Operating Instructions

Transcription

1 Operating Instructions METTLER TOLEDO FlowPac-M MAX I D 7 Date 8 Time 9 Reset +5% MIN Co de 4 Prt % 5 6 Clear -5% 0 Mo de Preset Tol % 2 3 Print STOP M-TARE ++ /- 0 FILL. - ENTER

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3 Contents. Preparation 2. Display and controls 3. Input ranges and default settings 4. Operating modes 5. FlowPac operation 6. Interfaces 7. Error messages 8. What if...? 9. Appendix. The METTLER TOLEDO FlowPac.2 Attaching the keypad and instruments to the scale.3 Inserting the program cassette.4 Configuration register with FlowPac 2. Display 2.2 Keypad 4. Selecting the operating mode 5. Installation 5.2 Closed-loop control 5.3 Measurement 6. General information 6.2 Interface for pumps, valves and alarm devices 6.3 Interface for a printer or computer 9. Measurement accuracy 9.2 Control accuracy 9.3 Record 9.4 METTLER TOLEDO accessories 9.5 Selecting the pump Page

4 2. Preparation. The METTLER TOLEDO FlowPac The METTLER TOLEDO FlowPac has been specially developed for use in the lab. It comprises a keypad and a plug-in program cassette. When attached to a METTLER TOLEDO scale employing the M-technology, the FlowPac can control or measure mass flow rates. Closed-loop control: - Mass flow control by pumps with frequency or analog signal control. - Mass flow control with an electromagnetic valve for gases and liquids. - Continuous computer-controlled mass mixing. Measurement: - Measurement and recording of mass flows for the calibration or certification of pumps, valves or measuring instruments. - Determination of filter efficiencies..2 Attaching the keypad and instruments to the scale DATA I/O GM V: T 63 ma 0-20 V: T 25 ma The two connection sockets at the rear of the scale are intended for the following instruments: Socket DATA I/O : Instruments with RS232C or CL interface, e.g. GA44 Printer. Socket GM : FlowPac keypad and GM instruments with adapter plug, e.g. GM54 Process Interface. The coding pins at the sockets prevent improper insertion of the connection cables.

5 .3 Inserting the program cassette Insertion of the program cassette is described in the operating instructions of the scale used. Note: Please keep the standard program cassette in a safe place. It will be needed again when the scale is operated without the FlowPac..4 Configuration register with FlowPac The FlowPac can be matched to features specific to the application. In the Unit sector of the configuration register (see operating instructions of the scale, Configuration section), the following can be selected notwithstanding the standard software of the scale: Language: -E -Yes- English (default setting) -F -Oui- French -d -Ja- German Date: EU-date Day, month, year (default setting) US-date Month, day, year Record: AU-Prot Automatic printout (default setting) SEL-Prot Printout only with Print key. Notes: If the configuration register can not be selected, the jumper of the program cassette must be set to the unsecured position (see operating instructions of the scale, Configuration section). Language and date are not reset when the Reset key is pressed. 3

6 4 2. Display and controls 2. Display When used with the FlowPac, the scale operates with three display ranges: () Status display (2) Value display (3) METTLER DeltaTrac Status display This display indicates the current operational status. The following displays are possible: _ Minimum fill level reached = Refilling Siphoning off (maximum fill level reached) h Manual refill key pressed Normal operation (no status display) - Tolerance limit Set value + Tolerance limit Fine display Coarse display Value display In this display the following values are shown in the different operating phases: Normal operation display of the actual value of the mass flow rate in g/h. Refill phase display of the net weight. Entry mode display of the keyed-in entry. METTLER DeltaTrac The METTLER DeltaTrac shows the deviation of the actual value from the set value. The tolerance limits are also displayed. The DeltaTrac has a coarse and a fine display. Interpretation of the indicator position: - Fine display at 2 o clock : Actual value = set value - Fine display on : Lower tolerance limit reached (alarm) - Fine display on : Upper tolerance limit reached (alarm)

