Milltronics COMPUFLO III Instruction Manual
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Milltronics COMPUFLO III Instruction Manual

Milltronics COMPUFLO III Instruction Manual

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

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  • Page 1 COMPUFLO III FLOWMETER INTEGRATOR Instruction Manual PL-368 March 1993 33453680 PRR 1.1...

  • Page 3: Table Of Contents

    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 –...
  • Page 4 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 –...

  • Page 5: General Information

    All programming and calibration information is stored 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.

  • Page 6: About This Manual

    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.

  • Page 7: Specifications

    SPECIFICATIONS COMPUFLO III » 100/115/200/230 V AC ±10%, jumper Power: 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)

  • Page 8: Options

    » 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 »...

  • Page 9: Installation

    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.

  • Page 11: Start Up

    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.
  • Page 12 PORT 2 BAUD RATE The CompuFlo III TB2 communication port baud rate is independent of the PORT 1 baud rate, and is set by SW2 contacts 1 and 2. Set the baud as required by the device connected. The factory setting is 300 baud.

  • Page 13: Pre Start Up Checks

    »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 connections are secure. Do not operate the CompuFlo III with the ground (earth) wire disconnected.
  • Page 14 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: MULTISPAN...

  • Page 15: Programming

    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)

  • Page 16: Parameter Entry

    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.

  • Page 17: Altering Parameter Values

    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.

  • Page 19: Calibration

    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.

  • Page 20: Zero

    With [CALIB] displayed in the CALIB field, apply the Test 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.

  • Page 21: Calibration Alternatives

    This feature automatically performs a Zero calibration, whenever material flow ceases in the RUN mode. If the Auto Zero feature is desired, provide a dry contact input to the CompuFlo III terminals TB1-34 and TB1-37. The contact may be activated by a material feed controlling device such as a motor control, material control gate, or valve.

  • Page 22: Alternate Test References

    The CompuFlo III On-Line material total is compared to the weight of material discharged from the weigh bin between the high and low limits (reference weight). The deviation between these values is displayed as a percent of span in the VALUE field.

  • Page 23: Parameters

    The SW1-5 position and the value of P0 should be set before any other programming. To alter the Rate Units of a programmed CompuFlo III, set SW1-5 as desired, perform a Reset (refer to Parameters / P99 Reset) and set P0 to the desired value.
  • Page 24 SPAN ADJUST Adjusts the test reference calibration results to improve material flowrate measurement accuracy. % CHANGE - Calculate the deviation between the CompuFlo III Total and the actual material weight. A positive value reduces (negative increases) the Rate displayed. % Span Error = CompuFlo III Total - Actual Material Weight x 100...
  • Page 25 Adjusts the Test Reference value (P7) of the Test Reference selected (P20). After the CompuFlo III is calibrated utilizing a known Test Reference (e.g. Test Weight representing 20 T/h), the material flowrate represented by an unknown Test Reference (e.g. alternate Test Weight), may be established.
  • Page 26 RATE DISPLAY DAMPING Defines the level of damping to be applied to the Rate display. Range = 1 to 999 This may be used to stabilize a fluctuating rate display without affecting accuracy. Higher values provide more stabilization. Press "RUN" to instantly update the Rate display to the current rate. enter: desired value (F = 1) RATE OUTPUT DAMPING Defines the level of damping to be applied to the Rate Output.
  • Page 27 RATE OUTPUT MAX Adjusts the Rate Output reference value for maximum material flowrate. Range = 0 to 4095. With Change Mode activated and mA meter in series with the load connected to TB1-20,21, Press "CLEAR" before keying in the estimated reference value, and pressing "ENTER". Repeat step b) as required to produce the desired maximum Rate Output.
  • Page 28 ECAL is adjusted in the RUN mode with no material flow or Test Weight applied to the flowmeter. When the Adjust option is selected, the simulated flowmeter input is applied to the CompuFlo III. Record all totalizer values before and after adjusting ECAL. To adjust ECAL : a) Enter the RUN mode before accessing P22 and selecting the adjust option.
  • Page 29 If operation still seems to be non-linear, perform the following tests at 25%, 50%, and 75% of the P1 Rate. With material flow stopped, reset the Sub Total. Run a batch of material (larger is better) through the flowmeter, maintaining a constant flowrate. Record the batch Sub Total Weigh the material batch (if the actual batch weight is not already known).
  • Page 30 (TB1-38,39,40, and 41 contacts must be open), (F = 0). ON-LINE: INPUT CALIBRATION Calibrates the CompuFlo III for the Zero and Span mA input from the bin weighing system. These values represent the empty and full weight of the On-line calibration weigh bin. Range = 0.000 to 25.00 enter: 0 = On-line calibration not required (F) 1 = Zero calibration (with weigh bin empty, press "ENTER"...
  • Page 31 0 = On-Line calibration not required (F) 1 = Activate On-Line calibration CALIBRATION DURATION Defines the number of 10 second time periods the CompuFlo III will utilize to perform a Zero or Span calibration, Factoring (P9), or Verification Totalizer (P31) operation. Range = 0.01 to 99 A low value reduces calibration time, while a high value increases calibration accuracy.
  • Page 32 Range = 0 to 99999 The Data Transmit Interval may be adjusted as required to control the level of message traffic between the CompuFlo III and the external device(s) connected to the PORT 1 and/or PORT 2 bipolar current loop or RS-232C communication connections.
  • Page 33 RELAY 1 Defines the operation of Relay 1 as a Rate Alarm or On-Line calibration prefeed control. If the Rate Alarm function is selected, the High Limit, Low Limit, and Deadband values are entered as a percent of span. The High Limit is the high alarm set point value which will cause the relay to de-energize. If a high limit is not required, set the high limit to 0.
  • Page 34 If the Rate function was selected, the High Limit may now be set. enter: desired High Limit value, (Range = 0.000 to 100.0, F = 98), advances to Low Limit desired Low Limit value, (Range = 0.000 to 100.0, F = 35), advances to Deadband desired Deadband value, (Range = 0.000 to 100.0, F = 5) 100% TEST REFERENCE (V) Displays the de sign Rate (P1) value.
  • Page 35 SECURITY LEVEL Defines the level of operator access permitted. This feature may be utilized to ensure the programming and/or calibration is not inadvertently altered. Access to all RUN mode displays and the P66 value is permitted at all Security levels. When a security level is selected, Security is not invoked until the RUN mode is entered.
  • Page 36 Displays the sum of the amplified load sensor (P21) input voltage(s). Range = -1.00 to 4.00. ON-LINE CALIBRATION (Input Current) (V) Displays the CompuFlo III TB1-18,19 mA input from the bin weighing system. Range = 0.00 to 25.00. INITIAL SPAN RESET Performs a Span calibration to establish a new Initial Span count value.
  • Page 37 When the loadcell balancing procedure is completed, perform a Zero and Span calibraton before entering the Run mode. enter: 0 = load cell balancing not required (F) 1 = balancing procedure required, (press "1", "ENTER" to advance to P91) P91 POS B LC (A+B) (V) Displays the summed load cell input counts.
  • Page 38 This feature clears memory locations and restores parameter values to their original factory settings. The implementation of a Reset necessitates CompuFlo III reprogramming and recalibration. Neither Reset Level affects the Clock/Calendar settings. A Partial Reset maintains the previous, P17, P18, P20, P21, P22, P27, P40, P41, P42, P43 and load cell balancing settings.

