GPI GBT 110 User manual

99878 05/20/03
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.
Application
The unit is normally used for batch control or inventory tracking. The display may be toggled between
batch, rate, and grand total. A programmable K-factor makes keying-in engineering units easy. The unit
accepts pulse or contact closure inputs and provides two separate preset controls.
GBT
Principle of Operation
The batcher receives an input from a pulse producing flowmeter through a sensor. The user programs
the batcher to condition the incoming pulses signal and compute the batch flow and flow rate. A wide
variety of different functions can then be performed based on the programmed configurations such as
start/stop functions, totalizing, and/or flow rate monitoring.
GBT Series Technical Manual
GBTGBT
GBTGBT
GBT
Installation and Operating Manual
Features
❑Start/Stop Buttons & Remote Inputs
❑Separate 8 Digit K-Factors For Rate & Total
❑Accepts Pulse Inputs
❑Displays Rate, Total and Grand Total
❑Security Lockout with Missing Pulse Detection
❑Scaled Pulse Output
❑2 Setpoints For Two Stage Valve Control
❑NEMA 4X (IP65) Front Panel

!
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.
•The instrument must be installed, operated and maintained by
personnel who have been properly trained. Personnel must read and
understand this manual prior to installation and operation of the
instrument.
•The manufacturer assumes no liability for damage caused by incorrect
use of the instrument or for modifications or changes made to the
instrument.
Technical Improvements
•The manufacturer reserves the right to modify technical data without
prior notice.

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 ............................................................... 3
1-5 Specifications .......................................................................................................... 4
1-6 Dimensions ............................................................................................................. 5
2. INSTALLATION
2-1 Receipt of Equipment.............................................................................................. 6
2-2 Return Shipment ..................................................................................................... 6
2-3 Panel Mounting ....................................................................................................... 6
2-4 Electrical Connections............................................................................................. 6
2-5 Wiring Connections and Diagrams.......................................................................... 7
3. OPERATION
3-1 Front Panel Operation............................................................................................. 8
3-2 Programming........................................................................................................... 9
3-3 K-Factor Programming............................................................................................ 9
3-4 Programming Flow Chart ...................................................................................... 10
3-5 How to Program .....................................................................................................11
3-6 Frequently Asked Questions About Setting Up The Batcher..................................11
3-7 Setup Procedure For The Batcher ........................................................................ 12
3-8 Run Mode.............................................................................................................. 20
3-9 Internal Operation ................................................................................................. 21
4. INPUTS
4-1 Digital Pulse Inputs ............................................................................................... 22
4-2 DC Power Inputs ................................................................................................... 24
4-3 AC Power Inputs ................................................................................................... 24
CONTENTS

5. OUTPUTS
5-1 Frequency Output ................................................................................................. 24
5-2 Control Outputs ..................................................................................................... 25
6. TROUBLE SHOOTING AND MAINTENANCE GUIDE
6-1 Warning Messages................................................................................................ 26
6-2 Troubleshooting..................................................................................................... 27
6-3 Removing The Case ............................................................................................. 28
6-4 Maintenance.......................................................................................................... 28
7. CALCULATING THE K FACTORS
7-1 General ................................................................................................................. 28
7-2 Calculating the K Factors ...................................................................................... 29
8. Programming Worksheet ................................................................................................ 30
CONTENTS

