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Kobold DOR Series Paddle Wheel Flow Meter Manual

1. 22 a or pipe ID mm Calculate K factor pulses litre using the above graph and the metric constant of 1273 2 as follows Pulses litre 1273 2 x A from graph pipe ID mm Example a K factor for 100mm pipe 1 from graph 100mm ID A 24 0 2 pulses litre 1273 2 x 24 0 10000 3 056 p litre K factor for m multiply by 1000 eg K 3056 p m K factor for megalitres multiply by 1000000 eg K 3056000 p megalitre NOTE K factors for Reed Switch output option are 1 3 the standard factors of voltage pulse output page 13 4 4 Calculating K factors US gallons 7 6 7 7 5 4 7 4 7 3 4 7 2 7 1 4 Pipe ID 19 5 amp above A 6 86 7 0 A 6 9 6 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 pipe ID inches Calculate K factor pulses gallon using the above graph and the volumetric constant of 24 51 as follows Pulses US gal 24 51 x A
2. 24Vdc external power Troubleshooting 15 Display shows model number at all times example The instrument has not been fully programmed after power up enter the program mode amp enter program parameters be sure to exit the program mode before the 4 minute no data entry time out or the instrument will revert back to model number display Display ghosting under external power The LCD display will ghost when the instrument is powered from an external 24Vdc power supply this is corrected by including two watt resistors 1 2K amp 3 3K on the input power source as shown below Scaleable pulse output counts on after flow has stopped The scaled pulse output has exceeded its output limit of 8Hz Allow the memory buffer to catch up or increase the pulse value number of litres etc per pulse clause 4 5 p12 Display shows random characters The instrument may have taken an electrical hit press the processor reset button p70 Cut from manual for increased security 16 Declaration of Conformance 7 Declaration of Conformance We KOBOLD Messring GmbH Hofheim Ts Germany declare under our sole responsibility that the product Battery Totaliser Model ZOD Z1 to which this declaration relates is in conformity with the standards noted below Optional for Equipment intended for use in Potentially Explosive Atmospheres ATEX Directive 94 9 EC EN 50014 1997 Amds 1 amp 2 Intrins
3. Loop load specification R V 10 0 02 where V loop voltage R max load Q Powering via 4 20mA loop Positive referenced Flow High flow alarm Input B Low flow alarm Optional wiring When wired in this manner the one loop power supply limited to 24Vdc may be used to also power active flow sensors scaled pulse amp alarm outputs at terminals 7 13 8 14 8 or multiple RT s if required Elow 4 20mA output InputA 4 20mA output 4 OV ground not used 8 24Vdc in not used A Pulse output OV ground 8 sonjooo Wiring requirements Use multi core screened twisted pair instrument cable 0 25 0 5mm2 for electrical connection between the ZOD Z3 and any remote flowmeter or receiving instrument The screen needs to be earthed to the signal ground of the receiving instrument only to protect the transmitted signal from mutual inductive interference Instrument cabling should not be run in a common conduit or parallel with power and high inductive load carrying cables power surges 8 power line frequencies may induce erroneous noise transients onto the signal Run instrument cables in a separate conduit or with other instrument cables 11 Installation Pulse 8 Alarm Outputs Current Sinking outputs NPN Current sinking derives its name from the fact that it sinks current from a load When activated the current flows from the load into the appropriate output 7 13 amp 14 Driv
4. Ground screen at OV 5 D 8 24Vdc in not used 9 Pulse output OV ground 8 2 Voltage Pulse 8 pulse wires 03 High flow alarm O Flow g o 2 All DIP swithes off InputB Lowflow alarm ol Flow 4 20mA output 12 N TG input A 4 20mA output Pa OV ground not used a dat gt lt Ground screen at 0V 5 SE Na EJ E Pulse output OV ground 81 3 Coil Turbine amp paddle style flowmeters minimum 15mV p p All DIP switches off position switch 1 O3 High flow alarm 14 ON if unit is effected by line noise x 02 a 14 aq OP Low flow alarm O C13 Elow 4 20mA output 02 N D Input A 4 20mA output OV ground not used 8 24Vdc in not used 9 Pulse output OV ground 8 9 Installation 3 2 Flowmeter connections powered sensors for l S installations refer to l S supplement 4 Hall effect 5 24Vdc open collector DIP SW2 sn up is on e Flow High flow alarm Ground old Ki B KA Wi Signal out J LI L at terminal 5 Flow 4 20mA output OV ground m JE sa Input A Hall effect _ Vac supply 4 20mA output OV ground not used 8 24Vac in not used 9 Pulse output OV ground 8 5 Namur inductive proximity switch DIP SW3 pull down is on 3 ge Flow High flow alarm N n Input B Low flow alarm Ol Flow 4 20mA output N at 2 Input A A 20mA output 41 OV ground not used 8 24Vdc in not used 9 Pulse output OV ground
5. Flow IMPORTANT Fix 1N4004 electrical surge suppression diode supplied across solenoid valve coil band to side Installation 11 Two Stage Control using relays 1 amp 2 Network Relay 2 high Relay 1 low Flow Batch status Input not used OV ground not used 8 24Vdc in Run inhibit 9 No flow alarm OV ground ES Flow gt a IMPORTANT See notation on 1N4004 diode When the solenoid valve coil is de energized it generates its own voltage sending a surge spike through the circuit Depending on the coil size and the number of amp turns it contains this generated voltage can be very high Installing the diode will suppress this spike and protect sensitive components of the electronic instrument Relay Control Logic i complete ENERGISED ENERGISED Relay 1 LOW FLOW OFF ENERGISED ENERGISED Relay 2 HIGH FLOW OFF Start delay gt gt a Start delay gt Pre stop 1 4 sec ENERGISED Batch amp network status NPN output OFF Batch amp network status end of batch occurs 1 4 seconds after relay 1 is off 12 Programming 4 PROGRAM PARAMETERS 4 1 PIN No Program Protection Any user defined PIN number other than 0000 will engage the program protection feature failure to input the correct PIN number will deny
