Stroke Counter/Batch Control

Stroke Counter/Batch Control
SERVICE AND OPERATING MANUAL
Stroke Counter/Batch Control
A General Overview of this Control System
This control functions in two modes of operation:
•strokecountermode
•batchcontrollermode
Thetwomodescanbeoperatedtogetheroralone.
The control receives a signal from the diaphragm pump for each
pumpstroke.ItaccomplishesthisthroughaRuppTech® Pulse Output
Interfacemountedonthepump.
RuppTech® Pulse Output Interface - (available ONLY
from Warren Rupp, Inc.)
The Pulse Output Interface mounts on the pump and provides
electrical signals to operate the Control. This creates an electrical
interfacebetweenthecontrolandtheair-poweredpump.
Eachpumpstrokegeneratesasignalthroughaproximityswitch(PNP)
oneitherendoftheairvalve.Astheairvalvereciprocatesbackandforth
duringpumpoperation,targetsoneitherendofthesleeveandspool
settriggertheirrespectiveproximityswitches.Eachtriggersignalsthe
controltoregisteronecountonthestrokecounter/batchcontrolunit.
Thismethodprovidesapositivesignalforeverypumpstroke.
ThePulseOutputInterfacearedesignedforeasyfieldinstallation.The
interfacesarealsoavailablefactory-installedonnewpumps.PulseOutput
Interfacescanbepurchasedseparatelyfromthecontrolunitforthose
applicationswhereaprocesscontrollerisalreadypresentinasystem.
This provides a direct interface with the pump and the customer’s
system.
Stroke Counter Mode
Inthismode,thecontrolkeepsarunningtallyofthetotalnumberof
strokesofthepump.Thecontrolsavesthistotaluntiltheaccumulated
countisresetfromthecontrol’skeyboard,orthecounterexceedsthe
10-digitcapacityofthedisplay.Thecountcanbepumpstrokes(onefor
everystroke),orameasureofvolume(i.e.gallons,liters,pounds)to
indicate total volume pumped.The stroke count could also be used
toindicatehowlongthepumphasrun.Thisishelpfulforpreventative
maintenance schedules, or to account for the volumes of fluid being
transported or consumed.The stroke counter function is cumulative,
evenifthepumpisturnedoffandonbysomemeansotherthanthe
control.Anytimethepumpisrunningandthecontrolispowered,itwill
storethetotalcountforfuturereference.
Toviewthetotalizedcount,pushandholdtheTotalCountbuttonon
thecontrolkeyboard.(ToextendthelifeoftheLEDdisplay,thecount
doesnotdisplaycontinuously.)RefertotheProgrammingInstructions
inthismanualtosetthescaleperstrokeorresetthecount.
249-006-000 • 100-120/240VAC • 50/60
hertz
NEMA 12 Enclosure
Height 6.1”
(15.5cm)
Width 6.54”
(16.6cm)
Depth 3.46”
(8.8cm)
10-digit LED display
4 push buttons for setup
10A relay output for solenoid valve
2 proximity sensor inputs
2 remote on/off switch inputs
WarrenRupp,Inc.AUnitofIDEXCorporation•P.O.Box1568•Mansfield,OH44901-1568USA•4195248388Fax4195227867www.warrenrupp.com
Warren
Rupp, Inc. A Unit of IDEX Corporation • P.O. Box 1568 • Mansfield, OH 44901-1568 USA • 419 524 8388 Fax 419 522 7867 www.warrenrupp.com
Batch-sc-rev0611
520-180-000 3/02
Batch Batch
Control/Stroke
Counter
Control / Stroke
Counter
Page
1 1
Page
Batch Controller Mode
Inthismode,theControlcanbeprogrammedtotransferafixed
volumeofproduct.APresetCountisprogrammedintooneoftheten
programstorageareas(P0-P9).Thistellsthepumphowmuchproduct
willbetransferred(one“batch”)eachtimetheControlisactivated.
ThereisaSTARTswitchandaSTOPswitchmountedonthefrontof
theControlforthispurpose.Thereisalsoaninternalconnectionfor
remoteSTARTandSTOPswitchesthatacustomermaywanttoinstall.
