Milltronics COMPUFLO III User manual

COMPUFLO III
FLOWMETER
INTEGRATOR
Instruction Manual
PL-368
March 1993
33453680
PRR 1.1

TABLE OF CONTENTS
TITLE PAGE #
General Information
About the CompuFlo III 1 – 1
About this Manual
General 1 – 2
Conventions 1 – 2
Specifications CompuFlo III 2 – 1
Options 2 – 2
Installation CompuFlo III 3 – 1
Interconnection 3 – 1
Hazardous Locations 3 – 1
Start Up Hardware Set Up 4 – 1
Pre Start Up Checks 4 – 3
Initial StartUp 4 – 3
Programming General 5 – 1
Keypad 5 – 1
Parameter Entry 5 – 2
Direct Parameter Access 5 – 2
Automatic Parameter Access 5 – 2
Altering Parameter Values 5 – 3
Last Parameter Recall 5 – 3
Parameter Reset 5 – 3
Programming Sequence 5 – 3
Quick Start Procedure 5 – 3
Calibration General 6 – 1
Initial Calibration References 6 – 1
Zero 6 – 2
Span 6 – 2
Calibration Accuracy 6 – 2
Calibration Alternatives 6 – 3
Auto Zero 6 – 3
Lockout Mode 6 – 3
On-Line Span Calibration 6 – 3
Alternate Test References 6 – 4
ECAL Calibration 6 – 4
PL-368 i

Parameters General 7 – 1
Parameters 7 – 1
Programming Chart 8 – 1
Operation Initial Operation 9 – 1
Normal Operation
Start Up 9 – 2
Zero Calibration Check 9 – 2
Span Calibration Check 9 – 2
Reset Total 9 – 2
Run 9 – 2
Communication General 10 – 1
Remote Communication 10 – 2
Host Communication 10 – 2
Serial Printer Communication 10 – 2
Protocol 10 – 3
Data Field Descriptions 10 – 3
Message Requests 10 – 4
Message Responses 10 – 4
Appendices Alphabetical Parameter Listing 11 – 1
Maintenance and Spare Parts 11 – 2
Error Messages 11 – 3
Trouble Shooting 11 – 4
Quick Start 11 – 5
Start Up 11 – 5
Calibration 11 – 6
Operation 11 – 7
Performance Enhancement 11 – 7
Figures FIG. 1 Outline and Mounting 12 – 1
FIG. 2 Layout 12 – 2
FIG .3 CompuFlo III / Flowmeter Interconnection 12 – 3
FIG. 4 Power, Auto Zero, & Rate Output Wiring 12 – 4
FIG. 5 Relay Wiring 12 – 5
FIG. 6 Communication Wiring 12 – 6
PL-368 ii

GENERAL INFORMATION
ABOUT THE COMPUFLO
The Milltronics CompuFlo III is a
microprocessor based integrator designed
specifically forbulk dry solids in-line
weighing applications.
The CompuFlo III integrates a signal
proportional to material flowrate (such as
from a Milltronics flowmeter) over time to
provide material totalization.
The CompuFlo III provides:
» Rate and Total displays
» an analog mA output proportional to rate
» a relay contact for remote totalizer or PLC operation
» 2 alarm/control relays based on rate and/or On-line Calibration
» 2 communication ports for computer, PLC, or serial printer connection
The CompuFlo III has three modes of operation;
program, calibrate and run.
The operator programs the CompuFlo III via the
keypad to provide displays and outputs in the
desiredunits of measure. The CompuFlo III
displays the name, range of acceptable values,
(and additional information/instruction) of the
parameter (programming feature) accessed.
In the calibrate mode, the system Zero (no flow) and Span (100% flowrate) calibration is established. A test
reference (test weight) is used to simulate the force of material impacting the flowmeter sensing plate during
the Span calibration. A material test is normally performed to verify the calibration accuracy. If necessary, the
material test results may be used to correct any deviation in calibration accuracy.
Calibration accuracy may be checked at any time. The results of this check are automatically compared to the
system calibration and the deviation is displayed. The operator may choose to continue operation with the
previous calibration or the results of the calibration check.
All programming and calibration information isstored in non-volatile memory. If desired, the security
parameter may be set to ensure the CompuFlo III programming and calibration is not inadvertently altered in
the run mode.
The runmode is the normal operating mode, providing dynamic measurement displays, analog mA output,
and a variety of other features.
T
1263957
TOTAL
150%100%50%0%-50%
MULTI SPAN NO: 1R2:RATE HI R1:SPEED LO
PL-368 1 – 1

