Contrec 414Q User manual

BATCH CONTROLLER
MODEL 414Q
July 2001

CONTENTS
1. Introduction 3
1.1 Model Number Designation 4
2. Specification 5
3. Operation 7
3.1 Front Panel Operation 8
3.2 Batch Operations 11
3.2.1 Control Relay Outputs 13
3.2.2 Signal Timeout 14
3.2.3 End of Batch 15
3.2.4 Auto Restart 16
3.2.5 Automatic Overrun Compensation 17
3.3 Single and Quadrature Inputs 18
3.4 Calculation of Rate and Total 19
3.4.1 Frequency Input 19
3.4.2 Filtering 20
3.5 Total Conversion 22
3.6 Non-Linearity Correction 23
3.7 The Output Pulse and Flow Alarm 25
4. Options 27
4.1 The RS232/422/485 Interface Option 27
4.1.1 Hardware 27
4.1.2 Multipoint Communication 28
4.1.3 Communication Protocol 30
5. Calibration 32
5.1 Programming the Setup Parameters 34
5.2 Entering the Batch Parameters 37
5.3 Programming Options 39
5.4 Checking the Input Signal 41

6. Input Circuits 42
6.1 Flow Inputs 42
6.2 Remote RUN and STOP Switches 48
7. Installation 49
7.1 General 49
7.2 Wiring Designations for the Model 414Q 51
7.3 Ex 410 Enclosure Dimensions 52
8. Trouble Shooting 53
8.1 Error Codes 56
Index 57

1. INTRODUCTION
The Model 414Q Batch Controller is designed for high accuracy flow
applications where it is required to batch liquids using a one or two stage valve
The Batch Controller includes such features as:
SINGLE or QUADRATURE pulse inputs.
NON-LINEARITY CORRECTION.
TICKET PRINTING or COMPUTER interface options.
The Model 414Q is ideally suited to custody transfer applications where high
accuracy and signal integrity is required.
The instrument is fully programmable, with all calculation constants set via the
front panel switches and stored permanently in a non-volatile memory.
This instrument conforms to the EMC-Directive of the Council of European
Communities 89/336/EEC and the following standards:
Generic Emission Standard EN 50081-1 Residential, Commercial & Light
Industry Environment.
Generic Emission Standard EN 50081-2 Industrial Environment.
Generic Immunity Standard EN 50082-1 Residential, Commercial & Light
Industry Environment.
Generic Immunity Standard EN 50082-2 Industrial Environment.
In order to comply with these standards, the wiring instructions in Section 7.1
must be followed.
Introduction 3

1.1 MODEL NUMBER DESIGNATION
The Model number of an instrument describes which input and output options are
installed and the AC mains voltage rating.
Model 414 Q. 1 0 E B
B for Backlite
C for Conformal Coating
E for 220/240 VAC
A for 110/120 VAC
D for DC Power Only
Options
0 for no option
2 for RS232/422/485
Mounting
1 for panel mounting
2 for field mounting
3 for explosionproof
The Model Number of the instrument is displayed on first entering the
Calibration Mode (see Section 5).
4Introduction

2. SPECIFICATION
General
Display: 6 digit LCD. 0.7" (17.8mm) high digits.
Display Update Rate: 0.25 seconds.
Transducer Supply: 8-24VDC field adjustable.
50mA maximum.
Power Requirements: 11.5 to 28.5 volts DC.
130 mA typical current (no options).
AC Mains: Set internally to 95 - 135 VAC or
190 - 260 VAC.
Operating Temperature: 0 to 55°C standard.
Dimensions: 5.7" (144mm) wide x 2.8" (72mm) high x
7.0" (178mm) deep.
Cutout:5.5" (139mm) wide x 2.6" (67mm) high.
Frequency Input
Frequency Range: Minimum: 0.25Hz on Rate.
0Hz on Total.
Maximum: 10KHz with a single input.
2.5KHz with a quadrature
input.
Input Circuits: Will accept most sine logic and proximity
switch inputs (see section 6.1).
Scaling Range: 0.1000 to 50,000.
Relay Outputs
Maximum Switching Power: 1250VA.
Maximum Switching Voltage: 250VAC, 30VDC.
Maximum Switching Current:5 Amps.
Specification 5

Pulse Output
Pulse Width: 10mSec (negative going pulse).
Maximum Duty Cycle: 49 pulses per second.
Scaling: The pulse output is scaled and outputs one
pulse each time the accumulated total
increments.
Non-linearity
Number of Points: 10 correction points maximum.
Correction between Points: Linear interpolation used.
6Specification

