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923-ST1SUM-FC Flow Computer

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/16/15 Proprietary Notice The information contained in this publication is derived in part from proprietary and patent data. This information has been prepared for the expressed purpose of assisting
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/16/15 Proprietary Notice The information contained in this publication is derived in part from proprietary and patent data. This information has been prepared for the expressed purpose of assisting operating and maintenance personnel in the efficient use of the instrument described herein. Publication of this information does not convey any rights to use or reproduce it or to use for any purpose other than in connection with the installation, operation and maintenance of the equipment described herein. Copyright 1999 Printed in USA. All Rights Reserved. WARNING! This instrument contains electronic components that are susceptible to damage by static electricity. Proper handling* procedures must be observed during the removal, installation, or handling of internal circuit boards or devices. *Handling Procedure 1. Power to unit must be removed. 2. Personnel must be grounded, via wrist strap or other safe, suitable means, before any printed circuit board or other internal device is installed, removed or adjusted. 3. Printed circuit boards must be transported in a conductive bag or other conductive container. Boards must not be removed from protective enclosure until the immediate time of installation. Removed boards must be placed immediately in protective container for transport, storage, or return to factory. Comments This instrument is not unique in its content of ESD (electrostatic discharge) sensitive components. Most modern electronic designs contain components that utilize metal oxide technology (NMOS, CMOS, etc.). Experience has proven that even small amounts of static electricity can damage or destroy these devices. Damaged components, even though they appear to function properly, may exhibit early failure. SAFETY INSTRUCTIONS The following instructions must be observed. This instrument was designed and is checked in accordance with regulations in force EN ( Safety of information technology equipment, including electrical business equipment ). A hazardous situation may occur if this instrument is not used for its intended purpose or 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 and understand this manual prior to installation and operation of the instrument. This instrument is internally fused. Replace the internal fuse with the following specified type and rating only: Input Power Recommended Fuse 115 VAC 160 ma slow blow fuse 230 VAC 80 ma slow blow fuse VDC 800 ma slow blow fuse Disconnect power supply before replacing fuse! The manufacturer assumes no liability for damage caused by incorrect use of the instrument or for modifications or changes made to the instrument. Symbols Used On Unit Number Symbol Publication Description 1 IEC 417, No Direct current 2 IEC 417, No Equipment protected throughout by DOUBLE INSULATION or REINFORCED INSULATION (equivalent to Class II of IEC 536 see annex H) 3 ISO 3864, No. B.3.1 Caution (refer to accompanying documents) Technical Improvements The manufacturer reserves the right to modify technical data without prior notice. CONTENTS 1. DESCRIPTION 1.1 Unit Description Unit Features Specifications INSTALLATION 2.1 General Mounting Hints Mounting Diagrams APPLICATIONS 3.1 Sum Liquid Volume Sum Corrected Liquid Volume Sum Liquid Mass WIRING 4.1 Typical Wiring Wiring In Hazardous Areas UNIT OPERATION 5.1 Front Panel Operation Concept for Run Mode General Operation Ratemeter/Totalizer Operation Password Protection for Rate/Total mode Relay Operation in Rate/Total mode Pulse Output in Rate/Total mode Analog Output in Rate/Total mode RS-232 Serial Port Operation in Rate/Total mode RS-485 Serial Port Operation in Rate/Total mode PROGRAMMING 6.1 Front Panel Operation Concept for Program Mode Setup Menus Setup Sub-Menus SELECT FLOW EQUATION SETUP INDICATORS (Total) SETUP INDICATORS (Density) SETUP INDICATORS (Rate) SETUP INDICATORS (Temperature) SETUP FLOW INPUT SETUP AUX1 INPUT SETUP AUX2 INPUT SET FLUID PROPERTIES SETUP PULSE OUTPUT SETUP ANALOG OUTPUT SETUP RELAYS SETUP CONTROL INPUTS SETUP REALTIME CLOCK(Time) SETUP REALTIME CLOCK(Date) SERIAL USAGE (RS-232/485) SERIAL USAGE (Modem Options) SET DATALOG/PRINT(Configure) SET DATALOG/PRINT (Select_list) ADMINISTRATIVE SETUP SETUP NETWORK CARD PRINCIPLE OF OPERATION 7.1 General Flow Equations Calculating the Expansion Factor Computation of Viscosity Coef. A and B Linearization Table Linearization Table General Information Linearization Table for Pulse Inputs Linearization Table Interpolation Universal Viscosity Curve (UVC) Strouhal Roshko Curve (StRo) i 8. TEST, SERVICE and MAINTENANCE CONTENTS 8.1 Test Menus Test Sub-Menus Audit Trail Error History Print System Setup Keypad test Display test Calibrate Aux1 