ABOUT THIS MANUAL
GENERAL
This instruction manual contains information essential to successful CompuFlo III operation.
SPECIFICATIONS, includes CompuFlo III environmental, physical, and operational characteristics.
INSTALLATION, indicates the typical mounting and interconnection procedure.
START UP, prepares the CompuFlo III for programming.
PROGRAMMING, details activities required to tailor the CompuFlo III to the particular application.
CALIBRATION, includes the CompuFlo III input signal to output feature correlation procedure.
PARAMETERS, describes the function, factory setting, and range of possible settings,
of each parameter.
PROGRAMMING CHART, provides a space to record programmed parameter values for future reference.
OPERATION, describes initial and normal CompuFlo III operation.
COMMUNICATION, provides CompuFlo III serial communication information.
APPENDICES, contains Quick Start, Alphabetical Parameter List, Maintenance and Spare Parts,
Error Messages and Trouble Shooting information.
FIGURES, includes a complete set of installation and interconnection drawings.
CONVENTIONS
Throughout this instruction manual the following symbols and presentation practices have been utilized:
[1234567ABCDEFG] alpha numeric characters enclosed within these brackets represents information
displayed by the CompuFlo III display.
[T/h] units of measure were arbitrarily chosen from the imperial set. The actual units
displayed or otherwise applicable will be dependent upon operator programming.
indicates the following CompuFlo III keypad button is to be pressed.
"RUN" or alpha numeric characters enclosed within quotation marks or this symbol
represent a key on the CompuFlo III keypad.
Italics are used to identify the defined word(s) or phrase within a definition statement.
Information of a higher order of importance, is indented from
both left and right margins and in bold print.
■
ENTER
PL-368 1 – 2

SPECIFICATIONS
COMPUFLO III
Power: » 100/115/200/230 V AC ±10%, jumper
selectable, 50/60 Hz, 65 VA
Fuse: » FU 1 » 3/4 Amp MDL SLO-BLO or equivalent
» FU 2 » 1/4 Amp MDL SLO-BLO or equivalent
Operating » -20 to 50°C (-5 to 122°F)
Temperature:
Accuracy: » 0.1% of span, typical
Resolution: » 0.02% of span, typical
Inputs: » Load cell: » -20 to +45 mV DC per load cell
» 2 load cells max.
» LVDT: » 0 to 0.75 Vrms, 3 kHz
» Multispan: » 4 contact inputs for up to 8 spans
» Keypad: » 20 key sealed membrane with tactile feedback
» On-Line: » 4-20 mA proportional to weight
(Calibration)
» Auto Zero » contactinput for enable
» Printer: » contact input for print request
Outputs: » Load cell: » 10 V DC, 250 mA max.
(excitation)
» LVDT: » 2.0 Vrms, 3 kHz, 50 mArms max.
(excitation)
» Analog: » 4-20 mA,(0-25 mA scaleable), isolated, proportional to rate
» 0.1% resolution
» 750 Ωmax. load
» Remote » SPST sealed relay
Totalizer:
» 1 form "A" contact rated 2A at 250 V AC, 100 VA max.
» 25 msec. minimum contact closure duration
» 15 closures per second max
PL-368 2 – 1

