BATCHER Software Versions 8.x & 12.x Installation and Operating Manual Description The Batcher is a programmable, microprocessor based unit which provides batch control, monitors flow rate and controls the flow of processing liquids. Start/Stop controls can be used in conjunction with prewarn and final relays to provide valve actuation or pump control. An optional configuration offers streamlined preset adjustments, remote Start, Stop & Reset, and weighted averaging.
SAFETY INSTRUCTIONS ! The following instructions must be observed. • This instrument was designed and is checked in accordance with regulations in force EN 60950 (“Safety of information technology equipment, including electrical business equipment”). A hazardous situation may occur if this instrument is not used for its intended purpose or is used incorrectly. Please note operating instructions provided in this manual.
CONTENTS 1. INTRODUCTION 1-1 General Description ................................................................................................ 1 1-2 Typical Application ................................................................................................... 1 1-3 Principles of Operation ............................................................................................ 1 1-4 STD PRE and EZ PRE Operation Modes ...............................................................
CONTENTS 6. TROUBLE SHOOTING AND MAINTENANCE GUIDE 6-1 Warning Messages................................................................................................ 34 6-2 Troubleshooting ..................................................................................................... 35 6-3 Removing The Case ............................................................................................. 36 6-4 Maintenance .................................................................................
1-3 Principles of Operation Presets 1-1 General Description When the start button is pushed, two relays engage simultaneously to start flow. When Sections 1 through 8 of this manual describe the prewarn number is reached, one relay the wiring, programming and functionality of drops out. When the preset number is the standard Batch controller. Section 9 de- reached, the other relay drops out.
1-3 Principles of Operation (continued) Counter The maximum count is 99999999. In the setup mode choose "RO" (Reset to Zero) for adding (count up) operation or "SP" (Set to Preset) for subtracting (count down) operation. At any time, the display can be made to flash the Grand Total by pressing the ENT button while in the run mode. Activating the CLR button while the Grand Total is flashing, resets the Grand Total counter. Frequency out The Batcher generates a pulse out for each factored count.
1-4 STD PRE and EZ PRE Operation Modes STD PRE and EZ PRE Operation Modes Version 8.7 of the batcher software allows the user to choose between STD PRE (Standard Preset) and EZ PRE (Easy Preset) operation modes. STD PRE operation is well suited for batch amounts that do not change, since the program mode must be entered to change the preset and the batch count must be cleared before starting a new batch. EZ PRE has been designed for users who frequently change the batch amount.
1-5 Specifications Reset Front push button: "CLR" resets displayed number and control output. Remote Input (Terminal 5): Open or 0 to 1 VDC (low), 3 to 30 VDC (high), 10K ohm input impedance to ground. Minimum pulse on / off time 5 msec. Housing: High impact plastic case with NEMA 4X front panel. Dimensions: See Section 1-5, Page 4. Display: 8 Digit, 0.55" High, 15 Segment, Red Orange, LED. Accuracy over full temperature range: Analog - Zero error: ±0.175% full scale max. Overall error: ±0.
1-5 Specifications (continued) 1-6 Dimensions Factored Output: One pulse per each factored count Sinking (NPN Transistor) Open Collector sinks 250 mA maximum to 1 volt maximum from 30 VDC maximum Internal buffer: 9999 pulses Output speed: user selectable (see table below) Speed (Hz) 10 A B 0.2 D 2 3 4 5 6 7 8 9 CLR 0 SET 3.31 (84) 8.17 (207.5) 7.375 (187.3) 200 2000 20000 Min. on/off (msec) 47.5 2.0 C 1 (NOM.) 0.
SECTION 2 INSTALLATION 1-5 Dimensions (continued) 2-1 Receipt of Equipment When the equipment is received, the outside packing case should be checked for damage incurred during shipment. If the packing case is damaged, the local carrier should be notified at once regarding his liability. A report should be submitted to the factory. Carefully remove the equipment from the packing case and inspect for damaged or missing parts.
Weighted Averaging 3-1 Front Panel Operation 1 2 3 4 5 6 START STOP RATE/TOTAL MENU 7 8 9 A B C D ENT 0 CLR A B C D ENT CLR Version 8.7 of the batcher software includes weighted averaging of the rate display. Weighted averaging is not available on units with 16 Point Linearization. Weighted averaging can be used to create a more stable display when the rate input is fluctuating.