7 2.2 Keypad MAX +5% MIN -5% 0 ID Date Time Code Prt % Mode Preset Tol % 2 3 Reset Clear Print The keypad is used to enter all parameters needed for operation. Several data can be stored in a fail-safe manner with the storage key (key symbol) (see section 3, Input ranges and default settings ). STOP M-Tare ++/-- 0 Fill. - ENTER Key functions Reset Clear Print ENTER Time 9 Reset key Clears all entries and resets the FlowPac to the default settings. Default settings, see section 3, Input ranges and default settings. Clear key Clears the last keystroke. On repeated pressing, the entire entry can be cancelled. Print key Printout of the current weight or the current parameters and a set of measured values. Enter key Each numeric entry must be closed with Enter. Time key Entry of the current time. Entry of the number 9. 5

8 6 Date 8 Date key Entry of the current date. Entry of the number 8. ID 7 Identification key Entry of a 7-digit identification number. Entry of the number 7. % 6 Start manipulated variable key Entry of the anticipated initial delivery rate of the pump in percent at start of delivery. The initial delivery rate can be ascertained automatically by pressing the Preset key. Entry of the number 6. Prt 5 Record timer key Entry of the time interval in minutes at which records should be printed out. If 0 is entered, no record is printed out. Entry of the number 5. Code 4 Tol % 3 Preset 2 Code key Entry of a 7-digit code number that should be printed out, but not stored. Entry of the number 4. Tolerance key Entry of the admissible tolerance of the set value in percent for the alarm function. Entry of the number 3. Preset key Determination of the pump delivery rate. Entry of the number 2.

9 Mode Mode key Entry of the characteristic number for selection of the operating mode (see section 4, Operating modes ). Entry of the number. Set value key Entry of the set value in grams or grams per hour (depending on the operating mode selected). Timer key Entry of operating time in minutes in the Control operating mode. The entry of 0 results in continuous operation. In the operating mode Measurement, the interval is entered in seconds. ++/-- 0 MAX MIN Fill. Flow direction key Entry of the flow direction. After this key has been pressed, the flow direction can be selected by entry of the following numbers. 0 = delivery to scale = transport from scale. Entry of the number 0. Maximum fill limit key Entry of the maximum net content at which the refilling operation should be stopped or the siphoning-off operation started. Refill limit key Entry of the minimum net content at which the refilling operation should be started or the siphoningoff operation stopped. Refilling operation start/stop key (manual refilling) Manual start or stop of the refilling operation. 7

10 8 0 M-Tare - Tare key Taring of the empty container on the scale. Manual tare key Numeric entry of a known tare value (when vessels full). Storage key Stores the entries in a fail-safe manner. Possible only with certain keys (shown in section 3, Input ranges and default settings, page 9). Start key Starts the FlowPac operation. STOP Stop key Stops the operation. Controller keys Controller on Manual switching on of the controller (closing of the control loop). +5% -5% Controller off Manual switching off of the controller. After execution of this function, operation is continued with the manipulated variable last used (opening of the control loop). Manual control of the final control element. Possible only when controller switched off. Increases the mass flow by 5%. Decreases the mass flow by 5%.

11 3. Input ranges and default settings The following values can be entered using the keypad: Key Storage Input range Unit Default setting Time Date EU: DD.MM.YY US: MM.DD.YY Identification (including point) 0 Code (including point) 0 Record timer X [min] 0 Start manipulated variable X 0-0 [%] 50 Mode X (see section 5) Tolerance X - [%] Max. fill limit X Entire weighing range [g] 0 Refill limit X Entire weighing range [g] 0 Manual tare X Entire weighing range [g] 0 Timer X [min] [s] 0 Set value X [g/h] [g] 0 Flow direction X 0 or 0 - The entries marked with X can be stored in a fail-safe manner. 9

