EMO-500. Opera on & Installa on Manual TWO-COMPONENT RATIO MONITOR. Rev. 6

Transcription

1 TWO-COMPONENT RATIO MONITOR Operaon & Installaon Manual Rev. 6

2 Table of Contents Safety Definitions and Information... 4 Unpacking... 4 Quick Start Guide... 5 Connect to Flow Transmitters... 5 Connect Unit to Power... 7 Overview of Display Screens... 8 Product Description... 9 Features... 9 Principle of Operation... 9 Technical Data... 9 Key Programming Features... 9 Technical Information... 9 Display Information Special Features Helpful Information For Using the EMO Sample Size Gate Time Serial Port Programming Hardware Connections Grounding Considerations Signal and Shielding External Resets and Controls (Hardware) External Resets and Controls (Definitions) Reset All Scroll Display Reset Job B - resets OFF-RATIO WARNING/ALARM (LIMIT 1 and 2) Reset Job A - resets OFF-RATIO WARNING/ALARM (LIMIT 1 and 2)

3 Enable Full Programming Quick Programming Activation Keys and Values F1 Ratio (Default Value = 1.00) F2 Gate Time (Default Value = 1.85) F3 Warning (Default Value = 5%) F4 Alarm (Default Value = 10%) F5 DP (Decimal Point) F6 Enter #0 Sample Size (Default = 200) #1 SG (Specific Gravity [Default = 1.0]) Full Programming Enable F F F F Off-Ration Warning and Alarm Settings Adjust Limits 3 and F F Explanation of Global Variables KFR for A (Default 100.0) FT for A (Default 10000) KFR for B KFT for B Units for Rate Units for Total Sample Size (Default 200)

4 8. Gate Time (Default 1.85 sec.) Analog Offset (Default 0000) Analog Gain (Default 10200) Analog Rule (Default 06) Unit Number (Default 001) Default Values Throughout the EMO Ratio Programming Limit Programming Meters/Units Programming Global Variables Ratio Feedback Mode Serial Port Operations Protocol Format Checksum Calculation Important Points for Serial Communication Address Information Appendixes Limited Warranty

5 Safety Definitions and Information Do not attempt to install or use your AW Gear Meters product until you have read the safety instructions in this section. Save this manual and keep it in an easily accessible place. Warning! Warning means that failure to follow this safety statement may result in extensive product damage, serious personal injury, or death. Caution Caution means that failure to follow this safety statement may result in minor or moderate personal injury, property or equipment damage. is a statement that informs about installation, operation, maintenance, performance issues, or general tips that are important but do not create a hazard or safety concern. Unpacking Separate the EMO-500 from packaging materials and check for any visual signs of damage. If you determine there has been damage caused by shipping, file a claim with the shipping company. If the flow monitor appears to have been improperly assembled or does not operate properly, return it for replacement or repair (see Limited Warranty information at the end of this manual). Caution Before connecting, programming, or operating the EMO-500, read this manual. 4

6 Quick Start Guide Caution As with any precision-engineered device, always operate the EMO-500 in accordance with the manufacturer s instructions. Connect to Flow Transmitters You will connect three wires from each of the two sensors to the back of the EMO-500 (see samples next page): Insert the two red wires (electrical power) to the two +18 volt terminals Insert the two white (signal) wires to the input terminals Insert the two black (ground) wires to the ground terminals Use a screwdriver to secure. Color of wires may vary. Connect the higher flow side to flow meter A as the Ratio calculation is A/B. 5

7 Figure 1: Sample pickup connections 6

8 Connect Unit to Power Before connecting to power source, connect ground, neutral and live wires to terminals on back of the EMO-500 (see diagram below). See shielding information on page 11. Warning! Connect wires to back of unit before applying power and wire the unit only as described on label on back of unit. Figure 2: Connections to power 7

9 Overview of Display Screens The 0 through 9, and F1 keys display these screens except when programming. 0-KEY = = => 1-KEY = = => RATIOA/B = 1.19 W=Y A=N I = 1.00 FLW A=139.3 CCM FLW B=136.3 CCM = = => Current Ratio A/B = = => Warning, Alarm, Ideal Ratio = = = > Flow A = = = > Flow B 2-KEY = = => JOB A= CC JOB B= CC = = = > Job Total A = = = > Job Total B 3-KEY = = => 4-KEY = = => GR A= CC GR B= CC J A+B CC G A+B CC = = = > Grand Total A = = = > Grand Total B = = = > Job Total (A+B) = = = > Grand Total (A+B) 5-KEY = = => 6-KEY = = => CURRENT RATIO LI WAR=005% ALA=010% SD1: AO=0000 IN=11111OUT=0000 = = = > Ratio Warning/Alarm Settings * = = = > Analog Out, = 0-20mA = = = > Inputs pins 1-5, Limits Out 7-KEY = = => SD2:FA=139FB=136 TA=10779TB=11793 = = = > Frequency A, B...(Hz) = = = > Total Impulses A, B 8-KEY = = => RATIO A/B=1.19 FL A+B CCM = = = > Current Ratio A/B = = = > Flow Rate (A+B) 9-KEY = = => F1-KEY ===> L1 L2 L3 L4 OFF OFF ON ON T A-B= CC F A-B= 15.4CCM = = = > Limit Status = = = > Total Differences = = = > Flow Differences * A no Ratio Mode when Limit 2 Rule is not on Ratio 8

