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Contrec 414Q Manual

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BATCH CONTROLLER
MODEL 414Q
July 2001

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  • Page 1 BATCH CONTROLLER MODEL 414Q July 2001...

  • Page 3: Table Of Contents

    CONTENTS 1. Introduction 1.1 Model Number Designation 2. Specification 3. Operation 3.1 Front Panel Operation 3.2 Batch Operations 3.2.1 Control Relay Outputs 3.2.2 Signal Timeout 3.2.3 End of Batch 3.2.4 Auto Restart 3.2.5 Automatic Overrun Compensation 3.3 Single and Quadrature Inputs 3.4 Calculation of Rate and Total 3.4.1 Frequency Input 3.4.2 Filtering...
  • Page 4 6. Input Circuits 6.1 Flow Inputs 6.2 Remote RUN and STOP Switches 7. Installation 7.1 General 7.2 Wiring Designations for the Model 414Q 7.3 Ex 410 Enclosure Dimensions 8. Trouble Shooting 8.1 Error Codes Index...

  • Page 5: Introduction

    SINGLE or QUADRATURE pulse inputs. NON-LINEARITY CORRECTION. TICKET PRINTING or COMPUTER interface options. The Model 414Q is ideally suited to custody transfer applications where high accuracy and signal integrity is required. The instrument is fully programmable, with all calculation constants set via the front panel switches and stored permanently in a non-volatile memory.

  • Page 6: Model Number Designation

    Introduction 1.1 MODEL NUMBER DESIGNATION The Model number of an instrument describes which input and output options are installed and the AC mains voltage rating. Model 414 Q. 1 0 E B B for Backlite C for Conformal Coating E for 220/240 VAC A for 110/120 VAC D for DC Power Only Options...

  • Page 7: Specification

    Specification 2. SPECIFICATION General Display: 6 digit LCD. 0.7" (17.8mm) high digits. Display Update Rate: 0.25 seconds. Transducer Supply: 8-24VDC field adjustable. 50mA maximum. Power Requirements: 11.5 to 28.5 volts DC. 130 mA typical current (no options). AC Mains: Set internally to 95 - 135 VAC or 190 - 260 VAC.
  • Page 8 Specification Pulse Output Pulse Width: 10mSec (negative going pulse). Maximum Duty Cycle: 49 pulses per second. Scaling: The pulse output is scaled and outputs one pulse each time the accumulated total increments. Non-linearity Number of Points: 10 correction points maximum. Correction between Points: Linear interpolation used.

  • Page 9: Operation

    Operation 3. OPERATION The Model 414Q uses a low power CMOS microprocessor to perform all control functions and calculations. The instrument is fully programmable with all operating parameters and calculation constants user programmable. (See Section 5 entitled "Calibration" for information on programming.) All parameters and constants are stored in a non-volatile memory which retains data without battery backup for a minimum of 10 years.

  • Page 10: Front Panel Operation

    Operation 3.1 FRONT PANEL OPERATION The four key operation of the Batch Controller is straight forward. SETTING THE BATCH QUANTITY The Batch quantity is programmed as follows: Switch Action Display Comments Press BATCH SET Batch "Batch" is displayed for one second followed by the batch quantity last entered.
  • Page 11 Operation The Batch quantity can only be set while the instrument is in non-operational state such as when the batch is complete, or if the batch process has been interrupted. However, the Batch key can be pressed while in the run state and the Batch quantity checked.
  • Page 12 Operation DISPLAYED INFORMATION The display will normally show the Batch Total, which is the total count for the current batch and is reset on each new batch. The DISPLAY key can be used to display the following additional information: Rate On the first press of the DISPLAY key, the display shows RATE for one second followed by the flowrate.

  • Page 13: Batch Operations

    Operation 3.2 BATCH OPERATIONS The Batch Control functions can be programmed, during Calibration, to operate in one of two ways. 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.) B a t c h P A U S E Q u a n t i t y...
  • Page 14 Operation If Automatic Reset is programmed, a new batch is commenced each time the RUN key is pressed. B a t c h P A U S E Q u a n t i t y R u n S t o p R u n R e a c h e d R u n...

  • Page 15: Control Relay Outputs

    Operation 3.2.1 Control Relay Outputs The two output relays can be set up to control a single valve or a dual valve with slow stop and/or slow start. Alternatively, the second relay can be used to control a pump. The relay operation is shown on the previous two pages. A time delay between the Start and the time when relay 2 energises can be programmed to provide a soft startup.

