process can then be
reset via the Reset key or continued by pressing the RUN key.
With the Model 430D, an open collector output on terminal 7 will also switch
"On" whenever the Flow Alarm condition exists (see Section 3.5).
430D-M-V3
Operation
17
3.2.3 End of Batch
An End of Batch is defined as being when the batch quantity is reached, the
flow has stopped and the Signal Timeout period has expired.
If the Signal Timeout is set to zero, the End of Batch is defined as being when
the batch quantity is reached, regardless of whether the flow has stopped.
The Batch Controller cannot be reset or restarted until the End of
Batch. Similarly, for an RS232/422/485 interface, data will not be output
until the End of Batch has been determined. Consequently, it is
strongly recommended that the Signal Timeout period be kept fairly
short.
Batch Quantity
Reached
Reset
Signal
End of
Batch
Signal Timeout
End of
Batch
(Timeout = 0)
End of Batch Signal
An End of Batch signal from an open collector transistor may be output
on terminal 30, if assigned as such, and the output is identical to the
Output Pulse circuit as shown in section 3.5.
When reaching the End of Batch, the output transistor is switched on, and
will remain in the "on" state until the instrument is reset.
430D-M-V3
18
Operation
3.2.4 Auto Restart
The Batch Controller can be programmed to continually repeat the batch
process.
This mode of operation is selected during the programming procedure.
The process is started by pressing the RUN key whereby the normal
batch operation is commenced. After reaching the End of Batch (see
section 3.2.3), the Batch Controller will then wait for a pre-programmed
period before automatically resetting and starting the batch process
once again.
The STOP key can be pressed at any time to interrupt the batching process
and continued using the RUN key. If, however, the process is to be aborted,
the Reset key is pressed. The Batch Controller is reset and to restart the
auto batching process the RUN key is pressed.
430D-M-V3
Operation
19
3.2.5 Automatic Overrun Compensation
The Batch Controller can be programmed to automatically compensate for any
overrun at the end of a batch.
Typically, this could be due to the slowness of a valve to close or a pump to stop
pumping on receiving a signal from the Batch Controller. The result is that the
batch quantity will always read higher than the batch quantity set.
Automatic Overrun Compensation can be enabled or disabled during the
Calibration procedure and should only be used if the overrun is repeatable. The
user is cautioned against using Automatic Overrun Compensation if the overrun
is erratic, such as may occur with changing back pressures or sticking valves.
In calculating the amount of overrun to be compensated for, the Batch
Controller uses the average overrun on the last three batches.
The overrun is defined as the difference between the batch quantity set by
the user and the batch total once the flow has stopped.
With Automatic Overrun Compensation, the Signal Timeout must be set to
a value greater than zero.
Once the Batch Controller de-energises both relays, the instrument looks for a
Signal Timeout, indicating that the maximum interval between pulses has
occurred and that the flow must, therefore, have stopped. It then uses the
overrun quantity measured during this period and averages this together with
the overrun on the last two batches. The resulting value is then subtracted from
the next batch.
430D-M-V3
20
Operation
3.3 CALCULATION OF RATE AND TOTAL
3.3.1 Frequency Input
The flowrate, R, is calculated as follows:
R = fxH
S
where f is the input frequency in Hz.
H is the time base of rate and is 1 for seconds, 60 for
minutes, 3600 for hours and 86,400 for days.
S is the Scaling Factor.
The Scaling Factor , S, is equal to the K-factor of the flowmeter
expressed in pulses per unit volume.
The user programs the Scaling Factor and selects the time base during
the Calibration procedure as detailed in Section 5.
430D-M-V3
Operation
21
3.3.2 Filtering
Frequency fluctuations, caused by pulsating flow through a flowmeter,
often make the Rate impossible to read with any precision. The Batch
Controller has a digital filter which will average out these fluctuations
and enable the Rate to be read to four digit accuracy. The ability to
select a suitable filtering level means that highly accurate and stable
readings can be obtained without excessive lag.
The diagram below shows a pulsating signal input together with the effect
of filtering.
Rate
Filtered Response
Unfiltered Response
Time
As a guide to the degree of filtering to be used, the following table shows
the response to a step change in input. The value, A, is the filter
constant which is programmed during the Calibration procedure. The
times for the display value to reach 90% and 99% of full swing are given in
seconds, for different values of A.
430D-M-V3
22
Operation
A
90%
99%
1
0
0
2
1
2
4
2
4
6
3
6
10
5
11
15
8
17
20
11
22
25
14
28
35
20
40
45
25
51
60
34
69
75
43
86
90
52
103
99
57
113
Table 1 - Response to a step Input (in
seconds).