3-2 VER 8.7 Programming 3-3 VER 8.7 K-Factor Programming (See Programming Flow Chart, Page 10) Overview: (For information on entering a K-Factor on a unit with 16 Point Linearization, see 16 Point Linearization Notes, page 11) The K-Factor is usually provided in pulses per unit, and will have to be modified before entering it into the unit. On most flowmeters, the K-Factor is stamped on the nameplate.
10 ↓ ENT Page 2, 19 D Page 2, 24 OUTFREQ↓ ENT D § Page 2, 23 ALG OUT↓ ENT D UNIT D 20000 2000 200 10 ↓ ↓ ENT ↓ ↓ UNIT ANLG RT↓ ENT ANLG CT↓ XX CLR LOW ENT ENT ENT ENT XXXX CLR B ⇒D CODE 0 BAUDRATE XXXX CLR ENT D ENT 300↓ 600↓ 1200↓ ENT 2400↓ 4800↓ 9600↓ 0 XXXX CLR D WEIGHT00 PARITY WEIGHTXX CLR ENT SET HIGH ENT D.E.C. . .L.O.C.
3-6 VER 12.0 16 Point Linearization Notes (See Programming Flow Chart, Page 12) 3-5 VER 12.0 Programming (Unit with 16 Point Linearization) Overview: A K-Factor and a Frequency must be entered for at least three points on a unit with Linearization. This Section of the manual provides an outline of programming procedures for the software version 12.0. Detailed descriptions and programming instructions for this unit are available in the following sections of this manual.
12 D OUTFREQ↓ ENT D 16 POINT↓ ENT D ALG OUT↓ ENT D OUTCARD↓ ENT D LOCKOUT↓ ENT D DEV TYP↓ ENT D PREWARN↓ ENT D PRESET ↓ ENT MENU D Run Mode 3-7 ↓ ↓ ENT ↓ ↓ D D 20000 2000 200 10 SECONDS↓ MINUTES↓ ENT HOURS↓ TEST↓ ENT ENT ENT POINT SET 00 ENT B⇒D 0 00 1 POINT CLR 01 ENT XXXX CLR XX CLR F ENT 00 SET HIGH ENT K XX CLR K XXXX CLR D Increment to next point (Ex. POINT 02, POINT 03, Etc.
3-8 How to Program The initial programming of the unit is accomplished by first depressing the MENU button. After pressing the MENU button once, the display will read preset. To cycle to the next control parameter option, merely press the MENU button and Prewarn will appear on the display. If the user does not wish to choose this section of the menu, depress MENU button again and the next control or parameter will appear.
3-10 Setup Procedure For The Batcher MENU ITEM 1 PRESET PRESS DISPLAY PRESET ↓ D Menu Button. Flashing PRESET number. ENT Enters Preset Routine. 0 Flashes. CLR Clears out existing PRESET. 1 2 3 4 1234 PRESET Flashes. Sample Preset. Last count, unit now in run mode. ENT Store new Preset. Final Preset is Set. MENU ITEM 2 PREWARN The Prewarn value is the amount before the Preset value that the Prewarn relay will deactivate.
3-10 Setup Procedure For The Batcher (continued) MENU ITEM 3 PRE TYP This menu item is used to set up the Preset Type. PRESS DISPLAY D PRESET ↓ D PREWARN ↓ D PRE TYP ↓ ENT STD PRE ↓ ↓ EZ PRE↓ Press D toggle between selections. ENT Enters displyed selection Run Mode The PRE TYP is Set. MENU ITEM 4 COUNT Setting the Counter PRESS DISPLAY D PRESET ↓ D PREWARN ↓ D PRE TYP ↓ D COUNT↓ ↓ ENT K FACTOR K FACTOR flashes then shows the current K Factor.
3-10 Setup Procedure For The Batcher (continued) MENU ITEM 4 COUNT (continued) PRESS DISPLAY ENT R0 ↓ SP ↓ Store new K Factor. RO is Reset to zero. SP is Reset to Preset. This selection determines whether the unit counts up or counts down. If RO is selected ( B is pressed), the unit will count in the "up" direction towards the Preset (dropping out the Prewarn, if passed).
3-10 Setup Procedure For The Batcher (continued) MENU ITEM 5 RATE Setting the Ratemeter PRESS DISPLAY D PRESET ↓ D PREWARN ↓ D D PRE TYP ↓ D RATE↓ ↓ COUNT↓ ↓ K FACTOR ENT This selects the Ratemeter portion of the menu. K FACTOR flashes then shows the current Ratemeter K Factor. Note: The K Factor setup is skipped if the unit has 16 Point option. The unit goes directly to WINDOW. CLR 0 Flashes. Clears out existing K FACTOR. 1 2 D 0 5 6 12.056 Flashes.
