KEPCO RTP Manual

15
RTP
Pulse Input Ratemeter and Totalizer
INSTALLATION & OPERATING INSTRUCTIONS
99716 02/19/07
KESSLER-ELLIS PRODUCTS
10IndustrialWayEast
Eatontown, NJ 07724
800-631-2165 • 732-649-7100
Fax: [phone]
http://www
.kep.com

Proprietary Notice
The information contained in this publication is derived in part from proprietary and patent
data. This information has been prepared for the expressed purpose of assisting operating
and maintenance personnel in the effi cient use of the instrument described herein. Publication
of this information does not convey any rights to use or reproduce it or to use for any purpose
other than in connection with the installation, operation and maintenance of the equipment
described herein.
Copyright 1990
Printed in USA. All Rights Reserved.
WARNING!
This instrument contains electronic components that are susceptible to damage by static
electricity. Proper handling* procedures must be observed during the removal, installation,
or handling of internal circuit boards or devices.
*Handling Procedure
1. Power to unit must be removed.
2. Personnel must be grounded, via wrist strap or other safe, suitable means, before any
printed circuit board or other internal device is installed, removed or adjusted.
3. Printed circuit boards must be transported in a conductive bag or other conductive con-
tainer. Boards must not be removed from protective enclosure until the immediate time of
installation. Removed boards must be placed immediately in protective container for transport,
storage, or return to factory.
Comments
This instrument is not unique in its content of ESD (electrostatic discharge) sensitive compo-
nents. Most modern electronic designs contain components that utilize metal oxide technology
(NMOS, CMOS, etc.). Experience has proven that even small amounts of static electricity
can damage or destroy these devices. Damaged components, even though they appear to
function properly, may exhibit early failure.
!

SAFETY INSTRUCTIONS
...........................................................
1
DESCRIPTION & SPECIFICATIONS
..........................................
2
MOUNTING
..................................................................................
3
WIRING
........................................................................................
3
PROGRAMMING MENU
..............................................................
5
PROGRAMMING FLOWCHART
..................................................
7
ANALOG OUTPUT CALIBRATION
..............................................
13
SOLDER JUMPERS
....................................................................
13
WARRANTY
.................................................................................
14
DECODING PART NUMBER
.......................................................
14
TABLE OF CONTENTS

1
!
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 use of an external line fuse is recommended. Add or replace the external fuse with
the following specifi ed type and rating only:
Input Power
Input Power
Recommended Fuse
115 VAC 100 mA slow blow fuse
230 VAC
50 mA slow blow fuse
24 VDC 250 mA slow blow fuse
Disconnect power supply before adding or replacing fuse!
• The manufacturer assumes no liability for damage caused by incorrect use of the
instrument or for modifi cations or changes made to the instrument.
Symbols Used On Unit
Number
Symbol
Symbol
Publication
Description
Description
1
IEC 417, No. 5031 Direct current
2
IEC 417, No. 5172 Equipment protected throughout by
DOUBLE INSULATION or REINFORCED
INSULATION (equivalent to Class II of IEC
536–see annex H)
3
!
ISO 3864, No. B.3.1 Caution (refer to accompanying documents)
Technical Improvements
• The manufacturer reserves the right to modify technical data without prior notice.

