Pulse Input or Analog Input Batch Controller

Automatic batch control for repetitive liquid fill operations

Batch controller by TD Micronic

Features

  • Provides automatic control for repetitive liquid fill operations
  • Available for turbine flow meter pulse signals from 0 Hz to 1 MHz or analog flow meter signals (4-20 mA, 0-1 mA or 0-10V)
  • 6-digit scalable display to ±999,999 for batch total, grand total, number of batches, or flow rate
  • Counts up from 0 to preset or down from preset to 0
  • Two or four control relays for with settable delay between cycles
  • Universal 85-264 Vac / 90-300 Vdc or 10-48 Vdc / 12-32 Vac power
  • Transducer excitation output (isolated)
  • Wide choice of options:
    - 2 or 4 relays, mechanical or solid state (isolated)
    - 1 or 2 analog outputs (isolated)
    - Serial data I/O: Ethernet, USB, RS485, RS232 (isolated)
Description
Input Batch Controller

The batch controller is a low cost, powerful and highly accurate batching controller for repetitive fill operations. It can use the FR dual channel pulse input signal conditioner for use with turbine flow meters, or the V-to-F analog signal conditioner for use with 4-20 mA, 0-1 mA or 0-10V conditioned flow meter signals. Relay control can be provided by two or four 8A contact relays, or by two or four 120 mA AC/DC solid state relays. Fill operations are repeated continually with a programmable delay from 10 ms to 199.99 sec, or based on an external control input.

Three items are tracked by the batch control software. These can each be scaled to engineering units of total or flow rate and displayed by the controller's six-digit LED display: Item #1 is the current batch total, which can be set up to count up from zero to a preset limit, or down from a preset limit to zero. Item #2 can be assigned to grand total or number of batches. Item #3 is the flow rate.

Two or four relays can be used. Relay #1 is assigned to batch total to control the filling operation. Relays #2, #3 and #4 can each be assigned by the user to Items #1, #2 or #3. For example, Relay #2 can be assigned to Item #1 (batch total) with a lower setpoint to serve as a pre-warn and slow down the fill rate near the batch setpoint, and Relay #3 can be assigned to the total number of batches to terminate the batching when a present number of bottles have been filled.

An optional serial communications board allows the batch controller to transmit Items #1, #2 and #3, as well as peak for item #3 (rate). If required, all four items can be displayed simultaneously by augmenting the batch controller with up to three remote displays. Each of these can have its own analog output and relays for alarm or control.

Batch Control with Turbine Flowmeters

pulse input batch controller The pulse-input batch controller utilizes the FR dual channel signal conditioner, which accepts pulses from turbine flow meters and most industrial transducers with a pulse output such as proximity switches with PNP or NPN output, TTL or CMOS logic, or magnetic pickup pulses down to 12 mV. The same signal is applied in parallel to the A and B input channels, which are used independently. Either channel can accept pulse rates from 0.005 Hz to 250 kHz, which exceeds the working range of turbine flow meters.

  • Channel A is used for totalizing. The measured total is scaled mathematically for control and display of volume in engineering units, such as liters.
  • Channel B is used for rate. The pulse frequency is determined by timing an integral number of periods over a specified gate time (plus 30 ms and 0-2 periods), and then taking the inverse of period. The inverse period approach allows much greater accuracy and faster update times than conventional rate meters which count signal pulses over a specified time interval. Update times can be as high as 25/sec. Rate in engineering units, such as liters per second, is obtained by multiplying the input by a scale factor.

Batch Control with Conditioned Flow Signals

DC Ammeter fully ScalableThe analog input batch controller utilizes the VF voltage-to-frequency converter signal conditioner board, which converts 4-20 mA, 0-1 mA or 0-1V conditioned flow meter signals to a frequency from 10 kHz to 110 kHz. This allows the counter controller to totalize flow, to count up to a preset value, or to count down to zero from a preset value for batch control. One of the relays is dedicated to On/Off batch control, while the other relay is available to slow down rate near the setpoint or to provide another alarm or control function based on rate or total.

Designed for System Use

Available plug-in boards in addition to relays include Ethernet and other serial communication board and single or dual isolated analog output boards. s may be powered from 85-264 Vac or optionally from 12-32 Vac or 10-48 Vdc. The display is available with red or green LEDs. The 1/8 DIN case meets NEMA 4X (IP65) specifications from the front when panel mounted. Any setup functions and front panel keys can be locked out for simplified usage and security. A built-in isolated 5, 10, or 24 Vdc excitation supply can power sensors and eliminate the need for an external power supply. All power and signal connections are via UL / VDE / CSA rated screw clamp plugs.

