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 732-935-9344

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

THIS PAGE IS BLANK

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

Figure 1-1

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234567890123456789012345678901212

12345678901234567890123456789012123

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

123

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.

Page 7

3-2 Frequently Asked Questions About

Setting Up The Unit

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 the 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 flash an error message.

Q. If the unit does not have serial

communications or analog output, does the

OUTCARD or ALG OUT sections of the menu

still have to be set up?

A. No, there are default settings from the factory

already in the unit. No setup of these menu

items is necessary for normal operation.

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 button is pushed?

A. No, in order for a Preset or K Factor to be

changed, the old number must be cleared out first

by depressing the

CLR button. Otherwise, new numbers will be

added to the end of the previous number.

Note: Sometimes the setup of the unit may seem

confusing. Worksheets have been provided with the

unit to make the setup easy. Most questions can be

answered simply by reviewing the manual. If you

still have problems or questions, please call your

local Distributor.

3-3 Setup Procedure For The Unit

SETTING PRESET A

PRESS DISPLAY

A PRESET A

PRE A Button.

Enters Preset Routine. Flashing PRESET A

number.

CLR 0 Flashes.

Clears out existing PRESET A.

1 2 3 4 1234 PRESET A

Flashes.

Sample Preset.

ENT Last count, unit now in run

Store new Preset. mode.

Preset A is Set.

Page 8

3-3 Setup Procedure For The Unit (continued)

SETTING PRESET B

PRESS DISPLAY

B PRESET B

PRE B Button.

Enters Preset Routine. Flashing PRESET B

number.

CLR 0 Flashes.

Clears out existing PRESET B.

1 2 3 4 1234 PRESET B

Flashes.

Sample Preset.

ENT Last count, unit now in run

Store new Preset. mode.

Preset B is Set.

MENU ITEM 1 DEV TYP

This menu item is used to set up the ratemeter and

totalizers. Please refer to the K Factor worksheets

(Section 7) or other notes you may have prepared.

Setting the Ratemeter.

PRESS DISPLAY

D Menu Button DEV TYP ↓

ENT RT ↓CNT ↓

Enters routine to program the Ratemeter or

Counter.

B K FACT A

This selects the Ratemeter portion of the unit.

K FACT A flashes then shows the current rate K

Factor for input A.

CLR 0 Flashes.

Clears out existing A K FACTOR.

1 2 D 0 5 6 12.056 Flashes.

Sample K Factor, or enter calculated value from

notes or worksheet.

ENT K FACT B

We are still in the Ratemeter portion of the unit.

K FACT B flashes then shows the current rate K

Factor for input B.

CLR 0 Flashes.

Clears out existing B K FACTOR.

7 6 D 2 8 76.28 Flashes.

Sample K Factor, or enter calculated value from

notes or worksheet.

ENT WEIGHT #.#

Store new K Factor.

The weight is a multiplier assigned to the old rate

that is averaged with the new sampled rate to

prevent erratic change. A 0.0 setting shows the

new rate immediately. A 9.9 setting averages the

new sampled rate with 9.9 times of old displayed

rate. (See section 3-5 Internal Operation.)

CLR WEIGHT 0.0

Clears out existing WEIGHT number value.

7 0 WEIGHT 7.0

As an example, averages 7X old rate with new

rate.

ENT WINDOW ##

Store new Weight.

The window sets the minimum rate sampling

time (02 to 24 sec). The unit accumulates the

input pulses for the

Page 9

3-3 Setup Procedure For The Unit (continued)

window amount of time and calculates the

averaged rate. The selected "weight" is then

averaged in. The display is updated after each

rate sample.

PRESS DISPLAY

CLR WINDOW 00

Clears out existing WINDOW number value.

5 WINDOW 05

As an example, extends the window to 5 seconds.

ENT SIG FIG ##

Store new WINDOW.

SIG FIG indicates how many meaningful

digits are shown. For example, if SIG FIG is

set at three; a rate of 24737.89 will be displayed

as 24700; a rate of 0.739216 will be displayed as

0.739. Note that trailing zeroes will be inserted

only if necessary. Digits beyond the SIG FIG

value are truncated and zeroes are inserted as

needed, no rounding is done.

CLR SIG FIG 00

Clears out existing SIG FIG number value.

4 SIG FIG 04

As an ex., display will show only 4 significant

figures.