3-10 Setup Procedure For The Batcher (continued) MENU ITEM 6 RATE (continued from previous page) From the previous page, we are in the SIG FIG setting portion of the Ratemeter setup Menu. PRESS DISPLAY ENT SIG FIG ## Store new WINDOW. SIG FIG indicates how many meaningful digits are shown. For example, if SIG FIG is set at three; a rate of 24737.89 will be displayed as 24700; a rate of 0.739216 will be displayed as 0.739. Note that trailing zeroes will be inserted only if necessary.
3-10 Setup Procedure For The Batcher (continued) MENU ITEM 6 LOCKOUT This menu item uses a 4 digit security code to prevent unwanted changes in the programming or improper use of the Batcher. The unit is shipped from the factory with a security setting of 00 and a lockout code of 1000. Security example: First set the security shut down time in the Lockout menu then go to the Run Mode. Press the START button. The word STARTED should briefly appear.
3-10 Setup Procedure For The Batcher (continued) From the previous page, we are in the CODE setting portion of the Lockout setup Menu. PRESS DISPLAY ENT CODE Store new security time. Enters device routine to program in a 4 digit Lockout Code. The word CODE appears briefly then the current Lockout Code number is displayed. CLR 0 Flashes. Clears out existing Lockout Code. 1 2 3 4 1234 Flashes. Sample Lockout Code, or enter desired value from notes or worksheet.
3-10 Setup Procedure For The Batcher (continued) MENU ITEM 7 OUTCARD If the unit is equipped with a serial communications card, the setup parameters in the following menu will make the Batcher compatible with the master terminal. The Unit Identification Number (if multiple units are used), Baud Rate (speed at which the signal is transmitted) and Parity are selectable. A 7 bit, ASCII character, with one start bit, one stop bit and the parity makes up the standard ten bit transmission character.
3-10 Setup Procedure For The Batcher (continued) From the previous page, we are in the BAUDRATE setting portion of the Outcard setup Menu. PRESS DISPLAY By pressing the D button repeatedly, the available Baud rates will be displayed. The menu will cycle through the rates again whenever the bottom of the list is reached. Simply stop on the Baud rate desired and hit the ENT button. The Baudrate is the speed at which the unit communicates.
3-10 Setup Procedure For The Batcher (continued) MENU ITEM 8 ALG OUT This section is for models of the batcher with the analog output feature. The Analog Output card is a (0 - 20) or (4 - 20) mA current sink. The low (0mA) or (4 mA) and high (20mA) settings may be set at any range. Attempting to set the high setting lower than or the same as the low setting will display the warning message HIGH ≤ LOW and send the unit back to the low setting section of the routine.
3-10 Setup Procedure For The Batcher (continued) From the previous page, we are in the SET HIGH setting portion of the ALG OUT setup Menu. PRESS DISPLAY CLR 0 Flashes. Clears out existing High Setpoint value. 6 7 5 9 D 5 6759.5 Flashes. Sample High Setpoint, or enter value from notes or worksheet. (D for decimal point.) If High Setpoint is too low, the warning HIGH≤LOW will be displayed and the unit will return to the SET LOW routine. ENT Last count, unit now in Run Mode. High Setpoint is stored.
3-10 Setup Procedure For The Batcher (continued) MENU ITEM 10 16 POINT This section is for models of the Batcher which have 16 Point Linearization. This option allows the user to key in from 3 to 16 different frequency points (inputs per second) and assign different K Factors dividers from 0.00011 to 999999 for each of these frequencies. Please refer to the K Factor worksheets (Section 7) or other notes you may have prepared. PRESS DISPLAY PRESET ↓ D D PREWARN ↓ D Press until . . .
3-10 Setup Procedure For The Batcher (continued) From the previous page, we are in the POINT setting portion of the 16 Point setup Menu. PRESS 1 then DISPLAY POINT 01 ENT ENT F 1 The unit displays the last frequency entered for Point 01. F CLR 0 Clears out existing frequency for Point 01. 1 0 0 F 100 Sample frequency, or enter desired value from worksheets. ENT K 1 The unit displays the last K Factor entered for Point 01. K CLR 0 Clears out existing K Factor for Point 01.
3-11 Run Mode 3-11.1 The Display In the Run Mode the display will initially display: a) Zero, if setup to reset to zero. b) Preset number, if set to reset to preset . c) A warning message (See Section 6-1) The unit will accept input signals and display Rate, Batch Total or Grand total. The Batch Total is displayed as a number. The Rate is displayed as "R" followed by a number. The Grand Total is displayed as a flashing number. (The Grand Total flashes so that it will not be confused with the Batch Total.