  • Page 16: Signal Timeout

    Operation 3.2.2 Signal Timeout The Signal Timeout period defines a time interval which is used to detect if the flow has stopped. If there is no signal input for a time greater than the Signal Timeout period the flow is deemed to have stopped. A Signal Timeout period has two functions: To detect the loss of signal midway through a batch when the relays are energised.

  • Page 17: End Of Batch

    Operation 3.2.3 End of Batch The End of Batch is defined as being when the Batch Quantity is reached, the flow has stopped and the Signal Timeout period has expired. If the Signal Timeout is set to zero, the End of Batch is defined as being when the Batch Quantity is reached, regardless of whether the flow has stopped.

  • Page 18: Auto Restart

    Operation 3.2.4 Auto Restart The Batch Controller can be programmed to continually repeat the batch process. This mode of operation is selected during the programming procedure. The process is started by pressing the RUN key whereby the normal batch operation is commenced. After reaching the End of Batch (see section 3.2.3), the Batch Controller will then wait for a pre-programmed period before automatically resetting and starting the batch process once again.

  • Page 19: Automatic Overrun Compensation

    Operation 3.2.5 Automatic Overrun Compensation The Batch Controller can be programmed to automatically compensate for any overrun at the end of a batch. Typically, this could be due to the slowness of a valve to close or a pump to stop pumping on receiving a signal from the Batch Controller.

  • Page 20: Single And Quadrature Inputs

    The Model 414Q can interface to flowmeters fitted with two sensors and connections to the flowmeters are outlined in Section 6.1.

  • Page 21: Calculation Of Rate And Total

    Operation 3.4 CALCULATION OF RATE AND TOTAL 3.4.1 Frequency Input The flowrate, R, is calculated as follows: f x H where f is the input frequency in Hz. H is the timebase of rate and is 1 for seconds, 60 for minutes, 3600 for hours and 86,400 for days.

  • Page 22: Filtering

    Operation 3.4.2 Filtering Frequency fluctuations caused by pulsating flow through a flowmeter, often makes the Rate impossible to read with any precision. The Batch Controller has a digital filter which will average out these fluctuations and enable the Rate to be read to four digit accuracy.
  • Page 23 Operation 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.

  • Page 24: Total Conversion

    Operation 3.5 TOTAL CONVERSION The Total Conversion feature enables the rate to be displayed in one engineering unit (eg. gallons/minute) and the totals to be displayed in another engineering unit (eg. barrels). The Scaling Factor is always programmed in the unit relating to Rate, and the Total Conversion constant is a division factor which can be used to convert the totals to the different unit.

  • Page 25: Non-Linearity Correction

    Operation 3.6 NON-LINEARITY CORRECTION Non-linearity correction enables the instrument to correct for known non-linearities in the flowmeter. Up to 10 frequencies and scaling factors can be programmed. Data on the flowmeter non-linearity can usually be supplied by the flowmeter manufacturer in the form of a Calibration Certificate, and is the result of individual tests on a flowmeter over a range of flowrates.
  • Page 26 Operation During Calibration, the program requires the user to input a frequency and the Scaling Factor (K-factor of the flowmeter) at up to 10 points on the curve. Generally these points will correspond to those shown on the Certificate. If any frequency is set to 0Hz (Frequency 6 in the preceding example), then the program will require no further correction points to be programmed.

  • Page 27: The Output Pulse And Flow Alarm

    Operation 3.7 THE OUTPUT PULSE AND FLOW ALARM An OUTPUT PULSE is available on terminal 10 for driving remote counters and produces a pulse each time the Accumulated Total increments by one digit. For example, if the Accumulated Total has a resolution of 0.01 litres, a pulse is produced each 0.01 litres.
  • Page 28 Operation Connection of Output Pulse and Flow Alarm are as follows: Relay or Impulse Counter 5.6 ohms 3 3 V Zener DC Supply Driving an External Relay or Impulse Counter DC Supply Out (8-24V) External Load Resistor 10K Logic Input 5.6 ohms 3 3 V Zener...

  • Page 29: Options

    Options 4. OPTIONS 4.1 THE RS232/422/485 INTERFACE OPTION With this option installed, the circuits for both the RS232 and RS422/485 are provided as standard. They can be used to interface to both printers and computers and a number of standard protocols are built into the instrument. 4.1.1 Hardware The following diagram provides an overview of the RS232/RS422/RS485 communications hardware.

