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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" and a list of commonly encountered codes
are given below:

Error Codes

Input Errors

Invalid input configuration programmed.

Flow error due to a Quadrature error (see Section 3.3) or Signal
Timeout (see Section 3.2.2).

Communications Input error (RS232/422/485 Interface).

Output Errors

Invalid output configuration.

Communications error - Baud rate not set.

Communications error - Printer fault.

Calibration Errors

Zero Value not Allowed.

Invalid Printer Type.

Invalid Volume Units selected.

56 Trouble Shooting

Summary of Contents for 414Q

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

Page 2: ......

Page 3: ...and Quadrature Inputs 18 3 4 Calculation of Rate and Total 19 3 4 1 Frequency Input 19 3 4 2 Filtering 20 3 5 Total Conversion 22 3 6 Non Linearity Correction 23 3 7 The Output Pulse and Flow Alarm 25 4 Options 27 4 1 The RS232 422 485 Interface Option 27 4 1 1 Hardware 27 4 1 2 Multipoint Communication 28 4 1 3 Communication Protocol 30 5 Calibration 32 5 1 Programming the Setup Parameters 34 5 2...

Page 4: ...2 6 1 Flow Inputs 42 6 2 Remote RUN and STOP Switches 48 7 Installation 49 7 1 General 49 7 2 Wiring Designations for the Model 414Q 51 7 3 Ex 410 Enclosure Dimensions 52 8 Trouble Shooting 53 8 1 Error Codes 56 Index 57 ...

Page 5: ...lly programmable with all calculation constants set via the front panel switches and stored permanently in a non volatile memory This instrument conforms to the EMC Directive of the Council of European Communities 89 336 EEC and the following standards Generic Emission Standard EN 50081 1 Residential Commercial Light Industry Environment Generic Emission Standard EN 50081 2 Industrial Environment ...

Page 6: ...ng 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 0 for no option 2 for RS232 422 485 Mounting 1 for panel mounting 2 for field mounting 3 for explosionproof The Model Number of the instrument is displayed on first entering the Calibration Mode see Section 5 4 Introduction ...

Page 7: ...ure 0 to 55 C standard Dimensions 5 7 144mm wide x 2 8 72mm high x 7 0 178mm deep Cutout 5 5 139mm wide x 2 6 67mm high Frequency Input Frequency Range Minimum 0 25Hz on Rate 0Hz on Total Maximum 10KHz with a single input 2 5KHz with a quadrature input 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 Switchi...

Page 8: ...m 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 6 Specification ...

Page 9: ...ich retains data without battery backup for a minimum of 10 years A block diagram of the instrument is shown below A DIL switch on the rear panel enables the frequency input circuit to be set to interface with a wide range of flowmeters including turbine flowmeters and flowmeters with Namur type sensors Operation 7 RS232 422 Option RS232 422 Output P C E O B Control Relay Outputs 2 Pulse Output Fl...

Page 10: ...hat it can be changed Press 2 2345 Pressing the DISPLAY key will increment the digit The up arrow on the Display key indicates to increment digit Press 2 2 345 Pressing the RUN key will change digit and enables the next digit to be incremented The right arrow on the RUN key indicates to change digit Press BATCH SET Set Once the desired number is entered press the BATCH SET key to return to the Run...

Page 11: ...3 2 STOPPING The process can be stopped at any time by pressing the STOP switch Once the process has been interrupted in this way it can be continued by pressing the RUN switch or the process can be aborted and the instrument reset by pressing the STOP switch a second time When the process is interrupted the STOP LED will flash to prompt the operator to either restart or abort the batch RESETTING ...

Page 12: ...isplay shows RATE for one second followed by the flowrate Accumulated Total On the next press of the DISPLAY key the display shows ACC for one second followed by the actual total The Accumulated Total cannot be reset during normal operation 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 preve...

Page 13: ...s 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 Operation 11 Relay 1 Relay 2 End of B a t c h Start Time Prestop Quantity End of Batch R u n Stop Run P A U S E B a t c h Quantity R e a c h e d Reset Run Count Down C o u n t U p ...