6. Terminal layout Wiring of analog output Wiring of flowmeter inputs Wiring of pulse outputs Wiring to external supplies Wiring requirements 14 16 17 11 12 12 12 11 12 18 18 10 8 9 11 10 10 Manufactured and sold by Kobold Messring GmbH Nordring 22 24 D 65719 Hofheim Tel 49 0 6192 2990 Fax 49 0 6192 23398 E Mail info de kobold com Internet www kobold com Version KO2 1010 22 Declaration of Conformance 9 Declaration of Conformance We KOBOLD Messring GmbH Hofheim Ts Germany declare under our sole responsibility that the product Flow Rate Totaliser Model ZOD Z5 Universal Mount Series to which this declaration relates is in conformity with the standards noted below Optional for Equipment intended for use in Potentially Explosive Atmospheres ATEX Directive 94 9 EC Z5 FLOW RATE TOTALISER with backlighting amp flow alarms EN 50014 1997 Amds 1 amp 2 Intrinsically Safe Electronics 1 S Optional mds ntrinsically Safe Electronics I S ptiona INSTRUCTION MANUAL EN 50020 2002 Intrinsically Safe Electronics 1 S Optional EN 60529 DIN VDE 0470 1 1992 11 I P Ingress Protection Classifications EN 61326 1 2006 10 Electrical equipment for control instrumentation technology and laboratory use EMC requirements Industrial area EN 61010 1 2002 08 Safety requirements for electrical equipment for measurement control and laboratory use 2008 35
7. May be link configured for PNP to drive compatible logic circuits NPN PNP solid state alarm or non scaleable pulse output terminal 7 5000hz max 1A maximum drive capability NPN open collector 0 1A dc resistive load max page 16 Eg Pulses litre gallon lb etc Programmable range is 0 001 9999999 999 with a floating decimal point during K factor entry Selectable Ltr gal m3 kgs los maximum 8 digits of batch Count UP or count DOWN selectable at program level AOC enabled disabled selection at programming level page 13 Batch size limits can be set at programming level page 13 Run key can be inhibited from an external source page 16 A two wire loop system can link up to 9 individual batch controllers with one common flowmeter to provide an economical multi source dispense interlocked batching system page 18 A IP66 67 high impact glass reinforced Polyamide enclosure B 3 x M20 or 2 NPT female conduit entries C 125mm diameter 5 x 61mm deep 2 5 x 400g 0 91b D Temperature range from 20 C to 80 C 4 F to 176 F 3 4 Introduction 1 3 Overview The ZOD B1 is a dc powered high speed batch controller specifically designed for liquid batching using a flowmeter with a pulse or frequency output ZOD B1 is push button programmable with PIN protection and an internal battery is provided allowing pre programming without applying power The large LCD provides batch quantity in
8. Use of a good quality DC power supply Select A Press to reset totaliser Select A is recommended Avoid using low cost response sec deadband 0 9 digital switch mode power packs PROGRAM PROGRAM loop wiring repeater pulse output Ma re A Number of excitation poles NOP si koki A of poles 1 32 for each revolution of the primary of poles 1 32 a i a PAR E The NPN pulse output is isolated PROGRAM measuring elements see page 2 PROGRAM 1 from the loop powered circuit YA and will support up to 30Vdc and O E drive to 100mA Run mode display defaulis Run mode display defaults savde to input frequency Hz to input frequency Hz Digits supply Press A to show Hz for 20mA flash when in alarm condition Press A to show Hz set point
9. A self generating pulse output which produces a strong 1 5 volt voltage spike of approximately 10 micro second duration with no dependence on rotor speed peteeneecnesecensenenaeseesesensesecaeseeansenssaeeneaens Screen z dw O A Pos m Yellow Green Square Wave Pulse Hall sensor also applies to non magnetic amp QP Hall outputs An NPN open collector transistor pulse output produced by a solid state Hall Effect device This three wire device requires 5 24vdc and produces an NPN square wave output 20mA max sink pulse width is 2 75 mSec The Hall output requires a pull up resistor these are generally incorporated in most receiving instruments For QP Quadrature pulse output refer details page 9 O a Screen 5 24vdc supply j i T L signal output Red White Ov ground Black Page 9 3 5 Quadrature outputs DOR series flow meters supplied with the QP option produce two NPN open collector pulse outputs from two Hall Effect sensors The outputs are phase offset in their timing so that external electronics are able to differentiate These outputs may be used to assure output signal integrity or to measure bi directional flow CU eee eee Screen Red Vdc White output 1 Blue output 2 Black OV 3 6 Bi directional flow The DOR flow transducer is capable of accurately measuring flow in both directions without modification Meter
10. Inhibit the integration amp registration of apparent flow which at times may be encountered on mobile installations where the movement of the vehicle or dead heading a pulsating pump may cause spurious flow signals which are not attributed to actual flow 3 Inhibit the integration amp registration of flow at input frequencies below what is considered the minimum accurate flow rate of the primary flow element flowmeter Caution If the low frequency cut off is set to any value other than 0 0Hz then the integration of rate and total will cease at frequencies on or below the set value HERTZ 2 5 Inhibit total see wiring schematic page 18 With the remote inhibit total switch closed the ZOD Z3 with display flow rate but at the same time will inhibit the resettable amp accumulative totalising functions 2 6 Keypad function matrix PROGRAM ES ATA rom an NON E NEERA N QQ Displays Accumulative Total when pressed refer clause 2 1 for options Toggles between Rate 8 resettable Total displays Resets the resettable total display to zero when it is being displayed 1 Pressing the Prog 8 Rate Total keys for 5 seconds enters you into the program mode 2 Displays model 8 software revision No No function No function 3 INSTALLATION 3 1 Remote Mounting Operation 6 No function No function No function 1 Each press steps you through each level of the program chart 2 Holding fo
11. LINK 7A select SPO or REP pulse O output see clause 4 8 o LINKS 13 amp 14 67 SPO scaled pulse SER select NPN or PNP REP repeater pulse style alarm outputs TA e Inhibit total switch B clause 2 5 Flow input EN conditioning DIP 3 A switches I ae REMOTE KEYS real OOOO NPN PNP LINK 7B Q o Select NPN or PNP style pulse output use momentary action switches SWITCH 3 ON engages 8200 pull down resister a SWITCH 2 ON engages 1 meg Q pull up resister reset program lt SWITCH 1 ON engages 0 01uf capacitor to accum total suppress reed switch bounce rate total lt 19 Rate dampening Response curve to 99 of actual flow rate Response curve to 90 of actual flow rate RESPONSE TIME seconds 9 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 ZOD Z3 DAMPENING VALUE Rate dampening value verses time to reach new reading for an instantaneous change in actual flow rate Dual flow inputs Dual flow inputs 20 When externally powered at terminals 5 8 6 the ZOD Z3 provides a dual flow input feature which can be configured for one of three available functions of A B A B or A B ratio The dual flow inputs are referred
