Technical guide
Contents
1. Doserate Limit Values According to DRLM Limit Wire Position ME335 model p units gt of o o n o o n o n ee inno 100 1000 1000 1000 200 300 4000 400 4000 4000 400 5000 500 Sono Soo Boo ono eoo __ 700 POD b 000 50D E000 eon 000 700 700 700 800 3000 somo 900 somo Manuf Oem 32 C Manu Electronics 2015 ME NE EE EN kono E _ 6000 ENN Batch Controller LM Batch Limit Start pad of Limit Wire is marked LM esti Shan bako 3 d TL 7j T Q NQ l T cn E BERE EE E d ry Tis II a 3 eocecrs it ae m EILIEPTOIZSITIT gt gt Ci E TEFNTLELI FEK euros gua E 0 2 2 7 i vett p B gk am mper IU LA LITI N i l 9 o UKE KIU SKO LEL Vemm db 2S S LJ AY DUM OB RUE E gt E a 3 o o qu ay Batch Limit wire is connectec o 8e eds A as seen on this view Batch Limit Values According to LM Limit Wire Position MESS5 model units gt of o o on oo oo oO o o o no o o mo 0 200 3 0n 400 4 50 50 50 So 5000 Sono Sono 5000 50000 Som 5000 50000 _ 60 eo eo 62. MILLILITRES PREACT HUNDREDS TENS a n b i mmu m L y LN m a m m y El m gt 4t a B Hu u E m a ManuHo C Manu Electronics 2015 9 N Batch Controller Service Adjustments to Safety Timings and Limits for ME995 INITIAL START T2 Once start toggle is pressed controller allows 1 5 seconds for pulses to arrive from the flowmeter CAUTION f there are no pulses within the 1 5 second time period controller will shut down the output voltage drive and will turn on the pulse fail LED and alarm warning n some applications the 1 5 second delay may not be long enough due to slow opening solenoids or slow pressure buildup pumps etc e The initial start time period can be increased by soldering a tantalum capacitor in parallel with the standard capacitor value found on the rear of the PCB FLOWRATE T1 f pulses do arrive within the allocated initial start time the controller then locks in pulserate safety e Most ManuFlo Batch Controllers have a standard 30 counts per second 30Hz pulserate safety setting e f the pulses from the flowmeter drop below the 30Hz the controller will shut down the output voltage drive and turn on the Pulse Fail LED and alarm warnings e The 30Hz standard setting is typical with concrete admixture dispensing systems using MES20 1ml 1 pulse flowmeters where if the flowrate drops below 30 mil
3. DHB DUAL HOUSING BOX Order Code Description SHB Single metal box houses one ME995 SHB1 Single with contactor pump outlet SHB2 Single with 2 contactors 2 pump outlets DHB Dual metal box houses two ME995s DHB2 Dual with 2 contactors 2 pump outlets Order Code DHB3 Dual with 3 contactors 3 pump outlets HB2500 IP65 Enclosure T Terminal strip entry in lieu of outlets HB2510 1 65 Enclosure with S S316 hing mE Options SSR Start Stop Reset command buttons Select a good viewing AND operating position for the Batch Controlh 240 Contactor internally wired 15 Amp 240vac 1phase Manuf Oem 38 C Manu Electronics 2015 Batch Controller Housing Box Use Do not install ME995 ME3000 with SHB DHB boxes outside exposed to rain or washdown areas use the HB2510 IP65 waterproof dust proof box Manuf Oem 39 C Manu Electronics 2015 ME995 Series Batch Controllers Connections Calibration knobs only on ME995 7 and ME995 7D to set to flowmeter s K Factor the pulses Litre Weidmuller 10 pin recepticle changeover and replacement is instant SPECIFICATIONS Power supply Output to flowmeter Relay outputs Frequency input Display Connection Fuse Batch selection Batch commands Rear of 995 7 controller Mounting Instrument housing External dimensions Panel cutout Weight with no rewiring necessary Serial No 220 260 vac optional 110 vac or 12 24