Note: If A is set to 1 there is no filtering of the input signal.
430D-M-V3
Operation
3.4 TOTAL CONVERSION
The Total Conversion feature enables the Rate to be displayed in one
engineering unit (eg. gallons/minute) and the totals to be displayed in
another engineering unit (eg. barrels).
The Scaling Factor is always programmed in the unit relating to R a t
e , a n d t h e Total Conversion constant is a division factor which can
be used to convert the totals to the different unit. The Total
Conversion factor affects the net, accumulated and gross totals and is
limited between 0.01 and 2000.
For Example.
If the Rate is required in gallons per minute:
1. The Scaling Factor would be programmed as pulses per gallon.
2. The time base would be programmed as minutes.
If the Totals are required in barrels:
3. The Total Conversion factor is programmed as 42 (there are 42
gallons in a barrel). All totals, including the Batch Quantity and
Batch Total, will now be in barrels.
Some common units are given below together with the Total Conversion
constant (TOTCON) which should be programmed.
Rate*
Gallons (US)/
Litres/
ml/
Mgallons/
Totals
Barrels (oil)
Kilolitres
Litres
Acre-feet
TOTCON
42.000
1000
1000
0.32587
* Units per second, minute, hour or day. The time base is
programmed separately during Calibration.
430D-M-V3
23
24
Operation
3.5 THE OUTPUT PULSE AND FLOW ALARM
An output pulse is available on terminal 10 for driving remote counters
and produces a pulse each time the Accumulated Total increments by
one digit. For example, if the Accumulated Total has a resolution of 0.01
litres, a pulse is produced each 0.01 litres.
The pulse is a current sinking pulse of approximately 10mSec produced by
an open collector transistor. The maximum pulse rate is limited to 49
pulses per second and the resolution on the Accumulated Total must be set
so that the Accumulated Total increments at less than 49 counts per
second.
Note: Due to the uneven pulse output spacing on this output, the pulse
output cannot be used to drive rate indicators.
The F l o w Alarm uses an identical circuit to the Output Pulse, and is on
terminal 7.
The Flow Alarm will output an alarm condition if there is no flow
registered during a batch for a time greater than the Signal Timeout
period, providing the Signal Timeout is greater than 0.
The Flow Alarm output will switch "on" (ie. the signal goes low) whenever
an alarm condition exists. The Alarm will switch "off" (ie. the signal goes
high) when the alarm is reset by pressing the STOP key.
430D-M-V3
Operation
Connection of Output Pulse and Flow Alarm are as follows:
Relay or
Impulse Counter
7/10
5.6 ohms
33V
Zener
12 dc Supply
Driving an External Relay or Impulse Counter
11
dcSupply
Out(8-24V)
ExternalLoad
Resistor10K
7/10
LogicInput
5.6ohms
33V
Zener
2
Driving a Logic Input such as a PLC or Electronic Counter
7 = Flow Alarm
10 = Output Pulse
430D-M-V3
25
26
Options
NB. Version 3 Models Only
4. OPTIONS
4.1 THE RS232/422/485 INTERFACE OPTION
With this option installed, the circuits for both the RS232 and RS422/485
are provided. They can be used to interface to printers and computers
and a number of standard protocols are built into the instrument.
4.1.1 Hardware
The following diagram provides an overview of the
RS232/RS422/RS485 communications hardware. All three interfaces
are available on the rear terminal strips and the user can select
either one by making the appropriate connections.
The RS232 interface is primarily used with printers or for simple
communication with a computer over a short distance. The RS422 and RS485
interfaces are used for communication over a long distance or in applications
requiring multi-point communication.
NB. Diagram refers to Version 3 Models Only
Version 3 models can be defined by having plug-off green terminals.
24
(+)
RS422 Out
(
23 - )
26
(+)
RS422 In
(
25 - )
21
Data In
22
Data Out
27
CTS
20
Ground
RS232
430D-M-V3
Options
27
4.1.2 Multi-point Communication
Multi-point Communication is a system whereby a number of instruments
can be addressed over a dual twisted pair interface. Up to 32 instruments can
be connected to a common bus using the RS422 and RS485 interfaces as
shown below.
To convert the RS422 interface to an RS485 interface, the RS422 (-) Data In
Terminal must be connected to the RS422 (-) Data Out Terminal and the
RS422 (+) Data In Terminal must be connected to the RS422 (+) Data Out
Terminal.
These connections will convert the RS422 4 wire interface to the RS485 2
wire interface, as shown in figure 2.