12. linear Linearity Repeatability Max pressure Temperature range Material Body Rotor Rotor shaft Bearing Seals Electronics Output frequency at max velocity Supply voltage Electronic features Wiring standard Transmission distance Cable entry terminal box Protection Class Straight piping requirement Weight page 3 0 3 10 m s equates to approx O 25 49 000 l s in DN40 to DN2500 pipes 0 15 10 m s when using the linearisation function of electronic type Z3 1 5 with well est flow profile 1 of f s at factory conditions and optimal straight runs 80 bar 40 100 C standard see max allowable medium temperature table for other options and restrictions stainless steel 1 4404 316L PVDF or PEEK depending on model stainless steel 1 4404 316L graphite PTFE FPM standard 15 200 C EPR ethylene propylene rubber 20 120 C for ketones only PTFE encapsulated FPM 20 200 C NBR Nitril 65 125 C 220 240 Hz hall effect and voltage output 73 80 Hz reed switch output see electrical output specifications and electronics comparison table in the data sheet see electronics comparison table in the data sheet 5 core screened cable length 3 meters 1 000 meters maximum without integrated electronics M20x1 5 standard 1 2 NPT adapter optional IP68 cable connection IP66 67 all other electrical connections Min
13. 14 High flow relay 2 Low flow relay 1 7B 0 0 0 lt Set jumper IMPORTANT NPN PNP to NPN For solenoid valve coils fix a 1N4004 electrical surge suppression diode across the coil refer page 10 7 5 Current Sourcing outputs PNP Current sourcing gets its name from the fact that it sources current to a load When activated the current flows from the output 7 13 amp 14 into the load When wired as below the output voltage pulse is the supply voltage of the load The load would normally have an internal pull down resistor on its input as shown A H PNP lt Set jumper s no NPN to PNP 13 14 High flow relay 2 Low flow relay 1 5 OV ground S 8 24Vdc in Alarm output 0V ground 7B o o o Set jumper NPN PNP to PNP ARE 4H Do not tie 0 volts of the logic input to O volts of the ZOD B1 when wired in PNP configuration 18 Networking Networking continued 19 8 CONTROLLER NETWORKING Multi point batching Flowmeter ZOD B1 has a unique networking feature which allows up to 9 individual batch controllers to be networked together with each being connected to one common flowmeter see opposite Typical applications are where one liquid is being dispensed to a number of individual outlets or a number of different liquids are to be batched via one common flowmeter In either application each batch controller is wired to the same flowmeter but controls its own proce
14. 2 Voltage Pulse 8 pulse wires Relay 2 high Relay 1 low All flow DIP swithes off Batch status OV ground 8 24Vdc in 3 Coil Turbine paddle style flowmeters Factory set do not change All flow DIP switches off position switch 1 ON if unit is effected by line noise Relay 2 high Relay 1 low Batch status Not used Not used Network loop OV ground 8 24Vdc in 3 2 Flowmeter connections powered sensors 4 Hall Effect open collector Flow input DIP SW2 is on loop Signal out T LI L a Fon A Vdc supply OV ground 8 24Vdc in 5 Namur inductive proximity switch Network Flow input DIP SW3 is on loop Input A an NAMUR i n Inductive Proximity OV ground 8 24Vdc in Pulse output NOTE Limit supply to 8 5Vdc through an approved barrier for intrinsically safe NAMUR proximities 6 Current modulated pulse 4mA to 20mA pulse amplitude Flow input DIP switches off Network NOTE Position a 1000 14W loop Resistor across terminals 3 amp 5 Flow Input A Coil with pre amp current modulated OV ground 8 24Vdc in Pulse output Network Installation Factory set do not change Relay 2 high Relay 1 low Batch status Factory set do not change Relay 2 high Relay 1 low Batch status Not used Not used OV ground Factory set do no
15. 7 x 0 3mm 0 5mm should be used for electrical PROGRAM key for 3 seconds to connection between the flowmeter and remote instrumentation Belden number 9363 or similar The cable drain enter program mode or screen should be terminated on a DC COMMON or a specifically assigned shield termination at the readout instrument end only in order to protect the transmitted signal from mutual inductive interference IMPORTANT tape Press B key to select function off amp isolate the shield at the flowmeter end of the cable b F I converter p Divider p Flow switch The cable should not be run in a common conduit or parallel with power and high inductive load carrying cables as power surges may induce erroneous noise transients onto the transmitted pulse signal or cause damage to the electronics Run the cable in a separate conduit or with low energy instrument cables only PROGRAM PROGRAM PROGRAM loop wiring The loop powered milliamp output is generally analog 4 to 20mA or may be programmed in Position Pm Select A gt Position field for status switching between 4 amp 20mA for decimal point divider factor decimal point either divided pulse or flow switch output GND PROGRAM PROGRAM PROGRAM MIZI PA 2 fl d D Selectfull A gt Selectfow A scale frequency Hz Switch point Hz PROGRAM PROGRAM FI A PERSE rus 24Vdc supply COH Run mode display defaults to a totaliser divided value
16. 8 Ground screen at terminal 5 NAMUR e Inductive Proximity NOTE Limit supply to 8 5Vdc through an approved barrier for intrinsically safe NAMUR proximities 6 Current modulated pulse 4mA to 20mA pulse amplitude DIP switches off NOTE Position a 1000 14W Resistor across terminals 3 amp 5 o 3 Flow High flow alarm 4 INPULB Low flow alarm Ground screen OG Flow 4 20mA output at terminal 5 N fit A 4 20mA Coil with pre amp B 4 20mA output current modulated A 0V od not used 8 24Vdc in not used 9 Pulse output OV ground 8 Installation 10 3 3 Wiring connections for l S installations refer to I S supplement External DC powering required for powered flow sensors flow alarms or pulse outputs amp dual flow inputs Flow High flow alarm InputB Low flow alarm Es E Flow 4 20mA output CAUTION Avoid using low cost digital switch mode 8 24Vdc Input A regulated supply a 4 20mMA output OV ground not used power packs 6 8 24Vdc in not used 9 Pulse output OV ground 8 Powering via 4 20mA loop Negative referenced High flow alarm Input B Low flow alarm Signal out JUL Negative effect Yde supply __ _J____ Flow 4 20mA output InputA 4 20mA mall v Pulse output OV ground 8 Shows powering of a Hall Effect device using the loop power source if required Optional wiring i