10 Product Description For use in steady or pulsing streams, the EMO-500 s primary purpose is to monitor the flow rates of two flow meters, measuring flow rates, comparing totals, and verifying the ratio of flow A to flow B. You can also wire an alarm to the EMO-500 so it can alert you to fluctuations from normal. The unit comes from the factory with default values already programmed. However, if programming parameters require change, you can input data from the front keypad; you can also do this from a computer. You can Quick Program the EMO-500, or take advantage of the Full Programming option. Program keys are in red on the unit s keyboard (some keys have a dual function). You can also program the EMO- 500 through the unit s serial port. As a security measure, you can block access to programming when in the Full and Serial Port programming modes. Features Seven different totalizers for record keeping and reports Nine programmable units of measure Net consumption display Ready-to-Hardwire function controls allow for remote resets, operation of displays, and Quick/Full Programming Four programmable relay switched limits for warnings, alarms, or automatic shut-down control RS-232 and RS-485 serial ports Analog outputs (4-20mA) and (0-5V) Principle of Operation After you connect two flow meters to the unit and power it up, the EMO-500 can begin monitoring flow, totals, and ratios. Monitor data on-screen; fine tune and adjust programming parameters as needed. Technical Data Key Programming Features Ideal Ratio: user-defined, compared to actual ratio Gate Time: time-before-the-flow rate display updates Sample Size: number of pulses counted before ratio updates Limits: Ratio, Flow Rate and Total Units of Measure: liter, cc, gal, oz, gr, kg, lb, rpm, Hz Technical Information Power Supply: input = 110 or 220 VAC; consumption = 4 watts Communication: type = RS-232 and RS-485; protocol type similar to OPTO 323 9

11 Environmental: storage = -40 C to 85 C; operating = 0 C to 50 C; humidity = 10 to 90%, noncondensing Limits: 10 amp, 110 V dry contact relays Display Information Ratio (ideal): Flow Rate A, Job Total A, Grand total A Ratio (actual): Flow Rate B, Job Total B, Grand Total B Limit Settings: Flow Rate A+B, Job Total A+B, Grand Total A+B Limit Status: Flow Rate A-B, Job Total A-B Special Features The EMO-500 is geared toward applications where the main interest is the ratio of components dispensed over a period of time, for example in a batch, rather than monitoring on an instantaneous basis. The unit is especially suited for use in dispensing systems with irregular flow patterns. The EMO- 500 features a programmable sampling size, which governs how often the ratio display updates and provides maximum control over the sampling period. The EMO-500 is easy to adjust to suit system parameters. Helpful Information For Using the EMO-500 Sample Size This is the number of impulses collected for the ratio calculation. To determine the ratio, the EMO-500 separately counts the total number of pulses from both flowmeters until the fastest one reaches the SAMPLE SIZE. The EMO-500 divides the number of pulses flowmeter A produces by flowmeter B s pulses, and the result is the ratio. The accuracy and response time of the ratio calculation is therefore dependent upon the SAMPLE SIZE. The flowmeter with the lowest pulse rate should produce 100 pulses before the ratio calculation updates to achieve a 1% accuracy. Default value is 200. The display screen #7 is a useful guide for this purpose. Gate Time This is the time period over which the EMO-500 makes Rate Calculations. The gate time (in seconds) is the time period during which the microprocessor collects pulses to perform rate calculations. Default value is Serial Port Programming You can program the EMO-500 through the serial port using RS-232- or RS-485-type communication. Refer to the Serial Port Operations on page 31 for complete information. 10

12 Hardware Connections Before connecting to power source, connect ground, neutral and live wires to terminals on back of the EMO-500: PIN 1= ground, PIN 2 = line 110 or 220 V, and PIN 3 = line neutral (see Figure 3). Warning! Wire the AC power only as labeled on the three pin connector. Figure 3: Connections to power Grounding Considerations The grounding is a most important consideration in an installation where microprocessor technology is applied. The EMO-500 is a panel-mounted unit where the casing connects to a sub-panel. If the sub-panel is metal, it should be grounded. If the sub-panel is made of non-conductive material, PIN 1 of the three-pin connector on the EMO-500 back panel must be grounded. To insure a proper ground, the factory recommends connecting PIN 1 of the three-pin connector to the panel's central ground point. Signal and Shielding The two flow meter pickups should be supplied with their respective 18-volt supply voltages and referenced to their respective grounds. This insures the input signals from the flow meters are referenced to the ground connections on pins 2 and 5. Most applications require some signal shielding; a solid-aluminum wrap shielding works well. Connect the shield to pins 2 and 5 on the flow meter connector. DO NOT connect the shielding at the flow transmitter. 11