Each instrument can be programmed with a unique address which is used by
the Master Controller (ie IBM/PC) to identify each instrument. The Controller
will send the address down the line and will alert the relevant instrument.
Subsequent software protocol will control the flow of data between the
Controller and the Instrument.
Load
120 ohms
TwistedPair
Load
120 ohms
Host
Computer
400 Series
Instrument
400 Series
Instrument
Figure 1 RS422 Interface
NB. Diagram refers to Version 3 Models Only
Version 3 models can be defined by having plug-off green terminals.
430D-M-V3
28
Options
Twisted Pair
+
Host
Computer
Load
120 ohms
Gnd
- +
In
Gnd - +
Out
400 Series
Instrument
- +
In
Gnd-
+
Out
400 Series
Instrument
Figure 2 RS485 Interface
NB. Diagram refers to Version 3 Models Only
Version 3 models can be defined by having plug-off green
terminals.
430D-M-V3
Options
29
4.1.3 Communication Protocol
The Model 430D has a real time clock which enables the time and date to be
set and printed on tickets. The date format can be European
(days/months/years) or USA (months/days/years), while the time is on a 24
hour clock.
Note that the clock will only retain its time for 3 days minimum if there is
no power connected to the instrument. After this period, the clock may
need to be reset. On latest models battery backup is provided the battery will
typically need replacing every two years of more frequently if extended power
downs are a feature of the installation. Battery type is CR2032 coin cell.
All new instruments are supplied with a ‘pullout battery life protection tab’
Please do not remove the tab until you are ready to install and apply power
to the instrument.
T h e b a u d r a t e , p a r i t y and word length can be programmed during
Calibration and the user must ensure that these correspond to the setting on
the printer or computer with which the 430D is communicating.
The software protocols can be selected during Calibration to provide standard
interfaces to a number of printers and computers. Since other interfaces
will continue to be added, the user should consult the manual "The
RS232/422/485 Communications Option for the 400 Series, Version 2", for
the latest protocols
and printer drivers.
Printer
When the Model 430D is used in the Batch Configuration, a ticket is printed each
time a batch is complete.
In the Rate Totaliser Configuration, a ticket is printed each time the Reset key is
pressed. The instrument prints a ticket before resetting the Resettable Totals.
Protocols are provided to drive the following printers:
1 Standard Computer Printer (Note that the printer must have an
RS232 Serial Interface).
2 EPSON CTM290 Slip Printer.
3 Contrec Model 624.
4 EPSON TM290-2 Slip Printer.
5 Contrec Model 632-2.
6 Syntest SP-210.
The tickets can also be printed with a number of different units, including litres
430D-M-V3
and gallons. The units are selectable from a pre-programmed list.
30
Options
A CTS input is provided, and will prevent the instrument from transmitting
any further characters to a printer if the printer buffer is full. The CTS input
is usually connected to the "Data Buffer Full" output from the printer.
If the printer buffer is large enough to handle the messages output from the
Batch Controller, then this input need not be used and can be left unconnected.
Computer
The instrument receives and transmits messages in ASCII, with all command
strings to the instrument terminated by a carriage return while replies from
the instrument are terminated with a carriage return and a line feed.
Xon/Xoff protocol is also supported, and the instrument will
automatically determine if the message sent by the host computer is
preceded by an Xoff character. If it does recognise an Xoff as the first
character of a command string, the instrument will automatically switch
to Xoff/Xon protocol, and begin & end all messages with Xoff and Xon
characters respectively. Xoff/Xon protocol is only available when the
RS232 interface is selected.
During Calibration,
full duplex or half
commands sent to
computer. In half
the instrument can be programmed to operate in a
duplex transmission mode. In full duplex mode, all
the instrument will be echoed back to the host
duplex, the commands are not echoed.
For more information on the computer interface please consult the manual "
T h e RS232/422/485 Communications Option for the 400 Series, Version 2".
430D-M-V3
Options
31
4.2 THE RELAY OUTPUT OPTION (RATE TOTALISER
MODE ONLY)
When the Model 430D is configured as a Rate Totaliser, a relay output
option becomes available. The relay output option consists of two From C
relays which can be preset during calibration to energise when the Rate or
displayed value exceeds or drops below the preset values.
The "low" relay is energised whenever the Rate is below the preset value, and
the "high" relay is energised whenever the Rate exceeds the preset value.
The preset values are programmed during Calibration, as described in Section
5.