Page 14: ...also be programmed during Calibration to either count up from zero on each batch or to count down from the preset batch quantity 12 Operation Relay 1 Relay 2 End of B a t c h Start Time Prestop Quantity End of Batch R u n Stop Run P A U S E B a t c h Quantity Reached Count Down C o u n t U p R u n Auto Restart T i m e ...

Page 15: ...can also be programmed to provide a slowdown of flow at the end of the batch thereby enabling precise quantities to be batched The process can be stopped at any time by pressing the STOP key whereby both relays will immediately de energise The process can then be aborted and the batcher reset by pressing the STOP key again or the process continued by pressing the RUN key If the process is continue...

Page 16: ... of overrun It is recommended that Signal Timeout periods are kept fairly short but long enough such that the period is significantly longer than the time period between successive input pulses from the flowmeter at the minimum flowrate The instrument enables the user to program a time interval of up to 99 seconds to detect an absence of signal input If the Signal Timeout is set to 0 this function...

Page 17: ... an RS232 422 485 interface data will not be output until the End of Batch has been determined Consequently it is strongly recommended that the Signal Timeout period be kept fairly short End of Batch Signal An End of Batch signal from an open collector transistor is output on terminal 30 and the output is identical to the Output Pulse circuit as shown in section 3 7 When reaching the End of Batch ...

Page 18: ... 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 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 re...

Page 19: ...ch as may occur with changing back pressures or sticking valves In calculating the amount of overrun to be compensated for the Batch Controller uses the average overrun on the last three batches The overrun is defined as the difference between the batch quantity set by the user and the batch total once the flow has stopped With Automatic Overrun Compensation the Signal Timeout must be set to a val...

Page 20: ... during delivery The instrument will alarm if the pulse difference since reset exceeds 1 in 1000 pulses When an alarm condition exists the totals will cease counting and will freeze at the last total prior to the alarm On detection of the alarm condition the alarm output on terminal 7 will go low energise the output relays will de energise and the stop LED will flash indicating that the batch can ...

Page 21: ...ling 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 When non linearity correction is programmed up to 10 scaling factors are programmed to cover different frequency ranges The instrument will then automatically select the cor...

Page 22: ...at highly accurate and stable readings can be obtained without excessive lag The diagram below shows a pulsating signal input together with the effect of filtering As a guideline to the degree of filtering to be used the following table shows the response to a step change in input The value A is the filter constant which is programmed during the Calibration routine The times for the display value ...

Page 23: ... 4 6 3 6 10 5 11 15 8 17 20 11 22 25 14 28 35 20 40 45 25 51 60 34 69 75 43 86 90 52 103 99 57 113 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 Operation 21 ...

Page 24: ...r Example If the Rate is required in gallons per minute 1 The Scaling Factor would be programmed as pulses per gallon 2 The timebase would be programmed as minutes If the Totals are required in barrels 3 The Total Conversion factor is programmed as 42 there are 42 gallons in a barrel All totals including the Batch Quantity and Batch Total will now be in barrels Some common units are given below to...

Page 25: ... flowrates or frequencies with the measured K factor eg pulses per gallon or litre at each flowrate The following diagram graphs the change in scaling factor with frequency for a hypothetical flowmeter The heavy black line represents the actual scaling factor of the flowmeter while the light black line is the approximation used in the instrument Linear Interpolation is used between points on the c...

Page 26: ...d 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 Hence the user can program any number of correction points up to a maximum of 10 Note that if all 10 correction points are required then Frequency 10 will automatically be assigned the value of 0Hz 24 Operation ...

Page 27: ...that due to the uneven pulse output spacing on this output the pulse output cannot be used to drive rate indicators The FLOW ALARM uses an identical circuit to the Output Pulse and is on terminal 7 The Flow Alarm is used by the Quadrature Input if selected and will output an error signal if there is a difference between the input pulses as described in Section 3 3 The Flow Alarm will also output a...