3-11 Run Mode (continued) 3-11.4 Start and Stop Operation (continued). 3-11.4 Start and Stop Operation. The Batcher is designed for batching operations. The batching operation is controlled by two internal relays, Preset and Prewarn settings and the CLR , START and STOP buttons on the front panel. A typical operation proceeds as follows: a) The Preset is accessed and changed to the amount desired. b) The unit accepts input signals c) The CLR button is pushed to reset the Batch Totalizer.
3-12 Internal Operation 3-12.2 Analog Inputs and Computations 3-11.1 Digital Inputs and Computations The 3-30 Volt input signal is filtered electronically (See Section 4-1, Digital Pulse Inputs). The Analog input signal is filtered electronically and converted to a 0 - 10000 Hz input frequency. (See Section 7, K Factor Calculation and Section 4-2, Analog Inputs).
4-1 Digital Pulse Inputs (continued) SECTION 4 INPUTS 4-1 Digital Pulse Inputs (Terminal 4) Digital Pulse Inputs: The input board is a separate board that is plugged into the mother board just behind the display. All digital inputs are on the same board. There are four dip switches on the board. The input conditioning characteristics may be altered by changing the dip switches. A valid pulse is one which makes a transition from the off state (low) to the on state (high): a positive going edge.
4-2 Analog Inputs (continued) 4-2.3 Analog Inputs Exchange 4-20 mA; 250 Ω input impedance. 0-20 mA; 250 Ω input impedance. 1-5 VDC; 15 KΩ input impedance. 0-5 VDC; 15 KΩ input impedance. 0-10 VDC; 15 KΩ input impedance. The above inputs take the analog signal and scale it from 0 to 10000 pulses per second by using a highly linear voltage to frequency converter. These pulses go to the processor to be scaled by the K Factors. To determine the K Factor, see Section 7, Calculating the K Factor.
4-3 DC Power Inputs (Terminals 12, 14) SECTION 5 OUTPUTS The Batcher may be powered by an external DC power supply. The supply must provide 12 - 27 Volts DC and at least 280 mA of current. The positive side (+DC) of the DC supply should be hooked to Terminal 14 and the negative (or Ground) side to Terminal 12. NOTE: Units powered by DC Voltages do not have an isolated voltage out on Terminals 15 and 16 or +12 VDC on Terminal 13.
5-1.2 Internal Buffer for Frequency Output An internal buffer will store up to 9,999 counts if the scaled input generates pulses faster than the output speed selected. The warning message "DATALOST" flashes on the screen when the buffer overflows (see Section 6-1, Warning Messages). This indicates that the counts being totalled and the scaled outputs may be incorrect.
5-3 Optional Analog Output (continued) SECTION 6 TROUBLE SHOOTING AND MAINTENANCE GUIDE 6-1 Warning Messages 12 • Ground (-DC) 13 • (+) 12 Volts Out 14 • (+) DC Power In 15 • Isolated 12 V (-) 16 • Isolated 12 V (+) 17 • AC In 18 • AC In 3 • Analog Output 4 • Input A 4-20 mA Out Wiring 6-1.1 PREWRONG Indicates that the values in Preset and Prewarn are not acceptable. This condition will occur when the Preset value is less than the Prewarn value.
6-1 Warning Messages (continued) 6-1.5 BAD FREQ Indicates that the values in the 16 Point setup are not acceptable. This condition will occur when the frequency values are not in ascending order. The display will continue to display this message until the error is corrected. To correct the error see Section 3-3, Setup Procedure. 6-1.6 SECURITY Indicates that no signal has come in for the duration time set in the Lockout menu. Lockout code must be entered before the unit will continue.
6-3 Removing the Case To install or change the input or data interface cards, the case must be removed. Remove all power before opening the case. CMOS logic is used so observe standard precautions against damage by static discharge. On units RS232 or RS422, two screws on the back, holding the top left connector, have to be removed. Next, remove the six (6) flat head screws behind the front bezel and lift off the bezel assembly. Slide the main board display out the front of the case by pushing from the rear.
7-2 Calculating the K Factors. The following steps are the recommended procedure forcalculating the K Factors. Take your time and go through the procedure slowly at first. After several tries you should be fairly adept at calculating the K Factor for any given input. 7-2.1 Calculating the K Factor for Digital Pulse Inputs. Step 1. Find out what value the pulses represent. This should be specified on your device or with its paper work.