Relay 1
Low Alarm
Relay 2
High Alarm
430D-M-V3
34
Normally Open
35
Normally Closed
36
Common
31
Normally Open
32
Normally Closed
33
Common
32
Calibration
5. CALIBRATION
The Calibration procedure enables the Set-up Parameters to be
programmed, as well as enabling the input signals to be checked.
The Calibration procedure can be entered in two ways:
1 By connecting a wire link (or switch) to the rear terminal strip
across terminals 1 and 2 or,
2 By pressing the STOP key and while still holding, press the Rate
key. Both keys must then be held for approximately 6 seconds.
This second method of access can be disabled during Calibration so
that it is only possible to enter the Calibration procedure via the
link across terminals 1 and 2.
The operation of the keypad during Calibration is as follows:
Where a parameter (see below) is to be changed the four operational keys are
used to modify the status of the parameter. Where a value is to be changed
the numeric keypad is used to enter the new value as described in Section 3.1.
Where a parameter is to be changed the front operational keys are used to affect
the change. All modifiable parameters except the setting up of decimal point
positions for the Rate, Total and Accumulated Total are altered as follows:
Rate
will change a parameter selection.
STOP
will accept the change and step onto the next parameter.
Modifying the decimal point settings for the Rate, Total, and Accumulated Total
is done as shown below.
RUN
430D-M-V3
will decrease the number of decimal points by one with each key
press. When the minimum number of decimal points is reached
(usually none) the next key press will reset the parameter to the
maximum number of decimal points allowable.
Calibration
33
Rate
will increase the number of decimal points by one with each key
press. When the maximum number of decimal points allowable
is reached the next key press will reset the number decimal
points to zero.
Reset
will reset the number of decimal points to zero.
STOP
will accept the change and step onto the next parameter.
In stepping through the program sequence, the Parameter Description is
always displayed first, followed by actual value or parameter. When a
parameter can be changed, it is always shown as flashing, and the LED's above
the keys are lit if that key can be used to change a parameter.
All values are always shown as steady (ie. not flashing) and are changed using
the numeric keypad as described above.
On first entering the Calibration routine, the display will show:
CAL
Batch
Option
Test
End
Setup Program parameters (see section 5.1).
Enter Batch parameters (see section 5.2)
Option - if installed (see Section 5.3).
Check Input Signals (see section 5.4)
Exit to Normal Operation.
The user can toggle between these modes using the Rate key and, by using
the STOP key, select the appropriate mode.
To exit Calibration, step through the Setup program, Batch program or Test
program until the end, and press the STOP key when E n d is displayed.
Note: ensure the calibration link is not connected.
430D-M-V3
34
Calibration
5.1 PROGRAMMING THE SETUP PARAMETERS
Step
Display
1
CAL
BATCH
OPTION
TEST
END
Description
Text
Ref
Select the Calibrate mode to setup
program parameters.
Select Batch to enter Batch Setup parameters.
Option (if installed).
Select the test mode to check input signals.
Exit to normal operation.
5.2
5.3
5.4
The following steps are displayed if CAL is selected.
2
RESTOT
Reset all totals to zero.
To reset all totals (resettable and accumulated)
press the Reset key once.
3
SCALE
Scaling Factor.
Fact
Enter the scaling factor ( K - f a c t o r )
flowmeter.
4
F dPt
Number of decimal points with which the R a t e
is to be displayed between 0 to 0.00000.
5
t.base
T h e Time base with which the Rate is
calculated must be entered as:
60secs
hours
days
secs
6
units/min
units/hour
units/day
units/second
FILTER
The filter constant for filtering the rate display .
1
No filtering.
to
99
430D-M-V3
3.3.1
Very heavy filtering.
3.3.2
Calibration
Step
Display
Description
Text
Ref
TOTCON
A division factor to convert the totals to different
units from those used for rate (ie gallons/min and3.4
barrels).
1
Rate and totals have the same engineering units.
x.xxxx
Other factors can be programmed between 0.01
and 2000.
8
t.dPt
Number of decimal points with which the
resettable total is displayed between 0 to 0.000.
9
A.dPt
Number of decimal points with which the
A c c u m u l a t e d (non resettable) total is
displayed between 0 to 0.000.
Enable access to calibration routine via the
front keypad only.
Enable access via front keypad.
Disable access via front keypad.
7
10 ACCESS
Front
No Acc
11
CONFIG
BATCHR
TOTAL
Configures the instrument as either a
Batch Controller or a Rate Totaliser.
Batch Controller mode enabled.
Rate Totaliser mode enabled.
Note: If the instrument is set-up as a
Rate Totaliser, the programming of Batch
Set-up Parameters (see Section 5.2) will be
disabled.
