Aalborg TIO User manual

OPERATING MANUAL
TIO
Totalizer-Input/Output
Flow Monitor/Controller
QUALITY SYSTEM REGISTERED
Technical Data Sheet No.: TD-TIO-0911 Rev B
Date of Issue: September 2011

Aalborg7is a registered trademark of Aalborg7Instruments & Controls.
NOTE: Aalborg7reserves the right to change designs and dimensions at its sole
discretion at any time without notice. For certified dimensions please contact Aalborg7.

TABLE OF CONTENTS
1. UNPACKING THE TIO TOTALIZER......................................................
1.1 Inspecting Package for External Damage..................................................................
1.2 Unpacking the TIO Totalizer.....................................................................................
1.3 Returning Merchandise for Repair.............................................................................
2. SAFETY INSTRUCTIONS / INTRODUCTION...............................................
3. SPECIFICATIONS.............................................................................
4. ELECTRICAL CONNECTIONS................................................................
4.1 Power Supply Connections........................................................................................
4.2 Process Variable (PV) Input Signal Connections..................................................
4.3 Set Point (SP) Output Signal Connections............................................................
4.4 Digital Communication Interface Connections......................................................
4.5 Digital and Pulse Optically-Isolated Output Connections....................................
5. LCD KEY-PAD OPERATION: DATA ENTRY AND CONFIGURATION.....................
5.1 Display Indications....................................................................................................
5.1.1 Set Point Control (only for devices set as controller)..........................................
5.2 Menu Structure....................................................................................................
5.3 Parameter Entry.........................................................................................................
5.3.1 Submenu “Change PP Password”.............................................................................
5.3.2 Submenu “Device Information”...........................................................................
5.3.3 Submenu “Measuring Units”................................................................................
5.3.4 Submenu “User-Defined Units”..................................................................................
5.3.5 Submenu “K-Factors Settings”.............................................................................
5.3.6 Submenu “Alarm Settings”........................................................................................
5.3.7 Submenu “Totalizer #1”............................................................................................
5.3.8 Submenu “Totalizer #2”.......................................................................................
5.3.9 Submenu “Pulse Output”...........................................................................................
5.3.10 Submenu “Opt. Outputs Settings”............................................................................
5.3.11 Submenu “Display Settings”.................................................................................
5.3.12 Submenu “Device Function”......................................................................................
5.3.13 Submenu “Communication Settings”....................................................................
5.3.14 Submenu “Device Calibration”..............................................................................
5.3.15 Submenu “Signal Conditioner”............................................................................
5.3.16 Submenu “Program Set Point”..................................................................................
5.3.17 Submenu “Event Register Menu”.........................................................................
5.3.18 Submenu “Diagnostic Menu” “Event Register Menu”...........................................
6. INSTALLATION............................................................................
6.1 General Directions.....................................................................................................
6.2 Hardware Installation............................................................................................
6.2.1 Connecting TIO to GFM series flow meter............................................................
6.2.2 Connecting TIO to GFC series flow controller...........................................................
6.2.3 Connecting TIO to flow meters / controllers from other manufacturers
(stand alone)............................................................................................................
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7. TROUBLESHOOTING....................................................................
7.1 Common Conditions...........................................................................................
7.2 Troubleshooting Guide........................................................................................
APPENDIX A TIO Totalizer Input/Output Flow Monitor/Controller EEPROM Variables
APPENDIX B Internal K-Factors Table
APPENDIX C Totalizer-IO ASCII Commands Set
APPENDIX D Mechanical Drawings
APPENDIX E Circuit Layout Diagrams
APPENDIX F Warranty
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1. UNPACKING THE TIO TOTALIZER
1.1 Inspect Package for External Damage
Your TIO Totalizer-Input/Output Flow Monitor/Controller was carefully packed in a
sturdy cardboard carton with anti-static cushioning materials to withstand ship-
ping shock. Upon receipt, inspect the package for possible external damage. In
case of external damage to the package, contact the shipping company immedi-
ately.
1.2 Unpack the TIO Totalizer
Open the carton carefully from the top and inspect for any sign of concealed ship-
ping damage. In addition to contacting the shipping carrier, please forward a copy
of any damage report to your distributor or to Aalborg7directly. When unpacking
the instrument make sure that you have all the items indicated on the Packing List.
Please promptly report any shortages.
1.3 Returning Merchandise for Repair
Please contact your distributor’s customer service representative, or Aalborg7if
you purchased your TIO instrument directly. Request a Return Authorization
Number (RAN). Equipment returned without an RAN will not be accepted.
Aalborg7reserves the right to charge the customer a fee for equipment returned
under warranty claims if the instruments are tested and found to be free from war-
rantied defects. Shipping charges are borne by the customer. Instruments
returned “collect” will not be accepted! It is mandatory that any equipment
returned for servicing be purged and neutralized of any dangerous contents
including but not limited to toxic, bacterially infectious, corrosive or radioac-
tive substances. No work shall be performed on a returned product unless the
customer submits a fully executed, signed SAFETY CERTIFICATE. Please
request form from the Service Manager.
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The TIO Totalizer-Input/Output Flow Monitor/Controller is a microcontroller-driven
device designed to linearize the flow meter/controller flow curve and to display
instantaneous Flow Rate, Total and Accumulated Total. This product is designed to
be used primarily with Aalborg7series GFM/GFC analog flow meters/controllers
but can be also used with any commercial flow meters/controllers with analog 0-
5 (0-10) Vdc or 4-20 mA interface.
The following functions and features are supported:
• Built-in Flow Linearizer (10 point linearization of the flow curve).
• Up to 47 different volumetric and mass flow engineering units (including user-
defined).
• Graphic LCD with large 13mm (0.51") digits for Flow Rate and 5.5mm (0.21")
for Total.
• User-adjustable LCD back light and contrast level.
• Digital RS-232 or RS-485 interface (multidrop capability for up to 64 devices).
• Compact design for unit mount, panel mount, wall mount or field mount
applications.
• Two independent programmable Totalizers.
• User-programmable, optically-isolated pulse output.
• Two programmable optically-isolated digital outputs for different events.
• Low and High Flow Alarms with programmable Action Delay.
• Flow controllers Set Point command control via local LCD or digital interface.
• Programmable Set Point table with ramping up/down capability for up to 16
steps.
• Free Configuration and Monitoring Utility Software.
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AALBORG7warranties and all other responsibilities by direct
or implied are voided if users fail to follow all instructions and
procedures described in this manual.
LIFE SUPPORT APPLICATIONS: The TIO is not designed for use in life
support applications where malfunctioning of the device may cause
personal injury. Customers using or selling this device for use in such
applications do so at their own risk and agree to be fully responsible
for any damages resulting from improper use or sale.

