Omega | DPU91-BC Series | Owner Manual | Omega DPU91-BC Series Owner Manual

Omega DPU91-BC Series Owner Manual
TM
User’s Guide
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DPU91-BC SERIES
Batch Controller System
TM
omega.com info@omega.com
Servicing North America:
U.S.A.
Headquarters:
Omega Engineering, Inc.
Toll-Free: 1-800-826-6342 (USA & Canada only)
Customer Service: 1-800-622-2378 (USA & Canada only)
Engineering Service: 1-800-872-9436 (USA & Canada only)
Tel: (203) 359-1660
Fax: (203) 359-7700
e-mail: info@omega.com
For Other Locations Visit omega.com/worldwide
The information contained in this document is believed to be correct, but OMEGA accepts no liability for any errors it contains, and reserves
the right to alter specifications without notice.
Contents
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17
18.
19.
20.
21.
22.
Safety .........................................................................................................................1
Compatibility ..............................................................................................................1
Description .................................................................................................................1
Dimensions ................................................................................................................4
Ordering Information ..................................................................................................5
Modules .....................................................................................................................6
Terminal Identification ................................................................................................7
Wiring .........................................................................................................................8
Sensor Wiring ............................................................................................................9
Power Wiring............................................................................................................10
Batch Module Wiring ................................................................................................10
Open Collector Wiring ..............................................................................................11
Relay Module Wiring ................................................................................................12
Relay Mode Settings ................................................................................................12
Operation .................................................................................................................15
System Setup...........................................................................................................16
Menu System ...........................................................................................................17
Error Messages........................................................................................................24
Alarm Acknowledgement Messages ........................................................................24
Calibration ................................................................................................................25
Specifications ...........................................................................................................26
Ordering Information ................................................................................................28
1. Safety
• Follow instructions carefully to avoid personal injury.
• This unit is designed to be connected to equipment which can be hazardous to
persons and property if used incorrectly. Read and understand all associated
equipment manuals and safety warnings before using with this product.
• Remove power to unit before wiring input and output connections.
• Wiring connections to this product should only be performed by qualified personnel.
• Do not use unit if display is cracked or broken.
2. Compatibility
The Omega DPU91-BC Batch Controller is compatible with the Omega models FP-5300,
FP-8500, FP-5600, FP-5200, FPB, FP-2540, FP-3-1500 paddlewheel flow sensors,
models FMG-3000 and FMG-550 insertion magmeters, and models FP-5070 and FP-5060
in-line flow sensors.
3. Description
Your new DPU91-BC Batch Controller system includes the following items:
• Omega DPU91P Transmitter (Generation II or later)
• Omega Relay Module DPU90-R
• Omega Batch Module DPU90-BCM
Note: Verify DPU91 Transmitter Generation under the OPTIONS Menu.
OMEGA DPU91-BC Batch Controller System
3
4. Dimensions
DPU91-BC Batch Controller System
99.06 mm
(3.90 in.)
99.06 mm
(3.90 in.)
®
29.97 mm
(1.18 in.)
91.44 mm
(3.60 in.)
8.13 mm
(0.32 in.)
4
OMEGA DPU91-BC Batch Controller System
54.10 mm
(2.13 in.)
5. Installation
System Start-up: Step 1
Prepare the Controller installation location.
If the back of the Controller is difficult to access when installed, wire the
removable terminal plugs first, then attach to DPU91P Transmitter.
Next step: Wiring (Step 2).
Do not mount in direct sunlight.
Panel Mount Installation
Tools and Equipment Required
• Fine-tooth file
• ¼ DIN punch or jigsaw suitable for cutting panel
opening to within 1 mm (0.04 in) tolerance.
• ¼ DIN punches are available and recommended
for creating clean, precise openings quickly and
easily in most instrument panels.
• If a punch is not available, a jigsaw or other
cutting tool can be used. An adhesive template
is provided to help guide the cutting process.
De-burr and smooth the opening with a file.
Recommended clearance on all sides between
instruments is 25 mm (1 in).
1. Place gasket on instrument, and install
through ¼ DIN size opening.
2. Slide mounting bracket over back of
instrument until bracket snaps into latches
on sides of instrument.
panel
gasket on front
side of panel
terminal
blocks
r
DC Powe
ge
Loop Volta
Quick-clip
mounting
bracket
Panel Cutout
Panel Cutout
92 x 92 mm
(+ 0.8, - 0 mm)
92 x 92 mm
(+ 0.8, - 0 mm)
3.6 x 3.6 in.
(+0.031, -0 in.)
3.6 x 3.6 in.
(+0.031, -0 in.)
minimum
clearance
25 mm
(1 in.)
To remove:
1. Secure instrument temporarily with tape
from front or grip from rear of instrument.
DO NOT RELEASE.
2. Press bracket clips outward and remove.
Panel Cutout
Panel Cutout
92 x 92 mm
(+ 0.8, - 0 mm)
92 x 92 mm
(+ 0.8, - 0 mm)
3.6 x 3.6 in.
(+0.031, -0 in.)
3.6 x 3.6 in.
(+0.031, -0 in.)
Field Mount Installation
The DPU91-BC unit can be installed in the optional Wall Mount Accessory DPU90-WM,
for field mount installation.
CAUTION:
Avoid Electrostatic Discharge (ESD)
• Minimize handling of plug-in modules to reduce the possibility of damage due to ESD.
• Handle modules by the edges. Never touch any exposed circuitry or contacts.
• Wear an anti-static wristband or stand on an anti-static mat, or keep one hand
touching a properly grounded pipe or other properly grounded piece of metal when
handling modules.
OMEGA DPU91-BC Batch Controller System
5
6. Modules
Batch Module
Convert a DPU91P Transmitter
(Generation II or later) to a DPU91-BC
Batch Controller System by plugging in
DPU90-BCM Batch Module.
Optional Module Wiring:
• Wire an external button or keypad
(customer supplied) to stop, start or
resume a batch remotely.
• Wire an external input that can inhibit
a batch from starting.
