AW-Lake AW Gear Meters MX 9000 Installation Operating & Maintenance Manual Download

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C O M PA N Y

Installation, Operating &

Maintenance Manual

MX 9000 Process Monitor

Summary of Contents for AW Gear Meters MX 9000

Page 2: ...put option board 1 11 120 240 VAC Input option board 2 11 Batch Controller Inputs option board 3 12 Run Mode Screens 12 Rate Screens 14 Total Grand Total Screens 14 LOGO Screen 14 STATUS Screen 15 RATIO A B B A Screens 16 RA TA RB TB Screens 16 ANALOG OUT Screen 17 L1 L2 Screen 17 RA RB Screen 18 TA TB Screen 18 RATE A B Screen 19 RATE A B Screen 19 TOTAL Grand Total A B Screen 19 BATCH TOTAL Scre...

Page 3: ...Settings Programming 34 Calibrating Analog Output 34 I O Manual Adjustment 36 installation 36 Analog Output Adjustment 36 Fine mA adjustment 37 Coarse mA adjustment 37 Frequency Adjustment 37 Fine Limit Output Adjustment 38 Coarse Limit Output Adjustment 38 ON OFF Output Adjustment 39 Monitor External Reset Input 39 Ratio A B B A Programming 39 ALARM AB ALARM B A 40 TARGET NBR 40 BATCH TOTAL Progr...

Page 4: ...he sensor s to the back of the MX 9000 An electrical power wire a signal wire and a ground wire NOTICE Dual input models use two sensors terminals for sensor 2 Insert the stripped end of the red wire into lower terminal 3 6 and use a screwdriver to secure Insert the stripped end of the white wire into lower terminal 4 7 and the stripped end of the black wire into lower terminal 5 8 Use a screwdriv...

Page 5: ...racters then the DOWN UP keys to change Press ENTER to store the value Use YES NO to enter other setup functions and EXIT when completed See Programming the MX 9000 beginning on page 21 for complete details Frequency Inputs 0 4 KHz sine square or saw tooth 4 volts minimum amplitude 3 3 Kohm maximum impedance Integrated Linearization Maximum 10 point linearization table for improved accuracy over r...

Page 6: ...monitor data and program the unit remotely Four model variations give the MX 9000 the capability of performing limit warning and alarm duties and batching Principle of Operation After first making connections to the power source and to flow transmitter input and output you can choose up to 22 display modes These include rates totals ratios limits and others based on the model purchased Then input ...

Page 7: ... controller No option board 1 2 3 4 X Communication protocol No additional options Technical Data Minimum Power Supply Requirements 16 VAC 250mA with supplied 110 VAC transformer or 18 24 VDC 250mA customer supplied direct current 120 240 VAC with option board 2 Flow Sensor Power Output 2 15 VDC 50 mA each Frequency Inputs 0 4 5 KHz sine square or saw tooth 5 volts minimum amplitude 3 3K Ohm imped...

Page 8: ...it 1 Relay NO Pin 6 Limit 1 Relay COM Pin 7 Analog Input Pin 8 Analog Input Pin 9 Frequency Out Pin 10 Frequency Out Pin 11 mA Loop 2 Output Pin 12 mA Loop 2 Output LOWER TERMINAL BLOCK CONNECTIONS Pin 1 18 24 VDC Supply Voltage 16 VAC Input Pin 2 18 24 VDC Supply Voltage Ground 16 VAC Input Pin 3 Sensor 1 Supply Voltage 15 VDC 25 mA MAX Pin 4 Sensor 1 Signal Input Pin 5 Sensor 1 Supply Signal Com...

Page 9: ...requency Out Pin 10 Frequency Out Pin 11 120 240 VAC Input Common Pin 12 120 240 VAC Input Line UPPER TERMINAL BLOCK CONNECTIONS Option Board 3 Pin 1 Limit 2 Relay NC Pin 2 Limit 2 Relay NO Pin 3 Limit 2 Relay COM Pin 4 Limit 1 Relay NC Pin 5 Limit 1 Relay NO Pin 6 Limit 1 Relay COM Pin 7 15 VDC for remote switch select Pin 8 Mode Change Input Pin 9 Batch Select Input Pin 10 Batch Reset Input Pin ...

Page 10: ...by cutting CT3 with a sharp knife Figure 3 Reset Input Sensor Pulse Inputs Pulse inputs are opto isolated and come referenced to signal ground Regulated 15 VDC at 50mA max is available for powering each sensor Inputs can also be isolated from the control power by cutting CT1 or CT2 with a sharp knife but then the internal 15 VDC supply is not available Minimum input voltage is 5 VDC peak for pulse...