7-2.3 Calculating the K Factor for Analog Inputs. 7-2.4 Analog K Factor Formulas. 10000 Maximum Input Signal Step 1. = Rate K Factor Find out what value the maximum input signal represents. This should be specified on your device or with its paper work. Rate K Factor = Count K Factor Example #1: 20 mA = 100 gal / min Time Conversion Factor Example #2: 5 V = 10 ft / sec Example #3: 10 V = 32 m3 / hr Q. Is it possible to count in one system of measurement and display rate in another? Step 2.
7-3 Calculating 16 Point K Factors Units equipped with the 16 Point option allow the user to enter in from 3 to 16 different frequency points (inputs per second) and assign different K Factor dividers from 0.00011 to 999999 for each of these frequencies. The 16 Point unit determines the incoming frequency and calculates a K Factor line slope from the two closest data points that had been entered. The specific K Factor is then proportionally interpolated using 8 position floating math.
SECTION 8 SERIAL COMMUNICATIONS 8-3 Parity Parity is a bit of information that is inThis section applies to units which have the serted before the stop bit and is used to Serial Communications interface option. Up help check if the transmission is correct. to 15 units can be linked together. Unit sta- In the OUTCARD setup mode, select betus can be accessed and new set points and tween: K Factors can be entered through the serial a) ODD (Parity bit is logical zero if total port.
8-5 RS232 Card Wiring This option has a subminiature D, 25 pin, female connector and is wired as a DCE (Data Communications Equipment) device. If it is connected to a DTE (Data Terminal Equipment) device, the interconnect cable should have wires 2 and 3 connected straight to the same pins on each end. If it is connected to another DCE device, Pins 2 and 3 must be crossed.
8-7 RS422 Card Wiring This option has a subminiature D, 37 pin, female connector and is wired as a DCE (Data Communications Equipment) device. It is designed to be connected to a DTE (Data Terminal Equipment) device. If it must be connected to a DCE device, it will be necessary to cross wires 4 and 6 as well as 22 and 24 at one end of the connector harness. 8-7.1 Wiring Diagram RS422 / Strobe (37 Pin Connector) 8-7.
8-9 Strobe Wiring 8-9.1 RS232 Strobe Wiring (RS232, 25 Pin Connector) The 3 data lines are hooked up to Pins 9, 10, and 11. These lines must be held high while a strobe of at least 25 milliseconds is given on Pin 18. Data is transmitted in RS232 serial format on the Transmit Data Line (Pin 3). a) Pin 9, Binary 1's Input b) Pin 10, Binary 2's Input c) Pin 11, Binary 4's Input d) Pin 18, Strobe Input e) Pin 3, Transmit Data f) Pin 7, Signal Ground for Reference Refer to 8-5.
8-10.2 RS232/RS422 Serial Input Codes 8-10.3 RS232/RS422 Serial Input Examples Example A: (S) = Space DXX(S) (Device and address number followed by space) activates the Batcher that had been assigned that number. That unit comes on line and transmits "Device XX:". Unit is now ready to receive a code or string of codes separated by a space. A "Carriage Return" (Enter) code enters the codes and processing of requests begins.
8-10.5 RS232/RS422 16 Point Serial Input Example Example : (S) = Space Transmit from terminal Receive from Batcher D11(S) [Unit 7 activated] Device #11 FC(S)500(S)KC(S)305 FC 500 KC 305 {Frequency for C (Point 03) is set to 500,} {K Factor for C (Point 03) is set to 305.} FC(S)KC(S)(ENTER) FC KC {Unit echoes back commands as sent.
9 Programming Worksheet Model # _____________________________ Serial # _____________________________ Unit # ______________________________ OUTput FREQuency PRESET _ _ _ _ _ _ _ _ PREWARN _ _ _ _ _ _ _ _ PREset TYPe ■ EZ PRE ■ STD PRE COUNTer K-FACTOR _ _ _ _ _ _ _ _ Reset to 0 ■ Set to Preset ■ Decimal Location (0-8) 8 7 6 5 4 3 2 1 0 ■ ■ ■ ■ ■ ■ ■ ■ ■ None RATEmeter K-FACTOR _ _ _ _ _ _ _ _ WINDOW (02-24) _ _ SIGnificant FIGures (1-6) _ WEIGHT (00-99) _ _ Terminals 123 123 123 123 123 123 123 123 123 123
Terminals 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 123 Ordering 1 - Not Used 2 - Scaled Pulse Output O.C.