Relay Module
In addition to the Open Collector output
in the DPU91P base unit, the DPU91-BC
includes a Relay Module (DPU90-R) which
adds two programmable dry-contact relays.
The Open Collector output in the base unit
uses the Relay 1 setting in the menus.
The Relay Module is assigned to
relays 2 and 3 in the menus.
Dry-contact relays are electromechanical
switches with a moving contact armature.
They are suitable for many general-purpose
applications, AC or DC, including AC loads
up to 250 V.
Install RC Filter Kits, FP90RC, on relays
used to switch motor or inductive loads.
• The Indicator LEDs on the front panel of
the DPU91-BC show the status of
Open Collector (relay 1) and relays 2 and 3.
• Hysteresis and time delay are adjustable
for each relay.
CAUTION:
Switching active loads (usually inductive)
can cause contact arcing sufficient to
damage the relays. The RC Filter Kit or
“snubber” (part number FP90RC) is
available as an accessory to reduce or
eliminate these damaging effects.
Recommended for inductive loads
greater than 50 VAC (remote relays,
solenoids, pumps, etc.).
6
OMEGA DPU91-BC Batch Controller System
•
•
•
•
Two SPDT dry-contact relay inputs
User programmable
250 V, 5 A maximum resistive loading (AC)
Can switch line voltage
(typically 120 to 240 VAC)
• Can switch DC voltage (< 30 VDC @ 5A)
• Larger voltage and current ratings than
Open Collector outputs
(30 VDC, 50 mA maximum)
To remove modules:
1)
2)
3)
4)
Remove power from the DPU91P
Remove the Relay module
Loosen bottom screw of Batch module
Carefully grip and squeeze the tabs
at the top of the module to release
5) Pull module away from the unit
6) Do not bend the connecting pins
Power
7. Terminal Identification
Terminals 1-2: DC Power
• Required by the instrument
• Provides power to sensors, relays and the LCD backlight
Terminals 3-4: 4 to 20 mA
• Passive 4 to 20 mA output
Terminals 5-6: Open Collector
• Software selectable for Normally Open or Normally Closed
Terminals 7-10: Digital (S3L)/Frequency Input
• Sensor wiring
• DPU90-COMM wiring
1
PWR +
2
PWR –
3
Loop +
4
Loop –
6
5
OC– OC+
Digital (S3L) /
Frequency
SHLD
GND
DATA
V+
The DPU91-BC requires regulated
10.8 to 35.2 VDC (24 VDC nominal)
from an external power supply.
Maximum current draw is 300 mA.
7 8 9 10
wer
DC Po
ltage
Loop Vo
Connect sensor wire
plug here as shown
on page 7.
Connect power and
open collector wire plug here
as shown on pages 8 and 9.
OMEGA DPU91-BC Batch Controller System
7
8. Wiring
System Start-up: Step 2
Wire the transmitter connections with the power off. Keep any 4 to 20 mA and
relay-actuated output devices that are connected to it offline at this time.
Wire the sensor (pg. 7), power (pg. 8) and Open Collector and relay(s) (pg. 9).
Next step: System Setup (Step 3).
Wiring Tips:
• Do not route the sensor or DC power cables in conduit containing
AC power wiring. Electrical noise may interfere with sensor signal.
• Routing the sensor cable in grounded metal conduit can help
prevent electrical noise and mechanical damage.
• Seal the cable entry points to prevent moisture damage.
• Only one wire should be inserted into a terminal.
• Splice double wires outside the terminal or use appropriate wire
ferrule, not to exceed 2 mm (0.08 in) diameter.
Tools Required
• Phillips
screwdriver
• Flat-head
screwdriver
• Wire strippers
CAUTION:
DO NOT bundle Relay Module
wiring with other wiring.
Doing so may cause injury and/or damage to
DPU91P Transmitter, Relay Module, and Batch Module.
All wiring connections to the DPU91-BC are made via removable terminal plugs.
In general:
• Terminals accept 12 to 24 AWG wire.
• Strip 7 mm (0.28 in.) of insulation from wire tips
and tin bare ends to eliminate fraying.
• Insert wire tip or ferrule completely into the terminal
and secure with the screw.
• Do not allow any AC leads that may be connected
to the internal relays to come in contact with low voltage wiring.
CAUTION:
Avoid Electrostatic Discharge (ESD)
• Minimize handling of plug-in modules to reduce the
possibility of damage due to ESD.
• Handle modules by the edges. Never touch any
exposed circuitry or contacts.
• Wear an anti-static wristband or stand on an antistatic mat, or keep one hand touching a properly
grounded pipe or other properly grounded piece of
metal when handling modules.
8
OMEGA DPU91-BC Batch Controller System
9. Sensor Wiring
SHLD
GND
DATA
V+
FP-5300, FP-5600,
FP-8500, FP-5200,
FP-5060, FP-5070
No connection
Black
Red
Shield
SHLD
GND
DATA
V+
FMG-3000*
Frequency
4
3
Black
Red
White
Shield
S3 L
4
FMG-3000
Technical Notes:
• When the blue jumper
illustrated is placed over both
pins, the FMG-3000
(Blind Magmeter) outputs an
open collector frequency signal.
When the jumper is removed
(or placed over one pin for
storage) the FMG-3000 outputs
a Digital (S3L) signal.
3
Connect the silver (shield)
wire to earth ground in case
of EMI noise interference.
FMG-550
*FMG-3000 Blind Magmeter
Output Selection Jumpers
S3L
Frequency
SHLD
GND
DATA
V+
SHLD
GND
DATA
V+
Black
Black
Brown
Brown
White
White
Blue
Blue
Shield
Shield
X No
connection
FMG-3000 & FMG-550
Technical Notes:
• Either Frequency or Digital
(S3L) may be used.
• The frequency output will be
displayed as positive flow
regardless of the flow direction.
• Omega recommends
configuring the FMG-3000
with the Digital (S3L) output
because it is more accurate.