12 4. Operating modes Mode The FlowPac distinguishes four different operating modes. Three operating modes are used for the open-loop control and one for the measurement of mass flow rates. After the operating mode has been selected, information regarding the nature of the pump interface, the alarm type and the type of refilling must also be entered. 4. Selecting the operating mode A B C D To select the operating mode, an operating code is used. It is entered in the form of a 4-digit number using the keypad. The required operating code should be compiled from the criteria listed in the following tables and then entered via the keypad. A Refill type Alarm type Interface type Operating mode Operating mode Control Function Mass flow delivery x [g/h] over y [min] Display Delivered mass in [g] divided by the time since delivery start Entries Set value [g/h] Duration [min] 2 Control 2 Mass flow delivery x [g/h] over y [min] Mean value of mass flow over the last 30 seconds Set value [g/h] Duration [min] 3 Control 3 Mass flow delivery x [g] over y [min] Delivered mass in [g] divided by the time since delivery start End value [g] Duration [min] 4 Measurement Mass flow measurement Mean value of mass flow over the last measurement interval Measurement interval [s] Record interval [min]

13 Example: You wish to deliver 200 g of a liquid over a 20-minute period (under A). A pump with analog signal control has been selected as the final control element (under B). For safety reasons the delivery should be discontinued if the alarm is triggered (under C). Automatic refilling is not required (under D). Operating code to be set: 342 B Interface type (pumps) Frequency controlled, max [storkes/h] Frequency controlled, max [storkes/h] Pulse width controlled Analog signal controlled GA37 A B C D C Alarm type No refilling Shut down after alarm Pump with analog signal control Delivery x [g] over y [min] 2 D Continue dispensing after alarm Shut down after alarm 2 Refill type Manual refilling Automatic refilling

14 2 5. FlowPac operation 5. Installation Prepare the scale for operation (see sections.2 through.4). Complete mechanical installation and set up instrument data and power connections (see GM54 operating instructions and operating instructions of the components of other manufacturers). Switch on scale and initialize with -Reset- (scale menu). For an external emergency shutdown, attach the METTLER TOLEDO transfer cable. Notes: The following sections Closed-loop control and Measurement should be viewed as examples and not as instructions. The entry of data and the described procedure can be designed to match your specific needs. If certain data are not entered, the Pac assumes the default settings (see section 3, Input ranges and default settings ). If the GA44 Printer or a scale employing the SM-technology is used in the FlowPac system, the Print keys of these instruments have an emergency OFF function. Owing to the absence of an RS232C interface, the METTLER TOLEDO GA44 Printer can not be used with the GA37. In such a case, we advise using a commercially available printer with an RS232C interface (e.g. Epson FX800).

15 Supply Refilling RS232C or CL Valve Record printer Regulated mass flow Pump GM bus GM bus Entry GM54 Alarm 5.2 Closed-loop control If the FlowPac is used to control mass flows, the system can be set up as follows: Place empty container or vessel on the weighing platform. Enter the following data using the keypad: - Time xxxxxx <Enter> Enter time - Date xxxxxx <Enter> Enter date - ID xxxxxx <Enter> Enter identification number - Code xxxxxx <Enter> Enter code number - Prt x <Enter> Enter record interval [min] - Valve % 50 <Enter> - Mode xxxx <Enter> Select operating mode (see section 4.) - Tol % xx <Enter> Enter tolerance limits - Max xxx <Enter> Enter upper limit - Min xxx <Enter> Enter lower fill limit - 0 Tare - M-Tare 0 <Enter> Enter manual tare if need be - Timer xxx <Enter> Enter duration of operation with timer key [min] Store entries in a fail-safe manner with the storage key. Fill containers/vessels. Set up pump/metering devices and adjust. Enter desired set value in grams per hour and store in a fail-safe manner. Check that delivery tubing is free from bubbles and then press the Preset key. Press the Start key. Notes: To obtain good results, the pump delivery rate during operation should be at least 5% of the max. pump capacity (including allowance for any loss of accuracy). In operation with analog-controlled pumps, the GA37 D/A Converter is attached to the RS232C interface. The converter is connected between the scale and the printer. For correct operation, it is essential to enter the data shown in boldface. 3