17. EN 13463 1 2009 Non electrical equipment for use in potentially explosive atmospheres When fitted with an integral EX ia certified instrument such as the ZOD Z3 or ZOD Z1 in combination with a Reed Switch only output the product also complies with 94 9 EC ATEX Directive page 15 Certificate about acknowledgement of quality assurance production Certificate number BVS 12 ATEX ZQS E110 Certification body DEKRA EXAM GmbH notified body No 0158 SIRA 06 ATEX M348 Only when equipped with integral ZOD Z3 or ZOD Z1 options Issued by Sira Certification United Kingdom EN 13980 2002 Potentially Explosive Atmospheres Application of Quality Systems 94 9 EC Articles IV and VII ATEX Directive H Peters M Wenzel General Manager Proxy Holder Hofheim 12 Nov 2013 11 Declaration of Conformance We KOBOLD Messring GmbH Hofheim Ts Germany declare under our sole responsibility that the product Batch Controller Model ZOD B1K to which this declaration relates is in conformity with the standards noted below Universal Mount Series EN 60529 DIN VDE 0470 1 1992 11 I P Ingress Protection Classifications EN 61326 1 2006 10 BATCH CONTROUER Model ZOD BIK Electrical equipment for control instrumentation technology and laboratory use EMC requirements Industrial area INSTRUCTION MANUAL EN 61010 1 2002 08 Safety requirements for electrical equipment for measurement control and laboratory use 2008 35 EC W
18. L hr the alarm will not switch off until the flow increases above BAND XX HIGH 105 L hr L22 DUAL INPUTS REQUIRED Y N DUAL Y N L23 ENTER NUMBER PULSES PER Ltr m3 kg gal Ib unit FOR INPUT B 00000 001 9999999 9 NO L24 SET DUAL INPUT FUNCTION A B A B A B program return 17 Programming 6 4 Program detail record Pencil your program details here mo n 0 0 0 00 10 000 mo Mon 10 00 10 000 mo 300 10 00 10 000 cl yes C no RCF Units Sec Min Hr Day yes no L11 pulse value L12 Non linear correction yes _ no baaa frequency 1 Power mode Ultrasave L Standby Continuous L14 Analog output yes no zero set point L16 span set point LI no lt D Ma Alarm outputs low set point percentage 3S low deadband high set point high deadband Yo L22 Dual flow inputs yes _ no L23 K factor for B input K L24 dual input function LI A B L A B A B Your back up 4 digit PIN number is 1820 Terminal designation 18 l TERMINAL DESIGNATION Terminal Terminal High fl 14 Terminals 1 2 amp 5 replicate l Flow S terminals 3 4 amp 5 for dual 2 input B Low flow alarm 13 flow inputs 3 Flow 4 20mA output 12 4 input A 4 20mA output 11 5 OV ground not used 10 6 8 24Vdc in not used 9 7 Pulse output OV ground 8 Terminal layout links amp remote switch inputs
19. Terminal layout Troubleshooting w Wiring connections Wiring practice 14 17 11 12 11 13 14 11 12 12 10 15 8 11 10 Universal Mount Series OBOLD O ZOD Z3 FLOW RATE TOTAUSER INSTRUCTION MANUAL Software version 16 12 04 27 04 07 Press amp hold Program key to show instrument model amp software version Replacement Batteries KOBOLD supplied batteries Non l S battery KOBOLD P No 1312007 A l S battery Kobold P No 1412028 Warning KOBOLD Intrinsically safe battery assembly only is approved for ZOD Z3 mounted in a hazardous area Suitable non l S batteries also available from R S Components Farnell Components Stock No 596 602 Order code 206 532 3 6V x 2 4Ah AA Lithium Thionyl Chloride non rechargeable cell TABLE OF CONTENTS INTRODUCTION 1 1 Model number designation 1 2 Specifications 1 3 Overview 1 4 LCD displays OPERATION 2 1 Accumulative total display 2 2 Resettable total display 2 3 Rate display 2 4 Low frequency cut off 2 9 Inhibit total function 2 6 Keypad function matrix INSTALLATION 3 1 Mounting wall surface mount pipe mount panel mount 3 2 Flowmeter connections unpowered sensors powered sensors 3 3 Wiring connections external powering 4 20mA loop powering wiring requirements pulse outputs alarm outputs remote switches PROGRAM PARAMETERS 4 1 PIN number program protect
20. Total The batch value is displayed in all normal operational modes 2 5 Accumulative Total Accumulative total can be reset in the program mode The accumulative total is displayed momentarily by pressing the ACCUM TOTAL key 2 6 TNB display Total number of batches ZOD B1 will accumulate the total number of individual completed batches Reset of TNB is simultaneous with the resetting of the Accumulative total in program mode To view the TNB value simultaneously press amp hold the two top right hand keys Prog amp Accum Tot 2 7 Keypad functions KEY FUNCTION IN OPERATING MODE FUNCTION IN PROGRAM MODE 1 Enters amp Exits the batch set mode 2 May be pressed during batching to show batch pre set value this action will not No function interfere with the batch process Selects the digit to be Increments the selected digit Indexed digit will flash selected digit will be flashing Pressing PROG amp STOP keys for 5 sec gives entry to the program mode 1 Resets the batch to the last pre set value 2 Resets individual digits to zero when No function in the BATCH SET mode 1 Displays Unit ID number followed by the Accumulative Total as the key is held No functi 2 Displays total number of batches press O TUNCUON Accum Total 8 Prog keys at the same time 1 Pressing PROGRAM 8 STOP keys for 5 Pressing PROGRAM amp ACCUM TOTAL keys Seconds gives entry to the program mode displays the Total Number of
21. YN O cC L cl i nfo g OS ES Z O OSO O yB S Oy XA VOS OOo fH onto canada o EI TOO a P i 0o D 2535 oc Ty EO e roncrrrcrcrcrrrrrrrrrrcner no an oO Q c5G58a a gt b DELL kai k P 120398 L lt SaS DO D aa D Co HERE DHS O L pei os 2yg S pos OLSON 20005527 D ES pir BAJZra3 a jo 50C53 Too avo O 253538 22092 ng gt On ESO x copo acZdyod i Ge 00H S O 0US QV Ec dD E 7 CS CO ZE ope te Os ILLES OnsaraZszlce page 8 3 3 Instrument cable installation requirements Use twisted multi core low capacitance shielded instrument cable 22 AWG 7x 0 3 stranded for electrical connection between the flow meter and the remote instrumentation The screen should be earthed at the readout instrument end only to protect the transmitted signal from mutual inductive interference The cable should not be run in a common conduit or parallel with power and high inductive load carrying cables as power surges may induce erroneous noise transients onto the transmitted pulse signal Run the cable in separate conduit or with other low energy instrument cables 3 4 Pulse output selection standard outputs The standard flowmeter has two independent pulse output signals that are linearly proportional to volumetric flow rate Pulse transmission can be up to 1000 metres 3300 ft An optional I S Reed Switch output is available see page 7 Voltage pulse pulse wire output
