KEPCO BATCHtrol II Wiring diagram

99392 05/17/06
Description
The Batcher is a programmable, microprocessor based unit which provides batch control, monitors fl ow
rate and controls the fl ow of processing liquids. Start/Stop controls can be used in conjunction with pre-
warn and fi nal relays to provide valve actuation or pump control. An optional confi guration offers stream-
lined preset adjustments, remote Start, Stop & Reset, and weighted averaging.
Features
❑
Pulse or Analog Input
❑
Display Batch, Rate or Grand Total
❑
Pulse Count Input up to 20 KHz
❑ 16 Point Linearization
❑ 8 Digit K-Factors for Rate and Total
❑
Security Lockout
❑
2-Way RS232/422 Communications
❑
NEMA 4X/IP65 Front Panel
❑
Scalable 4-20 mA Output
❑
Scaled Pulse Output
❑
Optional Confi guration Includes:
- Streamlined Preset Adjustment (Easy Preset)
- Remote Start, Stop and Reset
- 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, contact closures or analog inputs and provides two separate preset controls.
BATCHtrol II
Principle of Operation
The batcher receives an input from a pulse producing fl owmeter through a sensor. The user programs
the batcher to condition the incoming pulses signal and compute the batch fl ow and fl ow rate. A wide
variety of different functions can then be performed based on the programmed confi gurations such as
start/stop functions, totalizing, and/or fl ow rate monitoring. Several other inputs, outputs and functions are
available.
BATCHtrol II Series Technical Manual
Kessler-Ellis Products Co.
BATCHtrol II
Software Versions 8.x & 12.x
Installation and Operating Manual
99 Washington Street
Melrose, MA 02176
Phone [phone]
Toll Free 1-800-517-8431
Visit us at www.TestEquipmentDepot.com
Pulse or Analog Input
Display Batch, Rate or Grand Total
Pulse Count Input up to 20 KHz
16 Point Linearization
8 Digit K-Factors for Rate and Total
Security Lockout
2-Way RS232/422 Communications
NEMA 4X/IP65 Front Panel
Scalable 4-20 mA Output
Scaled Pulse Output
Optional Confi guration Includes:
- Streamlined Preset Adjustment (Easy Preset)
- Remote Start, Stop and Reset
- Weighted Averaging
Pulse Count Input up to 20 KHz
16 Point Linearization
8 Digit K-Factors for Rate and Total
8 Digit K-Factors for Rate and Total
NEMA 4X/IP65 Front Panel
Scalable 4-20 mA Output
Scaled Pulse Output
- Remote Start, Stop and Reset

!
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 modifi cations 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 Specifi cations
...........................................................................................................
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 VER 8.7 Programming
..............................................................................................
9
3-3 VER 8.7 K-Factor Programming
...............................................................................
9
3-4 Software Version 8.7 Programming Flow Chart
.....................................................
10
3-5 VER 12.0 Programming
..........................................................................................
11
3-6 VER 12.0 16 Point Linearization Notes
..................................................................
11
3-7 Software Version 12.0 16 Pt. Programming Flow Chart
.........................................
12
3-8 How to Program
......................................................................................................
13
3-9 Frequently Asked Questions About Setting Up The Batcher
..................................
13
3-10 Setup Procedure For The Batcher
........................................................................
14
3-11 Run Mode
.............................................................................................................
27
3-12 Internal Operation
.................................................................................................
29
4. INPUTS
4-1 Digital Pulse Inputs
.................................................................................................
30
4-2 Analog Inputs
..........................................................................................................
30
4-3 DC Power Inputs
....................................................................................................
32
4-4 AC Power Inputs
.....................................................................................................
32
5. OUTPUTS
5-1 Frequency Output
...................................................................................................
32
5-2 Control Outputs
......................................................................................................
33
5-3 Optional Analog Output
..........................................................................................
33
5-4 Optional RS232 / RS422 Serial Communications
..................................................
34
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
...........................................................................................................
36
7. CALCULATING THE K FACTORS
7-1 General
...................................................................................................................
36
7-2 Calculating the K Factors
.......................................................................................
37
7-3 Calculating 16 Point K Factors
...............................................................................
39
8. SERIAL COMMUNICATIONS
8-1 Unit Code
................................................................................................................
40
8-2 Baud Rate
...............................................................................................................
40
8-3 Parity
......................................................................................................................
40
8-4 RS232 Electrical Requirements
..............................................................................
40
8-5 RS232 Card Wiring
.................................................................................................
41
8-6 RS422 Electrical Requirements
..............................................................................
41
8-7 RS422 Card Wiring
.................................................................................................
42
8-8 Strobe Input Electrical Requirements
.....................................................................
42
8-9 Strobe Wiring
..........................................................................................................
43
8-10 Serial Interface Operation
.....................................................................................
43
8-11 Strobe Address Operation
....................................................................................
45
9. Programming Worksheet
.................................................................................................
46
CONTENTS
Test Equipment Depot - 800.517.8431 - 99 Washington Street Melrose, MA 02176
FAX [phone] - TestEquipmentDepot.com

