DS Manual Cover Page.des - Anderson Instrument Co.,

DS Manual Cover Page.des - Anderson Instrument Co.,
Instruction
Manual
Anderson Instrument Co. Inc..
156 Auriesville Road
Fultonville, NY 12072
1-800-833-0081
Fax 518-922-8997
Www.andinst.com
Instrument Model Number
Instrument Serial Number
DS series Controller
With Printer and
Sampler
Form Number AIC2055
©September 2005
Revised: Oct 2015
Contents
1.
Description of System
2.
General DS Installation
3.
FTT-710 Manual
4.
IZMAG Manual
5.
PS Sampler Manual
6.
Replacement Parts
7.
Warranty
1
1. Description
The Anderson DS series Farm system offers multiple functions to satisfy the
needs of an advanced dairy farm. Using an IZMAG electromagnetic flowmeter
for measurement of milk flow, the system then collects the information in a
controller that offers the ability to totalize and print information based on an
external input defining animal groups, or totalizing the entire amount pumped into
a transport trailer or bulk cooler for comparison purposes. In addition to the
totalization and print capability, the system can be configured for use to control
the quantity of milk that is pumped into a transport trailer or tank to prevent the
over-filling of that container. In this instance a relay output is used to trigger an
alarm or directly stop the pumping of milk into the tank. If configured as a DS2
system, the ability to take a composite bacterialogical sample of milk which has
passed through the system is also possible using the pneumatic sampler which
is integrated into the control system. Proper use of this portion of the system is
defined in SOP document at the end of this manual. During the wash process
that takes place between milkings, a 110 VAC input is required to define this
period. When this input is received the recording of the meters measurement is
surpressed so that milk measurement values are not affected by wash water
flow. Also if equipped with the optional sampling function, the sampling system
will cycle on a time basis when this input is present for the purpose of cleaning
the sampler head and piping.
FTT Controller/Printer
Description
The FTT Controller/Printer is functions to provide the display of measured milk.
Along with displaying the measured quantity it is equipped with a tape printer
which will give a paper copy of measured volumes
Installation
All systems will have a display enclosure which should be mounted on a wall for
easy viewing. Mounting tabs are provided on the enclosure for this purpose.
Locate the enclosure in a easily accessible place within close proximity of the
trailer or tank that is being filled. This will make operation of the device
convenient when changeover occurs which is the time that it is most often
accessed. The unit is seldom located in the actual milking parlor due to the high
2
likelihood of water being sprayed into the tape printer if the door is left open.
Often a location in a hallway or in a office can prove to be a better choice. Wiring
The display will require that continuous 110 VAC power supply be made
available to give uninterrupted operation. The power source should be a clean
instrument electrical circuit. If the unit is to be used for group totals, a remote
print/ reset switch (shown in Fig.2.2 as AIC part # FTT-710-REM-BOX) will be
used to allow for remote printing of group totals from the milking parlor by dairy
personnel.
3
Electrical Connections DS1
The control enclosure for the DS1 is provided pre-wired with a 110VAC power
cord to be plugged directly into a standard power outlet In addition to the power
cord, 25’ of 2 conductor signal cable has been pre-wired for connection to the
flowmeter. Figure 1.1 identifies the 110VAC input from the farm wash panel which
is necessary to enable measurement suppression during the wash cycle. In
applications where the display is used for fill control the relay output from the
controller will need to be wired to turn on an alarm to alert dairy personnel of the
tank status. If the control is to be used for group production monitoring the
termination for a remote momentary contact switch is also indicated.
26
25
PE
Fig. 1.1
N
L
4
Electrical Connections DS2
The DS2 differs from the DS1 due to the addition of sampling capability. With the
need for additional electrical connections the DS2 enclosure is provided with (3)
1 2” electrical connection holes on the bottom of the enclosure to allow for
permanent rigid or flexible conduit connections to be made. It will be necessary
dependant on the environment to keep these connections water-tight. Fig. 1.2
identifies the necessary connections needed for a DS2 system . In addition to
the incoming power and the signal from the flowmeter, the DS2 also requires
connections to the air solenoid valves which operate the sampler. Note that the
solenoid wiring is 110VAC operating voltage and should be installed to the
samecodes and standards as other high voltage wiring in the facility.
5
1
A
3
4
PAPER
ADVANCE
2
C
6
BLK
WHT
5
7
BLK
WHT
8
RS232
PORT
9
P/N: TP-PL-180
TICKET PRINTER
17 18 19 20 21 22
1 2 3 4 5 6 7 8
DIP SWITCH
10 11 12 13 14 15 16
FTT-720
CONTROLLER
12 VOLT
POWER JACK/CABLE
FOR PRINTER
23 24
YEL
5AMP
Circuit
Breaker
BLK
(NOT
USED)
YEL
N
N
110 VAC
INPUT
L1
L1
T
TRANSFORMER
RPI: 120V 60Hz
SEC: 6.3V-OV-6.3V 1.2 AMP
17 12
17 12
Alarm
Output
N
N
11
11
12 N 11
N/0 COM N/C
PE 19 18
PE 19 18
MICROLOGIX 1000
I/0 I/1
7
7
6
6
5
5
PE
PE
4
4
4
2
2
2
3
3
Remote Switch
Input for Assignable
Controller Action
1
1
N GND O/0 O/0 O/1 O/1 O/2 O/2
110
VAC
WASH
8
8
L1
+24V COM COM
1
CR1
5
3
4
FTT-710-SA1 ENCLOSURE
6
PORT
3
PORT
1
16oz 475cc
NALGENE SAMPLER
BOTTLE
PORT
2
Inlet
Exhaust
11
N 12 PE
SA-70
12 N 11
26
21 22 23 24 25 26 33 34 31 32
25
IZML
110 VAC
Input
PE N L
110 VAC
INPUT
SA-70 & IZML ENCLOSURE
7
Component Location
The attached diagram (Fig 1.3) Illustrates the preferred locations within the
piping schematic of a typical dairy installation
DS
Solenoid
DS
Controller
DS
Sampler
IZMAG
Flowmeter
Fig 1.3
8
FTT-710-SA
CONTENTS
1. DESCRIPTION
1.1 Unit Description ........................................................................................................................... 1
1.2 Unit Features ............................................................................................................................... 1
1.3 Specifications .............................................................................................................................. 2
2. INSTALLATION
2.1 General Mounting Hints ............................................................................................................... 6
2.2 Mounting Diagrams ..................................................................................................................... 6
3. APPLICATIONS
3.1 Liquid Volume .............................................................................................................................. 7
3.2 Batching ....................................................................................................................................... 8
4. WIRING
4.1 Typical Batcher Wiring ................................................................................................................. 9
4.2 Typical Rate/Total Wiring ............................................................................................................. 9
5. UNIT OPERATION
5.1 Front Panel Operation Concept for Run Mode .......................................................................... 10
5.2 General Operation ..................................................................................................................... 11
5.3 Ratemeter/Totalizer Operation ................................................................................................... 11
5.3.1 Password Protection for Rate/Total mode ................................................................ 11
5.3.2 Relay Operation in Rate/Total mode ........................................................................ 11
5.3.3 Pulse Output in Rate/Total mode ............................................................................. 11
5.3.4 Analog Output in Rate/Total mode ........................................................................... 11
5.3.5 RS-232 Serial Port Operation in Rate/Total mode .................................................. 12
5.3.6 RS-485 Serial Port Operation in Rate/Total mode .................................................. 12
5.4 Batcher Operation ..................................................................................................................... 13
5.4.1 Batcher Configuration .............................................................................................. 13
5.4.2 Password Protection for Batcher mode .................................................................... 14
5.4.3 Relay Operation in Batcher mode ............................................................................ 14
5.4.4 Pulse Output in Batcher mode ................................................................................ 14
5.3.5 Analog Output in Batcher mode .............................................................................. 14
5.4.6 RS-232 Serial Port Operation in Batcher mode ...................................................... 15
5.4.7 RS-485 Serial Port Operation in Batcher mode ...................................................... 15
6. PROGRAMMING
6.1 Front Panel Operation Concept for Program Mode ................................................................... 16
6.2 EZ Setup .................................................................................................................................... 17
6.3 Setup Menus ............................................................................................................................. 18
6.4 Setup Sub-Menus ...................................................................................................................... 19
6.4.1 SELECT EZ SETUP ................................................................................................. 19
6.4.2 INSTRUMENT TYPE ............................................................................................... 19
6.4.3 SETUP INDICATORS (Total) ................................................................................... 21
6.4.4 SETUP INDICATORS (Rate) ................................................................................... 21
6.4.5 SETUP FLOW INPUT (Pulse - chA & chA=chB) ...................................................... 22
6.4.6 SETUP FLOW INPUT (Pulse - Quadrature, Qx1 or Qx2) ........................................ 23
6.4.7 SETUP PULSE OUTPUT ......................................................................................... 24
6.4.8 SETUP ANALOG OUTPUT ...................................................................................... 25
6.4.9 SETUP RELAYS ...................................................................................................... 25
6.4.10 SETUP CONTROL INPUTS (RATE/TOTAL) ......................................................... 27
6.4.11 SETUP CONTROL INPUTS (BATCH) .................................................................... 27
6.4.12 SETUP REALTIME CLOCK (Time) ........................................................................ 28
6.4.13 SETUP REALTIME CLOCK (Date) ........................................................................ 28
6.4.14 SERIAL USAGE ..................................................................................................... 29
6.4.15 SET DATALOG/PRINT (Configure) ........................................................................ 30
6.4.16 SET DATALOG/PRINT (Select_list) ....................................................................... 31
6.4.17 ADMINISTRATIVE SETUP ..................................................................................... 31
6.4.18 SETUP NETWORK CARD ..................................................................................... 32
i
7. PRINCIPLE OF OPERATION
7.1 General ...................................................................................................................................... 33
7.2 Flow Equations .......................................................................................................................... 33
7.3 Linearization Table ..................................................................................................................... 34
7.6.1 Linearization Table General Information ................................................................... 34
7.6.2 Linearization Table for Pulse Inputs ......................................................................... 34
7.6.3 Linearization Table Interpolation ............................................................................... 34
8. TEST, SERVICE and MAINTENANCE
8.1 Test Menus ................................................................................................................................ 35
8.2 Test Sub-Menus ......................................................................................................................... 36
8.2.1 Audit Trail ................................................................................................................. 36
8.2.2 Error History ............................................................................................................. 36
8.2.3 Print System Setup .................................................................................................. 36
8.2.4 Keypad test .............................................................................................................. 37
8.2.5 Display test ............................................................................................................... 37
8.2.6 Calibrate 0mA out ..................................................................................................... 37
8.2.7 Calibrate 20mA out ................................................................................................... 37
8.2.8 Pulse input test ......................................................................................................... 38
8.2.9 Analog out test ......................................................................................................... 38
8.2.10 Excitation out test ................................................................................................... 39
8.2.11 Pulse out test .......................................................................................................... 39
8.2.12 Relay test .............................................................................................................. 39
8.2.13 Control input test .................................................................................................... 39
8.2.14 Data logger utility ................................................................................................... 39
8.3 Internal Fuse Replacement ....................................................................................................... 40
9. GLOSSARY OF TERMS
9 Glossary Of Terms ........................................................................................................................ 41
10. DIAGNOSIS AND TROUBLESHOOTING
10.1 Response of FTT on Error or Alarm: ........................................................................................45
10.2 Diagnosis Flow Chart and Troubleshooting ..............................................................................46
10.3 Error & Warning Messages: ......................................................................................................47
13.3.1 Sensor/Process Alarms ...........................................................................................47
13.3.2 Self Test Alarms .......................................................................................................47
APPENDIX A
Setup Menu Flowchart ......................................................................................................................48
FTT-710 Reinitialize Sequence.........................................................................................................49
FTT-710 Factory Parameter Sequence.............................................................................................50
Parameter Configuration Table.........................................................................................................52
ii
1. Description
1.1 Unit Description:
The FTT Flow Computer satisfies the rate, total and batching instrument requirements
for a variety of pulse producing flowmeter types in liquid applications. Multiple flow equations and
instrument functions are available in a single unit with many advanced features.
The alphanumeric display shows measured and calculated parameters in easy to understand
format. Single key direct access to measurements and display scrolling is supported.
The versatility of the FTT permits a wide measure of versatility within the instrument
package. The various hardware inputs and outputs can be “soft” assigned to meet a variety of
common application needs. The user “soft selects” the usage of each input/output while configuring
the instrument. Consider the following illustrative examples.
The user can assign the standard RS-232 Serial Port for data logging, transaction printing, or for
connection to a modem for remote meter reading.
1.2 Unit Features:
The FTT Flow Computer offers the following features:
•
•
•
•
•
•
•
•
•
•
•
•
Compatible with Pulse Producing Flowmeters
Multiple Instrument Functions; Rate, Total, Batching
Menu Selectable Hardware & Software Features
Two Line LCD Display
Automatic Batch Overrun Compensation
Isolated Pulse Output Standard
Isolated Analog Output Standard
Versatile RS-232 Port Standard
Linearization Capability Standard
DIN Enclosure with Two Piece Connectors
EZ Setup Feature
Advanced Batching Features
1
Flow Inputs:
Pulse Inputs:
Number of Flow Inputs: one
Configurations supported: single input with or
without quadrature (menu selectable)
Input Impedance: 10 KΩ nominal
Pullup Resistance: 10 KΩ to 5 VDC (menu
selectable)
Pull Down Resistance: 10 KΩ to common
Trigger Level: (menu selectable)
High Level Input
Logic On:
3 to 30 VDC
Logic Off:
0 to 1 VDC
Low Level Input (mag pickup)
Selectable sensitivity: 10 mV & 100 mV
Minimum Count Speed: User selectable down to
1 pulse in 99 sec.
Maximum Count Speed: Selectable: 0 to 20kHz
Overvoltage Protection: 50 VDC
Fast Transient: Protected to 500 VDC
(Capacitive Clamp)
1.3 Specifications:
Specifications:
Environmental
Indoor Use
Altitude up to 2000m
Operating Temperature: 0°C to +50°C
(-20°C to 55°C optional)
Storage Temperature: -40°C to +85 C
Maximum Relative Humidity : 80% for temperatures
up to 31°C decreasing linearly to 50% RH at
40°C
Main supply voltage fluctuations not to exceed
±10% of the nominal voltage
Transient overvoltage according to INSTALLATION
CATEGORY II (see UL 3101-1 Annex J)
POLLUTION DEGREE 2 in accordance with
IEC 664 (see 3.7.3)
Materials: UL, CSA, VDE approved
Approvals:
CE Compliant Light Industrial,
UL File #: E192404, C/UL
Control Inputs
Switch Inputs are menu selectable for Start, Stop,
Reset, Lock, Inhibit, Alarm Acknowledge, Print or
Not Used.
Control Input Specifications
Input Scan Rate: 10 scans per second
Logic 1: 4 - 30 VDC
Logic 0: 0 - 0.8 VDC
Transient Suppression: 500 V fast transient
(Capacitive Clamp)
Input Impedance: 100 KΩ
Control Activation: Positive Edge or Pos. Level
based on product definition
Display
Type: 2 lines of 20 characters
Types: Backlit LCD
Character Size: 0.3" nominal
User selectable label descriptors and units of
measure
Keypad
Keypad Type: Membrane Keypad
Keypad Rating: Sealed to Nema 4
Number of keys: 16
Enclosure
Size: See Dimensions
Depth behind panel: 6.5" including mating
connector
Type: DIN
Materials: Plastic, UL94V-0, Flame retardant
Bezel: Textured per matt finish
Equipment Labels: Model, safety, and user wiring
Excitation Voltage
110/220 VAC Powered Units
Menu Selectable: 5, 12 or 24 VDC @ 100mA
24 VDC Powered Units
Menu Selectable: 5 or 12 VDC @ 100mA
12 VDC Powered Units
5 VDC @ 100mA
Power Input
The factory equipped power option is internally fused.
An internal line to line filter capacitor is provided for
added transient suppression.
Order Option 1: 110VAC: 85 to 127 Vrms, 50/60 Hz
Order Option 2: 220VAC: 170 to 276 Vrms, 50/60
Hz
Order Option 3: 12VDC: 10.5 to 14 VDC
Order Option 4: 24VDC: 18 to 24 VDC
2
Analog Output
The analog output is menu assignable to
correspond to the Rate or Total.
Type: Isolated Current Sourcing
Isolated I/P/C: 500 V
Available Ranges: 4-20 mA, 0-20 mA
Resolution: 12 bit
Accuracy: 0.05% FS at 20 Degrees C
Update Rate: 1 update/sec minimum
Temperature Drift: Less than 200 ppm/C
Maximum Load: 1000 ohms (at nominal line
voltage)
Compliance Effect: Less than .05% Span
60 Hz rejection: 40 dB minimum
Calibration: Operator assisted Learn Mode
Averaging: User entry of DSP Averaging constant
to cause an smooth control action.
Relay Outputs
The relay outputs are menu assignable to
(Individually for each relay) Low Rate Alarm, Hi
Rate Alarm, Prewarn Alarm, Preset Alarm, General
purpose warning (security), overrun or not used.
Number of relays: 2 (4 optional)
Contact Style: Form C contacts
Contact Ratings: 250 VAC @ 5 amps
30 VDC @ 5 amps
Fast Transient Threshold: 1000 V
Serial Communication
The serial port can be used for printing, datalogging,
modem connection and communication with a
computer.
RS-232:
Device ID: 01-99
Baud Rates: 300, 600, 1200, 2400, 4800, 9600,
19200
Parity: None, Odd, Even
Handshaking: None, Software, Hardware
Print Setup: Configurable print list and
formatting
RS-485:
Device ID: 01-247
Baud Rates: 2400, 4800, 9600, 19200
Parity: None, Odd, Even
Protocol: Modbus RTU (Half Duplex)
Isolated Pulse output
The isolated pulse is assigned to Volume Total.
Isolation I/O/P: 500 V
Pulse Output Form: Isolated Photomos Relay
Maximum On Current: 125 mA
Maximum Off Voltage: 30 VDC
Saturation Voltage: 1.0 VDC
Maximum Off Current: 0.1 mA
Pulse Duration: User selectable: 10mSec, 100mSec
Pulse output buffer: 8 bit
Fault Protection
Reverse polarity: Shunt Diode
Transient Protection: 500 VDC
(Capacitive Clamp)
3
Operating Mode
The Flow Computer can be thought of as making a
measurement of flow and then performing
calculations which are then updated periodically
on the display as rate and total. The pulse output,
analog output and the alarm relays are also
updated. The cycle then repeats itself.
Setup Mode
The setup mode is password protected by means
of a numeric lock out code established by the user.
In addition, a secret, manufacturers numeric unlock
entry sequence is available.
The system also provides a minimum
implementation of an “audit trail” which tracks
significant setup changes to the unit. This feature
is increasingly being found of benefit to users or
simply required by Weights and Measurement
Officials in systems used in commerce, trade, or
“custody transfer” applications.
Step 1: Update the measurements of input signalsRaw Input Measurements are made at each input.
Step 2 : Compute the Volumetric FlowUncompensated flow is the term given to the flow
in volume units. The value is computed based on
the flowmeter input type selected and augmented
by any performance enhancing linearization that
has been specified by the user.
A Worksheet is provided to assist the user in setting
up the instrument. An Easy Setup (EZ Setup)
feature is offered in the setup menu. The EZ
Setup routine is a quick and easy way to configure
the unit for the most commonly used instrument
functions.
Step 3: Check Flow AlarmsThe flow alarm functions have been assigned to
flow rate during the setup of the instrument. A
comparison is now made by comparing the current
flow rates against the specified hi and low limits.
The setup mode has numerous subgrouping of
parameters needed for flow calculations. There is
a well conceived hierarchy to the setup parameter
list. Selections made at the beginning of the setup
affect offerings further down in the lists.
Step 4: Compute the Flow Totals by SummationA flow total increment is computed for each flow
rate. This increment is computed by dividing the
pulses by the K-Factor and then summing. The
totalizer format also includes provisions for total
rollover.
In the setup mode, the flow computer activates the
correct setup variables based on the instrument
configuration, the flow equation, and the hardware
selections, the flow transmitter type, and meter
enhancements (linearization) options selected. All
required setup parameters are enabled. All setup
parameters not required are suppressed.
Step 5: Total Preset ComparisonsThe total associated with a preset function is then
compared against the corresponding preset value
and any required control actions taken.
Step 6: Pulse Output ServiceThe pulse output is next updated by scaling the
total increment which has just been determined by
the pulse output scaler and summing it to any
residual pulse output amount.
A help line prompt is provided for each entry. In
addition a help message is available which may be
accessed by depressing the “HELP” key.
Also note that in the setup mode are parameter
selections which have preassigned industry
standard values. The unit will assume these values
unless they are modified by the user.
Step 7: Compute the Analog OutputThis designated flow rate value is now used to
compute the analog output.
Step 8: Update Display and Printer OutputThe instrument finally runs a task to update the
various table entries associated with the front panel
display and serial outputs.
4
Maintenance (Test) Mode:
The Maintenance Mode of the FTT
provides a number of specialized utilities required
for instrument checkout on start-up, setup
documentation and data logger access.
Operation of Serial Communication Port with
Printers
FTT's RS-232 channel supports a
number of operating modes. One of these modes
is intended to support operation with a printer in
metering applications requiring transaction printing,
data logging and/or printing of maintenance reports.
A password is required to gain access to this
specialized mode of operation. Quality and
maintenance personnel will find this mode of
operation very useful. It is also useful for factory
testing.
For transaction printing, the user defines the items
to be included in the printed document. The user
can also select what initiates the transaction print
generated as part of the setup of the instrument.
The transaction document may be initiated via a
front panel key depression, a remote contact
closure, upon completion of a batch, time of day or
at a timed interval.
Many of these tests may be used during start-up of
a new system. Inputs signals may be read, and
output signals may be exercised to verify the
electrical interconnects before the entire system is
put on line.
In data logging, the user defines the items to be
included in each data log as a print list. The user
can also select when or how often he wishes a
data log to be made. This is done during the setup
of the instrument as either a time of day or as a
time interval between logging.
The following action items may be performed in
the Maintenance Mode:
Print Setup Report
Examine Audit Trail
Examine Error History
Perform Keypad Checkout
Perform Display Checkout
Perform Pulse Input Checkout
Perform Pulse Output Checkout
Perform Control Input Checkout
Perform Relay Output Checkout
Perform Analog Output Checkout
Calibrate Analog Output using the Learn Feature
Perform Excitation Output Test
Examine or Dump Data Logger
The system setup and maintenance report lists all
the instrument setup parameters and usage for the
current instrument configuration. In addition, the
Audit trail information is presented along with a
status report listing any observed malfunctions
which have not been corrected.
The user initiates the printing of this report at a
designated point in the menu by pressing the
requested key on the front panel.
RS-232 Serial Port
The FTT has a general purpose RS232 Port which may be used for any one of the
following purposes:
Operation of Serial Port with Modems (optional)
The FTT RS-232 channel supports a
number of operating modes. One of these modes
is intended to support operation with a modem in
remote metering applications.
Transaction Printing
Data Logging
Remote Metering by Modem (optional)
Computer Communication Link
Configuration by Computer
Print System Setup
Print Malfunction History
An external modem is intentionally being used with
the FTT. This permits use with the
variety of modem standards worldwide while
avoiding the specialized approvals required for
equipment that is deemed to fall under the category
of telecommunication equipment.
In the modem mode, the FTT is
assumed to be operating in a remote metering
role. In addition, the FTT will be capable
of initiating a call to a designed telephone number
in the event of a metering malfunction.