22. a normal condition as the circuit dissipates the excess input voltage Supplement 21 Remove a batterv Relay board plugs inte 16 amp 20 pin sockets Relay control output board with two SPCO relays shown with a ZOD Z3 N O contacts are rated to 5A amp the N C contacts 3A max Relay board held by Y battery cradle clips FI 420 Universal pulse processor board INSTRUCTION MANUAL SUPPLEMENT WOW ye ki go PWE A Mr to gt SPAN 4 20 w a Zn i ie fie 4 IMFI420 0212 Introduction 1 Specifications Programming On board programming via three tactile push buttons Display 4 digit seven segment LCD with 4 levels of contrast adjustment Input frequency Hall Effect amp Coil 1 0 9999 Hz frequencies below 1hz are not registered Reed Switch 1 0 80 0 Hz frequencies below 1hz are not registered Input sensor types Reed switch Hall Effect pulse wire or reluctance coil turbine meter Milliamp outputs Pulse repeater output Maximum loop powered voltage 1 Analog 4 20mA 600Q maximum drive capability 28Vac 2 Modulated between 4 and 20mA divided pulse amp flow switch Isolated NPN square wave 30Vdc x 100mA maximum load 28Vdc absolute maximum reverse polarity protected Accuracy 0 3 of span Response Programmable 1 9 seconds Full scale limit 20mA internally limited over range defaults to OmA Temperature range 10 C 80 C Processor 8 bit processing via 256 step
23. flow goes above the set point 2 Deadband a bANa or Reset Differential provides a buffer zone about the alarm set point in order to L d bANd avoid alarm output chattering on 8 off when the flow rate is hovering on or about an alarm set point XXXXXX The deadband applies above the Low set point and HI FL below the High set point Deadband is set as a O percentage of each set point Eg 5 deadband at a low alarm set point of 100 L hr will cause a low alarm when the flow drops to 100 L hr the alarm will not H d bANd switch off until the flow increases above 105 L hr N YES No ENd Prog YES Saves settings amp exits program 5 2 Program detail record User selected PIN No Engineering units K factor scale factor Decimal for reset Total L 0 C 0 0 C 0 00 10 000 Decimal for Accum total 0 L 0 0 L 0 00 10 000 L 0 L 0 0 0 00 10 000 Decimal for Rate Units Sec Min Hr Day Set at Deadband Set at Deadband Yo Time base for Rate Rate response Low frequency cut off Scaled pulse output Low flow alarm High flow alarm Your back up 4 digit PIN number is 1820 gl LI i BE E ki jo El Index ALPHABETICAL INDEX Accumulative total Battery Backlighting the LCD display DC power Decimal point Displays Display priority Engineering units External DC powering Flow alarms Flowmeter connections Flow rate Installation Input signals Keypad functio
24. from graph pipe ID inches Example b K factor for 10 pipe 1 from graph 10 ID A 7 01 2 pulses gal 24 51 x 7 01 100 1 718 p gal NOTE K factors for Reed Switch output option are 1 3 the standard factors of voltage pulse output page 14 5 0 Declaration of Conformance We KOBOLD Messring GmbH Hofheim Ts Germany declare under our sole responsibility that the product Bi Directional Insertion Flow Transducer Model DOR to which this declaration relates is in conformity with the standards noted below 97 23 EC Pressure Equipment Directive Pressure Accessory Insertion Flowmeter No CE Marking Article 3 Paragraph 3 Diagram 9 Piping Group II Liquids Article 3 Paragraph 3 Diagram 8 Piping Group Liquids with the following restrictions Connection Nominal Size Maximum Pressure Rating For Group Liquids 1 5 40 mm 50 bar 2 50 mm 40 bar 2002 96 EC Waste Electrical 4 Electronic Equipment WEEE 2002 95 EC Restriction of Hazardous Substances RoHS Also the following EEC guidelines are fulfilled 2004 108 EC EMC Directive Electromagnetic Compatibility Directive When fitted with an optional Reed Switch ONLY pulse output which is classified as a simple apparatus and when installed in accordance with Hazardous Area standards by a competent professional the product also complies with EN 60079 11 2011 Section 5 7 Equipment protected by Intrinsic Safety Simple Apparatus
25. if the battery is removed Environments The instrument is weatherproof to IP66 67 Nema 4X standards constructed in ADC12 aluminum alloy with Stainless screws 8 FKM O ring seals The instrument suits harsh indoor and outdoor environments amp conforms to EMC directive 89 336 EEC Electro Magnetic Compatibility Features PIN Protection NPN scaleable pulse output Low frequency cut off display priority amp large backlit digital display backlighting enabled under external DC power only Installation Specifically engineered to be directly mounted on a variety of flowmeters wall or surface mounted pipe or panel mounted Various mounting kits are available The instrument can be self powered or may be powered by an external dc supply or two wire loop powered 1 4 LCD displays Full LCD display test feature illuminates all Ltr display segments and script text displays for 5 seconds when entering the program mode l o l o l o l l o l o bs Resetable Total This large 6 digit display can m a l E rl See a be programmed for up to 3 decimal places AA gt a LI a a E A E a po A Accumulative Total The 8 digit display can be programmed for up to 3 decimal places Reset is only possible when in the program mode which can be PIN protected for security l l Rate display Rate is displayed with a flashing l followed by up to 5 digits of rate these are time base of either SEC min hr or dAy R programmable for
26. kit ERS ZOD 1522002 stainless steel 2 pipe mount kit ERS ZOD 1522011 DRT series cooling fin kit for flowmeters with integral instruments ERS ZOD 1522005 DOR amp Turbine stem adaptor metric M16 to M20 ERS ZOD 1522006 DOR 8 Turbine stem adaptor USA M16 to 1 2 NPT ERS ZOD 1323006 DOR 42 stem 100mm effective height threaded M16 male ERS ZOD1323011 DOR 52 stem 350mm effective height threaded M16 male ERS ZOD 1322071 3 4 BSPF fixed stem for Turbine flowmeters 3 4 BSPF to M16 ERS ZOD 132822101 1 NPTF universal swivel stem for Turbine flowmeters 3 4 BSPF to M16 ERS ZOD 1334001 DC switch mode DIN mount power supply 100 240Vac input ERS ZOD 1412063 Relay contol output board with two SPCO relays 3 Introduction 1 2 Specifications Display Signal Input Battery power External power Memory Pulse output Analog output 8 digit alpha numeric LCD characters 9mm 0 35 high with second line sub script text 8 digits totalising 5 digits rate Programmable 0 3 decimal places for all displays Universal pulse frequency input compatible with Reed switch Hall effect Namur proximity detectors Pulse wire voltage current amp Coil 15mV P P min Max input frequency 10Khz Minimum input frequency for rate display is 0 1hz with low frequency cut off feature enabled 0 3hz when disabled amp 0 7hz if the non linearity feature is enabled Totals have no minimum Battery life expec
