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Contrec 424 Manual

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BATCH CONTROLLER
MODEL 424
22 Jun 2018
424-M-V1.5

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  • Page 1 BATCH CONTROLLER MODEL 424 22 Jun 2018 424-M-V1.5...
  • Page 2 424-M-V1.5...

  • Page 3: Table Of Contents

    3.3 CALCULATION OF RATE AND TOTAL 3.3.1 Frequency Input 3.3.2 Filtering 3.4 TOTAL CONVERSION 3.5 THE OUTPUT PULSE AND FLOW ALARM 4. COMMS & OPTIONS 4.1 THE RS232/485 INTERFACE 4.1.1 Hardware 4.1.2 RS232 4.1.3 Multipoint Communication 4.1.4 Real Time Clock 424-M-V1.5...
  • Page 4 5.1 PROGRAMMING THE SETUP PARAMETERS 5.2 ENTERING THE BATCH PARAMETERS 5.3 PROGRAMMING OPTIONS 5.4 TEST MENU 6. INPUT CIRCUITS 6.1 INPUT CIRCUIT FOR THE MODEL 424 6.2 FREQUENCY INPUT CONNECTION 6.3 REMOTE SWITCHES 7. INSTALLATION & MAINTENANCE 7.1 GENERAL 7.2 WIRING DESIGNATIONS FOR THE 424...
  • Page 5 7.3 MAINTENANCE 8. TROUBLE SHOOTING 8.1 ERROR CODES Index 424-M-V1.5...
  • Page 6 424-M-V1.5...
  • Page 7 When powered from a mains supply this unit requires the provision of a suitable mains isolation device, capable of interrupting both poles of the supply and meeting your local wiring regulations, to be accessible near to the installed instrument. 424-M-V1.5...
  • Page 8 Properly shielded and grounded cables and connectors must be used in order to meet FCC emission limits. Contrec Ltd. is not responsible for any radio or television interference caused by using other than recommended cables and connectors or by unauthorized changes or modifications to this equipment.

  • Page 9: Introduction

    This manual covers both the Model 424.0 and 424.1. While both versions have identical software and outputs, the Model 424.1 includes a 4-20mA output circuit.
  • Page 10 – EMC requirements: Residential, Commercial & Light Industry Environment & Industrial Environment. • EN61010:2010 Safety requirements for electrical equipment for measurement, control, and laboratory use. In order to comply with these standards, the wiring instructions in Section 7.1 must be followed. 424-M-V1.5...

  • Page 11: Model Number Designation

    Introduction 3 1.1 MODEL NUMBER DESIGNATION The model number of an instrument describes which input and output options are installed. Model 424 . 1 0 U C C for Conformal Coating Power U for universal mains supply D for DC power only...

  • Page 12: Specification

    Maximum: 10KHz - Pulse, 2.5KHz Coil and Input Circuits: Will accept most sine logic and proximity switch inputs (see section 6.1). Scaling Range: 0.1000 to 50,000. Relay Outputs Maximum Switching Power: 1250VA. Maximum Switching Voltage: 250VAC, 30VDC. Maximum Switching Current: 5 Amps. 424-M-V1.5...
  • Page 13 E.g. With a pulse width setting of 10mSec the unit can output a maximum of 50 pulses per second. The scaling of t.dpt must be set so that the least significant digit of the accumulated total does not exceed 50 increments per second (Hz). 424-M-V1.5...

  • Page 14: Operation

    6 Operation 3. OPERATION The model 424 Batch Controllers use a low power CMOS microprocessor to perform all control functions and calculations. The instruments are fully programmable with all operating parameters and calculation constants user programmable. (See Section 5 entitled 'Calibration' for information on programming).

  • Page 15: Front Panel Operation

    Once the desired number is entered, press the BATCH SET key to return to the Run mode. The Batch Set LED will extinguish. Once programmed, the Batch quantity will be retained in the non-volatile memory and will not alter until changed by the user. 424-M-V1.5...
  • Page 16 Batch Total will then revert to the preset quantity. If it is programmed to count up, the Batch Total will clear to zero. � If Auto Reset is programmed, the Batch Total will automatically reset when the RUN key is pressed and then commence the next batch. 424-M-V1.5...
  • Page 17 LIMIT ON BATCH SIZE To prevent accidental entry of large batch quantities, a maximum batch limit can be programmed during calibration. The operator is then prevented from entering a batch quantity which exceeds this value. 424-M-V1.5...

  • Page 18: Batch Operations

    1. At the end of the batch, the STOP key must be pressed to reset the Batch Total. (This must be done before another batch can be started). Batch PAUSE Quantity Stop Run Stop Reached Count Down Count Up Relay 1 Relay 2 Start Time Prestop Quantity End of Batch End of Batch 424-M-V1.5...
  • Page 19 Start Time Prestop Auto Restart Quantity End of Time Batch End of Batch The Batch Controller can also be programmed, during Calibration, to either count up from zero on each batch, or to count down from the preset batch quantity. 424-M-V1.5...

