Equflow 6010BCPM001XX Instruction Manual
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Equflow 6010BCPM001XX Instruction Manual

Pulse input batch controller
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Equflow 6010BCPM Pulse Input Batch Controller
Instruction Manual
• Pulse, Open Collector, NPN, PNP, TTL, Switch Contact,
Sine Wave (Coil), Square Wave Inputs
• 5, 10, or 24 V Flowmeter Power Supply
• K-Factor, Internal Scaling, or External Calibration
• Start, Batch, Pause, & Stop with Front Panel Buttons
• Display Batch Total + Rate, Grand Total, Batch Count or Preset
• Single or Multi-Stage Batching
• Automatic Overflow Protection
• Manual Control or Automatic Batching
• Dual-Line Display
• NEMA 4X and IP65 Rated Front Panel
• CE Marked
• Display Features 0.6" & 0.46" Digits
• Six Full Digits on Each Line
• Free USB Programming Software & Cable
• Isolated 24 VDC @ 200 mA Transmitter Power Supply
• Modbus
®
RTU Communication Protocol Standard
Equflow BV - P.O. Box 35- NL-5370 AA Ravenstein - The Netherlands
T +31 (0)24 3792666 – E info@equflow.com
www.equflow.com
Batch Controller

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  • Page 1 • Free USB Programming Software & Cable • Isolated 24 VDC @ 200 mA Transmitter Power Supply • Modbus ® RTU Communication Protocol Standard Equflow BV - P.O. Box 35- NL-5370 AA Ravenstein - The Netherlands T +31 (0)24 3792666 – E info@equflow.com www.equflow.com...
  • Page 2 Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual Disclaimer The information contained in this document is subject to change without notice. Equflow makes no representations or warranties with respect to the contents hereof; and specifically disclaims any implied warranties of merchantability or fitness for a particular purpose.

  • Page 3: Table Of Contents

    Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual Table of Contents Setting the Display Parameter & Intensity (dsplay) Table of Contents ----------------------------------------- 3 ----------------------------------------------------------------- 29 Table of Figures ------------------------------------------- 4 Setting the Relay Operation (relay) ------------------ 30 Introduction ------------------------------------------------- 4...

  • Page 4: Table Of Figures

    Flowmeter ............12 Figure 19: Interlock Connection ......... 14 Introduction The Equflow 6010BCPM is an easy-to-use batch controller ideal for simplifying independent batch control operations where local control is preferred to expensive and expansive plant operation systems. The controller comes programmed for easy front panel start, pause, stop, and batch size (preset) changes.

  • Page 5: Specifications

    Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual Specifications Except where noted all specifications apply to operation at +25°C. Terminals P+ & P-: 24 VDC  10%. 12-24 VDC Isolated General Transmitter powered models selectable for 24, 10, or 5VDC Power Supply supply (internal jumper J4).

  • Page 6: Batch Controller Rate/Totalizer Display

    Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual Multi-Point 2 to 32 points Grand Total Up to seven, user selectable under setup Linearization Alarms menu. Any set point can be assigned to grand total and may be programmed Low-Flow 0-999999 (0 disables cutoff function)

  • Page 7: Modbus ® Rtu Serial Communications

    Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual ® Modbus RTU Serial Communications Relay Reset User selectable via front panel buttons, digital inputs, or PC 1 – 247 (Controller address) Slave Id 1. Automatic reset only (non-latching), Baud Rate 300 - 19,200 bps when the input passes the reset point or total is reset to zero.

  • Page 8: Compliance Information

    Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual Compliance Information Electromagnetic Compatibility EN 55022:2010 Emissions Class A ITE emissions requirements Radiated Class A Emissions AC Mains Class A Conducted Emissions Immunity EN 61326-1:2013 Measurement, control, and laboratory equipment EN 61000-6-2:2005...

  • Page 9: Safety Information

    Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual Safety Information CAUTION: Read complete WARNING: Risk of electric shock instructions prior to installation and or personal injury. operation of the controller. Hazardous voltages exist within enclosure. Installation and service should be performed only by trained service personnel.

  • Page 10: Mounting Dimensions

    Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual Mounting Dimensions Figure 2: Controller Dimensions - Side Figure 3: Controller Dimensions - Top View View Transmitter Supply Voltage Selection (P+, P-) All controllers, including models equipped with the 12-24 VDC power option, are shipped from the factory configured to provide 24 VDC power for the transmitter or sensor.

  • Page 11: Connections

    Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual Connections All connections are made to removable screw terminal connectors located at the rear of the controller. Use copper wire with 60°C or 60/75°C insulation for all line voltage connections. Observe all safety regulations. Electrical...

  • Page 12: Pulse Signal Connections

    Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual Pulse Signal Connections Signal connections are made to a six-terminal connector labeled SIGNAL on Figure 7. The COM (common) terminal is the return for the input signals. The following figures show examples of signal connections.

