Contrec 114D User manual

MAN-114D-V1.3 6
FIELD MOUNTED
BATCH CONTROLLER
MODEL 114D
APRIL 2019

MAN-114D-V1.3
CONTENTS
1. Introduction 1
2. Specification 2
3. Operation 4
3.1 Front Panel Operation 4
3.2 Test Mode 6
3.3 Batch Operations 7
3.3.1 Control Outputs 7
3.3.2 Signal Timeout 8
4. Programming 9
4.1 Program Steps 10
4.2 Example 11
5. Valve Control and DC Power 12
6. Battery Backup 14
7. Flowmeter Input 15
8. Installation 20
8.1 Wall Mounting 20
8.2 Removing the Front Panel 21
8.3 The Main Electronics 22
8.4 Wiring 23
8.5 Maintenance 23
8.6 Terminal Designations 23
9. Disposal 24
9.1 Instrument Disposal 24
9.2 Battery Disposal 24
Index 25

MAN-114D-V1.3 6

Introduction 1
MAN-114D-V1.3 6
1. INTRODUCTION
The Model 114 Batch Controller is a microprocessor based instrument which
accepts a frequency or pulse input from a wide range of flowmeters and
automatically controls the batching of fluids via a one stage or two stage control
valves. The instrument displays the Preset value, a Resettable Batch Total and an
Accumulated Total directly in engineering units.
The Model 114 is fully programmable from the front panel; the user can program
scaling factors, decimal point positions, valve delays and signal timeouts.
The instrument is compatible with a wide range of flowmeters. Links on the input
board enable the circuit to be configured for millivolt signals, reed switches,
Namur proximity switches and most other signal types.
The instrument is housed in an attractive polycarbonate enclosure which is
completely watertight. A universal bracket is supplied as standard for wall
mounting while optional pipe or panel mounting brackets are also available.
The Model 114 Batch Controller conforms to the EMC-Directive of the Council of
European Communities 2014/30/EU, the LVD directive 2014/35/EU and the
following standards:
EN61326:2013 Electrical equipment for
measurement, control and
laboratory use –EMC requirements :
Residential, Commercial & Light
Industry Environment & Industrial
Environment.
EN61010:2010 Safety requirements for electrical
equipment for measurement,
control, and laboratory use.
In order to comply with these standards, the wiring instructions in Section 9.5
must be adhered to.

2Specification
MAN-114D-V1.3
2. SPECIFICATION
General
Display: LCD which is continuously powered.
Batch Total: 7 digits with 10mm (0.4") high digits.
Accumulated Total: Displayed when the ACCUM TOTAL button is
pressed.
Preset: 5 digits with 8.5mm (0.33") high digits.
K-factor: The pulses per unit of measure (eg. pulses/gallon)
is programmable in the range 0.0001 to 999,999.
Decimal Points: Decimal point position is fully programmable for
the total and preset.
Frequency Range: 0Hz to 10kHz.
Signal Type: Link settable for sinewave (15mV P-P minimum),
open collector, reed switch, pulse or Namur
proximity switch.
DC Power Input: 9-28 Volt at 4mA maximum.
Battery Backup
Type: The two Lithium cells are 3.6V, AA types. e.g.
TADIRAN SL360/S, SAFT LS14500EX.
Note the battery polarity when replacing.
Battery Life: 2 years typical.
Outputs
Outputs: Two solid state relay outputs suitable for driving
DC solenoids or external relays.
Switching Power: 200mA. 30VDC maximum.
Supply Backup: Lithium battery.
Isolation: Both outputs are separately isolated via opto-
isolators.

Specification
MAN-114D-V1.3 6
3
Physical
Temperature: Operating temperature: -20 C to 60 C.
Dimensions: 98mm (3.9") high x 152mm (6.0") wide x 43mm
(1.7") deep (cable glands not included).
Protection: Sealed to Nema 4X or IP67 standards.
Cable Entry: By cable glands.
Material: Polycarbonate and ABS.
Wall Mounting: Universal mounting bracket supplied as standard.