13 Caution Never connect the shield to ground at both ends. Doing so can produce unwanted oscillations in the signal wires. External Resets and Controls (Hardware) Five inputs to the 15-pin connector help provide extra control without having to go through the keyboard. To activate the external resets and controls, connect the respective pin to the Common for 1 5 pin. See Figure 4. Pins 1-4 are edge-triggered; use momentary contact switches to activate them. Pin 5 (enable programming) is an on/off function; use a single-pole toggle switch for it. See Figure 5. Figure 4: Connecting five inputs to common Figure 5: Pin 1-4 and Pin 5 connections 12

14 External Resets and Controls (Definitions) Reset All This reset is the most powerful on the EMO-500. It resets: Ratio A/B Job Vol A, Job Vol B and Job Vol A+B Warning and Alarm Limits Limits 3 and 4 Grand Totals Analog Outputs to start point Scroll Display This input scrolls through all of the 11 screens available. It also allows access to the Quick Programming functions, which are highlighted in red on the upper keypad line. (See page 14 for more details on Quick Programming). Reset Job B - resets OFF-RATIO WARNING/ALARM (LIMIT 1 and 2) This input resets the Job B totalizer. It also resets the A/B RATIO to the IDEAL setting, which simultaneously resets the WARNING and ALARM LIMITS. Reset Job A - resets OFF-RATIO WARNING/ALARM (LIMIT 1 and 2) This resets the Job A total. It also resets the A/B RATIO to the IDEAL setting, which simultaneously resets the WARNING and ALARM LIMITS. Simultaneously pressing and holding RESET JOB A and RESET JOB B on the keyboard, or through the back-panel connections, actuates HOLD TOTAL. Enable Full Programming Enables the F2 through F6 keys to perform the programming functions shown in red on the banner strip above the keypad. F3, F4, and F5 serve as Job Resets in the Job Totals screen when the Enable Programming switch is OFF. 13

15 Quick Programming Figure 6: Quick Programming Display Screens Many programming variables such as KFR or meter selection only require a "one time" setting; other variables require some experimentation to find maximum efficiency settings. It is also desirable to allow field personnel the limited ability to make some quick adjustments. To accommodate these circumstances the EMO-500 s "Quick Programming" option allows you to jump directly into some limited programming functions. These functions are noted in red on the keypad on the top line of function keys F1 through F6, and the 0 and 1 keys (also see Figure 6). The keys and their functions are: F1 = Ideal Ratio F2= Gate Time F3 = Ratio Warning % F4 = Ratio Alarm % F5 = Decimal Point F6 = Enter 0 = Sample Size 1 = Specific Gravity Activation To activate Quick Programming, connect the Scroll Line Input (Pin 2) and the Common 1 5 (Pin 6) of the 15-Pin connector on the back panel of the EMO-500 with a momentary contact switch. With this connection established, push any one of the above keys. This does not work if full programming is enabled. A rate scaling factor. 14

16 Figure 7: Sample Connections, Inputs and Outputs 15

17 Keys and Values F1 Ratio (Default Value = 1.00) This function is the address of the IDEAL RATIO, which represents the desired ratio of FLOW A/FLOW B. The default is 1.00, which represents a 1 to 1 ratio. F2 Gate Time (Default Value = 1.85) The GATE TIME is the period of time, in seconds, during which the EMO-500 calculates the flow rate. The accuracy and response time of the flow rate display is therefore dependent upon this value. To achieve a 1% accuracy, the slowest pulse rate should deliver at least 100 pulses. F3 Warning (Default Value = 5%) The WARNING variable is set as a percent deviation from the Ideal Ratio. The first meter to deliver the number of pulses programmed as the SAMPLE AMOUNT triggers the ratio calculation. The calculation compares the measured ratio to the Ideal Ratio; if the difference in percent exceeds the programmed value, the warning activates. F4 Alarm (Default Value = 10%) Similar to the above Warning variable. F5 DP (Decimal Point) Use this key to locate the decimal point when programming the EMO-500. F6 Enter Use this key to lock in programmed values. #0 Sample Size (Default = 200) To determine the ratio, the EMO-500 separately counts the total number of pulses from both flowmeters until the fastest one reaches the SAMPLE SIZE. The EMO-500 divides the number of pulses flowmeter A produces by flowmeter B s pulses, and the result is the ratio. The accuracy and response time of the ratio calculation is therefore dependent upon the SAMPLE SIZE. The flowmeter with the lowest pulse rate should produce 100 pulses before the ratio calculation updates to achieve a 1% accuracy. The display screen #7 is an useful guide for this purpose. #1 SG (Specific Gravity [Default = 1.0]) If needed, enter specific gravity values for each metered flow. 16