27. pulse amplitude DIP switches off NOTE Position a 1000 14W Resistor across terminals 3 amp 5 OV ground Remote reset 03 Fa m2 fa Coil with pre amp B d1 current modulated A OV ground 6 8 24Vdc in 12 Installation 3 3 Wiring connections External DC powering required for powered flow sensors display backlighting or pulse outputs CAUTION Avoid using low cost digital switch mode power packs OV ground Remote reset Flow Input OV ground 8 24Vdc in A Pulse output 8 24Vdc regulated supply EN 2 3 a 5 6 Note Powering the instrument from an external DC source will cause the backlighting feature to turn on if this is not desirable at all times then install a power isolation switch in series with the DC power source as shown Remote reset Terminals 1 amp 2 cater for the connection of a remote reset switch this will reset the 6 digit resettable totaliser display but does not effect the 8 digit Accumulative totaliser The remote switch needs to have a momentary contact action only Remote reset switch AJO as a Remote reset switch is to have a momentary action normally open Wiring requirements Use multi core screened twisted pair instrument cable 0 25 0 5mm2 for electrical connection between the RT and any remote flowmeter or receiving instrument The screen needs to be earthed to the signal ground of the receiving instrument only to protect the tran
28. switches OV ground ES Feessseossoesosesssossseseseosooesosesssossoessseosoossesessoossoossseosoeesesesososesessseesooeesosesssosssosssoosoeesesesssossoossscosoeesesesssosssossscososesesesssossoessssesooee Flowmeter Reference information 20 9 REFERENCE INFORMATION 9 Program detail Pencil your program details here seconds seconds O inhibit network function 9 2 Error messages ZOD B1 has a series of error messages which are scrolled across the LCD display when ever an error condition exists NO POWER NO INPUT BATCH VALUE EXCEEDS BATCH LIMIT PRE STOP EXCEEDS BATCH VALUE WAIT 9 Go No power indicates that the instrument is on battery power only and needs to be supplied with an external power source in order to operate No input missing pulse detection indicates that no pulses were received at the controller input within the time out period at any stage of the batch cycle see clause 4 9 The new batch value will not be accepted because it exceeds the maximum batch limit value see clause 4 10 The new batch value will not be accepted as it is less than the pre stop value clause 4 7 This message will show if the RUN button is pressed whilst the controller is in the process of assessing the degree of overrun from the previous batch when AOC is enabled 1 Back up PIN number see clause 4 1 Cut from manual for increased security Yo
29. the instrument runs on 3 6Vdc the battery icon illuminates when the battery output falls below 3 1Vdc at this point the instrument will continue to operate for a short period but the battery should be change as soon as possible batteries are readily available from all major electronic component suppliers see page 2 for details External power Regulated 8 24Vdc x 50mA minimum Memory All programmed amp accumulated data is stored permanently in non volatile memory Pulse output NPN transistor scaleable 5Khz max 100mA maximum drive capability IP66 67 aluminum alloy with 0 3 magnesium 6 is maximum for mine sites 3 x M16 x 1 5 female conduit entries A B C 114mm 4 5 wide x 96mm 3 8 high x 62mm deep 2 5 x 480g 11b D Temperature range from 20 C to 80 C 4 F to 176 F Physical Configuring PIN protected data entry K factor range scale factor Eg Pulses litre gallon lb etc Programmable range is 0 001 99 999 999 with a floating decimal point during K factor entry Engineering units Selectable Ltr gal m3 kgs lbs total sec min hr or day rate 6 Introduction 1 3 Overview The instrument will display Flow Rate Resettable Total and an Accumulated Total in engineering units as programmed by the user Simple flow chart programming prompts you through the programming set up greatly reducing the need to refer to the instruction manual All user program data is retained
30. to as INPUT A at terminals 3 8 4 and INPUT B at terminals 1 amp 2 Function A B Both inputs are added together and displayed as one for Rate Resettable amp Accumulative Totals Displays Rate Reset Total Accum Total Outputs Scaled Pulse Alarms Analog Output Function A B The total of A B flow rates displayed as one rate The total of A B totals displayed as one total The total of A B accum totals displayed as one total Scaled pulse value is relative to the totalised values Alarms are taken relative to the displayed rate 4 20mA output is proportional to the displayed rate Input B is subtracted from input A the resultant is displayed as one for Rate Resettable amp Accumulative Totals Displays Rate Reset Total Accum Total Outputs Scaled Pulse Alarms Analog Output Function A B The difference of A B flow rates displayed as one rate The difference of A B totals displayed as one total The difference of A B accum tot displayed as one total Scaled pulse value is relative to the totalised values Alarms are taken relative to the displayed rate 4 20mA output is proportional to the displayed rate Input A is divided by input B the resultant is displayed as an instantaneous Ratio Resettable 4 Accumulative Totals are independently displayed for both A B inputs Displays Outputs Rate Reset Total input A Reset Total input B Accum Total input A Accum Total input B S
31. up to 3 floating decimal IM CO Imin A dis NOE a Time bases of units SEC amp units dAy are displayed to the left of the digital display whilst LEI le units min amp hr are to the right of the rate digits as shown Backlighting The LCD backlight feature will only work from an external dc power source in the range of 8 24Vdc M IO JAY 943 Operation 7 2 OPERATION 2 1 Accumulative Total Accumulative total can be reset in the program mode The accumulative total is displayed by pressing the ACCUM TOTAL key 2 2 Resettable Total The resettable total display remains visible at all times amp may be reset at any time by pressing the reset button for 1 2 seconds 2 3 Rate display The second line display toggles between Rate amp Accumulative Total as the appropriate keys are pressed The instrument will default out of the rate mode after 1 minute when under battery power this is to conserve the battery as the unit draws more current when it needs to calculate rate Under external power the instrument will remain on Rate or Accumulative Total as they are selected When rate is displayed the leading three alpha characters on the left of the display flash the time base for rate eg rate SEC rate dAy amp rate min or rate hr to the left of the rate digits Decimal points float to provide good resolution amp rangeability _Lltr SEC o SEL cr A bet litres second w litres second The minim
