KEPCO KEPtrol F/C User manual

99300 11/10/09
Description
The KEPtrol F/C is designed to measure the net flow of boiler fuel. Separate K-Factors can be entered
for A and B inputs. Two SPDT relay alarm outputs are standard. A scaled pulse output is standard for
interfacing with remote devices. An analog output option is also available to interface with strip chart
recorders.
Features
❑Flow (A) - Flow (B) Displays Net Rate & Net Total
❑ Pulse Input to 10 kHz Count Frequency
❑Separate K-Factors for A & B Inputs
❑Set Point Alarms
❑NEMA 4X / IP65 Front Panel
Application
The unit is normally used to measure the net flow of boiler fuel. The display may be toggled between net
rate, and net total. Two programmable K-factors make keying-in engineering units easy. The unit accepts
pulse or contact closures and provides two separate preset controls.
KEPtrol F/C
Kessler-Ellis Products Co.
C/FlortPEK C/FlortPEK C/FlortPEK C/FlortPEK
KEPtrol F/C
Net Ratemeter & Net Totalizer
KESSLER-ELLIS PRODUCTS
10 Industrial Way East
Eatontown, NJ 07724
800-631-2165 • 732-935-1320
Fax [phone]
http://www.kep.com

!
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.

SECTION 1 INTRODUCTION
1-1 General Description ................................... 1
1-2 Typical Application ..................................... 1
1-3 Principles of Operation ............................... 1
1-4 Specifications .............................................. 2
Full Size Panel Cutout Template ..................... 4
SECTION 2 INSTALLATION
2-1 Receipt of Equipment ................................ 5
2-2 Return Shipment ....................................... 5
2-3 Panel Mounting ......................................... 5
2-4 Electrical Connections ............................... 5
2-5 Wiring Connections and Diagrams ........... 5
SECTION 3 OPERATION
3-1 How to Program .......................................... 6
3-2 Frequently Asked Questions About
Setting Up The Unit .................................. 7
3-3 Setup Procedure For The Unit
SETTING PRESET A..................................... 7
SETTING PRESET B ..................................... 8
MENU ITEM 1 DEV TYP............................. 8
MENU ITEM 2 LOCKOUT........................... 10
MENU ITEM 3 OUTCARD............................ 11
MENU ITEM 4 ALG OUT............................ 11
MENU ITEM 4 OUTFREQ........................... 12
MENU ITEM 6 RELAY................................. 13
3-4 Run Mode
3-4.1 The Display .............................................. 13
3-4.2 Reseting (Clearing) the Totalizer............ 13
3-4.3 Locking the Unit ...................................... 14
3-4.4 Operation ................................................. 14
3-5 Internal Operation
Digital Inputs and Computations .................... 15
SECTION 4 INPUTS
4-1 Digital Pulse Inputs.................................... 15
4-1.1 Input 3A ................................................... 16
4-1.2 Input 3B ................................................... 16
4-1.3 Reset Input ............................................... 16
4-2 DC Power InputS ........................................ 16
4-3 AC Power Inputs ......................................... 16
SECTION 5 OUTPUTS
5-1 Control Outputs ......................................... 17
5-1.1 SPDT Relay Version ................................ 17
5-1.2 Open Collector Version ............................ 17
5-2 Scaled Pulse Output ................................... 17
5-3 Optional Analog Output ............................. 18
5-4 Optional RS232 / RS422
Serial Communications .................................... 18
SECTION 6 TROUBLE SHOOTING AND
MAINTENANCE GUIDE
6-1 Warning Messages ..................................... 18
6-1.1 RFFFFFFF......................................................... 18
6-1.2 LOCK ON ................................................ 18
6-2 Troubleshooting ......................................... 18
6-2.1 General ............................................................... 18
6-2.2 Problems ................................................... 19
6-3 Removing the Case ..................................... 19
6-3.1Input Card Modification .......................... 20
6-3.2 Serial Communications
Interface Installation ........................................ 20
6-4 Maintenance................................................ 20
SECTION 7 CALCULATING THE K FACTORS
7-1 General ........................................................ 20
7-1.1 What is a K Factor? ................................ 20
7-2 Calculating the K Factors. ......................... 20
7-2.1 Calculating the K Factor for
Digital Pulse Inputs .......................................... 21
7-2.2 Digital K Factor Formulas ...................... 21
SECTION 8 SERIAL COMMUNICATIONS
8-0 Outcard RS232/RS422
Serial/Strobe Interface ...................................... 22
8-1 Unit Code .................................................... 22
8-2 Baud Rate.................................................... 22
8-3 Parity ........................................................... 22
8-4 RS232 Electrical Requirements ................. 22
8-5 RS232 Card Wiring ..................................... 23
8-5.1 Wiring Diagram RS232 / Strobe ............. 23
8-5.2 RS232 Wiring Notes ............................... 23
8-6 RS422 Electrical Requirements ................. 23
8-7 RS422 Card Wiring ..................................... 24
8-7.1 Wiring Diagram RS422 / Strobe ............. 24
8-7.2 RS422 Wiring Notes ................................ 24
8-8 Strobe Input Electrical Requirements ....... 24
8-8.1 Strobe Input Levels ................................. 24
8-9 Strobe Wiring .............................................. 25
8-9.1 Strobe Wiring (RS232) ............................. 25
8-9.2 Strobe Wiring (RS422) ............................. 25
8-10 Serial Interface Operation ....................... 25
8-10.1 Serial Communications Timing ............ 26
8-10.2 RS232/RS422
Serial Input Codes ............................................ 26
8-10.3 RS232/RS422
Serial Input Examples ...................................... 26
8-11 Strobe Address Operation ........................ 27
8-11.1 Strobe Input Codes ................................ 27
CONCLUSION ........................................................... 27
DECODING PART NUMBER ................................... 27
WARRANTY ............................................................... 27
WORKSHEET.............................................................28
PROGRAMMING FLOW CHART.............................. 29
TABLE OF CONTENTS