  • Page 39: Programming Chart

    PROGRAMMING CHART NAME VALUE VALID RANGE (F or _ = factory setting) RATE UNITS IMP: 1(T/h),2(LT/h),3(lb/h),4(lb/min) Metric: 1(t/h),2(kg/h),3(kg/min) RATE 0.0001 to 99999 (F = 0.000) LOCAL TOTAL 1,2,or 5 x .0001 .001,.01,.1,1,10,100,or 1000 REMOTE TOTAL 1,2,or 5 x .0001 .001,.01,.1,1,10,100,or 1000 TEST REFERENCE 0.0001 to 99999 (F = 0) SPAN ADJUST...

  • Page 41: Operation

    All personnel should be instructed on the safe and proper operation of the CompuFlo III and be instructed when and if a calibration check should be performed, what level of zero and span deviation is acceptable, and when to reset the totalizer(s).

  • Page 42: Normal Operation

    START UP Ensure power is supplied to the CompuFlo III. When power is first applied, the CompuFlo III will automatically perform a series of tests for about 10 seconds and then resume operation in the last mode entered. The following procedures may be performed on a routine basis, as required. Access to the Zero and Span calibration, and Reset Total functions may be restricted.

  • Page 43: Communication

    The Bipolar Current Loop may be utilized for cable runs up to 1500 metres (5000 ft). If communication with an RS-232 device is required, the Milltronics BIC-II or CVCC may be used to convert the Bipolar Current Loop to RS-232. The BIC-II is also capable of Bipolar Current Loop to RS-422 conversion.

  • Page 44: Remote Communication

    REMOTE COMMUNICATION This mode provides complete access to all CompuFlo III functions via a Milltronics remote terminal. To receive communication from the CompuFlo III PORT 1 or PORT 2 connection, SW2-6 of the remote terminal must be closed. Alternatively, a remote terminal emulation software package is available for IBM PC compatible computers supporting colour graphics (VGA).

  • Page 45: Protocol

    PROTOCOL Protocol refers to the format, sequence and value of the data fields utilized in Host Mode communication messages. Each data field of a CompuFlo III message contains one or more bytes of ASCII binary code. Each byte contains: +20 mA »...