0mA Calibrate Aux1 20mA Calibrate Aux2 0mA Calibrate Aux2 20mA Calibrate Thermistor: 100 Ohms Calibrate Thermistor: Open Calibrate Aux2 0V Calibrate Aux2 10V Calibrate 100 ohm RTD Calibrate 4mA Out Calibrate 20mA Out Analog In Test Pulse input test Analog out test Excitation out test Pulse out test Relay test Control input test Battery Voltage test Data logger utility Internal Fuse Replacement RS-232 SERIAL PORT 9.1 RS-232 Serial Port Description Instrument Setup by PC Over Serial Port Operation of Serial Communication Port with Printers ST1SUM-FC RS-232 Port Pinout RS-485 SERIAL PORT 10.1 RS-485 Serial Port Description General Operation of Serial Communication Port with PC ST1SUM-FC RS-485 Port Pinout FLOW COMPUTER SETUP SOFTWARE 11.1 System Requirements Cable and Wiring Requirements Installation for Windows Using the Setup Software File Tab Setup Tab View Tab Misc. Tab GLOSSARY OF TERMS 12 Glossary Of Terms DIAGNOSIS AND TROUBLESHOOTING 13.1 Response of 923-ST1SUM-FC on Error or Alarm: Diagnosis Flow Chart and Troubleshooting Error & Warning Messages: Sensor/Process Alarms Self Test Alarms...63 APPENDIX A (FLUID PROPERTIES TABLE)...64 APPENDIX B (Setup Menus)...65 APPENDIX C (RS485 Modbus RTU Protocol) ii Unit Description 1. Description 1.1 Unit Description: The 923-ST1SUM-FC is a two channel flow computer intended for calculation of sum flow (A + B) rate and total of two separate lines. It operates with pulse producing flowmeters in liquid applications. The unit displays the rate/total of the Flow Line-A, Flow Line-B and sum of flows (A+B). Multiple flow equations and instrument functions are available in a single unit with many advanced features. Volume Flow, Corrected Volume Flow or Mass Flow calculations can be selected. The alphanumeric display shows measured and calculated parameters in easy to understand format. Single key direct access to measurements and display scrolling is supported The 923-ST1SUM-FC offers a wide measure of versatility within the instrument package. The various hardware inputs and outputs can be soft assigned to meet a variety of common application needs. The user soft selects the usage of each input/output while configuring the instrument. The excitation voltage, input termination and input filtering are chosen by means of a menu selection. The user can assign the standard RS-232 Serial Port for data recording, transaction printing, or for connection to a computer. Menu selectable linearization options include UVC, Strouhal/Roshko and 40 point linearization tables. A Service or Test mode is provided to assist the user during start-up system check out by monitoring inputs and exercising outputs and printing system setup. Unit Features 1.2 Unit Features: The 923-ST1SUM-FC offers the following features: Displays Rate/Total of Meter 1, Meter 2 and Sum of Meter 1 & Meter 2 Supports Pulse Producing Flowmeters Turbine, Positive Displacement, Coriolis, Compound Flowmeters Volume, Corrected Volume or Mass Equation Universal Viscosity Curve (UVC) and Strouhal/Roshko Advanced Linearization Methods API 2540 Equations for Petroleum Fluids User Entry of Fluid Properties (10 Selectable) Menu Selectable Hardware & Software Features Data Logging of Sum of Rate/Total Two Line LCD or VFD Display Isolated Pulse and Analog Outputs Standard RS-232 Port Standard, RS-485 Optional Windows Setup Software DDE Server & HMI Software Available 1 1.3 Specifications: Specifications: Flow Meters and Computations Meter Types: Supports pulse producing meters including: vortex, single rotor turbine, magnetic, PD flowmeter, Coriolis and compound flowmeters Linearization: 40 point table, UVC table or Strouhal/ Roshko Computations: Volume, Corrected Volume & Mass Fluid Computations: Density, Temperature, Viscosity in individual lines when needed Environmental Operating Temperature: 0 C to +50 C Storage Temperature: -40 C to +85 C Humidity : 0-95% Non-condensing Materials: U.L. approved Approvals: CE Compliant, UL/CUL Listed Display Type: 2 lines of 20 characters, Blue VFD or Backlit LCD Character Size: 0.2 nominal User programmable label descriptors and units of measure Keypad Keypad Type: Membrane Keypad with 16 keys Keypad Rating: Sealed to NEMA 4X Enclosure Size: See Dimensions Depth behind panel: 6.5 including mating connector Type: DIN Materials: Plastic, UL94V-0, Flame retardant Bezel: Textured per matt finish Fluid Types General Purpose, User entry of fluid properties for up to 10 fluids. Real Time Clock The 923-ST1SUM-FC is equipped with a battery backed real time clock with display of time and date. Format: 12 or 24 hour time display Day, Month, Year date display Excitation Voltage Menu Selectable: 5, 12 or ma (fault protected with self resetting fuse) DC powered units have limited selections. Power Input The factory equipped power option is internally fused. An internal line to line filter capacitor and MOV are provided for added transient suppression. 