1
SECTION 1 INTRODUCTION
1-1 General Description
1-1 General Description
Sections 1 through 8 of this manual describe
the wiring, programming and functionality of
the standard Batch controller. Section 9 de-
scribes the wiring, programming and function-
ality of Batch controllers with software version
8.7 (Option 6). Software version 8.7 incor-
porates Remote Start, Stop & Reset with EZ
PRE (easy preset). EZ PRE is a useful tool
for applications that require frequent changes
to the Preset amount.
The Batch controller uses the following soft-
ware versions:
VER 8.7 (Basic unit; Remote Start, Stop
& Reset with EZ PRE “Easy
Preset”)
VER 12.0 (Option 4; 16 point linearization)
1-2 Typical Application
1-2 Typical Application
The above application involves liquid fl ow.
The start button is pushed and the Batcher
receives pulses from the fl owmeter. The puls-
es are scaled by the K Factor and sent out via
the pulsed output to an external counter. The
Analog output is directed to a strip chart re-
corder which gives a hardcopy of the rate. As
the Prewarn is reached, the control valve par-
tially closes. When the fi nal Preset is reached
the valve shuts down completely. At any time
the fl ow can be suspended by hitting the stop
button. Through the serial communications, a
computer keeps a record of the daily events.
123456
Flowmeter
Computer
Solenoid V
alve
Solenoid ValveSolenoid V
Remote
T
otalizer
TotalizerT
Strip Chart
Recorder
Pulse Output
RS232
Output
Analog
Output
1-3 Principles of Operation
1-3 Principles of Operation
Presets
When the start button is pushed, two relays
engage simultaneously to start fl ow. When
the prewarn number is reached, one re-
lay 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 ac-
cept almost any number of pulses per unit of
measurement, sample from 2 to 24 seconds
maximum, and auto range up to 6 digits of
signifi cant information. The ratemeter with a
K Factor 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 puls-
es 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 Fac-
tors 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.
16 Point Linearization
(Optional)
This option extends the accurate range by al-
lowing users to dial in different K Factors for
different input rates. This option may be used
with digital or analog inputs. (See Section 7-
3.)

2
1-3 Principles of Operation
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 fl ash the Grand Total by pressing the ENT
button while in the run mode. Activating the
CLR button while the Grand Total is fl ashing,
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.
Analog Output
(Optional)
The Analog Output option is available on all
units except those with
Square Law
inputs.
Controlled by an Open Collector transistor, it
gives a 4 to 20mA (or 0-20mA) output which
corresponds to predefi ned rate or total read-
ings. In the Setup mode the user is prompted
to set the low and high (4 to 20 mA) values
and also decide if the analog signal will corre-
spond to the ratemeter or totalizer.
A sinking driver generates a linear current
across the user’s external device (such as a
strip chart recorder, PLC, computer, external
meter, etc). The Batcher can supply the 24
VDC to power the current loop. (Connect pin
15 to 13, Pin 16 is now +24 VDC with respect
to pin 12.) Connect Pin 16 to the + DC side of
the external device and connect Pin 3 to -DC
side of the external device.
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
selected 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” fl ashes 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.
Outcard
(Optional)
RS232 or RS422 serial two way communica-
tions are available. Up to 15 units can be
linked together in parallel and addressed
separately to transmit unit status or accept
new set points in the standard ASCII format.
Baud rates of 300, 600, 1200, 2400, 4800 or
9600 as well as choice of odd, even, space,
or mark parity can be selected by keypad con-
trol.