5
2. Installation
2.1 General Mounting Hints:
The FTT Flow Computer should be located in an area with a clean, dry atmosphere
which is relatively free of shock and vibration. The unit is installed in a 5.43" (138mm) wide by 2.68"
(68mm) high panel cutout. (see Mounting Dimensions) To mount the Flow Computer, proceed as
follows:
a. Prepare the panel opening.
b. Slide the unit through the panel cutout until the it touches the panel.
c. Install the screws (provided) in the mounting bracket and slip the bracket over the rear of the
case until it snaps in place.
d. Tighten the screws firmly to attach the bezel to the panel. 3 in. lb. of torque must be applied
and the bezel must be parallel to the panel.
Termination Connectors:
Minimum Wire Gauge:
22 AWG
Maximum Wire Gauge:
14 AWG
Voltage/current limits are limited by unit specifications.
Permanently Connected Equipment:
UL 3101-1, Section 6.12.2.1 specifies that:
• A switch or circuit breaker shall be included in the building installation;
• It shall be in close proximity to the equipment and within easy reach of the OPERATOR;
• It shall be marked as the disconnecting device for the equipment.
NOTE: Ensure that the switch or circuit breaker chosen is suitable for the power
requirements of the unit.
2.2 Mounting Diagrams:
Standard Mounting
Bezel Kit Mounting
FTT
Bezel Adaptor
Gasket
FTT
!
IMPORTANT!
To provide protection type
IP65/NEMA 4X, the unit
must be mounted with the
bezel adaptor and the
gasket (supplied with the
mounting kit). The bezel
must be glued to the unit
with silicon.
(see Instructions supplied
with the mounting kit)
Mounting Bracket
Mounting Bracket
Dimensions
5.67 (144)
0.28 (7.2)
3.43
(87)
RATE
147.43 GPM
TOTAL 267395.749 GAL
START
STOP
TOTAL
1
RATE
2
PRE 1
3
GRAND
6
SCROLL
7
PRE 2
8
PRINT
5
4
TIME
9
0
–
CLEAR
MENU
HELP
•
ENTER
6.15
(156)
0.4 (10)
Dotted Line Shows Optional Bezel Kit
Dimensions are in inches (mm)
6
5.43
(138)
Panel
Cutout
2.83
(72)
6.18
0.5
(13)
2.68
(68)
3. Applications
3.1 Liquid Volume
Measurements:
A flowmeter measures the actual volume in a liquid line.
Calculations:
• For Flowmeters with Pulse Outputs, Volume flow is calculated using the flowmeter frequency
output and the user entered K-Factor or Linearization Table.
Output Results:
• Display Results
Flow Rate, Resettable Total, Non-Resettable Total
• Pulse Output
Total
• Analog Output
Rate or Total
• Relay Outputs
Rate or Total Alarms
Applications:
The Flow Computer can monitor actual volume flow and total of any liquid. Flow alarms are
provided via relays and datalogging is available via serial outputs.
Liquid Volume
Illustration
START
STOP
TOTAL
1
RATE
2
PRE 1
3
F1
4
F3
5
GRAND
6
SCROLL
7
PRE 2
8
F2
9
F4
0
–
CLEAR
MENU
HELP
•
ENTER
Flowmeter
Calculations
Pulse Input; Average K-Factor or Linearization Table
input frequency * time scale factor
Volume Flow =
K-Factor
7
3.2 Batching
Measurements:
A flowmeter measures the actual volume in a liquid line.
Calculations:
• For Flowmeters with Pulse Outputs, Volume flow is calculated using the flowmeter frequency
output and the user entered K-Factor or Linearization Table.
Output Results:
• Display Results
Flow Rate, Batch Total, Non-Resettable Total
• Pulse Output
Total
• Analog Output
Rate or Total
• Relay Outputs
Batch Total, Rate, or Alarms
Applications:
Batching and monitoring flow and total of any liquid. Batching is accomplished via relays and
datalogging is available via serial outputs.
Batching Illustration
START
STOP
TOTAL
1
RATE
2
PRE 1
3
F1
4
F3
5
GRAND
6
SCROLL
7
PRE 2
8
F2
9
F4
0
–
CLEAR
MENU
HELP
•
ENTER
Flowmeter
Calculations
Solenoid Valve
Pulse Input; Average K-Factor or Linearization Table
input frequency * time scale factor
Volume Flow =
K-Factor
8
4 WIRING
4.1 Typical Batcher Wiring:
(+) V
Signal
Common
FLOW METER
with Pre Amp
Stop
Start
123456
Remote Electronic Counter
MOV
recommended
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
DC OUTPUT
PULSE IN 1
PULSE IN 2
COMMON
NOT USED
NOT USED
NOT USED
NOT USED
17
18
19
20
21
22
NC
COM RLY1
NO
NC
COM RLY2
NO
23
24
AC LINE
AC LINE
FLOW
IN
CNTR IN 1
CNTR IN 2
CNTR IN 3
COMMON
PULSE OUTPUT +
PULSE OUTPUT –
SEE USER
MANUAL
ANALOG OUT +
ANALOG OUT –
115 VAC
115 VAC
SOLENOID VALVE
115 VAC
4.2 Typical Rate/Total Wiring:
Signal
Common
FLOW SENSOR
with magnetic pickup
123456
Remote Electronic Counter
Alarm Relay 1
Alarm Relay 2
115 VAC
9
{
{
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
DC OUTPUT
PULSE IN 1
PULSE IN 2
COMMON
NOT USED
NOT USED
NOT USED
NOT USED
17
18
19
20
21
22
NC
COM RLY1
NO
NC
COM RLY2
NO
25
26
27
28
29
30
NC
COM RLY3
NO
NC
COM RLY4
NO
DC +
DC -
POWER IN
FLOW
IN
CNTR IN 1
CNTR IN 2
CNTR IN 3
COMMON
PULSE OUTPUT +
PULSE OUTPUT ANALOG OUT +
ANALOG OUT –
23 AC LINE
24 AC LINE
SEE USER
MANUAL
25
26
27
28
29
30
NC
COM RLY3
NO
NC
COM RLY4
NO
DC +
DC -
POWER IN
5. UNIT OPERATION
5.1 Front Panel Operation Concept for Run Mode
The FTT is fully programmable through
the front panel. Please review the following usage
summary before attempting to use the instrument.
START
STOP
TOTAL
1
RATE
2
PRE 1
3
F1
4
F3
5
GRAND
6
SCROLL
7
PRE 2
8
F2
9
F4
0
–
CLEAR
MENU
HELP
•
ENTER
HELP
On-line help is provided to assist the operator in using this product. The help is available during RUN and SETUP
modes simply by pressing the HELP key. The HELP key is used to enter decimals when entering numeric values.
FUNCTION KEYS
In the RUN mode, several keys have a special, direct access feature, to display an item of interest (i.e. RATE,
TOTAL, PRE 1, etc.). Press the key to view your choice. Press the SCROLL key to return to scrolling display.
CLEARING TOTALIZER
To clear the total, you must press the TOTAL Function Key 3 times quickly to select the total. Once the total is
selected, press the CLEAR key to reset the total. The operator will be prompted to enter password if the unit is
locked.
NOTE: In the Batcher Mode, simply press the CLEAR key to reset the total (the batcher must be stopped or finished
batching). It is not necessary to press the TOTAL Function Key first.
CLEARING GRAND TOTAL
To clear the grand total, you must press the GRAND Function Key 3 times quickly to select the grand total. Once the
grand total is selected, press the CLEAR key to reset the grand total. The operator will be prompted to enter
password if the unit is locked.
PRESET KEYS
In the RUN mode, PRE 1, PRE 2, F1 and F2 keys are used to view and/or change the preset setpoints. To view the
Presets, simply press the desired Preset key once. Rapidly press the Preset keys 3 times, then press the Clear key
for direct editing of the preset setpoints.
SCROLL
Rapidly press the Scroll key 3 times to setup a display list.
Press the CLEAR key to remove old scroll list.
Press the function key for the item you wish to add
Use the ∆ ∇ keys to assign the line.
Press the ENTER key to save scroll list.
PRINT
The PRINT key is used to print on demand. When the PRINT key is pressed, a user defined list of data (TOTAL,
RATE, PRE 1, etc.) is sent to the RS232 port. A timed message of "PRINTING" will be displayed to acknowledge the
print request.
SPECIAL BATCHING KEYS
The START and STOP keys are used only when batching to start and stop batches. The CLEAR key will clear the
total without first pressing the TOTAL key (unit must be stopped). All other keys work the same in both Rate/Total
mode and Batch mode. The Start and Stop keys operation are set by the control input settings. The Start options are:
START or RESET/START. The Stop options are: STOP or STOP/RESET.
MENU KEY
The MENU key is used to enter the Setup and Test modes. Press the MENU key to enter the Setup and Test modes.
The user will be prompted to enter a password if the unit is locked. (See section 6 for Setup mode, section 8 for Test
mode). The MENU key is also used as "escape" in Setup and Test Programming. Pressing the MENU key while
programming in the Sub-Menu groups will backup the display to that Sub-Menu group heading. Pressing the MENU
key while viewing the Sub-Menu groups will backup the display to the Top Level Menu.
ACKNOWLEDGING ALARMS
Most alarm messages are self-clearing. Press the ENTER key to acknowledge and clear alarms.
NOTE: Some keys and functions are password protected. Enter the password to gain access. The passwords are
factory set as follows: Operator = 0; Supervisor = 2000
TIME/DATE
The TIME key is reserved for displaying Time and Date. To View the Time or Date, press the TIME key once.
10
5.2 General Operation
The unit can display: Rate, Total, Grand Total, Presets and Time of Day. The unit can be programmed to
perform Ratemeter/Totalizer or Batching functions.
5.3 Ratemeter/Totalizer Operation
The Ratemeter/Totalizer mode is used primarily to monitor flowrate and accumulated total. The relays can
be used to trigger on flow rate, total, or alarms.
5.3.1 Password Protection for Rate/Total mode
After an Operator and/or Supervisor Password is entered in the setup mode (see section 6.3, SETUP
PASSWORD submenu), the unit will be locked. The unit will prompt the user for the password when trying to
perform the following functions:
Clear Total
Clear Grand Total
Enter Menu
Edit Preset 1 (PRE 1 Key)
Edit Preset 2 (PRE 2 Key)
Edit Preset 3 (4 Key)
Edit Preset 4 (9 Key)
The Supervisor password should be reserved for supervisors. The Supervisor password will allow access to
restricted areas of the Setup and Test menus.
5.3.2 Relay Operation in Rate/Total mode
Up to four relays are available (two standard) for alarm outputs. The relays can be assigned to trip according
to rate, total or general system alarms. The relays can be programmed for low or high alarms.
Preset 1 (RLY1) and Preset 2 (RLY2) are easily accessible by pressing the PRE 1 or PRE 2 key on the front
panel. Preset 3 and Preset 4 are accessible by pressing the 4 or 9 keys.
5.3.3 Pulse Output in Rate/Total mode
The isolated pulse output (open collector) is assigned to Volume Total. The pulse output duration can be
set for 10mS (50 Hz max) or 100mS (5 Hz max). A pulse output scale factor (pulse value) can be set to scale
the pulse output. The pulse output is ideal for connecting to remote totalizers or other devices such as a
PLC. See section 1.3 for electrical specifications.
5.3.4 Analog Output in Rate/Total mode
The analog output is menu assignable to correspond to the Volume Rate or Volume Total. The analog
output is ideal for "trend" tracking using strip chart recorders or other devices.
11
5.3.5 RS-232 Serial Port Operation in Rate/Total mode
The RS-232 serial port can be used for programming (using the Setup Disk) or for communicating to
printers and computers in the Operating Mode (Run Mode).
PC Communications:
The Setup Disk also allows the user to query the unit for operating status such as Flow Rate, Flow Total,
Presets, etc.
Operation of RS-232 Serial Port with Printers:
Transaction Printing
For transaction printing, the user defines the items to be included in the printed document (see section
6.3.20 SET DATA OUTPUT, Select_list). The transaction document can be initiated by pressing the
PRINT key or by a remote contact closure.
Data Logging
In data logging, the user defines the items to be included in each data log (see section 6.3.20 SET
PRINTER OUTPUT, Select_list). The user can also select when (time of day) or how often (print interval)
the data log is to be made (see section 6.3.19 SET PRINTER OUTPUT, Configure).
System Setup and Maintenance Report
The system setup and maintenance report lists all of the instrument setup parameters and usage for the
current instrument configuration. The audit trail information and a status report is also printed. This report
is initiated in the Test menu (see section 8.2.3 PRINT SYSTEM SETUP).
5.3.6 RS-485 Serial Port (optional)
RS-485 Port Description:
The optional RS-485 card utilizes Modbus RTU protocol to access a variety of process
parameters and totalizers. The Relays can be controlled via Modbus. In addition, action
routines can be executed. For further information, contact factory and request RS-485
Protocol manual.
Operation of Serial Communication Port with PC
The flow computer's RS-485 channel supports a number of Modbus RTU commands. Modbus
RTU drivers are available from third party sources for a variety of Man Machine Interface
software for IBM compatible PC's.
The user reads and writes information from/to the RS-485 using the Modbus RTU commands.
The FTT then responds to these information and command requests.
Process variables and totalizers are read in register pairs in floating point format. Time and
date are read as a series of integer register values. Alarms are individually read as coils.
Action routines are initiated by writing to coils.
12
5.4 Batcher Operation
The Batcher mode is used primarily to control batches. The main difference between the Batch mode and
Rate/Total mode is the relay operation. The Batch mode allows the operator to "START" the unit via the
front panel or remote input. Once started, the relays (RLY1 & RLY2) will energize and send a contact to a
flow control device (i.e. solenoid valve or pump). The flow sensor will send a signal to the unit and total
accumulation will begin. Just before the end of batch, when the Prewarn value (PRE 2) is reached, Relay 2
will drop out (this is ideal for flow slow down). When the final Batch amount (PRE 1) is reached, Relay 1 will
drop out and the Batch is complete.
Several messages will be displayed during normal batch operation (i.e. Batch Fill, Batch Stopped). The
keypad is disabled for the duration of these timed messages (approx. 2 sec).
5.4.1 Batcher Configuration.
When the unit is programmed for batch mode, several batch operation choices are available. These choices
include: EZ Preset, Up or Down Counting, Maximum Batch Preset, Batch Overrun Compensation, Auto
Batch Restart, Time Delay, Flow Signal Timeout, Maximum Drain Time, Slow Start Quantity, Start or Reset/
Start, and Stop or Stop/Reset.
EZ Preset
A selectable mode of batching where user can press "PRE 1", then "ENTER" then the quantity to be
batched, then "START" for a quick enter-start sequence.
Batch Count Mode
The Batch Count Mode allows the user to choose whether the unit will batch up to a preset value or batch
down from a preset value to zero.
Maximum Batch Preset
The Maximum Batch Preset allows the user to program the Maximum Batch value allowed to be entered by
the operator. If an operator should try to program a batch higher then this value, the unit will not allow the
value to be entered and will prompt the user with an error message saying that the permitted Maximum
Batch Preset size has been exceeded.
Batch Overrun
The Batch Overrun is used for batch applications that have slow responding valves and a consistent
batching flowrate. When the Batch Overrun is set, the unit will compensate for batch overruns by computing
an averaged overrun value from the last four batches. This average is used to internally adjust the batch
setpoint to minimize overrun. The maximum drain time must be set greater than the slowest valve response
time for proper operation of this feature.
Auto Batch Restart
The Auto Batch Restart function allows the user to set an amount of time to automatically restart a batch
after the completion of a batch. This time can be set from 1 to 99 seconds.
Flow Signal Timeout
The Flow Signal Timeout allows the user to enter a timeout of 0 to 99 seconds. If a batch is “Filling” and zero
flow persists for more than the user entered time then the batch will be aborted. This prevents over flows due
to faulty flow sensors and/or wiring.
Maximum Drain Time
The unit declares that a batch is “done” when the flow rate equals “0”. A flow rate may be present long after
the Preset Relay de-energizes due to slow reacting valves or leaky valves. The Maximum Drain Time allows
the user to enter an amount of time (0 to 99 seconds) to wait before declaring “Batch Done”. After the Preset
Batch quantity is reached, the unit will declare “Batch Done” when the flow rate is “0” or the Maximum Drain
Time has expired. The batch data will then be available for printing and datalogging.
Slow Start Quantity
The Slow Start Quantity is a function that allows an amount to be entered for a Slow Start of fill. This function
requires two stage valve control. RLY 1 (slow flow) will energize for Slow Start and RLY 2 (fast flow) will
energize after the Slow Start Quantity has been delivered. This helps reduce turbulence when filling an
empty container.
13
START, RESET/START and STOP, STOP/RESET
When configuring the control inputs, Control Input1 can be set for START or RESET/START. When set for
START, the unit will start batching when a signal is applied to Control Input 1 or the front panel Start key is
pressed. A separate Reset signal or CLEAR key depression must be used to clear the previous batch total.
When set for RESET/START, the unit will automatically reset then start when a signal is applied to Control
Input1 or the front panel Start key is pressed (provided that the pervious batch was completed). If a previous
batch was stopped during a batch cycle, the unit will Start from where it was stopped.
Control Input 2 can be set for STOP or STOP/RESET. When set for STOP, the unit will stop batching when
a signal is applied to Control Input 2 or the front panel Stop key is pressed. A separate Reset signal or
CLEAR key depression must be used to clear the batch total. When set for STOP/RESET, a running batch
will stop when a signal is applied to Control Input 2 or the front panel Stop key is pressed. If the unit is
Stopped or after a completed batch, the unit will reset when a signal is applied to Control Input 2 or the front
panel Stop key is pressed.
NOTE: Applying a voltage level to Control Input 2 will inhibit and override all Start inputs in either mode.
5.4.2 Password Protection for Batcher Mode
After an Operator and/or Supervisor Password is entered in the setup mode (see section 6.3, SETUP
PASSWORD Sub-menu), the unit will be locked. The unit will prompt the user for the password when trying
to perform the following functions:
Clear Grand Total
Enter Menu
The Supervisor password should be reserved for supervisors. The Supervisor password will allow access to
restricted areas of the Setup and Test menus.
The passwords are factory set as follows:
Operator = 0
Supervisor = 2000
NOTE: A password of "0" should not be used since it will leave the unit unlocked and open to accidental
changes.
5.4.3 Relay Operation in Batcher mode
Up to four relays are available (two standard) for alarm outputs. Preset 1 (RLY1) is reserved for batch
amount, Preset 2 (RLY2) is reserved for prewarn. (see section 5.4 Batcher Operation for Relay 1 & Relay 2
functions)
Preset 1 (RLY1) and Preset 2 (RLY2) are easily accessible by pressing the PRE 1 or PRE 2 key on the front
panel. Preset 3 and Preset 4 are accessible by pressing the 4 or 9 keys.
Relays 3 and 4 can be assigned to trip according to rate, total, overrun or alarm. When Rate is selected the
relays can be programmed for low or high alarms. When N.A (not assigned) is selected, the relays may be
tripped via serial commands. Alternately, Preset 2, 3 or 4 may be used to enter alternate information and
can be printed in the print list for transaction history.
5.4.4 Pulse Output in Batcher mode
The isolated pulse output (open collector) is assigned to Volume Total. The pulse output duration can be set
for 10mS (50 Hz max) or 100mS (5 Hz max). A pulse output scale factor (pulse value) can be set to scale
the pulse output. The pulse output is ideal for connecting to remote totalizers or other devices such as a
PLC. See section 1.3 for electrical specifications.
5.4.5 Analog Output in Batcher mode
The analog output is menu assignable to correspond to the Volume Rate or Volume Total. The analog
output is ideal for "trend" tracking using strip chart recorders or other devices.
14
5.4.6 RS-232 Serial Port Operation in Batcher mode
The RS-232 serial port can be used for programming (using the Setup Disk) or for communicating to printers
and computers in the Operating Mode (Run Mode).
PC Communications:
The Setup Disk also allows the user to query the unit for operating status such as Flow Rate, Flow Total,
Presets, etc.
Operation of RS-232 Serial Port with Printers:
Transaction Printing
For transaction printing, the user defines the items to be included in the printed document (see section
6.3.20 SET DATA OUTPUT, Select_list). The transaction document can be initiated by pressing the PRINT
key, by a remote contact closure or print at end of batch.
Data Logging
In data logging, the user defines the items to be included in each data log (see section 6.3.20 SET PRINTER
OUTPUT, Select_list). The user can also select when (time of day) or how often (print interval) the data log
is to be made (see section 6.3.19 SET PRINTER OUTPUT, Configure).
System Setup and Maintenance Report
The system setup and maintenance report lists all of the instrument setup parameters and usage for the
current instrument configuration. The audit trail information and a status report is also printed. This report is
initiated in the Test menu (see section 8.2.3 PRINT SYSTEM SETUP).
5.4.7 RS-485 Serial Port (optional)
RS-485 Port Description:
The optional RS-485 card utilizes Modbus RTU protocol to access a variety of process parameters and
totalizers. Batches/Relays can be controlled remotely via Modbus. In addition, action routines can be
executed. For further information, contact factory and request RS-485 Protocol manual.
Operation of Serial Communication Port with PC
The flow computer's RS-485 channel supports a number of Modbus RTU commands. Modbus RTU drivers
are available from third party sources for a variety of Man Machine Interface software for IBM compatible
PC's.
The user reads and writes information from/to the RS-485 using the Modbus RTU commands.
FTT then responds to these information and command requests.
The
Process variables and totalizers are read in register pairs in floating point format. Time and date are read as
a series of integer register values. Alarms are individually read as coils. Action routines are initiated by
writing to coils.
15
6. PROGRAMMING
6.1 Front Panel Operation Concept for Program Mode
The FTT is fully programmable through the front panel. Please review the following
usage summary before attempting to use the instrument.
START
STOP
TOTAL
1
RATE
2
PRE 1
3
F1
4
GRAND
6
SCROLL
7
PRE 2
8
F2
9
F3
5
F4
0
–
CLEAR
MENU
HELP
•
ENTER
Setup Mode:
MODE CHANGES
Pressing the MENU key will offer selections of RUN, SETUP, TEST. RUN is the normal operating
mode for the instrument. SETUP offers various sub-menus used for instrument setup. TEST
offers various sub-menus for Test, Calibration and System Start-up testing.
Sub-menu GROUP NAVIGATION
Use the UP and DOWN arrow keys to navigate up and down through the Sub-Menu groups when
in the SETUP or TEST mode. Press the ENTER key to enter a desired setup or test Sub-Menu
group.
SELECTION OF ITEM
During setup, the unit will often offer multiple choices for a given topic. The topic prompt appears
on the top line of the display. The choices are shown on the lower line of the display.
To select an item, press the key (in top row) beneath the desired choice. The selected
choice will blink. Press the ENTER key to accept the selected choice.
NUMERIC ENTRY
The keys labeled "0 - 9", "–", ".", CLEAR and ENTER are used to enter numerical values. A
leading 0 will assume that you intend to enter a minus "–" sign. Press the CLEAR key to clear the
existing value and to enable editing. Enter the digits of your desired values, press ENTER to
accept the value.
TEXT CHARACTER ENTRY
Some setup items (i.e. Descriptors, Units Label) require the user to enter text characters. Press
CLEAR to enable editing. The UP and DOWN arrow keys are used to scroll through the available
character sets for each individual character. Press the ENTER key to accept the character and
advance to the next character.
16
6.2 EZ Setup
The EZ Setup routine is a quick and easy way to configure the unit for the most commonly used
instrument functions. This setup assumes that you are measuring Volumetric Flow using a high
level, DC Pulsing flow sensor. Entering the EZ Setup mode automatically sets many features. This
may cause any previously programmed information to be lost or reset. For a complete customized
configuration, see sections 6.3 and 6.4.
Menus
Display
6.2.1
TOP LEVEL
SETUP MENU
Notes
Select Setup to enter the instrument setup routine.
SELECT OPERATE STATE
Run
Setup
Test
ENTER
6.2.2
EZ Setup
Sub-menu
Groups
Press ENTER to begin EZ Setup routine.
SELECT EZ SETUP
ENTER
Confirm that you want to run EZ Setup. Caution: Any
previous program settings may be lost or reset.