Some of the IC devices used in the TIO are static-sensitive and may
be damaged by improper handling. When adjusting or servicing the
device, use of a grounded wrist strap is recommended to prevent
inadvertent damage to the integral solid-state circuitry.
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2. SAFETY INSTRUCTIONS / INTRODUCTION

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3. SPECIFICATIONS
ADC/DAC RESOLUTION: 12 bit.
ACCURACY: ±0.1% F.S.
ANALOG INPUTS: 0-5 Vdc, 4-20 mA, 5-10 Vdc (jumper-selectable),
0-10 Vdc (special order).
ANALOG OUTPUTS: 0-5 Vdc, 4-20 mA (jumper-selectable), 0-10Vdc
(special order).
LCD: 128x64 graphic LCD with instantaneous Flow reading
and Total volume indication. Adjustable LCD contrast
and back light. Refresh rate 10 times/sec.
KEY-PAD: Local 6 tactical push buttons.
DATA PROTECTION: EEPROM backup of all settings, backup Totalizer #1
every one second. Data retention at least 10 years.
Password protection for configuration data.
PULSE OUTPUT: User-programmable, optically-isolated, with preset
active low time interval (10 – 6550 ms), UCE ≤
40Vdc, ICE ≤150 mA (Voltage Isolation: 250 Vrms).
DIGITAL OUTPUT: Two programmable, optically-isolated. UCE ≤40Vdc,
ICE ≤150 mA (Voltage Isolation: 250 Vrms).
DIGITAL INTERFACE: RS-232 or RS-485 (multidrop capability up to 64
devices).
POWER REQUIREMENTS: 12 – 26 Vdc, 100 mV maximum peak-to-peak output
noise (up to 60 mA maximum load).
Protocol: Proprietary ASCII software interface command set.
Speed: 1200 - 2400 - 4800 - 9600 -19200 – 38400 – 57600 – 115200
baud (user-selectable). Default 9600 baud.
Configuration: Stop bit: 1
Data bits: 8
Parity: None
Flow Control: None
Addressing: Maximum 255 addresses, default
address 11 hex. (for RS-485 option only).
Type: RS232 or RS485 2-wire.