110 VAC Power: 85 to 127 Vrms, 50/60 Hz 220 VAC Power: 170 to 276 Vrms, 50/60 Hz DC Power: 12 VDC (10 to 14 VDC) 24 VDC (14 to 28 VDC) Power Consumption: AC: 11.0 VA (11W) DC: 300 ma max. Flow Inputs: Pulse Inputs: Number of Flow Inputs: 2 Input Impedance: 10 KΩ nominal Pullup Resistance: 10 KΩ to 5 VDC (menu selectable) Pull Down Resistance: 10 KΩ to common Trigger Level: (menu selectable) High Level Input Logic On: 3 to 30 VDC Logic Off: 0 to 1 VDC Low Level Input (mag pickup) Sensitivity: 10 mv or 100 mv Minimum Count Speed: Menu selectable: 1-99 seconds Maximum Count Speed: Menu Selectable: Overvoltage Protection: 50 VDC 40Hz, 3000Hz or 20 khz Control Inputs Switch Inputs are menu selectable for Reset, Lock, Inhibit, Alarm Acknowledge, Print, or Not Used. Control Input Specifications Number of Control Inputs: 3 Input Scan Rate: 10 scans per second Logic 1: 4-30 VDC Logic 0: VDC Input Impedance: 100 KΩ Control Activation: Positive Edge or Pos. Level based on product definition for switch usage. Relay Outputs The relay outputs are menu assignable to (Individually for each relay) Low Rate Alarm (sum of rate or sum of total), Hi Rate Alarm (sum of rate or sum of total), Temperature, Density or General purpose warning (security). Number of relays: 2 (4 optional) Contact Style: Form C contacts Contact Ratings: 5 amp, 240 VAC or 30 VDC Capabilities: Alarm Delay, Setpoint, Hysteresis, Duration 2 Auxiliary / Compensation Inputs The auxiliary/compensation inputs are menu selectable for meter 1 temperature, meter 2 temperature or not used. These inputs are used for the compensated inputs when performing compensated flow calculations. They can also be used as a general purpose input for display and alarming. Number of inputs: 2 Operation: Ratiometric Accuracy: 0.02% FS at 20 C Basic Measurement Resolution: 16 bit Update Rate: 1 update/sec minimum Automatic Fault detection: Signal Over-range/under-range Current Loop Broken Fault mode to user defined default settings Fault Protection: Reverse Polarity: No ill effects Over-Voltage Limit (Voltage Input): 50 VDC Available Input Ranges Current (Two): 4-20 ma, 0-20 ma RTD: (One) 100 Ohm DIN RTD Standard Three Wire Thermistor (One) - Consult Factory Isolated Analog Output The analog output is menu assignable to correspond to the Sum Rate/Total, Temperature, Density. Type: Isolated Current Sourcing Available Ranges: 4-20 ma, 0-20 ma Resolution: 12 bit Accuracy: 0.05% FS at 20 C Update Rate: 1 update/sec minimum Temperature Drift: Less than 200 ppm/c Maximum Load: 1000 ohms (at nominal line voltage) Compliance Effect: Less than.05% Span 60 Hz rejection: 40 db minimum Calibration: Operator assisted Learn Mode Averaging: User entry of damping constant to cause a smooth control action Isolated Pulse output The isolated pulse output is menu assignable to Sum Total. Pulse Output Form: Photo MOS Relay Maximum On Current: 100 ma Maximum Off Voltage: 30 VDC Saturation Voltage: 1.0 VDC Maximum Off Current: 0.1 ma Pulse Duration: 10 msec or 100 msec (user selectable) Pulse output buffer: 256 Fault Protection Reverse polarity: Shunt Diode Serial Communication The serial port can be used for printing, data recording, and/or communication with a computer. RS-232: Device ID: Baud Rates: 300, 600, 1200, 2400, 4800, 9600, Parity: None, Odd, Even Handshaking: None, Software, Hardware Print Setup: Configurable print list and formatting RS-485: (optional 2nd COM port) Device ID: Baud Rates: 2400, 4800, 9600, Parity: None, Odd, Even Protocol: Modbus RTU (Half Duplex) Setup CD Capabilities Capabilities include: View Live Results Configure unit, Upload and Download to unit, Load and Save to file, Print Setup, Data Logging Capabilities Capabilities: Permits unit to automatically gather data during use. Data Log List: User selectable: includes Meter1/Meter2 Temperatures, Meter 1/Meter 2 Density, Meter 1/Meter 2 Viscosity, Meter 1, Meter 2 and Sum Ratemeters/Totalizers, Grand Totalizer, Time and Date, Fluid, Setpoint 1 & 2, Frequency 1 & 2, K-Factor 1 & 2. Data Log Event Trigger: selectable: includes interval, time of day, front key, external contact Data Log Format: selectable: Printer format, Database CSV format Data Transmission: Selectable: Output may be transmitted immediately or held in data log for later polling Remote Request Capabilities include: Send data log, clear data log External Modem Support Capabilities: Compatibility: Hayes Compatible Polling Capabilities: Answers incoming calls, responds to requests for information of action Call Out Capabilities: Can initiate call on user selectable event condition, or upon error Error Handling: Supports multiple retry, automatic disconnect upon loss of line or remote inactivity 3 Operating Mode The can be thought of as making a series of measurements of the Flow1 and Flow2 flow and temperature sensors and then performing calculations to arrive at a result(s) which is then updated periodically on the display. The analog output, the pulse output, and the alarm relays are also updated. The cycle then repeats itself. Step 1: Update the measurements of input signals- Raw Input Measurements are made at each input using equations based on input