1
SECTION 1 INTRODUCTION
1-1 General Description
Featuring8digitsofbright,.55inch,alphanumeric
display,theGBTcanacceptupto20,000pulses
per second of digital count. The user, with the
push of a button, can toggle the display to view
thetotalofthebatch,therateoffloworthegrand
total of flow.
The GBT may be thought of as two separate
countersandaratemeter. The"batching"counter
counts to prewarn and preset numbers entered
bytheuserandenablesseparatecontroloutputs.
The "totalizing" counter gives a cumulative
readingorgrandtotal.Theratemeterscalesthe
inputpulsestoprovidegallonsperminuteorany
other rate measurement without the totalizer
losing counts.
Setup is done through the front panel and the
menu driven software in the unit. Start-Stop
control can be activated via the front panel
buttons or remote inputs.
The unit uses an EEPROM to hold data a
minimum of 10 years if power is interrupted.
1-2 Typical Application
The above application involves liquid flow.
The start button is pushed and the Batcher
receives pulses from the flowmeter. The
pulses are scaled by the K Factor and sent
out via the pulsed output to an external
counter. As the Prewarn is reached, the
control valve partially closes. When the final
Preset is reached the valve shuts down com-
pletely. At any time the flow can be sus-
pended by hitting the stop button.
1-3 Principles of Operation
Presets
When the start button is pushed, two relays
engage simultaneously to start flow. When
the prewarn number is reached, one relay
drops out. When the preset number is
reached, the other relay drops out. The user
may enter the two numbers when setting up
the batch counter. The prewarn is set a cer-
tain number of counts less than the preset
number. If the prewarn is set larger than the
preset, the message "PREWRONG" will ap-
pear on the display.
Ratemeter
Accurate to 5 1/2 digits (±1 display digit). The
ratemeter can be programmed to accept al-
most any number of pulses per unit of mea-
surement, sample from 2 to 24 seconds maxi-
mum, and auto range up to 6 digits of signifi-
cant information. The ratemeter with a K Fac-
tor of 1 displays the rate of pulses per second.
Simply dial in the proper K Factor to display in
minutes, hours or other units of measurement.
Press the C button, while the unit is displaying
the batch, to display the rate; 'R' is displayed
on the left side of the display.
K Factor
The K Factor is used to convert the input
pulses or analog input into workable units.
The 8 digit K Factor is a divider with a range
of 0.00011 to 99999999 (the decimal point
may be keyed into any position). Separate K
Factors may be entered into the count and
rate sections of the Batcher. Thus, you may
batch in gallons and display rate in liters per
hour. The maximum factored count speed is
20000 Hz. The maximum factored rate is 7
digits.
123456
Flowmeter
Computer
Solenoid Valve
Remote
Totalizer
Strip Chart
Recorder
Pulse Output
RS232
Output
Analog
Output

2
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) opera-
tion. 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.
Lockout
Unauthorized front panel changes can be pre-
vented by entering a user selected, four digit
code, in the "Lockout" mode. The status of
the unit can be observed but "LOCK ON" ap-
pears if changes are attempted. Entering the
code again returns the unit to "LOCK OFF"
status.
Frequency out
The Batcher generates a pulse out for each
factored count. An NPN transistor output (Pin
2), can drive external devices at rates of 10,
200, 2000 or 20000 counts per second as se-
lected through the keypad menu. If the K
Factor scaled inputs generate pulses faster
than the output speed selected, an internal
buffer will store up to 9,999 counts before
"DATALOST" flashes on the screen. This in-
dicates that the counts being totaled and the
scaled outputs may be incorrect. Note that
all counts stored in the internal buffer will be
pulsed out at the selected frequency even if
the counter is reset.

3
STD PRE and EZ PRE Operation Modes
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. During EZ PRE operation, the preset can be viewed and changed
without entering the program mode and another batch can be started without resetting the unit.
Note:
Before a batch is started and after a batch is complete, the unit will continue to totalize all
inputs.
Using STD PRE
Programming
Select STD PRE - Go into the Program Mode and
select STD PRE in the PRE TYP sub menu.
Set the PRESET and PREWARN - Go into the
Program Mode and enter the desired values for
the PRESET and the PREWARN.
Program the Counter - Go into the Program
Mode and set up the counter in the COUNT sub
menu.
Operation
Start a Batch - In the Run Mode, reset the total
by pressing “CLR”, then press “A” to start.
When started, both relays energize and the
counter begins to count. When the batch is
complete, the relays drop out and the unit
displays the amount that was batched (0 if in
Set to Preset mode).
Stop a Batch - Press “B”, to temporarily stop
process by de-energizing the PRESET and
PREWARN relays. Press start, “A”, to continue
process.
Repeat a Batch - In the Run Mode, reset the total
and press the start button.
Change the Batch Size - Go to the Program
Mode and enter new PRESET and PREWARN
values.
Using EZ PRE
Programming
Select EZ PRE - Go into the Program Mode and
select EZ PRE in the PRE TYP sub menu.
Set the PRESET and PREWARN - Go into the
Program Mode and enter the desired values
for the PRESET and the PREWARN.
Program the Counter - Go into the Program
Mode and set up the counter in the COUNT
sub menu.
Operation
Start a Batch - In the Run Mode, press “A” to
start. When started, both relays energize and
the counter begins to total. When complete,
the relays drop out and the display flashes the
current PRESET value.
Stop a Batch - Press “B”, to temporarily stop
process by de-energizing the PRESET and
PREWARN relays. Press start, “A”, to continue
process.
Repeat a Batch - Press the start button.
Change the Batch Size - With the current
PRESET flashing on the display, type a new
number using the keypad. This number
becomes the PRESET.
Display Batch Total or Rate - With the current
PRESET flashing, press “ENT” to place the
PRESET value in memory and use the “C”
button to toggle between the Batch Total and
the Rate.
1-4 STD PRE and EZ PRE Operation Modes