CHANGES ALL SETUPS !
No
Yes
ENTER
Instrument Type.
INSTRUMENT TYPE
Rate/Tot
Batch
ENTER
RATE TIME BASE
Sec Min
Hour
Select the appropriate rate time base.
Day
ENTER
Enter the desired rate decimal location.
0-4 decimal places allowed.
RATE DEC PLACES(0-4)
0
ENTER
Enter the desired totalizer units label.
TOTAL VOLUME UNITS
gal
ENTER
Enter the desired totalizer decimal location. 0-3 decimal
places allowed.
TOT DEC PLACES (0-3)
0
ENTER
Enter the desired K-Factor Type.
K_FACTOR TYPE
Avg
LinTbl
Through
16 Points
ENTER
AVERAGE KA-FACTOR
####### P/gal
If Average selected, Enter the desired Average K-Factor.
LINEAR TABLE KA
Fre01:######## Hz
If LinTbl selected,
Enter the desired frequency/ K-Factor pair for each point
in the Linearization Table.
Enter a frequency of 0 for any point other than Fre01 to
exit Linearization Table setup.
ENTER
LINEAR TABLE KA
KA--01:##########
ENTER
Enter the desired full scale setting for the analog output.
FS ANALOG OUT 20mA
#######gal/m
ENTER
RATE
TOTAL
Return to Run Mode
00.0 gal/m
0 gal
17
6.3 Setup Menus
Display
Sub-menus
6.3.1
Top Level Setup Menu
Select Setup to enter the instrument setup routine.
SELECT OPERATE STATE
Run
Setup
Test
MENU
6.3.2
Sub-menu
Groups
Notes
ENTER
Refer to Page 17 for Details.
SELECT EZ SETUP
START
STOP
START
Refer to Page 19 for Details
INSTRUMENT TYPE
STOP
START
Refer to Page 21 for Details.
SETUP INDICATORS
STOP
START
Refer to Page 22 & 23 for Details.
SETUP FLOW INPUT
STOP
START
Refer to Pages 24 for Details.
SETUP PULSE OUTPUT
STOP
START
Refer to Pages 24 for Details.
SETUP ANALOG OUTPUT
STOP
START
Refer to Page 25 & 26 for Details.
SETUP RELAYS
STOP
START
Refer to Page 27 for Details.
SETUP CONTROL INPUTS
STOP
START
Refer to Page 28 for Details.
SETUP REALTIME CLOCK
STOP
START
Refer to Page 29 for Details.
SERIAL USAGE
STOP
START
Refer to Pages 30 & 31 for Details.
SETUP DATALOG/PRINT
STOP
START
Refer to Page 31 for Details.
ADMINISTRATIVE SETUP
STOP
START
STOP
Refer to Page 32 for Details.
(Setup Network Card menu will only appear on units
equipped with a network card)
SETUP NETWORK CARD
18
6.4 Setup Sub-Menus
Sub-menus
6.4.1
SELECT EZ SETUP
Display
Notes
SELECT EZ SETUP
Refer to page 17 for EZ Setup routine.
Press the DOWN (stop) key to advance to Instrument
Type. Press the UP (start) key to advance to
Administrative Setup.
STOP
START
Advance To
INSTRUMENT TYPE
6.4.2
INSTRUMENT TYPE
INSTRUMENT TYPE
Press ENTER to enter Instrument Type sub-menus.
ENTER
INSTRUMENT TYPE
Rate/Tot
Batch
Press ENTER when Rate/Total is flashing to configure
the instrument as a Ratemeter/Totalizer.
STOP
START
Rate/Tot
ENTER
Advance To
SELECT FLOW EQUATION
If Rate/Tot selected, advance to Setup Indicators.
INSTRUMENT TYPE
Press ENTER to enter Instrument Type sub-menus.
ENTER
Batch
INSTRUMENT TYPE
Rate/Tot
Batch
Press ENTER when Batch is flashing to configure the
instrument as a Batcher.
STOP
START
ENTER
SELECT PRESET TYPE
Standard
EZ-Preset
Select Standard for standard preset operation. Select
EZ-Preset for quick preset editing mode. (see section
5.4.1 Batcher Configuration.)
STOP
START
ENTER
BATCH COUNT MODE
Up
Down
Select UP to Reset to 0 and count up to preset. Select
DOWN to reset to Preset and count down to 0.
STOP
START
ENTER
Continue On Next Page
19
Sub-menus
6.4.2
INSTRUMENT TYPE
(continued)
Notes
MAXIMUM BATCH PRESET
1000.0 gal
STOP
START
See Section 5.4, see also
Max. Drain Time note.
ENTER
BATCH OVERRUN COMP
Off
On
STOP
START
ENTER
AUTO BATCH RESTART
Off
On
STOP
START
ENTER
TIME DELAY (1-99sec)
10
STOP
START
STOP
START
Select ON to set the unit to operate using a Batch
Overrun Compensation routine. Select OFF to inhibit
Batch Overrun Compensation routine.
Select On to enable the Auto Batch Restart. This will
automatically restart the unit at the end of each batch run
(after programmed timeout). Select Off to disable.
Enter Time Delay for Auto Batch Restart. When a batch
is completed, the next batch will start automatically after
the amount of time entered here has elapsed.
ENTER
FLOW SIGNAL TIMEOUT
10
NOTE: Max Drain time value
must be greater than the
slowest valve response time
when using Batch Overrun
Comp.
Enter the maximum allowable Batch Preset. The operator
will not be able to enter a batch preset larger than this
value.
Enter a timeout of 0 to 99 seconds. If a batch is “Filling”
and zero flow persists for more than this time, the batch
filling will be stopped.
ENTER
MAXIMUM DRAIN TIME
10
Enter time (0-99 sec.) for Max. Drain Time. After batch quantity is
reached, “Batch Done” is declared when the flow rate is “0” or the
Maximum Drain Time has expired.
ENTER
SLOW START QUANTITY
10
ENTER
Enter a quantity for a Slow Start up. RLY 1 (slow flow) will
energize for Slow Start and RLY 2 (fast flow) will energize
after the Slow Start Quantity has been delivered. Both
RLY 1 and RLY 2 are energized during "fast fill".
Advance To
SETUP INDICATORS
20
Sub-menus
6.4.3
SETUP
INDICATORS
(Total)
Display
Notes
Press ENTER to begin setup of the Indicators
SETUP INDICATORS
ENTER
Press ENTER when Total is flashing to configure the
Totalizer Indicators
SETUP INDICATORS
Total
Rate
ENTER
Enter the desired Total Descriptor text
TOTAL DESCRIPTOR
TOTAL
ENTER
Enter the desired Volume Units Label text for the
Totalizer.
TOTAL VOLUME UNITS
gal
ENTER
Select the desired Total Decimal Place.
0-3 decimal places allowed.
TOT DEC PLACES (0-3)
0
ENTER
Advance To
SETUP INDICATORS
(Rate)
6.4.4
SETUP
INDICATORS
(Rate)
Press ENTER when Rate is flashing to configure the
Ratemeter Indicators
SETUP INDICATORS
Total
Rate
ENTER
RATE TIME BASE
Sec Min
Hour
Select the desired Rate Time Base.
Day
ENTER
Enter the desired Descriptor text for the Ratemeter.
RATE DESCRIPTOR
RATE
ENTER
Select the desired Rate Decimal Place.
0-4 decimal places allowed.
RATE DEC PLACES(0-4)
4
ENTER
Enter desired Rate Averaging Filter. (see Definitions for
more details)
RATE AVG FILTER
0
ENTER
Enter desired Percent of Change for Quick Update. If
the current flowrate deviates by an amount greater than
the percentage value entered, the Rate Averaging is
inhibited.
(See Definitions for more details.)
QUICK UPDATE %
5
ENTER
Advance To
SETUP FLOW INPUT
21
Sub-menus
Display
6.4.5
SETUP
FLOW INPUT
(Pulse - chA &
chA=chB)
Notes
Press ENTER to begin setup of Flow Input.
SETUP FLOW INPUT
ENTER
Select the desired Excitation Voltage for your flow
sensor. Caution: Improper selection may cause damage
to sensor
EXCITATION VOLTAGE
5v
12v
24v
ENTER
NOTE:
Enter the desired Pulse type. See side note.
PULSE INPUT TYPE
chA chA=chB Qx1 Qx2
chA = Single Pulse
chA=chB = Pulse
checking
for missing
pulses
Qx1 = Quadrature
Qx2 = Quadrature x 2
ENTER
Select the desired Input Pulse Trigger Level.
PULSE TRIGGER LEVEL
10mV
100mV
2.5V
ENTER
Select the desired Low Pass Filter.
(Max. Count Speed). Use 3kHz with turbine flowmeters.
LOW PASS FILTER
40Hz
3KHz
20KHz
ENTER
Select the proper input termination.
INPUT TERMINATION
Pullup Pulldown None
ENTER
Enter the desired Maximum Sample Window Time (1-99
sec) that can occur at the lowest flowrate. Use 1 second
for turbine flowmeters.
MAX WINDOW (1-99)
1
ENTER
Enter the desired K-Factor Type.
K_FACTOR TYPE
Avg
LinTbl
ENTER
If Avg selected, Enter the desired Average K-Factor in
the units requested.
AVERAGE KA-FACTOR
####### P/gal
Through
16 Points
ENTER
If LinTbl selected,
Enter the desired frequency/ K-Factor pair for each point
in the Linearization Table.
NOTE: Enter 0 for Fre value of any point (other than
Fre01) to exit the routine and use the values
entered up to that point.
LINEAR TABLE KA
Fre01:######## Hz
LINEAR TABLE KA
KA--01:####### P/gal
ENTER
Enter the desired volumetric Low Rate Alarm.
This will trigger an alarm message if alarm conditions
occur. The relays are not affected.
LOW FLOW RATE ALARM
####### gal/m
ENTER
Enter the desired volumetric High Rate Alarm.
This will trigger an alarm message if alarm conditions
occur. The relays are not affected.
HIGH FLOW RATE ALARM
####### gal/m
ENTER
Advance To
SETUP PULSE OUTPUT
22
Sub-menus
Display
Notes
Press ENTER to begin setup of Flow Input.
SETUP FLOW INPUT
6.4.6
SETUP
FLOW INPUT
(Pulse - Quadrature,
Qx1 or Qx2)
ENTER
Select the desired Excitation Voltage.
EXCITATION VOLTAGE
5v
12v
24v
ENTER
Press ENTER when Pulse is flashing to configure the
flow input for Pulse signals.
FLOW INPUT TYPE
Pulse
ENTER
NOTE:
Enter the desired Pulse type. See side note.
PULSE INPUT TYPE
chA chA=chB Qx1 Qx2
chA = Single Pulse
chA=chB = Pulse
checking
for missing
pulses
Qx1 = Quadrature
Qx2 = Quadrature x 2
ENTER
Select the desired Input Pulse Trigger Level.
PULSE TRIGGER LEVEL
10mV
100mV
2.5V
ENTER
Select the desired Low Pass Filter.
(Max. Count Speed). . Use 3kHz with turbine flowmeters.
LOW PASS FILTER
40Hz
3KHz
20KHz
ENTER
Select the proper input termination.
INPUT TERMINATION
Pullup Pulldown None
ENTER
Enter the desired Maximum Sample Window Time (1-99
sec) that can occur at the lowest flowrate. Use 1Hz for
turbine flowmeters.
MAX WINDOW (1-99)
1
ENTER
K_FACTOR TYPE
Avg
LinTbl
Enter the desired K-Factor Type.
Through
16 Points
ENTER
AVERAGE KA-FACTOR
####### P/gal
If Avg selected, Enter the desired Average K-Factor (KA
for channel A).
AVERAGE KB-FACTOR
####### P/gal
Enter the desired Average K-Factor (KB for channel B).
LINEAR TABLE KA
Fre01:######## Hz
If LinTbl selected,
Enter the desired frequency/ K-Factor pair for each point
in the Linearization Table. (channel A)
NOTE: Enter 0 for Fre value of any point (other than
Fre01) to exit the routine and use the values
entered up to that point.
ENTER
LINEAR TABLE KA
KA--01:####### P/gal
ENTER
Enter the desired frequency/ K-Factor pair for each point
in the Linearization Table. (channel B)
NOTE: Enter 0 for Fre value of any point (other than
Fre01) to exit the routine and use the values
entered up to that point.
Through
16 Points
LINEAR TABLE KB
Fre01:######## Hz
ENTER
LINEAR TABLE KB
KA--01:####### P/gal
ENTER
LOW FLOW RATE ALARM
####### gal/m
Enter the desired volumetric Low Rate Alarm.
This will trigger an alarm message if alarm conditions
occur. The relays are not affected.
ENTER
HIGH FLOW RATE ALARM
####### gal/m
Enter the desired volumetric High Rate Alarm.
This will trigger an alarm message if alarm conditions
occur. The relays are not affected.
ENTER
Advance To
SETUP PULSE OUTPUT
23
Sub-menus
6.4.7
SETUP
PULSE OUTPUT
Display
Notes
Press ENTER at this prompt to setup the Pulse Output.
SETUP PULSE OUTPUT
ENTER
Select the desired Pulse Output Usage.
PULSE OUTPUT USAGE
Off
Volume
ENTER
PULSE WIDTH
10mS
Select the desired Pulse Width for the Pulse Output.
100mS
ENTER
Enter the desired Pulse Value for the Pulse Output
(Volume Units per Pulse).
PULSE VALUE
1000 gal/P
ENTER
Advance To
SETUP ANALOG OUTPUT
6.4.8
SETUP
ANALOG OUTPUT
Press ENTER when Analog is flashing to setup the
Analog Output.
SETUP ANALOG OUTPUT
ENTER
Select the desired Analog Output Usage.
ANALOG OUTPUT USAGE
Rate
Total
ENTER
Select the desired current range for the Analog Output.
ANALOG OUTPUT RANGE
4-20mA
0-20mA
ENTER
Enter desired Analog Output Low Scale Value.
NOTE: Units label will correspond with output usage
type selected.
LS ANALOG OUTPUT
0.0 gal/m
ENTER
Enter desired Analog Output Full Scale Value.
FS ANALOG OUT 20mA
1000.0 gal/m
ENTER
Enter the desired Analog Output Damping Constant. See
Definitions for additional information.
ANALOG OUT DAMPING
0.0
ENTER
Advance To
SETUP RELAYS
24
Sub-menus
6.4.9
SETUP RELAYS
(Relay 1 & Relay 2)
NOTE:
In Batch mode,
Relay 1 is reserved
for Preset,
Relay 2 is reserved
for Prewarn or NA
(not assigned).
Display
Notes
SETUP RELAYS
Rly1 Rly2 Rly3 Rly4
Select the desired Relay for setup.
(Relays 3 & 4 Optional, menus will always appear even if
option not installed)
ENTER
RELAY 1 USAGE
RATE
TOTAL
If Relay 1 or Relay 2 Selected,
Select Rate, Total or NA.
NA
ENTER
RELAY 1 DELAY
If Rate selected, enter desired relay activation delay
value. Alarm condition must be continuously present for
this amount of time before alarm will activate.
sec
0
ENTER
If Total Selected, Enter desired Relay Duration.
RELAY 1 DURATION
#####
ENTER
Select the desired Relay Activation.
Low: Relay activates when reading is below setpoint.
High: Relay activates when reading is above setpoint.
RELAY 1 MODE
LO_ALARM
HI_ALARM
ENTER
Enter the desired Setpoint. The Setpoint can be edited in
run mode using the PRE 1 key (PRE 2 key for Relay 2).
RELAY 1 SETPOINT
####### gal
ENTER
If Rate, selected, Enter desired Relay Hysteresis.
RELAY 1 HYSTERESIS
##### gal/m
ENTER
Advance To
SETUP RELAYS 3, 4
25
Sub-menus
6.4.9 (Continued)
SETUP RELAYS
(Relay 3 & Relay 4)
NOTE:
Settings for Relays
3 & 4 may be
entered even if
relays are not
supplied. The
settings will still
trigger display alarm
messages if
applicable.
Display
Notes
Select the desired Relay for setup.
(Relays 3 & 4 Optional)
SETUP RELAYS
Rly1 Rly2 Rly3 Rly4
ENTER
RELAY 3 USAGE
Rate Tot Alrm Ovr NA
If Instrument Type is set for BATCHER,
Choose Rate, Total, Alrm, Ovr or NA.
RELAY 4 USAGE
Rate Tot Alrm NA
If Instrument Type is set for RATE/TOTAL,
Choose Rate, Total, Alrm or NA.
ENTER
RELAY 3 DELAY
If Rate / Alrm selected, enter desired relay activation
delay value.
sec
0
ENTER
If Total Selected, Enter desired Relay Duration.
RELAY 3 DURATION
#####
ENTER
Select the Relay Activation for Rate/Alrm.
Low: Relay activates when reading is below setpoint.
High: Relay activates when reading is above setpoint.
RELAY 3 MODE
LO_ALARM
HI_ALARM
ENTER
Enter the desired Setpoint. The setpoint 3 can be edited
in the "Run Mode" using the 4 key (9 key for Relay 4).
RELAY 3 SETPOINT
####### gal
ENTER
If Rate, selected, Enter desired Relay Hysteresis.
RELAY 3 HYSTERESIS
##### gal/m
ENTER
Advance To
SETUP CONTROL INPUTS
RELAY NOTES & CONSIDERATIONS
1. Relay activation is based on the computed readings not the displayed value. Therefore the display
damping factor will not affect the relay response time. The RELAY DELAY feature allows the user
to enter a time delay for relay activation. This feature is very useful in applications where short over/
under range conditions are not considered alarm conditions.
2. When INSTRUMENT TYPE is set to batcher, Relay 1 is reserved for PRESET and Relay 2 is
reserved for PREWARN or NA (not assigned).
3. Setting the relays to NA (Not Assigned), will allow the relay activation to be controlled via the RS232 Serial and/or RS-485 Modbus ports. It also allows the Presets to be used for other numeric
entry values via serial commands which can be part of the print list.
4. Relay 3 and Relay 4 settings may be used to trigger display alarm conditions even if the relays are
not supplied.
26
Sub-menus
6.4.10
SETUP CONTROL
INPUTS
(RATE/TOTAL)
Display
Notes
Press Enter to begin setup of the Control Inputs.
SETUP CONTROL INPUTS
ENTER
Select the desired Control Input for setup.
SETUP CONTROL INPUTS
Input1 Input2 Input3
ENTER
CONTROL INPUT1 USAGE
INHIBIT_TOTAL
NA
If Control Input 1 Selected,
Select Inhibit Total or NA (Not Assigned).
CONTROL INPUT2 USAGE
RESET_TOTAL
NA
If Control Input 2 Selected,
Select Reset Total or NA (Not Assigned).
CONTROL INPUT3 USAGE
Prn Ack KeyLk NA
If Control Input 3 Selected,
Select Prn (Print), Ack (acknowledge), KeyLk (Keylock)
or NA (Not Assigned). ACK will acknowledge and clear
alarms and warning messages.
Note: Alarms may reassert themselves if alarm
conditions are still present.
ENTER
Advance To
SETUP REALTIME CLOCK
6.4.11
SETUP CONTROL
INPUTS
(BATCH)
Select the desired Control Input for setup.
SETUP CONTROL INPUTS
Input1 Input2 Input3
ENTER
CONTROL INPUT1 USAGE
Start Rst/Start NA
If Control Input 1 Selected,
Select Start ,Reset/Start, NA (Not Assigned).
CONTROL INPUT2 USAGE
Stop
Stop/Rst NA
If Control Input 2 Selected,
Select Stop, Stop/Reset, NA (Not Assigned).
CONTROL INPUT3 USAGE
Rst Prn KeyLk Ack NA
If Control Input 3 Selected,
Select Prn (Print), Ack (acknowledge), KeyLk (Keylock)
or NA (Not Assigned). ACK will acknowledge and clear
alarms and warning messages.
Note: Alarms may reassert themselves if alarm
conditions are still present.
ENTER
Advance To
SETUP REALTIME CLOCK
27
Sub-menus
6.4.12
SETUP REALTIME
CLOCK
(Time)
Display
Notes
Press Enter to begin setup of the Realtime Clock.
SETUP REALTIME CLOCK
ENTER
Select Time to set the time.
SETUP REALTIME CLOCK
Time
Date
ENTER
CLOCK TYPE
24HR
Select 24Hr or 12Hr clock
12HR
ENTER
If 12Hr Clock,
Enter AM or PM
SELECT CLOCK AM/PM
AM
PM
ENTER
Enter time of day.
TIME OF DAY HH:MM:SS
##:##:##
ENTER
Advance To
SETUP REALTIME CLOCK
(Date)
6.4.13
SETUP REALTIME
CLOCK
(Date)
Select Date to enter the date.
SETUP REALTIME CLOCK
Time
Date
ENTER
Enter the date. (Month, Day, Last two digits of Year, first
two digits of year will adjust accordingly)
DATE: MONTH,DAY,YEAR
##/##/####
ENTER
Advance To
SERIAL USAGE
28
Sub-menus
6.4.14
SERIAL USAGE
Display
Notes
Press Enter to begin setup of the Serial Port.
SERIAL USAGE
ENTER
Select Serial Hardware type for standard port. RS-232 is
standard. (See SETUP NETWORK CARD for RS485
Modbus option)
SERIAL HARDWARE
RS232
RS485
ENTER
Select the Device ID (0-99).
DEVICE ID
##
ENTER
BAUD RATE
300 600 1200 <more>
Select the desired Baud Rate.
BAUD RATE
2400 4800 9600 19200
(If <more> selected, additional baud rates are offered.
9600 is standard)
ENTER
PARITY
None
Select the desired Parity. (NONE is standard)
Odd
Even
ENTER
Set the Handshake. (NONE is standard)
HANDSHAKING
None Softwre Hardwre
ENTER
Choose end of line termination. Only choose <CR> if
your external device automatically assigns a line feed for
every <CR> carriage return.
DEVICE LINE FEED
<CR>
<CR+LF>
ENTER
MODEM CONTROL
No
Select "Yes" if the serial port will be used to control a
Hayes compatible modem.
Yes
ENTER
Select the desired Modem Auto Answer mode. Select
YES to setup modem to answer incoming calls.
MODEM AUTO ANSWER
No
Yes
ENTER
Enter the Call Out Phone Number to be dialed at "Call
Out Time" or upon "Call On Error/Alarm".
CALL OUT PHONE #
0
ENTER
Enter the time of day to perform Call Out transmission.
CALL OUT TIME
##:##:##
ENTER
Select "Yes" to have the unit perform a Call Out
transmission upon error/alarm condition.
CALL ON ERROR/ALARM
No
Yes
ENTER
Enter the number of redials to be performed on call out
time if busy or no answer. (error/alarm tries until
connected)
NUMBER OF REDIALS
0
ENTER
Select "Yes" to perform hang-up if there is inactivity for
more than 2 minutes for calls initiated by the SUPERtrol-I
LE
HANGUP IF 2MIN INACT
No
Yes
ENTER
Advance To
SETUP DATALOG/PRINT
29
Sub-menus
6.4.15
SETUP
DATALOG/PRINT
(Configure)
Display
Notes
Press Enter to setup the Datalog/Print information.
SETUP DATALOG/PRINT
ENTER
Select Config to configure the Datalog/Print information.
SETUP DATALOG/PRINT
Config
Select_list
ENTER
Select the type of Output Format.
OUTPUT FORMAT
Printer Term Dbase
ENTER
Enter the desired Page Length.
If Printer selected above.
PAGE LENGTH [99 max]
99
ENTER
TOP MARGIN
Enter the desired Top Margin.
If Printer selected above.
[99 max]
3
ENTER
DATALOG ONLY
No
Select Yes to record events to the datalogger only.
Events will not be sent to the serial port. Select NO to
output immediately and also log data.
Yes
ENTER
PRINT TIME
Enter Print Time, printer will print at this time every day.
Enter 00:00:00 to inhibit print time.