• Input sensor type is selected by
choosing between “SENSOR
FREQ” and "SENSOR S3L" in
the INPUT menu.
• 5 VDC power is provided to
the FMG-3000 Magmeter by
the DPU91-BC. No additional
power is required.
OMEGA DPU91-BC Batch Controller System
9
10. Power Wiring
CAUTION!
DO NOT connect your DPU91 to AC power.
The DPU91 MUST be powered by 10.8-35.2 VDC ONLY.
Stand-alone application
DPU91P
Terminals
Red
Black
PWR +
PWR –
Loop +
Loop –
+
–
Power
Supply
12 to 32 VDC
±10%
Connection to a 4 to 20 mA device
DPU91P
Terminals
Red
PWR +
PWR –
Loop +
Loop –
+
–
Power
Supply
12 to 32 VDC
±10%
Blue
+
–
Black
4 to 20 mA
Device
11. Batch Module Wiring
Connect an external button or keypad (not supplied) to remotely
control the DPU91-BC by wiring the Batch Module as shown.
Start
Stop
Start
Inhibit*
Stop/Inhibit
Resume
Resume
Common
DPU90-BCM
Batch Module
Common
*Wire an external input as override
for preventing batch from starting.
10
OMEGA DPU91-BC Batch Controller System
12. Open Collector Wiring
•
•
•
•
•
Longer life than a mechanical relay
No moving parts
Faster ON/OFF switching capabilities than mechanical relays
Can switch DC voltage only (< 30 VDC, < 50 mA)
Not recommended for use with inductive loads
Fail-Safe Behavior
No matter the setting, the Open Collector output turns off if the DPU91 loses power.
This must be taken into account when evaluating system failure consequences.
If the system layout requires a “closed” or “on” condition for the output in case of
power loss, a mechanical dry-contact relay (NC contacts) must be used instead of
the Open Collector (R1) output.
The DPU91 Open Collector (R1) output provides high-speed switching capability.
Signal frequencies can reach 400 pulses per minute.
The DPU91 Open Collector (R1) output connection is dependent upon the type of
circuit being controlled by the output.
Most indicating instruments or control system inputs require a signal voltage of 0 to 5 V
(TTL or CMOS logic levels) or 0 to 24 V. Therefore, the DPU91 Open Collector output
circuits must be equipped with a pull-up or pull-down resistor (not supplied), and a
quality regulated 5 to 24 V (depending on the application) power supply (not supplied)
is recommended to function properly.
NPN Style Wiring
PNP Style Wiring
Pull-Up Resistor
..ȍ:
9WR9
PWR +
PWR –
Loop +
Loop –
OC –
Gnd
3:5
3:5±
Loop +
/RRS±
Power
Supply
Input
PLC
2&±
Gnd
OC +
Input
OC +
PLC
Gnd
9WR9
Power
Supply
Gnd
Pull-Down Resistor
..ȍ:
If an external device needs logic 0
(logic LOW) input when the Open
Collector is de-energized in an NPN
configuration, set R1 NORMAL to
CLOSED in the RELAY menu.
Alarm
PWR +
PWR –
Loop +
Loop –
OC –
V+
Power
Supply
OC +
with NORMAL
set to OPEN.
Gnd
OMEGA DPU91-BC Batch Controller System
11
The alarm is OFF during normal
operation, and will go ON when
relay energizes according to
DPU91 Relay settings.
RELAY 2
The valve is OFF during normal
operation, and will go ON when
relay energizes according to
DPU91 Relay settings.
RELAY 3
13. Relay Module Wiring
NO
ALARM!
NC
C
AC or DC
power
NO
NC
C
AC or DC
power
Valve
• NO = normally open (closes when energized)
• NC = normally closed (opens when energized)
14. Relay Mode Settings
Flow
*Simple Mode
(See Input Menu - Page 17)
BATCH – Batch*:
0%
100%
Activates relay while batch is running
Relay energized
Time
Relay de-energized
% Batch Percentage
VOL PULS – Volumetric Pulse*:
Generates a pulse each time a user
defined volume is reached.
Relay energized
Relay de-energized
MISSING – Missing Signal*:
Activates relay when no flow is detected
in X seconds after a batch cycle starts.
(X is user defined) Default = 5 seconds.
0%
X
Flow Input
Relay energized
Relay de-energized
% Batch Percentage
12
OMEGA DPU91-BC Batch Controller System
Time
Relay Settings - continued
Advanced Mode
(See Input Menu - Page 17)
HI FLOW – High Flow:
In HI FLOW Mode, Relay is energized at
Set Flow value and will be de-energized
at Set Flow value minus Hysteresis value.
If STOP BATCH is set to YES, the
hysteresis is ignored. A batch stopped for
a high flow condition will not automatically
resume when the flow decreases below
the hysteresis level. User interaction is
required to resume the batch.
EOB PULS – End of Batch Pulse:
Process
High
Setpoint
Hysteresis
Time
Relay energized
Relay de-energized
0%
100%
Generates a pulse at the end of a batch
which can be used for external counter or
to start a second batch controller.
Relay energized
Time
Relay de-energized
% Batch Percentage
OVERRUN – Overrun:
Activates relay when Overrun reaches
the specified volume (see Set Overrun
Volume, pg. 19).
Note: The Overrun Alarm Volume must be
greater than the Manual Compensation
Volume. If the Overrun Alarm Volume
is less than or equal to the Manual
Compensation Volume, the Overrun
Alarm will activate on every batch.
0%
100% Overrun
Relay energized
Time
Relay de-energized
% Batch Percentage
SRC VOL – Source Volume:
Activates relay when Source Volume falls
to specified volume (only available when
"Source Volume" is ON).
Relay energized
Relay de-energized
OMEGA DPU91-BC Batch Controller System
13
Relay Settings - continued
Advanced Mode
(See Input Menu - Page 17)
TOT VOL – Totalizer Volume:
When resettable totalizer exceeds
specified volume, relay activates and
latches.
Requires Totalizer Volume Reset to
deactivate relay (see Reset Total, pg. 16).