ENT Last count, unit now in

Store new SIG FIG. Run Mode.

The Ratemeter portion of The Unit is now setup.

The next thing to do, is to set up the counter

portion of the unit. This requires going back into

the menu to DEV TYP.

MENU ITEM 1 DEV TYP (continued)

This menu item is used to set up the ratemeter and

totalizers. Please refer to the K Factor worksheets

(Section 7) or other notes you may have prepared.

Setting the Counter.

PRESS DISPLAY

D DEV TYP ↓

Menu Button.

ENT RT ↓CNT ↓

Enters routine to program the Ratemeter or

Counter.

D K FACT A

This selects the Counter portion of the unit.

K FACT A flashes then shows the current A K

Factor.

CLR 0 Flashes.

Clears out existing A K FACTOR.

3 7 D 6 37.6 Flashes.

Sample A K Factor, or enter calculated value

from notes or worksheet.

ENT K FACT B

This selects the Counter portion of the unit.

K FACT B flashes then shows the current B K

Factor.

CLR 0 Flashes.

Clears out existing B K FACTOR.

6 6 Flashes.

Sample B K Factor, or enter calculated value

from notes or worksheet.

ENT A+B ↓

Store new B K Factor.

Page 10

3-3 Setup Procedure For The Unit (continued)

A+B adds input pulses from A and B

together. A-B subtracts the pulses of input

B from input A. This selection determines the

calculation performed on the incoming data.

Caution: When selecting A-B. Nega

tive rates cannot be displayed only

absolute values will be displayed.

The display will go to all F's when the

net rate goes beyond 7 digits.

PRESS DISPLAY

D A-B↓

Pressing D toggles between selections.

ENT DEC LOC

Store calculation.

DEC LOC allows the user to choose where

the decimal point will be located when the

net total is displayed. The decimal point is for

display only and does not affect K Factors. Press

the keypad numbers to move the decimal point.

Only one decimal point can be displayed.

Pressing 0 turns off the decimal point.

4 DEC .LOC

As an example, the decimal point will move to the

right of the fourth digit from the right (displays

units and thousandths).

ENT Last count, unit now

in Run Store new DEC LOC. Mode.

The Counter portion of The Unit is now set up

and the unit is ready to run.

If you would like to:

a. lockout the unit to prevent unwanted changes

b. setup serial communications

c. setup analog output

Access the menu and refer to the manual's

appropriate section.

MENU ITEM 2 LOCKOUT

This menu item uses a 4 digit security code to

prevent tampering and unwanted changes in the

programming of The Unit. The unit is shipped

from the factory with a lockout code of 1000.

For example: To lock the unit, first make sure it

is in the Run Mode, then press 1 - 0 - 0 - 0. The

words LOCK ON should briefly appear. Once the

unit is locked:

a. You can still toggle between rate and total.

b. Presets A and B can still be accessed but not

changed.

c. The rest of the menu cannot be accessed.

To unlock the unit simply press 1 - 0 - 0 - 0. The

words LOCK OFF will appear briefly. When the

unit is unlocked all menu features are available

for change. To put in a different lockout code

follow this setup procedure.

PRESS DISPLAY

D DEV TYP ↓

Menu Button

D LOCKOUT ↓

ENT CODE

Enters device routine to program in a 4 digit

Lockout Code. The word CODE appears briefly

then the current Lockout Code number is

displayed.

CLR 0 Flashes.

Clears out existing Lockout Code.

Page 11

Page 21

3-3 Setup Procedure For The Unit (continued)

PRESS DISPLAY

1 1 1 1 1111 Flashes.

Sample Lockout Code, or enter desired value from

notes or worksheet. Be sure to record any

changes in the lockout code in case it is

forgotten!

ENT Last count, unit now in

Run Mode.

Store new LOCKOUT Code. (Sample tryout

below.)

1 1 1 1 LOCK ON

Enter the sample / new value . . . the unit is now

locked!

1 1 1 1 LOCK OFF

Enter the sample / new value. . .the unit is now

unlocked!

The lockout procedure is finished.

MENU ITEM 3 OUTCARD

If the unit is equipped with a serial communications

card, the setup parameters in the following menu

will make The Unit compatible with the master

terminal. The Unit Identification Number (if

multiple units are used), Baud Rate (speed at which

the signal is transmitted) and Parity are selectable.