4. Valve Pulse Output on Return Valve Solenoid Flowmeter e g MES20 Manuf o 7 C Manu Electronics 2015 ME995 Series Batch Controllers Safety Features LIMIT LM LED illuminates if batch cycle reaches locked internal maximum limit or circuit diagnostics detect internal chip problem with subsequent automatic shutoff of voltage contact drive PULSE FAIL PF LED activates if e no flowmeter pulses arrive within initial 1 5 seconds variable or pulses are interrupted or intermittent during batch cycle fall below variable pulse scanning time typical 30 Hz with subsequent automatic shutoff of voltage drive to pumg FLOW FL LED indicates pulses coming from field flowmeter or if test is used e CONTACT DRIVE CD LED output drive activated to pump or solenoid Audible ALARM sounds W c M e momentarily upon completion of batch cycle 86 continuously if PULSE FAIL or LIMIT occurs LEDs are activated or 8 if overflow runs 1000 ml variable past selected batch quantity Warning If Contact or Flow LED indicators are on but contoller is not counting discontinue use and call for service Manuf Oem 8 C Manu Electronics 2015 Batch Controllers Selection Questions 1 What is pulses per Litre of the connected flowmeter 2 Is Variable Dosage required If so 3 What dose units do you want 4 What is the maximum doserate 5 What batch quantity units do you want
5. 6 What is the minimum amp maximum batch quantity 7 What is the display to show total dose or delivered batch quantity Manuf u 9 C Manu Electronics 2015 Batch Controllers Batch Quanti Dosac Variable Max Setting Dosaqe Input from Flowmeter 2 PPL K factor r Code Accepted Adjustment a m a batch quantity o c z IE o o c c 5 E I mis x 10 cubic metre mis x 10 900x10 total dosage cubic metre mis x 10 batch quantity cubic metre mis x 10 900x10 batch quantity cubic metre mis x 10 total dosage 100 Kg total dosage j E I ig ox 38 5 9 mp 9 kg of mis x 10 900x10 total dosage cement 100 Kg mis x 10 batch quantity cement 100 Kg kg of 9000 mis x 10 900x10 batch quantity cement 100 Kg wo ue o _ wa o ME995 7D na batch quantity Li y ME995 7G 0 01 L batch quantity Li ME995 7H Litres batch quantity Litres y ME3000 m L KL from1mi 9 999 099KL batch quantity 0 001 9999 y Batch controller options 110vac supply 24 VDC supply external command plug stop start reset PL C Computer interfaces 2 product changeover switch Notes 1 ME995 G has as standard a 2 product selection switch with central computer hold and a 5P interface plug 2 Examples of 1000 pulse Litre flowmeters are MES20 MEA15 MEK20 NEW MODELS ME995 2CS Direct
6. LM limit wire Note Setting are B 1 4 e ra OEIL programmable M in the ME3000 To access PCB unscrew 6x screws located at rear of controller case Rear view of ME995 PCB ManuHo T C Manu Electronics 2015 Batch Controller T2 Initial Start and T1 Flowrate Timing caution Fo E oo pacton e s capacitor is on other side of PCB a Initial Start capacitor T2 T1 flowrate capacitor is programmable Add Tantalum capacitor in parallel to adjust Add capacitor in parallel to adjust Standard factory set values are T2 1 pF capacitor T1 0 02 pF Use the following tables to change factory set values Table 1 INITIAL START TIMING T2 Table 2 FLOWRATE TIMING 1 Extra Capacitor value Extra timing Total Capacitor value Frequency Hz pulses per second uF 1 5 seconds 0 01 uF 30 Hz 2 uF 3 0 seconds 0 02 uF 25 Hz 3 3 uF 4 seconds 0 03 uF 20 Hz low flowrate MES20 4 7 uF 5 8 seconds 0 1 uF 07 Hz 0 2 uF 03 Hz 1 0 uF 0 2 Hz PSM20 T flowmeters Manuf o C Manu Electronics 2015 Batch Controller DRLM Dose Rate Limit Doserate Models Only To change doserate limit move this end of the DRLM limit wire to a new pad on the rotary L Chace oe i 029 ee 9 Doserate Limit wire is connected to E the right most installed Doserate dial KP V 99965 as seen on this view 1N4148 signal diode
7. liquid may flow slower causing Pulse Fail We recomm Opening up the restriction valve OF Fitting the capacitor to change Batch Controller T1 timing Manuo c Manu Electronics 2015 48 Batch Controllers Troubleshooting o Pulse fails during batch cycle o Display digits count slowly after batch complete o Batch target display counter above batch selection o During calibration test more admix collected than indicated O O O O Flowrate too slow Flowrate too fast Blocked filter restricting flow Measuring chamber clutching Non return valve faulty jammed open Flowrate too fast excessive overflow Flowmeter chamber part missing Chamber excessively worn liquid is slipping through without registration S G below 1 0 MES20 under excessive pressure with AEA slippery admix O Open restriction gate valve or increase flowrate pulse fail timing capacitor see service guide Chamber clutching slow down flowrate via restrictor valve Check flowmeter specs for performance operating range Cleanout filter Cleanout chamber or replace Clean service or replace Clean service or replace Turn down gate valve to restrict flowrate or set preact overflow deduct function to compensate ME995 models Reduce delivery pipe diameter Check flow chamber check O rings are seated correctly MEK20 MES20 roller bush or O ring Replace with new chamber recheck calibration Replace chamber and r