This mode is useful to trigger a reminder
when a process is due, as for a
backwash cycle or filter change.
Relay energized
Relay de-energized
TWO STG – Two Stage:
This function is designed to prevent
overfilling or to minimize water hammer.
Both the mainline relay and the bypass
relay are energized when the batch
starts. The mainline relay then deenergizes at a programmed batch
percentage, allowing flow to continue
through a smaller bypass line to reduce
the fill rate (see diagram). After the batch
is dispensed, the bypass relay
de-energizes, completing the sequence.
NOTE: If Relay 1 is selected for
Two-Stage operation, relay 2 defaults to
Bypass. If Relay 2 is selected, relay 3
defaults to bypass. If Relay 3 is selected,
relay 2 defaults to bypass.
MULTIPLE – Multiple Mode:
Activates relay when any one of the four
enabled conditions are met. User can
select from Missing Signal, Overrun, High
Flow or Error.
ERROR – Error:
If using S3L flow sensor, activates relay
when no sensor is detected.
14
OMEGA DPU91-BC Batch Controller System
0%
90% 100%
Relay 1 Main
Relay 2 Bypass
Time
Relay energized
Relay de-energized
% Batch Percentage
Bypass valve
Overflow
Main line
flow
Valve
tank
to tank
15. Operation
Open Collector (R1)
Indicator LED
Mechanical Relay (R2)
Indicator LED
Backlight Sensor
(do not block)
Mechanical Relay (R3)
Indicator LED
Warning LED
Bar Graph
Units of Measure
(GPM, pH, sec, %, etc.)
Value
Label
Menu Indication
®
Menu Navigation Keys
ENTER
UP, DOWN keys
Scroll through Menu options or adjust values during editing.
Press both together to exit a menu or escape without saving.
RIGHT key
Select item or character to edit.
ENTER
ENTER key
Access menus
Save changes.
DOWN and RIGHT keys
Press both together to enable manual batch
or top off a previous batch. The valve will
open as long as the keys remained pressed.
OMEGA DPU91-BC Batch Controller System
15
16. System Setup
System Setup: Menu Navigation
3s
This basic operating procedure repeats
throughout the DPU91 program:
1. Press ENTER for 3 seconds to enter
EDIT menu.
2. Press ► to move to a specific menu item.
3. Press ENTER key to select the item for
editing.
4. Press ▲ or ▼ to edit the value/selection.
5. Press ENTER to store the new value/
selection.
6. Press ▲+▼ to select another menu item.
Repeat steps 3-5 as required.
7. Press ▲+▼ again to return to normal
operation.
®
ENTER
Edit
or
or
(Password may
be required)
ENTER
Input Edit
NOTE: The DPU91 displays
the BATCH instrument type
ONLY if the Remote Batch
Module is installed.
Input Edit Choices
The menu is constructed in a loop,
so you can move forward and
backward to select an item. After
any item is edited, the display will
return to the selected item.
(Password may
be required)
ENTER
or
Saves Changes
Or
+
2x
Or
Select another
Menu Item
Return to
View Mode
NOTE: Example only. Your display may be different.
16
OMEGA DPU91-BC Batch Controller System
17. Menu System
BATCH Setup Checklist
1. Set the Units of Measure in Input Menu.
2. Set Flow Timebase in Input Menu.
3. Set Sensor Type (Freq or S3L) in Input
Menu.
4. Set Batch Size in Input Menu.
5. Set K-Factor (pulses per Unit Volume)
from Flow Sensor manual in CAL Menu.
6. Set up relay functions and other settings
for your own application.
This is the normal display
(when batch is running).
VIEW Mode Menu - Batch Running
Stop Running Batch Press ENTER to stop batch that is running.
Note: ENTER button stops batch in any screen on VIEW Mode.
Time Left displays estimated time remaining (in minutes) until batch
is completed.
Percent Complete displays percent remaining or percent completed of
running batch. Count direction based on COUNT UP/DOWN setting in
INPUT menu.
Flow Rate displays current flow rate of running batch.
Output Current displays the output loop current in milliamperes (mA).
Source Volume displays the calculated remaining source volume.
Shown if SOURCE VOLUME is ON.
Relay Status displays relay status for Relays 1, 2 and 3. One of three
states (OFF, ON, PLS) for each relay will be displayed.
OMEGA DPU91-BC Batch Controller System
17
VIEW Mode Menu - Batch Stopped
Start Batch Press Up or Down arrows to select the desired batch number.
Press ENTER to start selected batch. Selected batch alternately displays on the
bottom line of the display.
(Confirmation screen or password screen are user-selectable in INPUT menu.)
Available batches determined by the number of stored batches whose size is not zero.
Resume/Cancel Batch Displays when a batch is stopped without completing. Press
the ► key to select either RESUME or CANCEL and then press ENTER to either
resume the batch or cancel it. A confirmation or password screen for resuming a
batch is user selectable. This screen will not display if the batch reaches completion.
Override Batch occurs when the user temporarily changes a batch size in View
Mode. The change is temporary and is only active until a batch is run. After any
batch is run, an overridden batch reverts back to its stored size. Only one batch can
be overridden at a time. If the user overrides a second batch, the first overridden
batch will revert to its stored size. The batch name will display OVERRIDE while it
is overridden. A batch is overridden by pressing ► to edit the batch size.
Manual Batch is used for “topping off” a batch. The Batch Controller will open the
valve as long as the user simultaneously holds down the ▼ and ► keys.
Note: A manual batch will cancel a batch in the RESUME/CANCEL state.
Source Volume shows the calculated remaining source volume. Displays if
SOURCE VOLUME is ON. Reset source volume with ► key.
Note: If PWD REQUIRED is set to YES, you may be prompted to enter your
password. PWD REQUIRED setting can be changed in the OPTIONS menu.
Reset Volume? Confirmation screen for resetting SOURCE VOLUME. Press ▲ or
▼ to select YES and press ENTER to reset source volume.