A 7 bit, ASCII character, with one start bit, one stop

bit and the parity makes up the standard ten bit

transmission character. For more details see

Section 8.

PRESS DISPLAY

D DEV TYP ↓

Menu Button

D LOCKOUT ↓

D OUTCARD ↓

ENT UNIT ##

The Unit ID Number identifies the unit for

multi-drop communications. Up to 15 units

may be on one line. A unit will stay off line until

its Unit ID number is received. It will then stay

on line until a carriage return is sent. At which

time, it will send any requested information and

take itself off line. The range of the unit ID

number is 00 to 15

Idea:

A Unit ID number of 00 will keep the unit

on line at all times. No Unit Number

prompt is needed and carriage returns will

not take the unit off line.

Regardless of the above, all requests for

information are replied to at the units earliest

convenience.

PRESS DISPLAY

CLR UNIT 00

Clears out existing Unit ID number.

1 4 UNIT 14

Sample Unit ID number.

ENT PL ↓SER ↓

Enters new Unit ID number. Note: PL selects

OptoMux® RS422. Make selection and hit enter

to continue.

ENT BAUDRATE

BAUDRATE flashes then shows current Baud

rate.

Page 12

3-3 Setup Procedure For The Unit (continued)

setting, the current driver will stay at 4 mA. This

allows for offsetting the low end of the output

signal. If the displayed rate or total exceeds the

20 mA setting the current driver will stay at 20

mA.

Note: The current sink follows (tracks) the

display.

PRESS DISPLAY

D Menu Button DEV TYP ↓

D LOCKOUT ↓

D OUTCARD ↓

D ALG OUT ↓

ENT ANLG RT ↓

The analog output may correspond to the

ratemeter or the totalizer. At this point, the

selection is made by pressing

ENT on the appropriate prompt. ANLG RT is

the prompt for the rate meter. ANLG CT is the

prompt for the totalizer.

D ANLG CT ↓

Press D to toggle between selections.

ENT SET LOW

Enters the routine for setting up the Analog

Output card.

SET LOW flashes then shows the 4 mA Setpoint

value.

CLR 0 Flashes.

Clears out existing Low Setpoint value.

1 7 5 D 5 175.5 Flashes.

Sample Low Setpoint, or enter value from notes

or worksheet. (Press D for decimal point.)

ENT SET HIGH

Low Setpoint is stored. SET HIGH flashes then

shows the 20 mA Setpoint value.

CLR 0 Flashes.

Clears out existing High Setpoint value.

6 7 5 9 D 5 6759.5 Flashes.

Sample High Setpoint, or enter value from notes

or worksheet. (Press D for decimal point.) If

High Setpoint is too low, the warning

HIGH≤LOW will be displayed and the unit will

return to the SET LOW routine.

ENT Last count, unit now in Run Mode. High

Setpoint is stored.

Analog Output is set.

MENU ITEM 5 OUTFREQ

All models of the Batcher have a pulse generator

built in to them. The output pulse duration is

selectable by choosing the corresponding frequency

(see Pg. 3). If the count speed exceeds the output

frequency selected, a 9999 pulse buffer is provided

to hold the excess pulses. If the buffer is completely

filled the warning message DATALOST will flash

on the display.

PRESS DISPLAY

D Menu Button DEV TYPE ↓

D LOCKOUT ↓

D Press until . . . OUT FREQ ↓

ENT 20000 ↓

Enters the routine for setting up the Frequency

Output.

The display shows the last Frequency selection.

D 2000 ↓

D 200 ↓

D 10 ↓

Press D to go to 20000 ↓

If output is not used, select 20000 to prevent

DATALOST error.

Press ENT at desired Frequency.

ENT Last count, unit now in Run Mode.

Pulse Output is now set.

Page 13

MENU ITEM 6 RELAY

This menu item is for assigning the function on

which the relays trip. Relays are used for

controlling rate or metering batch size.

Both relays are "Form C" relays with contact

ratings of 10A.

PRESS DISPLAY

D Menu Button DEV TYP ↓

D LOCKOUT ↓

D OUTCARD ↓

D ALG OUT ↓

D RELAY ↓

ENT A TOTAL ↓

The A relay output may correspond to the net

totalizer, rate of input A or the net rate.

Pressing D scrolls through the selections. At the

appropriate point, selection is made by pressing

ENT .