8. Backflow e Output Rate e Overbatch Configuration e Calibration I P e Output Pulse e Max output rate e Max batch limit e Max backflow e Min flow alarm level e Max flow alarm level e Start delay e Stop delay e 4 20 mA current o p e Preact overrun e Time amp date e Date last calibrated 53 ME995 ME3000 NEVV Configuration Updates Now available with e 24Vac or 24VDC powered options With open contact output drive to drive any voltage e ME995 2CS and ME995 3KS models Manuo d c Manu Electronics 2015 Portable Kits Batch Controller Flowmeter Systems 5 Concrete Batch Plant Admix System Kit Batch Controller order ME995 model of your choice to suit Batch Controller Housing Box order SHB DHB HB2500 options to suit Flowmeters order MES or MM flowmeter to suit Pump order pump to suit Ancillary Kit with filter gate valve non return valve elbows amp camlocks Cable order length of cable from flowmeter to Batch Controller Manuo C Manu Electronics 2015
9. C Manu Electronics 2015 ME995 2C Batch Controller For use with ManuFlo AMM15 MES20 and MEA15 1000 ppl flowmeters e Mainly used in manual batch plants Doserate e g 35 350 mls cubic metre Shows delivered Batch Quantity in cubic metres Batch Quantity up to 9 0 increment 0 1 e g w E 2 0 cubic metres LO oK hau Se 2 I E Manuo C Manu Electronics 2015 ME995 3 Batch Controller Ideal for Computer plants to compare volumetric display in MLs 5 Digit LED display IL Display ME995 3 4 X LED status indicators ME995 Variable doserate selection Doserate mis x 10 per 100k Display counts in total millilitres of dosage n 99 x ir Preact function and preset maximum limit Shows Total Missing pulse detection Dosage in ML e Interchangeable with earlier ME188 models For use with Manu MES20 MEA15 1000 ppl flowmeters Batch Quantity up to 9000 increment 10 Optional PLC and computer interface e Mainly used in computer PLC controlled batch plants Manuio KAL 16 C Manu Electronics 2015 ME995 3 Batch Controller For use with Manu AMM20 and MES20 1000 ppl flowmeters e Mainly used in computer PLC controlled batch plants Doserate Max 99 x10 e g 20 x 10ml 100kg Shows delivered Dose in ML Batch Quantity up to 9000 increment 10 e g 1000 kg Manuo C Manu Electronics 2015 Batc
10. VDC 12 VDC up to 100mA Max 240 vac 30 VDC 1 Amp o KHz x1 input 340 Hz x17 inputs 7 segment LED 14mm H 10 pin Weidmuller mating plug and socket 1 Amp 5 x 20mm case Visual rotary select switches Push toggle switches Preact knobs to adjust for overrun Fuse Panel mount ABS hi impact case 206 L 130 H 90 D mm 190 L 122 H mm 1 kg Manuf Oem AO C Manu Electronics 2015 Batch Controller Wiring Remove the detachable Weidmuller 10 pin plug from the rear of Batch Controller Connect the flowmeter signal cable into the 10pin Weidmuller plug When wiring the flowmeter use 2 core shielded cable use more cores if wiring more flowmeters this will supply the flowmeter with 12VDC from the Manu Batch controller Wire the 240VAC supply cables Wire the Active contact drive Neutral and Earth from the solenoid valve or return from the external contactor if driving a pump If starting a pump make sure the contactor is of sufficient amperage rating to handle the pump current draw e g 10 Amps for Onga4 13 pump Don t use cheap plug in relays in your installation they cannot handle pump surge currents and can stick fuse e Must have industrial grade contactors available from ManuFlo Order Code C240 rated 3kW 1 5hp Consider wiring an override button N O with spring return for manual batching or top up of admix which will be counted by the controller display e Power up the system Reset a