2
RESET OPTIONS
The entire unit, i.e. all counters and control outputs, or
Counter A, Counter B, Counter A+B, Counter A-B, Control
O/P A and Control O/P B can be individually programmed
to be reset on pressing the front panel RST key and also
by a positive edge signal to any of the Control I/Ps C, D
and E.
SERIAL COMMUNICATION
The serial strobed port can be used for serial printing of
Total or Rate data with descriptors. The unit can also
communicate with a master device through a Modbus-RTU
protocol. The data given for each parameter is in IEEE fl oat
format comprising of 2 words. The unit can be connected
in a network. Order Option 1 is RS-232 level format; Order
Option 2 is RS-422/485 level format.
CONTROL OUTPUTS
The RTP has the following Control Outputs:
RELAY / O.C.: 2 N.O. relays of 5 A and 250 V OR
2 Open Collector Outputs;
100 mA maximum.
ANALOG OUTPUT
Type: 4-20 mA output.
Accuracy: ± 50µA worst case.
This Analog O/P can be programmed to track any
parameter. Reverse tracking O/P is also available.
PRESETS
The unit supports fi ve counters, i.e. Counter A,
Counter B, Counter A+B, Counter A-B and Grand Total. The
counters can either be reset to zero or disabled. Relays can
be activated by any of the Total or Rate values. If a Total
preset activates the relay, the user can select an output
duration of 0.1 to 99.9 seconds with instant auto reset to
“0”. A 00.0 duration keeps the relay activated until externally
reset. If both presets are assigned to same counter, with
Relay A duration set to 00.0 and Preset A lower than Preset
B, Relay A pulls in at Preset A and drops out when Preset
B (having a duration other than 00.0) pulls in. Counter
recycles immediately, and Relay B stays activated for the
selected duration.
If activated by rate, the relay pulls in at High Preset or above
and remains on until rate falls below Low Preset.
LOCKOUT
The unit program and presets can be protected
with a lock code to prevent unauthorized front panel
changes. This code can be assigned with a maximum of 4
digits and is user selectable. It can be entered through front
panel LOCK key or by confi guring any of the Control I/Ps
to “Lock unit”. Alternate entry of the lock code or pulses
to that I/P will lock or unlock the unit.
DESCRIPTION:
The RTP is a presettable Ratemeter and Totalizer from two
pulse inputs. It can show rate and total at the same time on
the 2 X 16 backlit LCD display. Both inputs can have up to
16 point linearizing k factors. The unit can be connected
in a network for Data Acquisition.
SPECIFICATIONS:
INPUT POWER:
AC: 100 to 260 VAC; 6.5 VA
DC: +24 VDC ; 250 mA max.
THRESHOLD:
High: 4-24 VDC; Low: < 1Vdc or
open
INPUT A:
Count Input, 5 kHz max.
INPUT B:
Count Input, 5 kHz max.
INPUT C:
Control Input
INPUT D:
Control Input
INPUT E:
Control Input (Not Used with RS485
NOTE:
AC powered units have isolated inputs. DC units
share -DC with input common.
OUTPUT POWER:
+20VDC @50 mA (unreg), +/- 15%
DISPLAY:
2 lines of 16 characters, backlit LCD
(character size: 2.95mm x 5.55mm)
DISPLAY RESOLUTION:
6 Digit Total, 6 Digit Rate
BEZEL:
NEMA 4/IP65 rated membrane
keypad
INDICATORS:
Two LED’s to indicate control output
status. (Red = Output A, Green =
Output B)
MEMORY:
NVRAM retains data on power failure
TEMPERATURE:
Operating : 0 to 50 degrees C
Storage : -40 to 90 degrees C
HUMIDITY:
10% to 90% ( Non condensing )
SIZE:
Bezel: 103mm X 55 mm; Depth:97
mm
PANEL CUTOUT:
92 mm X 45 mm (1/8 DIN size cutout
)
IMMUNITY TO ESD:
Level 3 per IEC1000-4-2
IMMUNITY TO TRANSIENTS:
Level 3 per IEC1000-4-4
RADIATED SUSCEPTIBILITY:
Level 3 per IEC1000-4-3
EMISSIONS:
EN55011 CISPR A
PULSE INPUTS
The RTP can accept two pulse inputs ( A&B ). It computes
rate and total of A, B, A+B and A-B. For both inputs the
user can defi ne up to 16 points of “k” factors. This allows
linearization of the displayed rate, which is useful in
improving the accuracy of the fl owmeter.
The rate is computed within 300 ms per input. To stabilize
the rate display, the user can select normalizing factor,
which allows weighted average to be shown. Moreover,
for rate displays, a time delay of up to 25 seconds can also
be selected.
CONTROL INPUTS
The RTP has three Control Inputs, i.e. Input C, Input D
and Input E (Only C & D with RS485 option). Each input
can be confi gured to start/stop each counter or reset each
counter and Control Output. These inputs can also perform
different control actions like printing on serial port, lock unit
and freeze display.
DESCRIPTION & SPECIFICATIONS