D A RATE ↓

D A NET R ↓

ENT B TOTAL ↓

For Example: "A" Relay trips when net rate

meets or exceeds the value in Preset A.*

The B relay output may correspond to the net

totalizer, rate of input B or the net rate.

Pressing D scrolls through the selections. At

the appropriate point, selection is made by

pressing ENT .

D B RATE ↓

D B NET R ↓

D B TOTAL ↓

ENT DUR B 02

* Enters the routine for setting the duration that

the relay will stay tripped. This routine occurs

when either one of the relays is assigned to the

totalizer. The range is 1 to 99 seconds. Entering

00 for this value latches the relay until the unit is

reset.

3-3 Setup Procedure For The Unit (continued)

3-4 Run Mode

3-4.1 The Display

In the Run Mode the display will initially display

the last count.

The unit will accept input signals and

display Net Rate or Total.

The Total is displayed as a number.

The Net Rate is displayed as "R" followed by a

number.

To toggle between the Rate and Total, simply

press the C button.

3-4.2 Resetting (Clearing) the Totalizer.

To clear the Totalizer, and set relays to "rest"

state.

a) the unit must be in the Run Mode.

b) the unit must not be locked out.*

If the above conditions are met, simply press the

CLR

(clear) button. The display should then show the

preset or zero depending on how the unit is

configured.

* The unit may be reset if it is locked out

by putting

a 3-30 VDC signal to pin 5 on the rear of

the unit.

CLR DUR B 00

Clears out existing High Setpoint value.

1 5 DUR B 15

For Example: Relay trips and holds for 15 seconds

when the total is equal to or greater than Preset B.

ENT Last count, unit now in Run Mode.

Relay outputs are set up.

From the previous page, we are setting the

RELAY Menu.

Page 14

3-4 Run Mode (continued)

3-4.3 Locking the Unit

The unit is shipped from the factory unlocked. To

lock the unit, it must be in the Run Mode. The

unit is shipped from the factory with a Lockout

Code of 1000.

As a test, when you receive the unit, power it

up and press 1 then 0 three times. The

display should briefly show LOCK ON. This

means that the unit is now "locked out".

Press 1 then 0 three times again.

The display should then show LOCK OFF

briefly. This means that the unit is now

unlocked.

What LOCK ON or "Locked Out" means:

a) the Totalizer cannot be reset.

b) the Presets can be accessed but not

changed.

c) the Menu cannot be accessed.

The unit will still:

d) accept input signals

e) display Net Rate and Total.

LOCK OFF means that the unit functions

normally as described in this manual.

The Lockout code can be changed or viewed by

accessing Lockout in the setup Menu. (See

Section 3-3; Menu Item 4; Lockout.) The unit

must be Unlocked to do this so be sure to record

any Lockout code changes in case it is forgotten.

The Lock toggles back and forth from LOCK ON

to LOCK OFF each time the code sequence is

entered. The last four digits pressed, while in the

Run mode, are the ones that the unit checks for

Lockout code sequence. For example: while 1000

will unlock/lock a new unit from the factory, so

will the number 347191000 (the last four digits

are the code sequence, so, this number works

also!).

RECORD ALL LOCKOUT CODE CHANGES.

3-4.4 Operation.

A typical operation proceeds as follows:

a) Preset A is accessed and changed to the

amount desired.

b) The unit accepts input signals

c) The CLR button is pushed to reset the

Totalizer.

d) The process begins.

e) Stopping the input pulses at any time

halts the total. Upon continuation the

process resumes from where it stopped.

f) The display shows Net Rate or Total.

g) Preset A is reached and the relay halts

the process.

The Unit will always accept input pulses whether

the relay is tripped or not! All pulses on the

input terminal are counted and shown on the

display. For this reason, pressing the CLR

button before starting may be desirable. This

means that all post-run pulses will be recorded.

(The CLR button is discussed in section 3-4.2.)

Page 15

SECTION 4 INPUTS

4-1 Digital Pulse Inputs (Terminal 3, 4)

Digital Pulse Inputs: The input board is a

separate board that is plugged into the mother

board just behind the display. All digital inputs

are on the same board. There are four dip

switches on the board. The input conditioning

characteristics may be altered by changing the

dip switches. A valid pulse is one which makes a

transition from the off state (low) to the on state

(high): a positive going edge. The off state is 0 - 1

VDC with respect to Terminal 12 (Ground). The

on state is 3 - 30 VDC with respect to Terminal

12. The input impedance is 10 K ohms. At 30

VDC, the current draw will be 3 mA. This should

be the maximum current that the KEPtrol F/C

will draw. Acceptable pulse width is determined

by the dip switch settings (See Table 4-1 below).