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Page 1
SECTION 1 INTRODUCTION
1-1 General Description
The two-setpoint, electronic, controller, is a
microprocessor-based,panel-mounted, instrument.
It is designed to be used in conjunction with
primary flow sensors which have pulse or contact
closure output. The main function of the unit is
to provide net rate of flow, net totalization and
control of process batch size and/or flow.
1-2 Typical Application
The above application is a boiler fuel consumption
monitor. The Unit receives pulses from Feed and
Recirculating flowmeters for total and for rate.
Each pulse input is scaled by separate K Factors.
Pulses from B are subtracted from A to give a net
rate and total. The Analog output is directed to a
strip chart recorder which gives a hardcopy of
the net rate. Setpoint A alarms if net rate value
is exceeded. Setpoint B illuminates light when
set amount of fuel is consumed. Through the
serial communications, a computer keeps a record
of the daily events.
1-3 Principles of Operation
Presets
The user may assign the two preset setpoints to
any of the following: "A" rate input, "B" rate
input, the net rate or the net total. The presets
are accessed by pressing the A or B buttons on
the front panel. The 10A SPDT relays are
activated when the display meets or exceeds the
preset values.
Ratemeter
Accurate to 5 1/2 digits (±1 display digit). The
ratemeter can be programmed to accept almost
any number of pulses per unit of measurement by
using the proper K Factors for the "A" and "B"
inputs. It can sample from 2 to 24 seconds
maximum, and auto range up to 6 digits of
significant information. The ratemeter with both
K Factors at 1, displays the net rate of pulses per
second. Simply dial in the proper K Factors to
display in minutes, hours or other units of
measurement. The unit can be made to display
the net rate and the net total. Press the C button,
while the unit is displaying the net total, to
display the net rate; 'R' is displayed on the left
side of the display.
K Factors
The K Factors are used to convert the input
pulses into workable units. The 8 digit K Factors
are dividers with a range of 0.0001001 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 Unit.
Thus, you may total in gallons and display rate in
liters per hour. The maximum factored count
speed is 9.98 KHz. The maximum factored rate is
7 digits.
Counter
The maximum count is 99999999. All counts are
accumulated even if simultaneous pulses occur.
In the setup mode choose "A-B" (Subtract input B
from input A) or "A+B" (Adds both inputs
together). Activating the CLR button while in
the run mode, resets the Net Total counter. Net
totals less than zero are displayed with a negative
sign on the left.
Fuel Feed
Flowmeter Fuel Recirculate Flowmeter
Pulse Output A Pulse Output B
Low Fuel Indicator
Rate Alarm
4-20 mA Out to
Strip Chart Recorder
RS232 to
Computer

Page 2
1-3 Principles of Operation (continued)
Lockout
Unauthorized front panel changes can be
prevented by entering a user selected, four digit
code, in the "Lockout" mode. The status of the
unit can be observed but "LOCK ON" appears if
changes are attempted. Entering the code again
returns the unit to "LOCK OFF" status.
Scaled Pulse Output
The scaled pulse output corresponds to NET total.
The unit gives one pulse out for each positive
factored count. The output pulse duration is
selectable by choosing one of the following
frequencies: 20000, 2000, 200, 10. (see table
below)
Speed (Hz) 10 200 2000 200000
Min. ON/OFF (mSec) 47.5 2.0 0.2 0.013
NOTE: In the event where the unit counts down
(Input A signal momentarily lost), there will not
be any pulses present at Terminal 2. The output
pulses will be stored in an internal buffer. The
buffer will hold up to 10,000 pulses. The display
will show "DATALOST" if this buffer is filled.
When normal operation resumes and the counter
begins to count up, the output will remain OFF
until the amount of "up" counts equals the
amount of pulses in the buffer.
Analog Output (Optional)
The Analog Output option is controlled by an
Open Collector transistor; it gives a 4 to 20mA (or
0-20mA) output which corresponds to predefined
net rate or net total readings. 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 correspond to the ratemeter or
totalizer. The output for values below the "low"
setting will be 4 mA (0 mA). Compliance voltage
3 to 24 VDC. The output for values above the
"high" setting will be 20 mA.
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 Unit 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.
Outcard (Optional)
RS232 or RS422 serial two-way communication is
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 control. Special OptoMux® compatible
RS422M is also available (See Section 8-12).
1-4 Specifications
Housing:
High impact plastic case with NEMA 4X front
panel.
Dimensions:
Reference Figure 1-1
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
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)