3. OPERATION
The Model 414Q uses a low power CMOS microprocessor to perform all control
functions and calculations.
The instrument is fully programmable with all operating parameters and
calculation constants user programmable. (See Section 5 entitled "Calibration"
for information on programming.) All parameters and constants are stored in a
non-volatile memory which retains data without battery backup for a minimum of
10 years.
A block diagram of the instrument is shown below.
A DIL switch on the rear panel enables the frequency input circuit to be set to
interface with a wide range of flowmeters, including turbine flowmeters and
flowmeters with Namur type sensors.
Operation 7
RS232/422
Option RS232/422
Output
PC/EOB
Control
Relay Outputs (2)
Pulse
Output
Flow Alarm
DC Input Power
DC Power Output to Sensors
DC Power Ground
110/220V
AC Mains
Pulse Input
Channel 2
Signal
Common
Pulse Input
Channel 1
Relays
Model 414Q

3.1 FRONT PANEL OPERATION
The four key operation of the Batch Controller is straight forward.
SETTING THE BATCH QUANTITY
The Batch quantity is programmed as follows:
Switch Action Display Comments
Press BATCH SET Batch "Batch" is displayed for one second
followed by the batch quantity last
entered. The Batch Set LED lights.
"1"2345 The most significant digit flashes
indicating that it can be changed.
Press "2"2345 Pressing the DISPLAY key will
increment the digit. The up arrow on
the Display key indicates to increment
digit.
Press 2 "2"345 Pressing the RUN key will change digit
and enables the next digit to be
incremented. The right arrow on the
RUN key indicates to change digit.
Press BATCH SET Set Once the desired number is entered,
press the BATCH SET key to return to
the Run mode. The Batch Set LED will
extinguish.
Once programmed, the Batch quantity will be retained in the non-volatile
memory and will not alter until changed by the user.
8Operation

The Batch quantity can only be set while the instrument is in non-operational
state such as when the batch is complete, or if the batch process has been
interrupted. However, the Batch key can be pressed while in the run state and the
Batch quantity checked. All digits will flash to signal the quantity cannot be
changed.
STARTING A BATCH
To start the process the RUN key is pressed. The Run LED will light and the
instrument will begin to totalise from zero or, if programmed for the count down
mode, the display will decrement from the batch quantity.
The batcher has two output relays and these are energised and de-energised as
described in section 3.2.
STOPPING
The process can be stopped at any time by pressing the STOP switch. Once the
process has been interrupted in this way it can be continued by pressing the RUN
switch or the process can be aborted and the instrument reset by pressing the
STOP switch a second time.
When the process is interrupted, the STOP LED will flash to prompt the
operator to either restart or abort the batch.
RESETTING
The instrument can be programmed to reset in one of two ways.
At the end of a batch, the STOP key must be pressed to reset the Batch
Total. If the instrument is programmed to count down, the Batch Total
will then revert to the preset quantity. If it is programmed to count up,
the Batch Total will clear to zero.
If Auto Reset is programmed, the Batch Total will automatically reset
when the RUN key is pressed and then commence the next batch.
Operation 9

DISPLAYED INFORMATION
The display will normally show the Batch Total, which is the total count for the
current batch and is reset on each new batch.
The DISPLAY key can be used to display the following additional information:
Rate
On the first press of the DISPLAY key, the display shows RATE for
one second followed by the flowrate.
Accumulated Total
On the next press of the DISPLAY key, the display shows ACC for one
second followed by the actual total. The Accumulated Total cannot be
reset during normal operation.
LIMIT ON BATCH SIZE
To prevent accidental entry of large batch quantities, a maximum batch limit can
be programmed during calibration. The operator is then prevented from entering
a batch quantity which exceeds this value.
10 Operation

3.2 BATCH OPERATIONS
The Batch Control functions can be programmed, during Calibration, to operate
in one of two ways.
1. At the end of the batch, the STOP key must be pressed to reset the Batch
Total. (This must be done before another batch can be started.)
Operation 11
Relay 1
Relay 2
End of
Batch
Start Time Prestop
Quantity
End of Batch
Run Stop Run
PAUSE Batch
Quantity
Reached Reset Run
Count Down
Count Up

2. If Automatic Reset is programmed, a new batch is commenced each
time the RUN key is pressed.
The Batch Controller can also be programmed, during Calibration, to either
count up from zero on each batch, or to count down from the preset batch
quantity.
12 Operation
Relay 1
Relay 2
End of
Batch
Start Time Prestop
Quantity
End of Batch
Run Stop Run
PAUSE Batch
Quantity
Reached
Count Down
Count Up
Run
Auto Restart
Time

3.2.1 Control Relay Outputs
The two output relays can be set up to control a single valve or a dual valve with
slow stop and/or slow start. Alternatively, the second relay can be used to control
a pump.
The relay operation is shown on the previous two pages.
A time delay between the Start and the time when relay 2 energises can be
programmed to provide a soft startup. The delay can range from 0 (no delay) to
79 minutes and 59 seconds.
A Prestop 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.
The process can be stopped at any time by pressing the STOP key, whereby both
relays will immediately de-energise. 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 prestop 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.
Operation 13