Page 28: ...s Driving an External Relay or Impulse Counter Driving a Logic Input such as a PLC or Electronic Counter 26 Operation 5 6 ohms 33V Zener 12 DC Supply Relay or Impulse Counter 11 DC Supply Out 8 24V 5 6 ohms 33V Zener 2 External Load Resistor 10K Logic Input ...

Page 29: ... of the RS232 RS422 RS485 communications hardware All three interfaces are available on the rear terminal strips and the user can select either one by making the appropriate connections The RS232 interface is primarily used with printers or for simple communication with a computer over a short distance The RS422 and RS485 interfaces are used for communication over a long distance or in application...

Page 30: ...t be connected to the RS422 Data Out Terminal These connections will convert the RS422 4 wire interface to the RS485 2 wire interface as shown in figure 2 Each instrument can be programmed with a unique address which is used by the Master Controller ie IBM PC to identify each instrument The Controller will send the address down the line and will alert the relevant instrument Subsequent software pr...

Page 31: ...Figure 2 RS485 Interface Options 29 H o s t Computer Twisted Pair L o a d 120 ohms 400 Series Instrument 400 Series Instrument In Out In Out G n d G n d G n d ...

Page 32: ...The software protocols can be selected during Calibration to provide standard interfaces to a number of printers and computers Since other interfaces will continue to be added the user should consult the manual The RS232 422 485 Communications Option for the 400 Series Version 2 for the latest protocols and printer drivers Printer A ticket is printed each time a batch is complete Protocols are pro...

Page 33: ...tocol is also supported and the instrument will automatically determine if the message sent by the host computer is preceded by an Xoff character If it does recognise an Xoff as the first character of a command string the instrument will automatically switch to Xoff Xon protocol and begin end all messages with Xoff and Xon characters respectively Xoff Xon protocol is only available when the RS232 ...

Page 34: ...nk across terminals 1 and 2 The key switch actions during Calibration are as follows RUN will change a flashing digit to the next digit DISPLAY will increment a flashing digit or change a parameter selection BATCH SET will reset a flashing digit to zero STOP will step through the program sequences Note that the arrows in the RUN and DISPLAY key switches indicate that these switches can be used to ...

Page 35: ...3 Test Check Input Signals see section 5 4 End 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 To exit Calibration step through the Setup program Batch program or Test program until the end and press the STOP switch when End is displayed ensure the calibration link is not connected Calibration 33 ...

Page 36: ...to zero To reset all totals resettable and accumulated press the BATCH SET key once 3 FL INP Select either a single frequency input or a quadrature input ie two pulses from a single flowmeter 3 3 single quad Single Input Quadrature Input 4 CORRCT Linear Nonlin Select either a linear input or non linear correction for the flowmeter input Linear Correction or Non Linear Correction 3 6 5 SCALE If lin...

Page 37: ...or can be programmed in the range of 0 1000 to 50 000 Freq2 Freq2 is programmed to the second frequency point If any Freq is set to 0 no further correction points can be programmed and the non linearity correction is limited to that number of points Fact 2 Scaling Factor 2 to Fact 10 Scaling Factor 10 Note that Freq10 is not displayed since it must always be zero 6 F dPt Number of decimal points w...

Page 38: ...otals have the same engineering units x xxxx Other factors can be programmed between 0 01 and 2000 10 t dPt Number of decimal points with which the resettable total is displayed between 0 to 0 000 11 A dPt Number of decimal points with which the Accumulated non resettable total is displayed between 0 to 0 000 12 ACCESS Front No Acc Enable access to calibration routine via the front keyboard only E...

Page 39: ...Set to 0 if no limit on batch size 3 2 3 AUTO S Off On xx xx Automatic restart feature Disable Enable If enabled automatically restarts the batch xx xx mins sec after the end of the last batch 3 2 4 4 START T xx xx Slow start time Time in minutes seconds when Relay 2 will energise once the batch has started 3 2 5 PREST xxxx Prestop Quantity Quantity at which Relay 2 will de energise before the end...