  • Page 46: Message Requests

    DEVICE for CompuFlo III # 1 material flow rate request end of message MESSAGE RESPONSES The CompuFlo III response to a flow rate (MT=50) message request will be in the following format. som DEVICE MT READING eom Example: Data ASCII...

  • Page 47: Alphabetical Parameter Listing

    ALPHABETICAL PARAMETER LISTING PARAMETER PARAMETER PARAMETER PARAMETER NAME NUMBER NAME NUMBER Balancing Procedure Parameter List P100 Baud Rate Rate Bar Graph Assignment Calibration Duration Rate Clock/Calendar Rate Output Average Converter Input (V/F) Rate Output Max Converter Output (V/F) Rate Output Min Damping, Rate Display Rate Units Damping, Rate Output...

  • Page 48: Maintenance And Spare Parts

    The CompuFlo III memory backup and calibrator batteries should be replaced annually. The 3.6 Volt lithium battery (located on the mother board top right corner) should only be replaced while the CompuFlo III power is ON. The 9 Volt calibrator battery is located on the back of the CompuFlo III door.

  • Page 49: Error Messages

    ERROR MESSAGES The following messages may be encountered during CompuFlo III programming, calibration, or operation. DISPLAY MESSAGE DESCRIPTION [ABORTED] The activated process or procedure was not completed correctly (or before "CLEAR" was pressed). Retry the feature attempted. [AUTO ZERO ABORTED] The Auto Zero was more than 2% of span from the last operator Zero before SW1-6 was closed.

  • Page 50: Trouble Shooting

    TROUBLE SHOOTING Every CompuFlo III integrator is subjected to extensive quality assurance procedures to ensure the highest possible degree of quality, reliability, and performance is achieved. The following listing indicates the probable cause, and proper course of action to be taken should the specified fault symptom occur.

  • Page 51: Quick Start

    QUICK START START UP Flip the POWER switch to ON. The CompuFlo III will perform a self test for 10 seconds. MASTER RESET - Prepares the CompuFlo III for initial programming or complete reprogramming. Proceed to OPERATION if previous programming and calibration is to be retained.

  • Page 52: Calibration

    ENTER CALIBRATION - Prepares the CompuFlo III for operation. If [ZERO OUT OF RANGE] or [SPAN OUT OF RANGE] is displayed after a calibration attempt, refer to the PARAMETERS section for Initial Zero Reset (P77) and/or Initial Span Reset (P88) instructions.

  • Page 53: Operation

    RESET CLEAR TOTAL PERFORMANCE ENHANCEMENT For optimum accuracy, perform Zero and Span calibrations frequently. Read this manual thoroughly for details on all CompuFlo III features. A material test utilizing the Span Adjust (P8) parameter, is recommended. Pl-368 11 – 7...
  • Page 55 OUTLINE and MOUNTING 330 mm ( 13" ) 101 mm 11 mm dia. ( 4" ) 178 mm ( 0.4" ) ( 7" ) 4 places 406 mm 435 mm ( 16" ) ( 17.1" ) enclosure bottom plate ( for cable / conduit entrance ) FIG.
  • Page 56 COMPUFLO III LAYOUT calibrator battery calibrator (door mount) memory/ clock MILLTRONICS CALIBRATOR IV PN 24751327-01 ML 51026351 MADE IN CANADA PETERBOROUGH ONTARIO battery SW 1 EPROM 1 TIME / DATE / MEMORY EPROM 1 3.6 VOLT LITHIUM BATTERY PIN 1...

  • Page 57: Fig .3 Compuflo Iii / Flowmeter Interconnection

    CompuFlo III DUAL LOAD CELLS CompuFlo III Where a flowmeter must be installed in a hazardous area consult Milltronics or your distributor for wiring instructions. Where the integrator to load cell flowmeter cable exceeds 150m (500 ft): A) remove jumpers from CompuFlo III, TB1 - 9,10 and TB1 - 11,12 B) run an additional shielded conductor to the junction box nearest the load cell(s) from: »...

  • Page 58: Fig. 4

    750 Ω Max load Ensure the CompuFlo III J1 position matches the power to be applied to TB1 - 51,52. The Auto Zero contact must be closed when the material feed is stopped, if Auto Zero calibration is desired.

  • Page 59: Fig. 1 Fig

    RELAY WIRING ALARM / CONTROL RELAYS CompuFlo III Relay contacts are shown in de-energized condition. (Power OFF and Alarm Status) to alarm / control devices REMOTE TOTALIZER RELAY AC TOTALIZER DC TOTALIZER CompuScale III CompuFlo III CompuScale III CompuFlo III...

  • Page 60: Fig. 4 Fig

    RS-232 device Unit I.D. # 01 CompuFlo III Unit I.D. # N (max N=15) Power may be disconnected from any CompuFlo III in a multiple current loop without affecting the communication of the other CompuFlo III’s. FIG.6 PL-368 12 – 6...

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