Page 3
1-4 Specifications (continued)
Memory:
EEPROM stores all program 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., positive edge triggered.
Accuracy over full temperature range:
Digital - 100% (within specified 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. 9980 Hz
maximum speed (min. on / off 50.1 usec).
3B: Same as 3A except 4.7 K ohm pull up
resistor to +5 VDC with respect to Terminal
12.
Scaled Pulse Output (Terminal 2):
NPN Open Collector; Sinks max. 100mA from
a maximum of 30 VDC to a maximum 1 VDC.
Analog output:
4-20 mA (or 0-20 mA)
Sinking, (NPN transistor), Open Collector
Compliance voltage: 3 - 24 VDC, noninductive
Accuracy: ±100 uA worst case
Update Rate:
Tracking Rate: follows displayed rate.
Tracking Total: approximately 5 updates
per second
Control Outputs (Each of two outputs):
1. NPN Transistor Version: (Optional)
Open Collector sinks maximum of 250 mA at 30
VDC when active
Note: When relays are used, 10 VDC is
provided at transistor outputs 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.
2. SPDT Relay Version: (Standard)
Contact rating: 10 A 120/240 VAC or 28
VDC.

Page 4
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Full Size Panel Cutout
Template

Page 5
SECTION 2 INSTALLATION
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 notified at
once regarding his liability. A report should be
submitted to the distributor.
Remove the Installation and Operation
Instructions. Carefully remove the equipment
from the packing case and inspect for damaged or
missing parts.
2-2 Return Shipment
Do not return assembly or part without a Return
Material Authorization. The RMA is obtained by
calling your local authorized 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 Unit 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. Slip the gasket (provided) over the rear of the
counter case and slide it forward until it
engages the inner surface of the front bezel.
c. Install the screws (provided) in the mounting
brackets and insert in the holes located on both
sides of The Unit.
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 blocks
located at the rear of the case. Make sure all
power is disconnected before making any
electrical connections. In cases where cables are
situated in areas with heavy electrical
fields, shielding is required for maximum
noise immunity. One end of the shielding
should be connected to earth ground. Relays
or inductive coils connected to or located in
the immediate area should be arc suppressed
with appropriate diodes, MOV's, or resistor
capacitor networks.
2-5 Wiring Connections and Diagrams
1- Not Used
2- Scaled Pulse Output (Open Collector)
3- Input B
4- Input A
5- Reset Input
6- Not Used
7- Not Used
8- Not Used
9- Not Used
10- Analog Output (Sink)
11- Ground (-DC)
12- Ground (-DC)
13- (+) 12 VDC Output
14- (+) DC Power In
15- Isolated -12 Volts
16- Isolated +12 Volts
17- AC In
18- AC In
19- Preset B Transistor O.C.
20- Preset A Transistor O.C.
R1- N.O
R2- N.C. Preset A
R3- Common
R4- N.O
R5- N.C. Preset B
R6- Common
Figure 2-1 Terminal Block Connections
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Page 6
2-5 Wiring Connections and Diagrams (continued)
Figure 2-3 24 Volt DC Output Wiring Connec-
tions
Figure 2-2 Typical Digital Input Wiring
Connections
SECTION 3 OPERATION
3-1 How to Program
The initial programming of the unit is
accomplished by first depressing the MENU
button. After pressing the MENU button once,
the display will read DEV TYP. To cycle to the
next control parameter option, merely press the
MENU button and LOCKOUT will appear on the
display. If the user does not wish to choose this
section of the menu, depress MENU button again
and the next control or parameter will appear.
Selection of all MENU control parameters is
accomplished through the routine described for
DEV TYP.
The following is the sequence for entering a
Preset quantity.
1. Depress the PRE A A button once. The
display will read PRESET. After a one second
pause the display will show the preset number.
2. The display will flash indicating that you are
not in the Run Mode and not displaying the
current rate or total.
3. If the displayed setpoint 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 a new number. Example:
Suppose "250" is the new batch size. Press 2 ,
then 5 , then 0 . When the display holds the
desired value, depress the ENT button. The
new set point will be stored in memory and
simultaneously The Unit will return to the Run
Mode.