430D-M-V3
35
36
Calibration
5.2 ENTERING THE BATCH PARAMETERS
Step
1
Display
BATCH
OPTION
TEST
END
CAL
Description
Enter Batch Parameters (if enabled).
Option (if installed)
Check Input Signals.
Exit to normal operation.
Program Setup Parameters.
Text
Ref
5.3
5.4
5.1
The following steps are displayed if BATCH is selected.
2
BATCH L
xxxxxx
3
4
5
430D-M-V3
AUTO S
Off
On
xx.xx
START. T
xx.xx
PREST
xxxx
Maximum Batch Size which can be
entered.
Set to 0 if no limit on batch size.
Automatic restart feature.
Disable.
Enable.
If enabled, automatically restarts
the batch xx:xx (mins:sec) after
the end of
Slow start time.
Time, in (minutes:seconds), when
Relay 2 will energise once the batch
has started.
Prestop Quantity.
Quantity at which Relay 2 will
de-energise before the end of the
batch.
(Eg. If the batch quantity is 100 litres
and Prest is 2 litres, relay 2 will
de-energise after 98 litres.)
3.2
3.2.4
3.2
3.2
Calibration
Step
6
7
8
Display
COUNT
dn
up
T OUT
AOC
En
Dis
9
AUTO R
Off
On
430D-M-V3
Description
The Batch Total counts Up or Down.
Count down from the batch
quantity.
Count up from zero.
The Signal Timeout in seconds.
(Setting to 00 disables this feature.)
Automatic Overrun Compensation.
Note: the Signal Timeout must
be greater than 0 (ie. enabled)
for this eature to work.
Enable.
Disable.
Text
Ref
3.2
3.2.2
3.2.5
A u t o R e s e t (not displayed if Auto
Restart is programmed - Step 3 above).
Batch Total must be manually reset
before starting the next batch.
The Batch can be automatically reset
3.2
and started by pressing only the RUN
key.
37
38
Calibration
5.3 PROGRAMMING OPTIONS
Step
1
Display
OPTIONS
Test
End
CAL
Batch
Description
Options (if installed).
Check the Input Signals.
Exit to normal operation.
Program Setup Parameters.
Set Batch Parameters.
Text
Ref
5.4
5.1
5.2
If the RS232/422/485 option is installed, the following will be
displayed:
2
DF
Eur
USA
Date Format.
European (ie.
days/months/years).
USA (ie. months/days/years).
4.1
3
Date
xx.xx.xx
Enter date as:
Years:Months:Days. All six digits must
be entered.
4.1
4
HOUR
xx.xx
Enter time as a 24 hour clock.
Hours:Minutes. All four digits must
be entered.
5
BAUD
xxxx
Baudrate
300, 600, 1200, 2400, 4800 and 9600.
6
DATA
7
8
Word length.
7 bits.
8 bits.
7
PARITY
NP
OP
EP
Parity.
No Parity.
Odd Parity.
Even Parity.
430D-M-V3
Calibration
Step
Display
Description
8
SIGNAL
rs232
rs422
Signal Type.
RS232.
RS422/RS485.
9
10
10
10
430D-M-V3
Unit Identification Number.
None.
ID number.
ID NO
0
1 - 99
P TYPE xx
Printer/Computer Type.
00
01
02
03
04
05
Standard Computer Printer.
EPSON CTM 290 Slip Printer.
Contrec Model 624 Printer.
EPSON TM 290-2 Slip Printer.
Contrec Model 632-2 Printer.
Syntest SP-210 Printer.
20
Computer.
If a Printer Protocol is selected, the following message is
displayed:
Units of measurement printed.
UNIT
xx
None.
00
Litres (Ltrs).
01
Gallons (Gals).
02
Barrels (bbls).
03
Pounds (lbs).
04
Grams (gms).
05
Kilograms (kgs).
06
Tons (tons).
If a Computer Protocol is selected, the following message is
displayed:
ECHO Command.
ECHO
Echo (Full Duplex).
On
No Echo (Half Duplex).
Off
Text
Ref
39
40
Calibration
Step
Display
Description
Text
Ref
If the Model 430D is configured as a Rate Totaliser, the
following message is displayed:
11
AL: Hi
xxxxxx
High Alarm switching point. The high relay
will energise of the flow rate exceeds
4.2
this value.
12
AL: Lo
xxxxxx
Low Alarm switching point. The low relay
will energise if the flow rate falls below
this value.
430D-M-V3
Calibration
41
5.4 CHECKING THE INPUT SIGNAL
Step
Display
Description
1
TEST
OPTIONS
CAL
BATCH
END
Check the Input Signals.
Options (if installed).
Program Setup
Parameters.
Set Batch Parameters.
Text
Ref
The following steps are displayed if TEST is selected.
2
Sr x.xx
Software revision number.
3
Freq
Displayed for 1 second followed by the actual
frequency.
Frequency in Hz.
xxxx.x
If the RS232/422/485 option is installed, the display will then
show:
4
430D-M-V3
CLOC
xx.xx.xx
Clock.
Time in Hours:Mins:Sec.
5.3
5.1
5.2
42
Input Circuits
6. INPUT CIRCUITS
The Model 430D has a regulated output which can be used to power sensors.
A trimpot on the rear of the instrument allows the voltage to be adjusted in
the range of 8-24 Volts and the output can supply a maximum of 50mA.
6.1 INPUT CIRCUIT
The Model 430D has an input conditioning card which will accept signals
from most pulse or frequency producing flowmeters. An 8 position DIL
switch on the rear panel enables the input circuit to be configured for
different signal types.
The input will interface directly to:
- Turbine Flowmeters
- Open Collector Outputs
- Reed Switches
- Logic Signals
- Two Wire Proximity Switches.
The following pages give examples of interconnection to various signal outputs,
and a circuit diagram of the input is also provided.
430D-M-V3
Input Circuits
43
Switch Settings
The following switch settings are recommended for different input signal
types.
Input
Terminals
Input Signal Type
CH1
A. Logic Signal,
CMOS,Pulse
B.Open Collector
Reed Switch
C. Namur
Proximity (set DC
out to 8 volts)
D. Switch or
Reed Switch with
debounce circuit
E. Coil (20m V
Switch Settings
+
-
1
2
3
4
5
6
7
8
9
8
Not used
off
off
off
on
Not used
off
off
9
8
Not used
off
off
off
on
Not used
on
off
11
9
Not used
off
on
on
9
8
Not used
off
off
off
9
8
Not used
on
off
off
or
on
Not used
off
off
on
Not used
on
on
off
Not used
off
off
P-P minimum)
General Specification
430D-M-V3
Switching Threshold:
2.5 Volts (except for input type c, e and f)
Maximum Input Voltage:
50V peak
Input Impedance
Input type a:
Input types b & d:
Input type c:
Input type e:
100K
10K
1K
100K
44
Input Circuits
+5V
10K
S7
1K
INPUT COMPARATOR
100K
Pulse Input
(9)
S8
S3
+
100R
Common
.01
1uF
+5V
(8)
33K
S2
S5
S4
33K
The Frequency Input Circuits
430D-M-V3
1K2
Input Circuits
1. Squarewave, CMOS or Pulse
Model 430D
on
9
Common
8
1
8
eg. vortex, pre-amplifiers
or magnetic flowmeters
2. Open-Collector
Model 430D
on
9
Common
8
1
8
eg. hall effect
sensors
3. Reed Switch
Model 430D
on
9
1
8
8
eg. positive displacement
flowmeters with reed switch
430D-M-V3
45
46
Input Circuits
4. Coils
on
Model 430D
9
8
Use shielded
cable
1
to case earth
8
eg. millivolt signal
from a turbine flowmeter
(single input only)
5. Namur Proximity Switch
+8V
on
Model 430D
11
9
1
8
eg. positive displacement
flowmeters with 2 wire
proximity switch outputs
6. Opto-Sensors
Resistor
on
Model 430D
11
1
9
Common
8
8
eg. pre-amplifiers
and opto-sensors.
Note: A current limiting
resistor may be required.
See the flowmeter
manufacturer's data.
430D-M-V3
Input Circuits
47
6.2 REMOTE SWITCHES
Remote push-buttons can be connected to the Model 430D to duplicate the
four operational switches on the front panel. On the Model 430D, all four
switches are taken to the rear terminals.
The switches are wired as follows:
2
RUN
3
RATE
4
RESET
5
STOP
6
430D-M-V3
48
Installation
7. INSTALLATION
7.1 GENERAL
Terminal designations for the Model 430D Batch Controller are given on the
following pages. The cutout hole in the panel should be 5.5" (139mm) wide x
2.6" (67mm) high. Two side clips are supplied to secure the instruments into
panel.
A case earthing point is provided via an earth lug on the side of the case.
Note that this earthing point is for the case only and there is complete electrical
isolation between this point and all electronic circuits. For EMC purposes, or
when the instrument is connected to mains, this point must be connected to a
good earth using a multi-stranded, braided wire or strap. All relay outputs are
totally isolated from the case and from the internal circuitry.