NOTE: Use a momentary contact switch when using a remote
start/stop control.
Inthebatchcontrolmode,theTotalCountfunctionremainsactive.
Attheendofashift(severalprogrammed“batches”)thecustomercan
referencethetotalstrokecountortransferredvolumeoffluidhandled
duringthetimeperiod.Allotherbasicfunctionsremainactive(Scale
Factor,ResetTotalCount),aswellasadvancedfunctions(i.e.Preset
Count, multiple program storage, Reset Preset Count) which are
explainedlaterinthismanual.
TheBatchControllerModealsousesthePulseOutputInterfaceto
receiveacountfromthepump.Itrequiresanelectricsolenoidvalve
(availablefromWarrenRupp)intheairlinetothepump.Thisvalveis
anormallyclosed,3-way,ACvoltage(standardcontrol)unit,andis
purchasedseparately.Thesolenoidstartsandstopsthepumpthrough
thecontrol.Thepumpisstoppedbyturningofftheairsupplytothe
pump,afterithastransferredabatch,volumeorcountprogrammed
intothecontrol.Thepumpisrestartedbyturningontheairsupplyto
thepump.
In this Mode of operation the pump will start pumping when it
receivesasignalfromthecontrol.Thisopensthevalveintheairline.
Thesignalcanbeactivatedfromthecontrolmountedswitchorfroma
remotesignal.ThepumpwillstopautomaticallyoncethePresetCount
has been reached.The pump can also be stopped mid-operation,
usingthecontrolmountedSTOPswitchorfromaremoteSTOPsignal.
Whenrestarted,thepumpwillcontinuetheoperationfromthepoint
ofinterruption.
Ifpowertothecontrolislostduringoperation,thepumpwillstop.
Whenpowerisrestored,thecontrolresetstotheP0program.The
pumpwillnotcontinueoperationwithoutreceivingaSTARTsignal.This
functionistopreventaccidentsorproductspillage.Beforere-starting
theunit,becertaintoselecttheprogramwhichwasinterrupted.When
thepumphascompletedacycle,thePresetCountdisplaywillflash
untilitisactivatedagain.Whenreactivated,thedisplaywillresetand
restartthecountfromthePresetCountselected.Ifthecountisstopped
mid-cyclefromtheSTOPswitch,thedisplaywillnotflush.
Programming for Accuracy:
Batch Control Mode
Published pump performance is the starting
point for programming the batch controller.
But your actual system performance must be
verified, to achieve the expected 1 to 3% accuracy. This is accomplished through initial test
runs and measurement. On the following page
you will find an example showing the recommended sequence for verifying your system’s
actual performance.
When viewing the PRESET COUNT, a flashing LED display means
the pump was stopped after COMPLETING the programmed
cycle.
If the STOP button is used to stop the operation mid-cycle, the
display will not flash. When reactivated, the pump will continue
the cycle from the point of interruption.
Batch-sc-rev0611
520-180-000
3/02
Batch
Control/Stroke
Counter
Batch
Control
/ Stroke Counter
Page
Page
2 2
Programming for Accuracy
Topresetaccuratebatchprograms,itisimportanttoknowactualsystem
performance.Gatherthisinformationbymeasuringoutputvolumesgeneratedbytestrunsofthesystems,usingpublishedpumpperformanceas
astartingprogram.Carefulmeasurementwilltellyouhowmuchvolume
yoursystemisactuallydischargingoneverystroke.Youcanthenadjust
theprogramaccordingly.Hereisanexample.
EXAMPLE OF USE:
Aproductisblendedbasedonincomingorders.Twoingredientsare
mixedinaratioof3to1,creatingthefinalproduct.
Ordervolumesaretypically50,500,1000,1500and2000gallons.Two
pumpstransfertheingredientstoamixingareafor“batching”.
Pump#1inthisexampleisthetransferpumpforthemainelement.Its
controlhasPresetCountssetasfollows:
Pump#1PresetCounts:......... PO-37.5gallons..... P1-375gallons
................................................ P2-750gallons....... P3-1125gallons.