3
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. 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.
Note:
EZ PRE is not available on units with 16 Point Linearization.
Using STD PRE
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
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 fl ashes 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 fl ashing on the display, type a
new number using the keypad. This number
becomes the PRESET.
Display Batch Total or Rate
- With the current
PRESET fl ashing, 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
1-4 STD PRE and EZ PRE Operation Modes

4
1-5 Specifi cations
1-5 Specifi cations
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:
Analog - Zero error: ±0.175% full scale max.
Overall error: ±0.5% full scale max.
Digital - 100% (within specifi ed voltage
ranges)
Pulse Inputs:
3A: Standard. High impedance pulse input.
Open or 0 to 1 VDC (low), 3 to 30 VDC (high),
10K ohm input impedance. 20 KHz maximum
speed (min. on / off 25 usec).
3B: Same as 3A except 4.7 K ohm pull up re-
sistor to +5 VDC with respect to Terminal 12.
Analog Inputs:
The current or voltage input is converted to
a highly linear 0 to 10 KHz frequency. This
frequency can then be scaled by 8 digit K-fac-
tors to display rate or count in the appropriate
engineering units.
5A:
4-20 mA; 250
Ω
input impedance.
5B:
0-20 mA; 250
Ω
input impedance.
5C:
1-5 VDC; 15 K
Ω
input impedance.
5D:
0-5 VDC; 15 K
Ω
input impedance.
5E:
0-10 VDC; 15 K
Ω
input imped-
ance.
6A:
Square Law: 4-20 mA; 250
Ω
in-
put impedance.

5
1-5 Specifi cations
1-5 Specifi cations
(continued)
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) 10 200 2000 20000
Min. on/off (msec) 47.5 2.0 0.2 0.013
Analog output:
(Not available with 4-20 mA, Square Law
input type)
4-20 mA (or 0-20 mA)
Sinking, (NPN transistor), Open Collector
Compliance voltage: 3-24 VDC, non-inductive
Accuracy: ±100 uA worst case
Update Rate: Follows ratemeter
Control Outputs:
SPDT Relays
Contact rating: 10 A 120/240 VAC or 28
VDC.
NPN Transistor Output
Open Collector sinks maximum of 100 mA from
10 VDC when active
Note: 10 VDC is provided at transistor outputs
through
through
the relay coils. If current greater than
2 mA is drawn, the relay will remain energized.
Applying greater than 10 VDC may destroy the
unit. The transistor will sink 100 mA in the “ON”
state with relays installed.
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.)
A B C D
1 2 3
4 5 6
7 8 9
CLR 0SET
8.17
(207.5)
3.31
(84)
1-6 Dimensions
All Dimensions in inches (mm)
Speed (Hz) 10 200 2000 20000
Min. on/off (msec) 47.5 2.0 0.2 0.013
Speed (Hz) 10 200 2000 20000
Min. on/off (msec) 47.5 2.0 0.2 0.013
Speed (Hz) 10 200 2000 20000
Min. on/off (msec) 47.5 2.0 0.2 0.013
Speed (Hz) 10 200 2000 20000
Min. on/off (msec) 47.5 2.0 0.2 0.013

6
Full Size Panel Cutout Template
(copy before using)
SECTION 2 INSTALLATION
2-1 Receipt of Equipment
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 notifi ed
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
2-2 Return Shipment
Do not return assembly or part with out a Return
Material Authorization. The RMA is obtained by
calling your local distributor.
2-3 Panel Mounting
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 pro-
ceed as follows:
a. Prepare the panel opening.
b. Slip the gasket (provided) over the rear of
the counter case and slide it forward until it
engages the inner surface of the front be-
zel.
c. Install the screws (provided) in the mounting
brackets and insert in the holes located on
both sides of the Batcher.
d. Tighten the screws fi rmly to attach the coun-
ter bezel to the panel.
2-4 Electrical Connections
(Reference Figures
2-1 to 2-3)
All connections are completed at terminal blocks
located at the rear of the case. Make sure all
power is disconnected before making any elec-
trical connections. In cases where cables are
situated in areas with heavy electrical fi elds,
1-5 Dimensions
(continued)