16 4 5.3 Measurement RS232C or CL Record printer Inflow Device under test Outflow GM bus Set value entry If the FlowPac is used for the measurement of mass flows, the system can be set up as follows: Place empty container or vessel on the weighing platform. Enter the following data using the keypad: - Time xxxxxx <Enter> Enter time - Date xxxxxx <Enter> Enter date - ID xxxxxx <Enter> Enter identification number - Code xxxxxx <Enter> Enter code number - Prt x <Enter> Enter record interval [min] - Mode 4xxx <Enter> Select operating mode (see section 4.) - Tol % xx <Enter> Enter tolerance limits - Max xxx <Enter> Enter upper limit - Min xxx <Enter> Enter lower fill limit - 0 Tare - M-Tare 0 <Enter> Enter manual tare if need be - Timer xx <Enter> Enter measurement interval with timer key [min] Store entries in a fail-safe manner with the backup key. Fill container/vessel and press the Start key. Note: For correct operation, it is essential to enter the data shown in boldface.

17 6. Interfaces DATA I/O GM Scale V: T 63 ma 0-20 V: T 25 ma 6. General information The system includes an RS232C or CL interface at the scale for the attachment of a printer or a computer. A GM interface is also available for the attachment of the FlowPac keypad and GM units from METTLER TOLEDO. 6.2 Interface for pumps, valves and alarm devices For the attachment of pumps or valves to the FlowPac, the GM54 Process Interface is used. Pumps with the following types of control can be attached: GM 54 0 Pump / Valve Refilling 3 Alarm 4 Consumption measurement active 5 Control loop passive 6 Control loop active Contact number of GM54 METTLER GA37 GM54 GA37 frequency-controlled pumps, the delivery rate depends on the number of pulses; electromagnetic valves with control of the opening time, the delivery rate depends on the pulse duration; current- or voltage-controlled pumps, the delivery rate depends on the value of the analog signal (current or voltage). If analog controlled pumps are used, the GA37 D/A Converter must also be installed. In the control of pumps and valves, the limit data shown below must be observed. At relatively high load, a commercial switching amplifier must be installed between the GM54 and the pump/valve. Pumps with control of the frequency or opening time Maximum contact voltage (open contact) 36 V (< ma) DC Maximum contact current (closed contact) 0 ma (<.8 V) DC Pumps with control of current/voltage Control current: 0-20 ma or 4-20 ma Control voltage: - V to + V or 0... V Note: The GA37 receives the manipulated variables from the RS232C interface of the scale. 5

18 6 Write commands Read commands 6.3 Interface for a printer or computer The scale with FlowPac has a bidirectional RS232C/CL (20 ma) data interface that can be used to control the FlowPac. All entries that are possible via the keypad can also be performed via the interface. In such a case, the FlowPac keypad can be removed. Commands can be issued to the FlowPac and operating parameters transferred or read. Correct functioning requires adherence to the command formats described in the following sections: Notes: For successful communication between computer and scale, the following transmission parameters of the interfaces must match: - Transmission rate (baud rate) - Parity - Handshake (type and cable wiring) The data formats, data types and ranges of values can be found in section 3, Input ranges and default settings.

19 6.3. Writing to the FlowPac When commands are issued to the FlowPac or operating parameters have to be set, the following command formats must be observed: Definition: X An ASCII character _ Space Operating parameter Several ASCII characters Issuing commands A W 0 C R L F A W C R L F A W 2 C R L F A W 3 C R L F A W 4 C R L F A R F W 8 C L A R F W 2 0 C L A R F W 2 C L A R F W 2 2 C L A R F W 2 3 C L A R F W 2 4 C L Start Stop Switch off control (open control loop) Switch on control (close control loop) Fill (GM54 refill contact closes) Set zero load (2) Store in fail-safe manner Increase manipulated variable by 5% Decrease manipulated variable by 5% Print (read measured value set) Execute Preset function (learning) 7