18 Full Programming The three methods of programming the unit are: Quick Programming Full Programming, and Serial Programming You can change all of the default program variables to alternative values through the keypad or by a host computer with an RS-232 serial port. For information about Quick Programming, go to page 14. For information about Serial Programming, go to page 31. See below for Full Programming instructions. Full and Serial Programming have lockout features to prevent unauthorized access. Enable Quick Programming functions allocated to certain keys are in red on the keypad. Keys F1 through F6 have multiple functions and are also used for Full Programming. A banner on the keypad immediately above specific keys indicates the alternative function each key has in the Full Programming Mode. When full programming is not enabled, F3/F4/F5 serve as Job Resets, and you can use keys 0 through 9 to select from the 11 operating displays shown on page 8. IMPORTANT: The higher flow side should be connected to flow meter A as the Ratio calculation is A/B. To access the Full Programming menu, place a jumper between pin 5 (enable programming) and pin 6 (common). Use the F2 key to page through the menu of programming options, which are indicated in red lettering on a banner above the upper function keys (representation below). ESCAPE ACCESS RATIO LIMITS METERS GLOBALS PROGRAMMING As a security measure, access is denied to F3, F4, and F5 until you press F2 first. Reminder: Quick Programming activates the functions indicated in red on the F1 - F6 and 0-1 keys. See page 14. After jumpering pin 5 to pin 6, the access sequence is: 17

19 MAIN MENU F2 OPTIONS F3 F4 F5 F6 RATIO PRG. LIMIT PRG. METER/UNIT PRG. GLOBALS PRG. Enable Prog --> F2 --> --> --> --> F3 F4 F5 F6 (Access to Ratio Prog) (Access to Limit Prog) (Access to Meter/Units) (Access to Global Prog) F1 Serves as an ESCAPE key to leave the programming functions and return to the last screen displayed. F2 Pages you through the programming options above AND IS REQUIRED TO ALLOW FURTHER ACCESS. F3 Ratio programming (see below): 18

20 Enter the Ideal Ratio. This number represents the desired Ratio of Flow Amount A to Flow Amount B. The default is 1.00, meaning a 1 to 1 ratio. Enter the Ratio Warning. This number represents the percentage of error between the actual measured ratio and the desired ideal ratio. The default is 5%; therefore, if the actual and measured ratio differ by more than 5%, the Limit 1 relay closes. Enter the Ratio Alarm. This number works the same as Ratio Warning except that after the warning, the EMO-500 waits for one more sample amount before closing the Limit 2 Relay if the ratio error is greater than the programmed percentage. Default is 10%. F4 Limit programming. Off-Ration Warning and Alarm Settings Since the EMO-500 is primarily a Ratio Monitor, Limits 1 and 2 are factory-set, which an off condition triggers. Default values are: Limit 1 = Warning 5% Limit 2 = Alarm 10% For example, if you program the RATIO WARNING at +/- 10%, the LIMIT 1 contact closes when this event occurs. The programmed value similarly activates LIMIT 2 in the RATIO ALARM. Press key #5 to review the current ratio alarm settings and key #9 to review the limit status. Press either F3 (Reset A) or F4 (Reset B) to reset off-ratio alarms. 19

21 As mentioned previously, Limits 1 and 2 are preset for ratio alarms, which you can easily adjust for different ratio settings via Quick Programming. Adjust Limits 3 and 4 Limits 3 and 4 are used to warn of other monitored parameters such as flow rates or totalized fluid volumes. Adjust these settings as follows: Three parts make up the Limit Programming section; do each part in order: 1. Limit 3 Rule and value 2. Limit 4 Rule and value 3. Limit 2 Rule and/or value 20

22 This procedure is also shown pictorially on the previous page. 1. Enter the Limit 3 Rule. This means you must select the function to trigger the Limit 3 relay. Options are: Job Total for A Job Total for B Job Total for A+B Flow A Flow B Flow A+B Press F4 to page through the options; press F6 to enter your selection. The display flashes DP Location Will Match KFT/KFR. This means the number you entered for the Limit trip point automatically takes the same decimal point location as the Total Scaling Factor (KFT) for Total Limits, or Rate Scaling Factor (KFR) for Flow Rate Limits. 2. Type in the Limit 3 value; press F6 to enter (you must enter the Limit 3 number to proceed to Limit 4). 3. Enter the Limit 4 Rule and number exactly as above (you must enter the Limit 4 number to proceed to Limit 2). 4. Enter the Limit 2 Rule. If you select Ratio A/B, the Limits 1 and 2 operate on the ratio percentage of error under F3 Ratio Programming. Therefore, if you select Ratio A/B, limit programming is complete. In another scenario, you can program Limit 1 and 2 for Warning and Alarm settings on Flow A, while you can allocate Limit 3 and 4 to Warning and Alarm for Flow B or Flow A+B and Total B, respectively. In this case, you can select Limits 3 and 4 independently but you cannot separate 1 and 2. Other options are as follows (page using F4; enter, F6): Ratio A/B Job Total for A Job Total for B Job Total for A+B Flow A 21