4
1-5 Specifications
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.
Input Power:
A: 110 VAC ±15% or 12 to 27 VDC
B: 220 VAC ±15% or 12 to 27 VDC
NOTE: AC Inputs are internally fused with a
160mA slow blow fuse.
Current:
Maximum 280 mA DC or 5.3 VA at rated AC
voltage.
Output Power:
(On AC powered units only): +12 VDC at 100
mA. Separate Isolated 12 VDC at 100 mA to
allow ±12 VDC or +24 VDC, regulated ±5%
worst case.
Temperature:
Operating: +32°F (0°C) to +130 °F (+54°C)
Storage: -40°F (-40°C) to +200 °F (+93°C)
(Extended operating temperature range
available, consult factory)
Memory:
EEPROM stores all program, display mode
and count data for a minimum of 10 years if
power is lost.
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.
Accuracy over full temperature range:
Digital - 100% (within specified voltage
ranges)
Pulse Inputs:
Standard, High impedance pulse input.
Low: Open or 0 to 1 VDC
High: 3 to 30 VDC, 10K Ohm impedance
Count Speed (Switch selectable):
100 Hz, 1000Hz, 20000Hz
Termination Resistance (Switch selectable):
10K pull down, 4.7K pull up
Factored Output:
One pulse per each factored count
Sinking (NPN Transistor)
OpenCollectorsinks250mAmaximum to1volt
maximum from 30 VDC maximum
Internal buffer: 9999 pulses
Output speed: user selectable (see table
below)
Speed (Hz) 10 200 2000 20000
Min. on/off (msec) 47.5 2.0 0.2 0.013
Control Outputs:
SPDT Relays
Contact rating: 10 A 120/240 VAC or 28
VDC.

5
1-6 Dimensions
PANEL
CUTOUT 2.50 -0, +0.02
(63.5 -0, +0.5)
7.375 -0, +0.04
(187.3 -0, +1)
7.375
(187.3)
(NOM.)
0.53
(13.5)
6.0
(152.4)
2.48
(63)
(NOM.)
(NOM.)
ABCD
1 2 3
4 5 6
7 8 9
CLR
0
SET
8.17
(207.5)
3.31
(84)
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Full Size Panel Cutout Template
(copy before using)

6
!
SECTION 2 INSTALLATION
2-1 Receipt of Equipment
When the equipment is received, the outside
packing case should be checked for damage
incurredduringshipment. If thepackingcaseis
damaged, thelocalcarrier shouldbenotified at
once regarding his liability. A report should be
submitted to the factory.
Carefully remove the equipment from the pack-
ing case and inspect for damaged or missing
parts.
2-2 Return Shipment
DonotreturnassemblyorpartwithoutaReturn
MaterialAuthorization. TheRMAisobtainedby
calling your local distributor.
2-3 Panel Mounting
The controller should be located in an area with
a clean, dry atmosphere which is relatively free
of shock and vibration. The Batcher is installed
in a 7.365" (187 mm) wide by 2.495" (63.4 mm)
high panel cutout. To mount the controller
proceed as follows:
a. Prepare the panel opening.
b. Slipthegasket(provided)overtherearofthe
counter case and slide it forward until it
engagestheinnersurfaceof thefrontbezel.
c. Installthescrews(provided)inthemounting
brackets and insert in the holes located on
both sides of the Batcher.
d. Tighten the screws firmly to attach the
counter bezel to the panel.
2-4 Electrical Connections (Reference Figures
2-1 to 2-3)
All connections are completed at terminal
blockslocatedattherearofthecase. Makesure
all power is disconnected before making any
electrical connections. In cases where cables
aresituatedinareaswithheavyelectricalfields,
shielding is required for maximum noise im-
munity. One end of the shielding should be
connected to earth ground. Relays or induc-
tive coils connected to or located in the imme-
diate area should be arc suppressed with ap-
propriate diodes, MOV's or resistor capacitor
networks.
Caution: An external fuse is required:
DC Power: 0.5 Amp
AC Power: 0.125 Amp