Micron Meters- Batch Controller

Standard Features

Provides automatic control for repetitive liquid fill operations
Accepts turbine flow meter pulse signals from 0 Hz to 1 MHz
Accepts 4-20 mA, 0-1 mA or 0-10V analog flow meter signals
6-digit display scalable to ±999,999
Selectable display of batch total, grand total, number of batches, or flow rate
Counts up from 0 to preset or down from preset to 0
Dual 8A relays for control with settable delay between cycles
Isolated 5, 10 or 24 Vdc excitation supply
Universal AC power, 85-264 Vac
External controls for reset, meter hold and decimal points
NEMA 4X, 1/8 DIN case
Options:
Low voltage power: 10-48 Vdc or 12-30 Vac
Dual or Quad Form A solid state relays in lieu of contact relays
Analog output: Isolated, 4-20 mA, 0-20 mA, 0-10V, -10 to +10V
Serial communications: RS232, RS485, Modbus RS485, USB, USB-to-RS485 converter
Certified to UL 61010C-1 (UL mark), EN 61010-1 (CE mark), and RoHS

Description

The Micron batch controller is a low cost, powerful and highly accurate batching controller for repetitive fill operations. It can use the Micron FR dual channel pulse input signal conditioner for use with turbine flow meters, or the Micron V-to-F analog signal conditioner for use with 4-20 mA, 0-1 mA or 0-10V conditioned flowmeter signals. Relay control is provided by dual or quad 8A contact relays or dual or quad 130 mA AC/DC solid state relays.

The batch controller's built-in six digit LED display can show the current batch total (Item #1), grand total or number of batches (Item #2), and flow rate (Item #3). All displayed values are scaled to engineering units of volume or flow. The batch total (Item #1) can be set up to count up from zero to a preset limit, or down from a preset limit to zero.

Relay 1 of the dual relay board is used for batch total (Item #1). Relay 2 can be used for pre-warn to slow down filling near the setpoint, to grand total or number of batches (Item #2), or to flow rate (Item #3). Fill operations are repeated continually with a programmable delay from 10 ms to 199.99 sec, or based on an external control input.

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

pulse input batch controller Batch Control with Turbine Flowmeters

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.

DC Ammeter fully Scalable Batch Control with Conditioned Flow Signals

The analog input batch controller utilizes the Micron VF voltage-to-frequency converter signal conditioner to accept 4-20 mA, 0-1 mA or 0-1V conditioned flow meter signals, which it then converts to a frequency of 10 kHz to 110 kHz. This allows the controller to totalize flow, to count up to a preset value, or to count down to zero from a preset value for batch control. Again, 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.

Other Features

The 1/8 DIN case of Micron meters and counters meets NEMA 4X (IP-65) standards from the front for high pressure wash-down when panel mounted. All power and signal connections are via UL / VDE / CSA rated screw clamp plugs, which are standard.

BATCH CONTROLLER SPECIFICATIONS

Display
Readout Display Range Zero Adjust Span Adjust Indicators	6 LED digits, 7-segment, 14.2 mm (.56"), red or green -999999 to +999999, XXXXEX scientific notation beyond 999999 -999999 to +999999 0 to 999999 Four LED lamps
Pulse Inputs (FR signal conditioner)
Signal Types Ch A Frequency, Max Ch B Frequency, Max Signal Ground Minimum Signal Maximum Signal Maximum Frequency Conversion Technique Delay between batches	AC, pulses from NPN, PNP transistors, contact closures, magnetic pickups. 1 MHz 250 kHz Common ground for channels A & B Nine ranges from (-12 to +12 mV) to (+1.25 to +2.1V) 250 Vac 1 MHz, 30 kHz, 250 Hz (selectable) Inverse period Selectable 10 ms to 199.99 s
Analog Input (V-to-F signal conditioner)
Signal Types Conversion Technique Update Rate Gate Time	0-1 mA, 4-20 mA, 0-10V Inverse period applied to 10 kHz- 110 kHz 50 ms (max) Selectable 10 ms to 199.99 s
Power
Voltage, standard Voltage, optional Frequency Power Isolation	85-264 Vac or 90-300 Vdc (DC operation not UL approved) 12-30 Vac or 10-48 Vdc DC or 47-63 Hz 250V rms working, 2.3 kV rms per 1 min test
Excitation Output (standard)
5 Vdc 10 Vdc 24 Vdc Output isolation	5 Vdc ±5%, 100 mA 10 Vdc ±5%, 120 mA 24 Vdc ±5%, 50 mA 50 Vdc to meter ground
Analog Output (optional)
Output levels Current compliance Voltage compliance Scaling Resolution Isolation	4-20 mA, 0-20 mA, 0-10V, -10 to +10V (jumper selectable) 2 mA at 10V ( > 5 kOhm load) 12V at 20 mA ( < 600 Ohm load) Zero and full scale adjustable from -99999 to +99999 16 bits (0.0015% of full scale) 250V rms working, 2.3 kV rms per 1 min test
Dual or Quad Contact Relay Outputs (selectable)
Relay Type Load Rating Isolation	Form C 8A at 250 Vac or 24 Vdc 250V rms working, 2.3 kV rms per 1 min test
Dual or Quad Solid State Relay Outputs (selectable)
Relay Type Load Rating Isolation	Form A, SPST, normally open 130 mA at 140 Vac or 180 Vdc 250V rms working, 2.3 kV rms per 1 min test
Serial Data I/O (optional)
Board Selections Protocols Data Rates Digital Addresses Isolation	RS232, RS485, Modbus RS485, USB, USB-to-RS485 converter Modbus RTU, Modbus ASCII, simpler Micron ASCII 300 to 19200 bps 247 (Modbus), 31 (Micron ASCII), 250V rms working, 2.3 kV rms per 1 min test
Environmental
Operating Temperature Storage Temperature Relative Humidity Protection	0°C to 60°C -40°C to 85°C 95% at 40°C, non-condensing NEMA-4X (IP-65) when panel mounted
Signal Connections

Up-Counting Batch Control
	In up-counting batch control, the Micron 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
	In down-counting batch control, the Micron 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
	The Micron batch controller is ideal for discrete manufacturing as well as repetitive fill operations. In this example, the Micron counts bottles which it then groups into sixpacks. Its Grand Total capability can be used to track bottles or sixpacks.

Typical Batching Applications
Drum Filling Application Utilizing Two Relay Outputs
	In this drum filling application, the Micron 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
	Multiple Micron 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 Micron. Controller setup and monitoring of the mixing operation are facilitated by optional serial communications. RS-485 allows a single data line to handle multiple controllers.

Pulse Input or Analog Input Batch Controller

Automatic batch control for repetitive liquid fill operations

Standard Features

Description

BATCH CONTROLLER SPECIFICATIONS

Typical Batching Applications