23 Flow B Flow A+B If you select any function other than Ratio A/B for the Limit 2 Rule, the EMO-500 still monitors the ratio of flow A/B, but no Warning or Alarm trips when flow is out of the error percentages. Display 5 indicates NO RATIO MODE FOR LIMITS 1 & 2. F5 In the Meters/Units programming section, you select from nine Flow Meters and three Engineering Units. Scroll through the Meters until the selection desired appears on the display and enter your selection with the F6 key. The EMO-500 automatically enters the Rate Scaling Factors (KFR) and Total Scaling Factors (KFT) for each of the selections below. Flow Meter Approximate K-factor ZHM01 ZHM03 HPM-15 ZHM02 ZHM04 HPM-20 ZHM02 ZHM05 HPM PPG 6600 PPG PPG PPG 1800 PPG PPG PPG 500 PPG 6600 PPG The unit then asks you to select the Engineering Units in the same manner. Choose from: CC & CCPM GAL & GPM OZ & OZM The EMO-500 flashes Direct Selection, Meter A or B and the display reads F2=A, F3=B, F4=A&B. This is where you choose the Flow Meter and set the Engineering Unit. The display reads More Selections?, F2=Yes, F3=No. If both Flow Meters are programmed, select F3; if not, press F2 to start the Meters/Units Program section again. 22

24 The Engineering Units for A and B should be the same. The KFR and KFT values in Meters/Units Programming are only approximations because the K-factors of the above flow meters are only approximations. Calculate the (KFR) and (KFT) using the calibrated K-factor whenever possible. See the Global Programming section on page

25 F6 The F6 key calls up Global Programming. Global Default Values 1. KFR for A KFT for A KFR for B KFT for B Units for Rate Hz 6. Units for Total impulses 7. Sample Size impulses 8. Gate Time seconds 9. Analog Offset Analog Gain Analog Rule Ratio 12. Unit Number Explanation of Global Variables 1. KFR for A (Default 100.0) In order to display the correct rate in an engineering unit such as GPM, the EMO-500 must calculate a scaling factor. This Rate Scaling Factor is called the KFR. The EMO-500 uses the K-factor of the flow transmitter being monitored to calculate the KFR. The K-factor is the number of impulses per engineering unit established by a calibration test. For example, a flow meter could have a K-factor of 6304 imp/gal. To calculate the KFR multiplier for the EMO-500, apply the following formula: 24

26 KFR = 6000 K -factor 100 is the constant for seconds 6000 is the constant for minutes is the constant for hours Enter this KFR number in the Global Programming section. The K-factor is the number the manufacturer provides as the average K-factor for the transmitter. For example, a flow meter has the K-factor imp/gal and the display should show Gallons/minute. KFR = = GPM Enter 2921 as the KFR; use the DP (decimal point) key to move the DP to the number Calculator mathematics produce insignificant decimal numbers for our purposes. These produce a misleading level of precision in the display. The factory recommends using a maximum of four digits regardless of the decimal point position. Example: for , enter for , enter The largest number you can enter as a KFR is 65000, ignoring the decimal point position. A message alerts you if the number you enter is too large. 2. FT for A (Default 10000) In order to make the EMO-500 display the correct Totalized Value in Engineering Units, again the most important thing to know is the K-factor of the flow meter. The K-factor is the relationship between the amount of the impulses and the engineering units. To calculate the KFT, apply the following formula: KFT = K-factor 25

27 Enter the KFT in the Global Programming section. The K-factor is the number manufacturer provides as the average K-factor for the transmitter. If this is in imp/gal, set the totalizer in, say cc s, by converting the K-factor to imp/cc is a constant. For example, a flow meter has a K-factor of imp/gal and the display should show gallons/minute: KFT = =.9376 Gal Enter 9376 as the KFT and move the DP to (See note below). Calculator mathematics produce insignificant decimal numbers for our purposes. These produce a misleading level of precision in the display. The factory recommends using a maximum of four digits regardless of the decimal point position. For example, for , enter 60.6; for , enter The largest number you can enter as a KFT is Refer to KFR note above. 3. KFR for B The same as KFR for A. 4. KFT for B The same as KFT for A. 5. Units for Rate. This variable displays the Engineering Units required for the flow rate display. It is strictly a display and does not perform the actual conversion of raw counted impulses; the KFR handles those calculations. Enter the two-digit number for the desired Units for Rate: 00 - cc/min 06 - gram/sec 01 - liter/min 07 - lb/min 02 - gallon/min 08 - Kg/min 03 - ounce/min 09 - Kg/sec 04 - RPM 10 - lb/sec 05 - gram/min 11 - lb/hr 12 - Hz (impulses/sec) 26