20 8 Setting operating parameters W 5 _ Identification No. C L A R F W 6 _ Date C L A R F W 7 _ Time C L A R F W 8 _ Code No. C L A R F _ A W 9 Tolerance _ % C R L F _ Set value A W 0 _ g C R L F W _ Duration C L A R F W 2 _ Interval C L A R F _ Start value A W 3 _ % C R L F W 4 _ Operating code C L A R F W 5 _ Flow direction C L A R F _ Max. refill limit A W 6 _ g C R L F _ Min. refill limit A W 7 _ g C R L F W 9 _ Numeric tare C L A R F Set identification number Set date Set time Set code number Set tolerance band (alarm) Set set value Set operating time. In the operating mode Control, the entry is in minutes, in the operating mode Measurement in seconds. Set record timer Set initial set value of the pump Set 4-digit operating code Select flow direction (0 = deliver to scale, = transport from scale) Set upper refill limit Set lower refill limit Set numeric value of tare (M-tare)

21 6.3.2 Reading from FlowPac If data are requested from the FlowPac, it has to be sent a read string. The formats of the read strings and their meaning are shown in the following list: Read strings A R 5 C R L F A R 6 C R L F A R 7 C R L F A R 9 C R L F A R 0 C R L F A R C R L F A R 2 C R L F A R 3 C R L F A R 4 C R L F A R 5 C R L F A R 6 C R L F A R 7 C R L F A R 9 C R L F A R 2 6 C R L F Request identification number Request date Request time Request tolerance limits Request set value Request operating time (timer) Request record timer Request initial set value of the pump Request operating code Request flow direction Request upper fill limit Request lower fill limit Request numeric tare Request status condition of GM54 switches 9

22 Response formats The FlowPac responds to received commands or read strings with a response string. The following response formats are possible: A B C R L F Issued command has been understood and executed by the FlowPac. A B C R L F Designation _ Value C R L F - Inputted operating parameter has been set. The designation of the parameter and the set value are also outputted as an acknowledgement. - Operating parameter has been requested. The designation of the parameter and the set value are outputted. The designation corresponds to the text of the printer record. E L C R L F Error message of Pac. The issued command or read string has not been understood by the FlowPac.

23 7. Error messages The FlowPac can recognize operating errors in entries via the keypad and displays these with the following messages: Error message Meaning Err 0 Inputted number too large/overflow error Err Timeout in entry mode Err 3 Input values outside the admissible value range Err 4 Unsuitable operating point of the pump (x < 5% or x > 90%) Err 5 Input error date, time Err 6 Set value exceeds delivery capacity of pump 2

24 22 8. What if...? Error Pump stops unexpectedly Refill function does not work Computer transfer faulty Printer inoperative/faulty FlowPac controls/measures inaccurately Inputted values are lost Possible cause Automatic shutdown owing to alarm Operating time has run out Refill limit not set Wiring fault in vicinity of valve Switching amplifier input polarized wrongly Transmission parameters set wrongly Interface wired wrongly (handshake lines block transmission) Software defective Transfer cycle set wrongly Connection cable faulty Interface parameters set wrongly (parity, rate, handshake) Insufficient resolution of scale Unsuitable operating point of pump Air bubbles or dirt in suction tubing Insufficient stability of scale support Pump tubing touching vessel on scale Power outage Rectification Rectify cause of alarm or change operating mode Enter correct operating time Enter refill limit Check wiring and correct if need be Interchange connection leads (polarization) Match transmission parameters Check interface connection and correct if need be Consult specialists Set transfer cycle to second Check cable and replace if need be Match interface parameters Change scale type Select proper operating point Clean tubing or remove bubbles Select different support Rearrange tubing Store values in fail-safe manner. The time, date, ID and Preset function data are always cleared on power outage.