HH:MM:SS
00:00:00
ENTER
Enter Print Interval, (HH:MM:SS)
Enter 00:00:00 to inhibit print interval.
PRINT INTERVAL
00:00:00
ENTER
Select YES to enable Print Key.
Select NO to disable Print Key
ENABLE PRINT KEY
NO
YES
ENTER
Batch mode only.
Select Yes to print at end of batch.
PRINT END OF BATCH
NO
YES
ENTER
Advance To
SETUP DATALOG/PRINT
(Select_list)
30
Sub-menus
Display
6.4.16
SETUP
DATALOG/PRINT
(Select_list)
SET DATALOG/PRINT
Notes
Press enter to begin Setup Datalog/Print routine.
ENTER
SET DATALOG/PRINT
Config
Select_list
Press enter when Select_list is selected to setup print list.
PRINT LIST ITEMS
TOTAL
YES
STOP
START
PRINT LIST ITEMS
RATE
YES
List Items:
TOTAL
RATE
PRE1
PRE3
GRAND
PRE2
PRE4
TIME
PRINT LIST ITEMS
PRE 1
YES
6.4.17
ADMINISTRATIVE
SETUP
ADMINISTRATIVE SETUP
NOTE: Accessed
only with supervisor
password.
Use Up and Down arrow keys to view list status.
Press the PRINT key to add or remove items from the
list. Items marked with Yes will be added to the list,
items marked with No will be removed from the list. Press
ENTER to accept list when ready
ENTER
PRINT LIST ITEMS
DataLog size =001489
ENTER
The Select Print List Information display shows the
current possible Datalog size after your list has been
entered.
Advance To
ADMINISTRATIVE SETUP
Press Enter to begin Administrative Setup.
ENTER
Enter Operator Password. (Factory Set to 0) Define a
nonzero value for each unit to lock unit and prevent
accidental menu changes.
OPERATOR PASSWORD
****
ENTER
Enter Supervisor Password.
(Factory Set to 2000)
SUPERVISOR PASSWORD
****
ENTER
This display is used to show the software version of the
installed software.
SOFTWARE VERSION
vxx.xx
ENTER
This display is used to show the product order code
(model number). Factory set.
PRODUCT ORDER CODE
SL90xxxxxxx
ENTER
This display is used to show the unit's serial number.
Factory set.
UNIT SERIAL NUMBER
00000
ENTER
This display is used to edit and show the sensor's serial
number.
SENSOR SERIAL NUMBER
00000
ENTER
Advance To
SETUP NETWORK CARD
31
Sub-menus
6.4.18
SETUP
NETWORK CARD
(optional)
Display
Notes
Press Enter to setup Network Card
SETUP NETWORK CARD
ENTER
Select desired Network Protocol. (only Modbus RTU is
supported)
SELECT NETW PROTOCOL
Mod
ENTER
NETWORK DEVICE ID
Enter the device address on network (00-247).
1
ENTER
Select the desired Baud Rate.
BAUD RATE
2400 4800 9600 19200
ENTER
PARITY
None
Select the desired Parity.
Odd
Even
ENTER
Advance To
DO EZ SETUP?
32
7. Principals Of Operation
7.1 General:
The FTT Flow Computer uses several internal calculations to compute the input frequency based
on specific data input. Several computations are performed to yield flow or linearized flow.
7.2 Flow Equations:
Uncompensated Flow Computation:
Pulse Input; Average K-Factor
input frequency • time scale factor
Volume Flow =
K-Factor
Pulse Input; Linear Table
input frequency • time scale factor
Volume Flow =
K-Factor (Hz)
Where K-Factor (Hz) is the K-Factor returned at frequency (Hz) from interpolation of the 16 point table.
33
7.3 Linearization Table
7.3.1 Linearization Table General Information
The Linearization Table is used when the flow input device gives a nonlinear input signal. The
unit uses up to 16 different points, as entered by the operator, to form a curve for linearizing the
input signal.
Notes:
1) A minimum of three points must be set up.
2) If "0" is entered for the frequency of any point other than point 1, the Flow Computer assumes
there are no more points above the points that preceded them. The display will advance to the
next setup prompt.
3) If the input frequency is above the highest or below the lowest frequency programmed, the unit
will use the last known point for the K factor in computing the resulting actual flow.
4) Frequency- Point pairs should be entered in ascending order of frequency.
7.3.2 Linearization Table for Pulse Inputs
The linearization table for pulse inputs programming is quite simple when values of frequency and
K-Factors are known. The Flow Computer asks for 16 different frequencies (Freq) and 16
corresponding K factors (K). It then uses this data to determine what the actual flow is for any
given input frequency. Usually the necessary data is provided with the flowmeter.
7.3.3 Linearization Table Interpolation
The Linearization Table routine uses the entered data to determine the K factor for any given input
frequency signal. This is done by taking the closest data points above and below the input signal,
then using those points to interpolate the K factor (correction factor), then calculating the flow
from the data. Below are the formulas.
K factor
Parameters:
Determine closest point above input signal
signal = X,
K factor (correction factor) = KA
Determine closest point below input signal
signal = Y,
K factor (correction factor) = KB
Let input signal = H,
unknown K factor (correction factor) = KN
KA
KN
KB
Y H X
Input
To find KN use this formula:
H-Y
X - Y x (KA - KB) + KB = KN
34
8. Test, Service and Maintenance
8.1 Test Menus
Notes
Display
Sub-menus
8.1.1
TOP LEVEL
TEST MENUS
Select Test to enter the instrument test & calibration
routine.
NOTE: Supervisor (Service) password required to gain
access to this mode.
SELECT OPERATE STATE
Run
Setup
Test
MENU
ENTER
Refer to Page 36 for Details.
Audit Trail
START
STOP
START
Refer to Page 36 for Details.
Error history
STOP
START
Refer to Page 36 for Details.
Print System Setup
STOP
START
Refer to Page 37 Details.
Keypad Test
STOP
START
Refer to Page 37 for Details.
Display test
STOP
START
Refer to Page 37 Details.
Calibrate
STOP
START
Refer to Page 38 Details.
Pulse input test
STOP
START
Refer to Page 38 for Details.
Analog out test
STOP
START
Refer to Page 38 for Details.
Excitation out test
STOP
START
Refer to Page 39 for Details.
Pulse out test
STOP
START
Refer to Page 39 for Details.
Relay Test
STOP
START
Refer to Page 39 for Details.
Control inputs test
STOP
START
STOP
Refer to Page 39 for Details.
Data logger utility
35
8.2 Test Sub-Menus
Sub-menus
8.2.1
Audit Trail
Sub-menu Group
Display
Notes
Press Enter to view the audit trail information.
Audit Trail
ENTER
The configuration audit trail format:
nnnnn= number of critical menu changes,
hh:mm:ss; mm/dd/yy = time and date of last change.
Config_Audit
nnnnn
hh:mm:ss
mm/dd/yy
ENTER
Cal_Audit
hh:mm:ss
The calibration audit trail format:
nnnnn= number of calibration changes,
hh:mm:ss; mm/dd/yy = time and date of last change.
nnnnn
mm/dd/yy
ENTER
8.2.2
Error History
Sub-menu Group
Audit Trail
Press Menu to get back to audit trail top-level menu.
Error history
Press Enter to view error history.
NOTE: Press Print Key to print Error History. Printout will
include time/date of each errors first occurrence.
ENTER
Press Up/Down arrow keys to scroll through error
message history. Press CLEAR to clear entire error log.
Error history
Flow rate alarm low
ENTER
8.2.3
Print System Setup
Sub-menu Group
Error history
Press Menu to get back to error history top-level menu.
Print System Setup
Press enter key to enter print system setup Sub-menu
ENTER
Press enter to begin printing the system setup.
Print System Setup
Press ENTER to print
ENTER
This message will display as the data transmission takes
place.
Print System Setup
—— Printing ——ENTER
Press Menu to get back to print system setup top-level
menu.
Print System Setup
36
Sub-menus
8.2.4
Keypad test
Sub-menu Group
Display
Notes
Press Enter to enter keypad test
Keypad test
ENTER
Press the various keys and the display will show the key
that was pressed. Press Menu to exit the test
Keypad test
Key pressed—> ENTER
ENTER
8.2.5
Display test
Sub-menu Group
Keypad test
Press Menu to get back to Keypad test top-level menu.
Display test
Press Enter to enter display test.
ENTER
Upon pressing enter the each digit on the display will
scroll 0-9 then A-Z. Press menu to exit the test.
00000000000000000000
00000000000000000000
ENTER
Press Menu to get back to Display test top-level menu.
Display test
Calibrate Sub-menu group
Calibrate
ENTER
8.2.6
Calibrate 0 mA Out
Sub-menu Group
Calibrate
+ TB1-15
Connect ammeter to (+) TB1-15, (-) TB1-16. Press enter.
0mA out
- TB1-16
ENTER
To trim 0mA output: Press CLEAR to enable editing and
enter a small negative number (i.e. -0.100) to force a
display reading, then clear and enter small quantity
measured on your meter.
Calibrate 0mA out
Enter mA: 0.00000
ENTER
Calibrate
+ TB1-15
The display will return to Calibrate 0mA out. Press the
down arrow key to advance to Cal. 20mA out or repeat
above if necessary.
0mA out
- TB1-16
ENTER
8.2.7
Calibrate 20mA Out
Sub-menu Group
Connect ammeter to (+) TB1-15, (-) TB1-16. Press enter.
Calibrate 20mA out
+ TB1-15
- TB1-16
ENTER
To trim 20mA output: Press CLEAR to enable editing and
enter the current reading that is on the ammeter display.
Press enter.
Calibrate 20mA out
Enter mA: 20.00000
ENTER
The display will automatically return to the Calibrate
20mA out Sub-menu. Calibration is complete.
Calibrate 20mA out
+ TB1-15
- TB1-16
ENTER
Press the Menu key to go back to Calibrate top-level
menu.
Calibrate
37
Sub-menus
8.2.8
Pulse input test
Sub-menu Group
2.5V
10mV
100mV
Display
Notes
Press Enter key to test the pulse input.
Pulse input test
ENTER
START
STOP
Use the Up/Down arrow keys to select the appropriate
trigger level.
Pulse input test
Trigger level 2.5V
ENTER
40Hz
3KHz
20kHz
START
STOP
Use the Up/Down arrow keys to select the appropriate
frequency range.
Pulse input test
count speed
3kHz
ENTER
Pulse input test
F1:
0 F2:
To check Pulse input accuracy: Use TB1-4 as reference
ground, input a frequency F1 on TB1-2, frequency F2 on
TB1-3. The display should show frequency being input.
Use a frequency counter to verify input.
0
ENTER
8.2.9
Analog out test
Sub-menu Group
Pulse input test
Press Menu key to return to Pulse input test top-level
menu.
Analog out test
Press Enter to test the analog output.
ENTER
To simulate analog output: Connect an ammeter to (+)
TB1-15, (-) TB1-16. Press the key under the desired
current setting to move the asterisk (*). The unit should
output the selected current.
Analog out test
*0 4 10 15 20 mA
ENTER
8.2.10
Excitation out test
Sub-menu Group
Analog out test
Press Menu key to return to Analog out test top-level
menu.
Excitation out test
Press Enter to test the excitation output.
ENTER
To test the excitation output: Connect a voltmeter to (+)
TB1-1, (-) TB1-4. Press the key under the desired
voltage setting to move the asterisk (*). The unit should
output the selected voltage.
Excitation out test
*5v
12v
24v
ENTER
Press Menu key to return to Excitation out test top-level
menu.
Excitation out test
38
8.2.11
Pulse out test
Sub-menu Group
Press Enter key to test the pulse output.
Pulse out test
To simulate a frequency on the pulse output: Connect a
frequency counter to (+)TB1-13,
(-)TB1-14. Press the key under the desired frequency
setting to move the asterisk (*). The unit should output
the selected frequency.
ENTER
Pulse out test
*0Hz 1Hz 10Hz
20Hz
ENTER
8.2.12
Relay test
Sub-menu Group
Pulse out test
Press Menu key to return to Pulse out test top-level
menu.
Relay Test
Press Enter to test the relays.
ENTER
To manually control the relay outputs: Press the key
under the desired relay to toggle the relays On/Off. Use
an ohmmeter to check the relay contacts.
Rly1 Rly2 Rly3 Rly4
Off Off Off Off
ENTER
Press Menu key to return to Relay Test top-level menu.
Relay Test
8.2.13
Control inputs test
Sub-menu Group
Press Enter to test the control inputs.
Control inputs test
ENTER
TB1-9
Off
To check the control inputs: Use TB1-12 as reference,
input a DC voltage (4-24VDC) signal to TB1-9, TB1-10
and/or TB1-11, The Display will show ON when input is
active, OFF when inactive.
TB1-10 TB1-11
Off
Off
ENTER
8.2.14
Data logger utility
Sub-menu Group
Control inputs test
Press Menu key to return to control input test top-level
menu.
Data logger utility
Press Enter to access data logger utility.
ENTER
The displays shows the number of Data Logs.
Press the Down arrow key to advance to PRT (print) or
CLR (clear) to clear datalog contents.
Data logger utility
Log 10
958 Max
ENTER
Press PRINT key to output data logger logs to printer,
Press CLEAR key to clear the data logger contents.
Data logger utility
Log 00001
PRT CLR
ENTER
Press Menu key to return to Data logger utility top-level
menu.
Data logger utility
39
8.3 Internal Fuse Replacement
Instructions:
1. Make sure you follow proper E.S.D. Precautions. All persons performing this
replacement must follow proper grounding procedures.
2. Turn the power to the unit off.
3. Disconnect the two piece connector rear terminal block, leaving all connections in place.
4. Remove the unit from the panel.
5. Remove the four machine screws (see fig. 1) which hold the two sections of the case
together.
6. The rear section of the case should detach from the rest of the case. With the rear
section of the case removed the fuse will be exposed (located near the rear terminal,
AC connection).
7. Locate the Fuse F1 (see fig. 2) and unplug the fuse from its socket.
8. Insert the new fuse into the socket. Insure that the pins are fully inserted and straight.
9. Reassemble the case and install the four machine screws which join the two sections of
the case.
10. Reinstall the unit into the panel.
11. Reconnect the rear terminal block.
12. Turn the unit back on.
Fuse Specifications:
110 VAC Power:
160mA/250V, TD FUS-BC-T5-R160(Wickman 19372-030-k) or equivalent
fig. 1
fig. 2
Screws
(4 places)
fuse
FUSE
40
9. Glossary Of Terms
Acknowledge & Clear Alarms
Acknowledge is used to clear alarm relays and remove any visual alarm messages from the display. In the run
mode, press the ENTER key or activate CONTROL INPUT 3 (if set for ACK) to momentarily clear alarms and
alarm messages. Alarms will reassert themselves if alarm conditions are still present.
Analog Output
The analog signal (4-20mA) that is generated by the FTT. It can correspond to the Rate or Total.
This output is used primarily for transmission of process information to remote systems.
Audit Trail
The audit trail is used to track the number of changes made to the units setup program and calibration.
Auto Batch Restart
The Auto Batch Restart function allows the user to set an amount of time to automatically restart a batch after the
completion of a batch. This time can be set from 1 to 99 seconds.
Batch Count Mode
Batch Count Mode specifies the user preference for count direction. The "Up" selection begins with a value of
"0" and counts up until the batch size is reached. The "Down" selection begins with a value equal to the desired
batch size and counts down to "0".
Batch Overrun
The FTT offers a batch overrun compensation routine. If batch overrun occurs due to slow valve
response time, the unit will compensate for the overrun amount on the next batch. This feature can be disabled if
desired.
NOTE: A nonzero MAX DRAIN TIME value is also required.
Batcher
An instrument which controls the dispensing of desired batch amounts. Liquid batching systems are usually
comprised of a batch controller (batcher), flowmeter and control valve. The batcher opens and closes the valve
through the use of relays and measures the amounts of liquid being dispensed via the flowmeter.
Baud Rate
The speed of serial communication transmissions, expressed in bits per second.
Custody Transfer
Weights and Measure metering codes often specify several requirements for instruments and mechanisms to
prevent and track changes in the setup of an instrument which may be used in the commercial sale of goods. The
FTT tracks changes via the Audit Trail.
Data Logger
The capturing of information for later use and the mechanism for specifying the conditions where a capture
should be made.
DC Output / Excitation Voltage
An on-board DC power supply used to power peripheral sensors. The FTT offers excitation voltages
of 5VDC, 12VDC or 24VDC when powered by AC voltage.
Default Value
The value to be used by the instrument if a sensor failure or out of range signal is detected.
EZ Setup
A utility that provides for rapid configuration of an instrument. The FTT EZ Setup provides the
following:
1) Prompts the user for only critical information.
2) Automatically sets specifications to common uses.
After following the EZ Setup procedure, the unit will be operational to perform the basic measurement. The setup
can be further customized using the setup menus.
41
Flow Alarm
A visual indication that the volumetric flowrate is above or below the flow alarm setpoint specified by the user.
Flow Signal Timeout
The Flow Signal Timeout allows the user to enter a timeout of 0 to 99 seconds. If a batch is “Filling” and zero flow
persists for more than the user entered time then the batch will be aborted. This prevents over flows due to faulty
flow sensors and/or wiring.
Flow Equation
A flow control expression or algorithm describing a mathematical equation to be solved by a flow computer in the
desired application.
Follow Alarm
Alarm relays which are non latching and whose output state is based solely on the comparison of the current
process value, the alarm setpoint (trip point) and hysteresis.
Function Key
A key on a push-button panel or keyboard (whose function is described by the key label) used to perform an
instrument function or special routine.
Handshake
A means of controlling the information flow between two pieces of equipment to prevent the sending device from
transmitting information at a rate faster than what can be accepted by the receiver.
Hysteresis
The relay hysteresis is a "dead band" setting which allows the relay to remain energized for a given amount below
the setpoint. This is used to prevent relay chatter when the process value is near the setpoint value.
Example: If the Preset is set at 100, and the hysteresis is set at 10, the relay will energize when the rate, temp or
dens. reaches 100, the relay will remain energized until the reading falls below 90.
Input Termination
Input signal lines on digital inputs often require pullup or pulldown resistor configurations to operate properly
with different sensor configurations. The FTT contains such resistors and may be enabled via the
setup menu.
Inhibit Totalizer
"Inhibit Total" is a Control Input 1 setting that is used to stop the totalization. If enabled, a voltage level on control
input 1 will inhibit the total as long as the voltage is present. This feature is useful during meter proving and in
applications that provide a sensor to signal the flow computer when liquid is present.
K-Factor
A scaling factor derived from the pulses produced by a flowmeter output, expressed in pulses per unit (i.e. pulses/
gallon)
LCD
Abbreviation for: Liquid Crystal Display
Limit Setpoint
An alarm trip point setting which specifies the value or magnitude of a process parameter necessary to activate an
alarm indicator or control relay.
Linear Flowmeter
A flow measurement device whose output is proportional to flow.
Linearization
The mathematical correction of a nonlinear device. The FTT uses a linearization Table which is made
up of input frequency and K-Factor values and makes interpolations of the table to arrive at a "linearized"
measurement.
42
LinTbl
Abbreviation for Linearization Table.
Low Flow Cutoff
A value set at which any flow measurements read below this value will be ignored.
Low Pass Filter
A low pass filter passes low input frequencies while blocking high frequencies. In the FTT, this is the
maximum input count speed to be encountered in an application. It is expressed in counts per second (Hz).
Maximum Batch Preset
The Maximum Batch Preset allows the user to program the Maximum Batch value allowed to be entered by the
operator. If an operator should try to program a batch higher then this value, the unit will not allow the value to be
entered and will prompt the user with an error message saying that the Maximum Batch Preset has been exceeded.
Maximum Drain Time
The unit declares that a batch is “done” when the flow rate equals “0”. A flow rate may be present long after the
Preset Relay de-energizes due to slow reacting valves or leaky valves. The Maximum Drain Time allows the user to
enter an amount of time (0 to 99 seconds) to wait before declaring “Batch Done”. After the Preset Batch quantity is
reached, the unit will declare “Batch Done” when the flow rate is “0” or the Maximum Drain Time has expired.
The batch data will then be available for printing and datalogging.
NOTE: A nonzero MAX DRAIN TIME value must be entered when using batch overrun compensation.
Max Window
The max. window time sets the maximum sample time (1 to 99 sec) for the ratemeter.
Operator Code
An operator password code which authorizes changes to the setup of the instrument but blocks access to the
Service/Calibration/Test mode. The operator code also blocks the clearing of the Grand Total.
Parity
A method for detecting errors in transmissions of serial communications data.
Preset
A set point used to trigger the relay outputs of the FTT.
Print Interval
The print interval allows the FTT to transmit information to the serial port at selectable time intervals.
Process Parameters
Any sensor information which has been scaled to engineering units including Flow, Temperature and Density.
Pulldown (Input Termination)
The termination of an input at which the input is pulled down to ground through a resistor. Inputs that are
terminated by this method need to be driven high with a positive voltage pulse.
Pullup (Input Termination)
The termination of an input at which the input is pulled up to a positive voltage through a resistor. Inputs that are
terminated by this method need to be pulled low with a sinking current or contact to ground .
Pulse Output
The pulse output of the FTT is available for remote accumulation of the total or sent to peripheral
devices, such as a PLC. The output can be scaled using the Pulse Output Scaling Constant.
Quad
Abbreviation for Quadrature. Quadrature signals are used for direction control. Two flowmeter signals are output
with a 90° phase shift. The counter counts UP when channel A precedes channel B, and counts DOWN when
Channel A lags Channel B.
43
Quick Update %
This feature is used to disable the rate averaging filter when a significant change in the flow rate occurs. The
user can enter the percent of change needed to be detected to disable the averaging feature. This is especially
useful during start-up and shutdown of flow.
Rate Averaging Filter
The rate averaging filter is used to stabilize fluctuating rate displays. Higher settings provide more averaging for
a more stable display. Derived from the equation:
((OLD DATA x "Avg. Filter") + NEW DATA)
("Avg. Filter" + 1)
Ratemeter
Any device used to display the speed of a process. The ratemeter in the FTT displays flow rate.
Reset/Start Control Input
In a batching system, a single operator activation of the START key or Control Input 1 will reset the total then
start the batch process.
Select Preset Type
This menu selection allows the user to choose between Standard Preset or EZ Preset. Select Standard for standard
preset operation. Select EZ-Preset for quick preset editing mode. (see section 5.4.1 Batcher Configuration.)
Single_Pulse
The Single_Pulse setting is used for flowmeters with single pulse outputs.
Slow Start Quantity
The Slow Start Quantity is a function that allows an amount to be entered for a Slow Start up. This function requires
two stage valve control. RLY 1 (slow flow) will energize for Slow Start and RLY 2 (fast flow) will energize after
the Slow Start Quantity has been delivered. This helps reduce turbulence when filling an empty container.
Stop/Reset Control Input
In a batching system, a single operator activation of the STOP key or Control Input 2 will stop the batch process
then reset the total.
Totalizer
Any device which accumulates and displays a total count.
Volume Flow
The measurement of volumetric flow.
44
10. Diagnosis and Troubleshooting
10.1 Response of FTT on Error or Alarm:
Error and warning indications which occur during operation are indicated
in the RUN mode alternately with the measured values. The FTT
Flow Computer has three types of error:
TYPE OF ERROR
DESCRIPTION
Sensor/Process Alarms
Errors detected due to sensor
failure or process alarm
conditions
Self Test Errors
Errors detected during self test.
System Alarms
Errors detected due to system
failure
Some alarms are self clearing. Other alarms require the user to
acknowledge and clear the alarm. Press the ENTER button to
acknowledged and clear alarms. Alarms may reassert themselves if
the alarm condition is still present.
NOTE: A historical error alarm log is available in the "Test Mode".
The following descriptions suggest possible causes and corrective
actions for each alarm message.