28 6. Units for Total. This variable determines the Engineering Units for Total displayed after the totalizer value. It too is a display only function and does not perform the actual conversion of total impulses to the correct value. The KFT handles those calculations. Enter the two-digit number for the desired Units for Total: 00 - cc 04 - revolution 01 - liter 05 - gram 02 - gallon 06 - lb 03 - ounce 07 - kg 08 - impulses 7. Sample Size (Default 200) To determine the ratio, the EMO-500 separately counts the total number of pulses from both flow meters until one of them reaches the programmed Sample Size. The number of pulses from flow meter A is then divided by the number of pulses received from flow meter B. The accuracy and response time of the ratio calculation are therefore dependent on the Sample Size. To determine a reasonable number to program for Sample Size, the main factor is the flow meter with the lowest pulse rate, but with at least 100 pulses before the Ratio calculation. If 100 pulses are counted on the slowest moving totalizer then the accuracy of the ratio calculation should be about 1%. The pulses counted are straight from the flow meter, not scaled engineering unit values. The display screen #7 (Status Display 2) is a useful guide in this selection. The lower line shows the incoming raw pulse count. For example, if the Sample Amount is 1000, the ratio display updates each time the fastest total increments by Also by this method, the slower pulse count can be observed. Default value is Gate Time (Default 1.85 sec.) The gate time (in seconds) is the amount of time pulses are accepted before the EMO-500 performs flow rate calculations. The accuracy and response time of the flow rate display are dependent on the gate time. To achieve a 1% flow rate accuracy, the lowest pulse rate should produce 100 pulses before the device performs the rate calculation. In display #7 (Status Display 2), the lower line indicates incoming flow meter impulses, an estimate of the time elapsed for 100 pulses, to be accumulated by the slowest meter, which gives a good approximation of the minimum recommended gate time. 27

29 Another method is to change the default Gate Time value by trial and error until achieving the best results. 9. Analog Offset (Default 0000) The Analog Output Offset is a number from that becomes the bottom end of the 0-5 volt and 4-20 mamp analog outputs. For example: 0000 for 0 to 20mAmps and 0 to 5v. 819 for 4 to 20mAmps and 1 to 5v for 8 to 20mAmps and 2 to 5v for 12 to 20mAmps and 3 to 5v. 10. Analog Gain (Default 10200) The analog gain factor integrates the controller output range and speed with the rest of the system capabilities. If the gain factor is correct, the full range of the analog output signal can be used to cover the operating range of the equipment in which it is installed. Use this formula to determine the analog output: Analog Ouput = (Variable Value) X Gain 512 The Analog Output arrived at above should be a number from , which drives a D/A converter for a 4-20 mamp and a 0-5 volt output on Pins 7 and 8 of the 9 Pin connector. Therefore the gain factor can be estimated by re-arranging the analog output equation as follows: GAIN = (512) (Analog Out) Variable Value If the desired maximum output of the system is achieved at 5V or 20 mamp, this is equivalent to an Analog Out value of 4095 and the above equation would read: GAIN = (512) (4095) Variable Value The Variable Value is the true flow rate or volume capability of the system measured at the analog value discussed above and therefore depends upon the ANALOG RULE selected. The Analog Rule is discussed further below. 28

30 The value you enter ignores the decimal point position. For Example: In Ratio Mode (06) If Ideal Ratio = 5.00, variable value = 500 If Ideal Ratio = 10.00, variable value = 1000 In Flow Mode (00-02) If Flow Rate = 80.0 cc/m, variable value = 800 If Flow Rate = cc/m, variable value = 2000 If Flow Rate = 5.25 GPM, variable value = 525 In Flow Mode (03-05) If Total Flow = Gal, variable value = Analog Rule (Default 06) The analog rule allows you to set the analog output to follow any of the variables listed below. Enter a number as the Analog Rule Flow A 06 - Ratio 01 - Flow B 07 - Ratio Feedback Mode 02 - Flow A+B 08 - Ratio w/reset 03 - Total A 09 - Ratio Feedback w/reset 04 - Total B 10 - A - B Job Total 05 - Total A+B 11 - A - B Flow Rate These variables are used in the computations as numbers in Engineering Units (ccpm, gals, ozs., etc.). This means that any Decimal Points are dropped. For example, 113.7ccpm is 1137 for computation purposes. 29

31 12. Unit Number (Default 001) This variable is used for Serial Communication with a host computer. It identifies each EMO-500 unit if there is more than one on the communication line. Unit #1 is 01, unit #2 is 02, etc. Default Values Throughout the EMO-500 Ratio Programming Ideal Ratio = 1.00 Ratio Warning = 5% Ratio Alarm = 10% Limit Programming Limit Rule 3 = Job Total A, value = 3000 Limit Rule 4 = Job Total A, value = 4000 Meters/Units Programming Meter = Hz Units = IMPULSES Global Variables KFR for A = KFT for A = KFR for B = KFT for B = Units Rate = 12 Units Total = 08 Sample Size = 200 Gate Time = 1.85 Analog Offset = 0000 Analog Gain = Analog Rule = 06 Unit Number = 01 30

32 Ratio Feedback Mode The Ratio Feedback Mode compares the Ideal Ratio and the Actual Measured Ratio. The EMO-500 generates a 4-20 ma signal to control one of the Flow Rates. This maintains the Ideal Ratio over a wide range of flow rates. The formula used to determine the correct analog output is: Analog Output = Half Range + (Ideal Ratio-Actual Ratio) X Gain Half Range refers to the middle point of the Analog Output. If the output varies from 0 to 20mAmp., the half point is 10mAmp. If the Analog Offset is set to give an output of 4 to 20mAmp., the Half Point is 12mAmp. To use the Ratio Feedback Mode, enter 07 as the Analog Rule (see page 29). The Ratio Feedback Mode w/reset works in exactly the same manner except that the analog output goes to the start point (mid-point) on Reset All. Serial Port Operations The EMO-500 has standard RS-232 and RS-485 serial port connections on the 9-pin back panel. You can connect this port to a host computer and then Read or Write to any memory location in the EMO-500. The RS-232 pins on the 9-pin connector are: pin 3 (TX transmit) pin 2 (RX receive) pin 5 (Ground) The RS-485 connections are: pin 6 (RX) pin 7 (TX) pin 8 (RX) pin 9 (TX) Warning! The communications port does not discriminate addresses. This means that any address can be written to as well as read from. Writing to certain addresses changes the operation of the EMO-500 drastically. Caution is a must when programming through a host computer. Double check addresses and variables before writing to the EMO