3
WIRING
MOUNTING
HOW TO MOUNT:
Slide the body of the unit through the rubber gasket. Insert
the unit into the panel. Slide the brackets up the groove to
press against the back of the panel. Insert the screws into
the rear of the brackets.
Tighten the screws evenly and alternately. A panel less
than .1” may distort if the clamps are screwed too tightly.
Do not over tighten! A normal level of torque is required.
Maximum torque should be 3” pounds.
The panel must be parallel to the bezel to assure proper
seal. Unit seals to NEMA 4/IP65 if properly mounted.
DIMENSIONS:
123456789
10
11
12
13
14
15
16
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
9
9
17
18
4.05” (103mm)
3.62” (92mm)
3.62” (92mm)
2.17” (55mm)
1.7” (45mm)
Bezel
Gasket
Panel
3.82” (97mm)
RS-232 Port
WIRING CONSIDERATIONS:
AC / DC CONNECTIONS:
NOTE: Connect power only after other connections are
fi nished. Do not touch the live AC power terminals. The
unit has been designed with an isolated AC input, therefore
polarity is not a concern for the AC power.
This Product complies with requirements of the European
Community Directive 89/336/EEC [Electromagnetic Compat-
ibility]. However, electrical noise or intense electromagnetic
fi elds in the vicinity of the unit may disturb the microproces-
sor. Users should exercise care and should take proper
precautions to avoid microprocessor disturbance.
Four common sources of noise are:
1) AC power line noise- The input power lines should not
be common to power lines for motors, pumps, contactors,
etc. If the unit cannot be connected to an electrically clean
power source, an inductive load suppressing device (MOV
as GE#V130LA1 or Resistor Capacitor as Paktron# .2uf/220
ohm @ 400V) can be installed. Although locating the sup-
pressor across the AC supply at the unit should help, best
results are obtained by connecting the suppressor across
the leads of the “load” at the device causing the spikes.
2) Input line noise- The noise is carried on the input and
DC ground lines. Make sure the input wires are not run into
the unit in a bundle with power input lines. We recommend
using shielded cable. Connect the shield to DC ground of
the unit and “earth” at one point in the circuit preferably at
the DC ground terminal of the unit.
3) Output lines- The unit has two open collector outputs and
two optional relay outputs. When these outputs are used to
run external relays or solenoids, spikes can be generated
upon activation. This noise can spread through the instru-
ment causing operating problems. If the source is a D.C.
operated device, a general purpose diode (IN4004) placed
across the solenoid prevents electrical noise spikes. Con-
nect the cathode (banded side) to the more positive side
of the coil. If the source is an A.C. operated device, use a
Resistor Capacitor or MOV across the coil.
4) 20 VDC (unregulated) output supply- Noise can be gen-
erated on the 20 VDC output supply if it is used to drive
inductive loads or if the current draw exceeds 50mA. Insure
that all inductive loads have a diode (such as IN4004) across
the coil and that the current does not exceed 50mA.

4
Flowmeter
A
–
+
signal
1 • AC1 (100 to 260 VAC) 2 • AC2 (100 to 260 VAC) 3 • Relay A (N.O.) 4 • Common 5 • Relay A (N.C.) 6 • Relay B (N.O.) 7 • Common 8 • Relay B (N.C.) 9 • (+) 20VDC Out (50mA) 10 • (–) 20VDC Out (50mA) 11 • Analog O/P (+) 12 • Analog O/P (–) 13 • CTRL I/P E 14 • CTRL I/P D 15 • CTRL I/P C 16 • Pulse I/P B 17 • Pulse I/P A 18 • Input GND
100-260
VA
C
60/50 Hz
Flowmeter
B
–
+
signal
1 • AC1 (100 to 260 VAC) 2 • AC2 (100 to 260 VAC) 3 • Relay A (N.O.) 4 • Common 5 • Relay A (N.C.) 6 • Relay B (N.O.) 7 • Common 8 • Relay B (N.C.) 9 • (+) 20VDC Out (50mA) 10 • (–) 20VDC Out (50mA) 11 • Analog O/P (+) 12 • Analog O/P (–) 13 • CTRL I/P E 14 • CTRL I/P D 15 • CTRL I/P C 16 • Pulse I/P B 17 • Pulse I/P A 18 • Input GND
100-260
VA
C
60/50 Hz
TERMINAL DESIGNATIONS:
1 • + DC INPUT (24VDC ± 10%)
2 • – DC INPUT (24VDC ± 10%)
3 • RELAY A (N.O.)
4 • COMMON
5 • RELAY A (N.C.)
6 • RELAY B (N.O.)
7 • COMMON
8 • RELAY B (N.C.)
9 • (+) 20VDC OUT (50
m
A)
10 • (–) 20VDC OUT (50
m
A)
11 • ANALOG O/P (+)
12 • ANALOG O/P (–)
13 • CTRL I/P E
14 • CTRL I/P D
15 • CTRL I/P C
16 • PULSE I/P B
17 • PULSE I/P A
18 • INPUT GND
WIRING
(CONTINUED)
1 • AC1 100 TO 260 VAC
2 • AC2 100 TO 260 VAC
3 • RELAY A (N.O.)
4 • COMMON
5 • RELAY A (N.C.)
6 • RELAY B (N.O.)
7 • COMMON
8 • RELAY B (N.C.)
9 • (+) 20VDC OUT (50
m
A)
10 • (–) 20VDC OUT (50
m
A)
11 • ANALOG O/P (+)
12 • ANALOG O/P (–)
13 • CTRL I/P E
14 • CTRL I/P D
15 • CTRL I/P C
16 • PULSE I/P B
17 • PULSE I/P A
18 • INPUT GND
AC Power
DC Power
TYPICAL WIRING HOOKUPS:
•3 N.O.
•4 Common
•6 N.O.
•7 Common
Output
A
AC Supply
MOV
recommended
for inductive
loads
Neutral
LOAD
- +
- +
- +
- +
- +
- +
DC
- +
DC
- +
Supply
LOAD
-
+
Diode
recommende
d
for inductive
loads
Output
B
INPUT A
INPUT A
INPUT B
INPUT B
RELAY OUTPUTS
COMMUNICATION PORT
TERMINAL DESIGNATIONS:
RS-232 Port:
(DB9 Female)
6 - NC
7 - CMOS TXD
8 - TX
9 - RX
1
2
3
4
5
6
7
8
9
RS-485 Port:
(DB9 Female)
1 - TX+
2 - TXD
3 - RXD
4 - RX+
5 - GND