45
10.2 Diagnosis Flow Chart and Troubleshooting
All instruments undergo various stages of quality control during production. The last of these stages is a complete calibration carried out
on state-of-the-art calibration rigs.
A summary of possible causes is given below to help you identify
faults.
Is there an input power
supply voltage across
Terminals 23 and 24?
No
Yes
Is the Display Backlight
Visible?
Check the connections
according to the circuit
diagrams.
Check junction box fuses.
No
Check/Replace internal
fuse. If fuse is OK,
Factory Service Required.
Yes
Are the Display
Characters Visible?
No
Yes
Is there a black bar
across the display?
The display may not be
visible with ambient
temperatures below -10 °C
Allow the instrument to
warm up.
Contact factory if
necessary
Yes
Check line voltage.
If voltage is OK,
Factory Service Required.
Yes
Check line voltage.
If voltage is OK,
Factory Service Required.
No
Does the display
alternate between blank
and sign on message?
No
Does the display show
an error message?
Yes
No
No system or process
errors present.
46
Contact Technical Service
at 800-833-0081
10.3 Error & Warning Messages:
10.3.1
Sensor/Process Alarms
Error/Warning Message
Cause
Remedy
TOTALIZER ROLLOVER
Displayed when totalizer rolls
over
Acknowledge
Rollover,
Remedy not required
RATE OVERFLOW ERROR
Pulse counter overflowed. The
totalizer may have lost counts.
• Report error to factory
• Check application
conditions
• Check wiring
PULSE OUT OVERFLOW
Calculated pulse frequency
too large:
• Pulse width setting too long
• Larger pulse scaler needed
• Adjust pulse value
• Adjust pulse width
• Check process
conditions
FLOW RATE ALARM LOW
FLOW RATE ALARM HIGH
Limit value exceeded.
• Check application if
necessary
• Check limit value
• Adjust the limit value if
required
BATCH OVERRUN ALARM
Batch size exceeded by more
than set limit.
• Check valves in
system for proper
operation and/or leaks
• Check limit value
• Adjust the limit value if
required
MODEM NOT PRESENT
The setup expects modem
usage and a modem is not
responding.
• Check setup for proper
baud rate, parity, etc.
• Check modem
connection and cycle
power FTT
• Replace modem
10.3.2
Self Test Alarms
• Report error to factory
SOFTWARE ERROR RESET
Software error
EXTENDED PFI LOCKUP
Unit was operated with an input • Check data in unit.
Totalizer may have
power level lower than safe
inaccuracies
operating range for an extended
• Investigate brownout
period of time.
cause.
Error/Warning Message
Cause
Remedy
BATTERY LOW WARNING
Battery voltage too low
• Replace Battery
• Consult Factory for
service information
TIME CLOCK ERROR
The correct time/date is no
longer shown
• Re-enter time and
date.
• If error occurs again
contact factory
CAL CHECKSUM ERROR
Calibration constants have
been corrupted
• Report error to factory
SETUP CHECKSUM ERROR
The units setup has been
corrupted
• Report error to factory
47
48
SETUP NETWORK CARD
ADMINISTRATIVE SETUP
SETUP
DATALOG/PRINT
SERIAL USAGE
SETUP REAL TIME CLOCK
SETUP CONTROL INPUTS
SETUP RELAYS
SETUP ANALOG OUTPUT
RELAY USAGE
RELAY
DELAY
ANALOG OUTPUT ANALOG OUT LOW
RANGE
SCALE
RELAY
DURATION
ANALOG OUT
FULL SCALE
LOW PASS
FILTER
PULSE TRIGGER
TYPE
PULSE VALUE
TOTAL DECIMAL
PLACES
MAX. BATCH
PRESET
VOLUME UNITS
BATCH COUNT
MODE
SELECT
NETWORK
PROTOCOL
OPERATOR
PASSWORD
NETWORK
DEVICE ID
SUPERVISOR
PASSWORD
OUTPUT FORMAT
DEVICE ID
SERIAL
HARDWARE
SETUP
DATALOG/PRINT
CLOCK TYPE
SETUP REAL
TIME CLOCK
BAUD RATE
SOFTWARE
VERSION
PAGE LENGTH
BAUD RATE
SELECT CLOCK
AM/PM
PARITY
PRODUCT ORDER
CODE
TOP MARGIN
PARITY
TIME OF DAY
SETUP
CONTROL INPUTS CONTROL INPUT 1 CONTROL INPUT 2 CONTROL INPUT 3
USAGE
USAGE
USAGE
1, 2, 3
SETUP
RELAYS
1, 2, 3, 4
ANALOG OUPUT
USAGE
PULSE WIDTH
PULSE INPUT
TYPE
EXCITATION
VOLTAGE
SETUP FLOW INPUT
PULSE OUPUT
USAGE
TOTAL
DESCRIPTOR
SETUP
INDICATORS
SETUP INDICATORS
SETUP PULSE OUTPUT
SELECT PRESET
TYPE
INSTRUMENT
TYPE
INSTRUMENT
TYPE
SELECT
EZ SETUP
START HERE
UNIT
SERIAL
NUMBER
DATALOG
ONLY
HANDSHAKE
ENTER DATE
RELAY MODE
ANALOG OUT
DAMPING
INPUT
TERMINATION
RATE TIME BASE
BATCH OVERRUN
COMP.
RELAY
HYSTERESIS
K-FACTOR TYPE
RATE DECIMAL
PLACES
TIME DELAY
SENSOR SERIAL
NUMBER
PRINT TIME
PRINT INTERVAL
DEVICE LINE FEED MODEM CONTROL
RELAY SETPOINT
MAX WINDOW
RATE
DESCRIPTOR
AUTO BATCH
RESTART
SETUP MENUS
ENABLE PRINT
KEY
MODEM AUTO
ANSWER
AVERAGE
KA-FACTOR
RATE
AVERAGE FILTER
FLOW SIGNAL
TIMEOUT
CHANGE TABLE
A
SLOW START
QUANTITY
CHANGE TABLE
B
LOW FLOW
RATE ALARM
HIGH FLOW
RATE ALARM
PRINT END OF
BATCH
CALL OUT NO
CLEAR TOTAL IF
PRINT
CALL OUT TIME
SELECT PRINT
LIST ITEMS
CALL ON
ERROR/ALARM
NUMBER OF
REDIALS
HANG-UP IF
2MIN. INACTIVE
These functions will only appear with appropriate settings in other functions.
AVERAGE
KB-FACTOR
QUICK
UPDATE %
MAX. DRAIN TIME
Appendix A - Setup Menus
FTT-710 REINITIALIZE SEQUENCE
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Remove power from the FTT-710 controller.
Press and hold the START and MENU keys while applying power.
Release keys when display indicated “FLOW COMPUTER INITIALIZING UNIT”.
Press the MENU key.
Display indicates “ENTER PASSWORD”.
Enter the 2000 and press the ENTER key.
Display indicates “SELECT OPERATE STATE”.
Select “TEST” by pressing the 5 key then ENTER.
Display indicates “AUDIT TRAIL”.
Press the STOP key and “ERROR HISTORY” is displayed.
Press the ENTER key.
Indicated errors can be cleared by pressing the CLEAR key.
Press the MENU key until the display indicates “SELECT OPTERATE STATE”.
Select “SETUP” by pressing the 3 key then ENTER. (see factory configuration table)
49
FTT-710 FACTORY PARAMETER SEQUENCE
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
Press MENU key
Enter password 0000 select the ENTER key.
Display indicates OK PASSWORD VALID.
At “SELECT OPERATE STATE” Press 3, select the ENTER key. (See manual page 18)
Display indicates SELECT EZ SETUP
Use STOP key to arrow down to SET UP INDICATORS, select the ENTER key.
Display indicates SETUP INDICATORS with TOTAL flashing, select the ENTER key
Display indicates TOTAL DESCRIPTOR with TOTAL on the screen, Select the ENTER
key.
Display indicates TOTAL VOLUME UNITS with gal on the screen.
Change gal to lbs by pressing CLEAR then START key to arrow up to desired letter then
select the ENTER key.
Display indicates TOT DEC PLACES (0-3) with 0 highlighted select the ENTER key.
Display indicates SETUP INDICATORS with RATE flashing, select the ENTER key.
RATE TIME BASE is displayed, select MIN by pressing “3”, select the ENTER key.
RATE DESCRIPTOR is displayed with RATE highlighted, select the enter key.
RATE DEC PLACES (0-4) is displayed with 3 highlighted, press CLEAR, select 1 then
select the ENTER key.
RATE AVG FILTER is displayed, 0 is selected, select the ENTER key.
QUICK UPDATE % is displayed, 1 is selected, select the ENTER key.
Display indicates SETUP FLOW INPUT select the ENTER key.
EXCITATION VOLTAGE is displayed, select 12V select the ENTER key.
PULSE INPUT TYPE is displayed, select chA, select the ENTER key.
PULSE TRIGGER LEVEL is displayed, select 2.5V select the ENTER key.
LOW PASS FILTER is displayed, select 20KHz, select the ENTER key.
INPUT TERMINATION is displayed, with Pulldown highlighted , select the ENTER key.
MAX WINDOW (1.99) is displayed, 1 sec is selected, select the ENTER key.
K_FACTOR TYPE is displayed, select Avg, select the ENTER key
AVERAGE KA-FACTOR is displayed, press CLEAR. •Enter 11.6279 then select the
ENTER key.
Select the ENTER key 2 times.
Display indicates SETUP PULSE OUTPUT, select the ENTER key.
PULSE OUTPUT USAGE is displayed, select Volume by pressing #5, select the ENTER
key.
PULSE WIDTH is displayed, select 100 mS by pressing #5, select the ENTER key.
PULSE VALUE is displayed, press CLEAR.
Enter 110 then select the ENTER key.
Display indicates SETUP ANALOG OUTPUT, press the STOP (DOWN ARROW) key
three times.
SETUP REALTIME CLOCK is displayed, select the ENTER key.
SETUP REALTIME CLOCK is displayed, select Time, select the ENTER key.
CLOCK TYPE is displayed, select 24HR, select the ENTER key.
TIME OF DAY is displayed, use arrow keys to change flashing digit, once the selected
digit is correct, select the ENTER key, to get to the next digit until (CORRECT TIME OF
DAY ) is displayed, select the ENTER key.
SETUP REALTIME CLOCK is displayed, select Date, select the ENTER key.
Enter the date using XX,XX,XX (MONTH, DAY, LAST TWO DIGITS OF THE YEAR)
format, select the ENTER key.
SERIAL USAGE is displayed, select the ENTER key.
SERIAL HARDWARE is displayed, select RS232, select the ENTER key.
DEVICE ID is displayed, select 1,select the ENTER key.
BAUD RATE is displayed, select 9600 which is not displayed yet so, select the ENTER
key.
BAUD RATE is displayed, select 9600, select the ENTER key.
50
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
PARITY is displayed, select NONE, select the ENTER key.
HANDSHAKING is displayed, select NONE, select the ENTER key.
DEVICE LINE FEED is displayed, select (CR + LF), select the ENTER key.
MODEM CONTROL is displayed, select NO, select the ENTER key.
SETUP DATALOG/PRINT is displayed, select the ENTER key.
SETUP DATALOG/PRINT is displayed, select Config, select the ENTER key.
OUTPUT FORMAT is displayed, select Printer, select the ENTER key.
PAGE LENGTH (99 max) is displayed, enter 0, select the ENTER key.
TOP MARGIN (99 max) is displayed, select 3, select the ENTER key.
DATALOG ONLY is displayed, select No, select the ENTER key.
PRINT TIME is displayed, select the ENTER key with 00:00:00 displayed.
PRINT INTERVAL is displayed, select the ENTER key with 00:00:00 displayed.
ENABLE PRINT KEY is displayed, select YES, select the ENTER key.
CLEAR TOTAL IF PRINT is displayed, select NO, select the ENTER key.
SETUP DATALOG/PRINT is displayed, select Select_list, select the ENTER key. Use the
UP (START) and DOWN (STOP) arrow keys to view list status. Press the print key (F3)
to add or remove from the list. Items marked with YES will be added to the list, items
marked with NO will be removed from the list. Select TOTAL, TIME, and GRAND to be
printed on the ticket. Remove PRE1, PRE2, PRE3, PRE4 and RATE from the list of
printed items. Press the ENTER key when the list is complete.
51
PARAMETER CONFIGURATION TABLE.
SETUP INDICATORS (See manual page 21)
SETUP DESCRIPTOR
TOTAL
TOTAL VOLUME UNITS
LBS
TOT DEC PLACES
0
RATE TIME BASE
Min
RATE DESCRIPTOR
RATE
RATE DEC PLACES (0-4)
1
RATE AVG FILTER
0
QUICK UPDATE %
1
SETUP FLOW INPUT (See manual page 22)
EXCITATION VOTAGE
12V
PULSE INPUT TYPE
ChA
PULSE TRIGGER LEVEL
2.5V
LOW PASS FILTER
20KHz
INPUTE TERMINATION
Pulldown
MAX WINDOW
1
K_FACTOR TYPE
Avg
AVERAGE KA-FACTOR
11.6279
LOW FLOW RATE ALARM
NA
HI FLOW RATE ALARM
NA
SETUP PULSE OUTPUT (See manual page 24)
PULSE OUTPUT USAGE
Volume
PULSE WIDTH
100ms
PULSE VALUE
110
SETUP REALTIME CLOCK (See manual page 28)
CLOCK TYPE
24HR
SELECT CLOCK AM/PM
CURRENT TIME
TIME OF DAY
CURRENT TIME
DATE: MONTH,DAY,YEAR
CURRENT DATE
SERIAL USAGE (See manual page 29)
SERIAL HARDWARE
RS232
DEVICE ID
1
BUAD RATE
9600
PARITY
NONE
HANDSHAKING
NONE
DEVICE LINE FEED
(CR+LF)
MODEM CONTROL
NO
SETUP DATALOG PRINT (See manual page 30/31)
OUTPUT FORMAT
Printer
PAGE LENGTH
0
TOP MARGIN
3
DATALOG ONLY
No
PRINT TIME
00:00:00
PRINT INTERVAL
00:00:00
ENABLE PRINT KEY
YES
CLEAR TOTAL IF PRINT
NO
PRINT LIST ITEMS
TOTAL,TIME,GRAND
52
IZM$*
Anderson
2070-IZMAG
Table of contents
Table of contents
1.
General description .................................................................................................. 4
1.1.
1.2.
1.3.
1.4.
1.5.
1.6.
1.7.
1.8.
2.
Transport ................................................................................................................. 11
2.1.
2.2.
2.3.
3.
3.2.
3.3.
Conditions required for the transmitter ................................................................ 13
3.1.1. Measuring of air and gas ............................................................................ 13
3.1.2. Solids.......................................................................................................... 13
3.1.3. Mounting position – electrode axis .............................................................. 14
3.1.4. Inlet and outlet pipe sections ...................................................................... 17
3.1.5. Conductivity conditions ............................................................................... 17
3.1.6. Interference fields ....................................................................................... 17
3.1.7. Earthing/grounding conditions..................................................................... 17
3.1.8. Meter tube lining ......................................................................................... 18
Flow direction ......................................................................................................... 18
Conditions required for the converter .................................................................. 19
Installation ............................................................................................................... 20
4.1.
4.2.
4.3.
5.
General information ............................................................................................... 11
Special notes .......................................................................................................... 11
Dimensions ............................................................................................................. 12
2.3.1. Integral version ........................................................................................... 12
Application .............................................................................................................. 13
3.1.
4.
Preface ...................................................................................................................... 4
Structure and Identification of the device .............................................................. 4
Function .................................................................................................................... 4
Technical data .......................................................................................................... 5
1.4.1. Converter ...................................................................................................... 5
1.4.2. Transmitter in integral design ........................................................................ 5
1.4.3. Measuring ranges and error limits ................................................................. 6
General remarks ....................................................................................................... 6
1.5.1. Special attention of the user ......................................................................... 6
1.5.2. General safety instructions ........................................................................... 8
Intended use ............................................................................................................. 9
Special safety instructions and devices ................................................................. 9
Explanation of the safety symbols used............................................................... 10
Installation instructions for the transmitter .......................................................... 20
Installation instructions for the converter ............................................................ 21
4.2.1. Installation of the electrical power supply .................................................... 21
Electrical connection of peripherals ..................................................................... 24
4.3.1. Digital output............................................................................................... 25
4.3.2. Digital input ................................................................................................. 26
4.3.3. Analog output - current output..................................................................... 26
4.3.4. CS3-Bus ..................................................................................................... 27
Commissioning ....................................................................................................... 27
5.1.
5.2.
5.3.
5.4.
General information ............................................................................................... 27
Advice for starting-up the IZMAG.......................................................................... 28
Basic settings upon delivery ................................................................................. 28
5.3.1. System structure and operating elements ................................................... 28
Flow direction ......................................................................................................... 28
Anderson
2070-IZMAG
Table of contents
5.5.
5.6.
5.7.
5.8.
5.9.
6.
Zero point adjustment (“ZERO adjust”) ................................................................ 29
Metering interruption (assignment of the digital input) ....................................... 29
Metering with an empty meter tube ....................................................................... 29
5.7.1. Internal "EMPTY pipe detection" ................................................................. 29
Metering at low conductivities............................................................................... 29
Use of the internal BUS interface .......................................................................... 30
Operation ................................................................................................................. 30
6.1.
6.2.
6.3.
Basic keypad functions.......................................................................................... 31
Image navigator ...................................................................................................... 31
................................................................................................................................. 33
6.3.1. Zero reset of the volume counter ................................................................ 34
6.3.2. How to delete malfunction messages .......................................................... 34
6.3.3. Parameter change ...................................................................................... 34
6.3.4. How to release a parameter change: .......................................................... 35
6.3.5. How to release the service functions: .......................................................... 35
6.3.6. 36
6.4.
Image level: Measured values ............................................................................... 36
6.4.1. Measured value: Volume ............................................................................ 36
6.4.2. Measured value: Flow rate .......................................................................... 36
6.4.3. Measured value: Flow rate and volume....................................................... 36
6.5.
Image level: Base parameters ............................................................................... 36
6.5.1. Language .................................................................................................... 37
6.5.2. CS3Bus address ......................................................................................... 37
6.5.3. Dimension ................................................................................................... 37
6.5.4. Profibus address ......................................................................................... 37
6.5.5. Parameter Mode ......................................................................................... 38
6.6.
Image level: Pulse output ...................................................................................... 38
6.6.1. Pulse mode ................................................................................................. 38
6.6.2. PV1 ............................................................................................................. 39
6.6.3. TP1 ............................................................................................................. 39
6.6.4. PV2 ............................................................................................................. 39
6.6.5. TP2 ............................................................................................................. 40
6.7.
Image level: Digital input ....................................................................................... 40
6.7.1. Function: Digital input ................................................................................. 40
6.7.2. IT1 .............................................................................................................. 40
6.8.
Image level: Current output ................................................................................... 41
6.8.1. Current output mode ................................................................................... 42
6.8.2. Qmax .......................................................................................................... 42
6.8.3. TP3 ............................................................................................................. 42
6.9.
Image level: Metering parameters ......................................................................... 42
6.9.1. LFS ............................................................................................................. 43
6.9.2. MSPE ......................................................................................................... 43
6.9.3. BSPE .......................................................................................................... 43
6.9.4. Average ...................................................................................................... 43
6.9.5. Offset .......................................................................................................... 44
6.9.6. SPAN .......................................................................................................... 44
6.9.7. Pipe Detect (recognition of an empty meter tube) ....................................... 44
6.9.8. Nominal width ............................................................................................. 44
6.10. Image level: Special functions............................................................................... 45
6.10.1. Zero adjust .................................................................................................. 45
6.10.2. Factory setting ............................................................................................ 45
6.11. Image level: Service level ...................................................................................... 45
Anderson
2070-IZMAG
Table of contents
6.11.1. Error register: Metering ............................................................................... 46
6.11.2. Error register: Operating system ................................................................. 46
6.11.3. Simulation of the current output .................................................................. 46
6.11.4. Simulation of the pulse outputs ................................................................... 46
6.11.5. Simulation of the flow rate........................................................................... 47
6.12. Image level: Info ..................................................................................................... 47
6.12.1. Info1 ........................................................................................................... 47
6.12.2. Info2 ........................................................................................................... 47
7.
Parameterization ..................................................................................................... 48
7.1.
7.2.
8.
Troubleshooting...................................................................................................... 51
8.1.
8.2.
8.3.
9.
Adjustments ........................................................................................................... 50
7.1.1. Adjustment by calibration factor "m spe" ..................................................... 50
Measuring accuracy: .............................................................................................. 51
Error diagnosis ....................................................................................................... 51
8.1.1. Error diagnosis via the display .................................................................... 51
8.1.2. Error list ...................................................................................................... 52
Typical effects or error sources ............................................................................ 53
8.2.1. Flow without flow rate indication: ................................................................ 53
8.2.2. No pulse transmission despite displayed flow ............................................. 53
8.2.3. No analog signal available .......................................................................... 53
8.2.4. Deviations of measured values ................................................................... 54
Error reset ............................................................................................................... 55
8.3.1. Visual check ............................................................................................... 55
Maintenance ............................................................................................................ 56
9.1.
9.2.
9.3.
9.4.
9.5.
Safety instructions for maintenance work............................................................ 56
Routine maintenance ............................................................................................. 56
9.2.1. Preventive maintenance steps .................................................................... 57
Repairs .................................................................................................................... 58
9.3.1. Sending-in the flow meter to the manufacturer............................................ 58
9.3.2. Repair Work................................................................................................ 58
Special program functions .................................................................................... 59
9.4.1. Flow simulation ........................................................................................... 59
9.4.2. Simulation via the display unit ..................................................................... 60
Spare parts to be kept available on stock ............................................................ 60
10. Decommissioning ................................................................................................... 61
10.1. Temporary decommissioning................................................................................ 61
10.2. Final decommissioning / disposal ........................................................................ 61
Anderson
2070-IZMAG
Safety instructions
1.
General description
1.1.
Preface
This documentation includes some information protected by copyright. Without prior
authorization by Anderson Instrument Company this instruction manual is not allowed to
be photocopied, copied, duplicated, translated, or recorded on data carriers (neither
completely nor in extracts).
This instruction manual should be carefully read before the installation and operation of
the device is started. It should be kept in the direct proximity of the device described
and readily accessible to all persons concerned.
The safety instructions have to be strictly observed.
Anderson cannot assume any liability or legal responsibility for operating errors
caused by the non-observance of these directions.
1.2.
Structure and Identification of the device
This instruction manual refers to the integral all-in-one design of the electromagnetic flow
meter.
The IZMAG™ is available in the following versions:
operated by DC power supply, integral version
operated by AC power supply, integral version
Integral version:
Transmitter and converter form a single unit.
This instruction manual does not deal with the Weights and Measures-approved versions of
the flow meter.
1.3.
Function
The electromagnetic flow meter, type IZMAG™, measures both the flow rate and the
volume of liquid flows at a high precision.
The measuring device is suitable for measuring conductive liquids.
The IZMAG converter is a microprocessor based device that supplies the transmitter with a
switched and regulated coil current.
The signal generated at the electrodes is amplified in the converter, conditioned and shown
in the internal measuring registers both as flow rate and volume information.
Volume pulses (pulses per volume unit) are output for controlling and measuring uses.
The instantaneous flow rate is output as an analog signal of 0 or 4...20 mA according to the
desired range of 0...100 %.
When leaving the factory, each device is adjusted such that only the power supply and any
peripherals will have to be connected.
-4-
Anderson
2070-IZMAG
Safety instructions
1.4.