» Alarm: » 2 multipurpose relays for Rate or On-line Calibration
assignment
» 1 Form "C" SPDT contact per relay, rated 5A at 230 V AC
» Communication: » 1 relay, 4PDT used for communication loop dropout,
rated 1A at 230 V AC
» Display: » illuminated 256 x 128 dot matrix
Communication: » 2 serial ports
» RS232C and ±20 mA current loop
Enclosure: » NEMA 4 style, steel construction with polycarbonate window
» 330 mm W x 406 mm H x 102 mm D
(13" W x 16" H x 4" D)
Shipping Weight: » 11.0 Kg (24.3 lbs), no options
OPTIONS
Cable: » Single loadcell, 150m (500 ft) max. 20 AWG, 4 wire shielded,
Belden 8404 or equivalent
» Single loadcell, 300m (1000 ft) max. 20 AWG, 6 wire shielded,
Belden 8426 or equivalent
» Dual load cell, 150 m (500 ft) max. 20 AWG, 6 wire shielded,
Belden 8426 or equivalent
» Dual load cell, 300 m (1000 ft) max. 20 AWG, 8 wire shielded,
Belden 8418 or equivalent
» LVDT, 150 m (500 ft) max. 20 AWG, 4 wire shielded,
Belden 8404 or equivalent
Barrier Strips: » For hazardous location flowmeters
Enclosure Heater: » Recommended for operating temperatures below -10°C
(14°F) or excessive humidity
Relay: » Food Grade remote totalizer relay
CVCC: » For bipolar current loop/RS-232C conversion
BIC-II: » For 6 port bipolar current loop/RS-232C or RS-422 conversion.
■
PL-368 2 – 2

INSTALLATION
CompuFlo III
The CompuFlo III should be mounted in an area that is within the specified temperature range, and that is
suitable for NEMA 4 style enclosures. The front cover should be accessible for keypad operation, display
viewing, and have sufficient room to swing open.
It is advisable to keep the CompuFlo III away from high voltage or current runs, contactors, SCR control
drives and RF interference.
For proper totalizer relay operation, the CompuFlo III must be mounted within 30° from vertical.
Do not mount the CompuFlo III in directsunlight without the use of a sun shield.
INTERCONNECTION
Remove the enclosure bottom plate prior to drilling or punching cable/conduit entrance(s), to ensure metal
filings do not come in contact with the CompuFlo III electronics.
Load cell or LVDT, rate output, On-Line Calibration input, communication, and low voltage contact wiring may
be run in a common conduit separated from power and high voltage contact wiring. Refer to Figures.
The power ground (TB1-50) is internally connected to SHLD connections (TB1-13,26, TB2-5), and to the
mother board bottom mounting lugs. COM connections (TB1-15,29,32,36,37,and TB2-8) are connected to
power ground via jumper J2 (below TB1, between the mounting lugs). If the COM connections must be
isolated from power ground, remove J2.
Refer to FIGURES
All wiring mustbe performed in accordance with all governing regulations.
HAZARDOUS LOCATIONS
The CompuFlo III cannot be mounted in an area classed as hazardous. Where the associated flowmeter is
mounted in a hazardous area, barrier strips must be used to isolate the CompuFlo III from thehazardous area
for intrinsic safety. Encapsulated LVDT transducing elementsare also available. ContactMilltronics or your
local representative for hazardous application information.
■
PL-368 3 – 1

START UP
HARDWARE SET UP
UNIT I.D.
The CompuFlo III identification code factory setting is 00,
as set by SW1 contacts 1 - 4.
When more than one CompuFlo III is connected to a
host computer or PLC, the identification code of each
CompuFlo III must be set to a different value.
O = switch contact open C = switch contact closed
UNITS OF MEASURE
Two sets of Units are available; Imperial and Metric. Leave SW1 contact 5 (SW1-5) in the open position
for Imperial, or closed for Metric units. Refer to PARAMETERS / P0 - RATE UNITS for the Rate Unit
options available.
SW1-5 must be set to the desired position before initial programming is performed.
To alter the Units of Measure of a programmed CompuFlo III, set SW1-5 as desired,
then perform a Reset. Refer to Parameters / P99 Reset.
LOCKOUT
Leave SW1 contact 6 (SW1-6) in the open position for normal applications. Close SW1-6 for Lockout Mode
operation, after all programming and calibration is complete. Refer to Calibration / Calibration Alternatives.
TOTALIZER RESET
Leave SW1 contact 7 (SW1-7) in the open position for normal operation. When this contact is closed, the
Main Total Display cannot be reset.
TEST MODE
Leave SW1 contact 8 (SW1-8) in the open position for normal operation. The closed position is reserved for
Milltronics service personnel.
IMPERIAL
UNIT I. D. # MAIN
TOTAL
RESET
LOCKOUT TEST
METRIC
NORMAL
124 8
0000
SW1
UNIT SW 1
I. D. 1 2 3 4
08 O O O C
09 C O O C
10 O C O C
11 C C O C
12 O O C C
13 C O C C
14 O C C C
15 C C C C
UNIT SW 1
I. D. 1 2 3 4
00 O O O O
01 C O O O
02 O C O O
03 C C O O
04 O O C O
05 C O C O
06 O C C O
07 C C C O
PL-368 4 – 1