  • Page 30: Multipoint Communication

    Options 4.1.2 Multipoint Communication Multipoint Communication is a system whereby a number of instruments can be addressed over a dual twisted pair interface. Up to 32 instruments can be connected to a common bus using the RS422 and RS485 interfaces as shown below.
  • Page 31 Options Twisted Pair L o a d 120 ohms H o s t C o m p u t e r G n d G n d G n d O u t O u t 400 Series 400 Series Instrument Instrument Figure 2 RS485 Interface...

  • Page 32: Communication Protocol

    Options 4.1.3 Communication Protocol The Model 414Q 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 33 Options A CTS input is provided, and will prevent the instrument from transmitting any further characters to a printer if the printer buffer is full. The CTS input is usually connected to the "Data Buffer Full" output from the printer. If the printer buffer is large enough to handle the messages output from the Batch Controller, then this input need not be used and can be left unconnected.

  • Page 34: Calibration

    Calibration 5. CALIBRATION The Calibration routine enables the Setup Parameters to be programmed, as well as enabling the input signals to be checked. The calibration routine can be entered in two ways: 1 By connecting a wire link (or switch) to the rear terminal strip across terminals 1 and 2 or, 2 By pressing the STOP key and while still holding, press the DISPLAY key.
  • Page 35 Calibration On first entering the Calibration routine, the display will show: Setup Program parameters (see section 5.1). Batch Enter Batch parameters (see section 5.2) Option Option - if installed (see Section 5.3). Test Check Input Signals (see section 5.4) Exit to Normal Operation. The user can toggle between these modes using the DISPLAY switch and by using the STOP switch, select the appropriate mode.

  • Page 36: Programming The Setup Parameters

    Calibration 5.1 PROGRAMMING THE SETUP PARAMETERS Step Display Description Text Select the Calibrate mode to setup program parameters. BATCH Select Batch to enter Batch Setup parameters. OPTION Option (if installed). TEST Select the test mode to check input signals. Exit to normal operation. The following steps are displayed if CAL is selected.
  • Page 37 Calibration Step Display Description Text If non-linearity correction is to be programmed, up to 10 frequencies and scaling factors can be entered. Freq 1 Freq1 is programmed to the first frequency point in the range of 0 to 9999Hz. Fact 1 This is the K-factor of the flowmeter (ie.
  • Page 38 Calibration Step Display Description Text FILTER The filter constant for filtering the rate display . 3.4.2 No filtering. Very heavy filtering. TOTCON A division factor to convert the totals to different units from those used for rate (ie gallons/min and barrels).

  • Page 39: Entering The Batch Parameters

    Calibration 5.2 ENTERING THE BATCH PARAMETERS Step Display Description Text BATCH Enter Batch Parameters. OPTION Option (if installed) TEST Check Input Signals. Exit to normal operation. Program Setup Parameters. The following steps are displayed if BATCH is selected. BATCH L Maximum Batch Size which can be entered.
  • Page 40 Calibration Step Display Description Text COUNT The Batch Total counts Up or Down. Count down from the batch quantity. Count up from zero. T OUT The Signal Timeout in seconds. (Setting to 00 disables this feature.) 3.2.2 Automatic Overrun Compensation. Note that the Signal Timeout must be 3.2.5 greater than 0 (ie enabled) for this...

  • Page 41: Programming Options

    Calibration 5.3 PROGRAMMING OPTIONS Step Display Description Text OPTIONS Options (if installed). Test Check the Input Signals. Exit to normal operation. Program Setup Parameters. Batch Set Batch Parameters. If the RS232/422/485 option is installed, the following will be displayed: Date Format. European (ie.
  • Page 42 Id number. P TYPE xx Printer/Computer Type. Standard Computer Printer. EPSON CTM 290 Slip Printer. Contrec Model 624 Printer. EPSON TM290-2 Slip Printer. Contrec Model 632-2 Printer. Syntest SP-210 Printer. Computer. If a Printer Protocol is selected, the following message is displayed: UNIT Units of measurement printed.