33 Communication through the serial port does not work if the EMO-500 is in programming mode. Protocol Format The EMO-500 uses a protocol format that follows OPTO 22 Company s OPTOMUX. ^ means add one letter or digit ; ^^ means add two letters or digits, ^^^ means add three letters or digits, etc.; cr means carriage return. The format for reading from the EMO-500 is as follows: >01K0F3404XXcr ^...start of string must use the > sign ^^...unit number (under global variables) ^...read command K (use J to write) ^^^^...address to read from ^^...number of bytes to read ^^...checksum for the string 01K0F carriage return (ASCII 13) ends the string The answer received back from the EMO-500 looks like this: A03E36712XXcr ^...all answers start with A ^^...low byte (at address 0F34) ^^...next byte(at address 0F35) ^^...next byte(at address 0F36) ^^...high byte(at address 0F37) ^^...checksum...carriage return ends the string The protocol format for writing to the EMO-500 is as follows: 32

34 >01J03340F3587XXcr ^...start of string must use the > sign ^^...unit number ^...write command J (use K to read) ^^^^...address to write into ^^...byte written to 0334 ^^...byte written to 0335 ^^...byte written to 0336 ^^...checksum...carriage return If the operation was successful, the EMO-500 answers with: Acr. The following error messages have been implemented in the EMO-500 protocol: NO1cr - Undefined command (something other than K/J) NO2cr - Checksum error NO3cr - Non printable ASCII character OPTO 22 has published a booklet on the protocol format. Checksum Calculation The calculation for the string variables in the read command would be as follows: >01K0F3404XXcr ^^^^^^^^^...these characters are used in the calculation. Add the values for the ASCII Decimal variables. HEX K F ASCII = 493 To calculate the final checksum, convert the decimal number 493 into HEX (493=1EDh) and take the last two characters (ED) for the checksum. The final string would look like this: >01K0F3404Edcr 33

35 Important Points for Serial Communication 1. Serial communication is disabled if the EMO-500 is in programming mode. 2. All characters in the communication string should be in CAPITALS. Example: the EMO-500 recognizes K is ASCII 75, but it does not recognize k is ASCII All numbers in the communication string are represented in hexadecimal format. 4. Do not try to read or write more than 12 bytes at a time due to limitations of the EMO-500's serial buffers. 5. The least significant byte of a number is stored at the lower address. 6. The > in the transmit string and the A in the reply string are not used in the checksum calculation. The ASCII characters needed for checksum calculations are: ASCII Decimal ASCII Decimal 0 48 A B C D E F J K 75 34

36 Warning! The communications port does not discriminate any addresses. This means that any address can be written to as well as read from. Writing to certain addresses changes the operation of the EMO-500 drastically. Caution is a must! Double check addresses and variables before writing to the EMO-500. The bytes are always arranged such that the low byte (LSB) is first and the more significant bytes (MSB) follow. In the EMO-500, the least significant byte is at the lower address. For example, if the data from the totalizer is read as: 90D58901 the LSB is 90 and the MSB is 01. The arrangement of these four bytes in the EMO-500 memory is: Address = 05A0H 05A1H 05A2H 05A3H Vaule = 90H D5H 89H 01H Interpret the totalizer value as: 0189D590H = 25,810,320 (in decimal) Address Information When writing to the EMO-500, there are always two locations to be changed for a permanent entry into the memory. This is because there are locations for data running currently in the RAM and for data that is battery-backed. If the information has been written to the running locations alone, it is lost when the EMO-500 is turned off. Below is a QBASIC program that allows you to communicate with the EMO-500 by initiating serial port #1 and prompting for read and write strings. The strings must use the OPTO 22 protocol format described on page

37 DEFINT A-Z '* Serial Communication Test Program for OPTOMUX Code '* For use with AW Company's EMO-Series Flow Computers '* Open serial port #1 to 9600 baud OPEN "COM1:9600,N,8,1,RS,CS,DS,CD" FOR RANDOM AS #1 '* set up loop for transmitting several strings CLS DO PRINT "Enter String to send. (Press ENTER alone to END)" INPUT "Transmitting String: >", Transm$ IF LEN(Transm$) = 0 THEN END '* Calculate Chksum Chk = 0 FOR Char = 1 TO LEN(Transm$) Chk = Chk + ASC(MID$(Transm$, Char, 1)) NEXT Chk$ = HEX$(Chk) '* Must be 2 characters, 1 byte IF LEN(Chk$) < 2 THEN Chk$ = "0" + Chk$ '* Add the recognition character plus checksum '* use only the last byte of checksum Transm$ = ">" + Transm$ + RIGHT$(Chk$, 2) '* Send it to the EMO PRINT #1, ; Transm$; CHR$(13); '* Read what the EMO sending back LINE INPUT #1, Receive$ PRINT "Received: "; Receive$ PRINT LOOP Warning! The communications port does not discriminate any addresses. This means that any address can be written to as well as read from. Writing to certain addresses changes the operation of the EMO-500 drastically. Caution is a must! Double check addresses and variables before writing to the EMO