32. Batches TNB 2 Steps you through the program ladder 3 Holding for 3 secs fast tracks to end prog 1 Starts a batch 2 Resumes a batch if paused Pauses a batch during batching D0000Y0 6 Installation Installation 7 3 1 Mounting 3 1 Mounting Integral meter Vertical pipe mount mounts order Pipe mount kit P No APM comprising two brackets screws and worm drive clamps Panel mount Horizontal R pipe mount E Surface mount footprint use 4 screws supplied doooeoeeeanencnCCCoCCSS Wall mount usina optional 3 Conduit entries have an integral a bracket set a ANY jen a moulded seal to remove break Cuta 106 5mm 4 2 96mm 3 8 i i 18mm seal out using suitable lever diameter hole in panel di eg screwdriver or rod 8 Installation 3 2 Flowmeter connections un powered sensors Flow input switch functions Factory set network default settings do not change 3 Switch 1 ON engages 0 01uf capacitor to suppress reed switch bounce Flow Input Switch 2 ON engages 1 meg Q pull up resister Switch 3 ON engages 8200 pull down resister Factory set do not change 1 Reed switch 200hz max Relay 2 high Flow DIP switches 1 4 2 are on Relay 1 low Batch status Not used Not used Network loop ground 8 24Vdc in on gt Ground screen at OV 5 Factory set do not change
33. CUM TOTAL STOP BAT LOW HIGH RATE Lanp hy al al OJI LOW HIGH LILI T ss TOTAL ACCUM TOTAL Full LCD display test feature illuminates all display segments and script text displays for 5 seconds when entering the program mode Up to 8 digits of Batch quantity programmable for up to 3 decimal places English prompts clearly show the status of the batch An 5 digit TNB display shows the Total number of batches dispensed since last reset reset of TNB and Accumulative Total is only possible whilst in the program mode The 8 digit Accumulative Total display can be programmed for up to 3 decimal places Reset is only possible when in the program mode which can be PIN protected for security Operation 5 2 OPERATION 2 1 Batch set Pressing the Batch set key allows the user to enter a batch value by using the arrowed keys to select the appropriate digits and change their value Pressing Batch set again enters amp confirms that the new batch value has been entered 2 2 Run Press RESET then RUN to start the batch If there are no interruptions the batch controller will automatically stop the batch once the batch value has been reached 2 3 Stop Pressing the STOP key at any time during the batch will cause the batcher to go into a PAUSED state and the output relays will be turned off At this point the user can resume batching by pressing the RUN key or abort the batch by pressing the RESET key 2 4 Batch
34. EC Waste Electrical amp Electronic Equipment WEEE Also the following EEC guidelines are fulfilled 2004 108EC EMC Directive 2006 95 EC Low Voltage Directive ALE Ya I Hofheim 17 Sep 2010 H Peters M Wenzel General Manager Proxy Holder K01 1110 Software issue ED Press amp hold Program key to show instrument software version Replacement Batteries battery P No 1312007 O R S Components Farnell Components Stock No 596 602 Order code 206 532 3 6V x 2 4Ah AA Lithium Thionyl Chloride non rechargeable cell TABLE OF CONTENTS INTRODUCTION 1 1 Order Details 1 2 Specifications 1 3 Overview 1 4 LCD displays OPERATION 2 1 Accumulative total display 2 2 Resettable total display 2 3 Rate display 2 4 Keypad function matrix INSTALLATION 3 1 Remote mounting Surface mount footprint wall surface mount panel mount pipe mount facia protector option 3 2 Flowmeter connections unpowered sensors powered sensors 3 3 Wiring connections external powering remote reset wiring requirements scaled pulse output PROGRAM PARAMETERS 4 1 PIN number program protection 4 2 Resetting accumulative total 4 3 Engineering units 4 4 K factor flow input scale factor 4 6 Rate response 4 7 Low frequency cut off refer clause 2 4 page 5 PROGRAMMING 5 1 Programming ladder chart 5 2 Program detail record PANEL MOUNT DRILL TEMPLATE Supplement Declaration of Co
35. K03 1213 Manufactured and sold by Kobold Messring GmbH Nordring 22 24 D 65719 Hofheim Tel 49 0 6192 2990 Fax 49 0 6192 23398 BI DIRECTIONAL INSERTION FLOW TRANSDUCER Model DOR INSTRUCTION MANUAL BIL A Air ot or Mo IMPORTANT INFORMATION Thank you for purchasing a Kobold Insertion Flowmeter It is important that you read this manual to gain a full understanding of the capability and operational aspects of the equipment you are about to install This information is provided only to assist in the installation of the product and does not diminish your obligation to read the manual 1 Select a location that meets the requirements as illustrated on the guideline sheet please see the data sheet order codes An ideal installation would provide for 25 diameters of straight pipe upstream from the meter and 10 diameters downstream You will also need to know the pipe internal diameter NB and pipe wall thickness for calculation of the insertion depth refer page 5 Non ideal installations may require in situ calibration refer to the factory for details 2 After screwing the flowmeter in place ensure the flow alignment mark located on the top positioning collar of the meter aligns with the flow in the pipe refer page 5 This ensures the paddle is correctly aligned to the flow Note the meter is bi directional so a flow direction arrow is not provided 3 Calculate and adjust the height of the flowme
36. OR 52 stem 350mm effective height threaded M16 male Relay contol output board with two SPCO relays DOM series cooling fin kit for flowmeters with integral instruments 1 2 Specifications Display Functions Configuration Signal Input Power requirement Battery Control outputs Alarm pulse output Batch status output K factor range Engineering units Count direction Automatic overrun compensation Batch limiting Run inhibit input Network I O Physical Introduction 8 digit aloha numeric LCD characters 9mm 0 35 high with second line sub script text 8 digits totalising 3 programmable decimal points 5 digits for Total number of batches Batch total Accumulated total amp Total number of batches TNB Flow chart entry of data with scrolling English text prompts User selectable 4 digit PIN number set up protection Programmable decimal points and K factors All programmed data and batch status are EPROM protected in the event of a power failure Universal pulse frequency input compatible with Reed switch Hall effect Namur proximity detectors Pulse wire voltage current amp Coil 15mV P P min Max input frequency 10Khz Regulated 12 24Vdc x 50mA add switched current 3 6Vdc lithium battery annunciates a power loss amp preserves batch settings amp progress at time of power loss Two independent NPN open collectors 1A dc resistive load max