25 9. Appendix 9. Measurement accuracy The measurement accuracy of the system can be calculated from the following formula: Scale resolution [g] x Measurement accuracy [%] = Measurement interval [s] x mass flow rate [g/h] The below table contains several calculated standard values of the measurement accuracy with reference to the scale used. Measurement accuracy [%] Mass flow rate [g/h] Measurement interval [s] Scale type Max. mass flow rate 0,04 0, AM0 max. 0 g resolution 0. mg 200 g/h 0,04 0, PM400 max. 400 g resolution mg 00 g/h 23

26 24 Measurement accuracy [%] Mass flow rate [g/h] Measurement interval [s] Scale type Max. mass flow rate 0,04 0, PM4000 max g resolution mg kg/h 0,04 0, PM/SM6000 max g resolution 0. g 0 kg/h 0,04 0, PM30 max g resolution g 00 kg/h All scale types employing the METTLER TOLEDO M-technology can be used.

27 9.2 Control accuracy The control accuracy depends on the following factors: Resolution of the scale True running characteristics with peristaltic pumps Stroke frequency with diaphragm and piston pumps Inherent stability of the pump Operating point of the pump The following table contains several suggestions for selection of a suitable scale type in regard to the desired mass flow rate and the control accuracy. Desired controlled mass flow rate [g/h] (set value) Resolution of the scale Scale type (suggestion) Accuracy (observation period = 30 s) Accuracy (observation period = 20 s) 5 g/h up to 50 g/h 50 g/h up to 500 g/h 500 g/h up to 5000 g/h 5000 g/h up to g/h 0. mg.0 mg.0 mg / 0.0 g 0.0 mg / 0. g AM 0 PM 200 PM 4000 PM 6 better than 0.5% better than 0.5% better than 0.5% better than 0.5% better than 0.% better than 0.% better than 0.% better than 0.% 25

28 Record The FlowPac allows attachment of a printer to record the operational sequence. Interpretation of the record printouts is shown below: Record printout Meaning set-pt Set value of mass flow rate timer Duration of the mass transport rec.int Printer time interval st.pump Manipulated variable of pump ID Identification number hilevel Maximum fill level lolevel Minimum fill level preload Preload tare Manual tare code Code op.mode Operating mode ++/- - Flow direction tol Tolerance band pump Current pump capacity in % flow l Mass flow (long-term flow) flow c Mass flow (short-term flow over 30 seconds) net Net weight on the scale fill on Refill function active fill off Refill function passive open loop Control switched on closed loop Control switched off

29 9.4 METTLER TOLEDO accessories The following components are available as accessories to match the FlowPac to special requirements: Designation Order No. GM49 Secondary Display GA44 Printer GM54 Process Interface GA37 D/A Converter (after March 990) CL249 CL/RS Converter CL250 CL/RS Converter with handshake CL24 CL/IEEE 488 Converter CL3 Multiplexer Solderable I/O MiniMETTLER connector Cable (IBM PC, 9-pin) 2493 Cable (IBM PC, 25-pin) 249 Extension cable for GM54,.5 m Extension cable for keypad,.5 m Transfer cable (emergency shutdown)

30 Selecting the pump The pump should be selected on the basis of the following criteria: Set value of the mass flow to be delivered The maximum capacity of the pump should be approx. double the set value. Nature of the material to be delivered - solid, liquid, gas. Chemical compatibility Type of metering - pulsed, continuous. Special features of the material to be delivered - fire hazard, explosion hazard, polymerizing, contaminated, viscous/mobile. To match the pump to your special needs, consult the appropriate pump manufacturer. Recommended pump and valve manufacturers Pulsed delivery Continuous delivery Valves (liquid, gas) - Prominent - Lewa - Masterflex - Watson Marlow - Ismatec - Verder - Wangen - Alldos - Galtek

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32 To protect your METTLER TOLEDO product s future: METTLER TOLEDO Service assures the quality, measuring accuracy and preservation of value of all METTLER TOLEDO products for years to come. Please send for full details about our attractive terms of service. Thank you. *P70442* Subject to technical changes and to the availability of the accessories supplied with the instruments. Mettler-Toledo GmbH Printed in Switzerland 9909/2.2 Mettler-Toledo GmbH, Laboratory & Weighing Technologies, CH-8606 Greifensee, Switzerland Phone , Fax , Internet: