KEP BATCHtrol II Installing & Operating Manual Download Page 39

35

6-1 Warning Messages 

6-1 Warning Messages (continued)

6-1.5 BAD FREQ
Indicates that the values in the 16 Point setup 
are  not  acceptable.    This  condition  will  occur 
when the frequency values are not in ascending 
order.  The display will continue to display  this 
message until  the error is corrected.  To correct 
the error see Section 3-3, Setup Procedure.

6-1.6 SECURITY
Indicates that no signal has come in for the dura-
tion time set in the Lockout menu.  Lockout code 
must be entered before the unit will continue.  
Section 3-3, Setup Procedure.

6-2  Troubleshooting

6-2  Troubleshooting

6-2.1 General
The following troubleshooting procedures have 
been developed as an aid in locating defects.  
Not  every  possible  problem  has  been  listed, 
but  a  general  isolation  procedure  for  tracking 
down  problems  has  been  given.    A  standard 
recommendation is the removal of power for 2 
seconds.  This allows the microprocessor to go 
through a reinitialization cycle at power up.  If 
it is determined that the unit is faulty, contact 
your local  Factory Representative or Sales Of-
fi ce  concerning  replacement.    The  Batcher  is 
not fi eld serviceable and all repairs should be 
performed by the factory. 

6-2.2 Problems
Symptom:  

Display will not light.

Possible Cause: No power to unit, power to unit 
not to specifi cations or bad connection between 
display board and mother board.
Test Procedure:  See Specifi cations Section 1-4 
for proper input voltages.  Then;

a)

  Check AC voltage input on terminals 17 & 

18.

b)

  (if DC Powered unit)  Check DC voltage input 

on terminals 12 & 14.

c)

  Check connection of display board to mother 

board

Corrective Action:

   If all checks okay, replace 

Corrective Action:

Corrective Action:

unit.

6-2.2 Problems
Symptom:  

Unable to start batch.

Possible Cause #1: Displayed Batch count al-
ready exceeds the Preset value.
Test  Procedure:  Check  Preset  value  against 
the displayed value. If the Preset is less, go to 
corrective action.

Corrective  Action:

    Reset  the  unit  by  press-

Corrective  Action:

Corrective  Action:

ing the CLR button or change the Preset to a 
larger value.

Possible Cause #2: Incorrect programming.
Test  Procedure:  Check  for  programming  er-
rors, review manual.

Corrective  Action:

  Reprogram  unit  as  re-

quired.

Possible Cause #3: Defective Circuit board or 
component.
Test  Procedure:    Press  the  Start  button  and 
check for relay action.  An OHM meter across 
the  appropriate  relay  terminals  should  give 
the  proper  indication.  (Be  sure  to  disconnect 
all power to the relay terminals fi rst!)

Corrective Action:

      If  no  relay  action  replace 

Corrective Action:

Corrective Action:

unit.

Symptom:  

Unit not totalizing. 

Possible Cause #1: Incorrect programming.
Test Procedure:   Check for programming er-
rors,  review  manual.    For  Example,  if  the  K 
Factor is too large it may take some time be-
fore a count is registered on the display.

Corrective  Action:

      Reprogram  unit  as  re-

Corrective  Action:

Corrective  Action:

quired.

Possible Cause #2: Input signal invalid.
Test  Procedure:    See  Specifi cations  Section 
1-4  for  proper  input  signals.    Then  use  oscil-
loscope to;

a)

  Check Analog input on terminals 3 and 

12 for proper current or voltage levels.

b)

 (if Digital unit)  Check Digital voltage in-

put on terminals 3 and 12.

Corrective Action:

      If  inputs  check  okay,  re-

Corrective Action:

Corrective Action:

place unit.

Summary of Contents for BATCHtrol II

Page 1: ...rol II Principle of Operation The batcher receives an input from a pulse producing owmeter through a sensor The user programs the batcher to condition the incoming pulses signal and compute the batch...

Page 2: ...is used incorrectly Please note operating instructions provided in this manual The instrument must be installed operated and maintained by personnel who have been properly trained Personnel must read...

Page 3: ...Programming 9 3 4 Software Version 8 7 Programming Flow Chart 10 3 5 VER 12 0 Programming 11 3 6 VER 12 0 16 Point Linearization Notes 11 3 7 Software Version 12 0 16 Pt Programming Flow Chart 12 3 8...

Page 4: ...ICATIONS 8 1 Unit Code 40 8 2 Baud Rate 40 8 3 Parity 40 8 4 RS232 Electrical Requirements 40 8 5 RS232 Card Wiring 41 8 6 RS422 Electrical Requirements 41 8 7 RS422 Card Wiring 42 8 8 Strobe Input El...

Page 5: ...on 1 3 Principles of Operation Presets When the start button is pushed two relays engage simultaneously to start ow When the prewarn number is reached one re lay drops out When the preset number is re...

Page 6: ...g driver generates a linear current across the user s external device such as a strip chart recorder PLC computer external meter etc The Batcher can supply the 24 VDC to power the current loop Connect...