................................................ P4-1500gallons
StrokeScaleValve:................. 0.34gallonsperstroke
Thecontrol’sStrokeScaleValueissetatthedisplacementperstrokeof
the1½-inchpumptowhichitisconnected,.34gallons.
Pump #2 in this example is the transfer pump for the second element.
ItscontrolhasPresetCountssetasfollows,basedonthe3to1mixing
ratio:
Pump#2PresetCounts:......... PO-12.5gallons..... P1-125gallons
................................................ P2-250gallons....... P3-375gallons
................................................ P4-500gallons
StrokeScaleValve:................. 0.09gallonsperstroke
Pump#2’scontrolhastheStrokeScaleValuesetatthedisplacement
perstrokeofthe1-inchpumptowhichitisconnected,.09gallons.
Thougheachpumprequiresitsowncontrolunit,bothcontrolscanbe
tiedtogetherwithoneremoteStart/Stopswitchrunningbothunits.
WHERE TO FIND PUBLISHED PUMP
PERFORMANCE
Published pump performance is found on the data sheet
issued for model pump. Displacement is shown to the right
of the performance curve.
TESTING THE SYSTEM
Sinceeachcontrolgetsonepulseorsignal
from its pump for each stroke, the volumes
referencedintheexampleshouldbesetforthe
closesttotalvolumeavailable.
For example:
Pump#1.............P1-375gallons@
............................0.34gal.perstroke
............................=1102.94strokes
Adjusting for 1103 strokes would deliver
375.02gallons,assuming100%efficiencyfrom
pumpandsystem.Realisticexpectationsofa
well-designedandimplementedsystemfallin
therangeof1%to3%.
Basedondataobtainedfromthesystem,
it becomes evident where the system will
perform from an accuracy and efficiency
standpoint.This will indicate adjustments to
bemade.
For example:
Testing showed in the example system
thatPump#1delivered363.93gallons,within
the 3% range of accuracy. Since the Stroke
ScaleValuewassetat.34gallonsperstroke,
1103 strokes actually produced .329 gallons
perstroke.
Formula is:
Flow÷Strokes=GallonsperStroke
363.93÷ 1103=0.329gal./stroke
This test indicates the system should be
resettoproduceatotalflowclosertothebatch
targetof375gallons.
Formula is:
BatchTarget÷Gal.perStroke=#Strokes
375 ÷0.329=1139.81
Roundedto1140strokes
The controller cannot count a fractional
stroke, so the number of strokes is rounded
tothenearestwholenumber,1140.Thisgets
closertothetargetbatchsizeof375gallons,
actuallyproducing375.06gallons.
Thesametypeoftesting,calculationand
adjustmentwouldbeappliedtoallpumpsin
a system. Each pump’s performance will be
effected by the application and system
intotal.
If you do not have the appropriate data sheet, contact your
local Warren Rupp or Marathon distributor for a copy. Or
you can contact the Factory Literature Department at the
number shown below.
To receive the correct sheet, be sure to verify the pump
model and type, which is shown on the pump nameplate.
Batch-sc-rev0611
520-180-000 3/02
Batch Batch
Control/Stroke
Counter
Control / Stroke
Counter
Page
3 3
Page
Panel Button Functions
PROGRAMMING QUICK
REFERENCE
BUTTON ....................................... FUNCTION(S)
Total Count .................................. Display the total or accumulated count.
Digit Select/Reset ....................... Resets the count displayed
(Preset or Total).
Preset Count ............................... Displays the batch size.
Setting the Decimal Point
1.PressandholdTotalCount.
a.Repeatedlypressandrelease
IncreaseDigittomovedecimal
pointfromrighttoleft.
Press and hold: Total Count
then press: Increase Digit ........... Moves decimal point.
Press at the same time and hold:
Total Count + Preset Count
then press: Digit Select
Selects digit for programming Stroke
Scale Valve. Selected digit will flash.
then press: Increase Digit ........... To program valve to the selected
(flashing) digit.