Page 11: ...o note that the MX 9000 requires an external power supply to power the loop as shown below Frequency Output option boards 1 and 2 An opto isolated NPN open collector output can sink or source depending on connection Attention must be paid to polarity of connections Limit circuit current to 50 mA and 30 VDC for this circuit Figure 4 Analog Outputs Relay Outputs Two form C relay outputs are availabl...

Page 12: ...pins 3 5 and 4 6 For 0 10 VDC use jumper pins 3 5 only Pins are identified on the printed circuit board Remove back cover to access 120 240 VAC Input option board 2 The line voltage input is available on option board 2 It can be configured for 120 or 240 volt input using jumper pins 1 For 120 volt input jumper both sets of outside pins see decal on board For 240 volt input jumper only the center t...

Page 13: ...able for remote control of the batch process You must have ordered the batch model to access these inputs MX9 B A 15 VDC output is provided as a supply for the inputs Program Run uses a maintained contact switch and the other inputs require momentary signals Figure 9 Batch Controller Inputs ...

Page 14: ... Pulses for total RATIO A B screen displays rate ratio in between A B flows RATIO B A screen displays rate ratio in between B A flows RT TO screen A shows both the flow rate and total values in programmed engineering units RT TO screen B shows both the flow rate and total values in programmed engineering units ANALOG OUT screen shows the mA value the MX 9000 is outputting Limits screen shows statu...

Page 15: ...hows the firmware version of the unit Pushing the SELECT button on the LOGO screen will show the actual model number of the MX 9000 As the features vary with the model please make a note of this while reading through this manual Rate Screens RATE A B 600 00 GPM The RATE screen displays the flow rate of A or B in the programmed engineering units If the linearizer is active LN shows in lower left co...

Page 16: ...to zero 0 Note that both grand totals must be reset independent of one another The STATUS screen is a raw data display of the current major properties of STATUS L1 OFF L2 OFF RTA 100 14 TOA 15400 RTB 150 32 TOB 03561 ANLG 04 00 mA STATUS Screen the monitor The rates are shown as Hz total in pulses limits as on or off and current loop output main loop only in programmed mA DC NOTE The Gate Time fil...

Page 17: ...E The units of both flows must be the same for this display to work properly RATIO AB BA 1 00 RATIO A B B A Screens RA 1234 56 GPM TA 123456 00 GAL RA TA RB TB Screens The dual rate total screen are a convenient way of showing both the flow and total at the same time Pressing the RESET button resets the total value back to zero 0 If the gate time or linearizer are active those will also be indicat...

Page 18: ...ed to represent the GRAND TOTAL value If the linearizer is active LN shows in lower left corner If the Gate Time filter is active GT shows in lower right corner L1 OFF OFF L2 OFF OFF L1 L2 Screen The L1 L2 screen shows what the Limits are programmed to represent and the state of the output The first line of each limit represents what the Limit is programmed for 1 OFF Limit output has been turned o...

Page 19: ... linearizer are active those will also be indicated by a LN in the lower left or GT in the lower right of the display TA 500 00 GAL TB 800 00 GAL TA TB Screen The total A and B screen is another dual combination screen that provides visibility to both totals at the same time If the gate time or linearizer are active those will also be indicated by a LN in the lower left or GT in the lower right of...

Page 20: ...e same for this display to work properly You will receive a warning message if you do not have them matching RATE A B Screen RATE A B 0 16 GPM The rate A B screen shows the mathematical difference of the two flows of dual channel units If the gate time or linearizer are active those will also be indicated by a LN in the lower left or GT in the lower right of the display NOTE the units of both flow...

Page 21: ...n when enabled will turn on relay 1 and 2 when set points 1 and 2 are reached Hold the ENTER key in for 5 seconds then you will be taken to the S1 set point screen Enter the value to trigger relay 1 using the UP DOWN SELECT buttons The screen will also turn to blue indicating that set point 1 is being set Push ENTER to change to the S2 set point screen Again enter the value to trigger relay 2 usin...

Page 22: ...e screens When exiting the programming menu the MX 9000 will always return to the run mode screen from which the programming menu was entered Figure 10 Programming Mode Changing Values and Making Selections When in a programming screen which requires a value to be changed the active character is indicated by an underscore To increment the value use the UP button and to decrease the value use the D...

Page 23: ...If an incorrect value is programmed a warning or error screen will appear Press any button to exit a warning screen but you must correct an error before moving on RATE TOTAL and GRAND TOTAL Scaling Figure 11 Programming Mode K factor scaling factor The MX 9000 uses one K factor for each channel for scaling displays This value is always entered in units of Pulses per Gallon Once the rate and total ...

Page 24: ...nits to define the flow rate unit The available time units are Seconds Minutes Hours Days When the correct time base is showing press ENTER to continue NOTE If the rate unit time base are selected as PUL Seconds the RATE screen will show the unit as Hz NOT PUL SEC TOTAL units Use the UP and DOWN buttons to scroll through the available units to scale the TOTAL and GRAND TOTAL screens The available ...

Page 25: ...ave to be the same Once the desired unit is showing pressing ENTER completes the scaling programming for channel A Repeat the above to program channel B When done you will be at the Analog programming menu Figure 12 Analog Output Scaling ...

Page 26: ...he mA output can represent a fixed mA output value input flow rate A or B the totalizer value A or B or the grand totalizer value A or B Press ENTER when desired choice is showing Fixed output source This option allows the user to select a constant mA value the MX 9000 will output regardless of any changing values A constant mA signal could be used as an external indicator showing if the MX 9000 i...

Page 27: ...value is entered the user will also be asked to enter a mA value to represent zero flow Min Flow mA Enter the mA to represent the above entered minimum flow rate Value must be equal to or greater than 2mA Max Flow Rate Enter the maximum flow rate to monitor Max Flow mA Enter the mA value to represent the above entered maximum flow rate value 20mA is the maximum allowable value Zero Flow mA This sc...

Page 28: ...RAND TOTAL source Figure 16 Grand Total Source GRAND TOTAL source allows the user to configure the mA output to represent the Grand Total value If the Grand Total value goes above the programmed maximum Grand Total value the analog output will continue to increase up to a maximum of 22mA This is useful for system fault detection Zero Grand Total mA Enter the mA value to represent a zero Grand Tota...

Page 29: ...t to be programmed is selected All three outputs can be independently setup and if any of the outputs are not to be used they can be turned off Limit 1 and Limit 2 can be configured as a rate monitor to trigger on a set value of the Total or Grand Total ratio differences between the two inputs either warning or alarm or cycle output The Frequency Out can only be used to output the incoming frequen...

Page 30: ...ising and falling edge is the cycle value The total accumulated between any two rising edges is twice the cycle value You enter the cycle value in programmed engineering total units CYCLE AM OUNT CYCLE AM OUNT CYCLE AM OUNT CYCLE AM OUNT CYCLE AM OUNT LIM IT ON LIM IT ON LIM IT OFF LIM IT OFF LIM IT OFF 2x CYCLE AM OUNT CYCLE OUT PULSE OUTPUT Lim it Function Figure 19 Cycle out Limit Function CAUT...

Page 31: ... Rate Limit functions as an absolute limit or activates within a margin or window around the programmed Rate Value When the Limit Margin is programmed as zero the limit activates whenever the flow rate equals or exceeds the programmed value When you enter a Limit Margin value other than zero the limit is active whenever the selected flow rate is within the window of the programmed Rate Value plus ...

Page 32: ...affected by the Gate Time filter and cannot be linearized It is always the raw incoming frequency from the selected sensor Gate Time Filter This variable sets the sample time on the incoming frequency for the RATE displays Programmed in tenths of a second with an allowable range from 0 1 to 999 9 seconds this variable affects the update of the display and analog output and is useful in stabilizing...

Page 33: ...s it may be necessary to have a separate calibration done on the flow meter ahead of time Often this information can be found on the original calibration sheet from the manufacturer Freq variable When populating the linearizer table it is required that Point 1 has the lowest frequency and each sub sequent table point frequency must be in continuously increasing frequency value The frequency value ...

Page 34: ...able first table point whose Freq is zero to exit the table Adding linearizer table point To add more table points it must be noted that data can only be added to the end of a table Therefore if the additional point s to add do not have a frequency greater than the last entered point it will require the user to manually shift the table points by entering the new points after the next smallest exis...

Page 35: ...on of the backlight for the LCD for the screen is available Color coding of the limit alarms can be useful for visual indication of totals reached or rates that are out of tolerance Default settings are green for normal operation blue for Limit one exceeded and red for limit 2 exceeded Use ENTER to move from line to line and SELECT to change colors as desired Calibrating Analog Output The analog o...

Page 36: ... value on the screen to match the value shown on the user s readout equipment and press ENTER when done At the second mA adjustment screen the MX 9000 outputs the value that should equal 20mA output Change the mA value on the screen to match the value shown on the user s readout equipment and press ENTER when done At the next screen the MX 9000 outputs the corrected 4mA value for loop 1 At the las...