7
2-5 Wiring Connections and Diagrams
2-5 Wiring Connections and Diagrams
Figure 2-2
Typical Digital Wiring Connections
Figure 2-3
Typical Analog Wiring Connections
2-4 Electrical Connections
(continued)
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
2-5 Wiring Connections and Diagrams
2-5 Wiring Connections and Diagrams
1 - Not Used
2 - Scaled Pulse Output O.C.
3 - Analog Output
4 - Input A (Pulse/Analog)
5 - Remote Stop/Reset Input
6 - Not Used
7 - Not Used
8 - Not Used
9 - Not Used
10 - Remote Start Input
11 - Ground (-DC), Input Common
12 - Ground (-DC), Input Common
13 - +12 Volts Out
14 - DC Power In (12 - 27 VDC)
15 - Isolate -12 Volts
16 - Isolate +12 Volts
17 - AC In
18 - AC In
19-Prewarn Transistor O.C.
19-Prewarn Transistor O.C.
19-Prewarn Transistor O.C.
19-Prewarn Transistor O.C.
19-Prewarn Transistor O.C.
19-Prewarn Transistor O.C.
19-Prewarn Transistor O.C.
19-Prewarn Transistor O.C.
19-Prewarn Transistor O.C.
20-Preset Transistor O.C.
20-Preset Transistor O.C.
20-Preset Transistor O.C.
20-Preset Transistor O.C.
20-Preset Transistor O.C.
20-Preset Transistor O.C.
20-Preset Transistor O.C.
20-Preset Transistor O.C.
20-Preset Transistor O.C.
R1-N.O
R1-N.O
R1-N.O
R1-N.O
R1-N.O
R1-N.O
R1-N.O
R1-N.O
R1-N.O
R2-N.C. Preset
R2-N.C. Preset
R2-N.C. Preset
R2-N.C. Preset
R2-N.C. Preset
R2-N.C. Preset
R2-N.C. Preset
R2-N.C. Preset
R2-N.C. Preset
R2-N.C. Preset
R2-N.C. Preset
R2-N.C. Preset
R2-N.C. Preset
R3-Common
R3-Common
R3-Common
R3-Common
R3-Common
R3-Common
R3-Common
R3-Common
R3-Common
R4-N.O
R4-N.O
R4-N.O
R4-N.O
R4-N.O
R4-N.O
R4-N.O
R4-N.O
R4-N.O
R5-N.C. Prewarn
R5-N.C. Prewarn
R5-N.C. Prewarn
R5-N.C. Prewarn
R5-N.C. Prewarn
R5-N.C. Prewarn
R5-N.C. Prewarn
R5-N.C. Prewarn
R5-N.C. Prewarn
R5-N.C. Prewarn
R5-N.C. Prewarn
R5-N.C. Prewarn
R5-N.C. Prewarn
R6-Common
R6-Common
R6-Common
R6-Common
R6-Common
R6-Common
R6-Common
R6-Common
R6-Common
Figure 2-1 Terminal Block Connections
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
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







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
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


8
3-1 Front Panel Operation
START
- Pressing “A”, starts the
process by energizing the PRESET and
PREWARN relays. Press “CLR” to reset
Batch Total before starting new batch.
STOP
- Pressing “B”, will temporarily
stop the process by de-energizing the
PRESET and PREWARN relays. Use
START to continue the process from
where it stopped.
RATE/TOTAL
- Pressing “C” toggles
between rate and total count displays.
The rate display has an “R” on the left
side of the screen.
MENU
- Pressing “D” takes the unit out of
the Run Mode and into the Programming
Mode (See Programming, Page 43 and
45). “D” is also used make to some
programming selections.
ENT
- With Count showing in the Run
Mode, pressing “ENT” displays the
Grand Total, which begins fl ashing on
the screen. Press “ENT” again to return
to the Count. In the Programming Mode,
“ENT” is used to accept a selection (See
Programming, Page 43 and 45).
CLR
- When the count total is displayed,
pressing “CLR” will reset the counter to 0
or to Preset A depending on how it was
programmed. When the Grand Total is
displayed, pressing “CLR” will reset it to
0. When the Preset or Program Mode
values are displayed, pressing “CLR” will
reset them to 0, so that new values can
be entered.
A
B
C
D
ENT
CLR
Weighted Averaging
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 fl uctuating.
A weight, “W”, from 00 to 99 is applied to the old
rate data before the new rate data is sent to the
display. The following equation is used:
W = Weight (00-99)
If a weight of 00 is used, the new rate data will
go directly to the display without being averaged.
If a number other than 00 is entered for the
weight, then the new data will be averaged with
the old data before being sent to the display.
Higher weight numbers will create a more stable
rate display. Small rate changes will be more
noticeable when lower weight numbers are used.
Programming Weighted Averaging
1. In the Program Mode, got to the RATE sub menu
and program the K-FACTOR, the WINDOW, and
the SIG FIG parameters.
2. When the display shows WEIGHTXX (XX
represents the current WEIGHT value), either
accept the current value and return to the Run
Mode by pressing “ENT” or clear the current value
by pressing “CLR”.
3. If the current value was cleared, the display
shows WEIGHT00. Using the keypad, enter a
new WEIGHT value from 00 to 99. Press “ENT” to
accept the new value and return to the Run Mode.
(Old Data x W + New Data)
(Old Data x W + New Data)
(W + 1)
Rate Display =
Remote Start, Stop, and Reset
A 4 to 30 VDC positive pulse will activate these
inputs. Remote Start, Stop, and Reset is not
available on units ordered with the Control Input
option 7A (4-20 mA In, 4-20 mA Out).
START (Pin 10):
When activated, the unit will
START as described in Front Panel Operation.
STOP/RESET (Pin 5):
When activated, the unit will
STOP (If the unit is started and the batch is not
complete). A second pulse to pin 5 will reset the
counter (When the unit is stopped or when the
batch is complete). If pin 5 is held high (4 to 30
VDC), the display will fl ash “STOPPED” and any
start inputs will be inhibited.
STOP
D
START
RATE/TOTAL MENU
CBA
ENT
0
7
4
123
6
5
89
CLR