Increase Digit .............................. Increases value of selected (flashing)
digit. --ALSO-- Selects storage register
for program storage. (P0-P9)
Programming & Set-up Functions (with pump stopped)
Setting the Multiplier or Stroke Scale Value
Each input signal from the Pulse Output Interface mounted on the pump
registersonecountintothecontrol.Thevalueofthiscountmustbedetermined
at the initial set-up for display purposes. For example, to count only pump
strokes,theStrokeScaleValuewouldbesetat1(one).Onepulsewouldequal
onestroke.
To set the Stroke ScaleValue, simultaneously press theTotal Count and
PresetCountbuttonsinandhold.ThenusetheIncreaseDigitbuttontoenterthe
valueassignedtotheflashingdigit.Toprogram,thedigittothefarrightofthe
displayshouldbeflashing.Ifitisnotflashing,presstheDigitSelectbuttonuntil
thedigittobeprogrammedbeginstoflash.Thedecimalpointshouldbetothe
farright.
Setting the Multiplier or Stroke Scale
1. Pressandhold:
TotalCount+PresetCount.
a.PressandreleaseDigitSelect
untildigitflashes.
b.PressIncreaseDigitto programtheflashingdigit.
Moving the Decimal Point for Fractional Volumes
Ifthevalueyouwishtouseisafractionalvolume,suchasdisplacementper
pumpstroke,thedecimalpointmustbemovedintotheproperlocationBEFORE
aStrokeScaleValueisentered.
WhilepressingtheTotalCountbutton,pressandreleasetheIncreaseDigit
buttonuntildecimalpointisinposition.AstheIncreaseDigitbuttonispressed
andreleased,thedecimalpointlocationwillmovefromrighttoleftonthedisplay.PressandreleaseIncreaseDigit,untilthedecimalpointisinthedesired
position.
Once the decimal point is positioned, set the Stroke ScaleValue.These
instructionsappearintheprevioussection.Also,pleaserefertotheprogramming
andtestingproceduresoutlinedearlierinthismanualfordetailedinstructions.
Thesectionisentitled,ProgrammingforAccuracy.
Batch-sc-rev0611
520-180-000
3/02
Batch
Control/Stroke
Counter
Batch
Control
/ Stroke Counter
Page
Page
4 4
Selecting & Storing a Preset Count
ToinitiallystoreorchangeaPresetCountvalue,selectoneofthetenprogram
storagelocations(P0throughP9).PressandholdtheIncreaseDigitbuttonto
displaythecurrentregisterlocation.ThedisplaywillshowP0throughP9forthese
locations.PressandreleasetheIncreaseDigitbuttontosequencethroughto
thelocationwhichwillstorethenewPresetCountvalue,ReleasetheIncrease
Digitbutton.
Afterselectingtheprogramstoragelocation,pressandholdthePresetCount
buttonuntilthefollowingsequenceiscompleted.PresstheResetbuttontoreset
thedisplaytoazerovalue.Thedigitpositionavailableforsettingwillflash.Press
andreleasetheIncreaseDigitbuttontochangethedigittotherequiredvalue.
RepeattheprocessusingtheDigitSelectbuttonuntileachdigitlocationisset
asrequired.
Resetting the Total Count
PressandholdintheTotalCountbutton.PressandreleasetheDigitSelect/
Resetbutton.Thedisplaywillresettozero.
Resetting the Preset Count
PressandholdinthePresetCountbutton.PressandreleasetheDigitSelect/
Resetbutton.Thedisplaywillresettozero.Toreprogram,refertotheprocedures
outlinedinSelecting&StoringaPresetCount.
PROGRAMMING QUICK
REFERENCE
Selecting a Program Storage Area
1.PressandreleaseIncrease Digittosequencethrough
programstorageareas
(P0throughP9).
2.Whenthedesiredstoragearea
appears,proceedwith
programingandstorage.
Functions (with the pump running)
START Button - NOTE: Use a momentary contact switch when using a remote
start/stop control.
ThisbuttonisusedonlywhenthecontrolisutilizedasaBatchController.In
thismodeofoperation,thecontrolisusedwithanelectricsolenoidairvalve,which
controlstheairsupplytothepump.Pressingthisbuttonstartsthepump.The
control has an internal connection for utilizing an external or remote
STARTbutton.