Page 7: ...mplete the relays drop out and the unit displays the amount that was batched 0 if in Set to Preset mode Stop a Batch Press B to temporarily stop process by de energizing the PRESET and PREWARN relays...

Page 8: ...esets displayed number and control output Remote Input Terminal 5 Open or 0 to 1 VDC low 3 to 30 VDC high 10K ohm input impedance to ground Minimum pulse on off time 5 msec Accuracy over full temperat...

Page 9: ...VDC NPN Transistor Output Open Collector sinks maximum of 100 mA from 10 VDC when active Note 10 VDC is provided at transistor outputs through through the relay coils If current greater than 2 mA is...

Page 10: ...er should be located in an area with a clean dry atmosphere which is relatively free of shock and vibration The Batcher is installed in a 7 365 187 mm wide by 2 495 63 4 mm high panel cutout To mount...

Page 11: ...O C 19 Prewarn Transistor O C 19 Prewarn Transistor O C 19 Prewarn Transistor O C 19 Prewarn Transistor O C 19 Prewarn Transistor O C 19 Prewarn Transistor O C 19 Prewarn Transistor O C 19 Prewarn Tr...

Page 12: ...ta before the new rate data is sent to the display The following equation is used W Weight 00 99 If a weight of 00 is used the new rate data will go directly to the display without being averaged If a...

Page 13: ...ng a new value 00 No Value Indicates that programmed value for that step has been cleared and a new number may be entered Keypad Use the front panel keypad to enter a value or select a decimal point l...

Page 14: ...RESET ENT D XXXX CLR PREWARN D XXXX CLR ENT PRE TYP ENT D D EZ PRE STD PRE ENT 0 ENT 0 ENT MENU D Run Mode Software Version 8 7 Programming Flow Chart On a Standard unit Without 16 Point Linearization...

Page 15: ...s play In the Run Mode the ow rate the batch total or the grand total will be displayed XX Current Value The number that is currently programmed for that step It must be cleared CLR button before ente...

Page 16: ...R0 SP ENT D B D E C L O C 8 7 6 5 4 3 2 1 ENT D B WINDOWXX CLR S I G F I G X X CLR WINDOW00 ENT S I G F I G 0 0 ENT 16 POINT ENT D D MINUTES HOURS ENT SECONDS TEST POINT 00 1 POINT 01 ENT F XX CLR F...

Page 17: ...d numbers can still be written over the Presets or K Factors Will these numbers be accepted if the ENT but ton is pushed A No in order for a Preset or K Factor to be changed the old number must be cle...

Page 18: ...the Preset and your Preset is 1234 then set your Prewarn at 10 not at 1224 Enter a Prewarn of 0 for the Prewarn and Preset relays to activate together To disable the Prewarn relay enter the same value...

Page 19: ...d selection Run Mode The PRE TYP is Set MENU ITEM 4 COUNT Setting the Counter PRESS DISPLAY PRESET PREWARN PRE TYP COUNT K FACTOR K FACTOR ashes then shows the current K Factor Note The K Factor setup...

Page 20: ...under the arrow by R0 or SP DEC LOC Store R0 or SP DEC LOC allows the user to choose where the decimal point will be located when the Batch Count or Grand Total are displayed The decimal point is for...

Page 21: ...056 Flashes Sample K Factor or enter calculated value from notes or worksheet WINDOW Store new K Factor Normally the ratemeter updates each second Normally the ratemeter updates each second If no sign...

Page 22: ...0 739 Note that trailing zeroes will be inserted only if necessary Digits beyond the SIG FIG value are truncated and zeroes are inserted as needed no round ing is done SIG FIG 00 Clears out existing...

Page 23: ...ill be accessed but cannot be changed but cannot be changed c the rest of the menu cannot be accessed To unlock the unit simply press 1 0 0 0 The words LOCK OFF will appear brie y When the unit is unl...

Page 24: ...4 Flashes Sample Lockout Code or enter desired value from notes or worksheet Be sure to record any changes in the lockout code in case it is forgotten Be sure to record any changes in the lockout code...

Page 25: ...r identi es the unit for multi drop communications Up to 15 units may be on one line A unit will stay off line until its Unit ID number is received It will then stay on line until a carriage return is...

Page 26: ...Simply stop on the Parity desired and hit the ENT button Parity is a way for the terminal to determine if the signal it received has reached it intact It does this by counting the number of bits recei...

Page 27: ...e exceeds the 20 mA setting the current driver will stay at 20 mA Note The current sink follows tracks the display The Analog Output option is not available on Square Law Analog Input units PRESS DISP...

Page 28: ...This Output Frequency generator sends pulses out which are scaled relative to the input signal via the counter K Factor This means that for every time the counter increments a pulse is available at t...

Page 29: ...cond from the incoming frequency and the spec i ed K Factor The rate can then be displayed in 3 ways SECONDS The base rate MINUTES The base rate times 60 HOURS The base rate times 3600 TEST TEST is us...

Page 30: ...is manner until up to 16 points are entered Note A minimum of 3 three points must be entered All frequencies of consecutive point All frequencies of consecutive point numbers must be entered in ascend...

Page 31: ...ear of the unit 3 11 3 Locking the Unit The unit is shipped from the factory unlocked To lock the unit it must be in the Run Mode The unit is shipped from the factory with a Lockout Code of 1000 As a...

Page 32: ...pre run and post run pulses will be recorded For this reason always press the CLR button before start The START button energizes the Preset and Prewarn relays The STOP button de energizes the Preset a...

Page 33: ...if Reset to Zero Count 0 if Reset to Preset 3 12 Internal Operation 3 12 Internal Operation 3 11 1 Digital Inputs and Computations The 3 30 Volt input signal is ltered electroni cally See Section 4 1...

Page 34: ...3 30 VDC source such as Terminal 13 a PNP transistor proximity switch or other device or an ampli ed signal from an inductive pickup Remember the input signal must be refer enced to Terminal 12 of the...

Page 35: ...q mA Input Freq mA Input Freq mA Input Freq 4 0000 10 6123 5 2500 12 7071 6 3535 16 8660 7 4330 18 9354 8 5000 20 10000 mA Input Freq mA Input Freq mA Input Freq mA Input Freq 4 0000 10 6123 5 2500 12...

Page 36: ...Batcher may be powered by an external DC power supply The supply must provide 12 27 Volts DC and at least 280 mA of current The positive side DC of the DC supply should be hooked to Terminal 14 and t...

Page 37: ...Section 5 2 1 above The Open Collector outputs are available on units with relay outputs but please observe the fol lowing precautions Note When relays are used 10 VDC is pro vided at the transistor...

Page 38: ...d or the data buffer is full In either case the display will not show the proper count or rate and the frequency output will be inaccurate There are three possible remedies a Check to see that your in...

Page 39: ...rective Action If all checks okay replace Corrective Action If all checks okay replace Corrective Action unit 6 2 2 Problems Symptom Unable to start batch Possible Cause 1 Displayed Batch count al rea...

Page 40: ...that plugs into the female connector next to the heat sink Choose the proper Interface card With components on top and subminia ture connector to the back plug in the harness and mount the card on the...

Page 41: ...in displaying total on the instrument from the fol lowing table DPF Table Desired Total Decimal Location DPF XXXXXX 1 XXXXX X 10 XXXX XX 100 XXX XXX 1000 XX XXXX 10000 X XXXXX 100000 Example for X X...

Page 42: ...playing total on the instrument from the fol lowing table DPF Table Desired Total Decimal Location DPF XXXXXX 1 XXXXX X 10 XXXX XX 100 XXX XXX 1000 XX XXXX 10000 X XXXXX 100000 Example for X X DPF 10...

Page 43: ...oint entry 4 Extrapolated K Factors are always positive numbers Make sure that the last two points do not project the K Factor slope towards zero 5 The dummy decimal point is still set up with DEC LOC...

Page 44: ...mpatible with the remote terminal 8 3 Parity 8 3 Parity Parity is a bit of information that is insert ed before the stop bit and is used to help check if the transmission is correct In the OUTCARD set...

Page 45: ...lly to echo back signals 8 6 RS422 Electrical Requirements 8 6 RS422 Electrical Requirements The input of the Batcher follows the standard EIA high impedance minimum of 12 K Ohms When the 422 A input...

Page 46: ...25 Request To Send Pins 9 27 Clear To Send Jumped internally to echo back signals b Pins 11 29 Data Set Ready Pins 13 31 Received Line Signal Detector Pins 12 30 Data Terminal Ready Jumped internally...

Page 47: ...erial transmit codes to request data or set a new value See Section 8 10 2 RS232 RS422 Serial Input Codes Up to 80 characters of data may be linked together and transmitted to the Batcher as long as t...

Page 48: ...o num ber ST Will stop the unit from the batch in progress See Section 8 10 4 for 16 Point Option data entry commands 8 10 3 RS232 RS422 Serial Input Examples 8 10 3 RS232 RS422 Serial Input Examples...

Page 49: ...4 DL2 DL1 Code Description DL4 DL2 DL1 Code Description DL4 DL2 DL1 Code Description DL4 DL2 DL1 Code Description DL4 DL2 DL1 Code Description DL4 DL2 DL1 Code Description DL4 DL2 DL1 Code Description...

Page 50: ...Even Mark Analog Output If applicable Rate Count SET LOW 4 mA _ _ _ _ _ _ _ _ SET HIGH 20 mA _ _ _ _ _ _ _ _ 9 Programming Worksheet 1 Not Used 2 Scaled Pulse Output O C 3 Analog Output 4 Input A Pul...

Page 51: ...or 12 to 27 VDC A 110 VAC 15 or 12 to 27 VDC B 220 VAC 15 or 12 to 27 VDC B 220 VAC 15 or 12 to 27 VDC Control Inputs 3A STD Pulse 3 30 VDC 20 kHz Max 3B As 3A with 4 7 K pull up resistors 5A 4 20 mA...

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