  • Page 13: Switching Inductive Loads

    Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual Switching Inductive Loads The use of suppressors (snubbers) is strongly recommended when switching inductive loads to prevent disrupting the microprocessor’s operation. The suppressors also prolong the life of the relay contacts. Suppression can be obtained with resistor-capacitor (RC) networks assembled by the user or purchased as complete assemblies.

  • Page 14: External Relay & Digital I/O Connections

    Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual External Relay & Digital I/O Connections The digital I/O expansion module 60101044 are connected to the controller using a CAT5 cable provided with each module. The two RJ45 connectors on the expansion modules are identical and interchangeable;...

  • Page 15: Basic Operation And Programming

    Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual Basic Operation and Programming The 6010BCPM has been factory calibrated to read input frequency in Hz (pulses/sec). The calibration equipment is certified to NIST standards. Overview Most setup and programming is done through the front panel buttons.

  • Page 16: Controller Operation

    Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual Controller Operation The 6010BCPM accepts pulses (e.g. ±40mV to ± 8V), square wave (0-5, 0-12V, or 0-24V), open collector NPN, PNP, TTL, or switch contact signals. These signals are scaled to represent rate in engineering units from -99999 to 999999. They may be scaled with a K-factor to represent a total for the batch, and grand total.

  • Page 17: Batch Control Operation Example

    Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual Batch Control Operation Example The following example shows how two stage batch control functions with a 6010BCPM. This setup will establish a 55 gallon preset for the batch, with a main valve (high flow) that will close at 50 gallons, and a trickle valve (low or restricted flow) that will close at 55 gallons.
  • Page 18 Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual...

  • Page 19: Meterview Pro Software

    Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual ® MeterView Pro Software The meter can also be programmed using the PC-based MeterView Pro software included with the meter. This software can be installed on any Microsoft® Windows® (XP/Vista/7/8/10) computer by connecting the meter’s onboard USB.

  • Page 20: Display Functions And Messages

    Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual Display Functions and Messages The controller displays various functions and messages during setup, programming, and operation. The following table shows the main menu functions and messages in the order they appear in the menu.
  • Page 21 Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual Display Parameter Action/Setting Display Parameter Action/Setting Description Description Lt-CLr Latching- Set relay for latching Relay goes to non-alarm cleared operation with manual reset condition when loop break only after alarm condition is detected...

  • Page 22: Setting Numeric Values

    Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual Main Menu Map The main menu consists of the most commonly used functions: Setup, Reset, Control, and Password. • Press Menu button when a batch is not running to enter Programming Mode then press the Up arrow button to scroll main menu.

  • Page 23: Setting Up The Batch Controller (Setup)

    Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual Setting Up the Batch Controller (setup) The Setup menu is used to select: 1. Input signal the controller will accept 2. Enable or disable totalizer and batching features 3. Select the display units/tags 4.

  • Page 24: Scaling And Calibration

    Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual Scaling and Calibration It is very important to read the following information, before proceeding to program the controller: • There is no need to recalibrate the controller when first received from the factory.

  • Page 25: Setting The Decimal Point (Dec Pt)

    Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual Setting the Decimal Point (dEc pt) The decimal point may be set with up to five decimal places or with no decimal point at all. The rate, total, and grand total decimal points are independent.

  • Page 26: Input Calibration Method (Incal)

    Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual Input Calibration Method (InCAL) There are three methods of calibrating (or scaling) the display to show the correct engineering units. • Use the Factor menu to enter a K-Factor. (Pulse input models only.) •...

  • Page 27: Scaling The Controller (Scale)

    Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual Scaling the Controller (SCALE) The process inputs (4-20 mA and 10 VDC) and frequency inputs can be scaled to display the process variable in engineering units. A signal source is not needed to scale the controller; simply program the inputs and corresponding display values.

  • Page 28: Batch Start Mode (Mode)

    Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual Batch Start Mode (mode) The batch controller may operate in manual or automatic mode. In manual mode, the controller operates as defined in Controller Operation as described on page 16. In automatic mode, the batch process will automatically begin after a completed batch.

  • Page 29: Setting The Display Parameter & Intensity (Dsplay)

    Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual Setting the Display Parameter & Intensity (dsplay) Display line 1 (line 1) can be programmed to display: 1. Display total 2. Display grand total 3. Toggle rate and total 4. Toggle rate and grand total 5.

  • Page 30: Setting The Relay Operation (Relay)

    Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual Setting the Relay Operation (relay) This menu is used to set up the operation of the relays. During setup, the relays do not follow the input and they will remain in the state found prior to entering the Relay menu.

  • Page 31: Relay Assignment (Assign)

    Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual Relay Assignment (Assign) The relays can be assigned to any of the following parameters: 1. Rate for low or high alarm indication 2. Total for batch control relays 3. Grand total for alarm indication...