Resettable Totalizer displays the resettable totalizer. Press ► to reset the
totalizer. Note: If PWD REQUIRED is set to YES, you may be prompted to enter
your password. PWD REQUIRED setting can be changed in the OPTIONS menu.
Reset Total? Confirmation screen for clearing the resettable Totalizer. Press ▲ or
▼ to select YES and press ENTER.
Permanent Totalizer displays the Permanent Totalizer value (note the "P"
indicating Permanent). Pressing ► displays units of measure.
Overrun displays the amount of overrun volume detected after the DPU91-BC
deactivates the batch relay, triggering valve closure. Overrun resets each time a
new batch starts.
Batch Count shows the number of batches which have run to at least 90% of
completion. Press ► to reset Batch Count.
Note: If PWD REQUIRED is set to YES, you may be prompted to enter your
password. PWD REQUIRED setting can be changed in the OPTIONS menu.
Reset Count? Confirmation screen for clearing the Batch Count. Press ▲ or ▼ to
select YES and press ENTER.
Customizable Label is the View name assigned to the DPU91P.
Default is BATCH for DPU91-BC.
18
OMEGA DPU91-BC Batch Controller System
CAL Menu
K- Factor Set K-Factor (pulses per unit volume) according to Flow Sensor manual.
Min: 0.0001, max: 999999. Cannot be zero. Default = 60.0000. In Simple Mode, the
K-Factor will be used for all batches. In Advanced Mode, there is one K-Factor for
each stored batch. See NOTE in Calibration section for Volume Calibration procedure.
T-Factor sets the volume of each count of the Totalizer as a multiple of the volume
unit of the K-Factor. Min: 0.0001, max 999999. Cannot be zero. Default = 1.0000.
Volume Calibration Enter the dispensed volume so the DPU91 can calculate a
K-Factor. Refer to Volume Calibration section on page 24 for procedure.
Note: Relays and 4 to 20 mA output will be suspended while Volume Calibration is
performed, except for relays used for Batch or Two Stage modes. Relays in pulse
mode will suspend pulsing while Volume Calibration is being performed.
Manual Overrun Compensation (ADVANCED Mode only) When Manual
Compensation is enabled, a batch will be stopped when the dispensed batch volume
reaches an amount equal to the batch size volume minus the Manual Overrun
Compensation volume.
Calibration Date Enter date of calibration (mm-dd-yyyy) and initials of calibrator (ii).
INPUT Menu
Customize Label If desired, a custom name can be entered. Enter 13-character
string. Default = BATCH.
Freq or S3L If your flow sensor is configured for frequency output, select FREQ. If
configured for Digital (S3L) output (recommended), select S3L. Default = FREQ.
Batch Size Set batch size and batch name of up to ten stored batches. Setting
batch size to zero hides the batch in VIEW Mode. One batch must be non-zero.
Note: Same batch names can be assigned to multiple batches.
Batch Units Enter up to four characters to define Batch Units. Default = GAL.
(Actual calculations are determined by the K-Factor).
Divide this unit by Flow Timebase to get Flow Units.
Totalizer Units Identifies the Totalizer Units. It has no effect on any calculation.
Default = GALLONS.
Flow Units Identifies the Flow Units. It has no effect on any calculation.
Flow Units equal Batch Units divided by Flow Timebase. Default = GPM.
Flow Timebase Select S (seconds), M (minutes), H (hours), or D (days).
Default = s.
Batch Confirmation Select Batch Confirmation option. Choose ON, OFF, or PWD
(password). Default = OFF.
OMEGA DPU91-BC Batch Controller System
19
INPUT Menu - continued
Mode Select Select ADVANCED or SIMPLE Mode. ADVANCED Mode enables
additional features in RELAY and LOOP Modes. Default = SIMPLE.
Count Up/Down Select count direction of Batch Volume and Percent Complete
(Source Volume always counts down). Default = Count Up.
Missing Signal? Determines if a Batch is stopped when No Flow is detected.
If YES is selected, Batch will be stopped; if NO is selected, Batch will continue.
Default = NO.
Note: This setting is independent of Missing Signal Relay Mode; see page 19.
Set On Delay Shown if MISSING SIGNAL is set to YES. Set desired ON delay
time in seconds. Default = 6 sec.
Select Batch Type To change desired instrument type (i.e., Flow, pH, etc.). The
bottom line will display ALL SETTINGS WILL BE RESET. ARE YOU SURE? The
top line of the display will blink NO. Press ▼ or ▲ to select YES. Press ENTER
again to finalize your selection. For other DPU91 instruments, BATCH will be
displayed only when the Batch Module is installed.
LOOP Menu
Loop Source In ADVANCED Mode, select COMPLETION or FLOW RATE. In
SIMPLE Mode, only COMPLETION is available for the loop source.
mA at Completion Shown if COMPLETION is selected. Enter mA value to be
output when batch is completed. Select 4.0 mA or 20 mA.
Error Value Shown if COMPLETION is selected. Set desired Loop output value
when sensor error (e.g., bad sensor, broken wire) is detected. Select 3.6 mA, 22 mA,
NONE. Default = 3.6.
4 mA Setpoint Shown if FLOW RATE is selected. Set flow rate value
corresponding to desired 4 mA output. Default = 0.
20 mA Setpoint Shown if FLOW RATE is selected. Set flow rate value
corresponding to desired 20 mA output. Default = 100.
Adjust 4 mA Allows fine-tuning to compensate for errors in other equipment
connected to the DPU91. The display value represents the precise current output.
Adjustment limits: 3.80 mA to 5.00 mA. Default = 4.00 mA.
Adjust 20 mA Allows fine-tuning to compensate for errors in other equipment
connected to the DPU91. The display value represents the precise current output.
Adjustment limits: 19.00 mA to 21.00 mA. Default = 20 mA.
Test Loop Press ▲ or ▼ to manually output a current value from 3.6 mA to 21.00
mA to test the output loop.
20
OMEGA DPU91-BC Batch Controller System
RELAY Menu
R1 Normal Open/Closed Set Open Collector (R1) as Normally Open or
Normally Closed. Default = NORMAL OPEN.