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INTERFACE CONNECTORS: Process I/O signals and digital RS-232/RS-485
interface: miniature 9 pin female D-SUB connector.
Digital optically-isolated outputs: TERMINAL BLOCK
HEADER 4POS 3.5MM male pins, Shrouded (Mated
connector: Tyco Electronics P/N: 284510-4).
ENVIRONMENT: Installation Level II; Pollution Degree II.
ELECTROMAGNETIC COMPATIBILITY:
Compliant ref. 89/336/EEC as amended. Emission.
Standard: EN 55011:1991, Group 1, Class A.
Immunity Standard: EN 55082-1:1992.
OPERATING TEMPERATURE:-10 °C to +70 °C (14 °F to +158 °F).
DIMENSIONS: 86.4 x 76.2 x 19.1 mm (3.4" x 3.0" x 0.75") - W x H x D.
WEIGHT: Approximately 125g / 0.3 lbs.

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4. ELECTRICAL CONNECTION
PIN FUNCTION NOTE
1Power supply, common Power input
2Power supply, positive Power input 12 – 26 Vdc
3RS232 RX, Optional RS485 (+) Communication (RS-232 – input, RS-485 –
input/output)
4Analog Input (+), PV input Input
5Analog Output (+), PV set point Output
6RS232 Signal GND (RS-485 GND
Optional)
Communication reference
7RS232 TX, Optional RS485 (-) Communication (RS-232 – output, RS-485 –
input/output)
8Analog Input/Output reference
(common for pins 4 and 5)
9+5Vdc reference input (for 5-10
Vdc interface only)
Figure 4.1 - TIO 9 PIN "D" CONNECTOR CONFIGURATION

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4.2 Process Variable (PV) Input Signal Connections
Depending on the jumper J2 configuration Input signal can be set to 0-5, 5-10,
0-10 Vdc or 4-20 mA.
CAUTION: Do not apply power voltage above 28Vdc.
Doing so will cause device damage or faulty operation.
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CAUTION: When connecting the external signals to the input terminals
always check actual jumper J2 configuration. Do not exceed the rated
values shown in the specifications (see Table 4.1). Failure to do so
might cause damage to this device. Be sure to check if the wiring
and the polarity of the power supply and PV signals are correct before
turning the power ON. Wiring error may cause damage or faulty
operation.
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Make sure power is OFF when connecting or disconnecting any
cables or wires in the system.
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The power supply (PS), process variable (PV) input, set point (SP) control out-
put, and digital communication interface signals are connected to the TIO via
miniature 9 pin female D-SUB connector.
4.1 Power Supply Connections
The power supply requirements for TIO are: 12 to 26 Vdc, (unipolar power sup-
ply).
DC Power (+) --------------- pin 2 of the 9 pin "D" connector
DC Power (-) --------------- pin 1 of the 9 pin "D" connector

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4.3 Set Point (SP) Output Signal Connections
Set Point (SP) output signal connection is required only if TIO is mated to the
flow controller and will be used as a source for a Set Point control signal.
Depending on the jumper J2 configuration, SP output signal can be set to 0-5,
0-10 Vdc or 4-20 mA.
Table 4.1 Maximum rated values for PV input signals
PV
INPUT
TYPE
J2 JUMPER
CONFIGURATION MAXIMUM
SIGNAL
LEVEL
NOTE
J2D J2E J2F
0-5 Vdc 10 -11 14 -15 17-18 ≤6 Vdc
5-10 Vdc 11 -12 14 -15 17-18 ≤11 Vdc +5Vdc reference signal
must be used (GFM/GFC option)
0-10 Vdc 11 -12 14 -15 17-18 ≤11 Vdc Special Order option! (PCB
hardware must be changed)
4-20 mA 10 -11 13 -14 16-17 ≤25 mA (249 Ohm passive, not isolated
current input)
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21
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19
ABCDEFG
Figure 4.2 - TIO Input/Output Configuration Jumpers
PV input (+) --------------- pin 4 of the 9 pin “D” connector.
PV input (-) --------------- pin 8 of the 9 pin “D” connector.