5
Main Menu:
The Main menu consists of the following steps:
Defi ne list of parameters used, Confi gure Inputs, Setup Coun-
ters, Setup Ratemeters, Setup Relays / O.C., Setup Security,
Setup 4-20mA Output, Setup Comm Port, Defi ne reset options
and Back to RUN mode (or Exit programming). The PROG key
allows scrolling through these steps. All these steps are given
in brief below:
Defi ne list of parameters used:
The unit is capable of showing nine different parameters. The
parameters are the readings
RTP
gives after a pulse input is
RTP gives after a pulse input is RTP
given to it. The parameter names are fi xed in
Default Mode
and
are user programmable in
Message Mode.
The parameter names in Default Mode are:
Rate A, Rate B, Rate A+B, Rate A-B, Total A, Total B, Total
A+B, Total A-B and Gr. Total.
The parameter names in Message Mode are user defi nable.
The length of these user defi ned names can be upto nine char-
acters. Valid characters are SPACE, A-Z, a-z, 0-9, /.
The menu also enables the user to defi ne the sequence in
which the parameters are to be viewed at Run time and the no.
of digits after the decimal point (0-3). It also enables the user to
program the message for each parameter.
Confi gure Inputs :
The unit has fi ve inputs, two of which are pulse inputs and the
remaining three are control inputs. The two pulse inputs are
Input A
and
Input B
. They can programmed to be either linear
or non-linear.
For linear input a six digit multiplier scaling factor has to be
entered (.00001 to 999999). This scaling factor is constant for a
linear input. For a non-linear input the scaling factor is different
at different frequencies so the points (Frequency, Factor) have
to be entered. The unit supports a maximum of sixteen such
points.
NOTE:
Set the average K-Factor to a suitable value before en-
tering the linearization table. This average K-Factor will
be used under the following special cases for process-
ing of pulse information :
1. When in the setup menus
2. When below the linearization table limit
3. When above the linearization table limit
Input B is normally a separate input with separate scaling. It
can also be programmed as a control input for up counting or
down counting of Total A. A High on Input B makes Total A
count up and a low on Input B makes Total A count down.
The remaining three inputs C, D and E are control inputs and
can be programmed to control actions such as start counting,
reset counting, stop counting, freeze display, lock unit and print
activities.
When freeze display is activated (or a pulse is applied to the
control input which is confi gured to freeze display) the unit stops
refreshing the display. The unit continues to run in the back-
ground.
Setup Counters:
RTP
has fi ve counting parameters:
RTP has fi ve counting parameters: RTP
Parameter Default name Function
Counter A
Total A
Counts pulses on A
Counter B
Total B
Counts pulses on B
Counter A+B
Total A+B
Adds counter A & B
Counter A-B Total A-B
Subtracts counter B from
counter A
Grand Total Grand Total
Tracks any of the above
four on which it is pro-
grammed to be dependent.
Each counter can be reset to zero or disabled. The Grand Total
is programmable and can be set to follow any of the remaining
counters.
Setup Ratemeters :
The parameters Rate A, Rate B, Rate A + B, Rate A - B can be
programmed to be rate/seconds, rate/minutes, rate/hours. The
user can use custom scaling if the units are different than RPS,
RPH, RPM e.g. rate/day, so that the rates can be converted to
engineering units. The custom scaling factor can be of 6 digits
ranging from 0.00001 to 999999. The normalizing factor rang-
ing from 0.1 to 99.9 can be programmed.
Normalizing Equation:
(Old Data x “Normalizing Factor” + New Data)
(Old Data x “Normalizing Factor” + New Data)
(“Normalizing Factor” + 1)
For rate display, a time of up to 25 seconds can also be applied.
Setup Relays:
The unit has two control outputs, N.O. Relay A or Open Col-
lector A and N.O. Relay B or Open Collector B. The control
outputs can be programmed to track any of the nine parameters
and can also be programmed to operate in
Timed Mode
(for
count) or
Hysterisis Mode
(for rate).
In Timed mode (count) a low preset value or a high preset
value can be entered. If
a
low preset
value is entered then the
control output will energize whenever the value of the param-
eter, which the control output is tracking goes
below
the preset
value. If a
high preset
value is entered then the control output
will energize whenever the value of the parameter, which the
control output is tracking goes
above
the preset value. In Timed
mode (count) after low preset or high preset have been entered
unit will ask for reset time (the time duration that the control out-
put will remain energized). Set time from 0.1 to 99.9 sec. with
auto reset of counter. If set to 00.0, count continues and output
is latched until reset by external or front panel reset.
In Hysterisis mode (rate)
both
the high preset and low preset
for the Hysterisis have to be entered. The control relay will acti-
vate when the rate parameter is
equal to
or
exceeds
the high
preset. The relay will remain energized until the rate parameter
fall
below
the low preset.
Counts pulses on A
Counts pulses on B
Parameter Default name Function
Counter A-B Total A-B
Grand Total Grand Total
Parameter Default name Function
PROGRAMMING MENU