4Operation
MAN114D-V1.3
3. OPERATION
The Model 114 Batch Controller accepts a frequency or pulse input from a wide
range of flowmeters. The instrument is fully programmable with all operating
parameters and calculation constants programmable from the front panel. The
setup parameters are stored in a non-volatile memory and are retained for at
least 10 years in the event of a power loss.
3.1 FRONT PANEL OPERATION
Three keys on the front of the instrument provide an easy and straight forward
method to set up batches and control operations. The three keys each have dual
functions as described below:
Front Panel Keys
SETTING THE PRESET QUANTITY
The Batch quantity is programmed as follows:
Switch Action
Display
Comments
Press PRESET
The Accumulated Total together with the
Preset quantity is displayed.
"1"2345
The most significant digit of the Preset
quantity flashes indicating that it can be
changed.
Press
"2"2345
Pressing the key will increment the digit.
(The up arrow on the Stop key indicates to
increment the digit.)

Operation
MAN-114D-V1.3 6
5
Switch Action
Display
Comments
Press
2 "2"345
Pressing the key will change digit and
enables the next digit to be incremented.
(The right arrow on the RUN key indicates
to change digit.)
Press PRESET
22345
Pressing PRESET returns the instrument to
the Run mode and batches can now be run.
Note: If there are no keys pressed within 10 seconds while the instrument is in
preset mode it will return to the run mode saving the current value as the preset
quantity.
Upon exit of preset mode the value is checked against the programmable batch
limit. If the value is greater than the batch limit the preset value is set to the
programmed limit. This check is disabled if the batch limit is programmed as zero.
Once programmed, the Preset quantity will be retained in memory and will not
alter until changed by the user. The Preset quantity can only be set while the
instrument is in a non-operational state such as when the batch is complete, or
has been cancelled.
STARTING A BATCH
To start a batch press the RUN key. The Total will then reset to zero and,
provided there is flow, the Total display will start counting upwards.
The batcher has two output transistors and these are switched on and off as
described in section 3.3.
STOPPING
The process can be stopped at any time by pressing the STOP switch. This is
indicated by the "Pause" message being displayed on the screen. Once the
process has been interrupted in this way, it can be continued by pressing the RUN
key or the process can be aborted by pressing the STOP switch a second time.

6Operation
MAN-114D-V1.3
ACCUMULATED TOTAL
During a batch run, the Accumulated Total can be displayed by pressing the
ACCUM TOTAL key. In the non-operational state (ie. when the batch is complete),
the ACCUM TOTAL key also functions as the PRESET key and enables the Preset
quantity to be changed.
The Accumulated Total cannot normally be reset, except by pressing the internal
Reset button (see section 9.4).
3.2 TEST MODE
The 114 has a Test Mode which can be entered and exited by pressing and
holding the front panel keys in certain sequences to avoid accidental entry or
falsely starting a batch. To enter Test Mode, the front panel keys should be
pressed and held in the following order: the STOP key and then the ACCUM
TOTAL key.
Note the test mode cannot be entered while the instrument is in program mode or
preset mode.
The tests are as follows:
Relay 1 Test By pressing the RUN key, the display will show the
test for Relay 1. The output will only activate
while the RUN key is being pressed.
Relay 2 Test By pressing the STOP key, the display will show the
test for Relay 2. The output will only activate
while the STOP key is being pressed.
Display Test By pressing the PROGRAM key, all segments of the
display will flash.
Note the relay outputs are only operated when external DC power is present. And
any batch in progress when test mode is entered is stopped and cannot be
resumed.

n
MAN-114D-V1.3 6
To exit Test Mode, the front panel keys should be pressed and held in the
following order: the ACCUM TOTAL key and then the STOP key.