The two output relays are changeover relays and both the "normally open" and
the "normally closed" terminals are available on the rear terminal strips. All
relay outputs are totally isolated from the case and from the internal circuitry.
A Supply Output voltage is provided to power sensors. This output will provide a
regulated voltage of 8 to 24 volts and the voltage is adjustable by means of the
potentiometer on the rear panel. Maximum current is 50mA and the instrument
comes with the voltage factory set at 24 Volts. When the instrument is powered
from a dc power source, the maximum output voltage on the Supply Output is the
dc Input Voltage less 3.5 volts.
The instrument will operate from either 12-28 Vdc or from the m a i n s . T h e
mains voltage is factory set to either 95-135 Vac (110 Vac nominal) or 190-60
Vac (220 Vac nominal). An internal mains transformer provides full isolation
between the mains and the electronic circuits.
The dc Ground terminal 12 provides a common ground for the 12-28 Volt power
input, the 8-24 Volt output, the pulse output and End of Batch output.
430D-M-V3
Installation
49
It is good practice to use shielded cable for all signal connections to the
Model 430D. Care must be taken to separate signal cables from power
cables so as to minimise interference.
Overall shields should be connected to the case earth at the instrument end
only.
This connection should be as short as possible and connected to the earthing
lug on the side of the case.
In order to comply with the requirements for Electromagnetic Compatibility
as per EMC-Directive 89/336/EEC of the Council of European Community,
this wiring practice is mandatory.
Although it is also possible to connect shields to the signal ground (terminal
2) this is not in accordance with EMC directives.
RC Networks for Interference Suppression
When driving highly inductive loads with the relay outputs, it is
recommended that RC suppression networks (often called "Snubbers") are
used for two reasons:
To limit the amount of electrical noise caused by arcing across
the contacts which may, in extreme cases, cause the
microprocessor to act erratically.
To protect the relay contacts against premature wear through
pitting.
RC suppression networks consist of a capacitor and series resistor and
are commonly available in the electrical industry. The values of R and
C are dependent entirely on the load. However, if the user is unsure
of the type of snubber to use, values of 0.25uF and 100 ohms will
usually suffice. Note that only mains rated UL approved RC
suppression networks should be used.
The basic principle of operation is that the capacitor prevent a series of
sparks arcing across the contact as the contact breaks. The series resistor
limits the current through the contact when the contact first makes.
430D-M-V3
50
Installation
7.2 WIRING DESIGNATIONS FOR THE MODEL 430D
Terminal
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Model 430D
Calibration Link
Signal Ground
Remote RUN Switch
Remote Rate Switch
Remote Reset Switch
Remote STOP switch
Flow Alarm
Flow Common (-)
Flow Pulse Input
Pulse Out
dc Power Out (8-24Vdc)
dc Ground
dc Power Input
Not To Be Used
Terminal
20
21
22
23
24
25
26
27
RS232/422/485 Option
RS232 Signal Ground
RS232 Data In
RS232 Data Out
RS422/485 (-) Data Out
RS422/485 (+) Data Out
RS422/485 (-) Data In
RS422/485 (+) Data In
RS232 CTS
Terminal
28
29
30
2B
31
32
33
34
35
36
Relay Output & Switches
Not To Be Used
Not To Be Used
End of Batch/Pump Control Signal
Signal Ground
Relay 2 - Normally Open
Relay 2 - Normally Closed
Relay 2 - Common
Relay 1 - Normally Open
Relay 1 - Normally Closed
Relay 1 - Common
430D-M-V3
51
8.
Trouble Shooting
TROUBLE SHOOTING
Batcher does not reset.
The Signal Timeout has been set to an excessively long
period and has not timed out at the end of the last batch.
Batch will not start or relay 1 will not close.
Ensure that the instrument has not timed out as
controlled by the Signal Timeout and that a Flow Alarm
condition does not prevail. Pressing the Stop switch will
cancel this condition.
Check for a fault on the flow input before restarting.
Batcher stops midway through a batch.
This could be due to the Signal Timeout having timed
out.
Check for a fault in the system. Ensure that the Signal
Timeout period is significantly longer than the period
between pulses from the flowmeter at the minimum flow
rate.
No display.
Check power to the instrument.
All 88888888 displayed.
The Batcher will display all eights on power up for 4 seconds
as a display test. If it continues to display all eights after this
period, this is symptomatic of the power supply voltage
being low. Check the power input voltage.