Technical data
1.4.1. Converter
Supply voltage:
IZMAG™ DC: 9 - 32 V DC
IZMAG™ AC: 100 - 240 V AC, 50/60 Hz
Power consumption:
10 VA max. / 8 watts
Electrical fuse connection: AC power supply: T 500 mA
DC power supply: T 1.5 A
Digital pulse output:
Maximum load:
3 x galvanically isolated optocoupler output
32 V / 20 mA / pulse sequence: 1 kHz max.
Analog output:
0 or 4 - 20 mA (active or passive), maximum load 500 Ω
(optional) 4-20 mA passive output with Hart communication
Max.500 Ω load
Digital input:
1 x galvanically isolated optocoupler input;
9 - 32 V, Ri < 3.2 kΩ, activation: 9 - 32V DC,
1 kHz max.
Serial interface:
RS485, CS3-Bus protocol
Ambient temperature:
-20°C ... +55°C
-20°C ... +45°C
DC power supply
AC power supply
For further technical data please refer to item 5.3.
1.4.2. Transmitter in integral design
Transmitter
Integral version
Process connection:
Aseptic flange
Nominal widths:
DN 15, 25, 32, 50, 65, 80, 100
Optional product connections:
Tri-Clamp, Cherry I-line
Materials:
Meter tube:
Material no.:
1.4404 / AISI 316 L
Liner:
PFA
Electrodes:
Material no.:
1.4404 / AISI 316 L
Housing:
Material no.:
1.4301 / AISI 304 (micro blasted)
Protection class:
IP67
Electrical connection:
Internal cable connection
Calibration data included in the associated converter
Product temperature:
100°C max.
Cleaning temperature:
130°C for a maximum period of 30 minutes
Product conductivity:
5 µS/cm at a minimum
Admissible pressure:
0.1 bar absolute at a maximum at 20°C, 10 bar max.
Flow velocities:
0.1 - 10 m/s
-5-
Anderson
2070-IZMAG
Safety instructions
1.4.3.
Size
15
25
32
50
65
80
100
Measuring ranges and error limits
Total measuring range
[gal/min ]
Flow rate at a
flow velocity of
Measuring
tolerance
1 m/s
[ gal/min ]
± 0.2 % *
Unit
.31
-
31
2.8
>
.31
Gal/min
.80
-
80
7.8
>
.80
Gal/min
1.3
-
130
12.8
>
1.3
Gal/min
3
-
300
30
>
3.0
Gal/min
5.2
-
525
53
>
5.2
Gal/min
8
-
800
80
>
8.0
Gal/min
12
-
1200
125
>
12.0
Gal/min
* see measuring accuracy 7.2
Safety instructions
Due to the great variety of possible uses, this instruction manual addresses the general
application conditions.
Special cases such as extraordinary ambient conditions or special safety instructions
require coordination with the manufacturer.
1.5.
General remarks
1.5.1. Special attention of the user
This measuring instrument has been designed and built in consideration of a risk analysis
and after a careful consideration of standards and technical specifications which
correspond to a product which is state of the art and offers an optimum in safety.
In practical use, however, that degree of safety can only be obtained when all measures
required in this respect will be really taken. It belongs to the user of the flow meter to plan
such measures and to check and survey if they are really fulfilled.
In particular, the user has to ensure that:
- The measuring instrument is only used for the intended application as directed (also
see the following chapter “Intended use”).
- The measuring instrument is operated in a correct and functioning condition and that
especially the safety devices are regularly checked for their proper operation.
- The personal protective equipment required for the operating, maintenance, and repair
staff is kept available and is used.
- The complete instruction manual in a legible condition is permanently available at the
location of the measuring device.
- The device is operated, serviced, and repaired by sufficiently qualified and authorized
personnel only.
- The personnel concerned are regularly trained for all applicable questions of the
protection of labor and environment and familiarized with the instruction manual and
especially the safety precautions included therein.
-6-
Anderson
2070-IZMAG
Safety instructions
- All the safety and warning instructions attached to the measuring instrument are not
removed and kept in a legible condition.
In case of problems that cannot be resolved by the user, contact the service department of
Anderson Instrument Co.
-7-
Anderson
2070-IZMAG
Safety instructions
1.5.2. General safety instructions
These safety instructions have to be strictly observed in order:
•
•
•
To not endanger the safety of persons and environment
To avoid any damages to the measuring instrument
To prevent any faulty batches upon the production
The electric connection may only be carried out by persons who have got the necessary
expert knowledge (e.g. trained electrical fitters or persons instructed in electrical
engineering) and the necessary authorization from the user.
Unauthorized persons are not allowed to
open a housing that shows this symbol!
Warning of
dangerous voltage!
The wiring of the voltage supply and the inputs and outputs of the control
circuits has to be carried out professionally in consideration of the up-to-date
state of the art. Also refer to chapter 5 “Installation”/”Electrical Connection”.
Important
information
In particular, the following references have to be observed:
• Safety instructions
• Electrical connection data
-8-
1.
All persons who are involved in the installation, commissioning, operation, service, and
maintenance of the flow meter have to be qualified accordingly.
2.
This instruction manual has to be strictly observed. The user of the flow meter has to
guarantee that the personnel concerned has read and fully understood the instruction
manual.
3.
All kinds of work have to be done with utmost care and may be carried out by
authorized and trained personnel only.
4.
The instruction manual has to be available close to the flow meter, easily accessible to
the operating staff.
5.
Before starting any cleaning, conversion, service or maintenance work, the measuring
device has to be switched off and disconnected from the mains power. This requires a
device for separating all live wires, e.g. a 2-pole main switch in the control cabinet. The
associated device has to be protected against unauthorized switching-on.
6.
Before starting any service and maintenance work, the system has to be flushed with
water and emptied. If the flow meter has to be removed from the pipe system, all
pipelines will have to be previously emptied and protected by means of some
appropriate emptying and shut-off measures.
7.
The flow meter fulfils the general safety requirements according to EN 61010.
Anderson
2070-IZMAG
Safety instructions
8.
Never remove or put out of action any safety devices by modifications to the flow
meter!
9.
Do not touch any part of the flow tube while the measuring instrument is cleaned.
Otherwise, you run the risk of getting burnt!
10. To minimize the danger of injury, the working area of the operator has to allow
sufficiently free space.
11. The technical data according to the instruction manual, nameplate and, if available, the
performance specification has to be considered.
If damage is done to the meter all warranties are void.
Dangers not resulting from the functionality of the device, but from the ambient and
operating conditions prevailing at the place of application, have to be referred to in
appropriate instructions to the operators and by the attachment of some danger signs!
The user of the device is exclusively responsible for the compliance with these
instructions!
1.6.
Intended use
The measuring instrument is only allowed to be used for the application that it has been
designed, dimensioned and built for:
-
the connection to an earthed monophase network or a direct current network (see the
nameplate)
in industrial areas according to EN 61000-6-2/4 for reasons of EMC
The intended purpose of the electromagnetic flow meter is the measurement of conductive
liquids in the food processing industry and in the cosmetic, pharmaceutical and chemical
industries.
This flow meter is not suitable for the measurement of hazardous, explosive, and
combustible liquids of PED group 1.
Any modifications to the measuring device that might have an influence on the function and
the safety devices of the flow meter are only allowed to be carried out by the engineering
specialists or authorized persons of Anderson.
Possible misuse
Any utilisation being in contradiction to the above-mentioned application means an
inadmissible misuse of the measuring instrument! In such a case Anderson does not
assume any responsibility for the safety.
Anderson has to be contacted before the flow meter will be used for any different
application, and after a careful investigation of all facts Anderson could possibly release the
flow meter for the intended new application.
1.7.
Special safety instructions and devices
The following dangers could be directly or indirectly caused by the flow meter, type IZMAG,
during operation or commissioning:
•
•
Electric shock if the electronic housing is opened improperly
Burns by touching hot pipe sections
-9-
Anderson
2070-IZMAG
Safety instructions
•
1.8.
Scalds and/or chemical burns by hot liquids or gas coming out through leaking flange
connections or because of an inexpert opening of the pipe system
Explanation of the safety symbols used
The IZMAG™ flow meters are reliable in operation and meet the highest technical
specifications. They leave our factory at a safety-related flawless condition. The devices
correspond to the relevant standards and directives according to EN 61010 “Electrical
safety testing for measurement and laboratory devices”. However, a hazard can originate
from the devices, if they are used inexpertly and not for their intended purpose. Therefore,
strictly observe the safety instructions of this instruction manual which are marked by the
following symbols:
Important
information
Warning of dangerous
voltage
- 10 -
Hot caustic solution can cause
serious chemical burns
Warning against
hand injuries
Warning against hot
liquids and steam
Warning against irritating
substances or media
detrimental to health
Endangered
electrostatic component
t
Electronic scrap
Caution
Warning against
hot surfaces
Warning
against
an
Es besteht
erhöhte
increased risk
skidding
Rutschgefahr
imof
Nassbereich!
in wet areas
Anderson
2070-IZMAG
Transport
2.
2.1.
Transport
General information
The following points have to be respected in order to avoid damages to the measuring
instrument or injuries during the transport of the device:
Transport work is only allowed to be carried out:
- By accordingly qualified and authorized persons
- By the aid of appropriate load suspension and fastening devices
- If any risk can be fully excluded while the device is lifted or conveyed
Caution
The packing of the measuring instruments is subject to the following labelling:
Fragile goods
Keep dry!
Check the added packing list before you will start opening the packing!
Compare by means of the packing list if all parts are really available or not!
Treat sensitive parts with special care!
Please do not fail to dispose of the packing material according to the appropriate
regulations.
2.2.
Special notes
When removing the packaging film, see to it that no components of the device (such as
display or keypad) are damaged.
- 11 -
Anderson
2070-IZMAG
Transport
2.3.
Dimensions
2.3.1. Integral version
7.87”
H
D
L1
L2
- 12 -
Anderson
2070-IZMAG
Application
3.
Application
3.1.
Conditions required for the transmitter
The transmitter has to be installed in the product line and the converter has to be supplied
with voltage.
When selecting the place for the installation of the measuring instrument you should in any
rate ensure that the housing can be opened for service work whenever desired and that the
flow meter can be simply removed, if necessary.
Cross-flows should be absolutely avoided, as they could cause some damages to the
electronic part.
In order to protect the transmitter against damages, select the place of
installation so that:
Caution
•
•
•
•
•
•
the process pressure is always kept within the admissible operating pressure
the product temperature is always kept within the admissible temperature
the transmitter is mechanically levelled out (e.g. to avoid vibration)
the meter tube can be emptied in case of the danger of frost
the measuring instrument is not arranged straight above a gully or sink hole
the connection housing is not permanently exposed to dripping water
3.1.1. Measuring of air and gas
The electromagnetic measuring instrument can supply perfect measuring results in case of
gas-free liquids only. Air locks or deaeration in a liquid will lead to faulty measurements.
Thus, make sure that air locks or other possible parts of gas are eliminated before the
measuring device e.g. by air eliminators or that deaeration can be excluded by a sufficient
working pressure.
The measuring device is not damaged e.g. by air locks.
3.1.2. Solids
Normally, solids do not have any negative influence on the volume measurement.
The pipe diameter should always be chosen sufficiently large in order to prevent the meter
tube from being clogged in case of products with solid particles.
Due to the fact that the flow velocity of solid matters is usually lower than that of the liquid
part of the product, a higher flow fluctuation can be caused while the flow rate is measured.
The measurement of abrasive materials can cause a drifting of the measuring accuracies
and, in the end, a deterioration of the transmitter.
- 13 -
Anderson
2070-IZMAG
Application
3.1.3. Mounting position – electrode axis
Due to the principle described, the fitting position – to a certain extent – can be selected
any way desired. The basic condition for accurate measuring results is, however, a full and
gas-free meter tube.
If possible, the electrode axis should be horizontally arranged, in order to avoid a deposition
of gas bubbles or solid particles on the surface of the electrodes. Therefore, a slightly
ascending pipeline is advisable, preferably with a deaerating possibility at its highest
position.
The fitting position should be chosen in such a way that a good readability and handling of
the operating unit is guaranteed.
The pipelines within the inlet and outlet pipe sections must not show any unevenness, e.g.
welding beads internally.
In the case of 3-A applications, the transmitter should not be mounted below the center
line of the flow tube.
max. 45°
Electrode axis
- 14 -
Anderson
2070-IZMAG
Application
General Installation Requirements
Wrong
At the highest point of the pipeline. Gas bubbles
accumulate in the transmitter. → incorrect
measurement!
<5m
freieroutlet
Auslauf
Wrong
Descending pipe:
At the end of the conveyance of the metered product
the pipe runs empty. → Measuring errors!
Correct
Preferred mounting position:
Rising pipeline and horizontal pipe section before an
Descending pipelines of a length of more than 5 m
have to be equipped with a deaeration valve after the
flow meter.
Correct
In case of a horizontal pipe the mounting position is
placed in slowly rising section to ensure fill.
outlet
freier
Auslauf
Correct
Provide a low spot in the pipe line to maintain pipe line
fill.
Installation requirements for 3-A sanitary applications
>5
O
Correct
In horizontal applications a slope of greater than 5
degrees is required to ensure that proper drainage
occurs in the pipeline
- 15 -
Anderson
2070-IZMAG
Application
Other Installation Considerations
Long lines after the flow meter always have to be
equipped with a shut-off device. If it is placed before the
flow meter, a vacuum will be caused in the metering pipe
by the big kinetic energy in the liquid column when
shutting off. This can damage the lining of the tube and
should be avoided!
Do not place the flow meter on the suction side of the
pump! → Danger of negative pressure!
Keep the recommended inlet and outlet sections!
5xDN
3xDN
Avoid curvatures of space before the flow meter!
- 16 -
Anderson
2070-IZMAG
Application
3.1.4. Inlet and outlet pipe sections
For the installation of electromagnetic transmitters DIN 1944 recommends an inlet pipe
section of 5 x DN and, accordingly, an outlet pipe section of 3 x DN in case of an
undisturbed flow. For an irregular flow (e.g. distorted rotational flow profile) the inlet and
outlet pipe sections have to be extended accordingly or a rectifying device for the flow has
to be installed in order to guarantee the specified measuring accuracy.
3.1.5. Conductivity conditions
The liquid to be measured has to show a minimum conductivity of ≥ 5 µS/cm.
Demineralised water requires a conductivity of ≥ 20 µS/cm.
A count suppressor for empty meter tubes belongs to the standard equipment of the
converter. That function will have to be switched off at conductivities below 50 µS/cm.
3.1.6. Interference fields
Direstly at the transmitter masses of iron or strong permanent or electromagnetic fields
must absolutely not exist, as they could influence the defined exciting magnetic field, thus
falsifying the signal.
3.1.7. Earthing/grounding conditions
A ideal earthing/grounding of the transmitter is an essential requirement for a reliable and
accurate measurement.
“Inductive measuring method” means that the metered liquid itself acts as an electric
conductor, i.e. a correct and careful earthing/grounding ensures that no additional
potentials will falsify the extremely low metering signal.
For that reason, the earthing/grounding resistance has to be smaller than 10 Ω. The
earth/ground wire used must not transfer any interference voltages, i.e. no other electric
devices must be connected to that line.
In case of a plastic pipe system no equipotential bonding is available between the inlet and
outlet sides, it will be necessary to take some appropriate measures for a potential
equalisation.
- 17 -
Anderson
2070-IZMAG
Application
The transmitter has to be earthed/grounded as
shown in this picture.
3.1.8. Meter tube lining
A damaged PFA lining can cause faulty measurements or even a failure of the flow meter.
Choose the place of installation in such a way that no negative pressure can be caused,
even not when the pump is switched off. An installation at the highest point of the pipeline
has to be avoided!
3.2.
Flow direction
The arrow on the nameplate shows the calibrated flow direction from MINUS to PLUS.
Inflow from the right to the left
results in a negative flow
indication
-
+
Inflow from the left to the right
results in a positive flow
indication
The flow meter can measure in both directions, in principle.
Provided that the recommended inlet and outlet conditions are kept, the accuracy of the
measurement in both directions is only slightly different.
- 18 -
Anderson
2070-IZMAG
Application
3.3.
Conditions required for the converter
In order to guard the converter against damages, always select the place of
installation so that:
Caution
•
•
•
•
the ambient temperature is within a range from –20...+55 °C
the field housing is fastened free from any mechanical distortion
no moisture can enter the field housing through the cable gland
the housing is not permanently strained by dripping water
Apart from that, please ensure that the housing can be easily opened for service purposes.
The converter has to be installed in such a way that reading and operation of the unit is
guaranteed!
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Anderson
2070-IZMAG
Operation
4.
Installation
Only qualified personnel with the authorization of the user are allowed to carry out the
installation work. The qualified personnel have to have read and fully understood this
instruction manual and follow all instructions given therein.
The current accepted practices must always be considered during the installation.
The following points should be taken into account after completion of the installation work:
•
•
•
•
•
•
It has to be checked whether all external supply connections really meet the
requirements specified in the technical data of the flow meter (e.g. pressure,
temperature, etc.).
The pipelines have to be flushed before the production is started.
All external supply joints have to be checked for their safe, leakproof, and nearly
stress-free connection to the transmitter.
The media supplied have to be cautiously adjusted to their required working pressure.
Occurring leaks have to be removed immediately.
All electrical lines have to be remote from the flow meter before welding work is started
at the pipeline.
The electric wiring of the voltage supply and the inputs and outputs of the control circuits
has to be carried out according to the wiring diagram.
4.1.
Installation instructions for the transmitter
Caution
Pay attention to the fact that the threaded fittings, clamps, or flanges are
correctly tightened! Otherwise, hot or caustic solutions or gasses could
come out of the gaps and clearances.
•
•
•
Leaking liquids can lead to slip hazard.
Leaking liquids have to be mopped up immediately and disposed of safely.
If combustible liquids come out, they could cause an explosion hazardous area around
that place which has to be marked accordingly.
If the transmitter is connected to existing process lines, those lines have to be
unpressurized and free from product.
Do not omit to insert the gaskets into connections!
In case of leaking pipe connections you should check the seals.
After installation of the measuring device you should not fail to ensure optimum
earthing/grounding, if some welding work is required.
The best solution is to separate the complete measuring device from the network and to
allow an electrically conductive bridging-over of the pipe connections of a possibly large
cross section.
Lead the mass electrode of the welding device as close as possible to the welding seam in
order to avoid any stray currents within the pipe system and the measuring device!
Always fix the mass electrode of the welding device at the side of the welding seam
opposite to the measuring device (in that case the current will flow away from the
measuring device)!
-20-
Anderson
2070-IZMAG
Operation
4.2.
Installation instructions for the converter
When installing the flow meter, pay special attention to the fact that no moisture by drip or
splash water can get onto the electronic board.
Metal particles, such as scobs or residues of the shielding braid, have to be removed from
the boards before the electric power supply is switched on.
See to it that the pipelines are supported in such a way that no forces and moments are
exerted on the measuring device.
The display must not be exposed to direct sunlight!
Caution
4.2.1. Installation of the electrical power supply
Caution
The following safety precautions have to be followed for the execution of the electrical
installation work:
This equipment must be connected to a wiring system in accordance with ANSI/NFPA 70,
NEC with CSA C22.1, CEC, Part 1
Intended use
The flow meter, type IZMAG, is exclusively destined for:
- The connection to an earthed/grounded monophase network
- The use in industrial areas for reason of EMC (according to definition EN 50 081-2)
Apart from that:
The supplying system has to guarantee an overvoltage protection for the device
according to category II.
The connection cables have to be secured by a cable strap (AC version) as shown in
the photograph on the next page.
- 21 -
Anderson
2070-IZMAG
Operation
Staff qualification
Necessary work to the flow meter, type IZMAG, is only allowed to be performed by trained
and qualified personnel in consideration of the relevant regulations for occupational safety.
The flow meter has to be correctly connected according to the electrical wiring diagrams.
The nameplate of the flow meter has to be considered for the electrical
connection. It is most important that the nominal voltage and the kind of
voltage (AC or DC) are equal to those of the flow meter.
Important
information
The electrical power supply is connected to terminal X1:
Connection of the AC power supply:
L line
N line
to
to
Protective conductor to
Connection cable:
5.7mm
X1 / L
X1 / N
X1 / PE
ÖPVC-JZ
3G0.75mm², 18 ga.
The terminal board is marked by additional AC stickers.
-22-
minimum
external
diameter:
Anderson
2070-IZMAG
Operation
Indicating labels for the AC version
Connection of the DC power supply:
Positive cable (plus)
Negative cable (minus)
Protective conductor
to
to
to
X1 / +
X1 / –
X1 / Case
In case of the DC version the protective conductor has to be connected, too.
Connection cable:
5.7mm
ÖPVC-JZ
3G0.75mm² (18ga.), Minimum
external
diameter:
The terminal board is marked by an additional DC sticker.
Indicating label for the DC version
The shielding braid has to be correctly connected to the cable gland in order to guarantee
an optimum operation of the device according to the EMC directives.
Caution
In case of hard-wired devices without any mains switch it is absolutely
necessary to install a 2-pole switch or a power switch in the structure of
the building. That switch has to be fixed in the direct vicinity of the device,
easily accessible to the user and clearly marked as a disconnecting or
isolating switch for the device.
This meter can be supplied by different voltages. The supply voltage type and range is
indicated on the nameplate.
- 23 -
Anderson
2070-IZMAG
Operation
4.3.
Electrical connection of peripherals
The following signal outputs are available:
3x
1x
1x
1x
digital outputs, configurable for volume pulses and status output
digital input, configurable for measuring interruption or setting to zero
analog current output for the flow rate, configurable for:
0...20 mA/active, 4...20 mA/active, and 4...20 mA/passive
CS3BUS interface (RS485 interface with AndersonCS3-Bus protocol)
The measured values of the IZMAG™ are usually put out as volume pulses (pulses per
gallon) through a digital pulse output:
X200  CS3BUS, data communication
-24-
X2
 Analog output / current output
X3
 Digital outputs and digital input
X1
 Connection of the power supply
Anderson
2070-IZMAG
Operation
4.3.1. Digital output
Digital output
Hardware
Auxiliary voltage
Output current
Voltage drop at the optocoupler at 20 mA
Output frequency
Optocoupler, passive
32 V max.
20 mA max.
0.5…1 V
1kHz max.
The following figure shows the basic wiring diagram of the pulse outputs.
The outputs switch off in case of overload. By removal of the overload the outputs will be
reactivated after a few seconds.
Figure 2: Pin assignment of the pulse outputs
Optocoupler
connected
Optocoupler
locks
Output signal at 1 kHz
The pulse duty cycle depends on the load, too. An electronic counter has to have an input
frequency of at least 5 kHz.
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Anderson
2070-IZMAG
Operation
4.3.2. Digital input
Digital input
Hardware
Auxiliary voltage
Input resistance
Input frequency
Function
Terminal X3 / No. 32
Terminal X3 / No. 31
Optocoupler, passive
9…32 V
< 3.2 kΩ
1kHz max.
Voltage ON  Function active
Plus
Minus
The following figure shows the basic wiring diagram of the control input:
Figure 3: Pin assignment of the digital input
4.3.3. Analog output - current output
Analog output
Hardware mode
Operating mode
Load
Error
Active or passive
4...20 mA / 0...20 mA
500 Ω max.
< 0.2 %
The analog output works in both flow directions!
Analog output,
active current output
Control valve
Figure 4: Pin assignment of the active current output
Analog output,
passive current output
4…20 mA
Power supply unit with evaluation 4…20 mA
Load
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Anderson
2070-IZMAG
Operation
Figure 5: Pin assignment of the passive current output
4.3.4. CS3-Bus
CS3-Bus
Hardware interface
Bus protocol
Baud rate
X200 / A
X200 / B
X200 / C
Cable length
Cable
RS485
AndersonCS3-Bus protocol
57600 Bauds
Signal A
Signal B
GND
100 m max.
LIYCY-0; 4 x 0.5 mm², shielded
The BUS is connected by a 3-pole plug-in terminal with the signals “A-B-C“.
Further BUS connections are always made 1 to 1, i.e. A is connected to A, B to B, and
C to C.
A BUS interface is available for a data communication. It can be used for the connection of
the IZMAG™ to the IVON service program.
5.
Commissioning
5.1.