Relay Mode Select the desired mode of operation for the open-collector (R1) output.
Simple Mode: BATCH, VOL PULS, MISSING.
Advanced Mode: OFF, BATCH, HI FLOW, VOL PULS, EOB PULS, MISSING,
OVERRUN, SRC VOL (if SOURCE VOL is set to ON; see OPTIONS menu),
TOT VOL, TWO STG, MULTIPLE, ERROR.
Defaults: Relay 1 = VOL PULS; Relay 2= BATCH; Relay 3 = MISSING.
Note: Same Relay Modes are available for Relays 2 and 3. See pg. 10-12.
Test Relay Select OFF or ON to test relay.
View Remote Button Status Press ► to view status of remote buttons.
Remote Button Status Displays status of Remote Buttons: STA (Start),
STP (Stop), RES (Resume). 1 = pressed, 0 = not pressed. Press ENTER to exit.
Set Flow In HI FLOW Mode, set flow value to activate relay.
Set Hysteresis Prevents the system from chattering around the set point.
In HI FLOW Mode, Relay is energized at Set Flow value and will be de-energized
at Set Flow value minus Hysteresis value.
Set On Delay In HI FLOW, ERROR, and MISSING Modes, set desired ON delay.
Default = 5 sec.
Stop Batch? In HI FLOW, MISSING, MULTIPLE, and ERROR Modes,
determines if a Batch is stopped when a Relay Activates. If YES is selected,
Batch will be stopped; if NO is selected, Batch will continue. Default = YES.
Set Overrun Volume In OVERRUN and MULTIPLE Modes, set desired
Overrun Volume.
Note: Overrun Volume must be greater than Manual Overrun Compensation,
otherwise the Overrun Alarm will activate at the end of every batch.
Set Totalizer Volume In TOT VOL Mode, set desired totalizer volume.
Note: This volume is resettable and totalizer volume must be reset to clear relay.
(see Resettable Totalizer, pg. 16)
Set Pulse Volume In VOL PULS Mode, set desired volume.
Set Pulse Width In VOL PULS Mode, set desired pulse width.
OMEGA DPU91-BC Batch Controller System
21
RELAY Menu - continued
RELAY MULTIPLE Mode options (see discussion on page 12)
Missing Signal On/Off Energizes selected relay if signal is missing.
Select ON or OFF.
Overrun On/Off Energizes selected relay if overrun occurs. Select ON or OFF.
Hi Flow On/Off Energizes selected relay if Hi Flow condition occurs. Select ON or OFF.
Error On/Off Energizes selected relay if an error condition occurs. Select ON or OFF.
RELAY TWO STAGE Mode option (see discussion on page 12)
Main Relay Select (ADVANCED Mode only) Selects the specified relay as the
main relay for two-stage valve control. This relay will be de-energized when the
batch volume reaches the setpoint percentage.
Setpoint Percent Select Selects the percentage of batch volume at which the
main relay will be de-energized. Default = 95%.
Bypass Relay Select Selects the specified relay as the Bypass relay for two-stage
valve control. This relay will remain energized while the batch is running.
Relay Bypassed The specified relay is in Bypass.
Note: A relay is taken out of bypass using the Bypass select screen, found under
the relay which is in TWO STG Mode.
22
OMEGA DPU91-BC Batch Controller System
OPTION Menu
Contrast Adjust the LCD contrast for best viewing. A setting of 1 is lowest
contrast, 5 is highest. In general, select lower contrast if the display is in warmer
surroundings. Default = 3.
Backlight Adjust backlight level. Select OFF, LOW, HIGH or AUTO.
Default = AUTO.
Batch Decimal Set the decimal to the best resolution for your application. The
display will automatically scale up to this resolution. Select -----., ----.-, ---.-- or
--.---. Default = ----.-.
Total Decimal Set the decimal to the best resolution for the Permanent Totalizer
display. The display will automatically scale up to this resolution. Select -----.,
----.-, ---.-- or --.---. Default = ----.-.
PWD REQUIRED requires password to reset TOTALIZER, BATCH OVERRIDE,
SOURCE VOLUME reset, and BATCH COUNT reset. Select YES/NO.
(Does not affect Permanent Totalizer.) Default = YES.
Source Volume Selects SOURCE VOLUME display option. Choose ON or OFF.
Default = OFF.
Volume Reset If SOURCE VOLUME is ON, set the reset value for the source
volume. Default = 1000 GAL.
Bar Graph Source If SOURCE VOLUME is ON, select source for Bar Graph
(choose BATCH VOLUME or SOURCE VOLUME). If SOURCE VOLUME is
OFF, Bar Graph source is the batch volume. Default = BATCH VOLUME.
Password Type Select STD or CODE. Default = STD.
Set Code If CODE is selected in PASSWORD TYPE, enter desired password
code. 4-character entry not displayed, ---- displayed instead.
Memo Enter 13-character string, if desired.
Remote Setup Enables Remote Setup to configure the DPU91 via a computer
and the PC COMM tool. Press ► and select YES to enable. REMOTE SETUP
flashes when mode is enabled.
Refer to the PC COMM Configuration/Diagnostic Tool manual, DPU90-CT,
included with your PC COMM tool.
Version Level Generation II or later indicates that the DPU91 is Batch-capable.
OMEGA DPU91-BC Batch Controller System
23
18. Error Messages
Remote Batch Module is missing.
No signal from Flow Sensor.
External Stop signal is preventing batch start or Remote Stop button is held down.
Bypass relay must be set on Bypass Relay Select option, under the Relay Menu.
See page 20, under Relay Two Stage mode.
Main relay shutoff percentage cannot be zero.
Volume entered during Volume Calibration is too low to calculate a K-Factor.
K-Factor error during volume calibration.
Value cannot be zero.
At least one batch must have a non-zero volume.
Batch size is less than or equal to Manual Compensation value.
Manual overrun compensation is greater than or equal to the size of at least one
of the stored batches.