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Table 4.2 Maximum rated load impedance for SP output signals
SP
OUTPUT
TYPE
J2 JUMPER
CONFIGURATION MAXIMUM
LOAD
IMPEDANCE
NOTE
J2A J2B J2C
0 - 5 Vdc 2 - 3 5 - 6 8 - 9 ≤1000 Ohm
0 - 10 Vdc 2 - 3 5 - 6 8 - 9 ≤5000 Ohm Special Order option! (PCB
hardware must be changed).
4 – 20 mA 1 - 2 4 - 5 7 - 8 ≤900 Ohm
(24 Vdc PS)
Self-powered (non-isolated)
current loop. For 12 Vdc PS
the load impedance should not
exceed 400 Ohm.
CAUTION: When connecting the load to the output terminals always
check actual jumper J2 configuration. Do not exceed the rated values
shown in the specifications (see Table 4.2). Failure to do so might
cause damage to this device. Be sure to check if the wiring and the
polarity of the power supply and SP signals are correct before
turning the power ON. Wiring error may cause damage or faulty
operation. Do not connect external voltage source to the SP
output terminals.
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PV output (+) --------------- pin 5 of the 9 pin "D" connector
PV output (-) --------------- pin 8 of the 9 pin "D" connector
WARNING: The 4-20 mA current loop output is self-powered (non-
isolated). Do not connect an external voltage source to the output
signals.
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4.4 Digital Communication Interface Connections
The digital interface operates via RS-232 (optional RS-485) and provides access
to all applicable internal configuration parameters and data.
Communication Settings for RS-232/RS-485 communication interface:
Baud rate: default 9600 baud (user-selectable. See specification section).
Stop bit: .................... 1
Data bits: .................... 8
Parity: .................... None
Flow Control: .................... None

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RS-232 Communication Interface Connection:
Crossover connection must be established:
RS-232 RX
(pin 2 on the host PC DB9 connector)------pin 7 of the 9 pin "D" connector (TX-)
RS-232 TX
(pin 3 on the host PC DB9 connector)------pin 3 of the 9 pin "D" connector (RX+)
RS-232 SIGNAL GND
(pin 5 on the host PC DB9 connector)------pin 6 of the 9 pin "D" connector
RS-485 Communication Interface Connection:
The RS485 converter/adapter must be configured for: multidrop, 2 wire, half
duplex mode (See Figure 4.3). The transmitter circuit must be enabled by TD or
RTS (depending on which is available on the converter/adapter). Settings for the
receiver circuit should follow the selection made for the transmitter circuit in order
to eliminate echo.
RS-485 T(-) or R(-) ----------------- pin 7 of the 9 pin "D" connector (TX-)
RS-485 T(+) or R(+) ----------------- pin 3 of the 9 pin "D" connector (RX+)
RS-485 GND (if available) ----------------- pin 6 of the 9 pin "D" connector

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Figure 4.3 RS-485 Multidrop Half Duplex Two Wire System

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When the TIO device is set as the last device on the RS-485 bus segment and
220 Ohm bus termination is required, set the jumper J2G to position 19-20. This
will result in connection 220 Ohm resistor between RS-485 (+) and (-) terminals.
4.5 Digital and Pulse Optically-Isolated Outputs
Connections
TIO is equipped with two programmable digital optically-isolated outputs. Each
output can be assigned to any one of many different system events or config-
ured as a pulse output (see Paragraph 5.3.9).
Digital optically-isolated outputs use dedicated 4 position 3.5mm male terminal
block header J1 located on the top side of the TIO enclosure (see Figure 6.1).
(Mated interface connector: Tyco Electronics P/N: 284510-4).
Optocoupler #1 - Terminal J1 (pins 1 and 2):
Plus (+) (passive) --------------- Terminal J1 pin 1
Minus (-) (passive) --------------- Terminal J1 pin 2
Optocoupler #2 - Terminal J1 (pins 3 and 4):
Plus (+) (passive) --------------- Terminal J1 pin 3
Minus (-) (passive) --------------- Terminal J1 pin 4
WARNING: Optically-isolated outputs require application of external
DC voltage across terminals. Do not exceed maximum allowed
limits for voltage and current provided below:
2 V < UCE < 40 V
0.2 mA < ICE < 150 mA
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WARNING: Optically-isolated outputs have maximum absolute
voltage rating 250 Vdc RMS. Do not exceed maximum allowed limits
for voltage. Doing so may cause personal injury or damage to this
device.
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5. LCD KEY-PAD OPERATION: DATA ENTRY AND
CONFIGURATION
5.1 Display Indications
Initially, after the power is first turned on, the Banner Screen is shown for 2 sec-
onds, then device firmware and EEPROM data base table revisions on the first line,
communication interface type on the second line, baud rate and RS-485 hexadec-
imal address value on third and fourth lines are shown for another 2 seconds.
Subsequently, the actual process information (PI) is displayed.
Figure 5.1: TIO Firmware and Communication Interface Info Screen
Based on device configuration (Device Function as flow meter or flow controller),
different parameters may be displayed in the Process Information (PI) screen by
pressing the UP or DN pushbuttons.
Process Information screens can be configured to be static or dynamic (see
Paragraph 5.3.11 “Display Menu”). Using Screen Mask settings user can enable
(unmask) or disable (mask) up to 4 different process information combinations
(see Figure 5.4). In the Static Mode the UP button pages through the PI screens
in the forward direction, the DN button pages through the PI screens in the reverse
direction. When the last PI screen is reached, the firmware “wraps around” and
scrolls to the initial PI screen once again.
In the Dynamic Display Mode, firmware initiates automatic screen sequencing with
user- adjustable screen Cycle Time (see Paragraph 5.3.11 “Display Menu”). When
the last PI screen is reached, the firmware “wraps around” and scrolls to the ini-
tial PI screen once again.
Fw: A002 Tbl: A001
Interface: RS-232
Baud Rate: 9600
RS485 address: 11
NOTE: Actual content of the LCD screen may vary depending on the
model and device configuration.
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NOTE: Actual content of the LCD screen may vary depending on the
model and device configuration.
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99.97
A:D litr/min
T1: 1589324.5 litr
99.97
S: 100.0 litr/min
T1: 1589324.5 litr
Figure 5.2: TIO Initial PI Screen (Device Function: Flow Meter)
Figure 5.3: TIO Initial PI Screen (Device Function: Flow Controller