9
3-2 VER 8.8 Programming
Overview:
This Section of the manual provides an outline of
programming procedures for the batcher software
version 8.7. Detailed descriptions and programming
instructions for this unit are available in previous
sections of this manual. Page number references
are included to help you fi nd related information in
this manual.
Programming Procedures:
Enter Program Mode
- Press the MENU button,
“D”, in the Run Mode.
Choosing a Sub Menu
- Once in the Program
Mode, continue pressing the “D” button until the
desired Sub Menu is displayed. Press “ENT” to
enter the selected Sub Menu.
Making a Selection
- An arrow, “
↓
↓
”, appearing over
only the “D” button indicates that “D” is used to
change the selection. When an arrow appears
over “B” and “D”, one must be selected.
Entering a Value
- The keypad is used to enter a
number. Use the “D” button to enter a decimal.
(Ex: 34.5 would be entered by pressing “3”, “4”,
“D”, and “5”)
Accept a Value or Selection
- Press “ENT” to ac-
cept the value and go to next step.
Exit Program Mode
- Program or skip each step
of one of the menus to return to the Run Mode.
Pressing “ENT” allows a step to be skipped with-
out changing its value.
Key to Programming Flow Chart:
■
Display
- This box represents the unit’s dis-
play. In the Run Mode, the fl ow rate, the batch
total, or the grand total will be displayed.
XX Current Value
- The number that is currently
programmed for that step. It must be cleared
(
CLR
button) before entering a new value.
00 No Value
- Indicates that programmed value
for that step has been cleared, and a new
number may be entered.
Keypad
- Use the front panel keypad to enter
a value or select a decimal point location for
this step.
3-3 VER 8.8 K-Factor Programming
(See Programming Flow Chart, Page 10)
The average sensor K-Factor is usually provided in
pulses per unit volume, and will have to be modifi ed
before entering it into the instrument. On most fl ow-
meters, the average sensor K-Factor is stamped
on the nameplate or provided on its documenta-
tion. (see section 7 for Calculating K-Factors, for a
complete example)
Count K-Factor:
The Count K-Factor must be modifi ed to allow for
the decimal point location chosen in the ”DEC LOC“
step.
DPF
- The Decimal Point Factor is a divider to com-
pensate for the displayed decimal point.
DPF Table
DPF Decimal
1 XXXXXX.
10 XXXXX.X
100 XXXX.XX
1000 XXX.XXX
10000 XX.XXXX
100000 X.XXXXX
Rate K-Factor:
The Rate K-Factor must be determined to dis-
play the rate in the desired time unit. The fl oating
decimal point displayed by the Rate Meter fl oats
according to the signifi cant fi gure setting used in
the SIG FIG step.
Where:
TF
- The Time Factor is a divider to adjust the
time units that the Rate Meter shows.
TF Table
TF Time Units Rate Display
TF Time Units Rate Display
1 Seconds Units per Second
60 Minutes Units per Minute
3600 Hours Units per Hour
86400 Days Units per Day
(For information on entering a K-Factor on a unit
with 16 Point Linearization, see
16 Point Linear-
ization Notes
, page 11)
Sensor K-Factor
Sensor K-Factor
TF
= Rate K-Factor
Sensor K-Factor
Sensor K-Factor
DPF
= Count K-Factor