Page 40: ...ture 3 2 2 8 AOC En Dis Automatic Overrun Compensation Note that the Signal Timeout must be greater than 0 ie enabled for this feature to work Enable Disable 3 2 5 9 AUTO R Off On Auto Reset not displayed if Auto Restart is programmed Step 3 above Batch Total must be manually reset before starting the next batch The Batch can be automatically reset and started by pressing only the RUN key 3 2 38 C...

Page 41: ...e RS232 422 485 option is installed the following will be displayed 2 DF Eur USA Date Format European ie days months years USA ie months days years 4 1 3 Date xx xx xx Enter date as Years Months Days 4 1 4 HOUR xx xx Enter time as a 24 hour clock Hours Minutes 5 BAUD xxx Baudrate 300 600 1200 2400 4800 and 9600 6 DATA 7 8 Word length 7 bits 8 bits 7 PARITY NP OP EP Parity No Parity Odd Parity Even...

Page 42: ...24 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 10 UNIT xx 00 01 02 03 04 05 06 07 Units of measurement printed None Litres Ltrs Gallons Gals Barrels bbls Pounds lbs Grams gms Kilograms kgs Tons tons If a Computer Protocol is selected the following message is displayed 10 ECHO On ...

Page 43: ...ion 5 3 5 1 5 2 The following steps are displayed if TEST is selected 2 Sr x xx Software revision number 3 Freq xxxx x Displayed for 1 second followed by the actual frequency Frequency in Hz If a quadrature input is selected and the flow is reversing a negative sign will appear If the RS232 422 485 option is installed the display will then show 4 CLOC xx xx xx Clock Time in Hours Mins Sec Calibrat...

Page 44: ...ecomes the 0 input while Channel 1 becomes the 90 input Channel 2 can interface directly to an Open Collector a Reed Switch 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: ...ector or Reed switch 9 8 3 8 off off off off on off on off c Namur Proximity set DC out to 8 volts 11 9 11 3 on off on on on on off off Channel 1 Only d Switch or Reed Switch with debounce circuit 200Hz max 9 8 off off off off on off on on e Coil 20mV P P minimum 9 8 off on off off off off off off General Specification Switching Threshold 2 5 Volts except for input type c and e Maximum Input Volta...

Page 46: ...t allows the voltage to be adjusted in the range of 8 24 Volts and the output can supply a maximum of 50mA Note that when using this DC output to power opto sensors some flowmeter manufacturers require that a current limiting resistor be used Please refer to the flowmeter manufacturers data sheet if this is the case 44 Input Circuits ...

Page 47: ...Channel 1 9 Common for Channels 1 2 Pulse Input Channel 2 8 3 5 V 1 0 K S 7 1 K S 3 S 8 100R 01 1 0 0 K 1uF S 5 S 2 I N P U T C O M P A R A T O R 5 V 3 3 K S 4 3 3 K 1 K 2 5 V 1 0 K 1 K S 1 100R 1 0 0 K 01 I N P U T C O M P A R A T O R 5 V 3 3 K 3 3 K 1 K 2 S 6 ...

Page 48: ...witch 46 Input Circuits 1 on 8 3 Ch 1 Common Ch 2 eg vortex pre amplifiers or magnetic flowmeters 8 9 on 1 8 9 8 3 Ch 2 Common Ch 1 eg preamplifiers and opto sensors 1 8 on 8 3 Reed Switches eg positive displacement flowmeters with reed switch outputs 9 ...

Page 49: ... flowmeters with 2 wire proximity switch outputs 1 8 on 11 Resistor Ch 1 Common and opto sensors Note that the current limiting resistor may be required See the flowmeter manufacturer s data eg pre amplifiers 8 9 on 1 9 8 Use shielded cable eg millivolt signal from a turbine flowmeter single input only 8 to case earth ...