6
PRO
G
VIEW
PRE
A
LOCK
RST
PRE
B
CLR
ENT
KEYPAD FUNCTIONS
Run Mode
Enter The Programming
Mode
VIEW key scrolls through the
selected viewing parameters
PRE A key allows Preset A
to be changed if unit is not
locked
PRE B key allows Preset B
to be changed if unit is not
locked
Lock Key allows the entry
of a lock code to lock/unlock
the unit
RST Key resets counters
(with/without confi rmation
Program Mode
Toggles between menus
Left key shifts digits in
number entry/characters in
message mode
Up key increments digits/
characters
CLR key clears the numeric
fi eld
ENT key saves changes and
steps to next menu
Unit comes out of
programming at any level
(stores all data entered)
KEY
KEY
Setup Security:
Unauthorized front panel changes can be prevented by entering
a user selectable four digit code. The unit can be in LOCK ALL
or LOCK PROGRAM mode. The unit can be locked while unit
is running by pressing the LOCK key three times continuously
in one second. If any of the control input (C, D, E) is confi gured
as to LOCK UNIT then the unit can be locked by only giving a
pulse at that input and not by pressing the LOCK key .
In LOCK PROGRAM mode only the runtime presets are acces-
sible through front panel. In LOCK ALL mode, programming
and the runtime presets are not accessible.
Setup 4-20 mA Analog Output :
The unit gives a 4-20 mA analog output and it can be pro-
grammed to track any of the nine parameters. The unit can be
programmed for reverse tracking (4mA value higher than 20mA
value). The analog output is isolated. Compliance voltage must
be 3 to 24 VDC. Accuracy ±50µA worst case.
PROGRAMMING MENU
(CONTINUED)
Setup Comm port :
In this menu, the unit can be assigned a unique ID and the com-
munication parameters, i.e. baudrate and parity.
The serial port can be used for serial printing or also for data ac-
quisition. The unit can communicate with a master device through
a Modbus-RTU protocol. The addresses for all nine parameters
that can be read from the unit are as follows (the data given for
each parameter is in IEEE fl oat format comprising of 2 words):
Rate A 100 Total A 500
Rate A 100 Total A 500
Rate B 300 Total B 700
Rate B 300 Total B 700
Rate A+B 900 Rate A-B 1100
Rate A+B 900 Rate A-B 1100
Rate A+B 900 Rate A-B 1100
Total A+B 1300 Total A-B 1500
Total A+B 1300 Total A-B 1500
Total A+B 1300 Total A-B 1500
Grand Total 1700
Defi ne Reset Options:
In this menu either the entire unit ( all counters and control out-
puts ) or Counter A, Counter B, Counter A + B, Counter A - B,
Relay A / Open Collector A or Relay B / Open Collector B can
be individually programmed to be reset on pressing the front
panel RST key or by positive edge signal to selected control
input.
Back to RUN mode
Exit programming :
Pressing ENT at this menu exits programming mode and the
unit enters the Run mode.
FRONT PANEL OPERATION