10
ENT
D
RATE
↓
↓
D
ENT
K-FACTOR
XXXX
CLR
WINDOWXX
CLR
SIGFIGXX
CLR
WEIGHTXX
LOCKOUT
↓
↓
ENT
D
SECUR XX
CLR
CODE
XXXX
CLR
UNIT XX
CLR
ALG OUT
↓
↓
OUTFREQ
↓
↓
ENT
D
ENT
D
D
ANLG RT
↓
↓
ANLG CT
↓
↓
ENT
SET LOW
XXXX
CLR
SET HIGH
D
2000
↓
↓
200
↓
↓
ENT
20000
↓
↓
10
↓
↓
0
ENT
WINDOW00
ENT
SIGFIG00
ENT
SECUR 00
ENT
0
UNIT 00
ENT
0
ENT
PL
↓
↓
SER
↓
↓
ENT
D
B
⇒
BAUDRATE
D
1200
↓
↓
2400
↓
↓
600
↓
↓
300
↓
↓
4800
↓
↓
9600
↓
↓
COUNT
↓
↓
ENT
D
K-FACTOR
XXXX
CLR
R0
↓
↓
SP
↓
↓
ENT
D
B
⇔
D.E.C. . .L.O.C.
87654321
ENT
0
ENT
PRESET
↓
↓
ENT
D
XXXX
CLR
PREWARN
↓
↓
D
XXXX
CLR
ENT
PRE TYP
↓
↓
ENT
D
D
EZ PRE
↓
↓
STD PRE
↓
↓
ENT
0
ENT
0
ENT
MENU
D
Run Mode
Software Version 8.7 Programming Flow Chart
◊
- On a Standard unit (Without 16 Point Linearization), the Count and/or the Rate must be programmed for basic operation.
§ - Sub menu will always appear, but feature may not be included in the unit. (Check Model Number).
Page
2, 24
§
Page
2, 23
§
Page 2, 21
Page 2, 19
◊
Page 1, 17
◊
Page 2, 15
Page 15
Page 1, 14
Page 1, 14
OUTCARD
↓
↓
CLR
XXXX
CLR
WEIGHT00
ENT
ENT
0
ENT
ENT
PARITY
D
ODD
↓
↓
MARK
↓
↓
ENT
EVEN
↓
↓
SPACE
↓
↓
3-4
Test Equipment Depot - 800.517.8431 - 99 Washington Street Melrose, MA 02176
FAX [phone] - TestEquipmentDepot.com

11
3-5 VER 12.0 Programming
(Unit with 16 Point Linearization)
Overview:
This Section of the manual provides an outline
of programming procedures for the software ver-
sion 12.0. Detailed descriptions and programming
instructions for this unit are available in the following
sections of this manual. Page number references
are included to help you fi nd related information in
this manual.
Programming Procedures:
Enter Program Mode
- Press the MENU button,
“D”, in the Run Mode.
Choosing a Sub Menu
- Once in the Program
Mode, continue pressing the “D” button until the
desired Sub Menu is displayed. Press “ENT” to
enter the selected Sub Menu.
Making a Selection
- An arrow, “
↓
↓
”, appearing over
only the “D” button indicates that “D” is used to
change the selection. When an arrow appears
over “B” and “D”, one must be selected.
Entering a Value
- The keypad is used to enter a
number. Use the “D” button to enter a decimal.
(Ex: 34.5 would be entered by pressing “3”, “4”,
“D”, and “5”)
Accept a Value or Selection
- Press “ENT” to ac-
cept the value and go to next step.
Exit Program Mode
- Program or skip each step
of one of the menus to return to the Run Mode.
Pressing “ENT” allows a step to be skipped with-
out changing its value. (Note: “B” or “D” must be
pressed on the fi rst step in the DEV TYP menu)
Key to Programming Flow Chart:
■
Display
- This box represents the unit’s dis-
play. In the Run Mode, the fl ow rate, the batch
total, or the grand total will be displayed.
XX Current Value
- The number that is currently
programmed for that step. It must be cleared
(
CLR
button) before entering a new value.
00 No Value
- Indicates that programmed value
for that step has been cleared, and a new
number may be entered.
Keypad
- Use the front panel keypad to enter
a value or select a decimal point location for
this step.
3-6 VER 12.0 16 Point Linearization Notes
(See Programming Flow Chart, Page 12)
A K-Factor and a Frequency must be entered for at
least three points on a unit with Linearization.
Linearization K-Factor:
The K-Factor for each
Linearization point must be modifi ed to allow for the
display decimal point location chosen in the “DEC
LOC” step of the “DEV TYP” menu. Modify each
K-Factor using the following equation:
DPF
- The Decimal Point Factor is a divider to
compensate for the displayed decimal point.
DPF Table
Desired Total
Decimal Location
:
DPF
XXXXXX. 1
XXXXX.X 10
XXXX.XX 100
XXX.XXX 1000
XX.XXXX 10000
X.XXXXX 100000
Example: for X.X, DPF = 10
Calculating K-Factors and Frequencies:
If a
Linearization table is not available, the K-Factor
and the frequency for each point can be calculated
using the Test Mode on the unit. Refer to Section 7-
3.2, Test Mode Operation and K-Factor Calculation,
on page 37.
Entering K-Factors and Frequencies:
Refer to
Section 7-3, Calculating 16 Point K-Factors, on
page 37 and the programming step listing on page
25.
K-Factor
K-Factor
DPF
= Linearization K-Factor