430D-M-V3
Trouble Shooting
52
Not counting.
If the Batcher does not count with the flowmeter connected
and flow passing through it, first check the connections and
then ensure the DIL switches on the rear of the instrument
are set as per section 6.
It is possible to manually test the input circuit of the Batcher
by setting the input configuration for a Reed Switch (see
Section 6) and pulsing across the signal (+) and (-) with a
wire link.
When doing this, the scaling factor should be set to 1 and
the resolution to whole numbers.
Counting erratically
This can be caused by two factors:
- setting the input circuit incorrectly
- lack of shielding on the input.
Shield the input signal with the shield earthed at the
Batch Controller only.
Instrument acting erratically
Erratic operation can be the result of severe
electrical interference. Considerable attention has
been given to designing the Batch Controller to
withstand electrical interference.
However, in extreme cases, loads may be encountered which
are exceptionally inductive and may require additional
protection.
One measure is to use an RC Suppression Network as
described in Section 7.
Another remedy for this problem is to use an isolating relay
to switch the load, and use the Batcher to drive the
isolating relay.
The isolating relay should be mounted away from the
Batcher and from signal wiring.
430D-M-V3
53
Trouble Shooting
No end of batch, pulse output or flow alarm.
This fault is usually caused by lack of a pullup resistor or
load on the output. The outputs themselves have no
internal pullups and rely on an external load.
430D-M-V3
Trouble Shooting
54
8.1 ERROR CODES
The instrument has extensive self test facilities and will display an error code
if it detects an invalid condition. If the instrument displays an error code
other than those listed below, please contact the factory.
Error codes are displayed as "Err 12" and a list of commonly encountered
codes are given below:
Error Codes
Input Errors
11
13
14
Invalid input configuration programmed.
Signal Timeout (see Section 3.2.2).
Communications Input error (RS232/422/485 Interface).
Output Errors
21
22
23
Invalid output configuration.
Communications error - Baud rate not set.
Communications error - Printer fault.
Calibration Errors
30
33
34
430D-M-V3
Zero Value not Allowed.
Invalid Printer Type.
Invalid Volume Units selected.
55
Index
Index
A
Access, 35
Auto Reset, 11
Auto Restart, 18
Automatic Overrun
Compensation, 19
B
Batch Limit, 12
Batch Set, 8
Battery, 29
Battery Backup, 7
Battery Protection
Tab, 29
Baud Rate, 29
E
M
Earth Lug, 48
Earthing Point, 48
End of Batch, 17
Error Codes, 54
Ex 410 Enclosure, 51
Mains, 48
Mains Voltage, 48
Model Number, 4
Multi-point
Communication, 27
F
N
Filtering, 21
Flow Alarm, 16
Frequency Input, 20
Frequency Range, 5
Front Panel Operation,
8
Namur Sensors, 42
Non-volatile Memory,
7
G
Ground, 48
C
I
Calibration, 32
Communication
Protocol, 29
Computer, 30
Control Functions,
13
Control Relay, 15
Count Down, 11
Count Up, 11
Cutout, 5
Input Circuits, 44
Input Impedance, 43
Installation, 48
Interference, 49
Introduction, 3
Isolation, 48
D
L
Date, 29
DC Input Voltage, 48
Decimal Points, 34
Dimensions, 5
Displayed
Information, 11
Limit on Batch, 12
Logic Signals, 42
Loss of Signal, 16
430D-M-V3
K
K-factor, 20
O
Open Collector
Outputs, 42
Operating
Temperature, 5
Operation, 7
Options, 26
Output Pulse, 24
Output Relays, 15
Overrun, 19
P
Parity, 29
Power Requirements,
5
Prestop, 15
Printer, 29
Pulse Output, 6, 24
Pulse Width, 6
R
Rate Key, 11
Reed Switches, 42
Remote Counters, 24
Remote Push-buttons,
47
Resetting, 11
Response, 21
RS232/422/485
Interface, 26
S
Scaling Range, 5
Set-up Parameters, 32
Setting the Batch, 8
Signal Timeout, 16
Slow Start, 15
Slow Stop, 15
Specification, 5
Starting, 10
Stop Key, 15
Stopping, 10
Switch Settings, 43
Switching Current, 5
Switching Power, 5
Switching Threshold, 43
T
Terminal, 50
Ticket, 29
Time Base, 20
Time Clock, 29
Time Delay, 15
Total Conversion, 23
Transducer Supply, 5
Trouble Shooting, 52
Turbine Flowmeters, 42
W
Wiring Designations, 50
430D-M-V3
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