signal type selected. The system notes the out of range input signal as an alarm condition. The unit alternates between Flow1 and Flow2 measurements. Step 2: Compute the Flowing Fluid Parameters- The temperature, viscosity, and density equations are computed as needed based on the flow equation and input usage selected by the user. Step 3 : Compute the Volumetric Flow- Uncompensated flow is the term given to the flow in volume units. The value is computed based on the flowmeter input type selected and augmented by any performance enhancing linearization that has been specified by the user. Step 4: Compute the Corrected Volume Flow at Reference Conditions- In the case of a corrected volume flow calculation, the Flow1, Flow2 and Sum corrected volume flows are computed as required by the selected compensation equation. Step 5 : Compute the Mass Flow- All required information is now available to compute the Flow1, Flow2 and Sum mass flow rates as volume flow times reference density. Step 6: Check Flow Alarms- The flow alarm functions have been assigned to either the Sum flow rate or temperatures during the setup of the instrument. A comparison is now made by comparing the current flow rates against the specified hi and low limits. Step 7: Compute the Analog Output- This Sum flow rate or Sum total value is now used to compute the analog output. Step 8: Compute the individual Flow Totals by Summation- A flow total increment is computed for each totalizer. The totalizer format also includes provisions for total rollover. Setup Mode The setup mode is password protected by means of numeric operator and supervisor lock out codes established by the user. In addition, a secret, manufacturers numeric unlock entry sequence is available. A jumper on Control Input 3 can also prevent access. The system also provides a minimum implementation of an audit trail which tracks significant setup changes to the unit. This feature is increasingly being found of benefit to users or simply required by Weights and Measurement Officials in systems used in commerce, trade, or custody transfer applications. A software program is also available which runs on a PC using a RS-232 Serial for connection to the. Illustrative examples may be downloaded in this manner. The setup mode has numerous subgrouping of parameters needed for flow calculations. There is a well conceived hierarchy to the setup parameter list. Selections made at the beginning of the setup affect offerings further down in the lists. In the setup mode, the flow computer activates the correct setup variables based on the instrument configuration, the flow equation, and the hardware selections made for the compensation transmitter type, the flow transmitter type, and meter enhancements (linearization) options selected. All required setup parameters are enabled. All setup parameters not required are suppressed. A help line prompt is provided for each entry. In addition a help message is available which may be accessed by depressing the HELP key. Also note that in the setup mode are parameter selections which have preassigned industry standard values. The unit will assume these values unless they are modified by the user. Most of the process input variables have available a default or emergency value which must be entered. These are the values that the unit assumes when a malfunction is determined to have occurred on the corresponding input. It is possible to enter in a nominal constant value for temperature or density by placing the desired nominal value into both the lo and hi values. This is also a convenience when performing bench top tests without simulators. Step 9: Total Preset Comparisons- The Sum total associated with a preset function is then compared against the corresponding preset value and any required control actions taken. Step 10: Pulse Output Service- The pulse output is next updated by scaling the Sum total increment which has just been determined by the pulse output scaler and summing it to any residual pulse output amount. Step 11: Update Display and Printer Output- The instrument finally runs a task to update the various table entries associated with the front panel display and serial outputs. 4 Maintenance (Test) Mode: The Maintenance Mode of the 923-ST1SUM-FC is the Test and Calibration Mode for the device. This mode provides a number of specialized utilities required for factory calibration, instrument checkout on start-up, and periodic calibration documentation. A supervisor password is required to gain access to this specialized mode of operation. Normally quality, calibration, and maintenance personnel will find this mode of operation very useful. It is also useful for factory testing. Many of these tests may be used during start-up of a new system. Inputs signals may be read, and output signals may be exercised to verify the electrical interconnects before the entire system is put on line. The following action items may be performed in the Maintenance Mode: Print Calibra
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