STOP Button - NOTE: Use a momentary contact switch when using a remote
start/stop control.
ThisbuttonisonlyusedwhenthecontrolisutilizedasaBatchController.
Pressingthisbuttonstopsthepump.Theunitcanberestartedbypressingthe
STARTbutton.Thecontrolhasaninternalconnectionforutilizinganexternalor
remoteSTOPbutton.WhenaPresetCounthasbeenstoppedbeforecompletion,
thedisplayvalvewillnotflash.Thisistoshowthecounthasbeenstopped.When
thepumpstopsaftercompletingaPresetCount,thedisplaypanelwillflash.
Programming & Storing a Preset
Count
1.PressandholdPresetCount
a.PressResettoresetthe displaytozero.
b.PressandreleaseIncrease
Digittochangetheflashing
digit.
c.PressDigitSelectuntileach
digitisset.
Resetting the Total Count
1.PressTotalCount.
a.PressandreleaseReset.
Resetting the Preset Count.
2.PressandholdPresetCount.
a.PressandreleaseDigit
Select/Reset.
Batch-sc-rev0611
520-180-000 3/02
Batch Batch
Control/Stroke
Counter
Control / Stroke
Counter
Page
5 5
Page
Wiring Diagram
100-120/240VAC
Jumper
DirectionArrowRefers120V
L1
L2
COMMONGROUND
RELAYOUTPUT
c
220V
STARTSWITCH
+
120VAC
120V
STOPSWITCH
+V
IMPORTANT!
PROXIMITYSENSORINPUT
If installing other RuppTech
components, such as the Pulse Output Kit
or Solenoid Kit, please refer to the separate
service pages supplied with the items.
GROUND
CHASSISGROUND
WiringDiagram249-006-000
Thisdeviceisfactorysetfor90-130VAC,50/60Hz.
For200-230VAC,50/60Hz,removeandrotatethejumperplugasshowbelow.
CAUTION!!! REMOVE POWER BEFORE SETTING!!!
FactorySet
90-130VAC
ARROW

Optional
220VAC

ARROW
Replace fuse with Type 3AG/250V, .5A, or equal, Fast Blow ONLY.
Batch-sc-rev0611
520-180-000
3/02
Batch
Control/Stroke
Counter
Batch
Control
/ Stroke Counter
Page
Page
6 6
Wiring Diagram
Connecting the control box to other
system components.
IMPORTANT!
If installing
other RuppTech
Wiring Diagram
for Interface components,
such as the Pulse
Output
Kit
or Solenoid
Kit,Counter (Non-Hazardous Location)
with 249-006-000 Batch
Control / Stroke
please refer to the separate service pages supplied
with the items.
Stroke counter/Batch Control
START
DIGIT
SELECT
PRESET
COUNT
TOTAL
COUNT
INCREASE
DIGIT
RESET
SandPIPER Air Valve
Mounted to Pump
STOP
WARREN RUPP PUMP CONTROLS
CHASSIS GROUND
GROUND
STOP SWITCH
24VDC
PROXIMITY SENSOR INPUT(S)
START SWITCH
100-120VAC
100-240VAC
COMMON GROUND
RELAY OUTPUT (+)
NEUTRAL
POWER 100-240VAC
RELAY OUTPUT COMMON
IDEX CORPORATION
#22 AWG Cable
Power Input
1
(+) Common
2
Output Channel #1
3
(-) Ground
4
Output Channel #2
Terminal #1
Neutral (Positive)
Terminal #2
Power (Negative)
NOTE: Use a momentary contact switch when using a remote
start/stop control.
1
2
Solenoid
Air Valve
Customer Supplied
Remote Control
®SandPIPER,RuppTechandWarrenRuppareregisteredtradenamesofWarrenRupp,Inc.
Momentary Switch
©2002WarrenRupp,Inc.Allrightsreserved.
Batch-sc-rev0611
520-180-000 3/02
3rd Terminal
for ground
Batch Batch
Control/Stroke
Counter
Control / Stroke
Counter
Page
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Page
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