11. faster flow consider larger flowmeters e g MES25 MES32 MES40 or Magflows Manuo c Manu Electronics 2015 36 Pump Selection Admixtures gt When 20mm MES20 flowmeters are used with fluids of specific gravity 1 1 25 then use centrifuge pumps of 0 5 1 horse power e g 1 Onga 413 or Davey XF1 1 pumps When using larger capacity flowmeters a proportionally larger pump will apply A flowrate upto 1 0 Litre per second can be achieved depending on head height You can restrict pump speed without damage to these type of pumps p For higher density fluids positive displacement PD pumps or other types of positive displacement pumps e g Mono are more suitable Because of the pressures generated by PD pumps the flow is best controlled by using an inlet to outlet bypass flow valve to recirculate the flow line 6 outlet Note This method of restriction of flow eliminates air being counted by MES flowmeters when admix storage tank is empty Manuf u 37 C Manu Electronics 2015 Batch Controller Housing Boxes e The SHB DHB housing boxes are for wall or bench mounting ME995 Batch Controllers Metal black powder coated paint finish hese boxes are also available fully wired with 110 or 240vac 15amp industrial contactors pump plug in 240vac power entries power cord and 10 pin Weidmuller mating plug Also available in a terminal strip entry version SHB SINGLE HOUSING BOX
12. j Filter alve Pulse Output Solenoid Flowmeter e g MES20 Manuo C Manu Electronics 2015 Semi Automatic Batching 3 Batch Controller starts pump opens solenoid to start flow Contact Drive umes LED goes on OO Batch Controller Contactor optional 3 Way Valve calibration point Gate Valve restricts flow outlet line at same level as Storage Tank tank Valve Non Return Valve Filter Non Return Valve Solenoid Pulse Output Flowmeter e g MES20 Manuf o 5 c Manu Electronics 2015 oemi Automatic Batching 4 Batch Controller monitors pulses from flowmeter to determine quantity delivered Contact Drive amp FLow umes LEDs on PROMO Batch Controller Contactor optional 3 Way Valve calibration point outlet line at same level as Storage Tank Gate Valve restricts flow tank Value Non Return Filt Valve Non Return Valve j ako Pulse Output Flowmeter e g MES20 Manuf o c Manu Electronics 2015 Semi Automatic Batching 5 When desired quantity dispensed Batch Controller stops CD then FL LED go off Controller optional 3 Way Gate Valve Valve outlet line at same level as Storage Tank restricts flow calibration point tank ka Valve Non Return s i Non Return Val
13. 000 eooo Sono eono sono eoo Eon 900 5000 80000 eooo eo _ 80 30 x KARI E I gg 2295 Pb OE Physical mods the right most installed batch dial programmable To change batch limit move this end of the LM limit wire to a new pad on the rotary tt PH BH 3k KH a PH io 10o 10 1000 1000 1000 1000 10000 100 1000 1000 10000 0 40000 4000 40 40 40 40 4000 4000 4000 4000 40 000 00 7000 so sow sooo sow sooo 9 000 _ 3000 Manufio C Manu Electronics 2015 EE NM 5 soon LB Lg 3 80 so som 8000 8000 000 20 000 8000 890 Plumbing Install Guide Admixtures Typical admixure dispensing system setup with MES flowmeters If the outlet point is above the top of the storage tank the most commonly used setup you will at least require the following equipment e A pump e Non return valves or spring loaded check valves 12psi e Flow restriction gate or ball valve a flowmeter with pulse output and optionally e A solenoid valve air assisted ball valve type for instant shut off of flow recommended to prevent the Venturi effect when injecting into water lines but may not be required if the installation has reasonable head height A UVV2Z A to nrovide an ez p ihle Alihratian noir outlet line above level of prevent Venturi effect Stora