PORT 2 BAUD RATE
The CompuFlo III TB2 communication port baud rate is independent of the PORT 1 baudrate, and is set by
SW2 contacts 1 and 2. Set the baud as required by the device connected. The factory setting is 300 baud.
O = switch contact open
C = switch contact closed
LANGUAGE
Leave SW2 contact 3 (SW2-3) in the open position for English, or closed for alternate language, CompuFlo III
displays.
REMOTE DISPLAY
Leave SW2 contact 6 (SW2-6) open for normal operation. If a remote mounted terminal is used, SW2-6 of the
remote terminal (only) must be closed.
PORT 2 COMMUNICATION MODE
Leave SW2 contact 7 (SW2-7) open for normal operation, or closed if a serial printer is connected to PORT 2.
TEST/ADJUST MODE
Leave SW2 contact 8 (SW2-8) in theopen position for normal operation. In the closed position, a test menu is
displayed.
When the keypad test is selected, a pictorial representation of the keypad is displayed. As each keypad
button is depressed, the display indicates successful operation.
When the display contrast adjustment is selected, pressing "4" increases, and pressing "8" decreases the
display contrast.
NORMAL
SPARE
ENGLISH
ALTERNATE
TB2 BAUD
SERIAL
PRINTER
REMOTE
TERMINAL TEST /
ADJUST
4
1
4
3
X
X
20
0
0
0
SW2
Baud SW2
Rate 1 2
300 O O
1200 C O
2400 O C
9600 C C
PL-368 4 – 2

PRE START UP CHECKS
After the CompuFlo III has been properly installed and interconnected, the following checks should be
performed prior to connecting power:
»all cable connections are correct and secure.
»the proper voltage has been selected (J1 on the mother board).
»SW1 and SW2 have been set as required.
»the POWER switch is in the OFF position.
Connect power to TB1-51,52 and ground to TB1-50 of the CompuFlo III. Ensure all connectionsare secure.
Do not operate the CompuFlo III with the
ground (earth) wire disconnected.
INITIAL START UP
Set the CompuFlo III POWER switch to the ON position. The CompuFlo III will enter the following
initialization routine:
COMPUSCALE/FLO III (REV DATE) (EPROM 2 REV)
TEST : (MESSAGES)
PL-368 4 – 3

When the display initialization routine is complete, the display reverts to the last operating mode accessed. If
the CompuFlo III is not programmed, the parameter entry display is accessed.
The CompuFlo III display is divided into the following fields:
FIELD DESCRIPTION
MULTISPAN current span calibration selected. If Multispan 0 is selected, the field is blank.
RELAY current relay status (run mode). If relays are not used, or in non-alarm, the field is blank.
FEATURE parameter number (parameter entry), calibration type (calibrate mode), Rate or Total (run mode)
ECAL indicates ECAL (simulated rate signal) is on. If ECAL is off, the field is blank.
CYCLE full cycles remaining before calibration completion (calibrate mode).
CALIB calibrate mode indicator. When displayed, totalizers are on HOLD (unless otherwise specified).
VALUE the current value associated with the feature selected.
UNITS the units of measure associated with the value displayed
AUX 1 parameter name (parameter entry), auxiliary message (calibrate mode), not used (run mode).
AUX 2 parameter value range (parameter entry), additional information or error message (any mode).
BAR GRAPH represents current rate, displayed as percent of span (run mode).
■
150%100%RATE0%
-50%
FEATURE
ECAL
VALUE
AUX 1
AUX 2
RELAY
CALIB
CYCLE
UNITS
RATE BAR
GRAPH
MULTISPAN
PL-368 4 – 4

PROGRAMMING
GENERAL
Information specific to a particular application is entered into the CompuFlo III memory, via the keypad, prior
to the calibration procedure.
KEYPAD
Button Operation Function
parameter entry numeric entries
parameter entry increase: analog mA output (P17 and P18 only), ECAL value (P22 only)
parameter entry decrease: analog mA output (P17 and P18 only), ECAL value (P22 only)
parameter entry decimal point
parameter entry negative entry or display previous parameter
any mode enter the run mode, return to previously selected display
any mode access parameter for entry or viewing
any mode access zero calibration, view current zero count
any mode access span calibration, view current span count
any mode enter the run mode, select rate or total display
any mode resetdisplayed totalizer value to zero (refer to Start Up\Hardware
Set Up\Totalizer Reset)
parameter entry clear entry
calibrate mode abort calibration
parameter entry display parameter value, or store altered parameter value,
or display next parameter
calibrate mode activate zero or span calibration, or acceptcalibration results
any mode with total displayed, switch to alternate total (main or sub)
8
0
–
9
RUN
PAR
ZERO
SPAN
ALT
DISP
RESET
TOTAL
CLEAR
ENTER
4
PL-368 5 – 1

PARAMETER ENTRY
Application information must be entered into the appropriate CompuFlo III memory locations. These locations
are identified by a Parameter Number (P#). The information entered is referred to as a Parameter Value
(Value). To enter information, the operator accesses the desired parameter number, views the parameter
value displayed, and then accepts or alters the current parameter value.
DIRECT PARAMETER ACCESS
To directly access any parameter, followed by the parameter number.
Only valid parameter numbers will be accepted. Refer to PARAMETERS for the list of valid parameter
numbers.
eg. [PARAMETER ] is displayed in theFEATURE field, if PARAMETER 0 is desired
[PARAMETER 0 ] is displayed in the FEATURE field,
[RATE UNITS ] is displayed in the AUX 1 field.
To view the current parameter value and auxiliary messages for the displayed parameter,
[PARAMETER 0 ] is displayed in the FEATURE field
[ 1 ] is displayed in theVALUE field (unless previously altered)
[RATE UNITS ] is displayed in the AUX 1 field
[1:T/h;2:LT/h;3:lb/h;4:lb/min ] is displayed in the AUX 2 field (with SW1-5 open)
AUTOMATIC PARAMETER ACCESS
Upon accessing any parameter value, pressing "ENTER" will automatically access the next parameter in the
programming sequence. Pressing "-" will automatically access the previous parameter.
eg. with the VALUE field of PARAMETER 0 displayed...
[PARAMETER 1 ] is displayed in the FEATURE field
[ 0.0000 ] is displayed in theVALUE field (unless previously altered)
[RATE ] is displayed in the AUX 1 field
[ENTER VALUE ] is displayed in the AUX 2 field
all fields associated withPARAMETER 0 are displayed
150%100%RATE0%
-50%
FEATURE
VALUE
AUX 2
UNITS
AUX 1
RATE BAR
GRAPH
Common Parameter Entry Display Fields
0
PAR
ENTER
PAR
ENTER
PL-368 5 – 2

ALTERING PARAMETER VALUES
Once the desired parameter number is accessed, the parameter value may be accepted or altered as
required.
eg. if the VALUE field ofPARAMETER 0 is 1 (T/h), however 2 (LT/h) is desired
[ 2 ] is displayedin the VALUE field
the new value (2) is now stored in memory
LAST PARAMETER RECALL
From the Calibrate or Run mode, the last parameter accessed in the Program mode, may be recalled.
the last parameter accessed is displayed.
PARAMETER RESET
To reset all parameters to factory settings, refer to PARAMETERS/P99 Master Reset.
PROGRAMMING SEQUENCE
Typically, the CompuFlo III is programmed as follows:
a) Referring to PARAMETERS, copy the selected parameter values to the spacesprovided on
the PROGRAMMING CHART fold out.
b) Perform a MASTER RESET (P99).
c) Access each parameter ( in sequence fromP0) and enter the parameter values
from the PROGRAMMING CHART.
d) Perform a Zero and Span calibration (refer to CALIBRATION)
e) Perform Span Adjust (P8) or Factoring (P9) procedures, as required.
Remember to copy any parameter value alterations onto
the PROGRAMMING CHART for future reference.
QUICK START PROCEDURE
The Quick Start Procedure describes the minimum start up, programming, and calibration requirements of the
CompuFlo III, to obtain successful RUN mode operation for most applications.
If desired, refer to APPENDICES/Quick Start. Parameters which are not included in the procedure may be
programmed after the RUN mode is entered.
■
ENTER
2
ENTER
PAR
PL-368 5 – 3