19. Alarm Acknowledgement Messages
Overrun was detected.
High flow was detected.
No S3L communication or a sensor was detected.
No flow was detected.
24
OMEGA DPU91-BC Batch Controller System
20. Calibration
NOTE:
In Advanced Mode the Batch Controller has a separate K-Factor for each stored batch.
In Simple Mode the stored batches use a common K-Factor. If you switch from Simple
Mode to Advanced Mode, the single K-Factor will be copied to the K-Factor for each
batch. If you switch from Advanced Mode to Simple Mode, the K-Factor for Batch 1 will
be copied to the single K-Factor used for all batches.
Volume Calibration Procedure
1. Press ENTER to start the volumetric calibration period.
The DPU91 activates the BATCH Relay and starts counting pulses
from the flow sensor.
2. Press ENTER to stop the volumetric calibration period.
The DPU91 deactivates the BATCH Relay and stops counting
pulses from the flow sensor.
3. Enter the volume of fluid known to have flowed past the
DPU91 during the volumetric calibration period.
This will modify the existing K-Factor.
4. The DPU91 displays the newly calculated K-Factor for your
reference.
Note: If the calculated K-Factor is less than 0.0001 or greater
than 999999 (out of range at either extreme), the DPU91 displays
"ERROR VOLUME TOO HIGH" (or LOW) and returns to
VOLUME CAL.
5. Press ENTER to accept the new K-Factor (DPU91 displays
"SAVING") or press ▲+▼ keys simultaneously to escape
without saving and return to Enter Volume.
NOTE:
• You may enter your own calculated K-Factor in the CAL menu.
• In Simple Mode, the calculated K-Factor will replace the current K-Factor.
• In Advanced Mode, the calculated K-Factor value will replace the first K-Factor.
• A K-Factor can be calculated for each batch. Repeat steps 1-5 for each batch and
enter calculated K-Factor for the corresponding batch.
OMEGA DPU91-BC Batch Controller System
25
21. Specifications
General
Input channels: ..One
Enclosure and Display
Case Material ....PBT
Window ..............Shatter-Resistant Glass
Keypad ..............4 buttons, injection-molded
silicone rubber seal
Display ...............Backlit, 7- and 14-segment
Indicators ...........“Dial-type” digital bar graph
Update rate ........1 s
LCD Contrast .....5 settings
Enclosure
Size....................¼ DIN
Color ..................Black
Mounting
Panel .................¼ DIN, ribbed on four sides
for panel mounting clip
inside panel
Wall ....................Large enclosure (sold as
an accessory) that encases
the transmitter
Environmental Requirements
Ambient operating temperature:
Backlit LCD ............. -10 °C to 70 °C
(14 °F to 158 °F)
Storage Temp ......... -15 °C to 70 °C
(5 °F to 158 °F)
Operating Temp ...... -10 °C to 70 °C
(14 °F to 158 °F)
Relative Humidity.... 0 to 100% condensing
for front only; 0 to 95%
non-condensing for
back side.
Maximum Altitude ... 4,000 m (13,123 ft)
Enclosure Rating .... Designed to meet
NEMA 4X/IP65
(front face only).
Performance Specifications
Accuracy................. ±0.2%
System Response:
• Primarily dependent upon the sensor.
Transmitter adds a maximum 150 ms
processing delay of the sensor
electronics.
• Minimum update period is 100 ms.
• System response is tempered by the
display rate.
26
OMEGA DPU91-BC Batch Controller System
Electrical Requirements
Power to Sensors:
Voltage: ......................... +4.9 to 5.5 VDC
@ 25 °C, regulated
Current: .........................20 mA max
Short Circuit ..................Protected
Terminal Blocks
• Pluggable screw type
• 14 AWG max wire gauge
Input Power Requirements
DC (preferred)...............24 VDC Input;
range: 10.8 to 35.2
VDC regulated
300 mA maximum
Overvoltage protection...48 Volt Transient
Protection Device
Current limiting for circuit protection
Reverse-Voltage protection
Loop Characteristics
With DC power input (preferred)
Max. loop impedance
@ 12 V loop power 250 Ω max.
@ 18 V loop power 500 Ω max.
@ 24 V loop power 750 Ω max.
Relay Specifications
Hysteresis .....................Adjustable (absolute
in Engineering Units)
Latch .............................Reset in test screen or
View Mode
On Delay .......................9999.9 seconds (max)
Test Mode .....................Set On or Off
Maximum pulse rate .....400 pulses/minute
Volumetric Pulse Width ..0.1 s to 3200 s
Open Collector
Type ..............................NPN
Max. Voltage Rating .....30 VDC
Max. Current Rating .....50 mA
Dry-Contact Relays
Type ..............................SPDT
Form ..............................C
Max. Voltage Rating .....30 VDC or 250 VAC
Max. Current Rating .....5 A
Shipping Weights
Base Unit .................... 0.63 kg (1.38 lb)
Batch Module.............. 0.16 kg (0.35 lb)
Relay Module.............. 0.19 kg (0.41 lb)
Input Specifications
Digital (S3L)................. Serial ASCII,
TTL level, 9600 bps
Frequency:
Sensitivity ............... 80 mV @ 5 Hz,
gradually increasing
with frequency
Range .................... 0.5 Hz to 1500 Hz @
TTL level input for
open collector
Accuracy ................ ± 0.5% of reading
max error @ 25 °C
Resolution .............. 1 μs
Repeatability .......... ± 0.2% of reading
Power Supply
Rejection ................ No Effect ± 1 μA/V
Short Circuit ........... Protected
Reverse Polarity..... Protected
Update Rate ............... (1/frequency) + 150 ms
Output Specifications
One 4 to 20 mA output
Current Loop Out .... ANSI-ISA 50.00.01
Class H
Span ....................... 3.8 to 21 mA
Zero ........................ 4.0 mA factory set;
user programmable
from 3.8 to 4.2 mA
Full Scale ................ 20.00 mA factory set;
user programmable
19.0 to 21.0 mA
Accuracy ................. ± 32 μA max. error
@ 25 °C @ 24 VDC
Resolution............... 6 μA or better
Temp. Drift .............. ± 1 μA per °C
Pwr Sply Rejection .. ± 1 μA per V
Isolation .................. Low voltage
(< 48 VAC/DC)
Voltage.................... 10.8 to 35.2 VDC
Max. Impedance ..... 250 Ω @ 12 VDC
....................... 500 Ω @ 18 VDC
....................... 750 Ω @ 24 VDC
Update Rate ........... 150 mS nominal
Short circuit and reverse polarity protected
Adjustable span, reversible
Error Condition ....... Selectable error
condition 3.6 or 22 mA
or NONE
Actual update rate .. Determined by
sensor type
Test Mode ............... Increment to
desired current
(range 3.6 to 21.00 mA)
OC Outputs............. 1
Analog Outputs ....... 1 passive
Linear scaling
OMEGA DPU91-BC Batch Controller System
27
22. Ordering Information
DPU91-BC Batch Controller System
Mfr. Part No
DPU91-BC
DPU91P
DPU90-R
DPU90-BCM
Description
Batch Controller System
DPU91 Panel Mount Transmitter
Relay Module - 2 DCR (dry-contact relays)
Batch Module
Accessories
DPU90-CT
PC COMM Configuration tool
DPU90-WM
Wall Mount Accessory
FPM-5000-LTCK Liquid Tight Connector Kit, NPT (1 pc.)