14. 5 Semi Automatic Batching with Batch Controllers Manuo c Manu Electronics 2015 Semi Automatic Batching Batch Controller starts and stops Batch Controller flow so that a requested quantity is accurately dispensed Contactor optional 3 Way Valve calibration point outlet line at same level as Storage Tank Gate Valve restricts flow tank Valve Non Return Filter Valve Non Return Valve Solenoid OPTIONAL Pulse Output Flowmeter WJl l e e lu u po Og MES20 ES various countries e g Asia Pacific South America Mi Quantity set by operator Delivery controlled by batch controll e Manuo C Manu Electronics 2015 Semi Automatic Batching 1 Operator sets batch quantity Batch Controller Contactor optional 3 Way Valve calibration point Outlet line at same level as Storage Tank Gate Valve restricts flow tank Valve Non Return l Filt Valve Non Return Valve i ilter Pulse Output Solenoid Flowmeter e g MES20 Manurio C Manu Electronics 2015 Semi Automatic Batching 2 Operator presses RESET then STARTs batch All LEDs off Batch Controller Contactor optional 3 Way Valve calibration point outlet line at same level as Storage Tank Gate Valve restricts flow tank Valve Non Return i Val Non Return Valve
15. C Manu Electronics 2015 ME995 6 Batch Controller For use with ManuFlo AMM20 and MES20 1000 ppl flowmeters Shows delivered Mi Batch Quantity lI in Litres Batch Quantity up to 99 9 increment 0 1 L e g 1 0 Litres Manuf o ow 23 c Manu Electronics 2015 UONWOHer FIE AGCL PREACT Calibrating inflight overflow deduct e 15 via two rotary knobs marked on ME995 3K HUNDREDS and TENS of mls located at the rear of the Batch Controller As the batch display will indicate total kilograms of cement at the selected doserate a calculation must be performed to convert the overrun displayed into actual overflow millilitres of dose ETI B slarfiantes Serial Xu KNOBS Manufio uM 24 C Manu Electronics 2015 Batch Controller Pre act Time Preact Time Manuo c Manu Electronics 2015 25 Batch Controller Preact ME995 3K Example 1 e Doserate was 10 x 10 mis 100kg i e 100 mls 100 kg e Total kgs cement load selected was 2000kg e Actual quantity delivered shown on display was 2060kg 60 kgs over at the selected doserate overbatch x Doserate Dose Overflow 60 kg x 10x10 mis 60 x 100 mis 60 mis 60 mis overflow 100 kg 100 Set the preact to HUNDREDS O and TENS 6 0x100 6x10 0 60 60 mls When doserate is set to 10x10 mis 100kg then it is easy to calculate preact Preact in mls qty delivered in kg shown on disp
16. MLS CUBIC METRE m3 Dosage versi ME995 3KS Direct MLS KG S of CEMENT Dosage versio Manufio KAL 10 C Manu Electronics 2015 i Older Model Batch Controllers ME188 Series ME995 Built 1995 to present E 1 88 1 n 2 9 i 1 D aie 4 oe x 1 E995 1 A ME188 2 ME188 3 ME188 6 ME188 7 um Manuf 11 C Manu Electronics 2015 ME995 2 Batch Controller For use with Manu AMM15 MES20 and MEA15 1000 ppl flowmeters Doserate Mainly used in computer PLC controlled batch plants Max 99 x10 e g 35 x 10 mls cubic metre DOZAGE MES 10 N Shows delivered Dose in ML MILLILITRE Batch Quantity up to 9 0 increment 0 1 e g 2 0 cubic metres Manuo 12 C Manu Electronics 2015 ME995 2 Batch Controller e For use with Manu AMM15 MES20 and MEA15 1000 ppl flowmeters Mainly used in computer PLC controlled batch plants Doserate e g 35 350 mls cubic metre DOSAGE MLS 10 CUME METRE Shows delivered Dose in ML MILLILITRE Batch Quantity up to 9 0 increment 0 1 e g 2 0 cubic metres Manu 13 C Manu Electronics 2015 ME995 2C Batch Controller For use with Manu MES20 and MEA15 1000 ppl flowmeters e Mainly used in manual batch plants Doserate e g 35 350 mls cubic metre Shows delivered Batch Quantity in cubic metres Batch Quantity up to 9 0 increment 0 1 e g 2 0 cubic metres Manuo KAL 14
17. al lants e In winter liquid can thicken because RE of the cold and so can flow slower 4 g If Pulse Fail continually happens in I winter on a ME188 ME995 series Batch Controller THROTTLE UP PUMP SPEED or fit a 0 01 uF capacitor to change flowrate timing 1 Note The ME3000 Batch Controller is programmable and so does not require any hardware modification Manuf u 45 C Manu Electronics 2015 Batch Controllers Troubleshooting IMPORTANT Questions to ask the batcher upon a batching problem e Which LEDs are on Describe what faults are eviden If there is repeated pulse fail ensure truck is removed from under the sock to avoid chemical overdose Manu u 46 C Manu Electronics 2015 Batch Controllers Troubleshooting Incorrect Batching 1 The selector knob number dials on the Batch Controller may not be aligned correctly and therefore do not correspond to the rotary switch numeric values 2 To test set all numbered dials to the zero position then press the RESET toggle The alarm should beep momentarily This will indicate correct alignment of dials If alarm does not beep this indicates incorrect alignment of number dials To rectify remove the grey colored cap from each dial unscrew knobs and pull knobs off e Check that the exposed switch black shaft flat sides are horizontal If not turn shafts horizontal and refit the numbered dial knob to the
18. estrict flowrate or recalibrate via controller certain models only or recalibrate via card Place restriction valve after pump and prior to flowmeter NOTE After servicing any flowmeter always perform a volumetric calibration test Make sure glands are sealed pulse cable is lopped downward and meters are under cover and protected from water ingress Manuo c Manu Electronics 2015 49 Batch Controllers Troubleshooting o Less admix collected than displayed o Controller starts counting when power switched on does not stop at batch complete o Controller not counting but flow and or contact drive LED s are on o Controller counts although pump off contact drive LED off o Controller counts up a batch cycle but no admixture delivered Possible syphoning effect if fed mixing into flowing water line Liquid flows backward after batches Active and contact power drive short circuited Contactor sticky or fused Controller malfunction IC failure Dried out main electro capacitor Flowmeter MES measuring air Manuo C Manu Electronics 2015 Fit ball valve solenoid or do not feed into flowing water line or check valve Non return valve faulty service or replace Short circuit on PCB check PCB or replace External pump contractor relay fused or need higher ampere rating replace contractor Replace controller ring ManuFlo for urgent advice Replace electrolytic capacitor Pre ME995 u
19. ge Tank LL ee mM when injecting into most common optional 3 Way Valve m water lines Contactor calibration point E tional Solenoid t Batch optional Solenoid to IE I tank Non Return Valve Filter Valve Gate Valve Flowmeter Non Return Valve restricts flow ManuHo C Manu Electronics 2015 34 Plumbing Install Guide Admixtures If the outlet point is below the level of the storage tank then the equipment you will at least require is flow control solenoid valve a flow restriction gate or ball valve and a flowmeter with pulse output outlet line below level of Me Storage Tank ontroller an optional pump may be used to Gate Valve speed up flowrate restricts flow Filter ES J Flowmeter ii Solenoid Manuo C Manu Electronics 2015 Plumbing Install Guide Admixtures Selection of Pipeline Diameters for MES20 20mm gt For low flowrates and small batch quantities of liquid approx lt 2000 use 72 diameter pipe or hose after the flowmeter gt For medium to high flowrates use 74 to 1 diameter pipe O gt For very high flowrates use 174 NOTE Pipeline can be Flexible reinforced hose NOT flexible expandable soft hose Rigid PVC e Metallic e For higher density chemicals higher head requirements or injecting into water lines consider positive displacement pumps to maintain or increase flowrates e For
20. h Quantity up to 9000 increment 10 e g 1000 kg ME995 3 Batch Controller Mainly used in computer PLC controlled batch plants Doserate e g 20 200ml 100kg Shows delivered 2000 TR Dose in ML elc MILLILITRES Manuf O 18 C Manu Electronics 2015 ME995 3K Batch Controller e Variable doserate blending preset batch controller e Rotary knob selector switches for easy select of o Doserate top 2 selectors o Batch Quantity bottom 4 selectors e 4 Digit LED display Display counts upward in 10 kg lots to kilograms of cement selected e 4 x LED status indicators MLs x 10 per 100KG Preact overflow deduct function Max Setting 99x10 e Preset maximum batch limit mE Shows Batch Missing pulse detection Quantity in KG e Contact output drive is via 1 or optionally 2 relays e For use with Manu MES20 MEA15 1000 ppl flowmeters e Optional PLC and computer interface Batch Quantity up to 9000 increment 10 e Mainly used in manual batch plants Manuo C Manu Electronics 2015 ME995 3K Batch Controller For use with ManuFlo AMM20 and MES20 1000 ppl flowmeters Manu u 20 C Manu Electronics 2015 ME995 3K Batch Controller Manuo c Manu Electronics 2015 ME995 4 Batch Controller For use with Manu AMM20 and MES20 1000 ppl flowmeters TEST STOP 3 RESET STAAT ON 1 1 Manu Oem 22
21. lay qty requested in kg dialed by operator UB i T 3 i e 2060 2000 60 mis preact Manuo c Manu Electronics 2015 26 Batch Controller Preact ME995 3K Example 2 e Doserate was 27 x 10 mlis 100kg i e 270 mls 100 kg Total kgs cement load selected was 2000kg e Actual quantity delivered shown on display was 2060kg 60 kgs over at the selected doserate overbatch x Doserate Dose Overflow 60 kg x 27x10 mis 60 x 2 0 mls 162 mls 160 mis overflow 100 kg 100 oet the preact to HUNDREDS 1 and TENS 6 1x100 6x10 100 60 160 mls MILLILITRES PREACT HUNDREDS TENS er al a im EA ui I x p Manuo Ni C Manu Electronics 2015 Batch Controller Preact ME995 3K Example 3 e Doserate 38 x 10 mls 100kg Total kgs cement load selected was 3150 kg Actual quantity delivered shown on display was 3290 kg What should preact be set to ManuHo C Manu Electronics 2015 N Batch Controller Preact ME995 3K Example 3 e Doserate 38 x 10 mls 100kg Total kgs cement load selected was 3150 kg actual quantity delivered shown on display was 3290 kg i e overran 140 kg Dose Overflow 140 kg x 38x10 mis 140 x 380 mls 532 mls 530 mls overflow 100 kg 100 Set the preact to HUNDREDS 5 and TENS 3 5x100 3x10 500 30 530 mls BEE E E EE EEE eB ee BEE EE SER Nou Nm mma BEE
22. lilitres per second the pulse fail safety will activate T e The flowrate frequency minimum setting can be adjusted by soldering a capacitor in parallel with the standard capacitor found on the PCB Physical mods not Note The flowrate safety timing is changed if required needed for ME3000 because of viscosity changes due to seasonal temperatures or by very low flowrate applications or when using flowmeters other than the most commonly used MES20 20mm 1 pulse 1ml output flowmeter with Batch Controllers that have K factor ppl calibration When controller flowmeter systems are ordered we supply the safety timing setting to suit your chosen flowmeter thus always providing the safest possible watchdog system is programmable BATCH LIMIT LM DOSERATE LIMIT DRLM on Doserate models only The maximum permissible batch is determined by the internal limit value The maximum permissible doserate is determined by the internal limit value The factory setting is always at the maximum value The factory setting is always at the maximum value The limit setting can be reduced by simply desoldering the limit lead wire connected The limit setting can be reduced by simply repositioning the limit wire at the to the rear of the rotary switch solder pads and resoldering to set the desired quantity rear of the rotary switch solder pads DRLM limit wire on Doserate models only T2 initial start cap T1 flowrate cap
23. locity by using a restriction gate valve avoid over batching by using the Preact function or installing a quick acting solenoid valve Note If the flow is restricted excessively Batch Controller Pulse Fail circuitry will shut down the system for safety reasons in which case open up the restriction gate valve Manurio C Manu Electronics 2015 Batch Controllers Common Operational Issues Common causes of batch overrun e Pump slow to stop To fix LJ adjust preact e Flowmeter is clutching or chamber is worn out Clutching can cause more liquid to be dispensed than is measured but if significant then the Batch Controller will Pulse Fail consistantly LJ clean or replace chamber e After flowmeter any restriction e g valve at end of flexible hose will allow expansion of hose line in hot conditions introducting a contraction expansion squeegee effect that affects the amount dispensed at the end of a batch Move valve to move restriction to before flowmeter 7 use rigid reinforced hose pipe N e Fluid particles block meter flowmeter flexible hose Use rigid hose instead LJ clean measuring chamber LJ install filter prior to flowmeter 800 1000 micron recommended ManuHo C Manu Electronics 2015 44 Batch Controllers Maintenance Acalibration check should be performed periodically say every 6 months Return for service after 5 10 years especially for manu