DIP SWITCH SETTINGS

SW1 SW2 SW3 SW4 Conditioning

ON ON --- --- 0-40 Hz

min. 12.5 msec on/off

ON OFF --- --- 0-400 Hz

min. 1.25 msec on/off

OFF OFF --- --- 0-9980 Hz

min. 50.1 usec on/off

--- --- OFF OFF needs sourcing input

(drive input high).

--- --- OFF ON needs sinking input

(pull input low).

↑

ON S1 S2 S3 S4

Table 4-1

3-5 Internal Operation

3-5.1 Digital Inputs and Computations

The 3-30 Volt input signal is filtered

electronically (See Section 4-1, Digital Pulse

Inputs).

Computations:

A Pulses In = A Count

A Count K Factor

B Pulses In = B Count

B Count K Factor

A Pulses In = A' Rate A' Rate = A Rate

A Rate K Factor Tau

B Pulses In = B' Rate B' Rate = B Rate

B Rate K Factor Tau

A+B Total

= A Count + B Count

(since last update)

A-B Total

= A Count - B Count

(since last update)

Net Rate

= A Rate - B Rate

(since last update)

If weighting is used:

Net rate

= (Old Rate x Weight) + New Rate

Weight + 1

Tau = 1 sec or WINDOW if (Rate / 1 sec) = 0

(See Sections 1-3 and 3-3, Setting the

Ratemeter)

Preset Out

Count ≥A Preset or B Rate ≥B Preset

or Count ≥B Preset or Net Rate ≥A Preset

or A Rate ≥A Preset or Net Rate ≥B Preset

Page 16

4-1 Digital Pulse Inputs (continued)

4-1.1 Input 3A - STANDARD:

High Impedance (Terminal 3, 4).

Has 10 K Ohm pull down resistors to ground

(Terminal 12) and must be driven high. Typical

drivers include a contact closure from a 3-30 VDC

source (such as Terminal 13), a PNP transistor

(proximity switch or other device) or an amplified

signal from an inductive pickup. Remember, the

input signal must be referenced to Terminal 12 of

The Unit. (See Section 2-2, Fig. 2-2 Typical

Digital Wiring Connections)

4-1.2 Input 3B

High Impedance with pull-up (Terminal 3, 4).

Has 4.7 K Ohm pull up resistors to +5 VDC and

must be pulled low. Typical drivers include a

contact closure to Ground (such as Terminal 12),

or an NPN transistor (proximity switch or other

device). Remember, the input signal must be

referenced to Terminal 12 of The Unit. (See

Section 2-2, Fig. 2-2 Typical Digital Wiring

Connections)

Idea: This input works well with TTL devices.

4-1.3 Reset Input (Terminal 5)

Identical to the Standard, High Impedance Input

with one exception. The input speed is fixed for a

minimum pulse width of 5 msec. For a

description of what the reset signal does, refer to

Section 3-4.2.

Note: The reset input will not be changed to a

sourcing type of input even if the dip switch is set

for pull up or is changed to the pull up settings.

4-2 DC Power Inputs (Terminals 12, 14)

The Unit may be powered by an external DC

power supply. The supply must provide 12 - 27

Volts DC and at least 280 mA of current. The

positive side (+DC) of the DC supply should be

hooked to Terminal 14 and the negative (or

Ground) side to Terminal 12.

NOTE: Units powered by DC Voltages do not

have an isolated voltage out on Terminals 15 and

16 or +12 VDC on Terminal 13.

4-3 AC Power Inputs (Terminals 17, 18)

The Unit may be ordered for 110 or 220 VAC

power. The unit requires single phase 50/60 Hz

AC power. The voltage range is ±15% of the rated

voltage. Voltages below this range will not power

the unit. Voltages above this range may damage

the unit. The Unit is relatively immune from

electrical noise on the AC lines. However, in

extremely noisy applications some line

conditioning or filtering may be necessary. If

fusing is required, external fusing must be

supplied.

Note: The Unit has no internal fuse to blow out.

If the unit does not function when power is

applied, contact the factory for assistance or to

arrange for repair.

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