  • Page 32: Programming Alarm Set And Reset Points

    Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual Programming Alarm Set and Reset Points High alarm indication: program set point above reset point. Low alarm indication: program set point below reset point. The deadband is determined by the difference between set and reset points. Minimum deadband is one display count.

  • Page 33: Relay Operation Details

    Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual Relay Operation Details Overview The relays of the controller can serve three roles, as batch control relays for single or multi-stage batching, as rate, or grand total alarm, or as a sampling relay based on grand total or rate alarm.

  • Page 34: Automatic Reset (Auto)

    Pump alternation control is not recommended when using this controller for batch control, as it is used only in level applications, and not with rate, total, or batching applications. For information on using pump alternation control for level, see the 60101FCPM instruction manuals available at www.equflow.com. Setting Up the Interlock Relay (Force On) Feature The relays can be set up as interlock relays.

  • Page 35: Sample Relay Operation

    Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual Sample Relay Operation The sampling function allows the operator to set a set point for a “sampling” relay. This can be done for the rate, total, or grand total. Each time the relay reaches the set point, it will close that relay’s contacts for a programmed period of time A rate sampling relay will activate for the sample time (sam t), up to 600.0 seconds, every time the set...

  • Page 36: Rate Relay Sampling Operation

    Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual Rate Relay Sampling Operation When the signal crosses the set point, the relay trips and the sample time starts. After the sample time has elapsed, the relay resets. The cycle repeats every time the set point is crossed, going up for high alarms and going down for low alarms.

  • Page 37: Time Delay Operation

    Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual Time Delay Operation The following graphs show the operation of the time delay function. When the signal crosses the set point, the On time delay timer starts and the relay trips when the time delay has elapsed.

  • Page 38: Reset Menu (Reset)

    Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual Reset Menu (reset) The Reset menu is used to reset the total, grand totals, batch count, maximum, or minimum reading (peak or valley) reached by the process; both maximum and minimum may be reset at the same time by selecting “reset high &...

  • Page 39: Grand Total Reset Password & Non-Resettable Total

    Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual Grand Total Reset Password & Non-Resettable Total The grand total can be password-protected to prevent unauthorized total resets. The grand total can be programmed as a non-resettable total by entering the password “050873”.

  • Page 40: Advanced Operation And Programming

    Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual Advanced Operation and Programming In addition to the functions described in Controller Operation on page 16, the following advanced operation and display features may be programmed. Configuring these features may disable some default batch controller features, or make running a batch operation impossible.

  • Page 41: Advanced Features Menu & Display Messages

    Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual Advanced Features Menu & Display Messages The following table shows the functions and messages of the Advanced Features menu in the order they appear in the menu. Display Parameter Action/Setting Display Parameter...

  • Page 42: Function Keys Operation

    Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual Function Keys Operation During operation, the programmable function keys operate according to the way they have been programmed in the Advanced Features – User menu. The following table shows the default setting for each of the function keys.

  • Page 43: Maximum/Minimum Readings

    Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual Maximum/Minimum Readings The max & min readings (peak & valley) reached by the process can be displayed either continuously or momentary: 1. Display briefly by assigning to the digital inputs in the User menu.

  • Page 44: Modbus Rtu Serial Communications (Serial)

    Note: More detailed instructions are provided with each optional serial communications adapter. Note: Refer to the Modbus Register Tables located at www.equflow.com for details. When using more than one controller in a multi-drop mode, each controller must be provided with its own unique address.

  • Page 45: Signal Conditioning Selection (Functn)

    Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual Signal Conditioning Selection (Functn) The Function menu is used to select the signal conditioning function applied to the input: linear, square root, or programmable exponent. The multi-point linearization is part of the linear function selection.
  • Page 46 Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual Function Keys & Digital I/O Available Settings Refer to the following table for descriptions of each available function key or digital I/O setting. Display Description Display Description disabl Start Disable the selected function key or...

  • Page 47: Troubleshooting

    Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual Troubleshooting Due to the many features and functions of the controller, it’s possible that the setup of the controller does not agree with what an operator expects to see. If the controller is not working as expected, refer to the Diagnostics menu and recommendations below.

  • Page 48: Factory Defaults & User Settings

    Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual Factory Defaults & User Settings The following table shows the factory setting for the major programmable parameters on the controller. Parameter Display Default Setting Parameter Display Default Setting Input Relay 2 Input type...

  • Page 49: Troubleshooting Tips

    Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual Parameter Display Default Setting Parameter Display Default Setting Pass 3 Password 3 000000 (unlocked) Grand total Gtotal 000000 (unlocked) password Total Total 000000 (unlocked) password Troubleshooting Tips Symptom Check/Action Check power at power connector...
  • Page 50 Equflow 6010BCPM Pulse Input Batch Controller Instruction Manual Equflow BV - P.O. Box 35- NL-5370 AA Ravenstein - The Netherlands T +31 (0)24 3792666 – E info@equflow.com www.equflow.com LIM6310EQ_A SFT039 Ver 4.010 & up 12/17...

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