8Operation
MAN114D-V1.3
3.3 BATCH OPERATIONS
The operation of the Batch Controller is shown below:
3.3.1 Control Outputs
The two solid state relay outputs can be set up to control a single valve or a dual
valve with slow stop and/or slow start. Alternatively, the second output can be
used to control a pump.
The output operation is shown above.
A time delay between the Start and the time when Output 2 switches on can be
programmed to provide a soft startup. The delay can range from 0 (no delay) to 9
seconds.
A Pre-stop quantity (ie. the quantity to the end of the batch) can also be
programmed to provide a slowdown of flow at the end of the batch, thereby
enabling precise quantities to be batched.
Run
PAUSE
Stop Run
Batch
Quantity
Reached Run
Output 1
Output 2
"on" state
"on" state
Start Time Prestop
Quantity
Two Stage Valve Control

MAN114D-V1.3
The process can be stopped at any time by pressing the STOP key, whereby both
outputs will immediately switch off. The process can then be aborted and the
batcher reset by pressing the STOP key again, or the process continued by
pressing the RUN key.
If the process is continued and the instrument was previously in the slow start or
main control phases (ie. not the pre-stop phase), the timer will be reset and a
slow start will occur with a full time delay to ensure a correct start up. The totals
will not be reset and the batch quantity will remain unchanged.
3.3.2 Signal Timeout
The Signal Timeout period defines a time interval which is used to detect if the
flow has stopped. If there is no signal input for a time greater than the Signal
Timeout period, the flow is deemed to have stopped. A Signal Timeout period
detects the loss of signal midway through a batch when the outputs are on. In
this case, the Batcher will enter a Flow Alarm condition and switch off the
outputs.
The Flow Alarm condition is maintained until acknowledged by pressing the STOP
switch. The alarm condition is also signalled to the operator by the PAUSE
message being flashed on the display.
The instrument enables the user to program a time interval of up to 99 seconds to
detect an absence of signal input.
If the Signal Timeout is set to 0, this function is disabled.

10 Operation
MAN114D-V1.3
4. PROGRAMMING
The Model 114 is fully programmable, with all parameters being stored in
memory.
The Program Mode can be entered in one of two ways:
1. By removing the lower cover strip (ie. the dark grey strip along the bottom
of the enclosure) and turning it end for end and replacing it. This brings a
small magnet, on the inside of the cover strip, in close vicinity of a reed
switch inside the instrument.
2. By removing the front section of the enclosure which contains the main
processor board and batteries. Once removed, the PRESET key is pressed
to enter the Program Mode.
The PRESET switch is used to step through the program (CAL sequence) and the
and keys on the front panel are used to change and increment the flashing
digits. Six CAL steps are accessible in the Calibration mode. The CAL number is
displayed on the lower display and the parameter is displayed on the upper
display.
Any batch in progress when the Program mode is entered, is stopped and cannot
be resumed. Also, no incoming pulses are totalised while the unit is in Program
mode.
To exit the Program mode the lower cover strip should be returned to its original
position or the front panel should be refitted.
Parameters in Program Mode that consist of the two parts, whole numbers and
digits after the decimal point, are restricted to having a maximum of 6 significant
digits. Therefore the number of significant digits entered in the whole numbers
determines the number of digits that are able to be entered in the digits after the
decimal point.
For Example
000001 in the whole numbers makes 0000 available after the decimal place.
000100 in the whole numbers makes 000 available after the decimal place.
010000 in the whole numbers makes 0 available after the decimal place.

MAN114D-V1.3
4.1 PROGRAM STEPS
Step
Comment
CAL 01
Scaling Factor - whole numbers.
CAL 02
Scaling Factor - digits after the decimal point.
The Scaling Factor is the pulses per unit of measure (eg.
pulses/litre, pulses/gallon, etc). The Scaling Factor can
be programmed in the range of 0.0001 - 999,999.
CAL 03
Decimal Point for Total Display.
The total and preset quantity can be displayed with 0, 1,
2 or 3 decimal point places.
CAL 04
Start Time Delay.
The time in seconds (0-9 sec) when Output 2 will switch
"on" once the RUN key is pressed.
CAL 05
Prestop Quantity
The quantity at which Output 2 will switch "off" before
the end of the batch (Eg. If the Preset quantity is 100
litres and the Prestop quantity is 2 litres, Output 2 will
switch off after 98 litres.)
CAL 06
Signal Timeout.
A time period between 0-99 seconds during which, if
there is no flow measured, the Outputs will both switch
"off" and the PAUSE message will be displayed.
CAL 07
Batch Limit.
This value determines the maximum preset value that
may be entered by the operator. A value of zero for the
batch limit disables this feature.
SOFT
Software Version.