  • Page 20: Control Relay Outputs

    (i.e. not the prestop phase), the timer will be reset and a slow start will occur with a full time delay to ensure a correct start up. The totals will not be reset and the batch quantity will remain unchanged. 424-M-V1.5...

  • Page 21: Signal Timeout

    LED. Once acknowledged the process can then be reset via the STOP switch or continued by pressing the RUN key. With the Model 424, an open collector output on terminal 25 will also switch 'On' whenever the Flow Alarm condition exists (see Section 3.5).

  • Page 22: End Of Batch

    Start of the batch and remain on either until the end of the batch is reached, or the batch is paused. If paused the output will turn on again if and when the current batch is resumed. 424-M-V1.5...

  • Page 23: Auto Restart

    The STOP button can be pressed at any time to interrupt the batching process and continued using the RUN key. If, however, the process is to be aborted, the STOP key is again pressed. The Batch Controller is reset and to restart the auto batching process the RUN key is pressed. 424-M-V1.5...

  • Page 24: Automatic Overrun Compensation

    AOC is recalibated at every power up. i.e. The first run of any session from power up will recalculate the amount of overun and then use this figure until conditions change. 424-M-V1.5...

  • Page 25: Calculation Of Rate And Total

    The Scaling Factor, S, is equal to the K-factor of the flowmeter expressed in pulses per unit volume. The user programs the Scaling Factor and selects the timebase during the Calibration procedure as detailed in Section 5 of this manual. 424-M-V1.5...

  • Page 26: Filtering

    The value, A, is the filter constant which is programmed during the Calibration routine. The times for the display value to reach 90% and 99% of full swing are given in seconds, for different values of A. 424-M-V1.5...
  • Page 27 Operation 19 Table 1 - Response to a step Input (in seconds). Note that if A is set to 1 there is no filtering of the input signal. 424-M-V1.5...

  • Page 28: Total Conversion

    Some common units are given below together with the Total Conversion constant (TOTCON) which should be programmed. Rate* Totals TOTCON Gallons (US)/ Barrels (oil) 42.000 Litres/ m³ 1000 Litres 1000 Mgallons/ Acre-feet 0.32587 * Units per second, minute, hour or day. The timebase is programmed separately during Calibration. 424-M-V1.5...

  • Page 29: The Output Pulse And Flow Alarm

    Signal Timeout is greater than 0). The Flow Alarm output will switch 'on' (i.e. the signal goes low) whenever an alarm condition exists. The Alarm will switch 'off' (i.e. the signal goes high) when the alarm is reset by pressing the STOP key. 424-M-V1.5...
  • Page 30 Driving an External Relay or Impulse Counter DC Supply Out (8-24V) External Load 11/25 Resistor 10K Logic Input 5.6 ohms Zener Driving a Logic Input such as a PLC or Electronic Counter 25 = Flow Alarm 11 = Output Pulse 424-M-V1.5...

  • Page 31: Comms & Options

    3m. The RS485 interface is used for communication over a long distance or in applications requiring multipoint communication. Screened twisted pair cable should be used for RS485 comms. RS485 Rx/Tx Data In RS232 Data Out Comms Ground 424-M-V1.5...

  • Page 32: Rs232

    Within the computer serial ports are generally termed COMx ( where x is the designated port number ). Computer Common 25 Pin 424 Series Instruments Connector Connection to Computers with 25 Pin Connectors Computer Common...

  • Page 33: Multipoint Communication

    Subsequent software protocol will control the flow of data between the Controller and the Instrument. Twisted Pair Load 120 ohms Host Computer 424 Series 424Series Instrument Instrument Figure 2 RS485 Interface 424-M-V1.5...

  • Page 34: Real Time Clock

    26 Comms & Options 4.1.4 Real Time Clock The 424 has a real time clock and enables the time and date to be set and printed on tickets. The date format can be European (days/months/years) or USA (months/days/years) while the time is on a 24 hour clock.

  • Page 35: Software Protocol

    The whole string or command is processed at one time after having received a carriage return. Regardless of the command, the time from the receipt of the carriage return terminating the command to the first character of the response is nominally less than 25ms. 424-M-V1.5...

  • Page 36: Commands And Responses

    It is also possible to determine which instrument is currently selected by sending the command: without the value x. On receiving this command the selected instrument will reply with its ID number. 424-M-V1.5...
  • Page 37 Comms & Options 29 The following commands are recognised by the 424 Batch Controller: Commands Select an instrument, where x is the ID number (x will be accepted with leading zeros). No serial response is returned. BVxx.x New batch value to be entered. The value xx.x is a variable length field.
  • Page 38 On receipt of a 'R?' request, the instrument sends the following: xx.x CRLF Rate Carriage Return Line Feed All values are variable length and as displayed on the instrument itself. The values are transmitted in ASCII with one or more spaces (ASCII Code 32) between each field. 424-M-V1.5...

  • Page 39: Printer Communications

    Comms & Options 31 4.4 PRINTER COMMUNICATIONS The following printers are supported by the Model 424: PTYPE 00. Standard Computer Printer - 80 Col. (Note that the printer must have an RS232 Serial Interface) 03. EPSON TM290-2 or TM295 Slip Printer - 42 Col.
  • Page 40 For the Epson CTM290-2 and TM-295, interconnect pins 6, 8 and 20 on the printer's 25 way connector and when CTS is not used, interconnect pins 4 and 5. When the 424 programmed for: 9600 baud 8 bits and no parity (none) set all DIP switches OFF on the slip printer.

  • Page 41: Operation

    Comms & Options 33 4.4.2 Operation The 424 Batch Controllers will print a ticket on reaching the 'End of Batch' (see instrument operating manual for a description of End of Batch). 4.4.3 Information Printed The format with which the data is printed depends on the type of printer selected.
  • Page 42 34 Comms & Options Example of a printout for a standard 80 Column computer printer (not to scale). No header is shown with this printout. 424-M-V1.5...
  • Page 43 Comms & Options 35 Example of a ticket printed on an Epson CTM290-2 printer (not to scale). Example of a ticket printed on a Porti Roll Printer (not to scale). 424-M-V1.5...

  • Page 44: The 4-20Ma Output Option

    3 wire transmission from an external loop supply. A block diagram of the output is shown below and various methods of interconnection are outlined on the following pages. DC to DC Terminal Convertor +15V Digital to Analog Convertor Opto-Isolation -15V 424-M-V1.5...

  • Page 45: Load Specification

    For rates or displayed values above and below the maximum and minimum values the output will remain at its 20mA or 4mA level respectively. It should be noted that the output will be updated every 0.25 seconds in unison with the display and, between updates, the output value is constant. 424-M-V1.5...
  • Page 46 * For driving high impedance loads (over 390 ohms), terminate to teminal 7 Two Wire Transmission (Internal Supply) Terminal +15V I (+) Load 950 ohm maximum I (-) External Supply -15V of 15 to 30 Vdc Three Wire Transmission (External Supply) 424-M-V1.5...

  • Page 47: Calibration

    When a value or parameter can be changed, it is always shown as flashing, and the LED's in the switch panels are lit if that key switch can be used to change a value. 424-M-V1.5...
  • Page 48 Test program until the end, and press the STOP switch when End is displayed, (ensure the calibration link is not removed if this method was used to enter calibration mode). If power is lost during Cal then any changes made will not be stored. 424-M-V1.5...

  • Page 49: Programming The Setup Parameters

    Number of decimal points with which the F dPt Rate is to be displayed between 0 to 0.00000. t.bASE The Timebase with which the Rate is (3.2.1) calculated must be entered as: SECS units/second 60SECS units/min HOUR units/hour dAYS units/day 424-M-V1.5...
  • Page 50 13 dc Out Sets the dc output from 8-24V in 0.2, 0.5 or 1V steps. 14 ACCESS E nable access to calibration routine via the front keyboard only. Front Enable access via front keyboard. No Acc Disable access via front keyboard. 424-M-V1.5...

  • Page 51: Entering The Batch Parameters

    Prestop Quantity. xxxx Quantity at which Relay 2 will de- energise before the end of the batch. (3.2) (E.g. If the batch quantity is 100 litres (3.2.1) and Prest is 2 litres, relay 2 will de- energise after 98 litres). 424-M-V1.5...
  • Page 52 RUN key. 10 EOb PC End of Batch Terminal behaviour. (3.2) Signal energises at the End of Batch. Pump Control :- Signal energises when Run is pressed and de-energises at the end of batch or when the delivery is paused. 424-M-V1.5...

  • Page 53: Programming Options

    PARITY No Parity. Odd Parity. Even Parity. PtYPE Printer Type or Computer . (4.1.5) None or Standard 80 col Computer Printer. EPSON TM290-2 or TM295 Slip Printer. M-Tech 32 column roll printer. Porti Roll 24 column roll printer. Computer. 424-M-V1.5...
  • Page 54 300, 600, 1200, 2400, 4800, 9600, 19200, xxxx (4.2) 57600,115200. 11A PARITY Parity. No Parity. Odd Parity. Even Parity. 12A ECHO ECHO Commands. Echo (Full Duplex). No Echo (Half Duplex). 13A ID NO Unit Identification Number. None. 01-99 Id Number. 424-M-V1.5...
  • Page 55 Alarm or 4-20mA settings then these values will be restricted to the maximum value which the display can accomodate within its 6 digits - e.g. 99.9999, 999.999 etc. 424-M-V1.5...

  • Page 56: Test Menu

    Enter Batch Parameters. Co Opt Comms and Options (if installed). (5.3) The following steps are displayed if TEST is selected. SR x.xx Software revision number. Displayed for one second. FREq xxx.xxx CLOC xx:xx:xx dAtE xx:xx:xx 5u:x.x Ui :x.x Uo :x.x PrnHdr 424-M-V1.5...

  • Page 57: Input Circuits

    6. INPUT CIRCUITS This section covers the connection of flowmeter signals. The Model 424 has a regulated output which can be used to power sensors. The voltage can be adjusted in the range of 8-24 Volts within the Cal menu and the output can supply a maximum of 80mA@24V or 1.9W.

  • Page 58: Frequency Input Connection

    They should never be terminated to DC gnd. Squarewave, CMOS or TTL Frequency Input (+) Signal Ground (-) Shield Open Collector Frequency Frequency Input (+) Input (+) Signal Ground (-) Signal Ground (-) Shield Shield Reed Relay Switch Frequency Input (+) Signal Ground (-) Shield 424-M-V1.5...
  • Page 59 Signal Ground (-) Shield Namur Proximity Switch Vo = 8V DC Frequency Input (+) Shield TTL - Switching point = 2V. AC input impedance 2.7k. NPS - Load = 680r. Coil - 15mV pk-pk min. Debounce On - Cut off <1KHz. 424-M-V1.5...

  • Page 60: Remote Switches

    Remote push-buttons can be connected to the Model 424 to duplicate the switches on the front panel and to provide remote Start and Stop capability. On the Model 424, all four switches are taken to the rear terminals. The switches are wired as follows:...

  • Page 61: Installation & Maintenance

    INSTALLATION & MAINTENANCE 7.1 GENERAL Terminal designations for the Model 424 Batch Controller are given on the following pages. The cutout hole in the panel should be 5.5" (139mm) wide x 2.6" (67mm) high. Two side clips are supplied to secure the instruments into panel.
  • Page 62 The basic principle of operation is that the capacitor prevent a series of sparks arcing across the contact as the contact breaks. The series resistor limits the current through the contact when the contact first makes. 424-M-V1.5...

  • Page 63: Wiring Designations For The 424

    Installation & Maintenance 55 7.2 WIRING DESIGNATIONS FOR THE 424 Terminal Model 424 Flow Common (-) Flow Signal Input (+) +15V (option) 4-20mA Power in - link to 3 or ext PSU (option) I (+) (option) Either I (-) 0V return - loads up to 390ohm (option)

  • Page 64: Maintenance

    Click the fresh battery in place. Re-assembly. 1. Replace the front and back panels. 2. Insert the four securing nuts and tighten them. 3. Re-connect all wiring plugs in their original postions. Power up. 424-M-V1.5...

  • Page 65: Trouble Shooting

    TTL input (see Section 5) and pulsing across the signal (+) and (-) with a wire link. When doing this, the scaling factor should be set to 1 and the resolution to whole numbers. 424-M-V1.5...
  • Page 66 . No end of batch, pulse output or flow alarm. This fault is usually caused by lack of a pullup resistor or load on the output. The outputs themselves have no internal pullups and rely on an external load. 424-M-V1.5...

  • Page 67: Error Codes

    PrnErr Communications error - Printer fault, Epson TN290-2, 295, P tYPE 03 only. Check that the printer is connected, switched on and not out of paper. To cancel press and hold Stop. This will cancel the error until the unit is powered off and on again. 424-M-V1.5...

  • Page 68: Index

    60 Index Display Key 7, 9 Index Displayed Information Earthing Point 4-20mA output Electrical Noise End of Batch 10, 14, 44 Error Codes Access 39, 42 Accumulated Total 9, 21 Auto Reset 8, 44 Filtering 18, 42 Auto Restart 15, 44 Flow Alarm 13, 21 Automatic Overrun...
  • Page 69 Index 61 Loss of Signal Response RS232/485 Interface Run Key 7, 8 Mains 4, 53 Model Number Multipoint Communication Scaling Factor Scaling Range Setting the Batch Setup Parameters 39, 41 Signal Timeout 13, 21, 44 Namur Sensors 50, 51 Slow Start 12, 43 Non Volatile Memory Slow Stop...
  • Page 70 This page has been left intentionally blank. 424-M-V1.5...

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