General information
This measuring device may only be operated by trained persons who have got the
necessary authorization from the owner of the device. The operators have to be familiar
with the process sequence, able to recognize possible dangers, and in a position to take
the necessary steps for the removal of accident risks.
Safety measures for the commissioning work
Caution
Both an orderly performed installation and a correct electrical connection are absolute
prerequisites for commissioning!
Pay attention to the following points upon the initial start-up of the flow meter:
•
Close the housings of transmitter and converter!
- Personal injury by electric shock can be caused, if the electric lines are touched.
- Instrument damage can be caused by moisture or metal parts on the electronic unit.
•
Ensure that all threaded joints at the measuring instrument and in the direct vicinity are
properly tightened.
•
- 27 -
Anderson
2070-IZMAG
Operation
5.2.
Advice for starting-up the IZMAG
1.
2.
3.
5.3.
First of all the measuring device has to be installed into the pipeline!
•
Pay attention to the flow direction.
•
The flow range adjusts itself automatically.
•
After the electrical start-up a “ZERO adjust” should be carried out by means of
the typical liquid to be measured (full meter tube and no flow!).
How to put into operation the analog output?
•
The output can be parameterized specific for the application and it can be
operated actively of passively. The current range can be adjusted to 4...20 mA or
0...20 mA. Factory setting: 4...20 mA.
•
Dependent on the flow rate, the analog output will produce a current of 0/4...20
mA.
•
The 20mA point is determined by setting the “QMAX value of the IZMAG.
•
The flow simulation can be used for a functional check.
Which other conditions should be taken into consideration?
•
Too low product conductivity?
At less than 50 µS/cm, the internal empty-pipe detection has to be switched off
by the respective parameter setting.
•
Is the analog output too unsteady?
A time constant can be set using the “Average” or TP3 parameters.
Basic settings upon delivery
At the factory the electromagnetic flow meter is adjusted and delivered with application
specific settings as standard.
5.3.1. System structure and operating elements
The electronics are permanently installed in the IZMAG™ converter. The display is
arranged on the front above the three optical keys. The electrical connections are on the
rear side of the converter.
The status of the device can be read on the display.
5.4.
Flow direction
The IZMAG™ measures the flows in both flow directions in principle.
The main flow direction is marked by
-28-
on the transmitter.
+
Anderson
2070-IZMAG
Operation
In the standard setting (output mode 1), the digital outputs release the volume pulses
independently of the flow direction.
Negative flows or quantities are displayed with a MINUS sign.
5.5.
Zero point adjustment (“ZERO adjust”)
Upon the first start-up of the flow meter it is recommendable to carry out a zero point
adjustment (“ZERO adjust”) for an adaptation of the flow meter to the conditions prevailing
in situ.
Normally, such an adaptation is not required for the integral flow meter version.
ATTENTION!
5.6.
The following conditions have to be observed for a “ZERO adjust”:
(1)
The device has to have reached its working temperature, i.e. it should have been
switched on at least 5 minutes before.
(2)
The transmitter has to be completely filled with the typical liquid free of air.
(3)
No flow is allowed to occur during the whole “ZERO adjust” measurement.
Metering interruption (assignment of the digital input)
To externally interrupt the measurement, e.g. during cleaning, a digital signal can be
connected to input IN1 on the terminal board.
The input is activated by a DC voltage between 9 V and 32 V DC at terminal X3 with PLUS
to no. 32 and MINUS to no. 31.
This function has to be switched on by the parameter settings.
5.7.
Metering with an empty meter tube
Metrologically accurate flow measurements are only possible, if the meter tube is
completely filled with liquid.
In order to avoid an undefined counting in case of an empty meter tube, the IZMAG™ offers
both an internal and an external possibility for measurement suppression:
5.7.1. Internal "EMPTY pipe detection"
The IZMAG™ is equipped with a special “EMPTY pipe detection” ("pipe detect"). The
setting is made via the parameters. Usually, the EMPTY pipe detection is switched on, i.e.
an undefined count will be suppressed in case of an empty meter tube.
At the following situations, the internal EMPTY pipe detection has to be switched off by the
parameter setting:
- At a product conductivity of less than 50µS/cm.
- At a heavily pulsating flow (piston, membrane or hose pumps).
5.8.
Metering at low conductivities
The IZMAG™ is capable of measuring liquids from a minimum conductivity of 5 µS/cm.
In order to obtain perfect results even at conductivities of less than 50µS/cm, the internal
“EMPTY pipe detection” has to be switched off in the parameters.
- 29 -
Anderson
2070-IZMAG
Operation
5.9.
Use of the internal BUS interface
Via the BUS interface it is possible to connect the intelligent AndersonCS3 systems to the
IZMAG™.
6.
Operation
Only qualified persons with authorization of the user are allowed to operate the IZMAG™.
During normal measurements the operation is restricted to the zero reset of the volume
registers. The keypad is dynamically controlled by the image navigator.
The display unit can be rotated in steps of 90°, thus enabling a proper orientation for
viewing and operating the meter.
The display is illuminated by a permanently switched on background lighting which permits
a stress free reading.
Elements of the operating unit:
Calibration switch
Display field
Optical keys
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Anderson
2070-IZMAG
Operation
6.1.
Basic keypad functions
The keypad consists of 3 optical keys. The functions of the keys are indicated by symbols
and texts. The function of the keypad is dynamically controlled by the image navigator:
To change the main image level
To return to the main image level or to the measuring image
To change to the next sub-image
To reset the volume to zero
To change the setting parameters, e.g. to change the pulse mode
This is only displayed, if the parameter setting is enabled.
To change the numerical parameters, e.g. low flow quantity
This is only displayed, if the parameter setting is enabled.
Key functions for the value input (numerical parameter):
Next input position
Changes the input position
ENTER, terminates the numeric input
6.2.
Image navigator
The display is divided into main images and sub-images. Sub-images are allocated to
each main image level.
To permit a quick overview of the parameterization the main image shows the most
important parameters and settings for the adjustment of the device.
The basic setting of the image navigator is the measured value level where the volume and
the flow rate are displayed. A timeout function makes sure that the IZMAG™ always returns
to that image level.
The image navigator is controlled by the keys
,
and
.
Basic functions of the image navigator:
• Reading the measured values
• Selecting the different functions
• Parameterization
• Service display
- 31 -
Anderson
2070-IZMAG
Operation
6.3.
- 33 -
Anderson
2070-IZMAG
Operation
6.3.1. Zero reset of the volume counter
The main image shows the total. “Zero reset” is a function which can be carried out without
any additional activation.
For a zero reset, please keep the
key depressed for about 5 seconds.
6.3.2. How to delete malfunction messages
Possible malfunction messages are deleted by resetting the volume counter.
6.3.3. Parameter change
There are two kinds of parameters, in principle:
Selected parameters, e.g. pulse mode
Numerical parameters, e.g. TP1
A setting parameter is changed by the
key. The
key opens an input field for
the entry of the numerical parameter selected.
A parameter change is only possible, if it has been unlocked before. Unless it is
unlocked, the input of the unlock code is requested automatically.
How to change a numerical parameter:
Press the
key and an input field will appear. The instantaneous value is shown
inversely, whereas the changeable position is shown as normal.
The
key changes the digit in the input position. The next left-hand input position is
selected by the
key. If the numerical parameter is set to the desired value, then
accept using the
key.
How to change a selected parameter:
The procedure is described by means of the example of the “pulse mode”.
The current pulse output mode is set to “Mode 1”. The next mode is selected and/or
adjusted by means of the
key.
- 34 -
Anderson
2070-IZMAG
Operation
The next pulse output mode appears on the display.
6.3.4. How to release a parameter change:
If a parameter has to be changed and the parameter change is open for change, the display
will request the input of the code number.
Input the code number as described in item 7.2.3. If the correct code number has been
input, the display will show the message “Parameter input unlocked”. In case of a wrong
code number the display will show “parameter input blocked”.
Code number for parameter changes: 222.
6.3.5. How to release the service functions:
Some service functions have to be released by a code number. Unless they are released,
the display will show a request to input the code number.
Input the code number as described in item 7.2.3. If the correct code number has been
input, the display will show the message "Service level unlocked". In case of a wrong code
number the display will show "Service level blocked".
Code number for the service level: 333.
-35-
Anderson
2070-IZMAG
Operation
6.3.6.
6.4.
Image level: Measured values
6.4.1. Measured value: Volume
A 4-seconds long activation of the
key will reset the volume to “0”.
The size of the digits is controlled by the size of the measured value.
The volume indication is the central image that is always shown after a reset.
6.4.2. Measured value: Flow rate
The size of the digits depends on the size of the measured value.
6.4.3. Measured value: Flow rate and volume
Joint indication of volume and flow rate
6.5.
Image level: Base parameters
The image level consists of the following pictures: BE2, BE2S1, BE2S2, and BE2S3.
This image level offers the possibility to make some basic settings. The main image shows
the current device setting.
- 36 -
Anderson
2070-IZMAG
Operation
6.5.1. Language
Use the key
for changing the language.
You might be prompted to first input an unlock code.
6.5.2. CS3Bus address
The CS3-Bus address can be changed by means of the key
You might be prompted to first input an unlock code.
.
6.5.3. Dimension
The
key can be used for changing the dimension (unit) of the measured value.
You might be prompted to first input an unlock code.
Abbreviation
l
m³
hl
ml
gal
gal
gal
lb
bbl
dm³
Unit
Litres
Cubic metres
Hectolitres
Millilitres
U.S. gallons
Gallons (CDN)
Imp. Gallons
lb raw milk
beer barrels
Cubic decimetres
m dim
1
0.001
0.01
1000
0.2642
0.21997
0.21997
2.27189
0.00611
1
6.5.4. Profibus address
The profibus address can be adjusted by means of the key.
-37-
Anderson
2070-IZMAG
Operation
6.5.5. Parameter Mode
The Parameter Mode can be changed by means of the key
.
Mode 0 Meter unlocked
Mode 1 Parameter locked until code entry
Mode 2 Parameter always requires code entry
If the parameter switch is locked (to the left) parameter changes are blocked in
Mode 2
You might be prompted to first input an unlock code.
6.6.
Image level: Pulse output
This image level serves for the setting of the pulse output. The main image shows the
current device setting.
6.6.1. Pulse mode
The pulse mode can be changed by means of key
You might be prompted to first input an unlock code.
- 38 -
.
Mode1
2 independent channels (IMP1 and IMP2) with different values (pv1 and pv2)
Pulse output independent of the flow direction.
Maximum pulse length of tp1 and tp2 in ms
0 ms = pulse-to-pause ratio 1:1.
Maximum frequency: 1000 Hz.
IMP3 determines the direction. Positive flow direction: IMP3 is connected.
Mode 5
2 independent channels (IMP1 and IMP2) with different values (pv1 and pv2)
Pulse output dependent of the flow direction output 1 forward flow, output 2
reverse flow
Maximum pulse length of tp1 and tp2 in ms
0 ms = pulse-to-pause ratio 1:1.
Maximum frequency: 1000 Hz.
IMP3 determines the direction. Positive flow direction: IMP3 is connected.
Anderson
2070-IZMAG
Operation
Mode6
3-channel, shifted by 120°: IMP1, IMP2 and IMP3.
Pulse value: pv1.
Pulse-to-pause ratio: 1:1
Maximum frequency: 333 Hz
In the event of an error IMP2 is switched off.
Mode7
2-channel, shifted by 90°: IMP1 and IMP2. Pulse value pv1.
Pulse-to-pause ratio: 1:1.
Maximum frequency: 500 Hz.
In the event of an error IMP3 is connected.
6.6.2. PV1
The pulse value PV1 can be changed by the
key.
PV1 is valid for Mode1, Mode 5, Mode7 and Mode6.
You might be prompted to first input an unlock code.
6.6.3. TP1
Use the key
to change the pulse length of TP1 to ms.
TP1 is valid for Mode1 & 5 only. The value of 0 ms sets the pulse-to-pause ratio to 1:1.
You might be prompted to first input an unlock code.
6.6.4. PV2
The key
can be used to change the pulse value PV2 for the output IMP2.
PV2 is valid for Mode1 and mode 5.
You might be prompted to first input an unlock code.
-39-
Anderson
2070-IZMAG
Operation
6.6.5. TP2
By means of the key
the pulse length of TP2 in ms can be changed for output IMP2.
TP1 is valid for Mode1 & 5 only. The value of 0 ms is used to set the pulse-to-pause ratio to
1:1.
You might be prompted to first input an unlock code.
6.7.
Image level: Digital input
The settings for the digital input are made on this image level. The main image shows the
current device setting.
6.7.1. Function: Digital input
The function of the digital input can be selected by means of key
The input can be set to:
• No function
• Count interruption
• Zero setting
.
The key
only appears if the unlock code has been activated before.
You might be prompted to first input an unlock code.
6.7.2. IT1
The
key can be used to change IT1 to ms. IT1 determines how long the signal will
have to be available for the input to permit the selected function to become active.
You might be prompted to first input an unlock code.
- 40 -
Anderson
2070-IZMAG
Operation
6.8.
Image level: Current output
On this image level the settings for the current output are made.
The main image shows the current setting of the device.
-41-
Anderson
2070-IZMAG
Operation
6.8.1. Current output mode
By this key
you can change the mode for the current output.
You can choose among 3 different modes:
4 – 20 mA active
4 – 20 mA passive
0 – 20 mA active
Active / passive - see analog output.
You might be prompted to first input an unlock code.
6.8.2. Qmax
The key
can be activated for changing the Qmax value for the current output.
Qmax is the value for 20 mA.
You might be prompted to first input an unlock code.
6.8.3. TP3
By means of the key
you can change the time delay TP3.
The current output is attenuated by this time.
You might be prompted to first input an unlock code.
6.9.
Image level: Metering parameters
The settings for the measurement are made on this image level.
The main image partially shows the current device settings.
- 42 -
Anderson
2070-IZMAG
Operation
6.9.1. LFS
The key
can be used to change the low-flow suppression LFS in %. The low-flow
volume is calculated from the Qmax value.
You might be prompted to first input an unlock code.
6.9.2. MSPE
By means of the key
you can change the dimensionless factor MSPE.
You might be prompted to first input an unlock code.
6.9.3. BSPE
Use the key
for changing the dimensionless offset BSPE.
You might be prompted to first input an unlock code.
6.9.4. Average
The average value can be changed by means of the key
You might be prompted to first input an unlock code.
.
-43-
Anderson
2070-IZMAG
Operation
6.9.5. Offset
Press the key
for changing the Offset value.
The Offset is a calibration value of the sensor which is normally not changed!
You might be prompted to first input an unlock code.
6.9.6. SPAN
The SPAN value can be changed by the aid of the
key.
The SPAN value is a calibration value of the sensor which is normally not changed!
You might be prompted to first input an unlock code.
6.9.7. Pipe Detect (recognition of an empty meter tube)
The empty pipe detection can be switched on and off by means of the
You might be prompted to first input an unlock code.
6.9.8. Nominal width
The display shows the nominal width of the transmitter.
- 44 -
key.
Anderson
2070-IZMAG
Operation
6.10.
Image level: Special functions
Special functions can be carried out on this image level.
6.10.1. Zero adjust
The “ZERO adjust” measurement is activated if the
key is depressed for a period of
1.5 seconds. The top line of the display shows the current ZERO value. The course of the
bargraph shows the progress of the measurement. The measurement is finished when the
bargraph is completely filled. The new ZERO value is displayed below the bargraph and
taken over.
Important
information
Prerequisite:
The meter tube has to be filled up with the liquid to be measured.
No flow rate is allowed to be available, the liquid rests.
Unless the prerequisites are observed, a faulty ZERO value will be determined
and the IZMAG™ will not be able work correctly.
6.10.2. Factory setting
All parameters are reset to the factory setting. After the execution of the function, the image
navigator will change back to the image of item 7.9.
You might be prompted to first input an unlock code.
6.11.
Image level: Service level
Only service values are displayed and service functions are performed on this service level.
-45-
Anderson
2070-IZMAG
Operation
6.11.1. Error register: Metering
This image shows the error numbers of the measurement.
The error number is reset while the flow meter is set back to zero.
6.11.2. Error register: Operating system
This image shows the error numbers of the operating system.
6.11.3. Simulation of the current output
The simulation can be used to check the cable connection or to adjust an analog
instrument.
The first value 20 mA is set to 100 % by means of the key
. Another activation of the
key
will set 12 mA, 50 %. After that the key
is used for the setting of the value
of 4 mA to 0 %. The simulated current value is determined by the current mode, see item
7.7.1. If the setting is 0...20 mA, the simulated values are 20 mA, 10 mA, and 0 mA.
You might be prompted to first input an unlock code.
6.11.4. Simulation of the pulse outputs
This simulation can be used for checking a cable connection or a counting instrument or
even a connected controller. According to the output mode, the number of pulses to be
simulated is shown in display lines 6 and 7. The simulation is started by the key
and
a bargraph is displayed. The simulation is finished when the bargraph is completely filled.
Then the bargraph is erased.
You might be prompted to first input an unlock code.
- 46 -
Anderson
2070-IZMAG
Operation
6.11.5. Simulation of the flow rate
This function can simulate the complete metrological functionality of the IZMAG™
converter, i.e. the pulse outputs and the current output behave like in the normal operation.
This function is suitable for the “dry” commissioning of a system or of system sections.
The
key starts the function. The flow reads 0 l/h. Each additional activation of the
key increases the flow in steps of 10% of Qmax. The function stops running after the
maximum value is reached.
You might be prompted to first input an unlock code.
6.12.
Image level: Info
6.12.1. Info1
The Info1 image shows the software versions and the date of the recent software
download.
6.12.2. Info2
The Info2 image shows the hardware version and the board number of the main board.
-47-
7.
Parameterization
At the factory the IZMAG™ is provided with standard parameters (factory settings).
Only trained persons authorized by the user of the flow meter are allowed to
set and/or change parameters. The persons concerned have to be familiar
with the process sequence. They have to be able to recognize possible risks
and to take the necessary steps to eliminate dangers of accident.
Take into account that interventions into the parameters of the flow
meter carried out while the production is running could lead to
undefined reactions!
Important
information
It is possible to modify the set parameters via the keypad and the display unit in principle.
The following table shows the functions of the different switch positions:
Parameters
Factory settings
Minimum value
Maximum value
CS3Bus address
32
32
64
Profibus address
5
0
255
Pulse mode
Output mode1
Refer to:
Pulse mode
Depending on output mode,
dimension and Qmax
PV1
1.0
0.0
TP1
125 ms
0 ms
16000 ms
PV2
Depending on the nominal width
0.0
Depending on
dimension und Qmax
TP2
125 ms
0 ms
16000 ms
Digital input mode
No function
IT1
125 ms
0 ms
32000 ms
Current output mode
4 – 20 mA active
Refer to:
Current output mode
Qmax 100% for 20mA
Depending on the nominal width
1.0
999999.0
TP3
0.2 s
0.0 s
30.0 s
LFS = Low Flow Suppression
1.0 %
0.0 %
10.0 %
MSPE
1.0
-1000.0
+1000.0
BSPE
0.0
-1.0
+1.0
Average
8
1
128
Offset
See nameplate
-1.0
+1.0
SPAN
See nameplate
0.000001
1000.0
Pipe detect
Pipe detect
No pipe detect
Pipe detect
Anderson
2070-IZMAG
Troubleshooting
Table of the abbreviations used and their meaning:
Abbreviation
Function
IMP1
Pulse output 1
IMP2
Pulse output 2
IMP3
Pulse output 3
IN1
Digital input 1
PV1
Pulse value for IMP1
TP1
Pulse length for IMP1
PV2
Pulse value for IMP2
TP2
Pulse length for IMP2
IT1
Pulse length for IN1
Q max.
TP3
Dimension
LFS
100% of the flow value for the current output
Time constant for the current output
Unit of the volume
Low-flow suppression
MSPE
Calibration factor
BSPE
Calibration offset
Average
Filter of the flow signal (averaging)
Offset
Calibration value of the sensor (Do not change!)
SPAN
Calibration value of the sensor (Do not change!)
Pipe-Detect
Internal EMPTY pipe detection
Description of the parameter “dimension”
When selecting the volume units “US gallons” and “Litres” you should take into account,
that fixed flow ranges are valid for the “4...20mA” output depending on the nominal width!
List of the STANDARD parameters set for the unit “LIT”
Designation
Function
Standard
Changeable
dimension
Unit of volume
Litres
different units
lfs
Low-flow suppression
1.00 %
0...10%
average
Flow signal filter (averaging)
8
64
currmode
Analog output range 0/4 mA
4 – 20 mA
0 – 20 mA
pipe detect
Internal EMPTY pipe detection
pipe detect
no pipe detect
Qmax
100% flow value for 20 mA
Dependent on the nominal width
pv1
Value of the volume pulses per litre
1
0,001...99999
tp1
Pulse length of the digital output
125 ms
0 … 9999 ms
tp3
Time constant for the 4...20 mA output
1.0 sec
99
m spe
Calibration factor (-10%...+ 10%)
1.0000
0.900...1.100
b spe
Calibration offset
0.0000
± 0.2000
- 49 -
7.1.
Adjustments
The IZMAG™ normally needs no adjustment.
Usually, the zero point adjustment (“ZERO adjust”) is carried out during the first
commissioning only.
If, however, some deviations have to be compensated which were determined e.g. upon a
comparison with a calibration vessel or a balance it is possible to make an adjustment via
the factor “m spe”.
However, before you will start carrying out an adjustment you should have clarified the
following questions in any rate:
•
Are you sure that the reference standard (reference meter, balance, or calibrated
vessel) does really deliver an exactly comparative value?
•
Is the limitation of quantities always equal from measurement to measurement?
Take into account that differently emptying pipelines, a missing break-off edge for the
liquid or temporary air occlusions will lead to faulty results during the measurement!
•
Have the production paths been unlocked? Or are there any manual valves or sampling
valves or any cross links possibly open?
•
Is the liquid really conveyed during the measurement without any air or gas?
•
Are the flow limits kept?
•
Is the conductivity of the product within the required tolerance?
An adjustment is only reasonable if similar (reproducible) deviations have been ascertained
during the comparative measurements.
7.1.1. Adjustment by calibration factor "m spe"
The adjustment by the calibration factor “m spe” can be set via the operating unit.
The standard value is set to 1.
The calibration factor is calculated by means of the following formula:
Vref

Target volume (e.g. calibration vessel, balance, or the like)
Vdis

IZMAG™ display
Anderson
2070-IZMAG
Troubleshooting
Example:
Deviation ∆F of +0.54% determined during a comparative measurement
Calibration vessel:
Vref
= 5000 L
Display:
Vdis
= 5027 L
m spe =
5000
______
• 1.0 = 0.9946
5027
7.2.
Measuring accuracy:
± 0.2 % ± 1 mm/s under reference conditions
Reference conditions for the determination of the measuring accuracy according to
DIN EN 29104 and VDI/VDE 2641:
•
Temperature of the measured product: +28°C ± 2 K
•
Ambient temperature:
+22°C ± 2 K
•
Warm-up period:
30 minutes
Installation:
•
Inlet pipe section
> 10 x DN
•
Outlet pipe section
> 5 x DN
•
Transmitter and converter are earthed/grounded.
•
The transmitter is positioned in the centre of the pipeline.
8.
Troubleshooting
8.1.
Error diagnosis
The IZMAG™ is equipped with an integrated self-monitoring function.
Malfunctions are recognized and automatically removed, if necessary.
8.1.1. Error diagnosis via the display
Displayed messages can support the troubleshooting in case of malfunction or faulty
measurement. A distinction is made between error messages for the measurement or for
the operating system. The messages are displayed on the service level:
- 51 -
Error message for the measurement
Error message for the operating system
Usually, all displayed messages are erased when the volume is reset to zero. In case of a
permanent malfunction, however, the message will be reactivated over and over again.