12 Programming
MAN114D-V1.3
4.2 EXAMPLE
A flowmeter produces 20.538 pulses per litre and has a maximum flowrate of 150
litres/minute. It is required to batch quantities in batches of around 300 litres
and to alarm if there is no flow once the batch has started.
To increase the accuracy of the batch, a two stage valve will be used and the flow
will be slow prior to the end of the batch to enable a more accurate cutoff.
It has also been decided to reduce the flowrate 10 litres prior to the end of the
batch. The instrument is then programmed as follows:
Step
Value of
Parameter
Description
CAL 01
00020
Scaling factor (Whole numbers).
CAL 02
5380
Scaling factor (Decimals).
CAL 03
1
One decimal place.
CAL 04
1
One second delay on full flow to stop
pipe hammer.
CAL 05
10
10 litre prestop.
CAL 06
2
Two second signal timeout.
CAL 07
350
350 litre batch limit.
SOFT
1.XX
Software Version.

MAN114D-V1.3
5. VALVE CONTROL AND
DC POWER
The Model 114 will operate from an external power source between 9-28VDC and
draws no more than 4mA. This enables the instrument to be powered from AC
mains adaptors and eliminate the need to run mains voltage in the field.
As the instrument has an internal battery backup it will power the instrument if
DC power is interrupted, but these batteries are not capable of powering the
solenoids or sensors if they require external power (see section 6 for further
description of operation with battery backup.)
Solid state relay outputs provide control to solenoids or relays and can sink up to
200mA. The outputs are internally protected against voltage spikes caused by
relays and coils. Connections for a dual stage applications is given on the
following page.
For single stage applications, only Output 1 is required.
Specification for Outputs
Maximum Current (sink): 200mA.
Maximum Voltage: 30VDC.
Saturation Voltage: 0.8VDC max across the outputs in the "on"
state.

12 Valve Control & DC Power
MAN114D-V1.3
Relays with DC Coils

MAN114D-V1.3
6. BATTERY BACKUP
The Model 114 has bettery backup for the instrument if the supply has been
interrupted. The lithium battery packs provide sufficient capacity to power the
instruments for up to 2 years and the operator is warned of a low power
condition by a message on the LCD display.
Note: No low battery warning will be displayed whilst there is external DC power
connected.
6.1 POWER INTERRUPTION
With battery backup the Model 114 has the ability to resume a batch if the DC
power is interrupted during a delivery. The 114 will also totalise any incoming
pulses while power is unavailable.
If a batch is in progress and the external DC power is lost, both relay outputs will
be deactivated and the batch will be paused. The paused batch can only be
restarted when the DC power returns. However, the paused batch will be
terminated if the STOP key is pressed or if any totalising of pulses causes the
Batch Total to exceed the Preset Value.

14 Battery Backup
MAN114D-V1.3
7. FLOWMETER INPUT
The Model 114 has an input conditioning circuit which will accept signals from
most pulse or frequency producing flowmeters. Links on the LCD panel enable
the input circuit to be configured for different signal types.
The input will interface directly to:
Turbine flowmeters.
Open collector outputs.
Reed switches.
Logic signals.
Two-wire proximity switches.
The following pages give examples of interconnection to various signal outputs. A
circuit diagram of the input is also provided.
For pulse or logic type signals, the input switching threshold is 1.3 volts. That is,
the input signal must have a "low" voltage of less than 1.2 volts and a "high"
voltage of greater than 1.4 volts.
For flowmeters with coils, the minimum input voltage is 15mV P-P.
All inputs are protected for over voltage up to 28 volts.