3.2.2 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 has
two functions:
To detect the loss of signal midway through a batch when the relays
are energised. In this case, the Batcher will enter a Flow Alarm
condition and de-energise the relays.
After the preset batch quantity has been reached and the relays
de-energised, some overrun of flow may occur due to slow valve
closure, etc. In this case, the Signal Timeout is used to determine
when the flow has ceased and thereby accurately determine the
amount of overrun.
It is recommended that Signal Timeout periods are kept fairly short, but long
enough such that the period is significantly longer than the time period between
successive input pulses from the flowmeter at the minimum flowrate.
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.
Flow Alarm
If the Signal Timeout is set at greater than 0, and loss of signal is detected
midway through a batch, a Flow Alarm signal is output on terminal 7. In
addition, both relays are de-energised. The Flow Alarm output and condition is
maintained until acknowledged by pressing the STOP switch. The alarm
condition is also signalled to the operator by the flashing STOP LED. Once
acknowledged, the process can then be reset via the STOP switch or continued by
pressing the RUN key.
14 Operation

3.2.3 End of Batch
The End of Batch is defined as being when the Batch Quantity is reached, the
flow has stopped and the Signal Timeout period has expired.
If the Signal Timeout is set to zero, the End of Batch is defined as being when the
Batch Quantity is reached, regardless of whether the flow has stopped.
The Batch Controller cannot be reset or restarted until the End of Batch and
similarly, for an RS232/422/485 interface, data will not be output until the End of
Batch has been determined. Consequently, it is strongly recommended that the
Signal Timeout period be kept fairly short.
End of Batch Signal
An End of Batch signal from an open collector transistor is output on terminal 30
and the output is identical to the Output Pulse circuit as shown in section 3.7).
When reaching the End of Batch, the output transistor is switched on, and will
remain in the "on" state until the instrument is reset.
Operation 15
Signal
End of
Batch
End of
Batch
(Timeout = 0)
Batch Quantity
Reached Reset
Signal Timeout

3.2.4 Auto Restart
The Batch Controller can be programmed to continually repeat the batch process.
This mode of operation is selected during the programming procedure.
The process is started by pressing the RUN key whereby the normal batch
operation is commenced. After reaching the End of Batch (see section 3.2.3), the
Batch Controller will then wait for a pre-programmed period before
automatically resetting and starting the batch process once again.
The STOP button can be pressed at any time to interrupt the batching process and
continued using the RUN key. If, however, the process is to be aborted, the
STOP key is again pressed. The Batch Controller is reset and to restart the auto
batching process the RUN key is pressed.
16 Operation

3.2.5 Automatic Overrun Compensation
The Batch Controller can be programmed to automatically compensate for any
overrun at the end of a batch.
Typically, this could be due to the slowness of a valve to close or a pump to stop
pumping on receiving a signal from the Batch Controller. The result is that the
batch quantity will always read higher than the batch quantity set.
The Automatic Overrun Compensation can be enabled or disabled during the
Calibration routine and this feature should only be used if the overrun is
repeatable. The user is cautioned against using Automatic Overrun
Compensation if the overrun is erratic, such as may occur with changing back
pressures or sticking valves.
In calculating the amount of overrun to be compensated for, the Batch Controller
uses the average overrun on the last three batches.
The overrun is defined as the difference between the batch quantity set by the
user and the batch total once the flow has stopped.
With Automatic Overrun Compensation, the Signal Timeout must be set to a
value greater than zero.
Once the Batch Controller de-energises both relays, the instrument looks for a
Signal Timeout, indicating that the maximum interval between pulses has
occurred and that the flow must, therefore, have stopped. It then uses the overrun
quantity measured during this period and averages this together with the overrun
on the last two batches. The resulting value is then subtracted from the next
batch.
Operation 17

3.3 SINGLE AND QUADRATURE INPUTS
In most industrial flowmetering applications, a frequency producing flowmeter
has only a single output.
However, in many custody transfer applications, it is a requirement that the
flowmeter has two outputs so that the integrity of the signal can be assured. This
usually requires a turbine meter to have two coils, or a positive displacement
meter to have two pulse units.
The Model 414Q can interface to flowmeters fitted with two sensors and
connections to the flowmeters are outlined in Section 6.1.
The quadrature input has two functions.
1To detect a difference in the number of pulses from each input
during delivery.
The instrument will alarm if the pulse difference (since reset) exceeds
1 in 1000 pulses. When an alarm condition exists the totals will cease
counting and will freeze at the last total prior to the alarm.
On detection of the alarm condition, the alarm output on terminal 7
will go low (energise), the output relays will de-energise and the stop
LED will flash, indicating that the batch can be continued by pressing
the RUN key or aborted using the STOP key. The display will also
periodically flash the error message, ERR 13.
2Bi-directional Flow.
The 414Q has the ability to detect forward and reverse flow. The
inputs must be connected with channel 1 being the 90° flow signal and
channel 2 being the 0° signal. For forward/reverse detection to
function correctly, there must be clear definition of the input signals.
18 Operation