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)