8.1.2. Error list
Error
No.:
901
903
Diagnosis
Measurement is continued after an interruption due to:
- Voltage drop (POWER-FAIL)
- Parameter change
- Activation of the digital input “IN1“
Signal overflow within the electronic unit due to:
- Too high flow rate ( > 12 m/s )
- Electrical influences that can occur in case of an
empty meter tube
- Defective electronics
Remedial actions
None
a. Check the flow rate!
b. If the meter tube is empty, a check will be possible
with short-circuited electrodes only.
905
Error found on the occasion of the internal examination
of the quantity registers
922
924
928
932
963
Reference voltage is missing
a. The measuring result can be falsified due to the
interference received.
- Reset the message by resetting the individual
quantity to zero!
b. Check the whole installation for possible EMC
interference sources; frequency converters have to
be laid into separate cable channels!
- Ensure good shieldings and earthings/groundings for
all devices!
- Use the integral device version for critical
installations!
Replace the converter!
Reference voltage is outside the tolerance
Replace the converter!
Coil current is outside the tolerance
Replace the converter!
No coil current is available
Parameters of the transmitter cannot be saved.
Check the connection of the transmitter!
- Adapt the flow rate!
- Reduce the pulse value “pv1“!
- Adapt the flow rate!
- Reduce the pulse value “pv2“!
Replace the converter!
The calibration parameters of the electronics are faulty.
Replace the converter!
Free parameters are faulty.
Parameters of the transmitter are defective:
Checksum error.
Base parameters for the measurement are faulty:
Checksum error.
Meter parameters are faulty:
Checksum error.
Pulse value “pv1” set for the counting output IMP1 is too
high (>1000 Hz).
Pulse value “pv2“”set for the counting output IMP2 is too
high (>1000 Hz).
One of the calibration factors is set to zero.
The “ZERO adjust” measurement has not been
accepted.
Replace the converter!
964
3031
3034
3035
3036
3037
3052
3063
3064
3070
3083
Pulse output of the output channel IMP1 is exceeded.
Pulse output of the output channel IMP2 is exceeded.
Replace the converter!
Replace the converter!
Replace the converter!
Reduce the pulse value “pv1”!
Reduce the pulse value “pv2”!
Input the respective factor (e.g. SPAN)!
During the adjustment the flow rate was not “zero”.
Anderson
2070-IZMAG
Troubleshooting
8.2.
Typical effects or error sources
Disturbances or malfunctions can normally be recognized by the aid of the display unit only.
8.2.1. Flow without flow rate indication:
(a) Is the conductivity higher than 5 µS/cm?
(b) Has the internal EMPTY pipe detection to be switched off?
Check whether the display shows “0 gal/min” while the flow is running!
If “adsum 0” is displayed, the internal EMPTY pipe detection is active! This is the case,
when:
• The conductivity of the liquid is below 50 µS/cm.
• The type of transmitter connected is smaller than DN 15.
• A heavily pulsating flow is present.
To make sure that the electronic part is working correctly, use the existing simulating
function (hardware or software) for your further diagnosis of the digital or analog output!
8.2.2. No pulse transmission despite displayed flow
(a) Check the electric circuit (the IZMAG™ outputs have to be supplied by an auxiliary
voltage of 24 V DC)!
(b)
(c)
Is the polarity of the pulse counter correctly connected?
Check the parameters:
- Is the pulse value too low? (Parameter setting)
Use the simulating function for your further diagnosis (hardware or software)!
8.2.3. No analog signal available
If no analog signal or a faulty analog signal is measured, the following checks are
recommended to be carried out:
a.
First the connected measuring system (digital display, PLC or the like) has to be
disconnected from the IZMAG™. The analog output signal has to be checked by the
simulating function by the aid of an ammeter:
- If the analog output is ZERO at a 50% simulation, the electronic part is defective, i.e.
it will be necessary to replace the complete converter.
- If the analog output remains constant at 20 mA, the internal “current mode”
parameter could be wrong. Verification is possible by means of the operating unit.
- 53 -
b.
c.
If the differences only occur after the disconnection of the external evaluating device, it
should be checked:
-
If the burden of the whole current loop is higher than 500 Ω? (Observe the
technical data sheets of the connected devices!)
-
If the input of the external evaluating device is erroneously designed as an
“active” analog output?
Faults can especially occur upon a connection to a PLC due to the fact that it
might both have an “active” and a “passive” configuration.
If nonlinearities occur over the whole range from 0 - 100%, it should be checked:
-
Whether the burden of the whole current loop is higher than 500 Ω?
8.2.4. Deviations of measured values
a)
Is there a time-related connection between the occurrence of the problem and some
modifications to a system in the vicinity of the measuring device?
b)
Does the deviation show more or less similar values or a constant shift or does it
heavily scatter into the positive or negative direction?
c)
Has something been repaired or replaced?
d)
Does the deviation always occur at a certain point of time (e.g. on Mondays at the start
of production, on the early shift, or the like) or at certain process steps?
e)
If a display unit is connected, the measuring signals can be checked by means of the
service data while the flow is static.
-
Change the display to the presentation of the measured values “adksum” which
may be fluctuating between -300 ... +300 units at a maximum.
-
If you carry out several zero point measurements (“ZERO adjust”):
The displayed value is not allowed to change by more than 10 units among the
repeated measurements.
Unless stability exists, the earthing/grounding of the transmitter will have to be
checked.
The same verification has to be carried out with a full meter tube while the transmitter is
removed as a whole. In that status any influences by electrical disturbances or a
leaking pipe system can be excluded.
f)
In case of moisture or other faults in the transmitter or converter it will be necessary to
replace the measuring instrument with a new one.
g) Check the pipe path for by-pass lines or air inclusions (faulty seals).
Anderson
2070-IZMAG
Troubleshooting
h) Check the reference measuring methods or the test procedure (reference meter such
as a balance):
•
•
Take into account the temperature compensation of the volume.
If different products are compared with the value of the balance, the conversion
will have to be carried out by means of the density.
Or the same volume differences always occur e.g. at different quantities!
If so, possible reasons could be:
• A start and stop of the measurement while the meter tube is empty.
• An undefined limitation of quantity due to the absence of a break-off edge.
• An undefined dropping-off behaviour due to the absence of an appropriate
draining sieve.
i)
8.3.
Low conductivities or pulsating flow upon the use of the internal EMPTY pipe
detection.
Error reset
Error messages can be reset:
(a)
(b)
By a zero reset of the quantity counter
Automatically after a maximum period of 30 seconds, unless any further fault did
occur.
8.3.1. Visual check
The transmitter can be optically checked while being disassembled:
Reason
Action
Humidity in the connection housing
Dry the housing and perform an insulation
test subsequently!
Damaged PFA liner
Replace the transmitter; check the seal!
Table: Visual check
- 55 -
9.
Maintenance
9.1.
Safety instructions for maintenance work
Maintenance and repair work must only be carried out by skilled and accordingly
trained personnel entrusted with the required authorization from the user.
The persons concerned have to be familiar with the process sequence and be able to
recognize possible dangers and to take all necessary steps to remove imminent risks
of accidents.
First ensure your personal safety before you will start
carrying out any service and maintenance work!
Caution
• Appropriate measures have to be taken to guarantee a safe stability (approved ladders,
lifting platforms, safety harnesses, etc.).
• Applicable tools and personal protective measures are necessary.
• Before you start working at electrical or rotating equipment, make absolutely sure that
the equipment concerned is disconnected from the power supply network! An
unintended restart has to be avoided by suitable safety precautions (e.g. information
signs or padlocks).
• Fittings and instruments and their contents can be hot! First permit them to cool down
before you will start working at such parts!
• If fittings and instruments have to be removed from the pipe system, the whole pipe
system has to be completely emptied, depressurized, and protected by some
appropriate shut-off fittings.
• Rinse the pipe system with clear water before the disassembly of fittings or instruments
in order to remove possible residuals of chemicals!
9.2.
Routine maintenance
On normal operating conditions the flow meter type IZMAG™ does not require any special
maintenance work.
Nevertheless, we wish to give you some recommendations for maintenance steps:
Cleaning
Deposits in the meter tube or at the electrodes will cause measuring errors or malfunctions.
Thus, ensure a regular and careful cleaning of both the pipelines and the flow meter!
See to it during the external cleaning that e.g. no high-pressure steam-jets are directed to
the housing parts!
In case of flow meters with integrated display the external cleaning temperature must not
exceed 50 °C.
The pane of the operating unit should only be cleaned by means of clear water and a soft
cloth.
The IZMAG™ transmitter is suitable for CIP.
Regarding the cleaning, disinfecting, and flushing agents and procedures we refer to the
manufacturers and the guidelines of the food processing industry.
Seals
That connection seals need periodic replacement.
Accuracy Test
Accuracy tests of the flow meter should be carried out by your in-house quality assurance.
A regular calibration by the Service Engineers of Andersonincreases the reliability of the
measuring instrument.
9.2.1. Preventive maintenance steps
A regular and careful maintenance of the measuring spot (flow meter in its fitting situation)
is indispensable in order:
•
•
•
To avert any danger for persons and the environment
Not to endanger the product quality
Not to reduce the service life of the system and its components
The preventive maintenance steps for the flow meter type IZMAG™ refer to the seals of
the pipe connections.
The recommended maintenance intervals result from the experience in other systems.
However, the actual required maintenance intervals can considerably different from that
experience for the following reasons:
•
•
•
•
•
Daily running time and number of the annual production days
Aggressiveness of the media
Frequency of cleaning phases, especially with hot water and caustic solution as well as
disinfectants
Duration and temperature of the cleaning phases
Possible beginning to dry of product residuals
Anderson recommends checking the measuring spot continuously, i.e.:
The operators of the system should currently pay attention to:
• occurring leaks
• unusual measuring results
Regular maintenance:
The following are suggestions for determining a maintenance schedule:
9.3.
1.
A replacement of all seals and wearing parts in regular intervals, e.g. every year.
Exceptions have to be allowed as a matter of course.
2.
Replacement of heavier stressed seals and wearing parts in short intervals (e.g. once a
year) and of less stressed parts in larger intervals (e.g. every 2 years). It is important
that the serviced components are marked accordingly.
3.
Exchange of the seals and wearing parts when required (e.g. when leaks occur). On
that occasion it is reasonable to replace the wearing parts in the whole adjoining area,
especially of the strongly stressed parts. It is indispensable to mark the serviced
components accordingly.
4.
Accuracy tests of the measuring instruments of the system in regular intervals under
the guidance of in-house quality assurance. Otherwise, the meter should be regularly
calibrated at the Anderson Instrument.
Repairs
9.3.1. Sending-in the flow meter to the manufacturer
If repairs have to be carried out at the factory, the following conditions will have to be
fulfilled in order to enable a quick and effective repair.
• The components/devices have to be packed in such a way that damage does not occur
in shipment.
• An RMA needs to be established with Anderson to identify the meter upon receipt and
determine the actions needed by Anderson instrument Company personnel.
• Without the above, delays will occur in the repair process.
9.3.2. Repair Work
Repairs should be restricted to skilled, trained personnel only. Service of the circuit boards
should not be attempted. Only complete circuit boards can be exchanged.
For each repair it is indispensable to strictly observe the general maintenance safety
instructions.
A replacement of components within the meter should not be done in the installed location
for the following reasons:
• Lock washers could drop out and be left on the electronic part when the fastening
screws are loosened.
• Metal particles could destroy the electronic part when the power supply is switched on.
• When the electronic housing is open there is the risk that moisture could drip down
onto the electronic boards. Moisture immediately destroys the electronic parts when the
power supply is switched on.
For all repairs of the flow meter it must be removed from the main power supply!
9.3.2.1.
Replacement of the sealing cover of the operating unit
The sealing cover will have to be replaced if the front pane is destroyed or scratched and if
the operating unit does not function.
9.3.2.2.
Replacement of the transmitter
Before replacing the transmitter, ensure that the pipe system is empty and unpressurized!
Flush the pipe system before the removal of the transmitter with clear cold water in order to
avoid any residues of chemicals or elevated temperatures.
The distribution voltage for the electronic part has to be switched off.
Carry out a zero point measurement (“ZERO adjust“) with the new transmitter in order to
optimize the accuracy of the flow meter!
9.4.
Special program functions
The program of the IZMAG offers some functions that could support a troubleshooting
process.
Moreover, it is possible to use those functions for the adjustment and verification of
connected devices.
9.4.1. Flow simulation
As an adjusting aid or for diagnosing purposes of connected devices the IZMAG offers the
possibility to simulate flow without any flowing product.
9.4.2. Simulation via the display unit
Select the “SIMULATION” function by means of the keypad.
During the simulation the analog output is set to 12.0 mA (4...20 mA setting) or 10.0 mA
(0...20mA setting). The volume pulses are produced for the flow of 50 % according to the
set pulse value.
9.5.
Spare parts to be kept available on stock
The spare parts list results from the experience in the different applications of the flow
meter. However, the actually required spare parts may be different from it for the following
reasons:
• Daily running time and number of the annual production days
• Aggressiveness of the media
• Frequency of the required cleaning phases, especially with hot water, caustic solution,
and disinfectants
• Duration and temperature of the cleaning phases
The following details are absolutely necessary and should never be missing in a spare parts
order:
• Quantity and unit
• Description
• Anderson part number
The appendix of this instruction manual includes some lists of wearing parts or spare parts.
10.
Decommissioning
10.1.
Temporary decommissioning
Should the device be put out of operation for a temporary period only, no special measures
have to be observed for its later recommissioning.
If the transmitter is removed out of the process line, the pipe system first has to be emptied
and depressurized.
Before removing the transmitter flush the pipe system with clear cold water in order to avoid
any residues of chemicals or elevated temperatures.
Attach the covering caps for the protection of the connections.
10.2.
Final decommissioning / disposal
If the whole device is defective beyond repair, you should take into account that system
components to be scraped will have to be disposed of according to the valid laws and
regulations for waste disposal.
PS Sampler
The DS2 Sampling System
Description
The pneumatic sampling system consists of a programmable logic controller
added to the DS1 electronic package, a set of air solenoids remote mounted in a
nonmetallic enclosure, and a PS-series pneumatic sampling head to be installed
in the process pipe. The pneumatic sampler operates similar to a diaphragm
pump to provide fixed volume samples from a flowing stream to an attached
sample bottle.
Theory Of Operation
The pneumatic sampler operates similar to a diaphragm pump. By alternating air
pressure across the diaphragm air ports, the diaphragm acts as the inlet and
outlet valves to control very precise and repeatable delivery of the sample
quantity.
In position A, air pressure is applied to air port-2. The product pressure allows
liquid to fill cavity B. Air pressure is applied to air port-1 causing the sample inlet
to close and seal. After a slight time delay, air pressure is applied to air port-3
and released from air port-2. The precise sample quantity is then forced or
“pumped” out into the sample bottle.
Specifications
Product line connections: 1-1/2”,2” sanitary clamp
Product contact materials: Sampler body: 304 SS, Diaphragm: 3-A approved
silicone
Insertion length: Face to Face 4”
Operational line pipe line pressure: 6-60 psi* (pressures below 6 psi require a vacuum source to
be connected to solenoid valve assembly exhaust)
Supply Air: Clean,dry, non lubricated 75 psi minimum
Air consumption:0.1 CFM @ 45 psi at sample rate of 60 samples/min.
Sample quantity : 1CC per cycle
Max. product temperature: 200 °F
Installation
Location in System
The PS-series sampler is placed at a point in the system after the milk chiller in a
vertical pipe where milk flow is in the upward direction.
Mounting in the pipe line
The PS-series sampler is designed to be used on the pressure side of a milk line.
Standard configuration for the sampler head with bottle is for a vertical pipeline
installation with the collection bottle hanging down. In dairy farm applications it is
necessary to refrigerate the sample bottle to maintain the integrity of the sample.
This is typically accomplished by routing the milk line through a small 1.0 cu.ft.
refrigerator to provide a chilled environment for the sample. It is recommended
that the refrigerator be equipped with a temperature recorder to ensure that the
temperature is maintained.
Solenoid enclosure
The solenoid enclosure needs to be located within 6 ft of the sampler head to
eliminate the possible dampening effect that can occur with longer air lines which
will adversely effect sampling.
Connection of vacuum source
A vacuum line from the milking system is connected to the solenoid valve
exhaust port to assist in consistent sampling during periods when line pressure
drops below 6 psi pressure. This vacuum line should be protected from the
possible failure of the sampler diaphragm which would introduce milk into the
vacuum system.
Electrical Wiring and Pneumatics
Wiring
Interconnecting wiring is needed between the controller/printer and the solenoid
enclosure. The voltage used to operate the solenoids is 110VAC and so
necessary precautions for connections and wiring should be used. Use wiring
diagram # ? for termination information.
Pneumatics
Included with the system is 20 ft. of 1⁄4” air line, cut the air line down to (3) equal
lengths and attach them to their respective solenoid ports on the SA70
enclosure. Next, shorten the tubing as needed and connect the air lines to their
respective ports on the sampler head paying close attention to their location
(refer to diagram?) Supply the SA70 solenoid enclosure with 125 psi @ .1 CFM
clean non-oiled air, use the supplied air pressure regulator to control the solenoid
supply pressure to 15 psi higher than the product line pressure. If the product line
pressure is not known, with the system flowing at maximum flow, lower the air
pressure using the regulator until a steady stream of milk flows out of the sampler
outlet pipe, then, note the pressure reading and increase the air pressure 15 psi
above this point.
Operation and Cleaning
Once connected to an operational controller/printer and given an air supply, the
PS sampler is ready for use. The system has been preconfigured to fill the 500ml
sample bottle for every 6500 gallons of milk that passes through the flow meter
and will automatically switch to cleaning mode once the controller/printer has
been given the input to do so from the wash panel. The basic protocol used for
proper operation is as follows:
1.) start of a new trailer should begin with the attachment of a new clean
bottle on the sampling system.
2.) At the completion of filling a transport trailer, the sampler bottle should be
removed and replaced with a new clean bottle to collect the sample for the
next truck. The product sample in the full bottle is representation of the
trailer load that has just been filled. In the event that a complete milking
has not filled the trailer, prior to the start of the cleaning cycle the sampler
bottle should be removed from the sampler and placed in a refrigerator
with a cover. A means of collecting wash water should be affixed to the
sampler discharge pipe during the cleaning cycle. A hose that directs the
solution back for recovery is recommended but other methods can be
used to recover the cleaning solution. Following the cleaning cycle, the
exterior surfaces of the bottle mount should be manually cleaned and
dried. Following the cleaning cycle the sample bottle containing the milk
from the prior milking should be reinstalled on the sampler to collect the
rest of the samples until the transport trailer is filled producing a single
bottle to represent each trailer load.
Assembly Of Sampler
When reassembling the sampler, follow the procedure below (refer to Drawing
97-9500-02).
1.
Check to see that locating pin (PSP-004) is in place.
2.
Insert diaphragm (PSD-51).
3.
Center top plate (PSP-002); locate hole in top plate over locating pin.
4.
Carefully assemble clamp fitting (GH13LAH-2) over top and bottom plate
and tighten clamp.
NOTES:
A.
Hand tighten clamp fitting only to the point sufficient to prevent leakage –
do not over tighten.
B.
When disassembling sampler, care should be taken to not damage any of
the sealing surfaces. Lay parts on a soft surface.
C.
Before assembling samplers, always check diaphragm PSD-51 for holes
or wear. (Stretch wear points over finger). Diaphragm should be changed
at first sign of wear or at least once a month. If sampler operates at
maximum pressure, a more frequent change may become necessary.
IZML FLOW METER REPLACEMENT PARTS
6
5
1
2
3
4
7
8
9
Item
Description
1
Conduit adapter
bushing
2
Cord Grip
3
Plug
4
Seal
5
6
7
8
9
Analog Board
Display Board
Power Supply Board
Main Board
Clamp
10
Gasket
(set of 2)
Adapter
(Upstream/Downstream)
11
10
11
Quantity Part Number
Additional Information
Optional Part
2
300-04B
Large Diameter Threaded Bushing
4
300-04C
Small Diameter Threaded Bushing
2
300-05B
Small Diameter Threaded Grip
2
300-05C
Large Diameter Threaded Grip
4
300-03C
Small Diameter Threaded Grip
2
300-03D
Large Diameter Threaded Plug
6
300-06A
For: 300-04B, and 300-04C
4
300-06B
For: 300-05B, 300-03C, and 300-05D
2
300-06C
For: 300-05C, and 300-03D
1
300-MBLC
1
300-MDSPCLVR
1
300-MB11AC AC Power Supply
1
300-MBL1N Provide SN with order.
2
GH13LAH-1.5 For: IZML032
2
GH13LAH-2 For: IZML050
1
300-33
Set for IZML032XXXX
1
300-51
Set for IZML050XXXX
2
300-32S
2
300-50S
Sampler Parts
1
Item
Description
Qty.
Part Number
1
2
3
4
5
6
Clamp
Connector
Top Plate
Diaphragm, Silicone
Locating Pin
Nalgene Bottle (16 oz.)
1
3
1
1
1
6
GH13LAH-2
PSP-005
PSP-002
PSD-51
PSP-004
PSB-64-PVC
2
3
4
5
6
TP-PL-180 PRINTER AND PARTS
TP-PL-180
PT-PL-180 Replacement Parts
1
2
Item
1
2
3
4
3
Description
Printer Cover
Paper roll
Spindle
Ink Ribbon
Part Number
TP-PL-180-COVER
TP-PL-180-TAPE
TP-PL-180-SPNDL
TP-PL-180 RIBN
4
FTT-710 PARTS
1
FTT-710P Replacement Parts
Item Description
Keypad and Front
1 Assembly
2 Fuse
Remote Print/Reset
3
Pushbutton Assembly
2
3
RESET/PRINT
Part Number
FTT-710P-FRTEND
FUS-BC-T5-R161
FTT-710-REM-BOX
Appendix F - Warranty and Return Statement
These products are sold by the Anderson Instrument Company (Anderson) under the
warranties set forth in the following paragraphs. Such warranties are extended only with
respect to a purchase of these products, as new merchandise, directly from Anderson or from
an Anderson distributor, representative or re-seller, and are extended only to the first buyer
thereof who purchases them other than for the purpose of resale.
Warranty
These products are warranted to be free from functional defects in materials and workmanship
at the time the products leave the Anderson factory and to conform at that time to the
specifications set forth in the relevant Anderson instruction manual or manuals, sheet or sheets,
for such products for a period of one year.
THERE ARE NO EXPRESSED OR IMPLIED WARRANTIES WHICH EXTEND BEYOND THE
WARRANTIES HEREIN AND ABOVE SET FORTH. ANDERSON MAKES NO WARRANTY OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WITH RESPECT TO THE
PRODUCTS.
Limitations
Anderson shall not be liable for any incidental damages, consequential damages, special
damages, or any other damages, costs or expenses with the exception of the cost or expense
of repair or replacement as described above.
Products must be installed and maintained in accordance with Anderson instructions. Users
are responsible for the suitability of the products to their application. There is no warranty
against damage resulting from corrosion, misapplication, improper specifications or other
operating conditions beyond our control. Claims against carriers for damage in transit must be
filed by the buyer.
This warranty is void if the purchaser uses non-factory approved replacement parts and
supplies, or if the purchaser attempts to repair the product themselves, or through a third party,
without Anderson authorization.
Returns
Anderson’s sole and exclusive obligation and buyer’s sole and exclusive remedy under the
above warranty is limited to repairing or replacing (at Anderson’s option), free of charge, the
products which are reported in writing to Anderson at its main office indicated below.
Anderson is to be advised of return requests during normal business hours, and such returns
are to include a statement of the observed deficiency. The buyer shall prepay shipping charges
for products returned, and Anderson, or its representative, shall pay for the return of the
products to the buyer.
Approved returns should be sent to:
ANDERSON INSTRUMENT COMPANY INC.
156 AURIESVILLE ROAD
FULTONVILLE, NY 12072 USA
ATTN: REPAIR DEPARTMENT
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