24. nd start a number of times to prime the system until fluid appears at the outlet line and the Batch Controller digits begin counting Manuo B C Manu Electronics 2015 ME995 Batch Controller Wiring VAC LUN SUPPLY EARTH IGROUNI ME995 WIRING DIAGRAM SHIELDED CABLE aptior 212 vac Solenoid to pre ve at Ve rwla fict whes jected lato watr las Manuo C Manu Electronics 2015 Batch Controller Calibration Test Volumetric Calibration Test should be performed when commissioning inste place a calibrated vessel at the discharge point on the Batch Controller select an amount of liquid e g 1000 mls press Reset then Start to batch the quantity e at the calibrated container check that the amount dispensed is as requested An overflow may occur due to the inability of the pump to stop instantly The amount of overflow will depend on how fast the liquid is being dispensed and or the closing time of the solenoid valve The Batch Controller will count the overflow as part of the displayed total dispensed e if the system is totally controlled via PLC Computer overflow will be adjusted by the computer otherwise e where a ME995 series Batch Controller is fitted with a Preact simply set the Preact to the amount of overflow i e overflow actual amount dispensed as shown on the Batch Controller display minus amount requested If required slow down flow ve
25. nits Can occur with positive displacement pumps Fit a recirculation line on inlet outlet of pump See install guide brochure 50 New ME995 Models No x10 Scaling on Doser Dials LE Straight mls m3 selection Straight mls 100kg selection o dials for direct selection of doserate o No longer mls x10 calculation required o First dial is fixed at zero Introduced due to some batchers miscalculating with the doserate mls x 10 option Manu o KAL 51 C Manu Electronics 2015 ME3000 Next Generation ManuFlo Batch Controller e Single channel 2 line x 16 character LCD display with batch set and target e Alarm messages shown on LCD display More safety features e Internal event log e RS232 output to printer computer e Fully programmable Can use with any flowmeter size See User Manual for full instructions http www manuelectronics com au pdfs ME3000 uman pdf Manuf u 52 C Manu Electronics 2015 ME3000 Next Generation ManuFlo Batch Controller Displays e Set Run Flowrate e Backflow e Grand Total resetable e Batch ld resetable 6 digits Alarms Features Batch Limit e Event log 500 batches e Max Flow Limit e Run flow output indicator LEDs Min Flow Limit Features Optional Computer control interface e RS232 interface for printing batch tickets and or downloading event log Front Port RS232 for easy access Manuo c Manu Electronics 2015
26. zero number setting e For dosage switches position to zero and push the TEST button Digits should not count except in the ME995 3 model If digits count then remove grey knob and check the numbered dial alignment 3 If batch controller is tested and found to be operating correctly then proceed to checking and testing flowmeter components Manuf u 47 C Manu Electronics 2015 Batch Controllers Troubleshooting o No power to batch controller displays not on o Pulse fails at start of batch OMO Ooo Blown fuse or holder not tight 12vdc and O V shorted No main power supply Air pocket Restriction gate valve closed Empty liquid tank Pump not turning Solenoid valve not opening Seized flowmeter chamber Flowmeter pulsehead faulty Signal cable cut or bad joint O O O O O O Check fuse tighten fuse holder at rear of controller Check wiring rear of controller amp at flowmeters replace cables Check power supply check wiring Prime line by shorting output drive C Contact amp A Active Open gate valve Check liquid level Check and service pump Check and service solenoid valve or non return valve stuck closed Service and clean flowmeter chamber replace if required Replace with new pulsehead or connections corroded Check signal cable WARNING In any pulse fail or repeat malfunction condition remove the truck mixer from the sock loading point NOTE In winter
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