12
OUTCARD
↓
↓
ENT
D
LOCKOUT
↓
↓
ENT
D
UNIT XX
CLR
ALG OUT
↓
↓
OUTFREQ
↓
↓
ENT
D
ENT
D
D
ANLG RT
↓
↓
ANLG CT
↓
↓
ENT
SET LOW
XXXX
CLR
SET HIGH
XXXX
CLR
D
2000
↓
↓
200
↓
↓
ENT
20000
↓
↓
10
↓
↓
UNIT 00
ENT
0
ENT
0
ENT
PL
↓
↓
SER
↓
↓
ENT
D
B
BAUDRATE
D
1200
↓
↓
2400
↓
↓
ENT
600
↓
↓
300
↓
↓
4800
↓
↓
9600
↓
↓
PARITY
D
ODD
↓
↓
MARK
↓
↓
ENT
EVEN
↓
↓
SPACE
↓
↓
PRESET
↓
↓
ENT
D
XXXX
CLR
PREWARN
↓
↓
D
XXXX
CLR
ENT
DEV TYP
↓
↓
ENT
D
0
ENT
0
ENT
MENU
D
Run Mode
Software Version 12.0 16 Point Linearization Programming Flow Chart
RT
↓
↓
CNT
↓
↓
R0
↓
↓
SP
↓
↓
ENT
D
B
D.E.C. . .L.O.C.
87654321
ENT
D
B
WINDOWXX
CLR
SIGFIGXX
CLR
WINDOW00
ENT
SIGFIG00
ENT
16 POINT
↓
↓
ENT
D
D
MINUTES
↓
↓
HOURS
↓
↓
ENT
SECONDS
↓
↓
TEST
↓
↓
POINT 00
1
POINT 01
ENT
F XX
CLR
F 00
ENT
K XX
CLR
K 00
ENT
ENT
CLR
To Exit
Increment to next point (Ex. POINT 02, POINT 03, Etc.
◊
- At least three points in the 16 Point Linearization sub menu must be programmed for basic operations.
Enter a Point # of “0” at any point to exit the 16 Point settupeep all data entered up to that point.
§ - Sub menu will always appear, but feature may not be included in the unit. (Check Model Number).
Do not use PL. Select SER.
CODE
XXXX
CLR
0
ENT
⇒
⇔
3-7

13
3-9 Frequently Asked Questions About
3-9 Frequently Asked Questions About
Setting Up The Batcher
Setting Up The Batcher
Q. Is there any way to backspace if the wrong
button is hit by accident?
A. No, you can depress the CLR button and
start entering the number all over again or
press ENT repeatedly until back in the Run
mode and start over again from there.
Q. Is there any way to put a decimal point in a
number such as a preset or K Factor?
A. Yes, simply press the D button after the
digit that you would like the decimal point.
It will appear to the right of the digit.
Q. Is there any way to enter a negative number
for one of the Presets or K Factors?
A. No, negative values are not allowed.
Q. Is there any way to ruin the unit or completely
erase it by entering a bad number?
A. No, if a number or entry is not valid the unit
will ignore it or fl ash an error message.
Q. If the unit does not have serial communica-
tions or analog out, does the OUTCARD and
ALG OUT sections of the menu still have to
be set up?
A. No, there are default settings from the fac-
tory already in the unit. No setup of these
menu items is necessary for normal opera-
tion.
Q. Does the Batcher have to be told what type
of input it has connected to it?
A. No, The input signals are conditioned in
hardware. This allows the input cards to
be interchanged without modifying the soft-
ware.
Q. If CLR is not pressed, numbers can still be
written over the Presets or K Factors. Will
these numbers be accepted if the ENT but-
ton is pushed?
A. No, in order for a Preset or K Factor to be
changed, the old number must be cleared
out
fi rst
by depressing the CLR button.
3-8 How to Program
3-8 How to Program
The initial programming of the unit is accom-
plished by fi rst 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 but-
ton again and the next control or parameter
will appear.
Selection of all MENU control parameters is
accomplished through the routine described
for Preset.
The following is the sequence for entering a
Preset quantity.
1. Depress the Menu D button once. The
display will read MENU. After a one sec-
ond pause the display will read PRESET.
2. Depress the Enter ENT button; the dis-
play will fl ash indicating that you are not in
the Run Mode and not displaying the cur-
rent batch total.
3. If the batch size is satisfactory, depress
the ENT button. This value will be entered
into memory. Simultaneously, the unit will
return to the Run Mode.
4. To change the preset value, depress the
CLR button and enter new number. Ex-
ample: Suppose “250” is the new batch
size. Press CLR, then 2 , then 5 , then 0 .
When the display holds the desired value,
depress the ENT button. The new batch
size will be stored in memory and simulta-
neously the batcher will return to the Run
Mode.