Page 37: ...When entering the I O programming mode from the STATUS and password screens use the UP or DOWN button to change the I O Function to Test output as shown above and press ENTER Next choose which I O to change and press YES Analog Output Adjustment The user can manually control the mA output to any value between 2mA to 20mA in one of two ways Fine adjustment allows user to program a specific mA value...

Page 38: ... pressing the UP button the screen value and mA output value increments by 1mA to a max of 20mA When pressing the DOWN button the screen value and mA output value decrements by 1mA to a min of 2mA This is the fastest way to test the mA output range if no specific mA output value is required Press the EXIT button to leave this mode Frequency Adjustment The Frequency output available on option board...

Page 39: ...X 9000 will output this value frequency output This also returns the screen to the adjustment type screen Press SELECT to see output value again and make new change Coarse Limit Output Adjustment When choosing the Coarse adjustment option the screen will appear where the frequency output value can be changed When pressing the UP button the screen value and Hz output value increments by 25Hz to a m...

Page 40: ... current state of the external Reset pin press the YES button from the Monitor Reset input screen The screen that follows will show what the current state of the pin is Using an external control signal toggle the voltage level between high and low and monitor that the MX 9000 also sees the change Ratio A B B A Programming The RATIO AB or RATIO BA screens set up the MX 9000 for use as a ratio monit...

Page 41: ...assign the L1 or L2 LIMIT to the WARNING function See LIMITS Programming on page 29 ALARM AB ALARM B A The MX 9000 uses these individual variables to set the percent ratio error at which the L1 or L2 ALARM limit activates The ratio error limits are 1 to 100 The initial value for either ALARM limit is 10 0 NOTE For the ratio alarm limit to function you must assign the L1 or L2 LIMIT to the ALARM fu...

Page 42: ... been previously assigned to a function other than TOTAL A the MX 9000 will respond by asking Limit mode different want to change it Use the YES or NO key to answer A YES response resets any previous limit assignment to Total A and zeros the limit value A NO response leaves the limit assigned to the previous function and the S1 or S2 display will read XXXX to indicate that it has no function in th...

Page 43: ...It is not possible to program the monitor using just the front panel pushbuttons A programming signal must be present on the Program Run input to enable the programming capability The batch select input is also utilized during this function To set the individual batch programs set the Program Run switch to the Program position Use the Batch Select switch to select the batch number to change It is ...

Page 44: ...H LIMITS Enter the value desired for this batch to activate the Limit 1 relay output using the DOWN UP SELECT buttons and press ENTER In an identical manner set the value for the S2 Limit 2 relay output batch total Select the desired engineering units for the display and press ENTER Continue to program all desired batch presets up to a total of 20 When finished return the Program Run switch to the...

Page 45: ...l energize When limit 1 S1 is reached relay 1 will turn off slowing the flow at that point When limit 2 S2 is reached relay 2 will shut off stopping the flow and the display will say DONE If the start stop button is pressed during a run both outputs will be turned off and the display will read PAUSE R Restoring Factory Defaults To restore the unit to factory default settings a special CLEAN SWEEP ...

Page 46: ...ing Current loop calibrations will also be set to default values and will need to be reset Use this function ONLY when all other troubleshooting methods have failed and unstable operation of the controller remains It is strongly suggested that the status screen be viewed prior to performing a restore defaults to see if the raw data shown on it looks nominal to the current process Also make sure th...

Page 47: ...47 Appendix A Physical Dimensions 5 5 139mm 5 2 132mm MX 9000 Process Monitor 2 8 72mm 3 8 97mm Option board Main board 2 58 65mm ...

Page 48: ...48 Back panel configuration will vary by model See pages 10 12 for terminal block connections Also refer to decal on terminal block for signal identification ...

Page 49: ...riable Values Analog output 2mA Fixed Frequency output OFF Gate Time 1 0 Seconds GRAND TOTAL units GAL always same as TOTAL units K factor 1 Limit 1 OFF Limit 2 OFF Linearizer OFF RATE unit GAL RATE time base Minutes TOTAL GAL ...

Page 50: ...50 ...

Page 51: ...me the risk of loss or damage in transit to prepay shipping charges to warranty location and use the original shipping container or equivalent For further information contact AW Lake Company 2440 W Corporate Preserve Dr 600 Oak Creek WI 53154 ALL EXPRESS AND IMPLIED WARRANTIES FOR THIS PRODUCT INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION ...

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