CALIBRATION
GENERAL
As material flow characteristics often vary, frequent calibration may be required to maintain calibration
accuracy. Normally, a Zero calibration is performed first, followed by a Span calibration.
When the CompuFlo III is first commissioned, several Zero and Span calibrations are normally performed to
verify the calibration results are repeatable.
A Zero or Span calibration (in progress) may be aborted by .
INITIAL CALIBRATION REFERENCES
The first calibration performed, establishes the Initial Zero and Initial Span calibration references. Subsequent
Zero and Span calibration resultsare compared to these references. The maximum acceptable deviation
between an Initial Calibration Reference and a subsequent calibration result is 12.0% of span. Otherwise,
[ZERO OUT OF RANGE] or [SPAN OUT OF RANGE] is displayed in the AUX 2 field.
While a calibration in progress is establishing an initial calibration reference, the dynamic count value is
displayed in the VALUE field. Otherwise, the dynamic rate value is displayed.
The initial calibration references may be reset. Refer to Parameters/P77 Initial Zero Reset and P88 Initial
Span Reset. Both initial calibration references (along with other programming) are erased by a Master Reset
(P99).
VALUE
150%100%RATE0%
-50%
CALIB
UNITS
RATE BAR
GRAPH
MULTISPAN
FEATURE
ECAL
AUX 1
AUX 2
CYCLE
CLEAR
PL-368 6 – 1

ZERO
The average no flow input fromthe flowmeter is calculated and stored in memory as a Zero count. With no
material flow or Test Weight applied to the flowmeter...
[ZERO] is displayed in theFEATURE field. The current Zero counts are displayed in the
VALUE field. [ENTER: CALIBRATE MODE] is displayed in the AUX 2 field.
to initiate the calibration. [CALIB] is displayed in the CALIB field and [ZERO IN PROGRESS]
is displayed in theAUX 2 field. The time required to complete the calibration (and calibration
accuracy) is dependent upon the Calibration Duration (Refer to Parameters/P30 Calibration
Duration). The number of full calibration cycles remaining until completion, is displayed in
the CYCLE field.
When complete, the deviation from the last Zero calibration is displayed in the VALUE field,
as a percent of span.
to accept the new calibration. Otherwise, investigate the reason for the deviation and
perform the Zero calibration again.
SPAN
The simulated material flow provided by the Test Weight (or number of Test Weights) is calculated and stored
in memory as a Span count. (Refer to Alternate Test References, if a Test Weight is not used.)
With no material flow or Test Weight applied to the flowmeter...
[SPAN] is displayed in theFEATURE field. The current Span counts are displayed in the
VALUE field.
With [CALIB] displayed in the CALIBfield, apply theTest Weight to the flowmeter
(as described in the flowmeter manual).
If [CALIB] is not displayed, respond to the CompuFlo III display prompts until this
indicator is obtained, before applying the Test Weight.
to initiate the calibration. The time required to complete the calibration (and calibration
accuracy) is dependent upon the Calibration Duration (Refer to Parameters/P30 Calibration
Duration). The number of full calibration cycles remaining until completion,
is displayed in theCYCLE field.
When complete, the deviation from the last Span calibration, is displayed in theVALUE field,
as a percent of span.
to accept the new calibration. Otherwise, investigate the reason for the deviation
and perform the Span calibration again.
CALIBRATION ACCURACY
With the Initial Zero and Initial Span calibration complete, RUN mode operation is possible, however greater
calibration accuracy may be required. The Test Reference value (P7) is an approximation, based on typical
material flowrate characteristics.
To adjust the Span calibration to suit the actual material flow characteristics encountered, perform a material
test. (Refer to Parameters/P8 Span Adjust). The Test Reference value is automatically adjusted so the Test
Weight will accurately simulate material flow during future Span calibrations.
The CompuFlo III is now ready to be putinto service, (refer to Operation).
SPAN
ENTER
ENTER
ENTER
ENTER
ZERO
PL-368 6 – 2