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Device Function: Flow Controller
Figure 5.4: TIO PI Screen (based on device function)
Device Function: Flow Meter
51.01
A:D litr/min
T1: 254898.0
litr
51.01
KF:D litr/min
T2: 436.5
litr
51.01 litr/min
A:D KF:D
T1: 254898.0 litr
T2: 436.5
litr
51.01 litr/min
A:D KF:D
Events Reg: No Events
PO:E U/P: 1.000 litr
DO# 1: Pulse Output
DO# 2: Disabled
51.01
S: 51.0 litr/min
T1: 254898.0
litr
51.01
KF:D litr/min
T2: 436.5
litr
51.01 litr/min
A:D KF:D
T1: 254898.0 litr
T2: 436.5
litr
51.01 litr/min
S 51.0 0.0s
CS: 1 0.0 0
M:D L:O S: Off
5.1.1 Set Point Control
(only for devices set as controller)
When TIO is configured as controller it can be used to control set point value for
mated flow controller using analog output interface.
NOTE: Your TIO device input / output jumpers were factory configured
according to your order. Make sure the mated flow controller has
an analog input interface compatible with the TIO analog output
configuration. Before applying the power and process signals make
sure the input /output jumpers are installed in the correct position
(See Table 6.5).
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The Set Point value can be adjusted locally using LCD/keypad, remotely via RS-
232/RS-485 digital interface or can be programmed in advance using user-preset
programs of up to sixteen steps (Program Set Point Mode).
a) Adjusting Set Point value using local LCD/keypad
Current Set Point value is displayed on the second line of the main PI screen, next
to the ‘S’ character.
Pressing the ENT button while in the main PI screen will activate Set Point adjust-
ment mode. The first character of the Set Point value will start to flash. Use UP or
DN button to increment / decrement digit value from 0-9. Use RIGHT or LEFT but-
ton to move cursor to another digit position. When desired Set Point value is
entered use the ENT button to accept (save in the EEPROM) new Set Point value.
If at the end of the Set Point value entry the ESC button is pressed instead ENT,
the original Set Point value will be restored and Set Point adjustment mode will be
deactivated. To exit from the Set Point adjustment mode before Set Point value is
accepted, press the ESC button.
b) Controlling Set Point value using Program Set Point mode
To activate Program Set Point mode the following must to be done:
1. Program Set Point mode must be Enabled (see paragraph 5.3.16 a).
2. Program Loop parameter must be set to desired value (On/Off).
3. Program Run parameter must be set to “On” (default settings is Off).
NOTE: Since the Set Point value entered via local LCD/keypad is
stored in the non-volatile memory (EEPROM), it will be executed on
the next device power up event.
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NOTE: If the Program Set Point mode is enabled and the program is
running, the Set Point value can be changed at any moment by the
execution of the next active step. The Set Point entered via local
LCD/keypad can be also changed via digital RS-232/RS-485 interface.
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99.97
S: 100.0 litr/min
T1: 1589324.5 litr