38 Running Address in HEX Back-up Address in HEX Bytes Description Default Value 05F KFR A A KFR A Decimal Pt KFR A Eng. Units 00 05FF 040A 2 KFT A C 040C 2 KFT A Decimal Pt KFT A Eng. Units 00 05F KFR B E KFR B Decimal Pt B KFR B Eng. Units E 2 KFT B KFT B Decimal Pt D KFT B Eng. Units A 042D 2 Limit 1 Value C 042F 2 Limit 2 Value E Limit 3 Value Limit 4 Value B 042C 2 Limit 1 & 2 Rule Limit 3 Rule A 2 Limit 4 Rule (4)* Ideal Ratio Ratio Alarm E 2 Ratio Warning D Analog Rule 06 05AA Analog Gain B Analog Offset A 2 Sample Size D** 041C 2 Gate Time C 1 Unit Number read only 4 Flow A xxxx 051A read only 4 Flow B xxxx 051E read only 4 Flow A & B xxxx 05B5 read only 4 Ratio A/B xxxx 05A0 read only 4 Job Total A (SD2) xxxxxxxx 05A6 read only 4 Job Total B (SD2) xxxxxxxx 05EF read only 4 Job Total A + B xxxxxxxx 052E read only 4 Grand Total A xxxxxxxx 0533 read only 4 Grand Total B xxxxxxxx 0504 read only 4 Grand Total A & B xxxxxxxx 05A4 read only 2 Analog Out xxx 37

39 Special variables (see previous page) function in the following manner: *Ideal Ratio The largest number that can be written into the Ideal Ratio without an overflow is 640. Variable at address 0426h is 3 bytes; at 0614h, 4 bytes. **Gate Time This variable is a converted number because the keypad entry is made in seconds and a constant must be applied for computations. Therefore after reading the Gate Time, the number read must be converted to decimal, then divided by 5388 for an answer in seconds. Job Total A (SD2) This variable shows twice the amount read from the Job A display. This is because the number is actually a raw count from the frequency input. The number read matches the totals seen in the Status Display 2 screen. Job Total B (SD2) Same as above. Grand Total A This variable is not stored into the backup memory until Job Volume A is reset. Therefore, the location reads zero until the count is stored away with the Reset Job A. Grand Total B Same as above. 38

40 Appendixes 39

41 40

42 41

43 42

44 43

45 44

46 45

47 Limited Warranty AW Gear Meters warrants the product to be in good working order for a period of 1 (one) year from the date of purchase from AW Gear Meters or an Authorized AW Gear Meters distributor. Should the product fail to be good working order at any time during this 1-year warranty period, AW Gear Meters will, at its option, repair or replace the product at no additional charge except as set forth below. Repair parts and replacement products will be furnished on an exchange basis and will be reconditioned or new. All replaced parts and products become the property of AW Gear Meters. This limited warranty does not include service to repair damage to the product resulting from accident, disaster, abuse, or a non AW Gear Meters modification to the product. Limited Warranty service may be obtained by delivering the product during the 1-year warranty period to AW Gear Meters and provide proof of purchase date. If this product is delivered by mail, you agree to insure the product or assume 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 Gear Meters 8809 Industrial Drive Franksville, WI Phone: (262) Fax: (262) ALL EXPRESS AND IMPLIED WARRANTIES FOR THIS PRODUCT INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE LIMITED IN DURATION TO A PERIOD OF 1 (ONE) YEAR FROM DATE OF PURCHASE, AND NO WARRANTIES, WHETHER EXPRESS OR IMPLIED, WILL APPLY AFTER THIS PERIOD. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU. IF THIS PRODUCT IS NOT IN GOOD WORKING ORDER AS WARRANTED ABOVE, YOUR SOLE REMEDY SHALL BE REPAIR OR REPLACEMENT AS PROVIDED ABOVE. IN NO EVENT WILL AW COMPANY BE LIABLE TO YOU FOR ANY DAMAGES, INCLUDING ANY LOST PROFITS, LOST SAVINGS OR INCIDENTAL OR CONSEQUENTIAL DAMAGE ARISING OUT OF THE USE OR INABILITY TO USE SUCH PRODUCT, EVEN IF AW GEAR METERS HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES, OR FOR ANY CLAIM BY ANY OTHER PARTY. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS, WHICH MAY VARY FROM STATE TO STATE. 46

48 8809 Industrial Drive Franksville, WI AW-Lake Company All rights reserved. Doc ID: EMO500MAN