Specifications
Display
Readout 6 LED digits, 7-segment, 14.2 mm (.56"), red or green
Display Range -999999 to +999999, XXXXEX scientific notation beyond 999999
Zero Adjust -999999 to +999999
Span Adjust 0 to 999999
Indicators Four LED lamps
Pulse Inputs (FR signal conditioner)
Signal Types AC, pulses from NPN, PNP transistors, contact closures,magnetic pickups.
Ch A Frequency, Max 1 MHz
Ch B Frequency, Max 250 kHz
Signal Ground Common ground for channels A & B
Minimum Signal Nine ranges from (-12 to +12 mV) to (+1.25 to +2.1V)
Maximum Signal 250 Vac
Maximum Frequency 1 MHz, 30 kHz, 250 Hz (selectable)
Conversion Technique Inverse period
Delay between batches Selectable 10 ms to 199.99 s
Analog Input (V-to-F signal conditioner)
Signal Types 0-1 mA, 4-20 mA, 0-10V
Conversion Technique Inverse period applied to 10 kHz- 110 kHz
Update Rate 50 ms (max)
Gate Time Selectable 10 ms to 199.99 s
Power
Voltage, standard 85-264 Vac or 90-300 Vdc
Voltage, optional 12-32 Vac or 10-48 Vdc
Frequency DC or 47-63 Hz
Power consumption 1.2W @ 120 Vac, 1.5W @ 240 Vac, 1.3W @ 10 Vdc, 1.4W @ 20 Vdc,
   (typical, base meter) 1.55W @ 30 Vdc, 1.8W @ 40 Vdc, 2.15W @ 48 Vdc
Power Isolation 250V rms working, 2.3 kV rms per 1 min test
Excitation Output (standard)
5 Vdc 5 Vdc ± 5%, 100 mA
10 Vdc 10 Vdc ± 5%, 120 mA
24 Vdc 24 Vdc ± 5%, 50 mA
Output Isolation 50 Vdc to meter ground
Analog Output (optional)
Output Levels 4-20 mA, 0-20 mA, 0-10V, -10 to +10V (single-output option)
Current compliance 4-20 mA, 0-20 mA, 0-10V (dual-output option)
Voltage compliance 2 mA at 10V ( > 5 kΩ load)
Scaling 12V at 20 mA ( < 600 Ω load)
Resolution Zero and full scale adjustable from -99999 to +99999 16 bits (0.0015% of full scale)
Isolation 250V rms working, 2.3 kV rms per 1 min test (dual analog outputs share the same ground)
Relay Outputs (minimum of 2 relays required)
Relay Types 2 Form C contact relays or 4 Form A contact relays (NO), 2 or 4 Form A, AC/DC solid state relays (NO)
Current Ratings 8A at 250 Vac or 24 Vdc for contact relays, 120 mA at 140 Vac or 180 Vdc for solid state relays
Output common Isolated commons for dual relays or each pair of quad relays
Isolation 250V rms working, 2.3 kV rms per 1 min test
Serial Data I/O (optional)
Board Selections RS232, RS485 (dual RJ11 or RJ45 connectors), USB, Ethernet, USB-to-RS485 converter, Ethernet-to-RS485 converter
Protocols Modbus RTU, Modbus ASCII, Modbus TCP (Ethernet), TDM ASCII
Data Rates 300 to 19200 baud
Digital Addresses 247 (Modbus), 31 (TDM ASCII),
Isolation 250V rms working, 2.3 kV rms per 1 min test
Environmental
Operating Temperature 0°C to 55&geg;C
Storage Temperature -40&geg;C to 85&geg;C
Relative Humidity 95% at 40&geg;C, non-condensing
Protection NEMA-4X (IP-65) when panel mounted
Signal Connections
Signal connections to TDM pulse input batch controller
Applications
Drum Filling Application Utilizing Two Relay Outputs
Drum filling batch controller application utilizing two relay outputs In this drum filling application, the pulse-input batch controller utilizes uses its two relays to control a pump. The Prewarn relay slows down the pump near the preset to avoid overshoot. The Batch relay stops the pump at the preset.
Controlling Chemical Mixing of Materials
Controlling mixing of materials using two  batch controllers Multiple batch controllers can be used in combination to control the mixing of materials in the proper ratio. Each feed line is equipped with its own pump, flowmeter, and . Controller setup and monitoring of the mixing operation are facilitated by optional serial communications. RS485 allows a single data line to handle multiple controllers.
Up-Counting Batch Control
Up-counting batch controller using the  Batch Controller In up-counting batch control, the counts up from zero to a preset maximum. A prewarn level is available to slow down filling near the preset to avoid overshoot. A time delay can be programmed from the end of each batch to the start of the next batch.
Down-Counting Batch Control
Down-counting batch control using the  Batch Controller In down-counting batch control, the counts down from the preset maximum to zero. A prewarn level is available to slow down filling or emptying near zero. Again, a time delay can be programmed from the end of each batch to the start of the next batch.
Discrete Filling and Batch Counting
Discrete filling and batch counting using the  Batch Controller The batch controller is ideal for discrete manufacturing as well as repetitive fill operations. In this example, the counts bottles which it then groups into sixpacks. Its Grand Total capability can be used to track bottles or sixpacks.

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