14
3-10 Setup Procedure For The Batcher
3-10 Setup Procedure For The Batcher
MENU ITEM 1
PRESET
PRESS
DISPLAY
PRESET
↓
↓
Menu Button.
Flashing PRESET number.
Enters Preset Routine.
0 Flashes.
Clears out existing PRESET.
1234 PRESET Flashes.
Sample Preset.
Last count, unit now in run mode.
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. For example, if
you want the Prewarn relay to drop out 10 counts before the Preset and your Preset is 1234, then set your Prewarn
at 10 (not at 1224). Enter a Prewarn of “0” for the Prewarn and Preset relays to activate together. To disable the
Prewarn relay, enter the same value for Preset and Prewarn.
PRESS
DISPLAY
PRESET
↓
↓
MENU Button.
PREWARN
↓
↓
Flashing PREWARN number.
Enters Prewarn Routine.
0 Flashes.
Clears out existing PREWARN.
1234 Prewarn Flashes.
Sample Prewarn.
Last count, unit now in Run Mode.
Store new Prewarn.
The Prewarn is Set.
Note: Remember, if the prewarn is a larger number than the preset, then the warning “
PREWRONG
” will fl ash on
the display. Enter a prewarn value that is less than or equal to the preset to clear this warning.
D
CLR
ENT
1 2 3 4
ENT
D
D
ENT
CLR
1 2 3 4
ENT

15
3-10 Setup Procedure For The Batcher
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
PRESET
↓
↓
PREWARN
↓
↓
PRE TYP
↓
↓
STD PRE
↓
↓
EZ PRE
↓
↓
Press D toggle between selections.
Enters displyed selection Run Mode
The PRE TYP is Set.
MENU ITEM 4
COUNT
Setting the Counter
PRESS
DISPLAY
PRESET
↓
↓
PREWARN
↓
↓
PRE TYP
↓
↓
COUNT
↓
↓
K FACTOR
K FACTOR fl ashes then shows the current K Factor.
Note: The K Factor setup is skipped if the unit has 16 Point option. The unit goes di-
rectly to R0 SP.
0 Flashes.
Clears out existing K FACTOR.
37.6 Flashes.
Sample K Factor, or enter calculated value from notes or worksheet.
continued on next page
D
D
D
ENT
ENT
D
D
D
ENT
D
CLR
3 7 D 6

16
3-10 Setup Procedure For The Batcher
3-10 Setup Procedure For The Batcher
(continued)
MENU ITEM 4
COUNT
(continued)
PRESS
DISPLAY
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). If SP is selected ( D
is pressed), the unit starts at the Preset and counts “down” towards zero (dropping out
the Prewarn at its set value.)
or Selects by moving the cursor under the
arrow by
R0
or
SP
DEC LOC
Store R0 or SP.
DEC LOC allows the user to choose where the decimal point will be located when
the Batch Count or Grand Total are displayed.
The decimal point is for display only
and does not affect K Factors. (The K Factor must be scaled to refl ect the DEC LOC,
see Section 7 for calculating the K Factors) Simply press the keypad numbers to move
the decimal point. Only one decimal point can be displayed, multiple decimal points are
not available. Pressing 0 turns off the decimal point.
DEC LOC
As an example, the decimal point will move to the right of the fourth digit from the right
(displays units and thousandths).
Run Mode.
Store new DEC LOC.
The Counter portion of the Batcher is now set up.
ENT
B
B
B
B
D
ENT
1 2 3 4
ENT