28
OMEGA DPU91-BC Batch Controller System
®
OMEGA DPU91-BC Batch Controller System
29
30
OMEGA DPU91-BC Batch Controller System
WARRANTY/DISCLAIMER
OMEGA ENGINEERING, INC. warrants this unit to be free of defects in materials and workmanship for a
period of 13 months from date of purchase. OMEGA’s WARRANTY adds an additional one (1) month
grace period to the normal one (1) year product warranty to cover handling and shipping time. This
ensures that OMEGA’s customers receive maximum coverage on each product.
If the unit malfunctions, it must be returned to the factory for evaluation. OMEGA’s Customer Service
Department will issue an Authorized Return (AR) number immediately upon phone or written request.
Upon examination by OMEGA, if the unit is found to be defective, it will be repaired or replaced at no
charge. OMEGA’s WARRANTY does not apply to defects resulting from any action of the purchaser,
including but not limited to mishandling, improper interfacing, operation outside of design limits,
improper repair, or unauthorized modification. This WARRANTY is VOID if the unit shows evidence of
having been tampered with or shows evidence of having been damaged as a result of excessive corrosion;
or current, heat, moisture or vibration; improper specification; misapplication; misuse or other operating
conditions outside of OMEGA’s control. Components in which wear is not warranted, include but are not
limited to contact points, fuses, and triacs.
OMEGA is pleased to offer suggestions on the use of its various products. However,
OMEGA neither assumes responsibility for any omissions or errors nor assumes liability for
any damages that result from the use of its products in accordance with information provided
by OMEGA, either verbal or written. OMEGA warrants only that the parts manufactured by the
company will be as specified and free of defects. OMEGA MAKES NO OTHER WARRANTIES OR
REPRESENTATIONS OF ANY KIND WHATSOEVER, EXPRESSED OR IMPLIED, EXCEPT THAT OF
TITLE, AND ALL IMPLIED WARRANTIES INCLUDING ANY WARRANTY OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY DISCLAIMED. LIMITATION OF
LIABILITY: The remedies of purchaser set forth herein are exclusive, and the total liability of
OMEGA with respect to this order, whether based on contract, warranty, negligence,
indemnification, strict liability or otherwise, shall not exceed the purchase price of the
component upon which liability is based. In no event shall OMEGA be liable for
consequential, incidental or special damages.
CONDITIONS: Equipment sold by OMEGA is not intended to be used, nor shall it be used: (1) as a “Basic
Component” under 10 CFR 21 (NRC), used in or with any nuclear installation or activity; or (2) in medical
applications or used on humans. Should any Product(s) be used in or with any nuclear installation or
activity, medical application, used on humans, or misused in any way, OMEGA assumes no responsibility
as set forth in our basic WARRANTY/DISCLAIMER language, and, additionally, purchaser will indemnify
OMEGA and hold OMEGA harmless from any liability or damage whatsoever arising out of the use of the
Product(s) in such a manner.
RETURN REQUESTS/INQUIRIES
Direct all warranty and repair requests/inquiries to the OMEGA Customer Service Department.
BEFORE RETURNING ANY PRODUCT(S) TO OMEGA, PURCHASER MUST OBTAIN AN AUTHORIZED
RETURN (AR) NUMBER FROM OMEGA’S CUSTOMER SERVICE DEPARTMENT (IN ORDER TO AVOID
PROCESSING DELAYS). The assigned AR number should then be marked on the outside of the return
package and on any correspondence.
The purchaser is responsible for shipping charges, freight, insurance and proper packaging to prevent
breakage in transit.
FOR WARRANTY RETURNS, please have the
following information available BEFORE contacting
OMEGA:
1. Purchase Order number under which the product
was PURCHASED,
2. Model and serial number of the product under
warranty, and
3. Repair instructions and/or specific problems
relative to the product.
FOR NON-WARRANTY REPAIRS, consult
OMEGA for current repair charges. Have
the following information available BEFORE
contacting OMEGA:
1. Purchase Order number to cover the COST
of the repair,
2. Model and serial number of the product, and
3. Repair instructions and/or specific problems
relative to the product.
OMEGA’s policy is to make running changes, not model changes, whenever an improvement is possible. This affords
our customers the latest in technology and engineering.
OMEGA is a trademark of OMEGA ENGINEERING, INC.
© Copyright 2018 OMEGA ENGINEERING, INC. All rights reserved. This document may not be copied,
photocopied, reproduced, translated, or reduced to any electronic medium or machine-readable form, in whole or in
part, without the prior written consent of OMEGA ENGINEERING, INC.
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