Page 50: ...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 48 Input Circuits 2 28 29 R U N S T O P ...

Page 51: ...ted from the case and from the internal circuitry A Supply Output voltage is provided to power sensors This output will provide a regulated voltage of 8 to 24 volts and the voltage is adjustable by means of the potentiometer on the rear panel Maximum current is 50mA and the instrument comes with the voltage factory set at 24 Volts When the instrument is powered from a DC power source the maximum o...

Page 52: ...en called Snubbers are used for two reasons To limit the amount of electrical noise caused by arcing across the contacts which may in extreme cases cause the microprocessor to act erratically To protect the relay contacts against premature wear through pitting RC suppression networks consist of a capacitor and series resistor and are commonly available in the electrical industry The values of R an...

Page 53: ...C Ground 13 DC Power Input 14 Not To Be Used Terminal RS232 422 485 Option 20 RS232 Signal Ground 21 RS232 Data In 22 RS232 Data Out 23 RS422 485 Data Out 24 RS422 485 Data Out 25 RS422 485 Data In 26 RS422 485 Data In 27 RS232 CTS Terminal Relay Output Switches 28 Remote RUN Switch 29 Remote STOP Switch 30 End of Batch 31 Relay 2 Normally Open 32 Relay 2 Normally Closed 33 Relay 2 Common 34 Relay...

Page 54: ... M25 Gland holes Enclosure with 3 x NPT Gland holes 71 5 71 5 70 0 70 0 130 0 130 0 Mounting Holes 4 x M8 Mounting Holes 4 x 5 16 UNF Gland Holes 3 x M20 Gland Holes 3 x NPT Door Hinge Mounting Holes 4 on rear Metric thread M8 NPT thread 5 16 UNF Bottom View Material Cast Aluminium Finish Light beige powdercoat Earth Point 115 0 ...

Page 55: ...n the flow input before restarting Batcher stops midway through a batch This could be due to the Signal Timeout having timed out Check for a fault in the system Ensure that the Signal Timeout period is significantly longer than the period between pulses from the flowmeter at the minimum flowrate No display Check power to the instrument All 88888888 displayed The Batcher will display all eights on ...

Page 56: ...circuit incorrectly lack of shielding on the input Shield the input signal with the shield earthed at the Batch Controller only Instrument acting erratically Erratic operation can be the result of severe electrical interference Considerable attention has been given to designing the Batch Controller to withstand electrical interference However in extreme cases loads may be encountered which are exc...

Page 57: ... 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 Trouble Shooting 55 ...

Page 58: ...countered codes are given below Error Codes Input Errors 11 Invalid input configuration programmed 13 Flow error due to a Quadrature error see Section 3 3 or Signal Timeout see Section 3 2 2 14 Communications Input error RS232 422 485 Interface Output Errors 21 Invalid output configuration 22 Communications error Baud rate not set 23 Communications error Printer fault Calibration Errors 30 Zero Va...

Page 59: ... Display Key 10 Displayed Information 10 E Earth Lug 49 Earthing Point 49 End of Batch 15 Error Codes 56 Ex 410 Enclosure 52 F Filtering 20 Flow Alarm 14 25 Frequency Input 19 Frequency Range 5 Front Panel Operation 8 G Ground 49 I Input Circuits 45 Input Impedance 43 Installation 49 Interference 50 Introduction 3 Isolation 49 K K factor 19 Key Operation 8 L Limit on Batch 10 Logic Signals 42 Loss...

Page 60: ...S232 422 485 Interface 27 Run Key 8 S Scaling Range 5 Setting the Batch 8 Setup Parameters 32 Signal Timeout 14 Slow Start 13 Slow Stop 13 Specification 5 Starting 9 Stop Key 13 Stopping 9 Switch Settings 43 Switching Current 5 Switching Power 5 Switching Threshold 43 T Terminal 51 Ticket 30 Time Clock 30 Time Delay 13 Timebase 19 Total Conversion 22 Transducer Supply 5 Trouble Shooting 53 Turbine...

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