  • Page 43: Checking The Input Signal

    Calibration 5.4 CHECKING THE INPUT SIGNAL Step Display Description Text TEST Check the Input Signals. OPTIONS Options (if installed). Program Setup Parameters. BATCH Set Batch Parameters. Exit to normal operation. The following steps are displayed if TEST is selected. Sr x.xx Software revision number.
  • Page 44 - a Logic Signal - a Namur Sensor The frequency input circuits for the Model 414Q can be configured by the user to interface with most flowmeters. A small 8 pole DIL switch on the rear of the instrument is used to set up the input circuit to operate with different types of signals.
  • Page 45 Input Circuits Switch Settings The following are recommended switch settings for different input signal types. Note, input types d and e are only available on Channel 1. Channel 2 is limited to signal types a to c. Input Signal Type Input Terminals Switch Settings a.
  • Page 46 Input Circuits Powering of Sensors The Model 414Q has a regulated DC output which can be used to power sensors. A trimpot on the rear of the instrument allows the voltage to be adjusted in the range of 8-24 Volts and the output can supply a maximum of 50mA.
  • Page 47 Input Circuits + 5 V 1 0 K I N P U T C O M P A R A T O R 1 0 0 K Pulse Input Channel 1 1 u F 1 0 0 R + 5 V 3 3 K C o m m o n f o r Channels 1 &...
  • Page 48 Input Circuits 1. Squarewave, CMOS or Pulse Ch. 1 Common eg. vortex, pre-amplifiers Ch. 2 or magnetic flowmeters 2. Open-Collector Ch. 1 Common eg. preamplifiers Ch. 2 and opto-sensors 3. Reed Switch eg. positive displacement flowmeters with reed switch outputs. Reed Switches...
  • Page 49 Input Circuits 4. Coils eg. millivolt signal Use shielded from a turbine flowmeter to case earth cable (single input only) 5. Namur Proximity Switch Ch. 1 eg. positive displacement Ch. 2 flowmeters with 2 wire proximity switch outputs 6. Opto-Sensors Resistor Ch.
  • Page 50 Input Circuits 6.2 REMOTE RUN AND STOP SWITCHES Remote push-buttons can be connected to the Model 414Q to start and stop baches. The switch functions are identical to the RUN and STOP switches on the front of the instrument. The switches are wired as follows:...
  • Page 51 7. INSTALLATION 7.1 GENERAL Terminal designations for the Model 414Q 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 instrument into panel.
  • Page 52 Installation Overall shields should be connected to the case earth at the instrument end only. This connection should be as short as possible and connected to the earthing lug on the side of the case. In order to comply with the requirements for Electromagnetic Compatibility as per EMC-Directive 89/336/EEC of the Council of European Community, this wiring practice is mandatory.
  • Page 53 Installation 7.2 WIRING DESIGNATIONS FOR THE MODEL 414Q Terminal Model 414Q Calibration Link Signal Ground Flow Pulse Input (Channel 2) Not To Be Used Not To Be Used Not To Be Used Flow Alarm Flow Common (-) Flow Pulse Input (Channel 1)
  • Page 54 Installation 7.3 EX 410 ENCLOSURE DIMENSIONS (all dimensions in mm) Mounting Holes (4) on rear Metric thread M8 Ex 410 Enclosure with 5 Keys NPT thread 5/16 UNF Door 115.0 Hinge Bottom View Mounting Holes Mounting Holes 4 x 5/16 UNF 4 x M8 Earth Point 70.0...
  • Page 55 Trouble Shooting 8. TROUBLE SHOOTING Batcher does not reset. The Signal Timeout has been set to an excessively long period and has not timed out at the end of the last batch. Batch will not start or relay 1 will not close. Ensure that the instrument has not timed out as controlled by the Signal Timeout and that a Flow Alarm condition does not prevail.
  • Page 56 Trouble Shooting Not counting. If the Batcher does not count with the flowmeter connected and flow passing through it, first check the connections and then ensure the DIP switches on the rear of the instrument are set as per section 6. It is possible to manually test the input circuit of the Batcher by setting the input configuration for a Reed Switch (see Section 6) and pulsing across the signal (+) and (-) with a wire link.
  • Page 57 Trouble Shooting 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.
  • Page 58 Trouble Shooting 8.1 ERROR CODES The instrument has extensive self test facilities and will display an error code if it detects an invalid condition. If the instrument displays an error code other than those listed below, please contact the factory. Error codes are displayed as "Err 12"...
  • Page 59 Index Index Date, 30 K-factor, 19 DC Input Voltage, 49 Key Operation, 8 DC Output, 44 Access, 36 Decimal Points, 35 Accumulated Total, 10 Dimensions, 5 Limit on Batch, 10 Auto Reset, 9 Display Key, 10 Logic Signals, 42 Auto Restart, 16 Displayed Loss of Signal, 14 Automatic Overrun...
  • Page 60 Index Switch Settings, 43 Switching Current, 5 Parity, 30 Switching Power, 5 Power Requirements, 5 Switching Threshold, 43 Powering of Sensors, 44 Prestop, 13 Printer, 30 Pulse Difference, 18 Terminal, 51 Pulse Output, 6, 25 Ticket, 30 Pulse Width, 6 Time Clock, 30 Time Delay, 13 Timebase, 19...

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