37. ORT 10 ESTOPN PAUSE NL Y TO RESUME 16 Secondary I O 7 SECONDARY I O 7 1 Batch Status Output A solid state NPN output signal is switched on at terminal 12 when a batch is started the signal remains on until the batch cycle is completely finished or the batch is stopped and aborted using the STOP 8 RESET keys The output is used to notify other control equipment when ZOD B1 is in operation or is paused by pressing STOP or inhibited through an input at terminal 9 RUN inhibit the signal remains on under all three conditions The signal can also be used to inhibit lock out other equipment whilst the controller is in use Batch status Flow refer 7 4 input OV ground 6 8 24Vdc in Run Inhibit 9 No flow alarm Alarm output OV ground 8 H T refer 7 4 amp 7 5 FON Run inhibit input closed inhibit RUN 7 2 Alarm Output An NPN PNP selectable solid state output signal ferminal 7 is activated when the missing pulse detection feature detects a no flow condition refer 4 9 NPN PNP selection is to be in accordance with the connection options on the following page 17 7 3 Run Inhibit Input The RUN inhibit feature enables ZOD B1 to interlock with other devices within the system or process when ZOD B1 is in use When a contact is made across the Run inhibit input at terminal 9 a batch cannot be started and at the same time an ENGAGED prompt will show on the LCD display If the inhibi
38. Pulse Width Modulation Resolution 62uA frequencies above 99 99 Hz are processed as whole numbers Program protection Overview All programmed amp accumulated data is stored in non volatile memory The FI 420 is a non volatile field programmable pulse converter which may be set to function as either a frequency to current converter F I a pulse divider or a single point flow rate alarm device for high or low flow rate detection The instrument also has an NPN pulse output which mirrors input pulse frequency this two wire signal may be used for remote totalisation and or rate indication The instrument is specifically designed to fit within the terminal housing of any of the propriety flowmeters or may be adapted to other styles of meters including Turbine and Insertion Paddle wheel flowmeters In all three functions the output signal remains as a milliamp signal as follows Function 1 frequency to current F I 4 20mA proportional to flow rate spanned as desired Function 2 frequency divider divider range 1 9999 output is 4mA pulse low and 20ma pulse high 25hz max Function 3 frequency flow rate alarm output is 4mA no alarm condition and 20ma flow rate alarm condition Calibration The philosophy behind the processor board rests on the origin of the flow input signal being expressed in terms of frequency rather than K factor scale factor however in order to derive the relevant frequency the user must work f
39. S 5 1 Analog Output loop powered The loop powered 4 20mA output can be spanned anywhere within the flow meter range Testing the current loop is available during programming when 4mA will output at programming level L15 and 20mA will output at level L16 page 16 Note If using the Rate Conversion Factor RCF the span for 20mA must be set in relation to the total units not the rate units 5 2 Flow Alarms The ZOD Z3 must be externally powered as per page 10 Two flow alarm FET transistor outputs may be programmed for Low amp High flow alarms 5 3 Flow Alarm Deadband Alarms are NPN PNP link selectable An adjustable deadband reset differential provides a trip buffer zone about the set point in order to overcome alarm chattering when the flow rate is fluctuating close to the alarm set point Deadband is entered as of each set point value refer to page 16 for an example 5 4 Dual Flow Inputs see also page 20 for complete description When externally powered at terminals 5 amp 6 the ZOD Z3 accepts inputs from two sources input A amp input B a separate scaling factor is entered for the second flow input the instrument is then programmed for one of the dual input functions of A B A B or A B ratio A B Both inputs are added and displayed as one for Rate amp Totals A B Input B is subtracted from input A amp the difference is displayed for both Rate amp Totals A B Totalises A 8 B separately amp Rate is a fu
40. S gallons Declaration of Conformance page 1 PAGE w 0 w ODIO oDVvooons Page 2 1 1 Model no designation Please see the data sheet 1 2 Overview Kobold insertion flow transducers provide a cost effective and simple means of measuring the flow of a wide range of low viscosity liquids Installation is quick and inexpensive for pipe diameters ranging from 40mm to 900mm 1 5 36 and up to 2500mm 100 nominal bore for the Hot tap capable model DOR 52 The flowmeter has a linear measuring range of 0 3 10 0 metres sec 1 33 ft sec Minimum detectable flow velocity is 0 15 m sec 0 5 ft sec When used in conjunction with the ZOD Z3 flow rate totaliser NLC feature the linear flow range is extended down to 0 15 m sec 0 5 ft sec with an improved linearity The flowmeter is constructed from 316 L 1 4404 stainless steel enabling use in many applications for metering water and low viscosity chemicals Two independent pulse outputs are standard amp can directly input to a wide range of ancillary instruments PLC s and computers Both pulse outputs have a high level of immunity to electrical interference Options include a reed switch 1 3 Operating principle Flow passes through a pipe causing the rotor to spin Magnets installed in the rotor pass by pulse sensors within the transducer body amp inturn this produces frequency outputs proportional to flow rate 1 4 Specifications Velocity measuring range
41. aste Electrical amp Electronic Equipment WEEE Also the following EWG guidelines are fulfilled 2004 108EC EMC Directive 2006 95 EC Low Voltage Directive Hofheim 8 Nov 2010 PE H Peters M Wenzel General Manager Proxy Holder Manufactured and sold by Kobold Messring GmbH Nordring 22 24 D 65719 Hofheim Tel 49 0 6192 2990 Fax 49 0 6192 23398 KO1 1110 Software versions n IONES AAA Replacement Battery P No ERS ZOD 1312007 3 6V x 2 4Ah AA Lithium Thionyl Chloride non rechargeable cell R S Components Stock No 596 602 Farnell Components Order code 206 532 Table of contents 1 10 INTRODUCTION 1 1 Model number designation 1 2 Specifications 1 8 Overview 1 4 LCD displays OPERATION 2 1 Batch Set 2 2 Batch RUN 2 3 Batch STOP 2 4 Batch Total 2 5 Accumulative total 2 6 Total Number of Batches TNB 2 1 Keypad function matrix INSTALLATION 3 1 Mounting integral mount wall mount pipe mount panel mount 3 2 Flowmeter connections unpowered sensors powered sensors 3 3 Wiring connections external powering remote switches wiring requirements single stage control two stage control relay control logic status amp relay connections PROGRAM PARAMETERS 4 1 PIN number protection 4 2 Resetting accumulative total 4 3 Engineering units 4 4 K factor scale factor 4 5 Decimal points 4 6 Count direction 4 7 Start delay amp Pr
42. bile installations where the movement of the vehicle or dead heading a pulsating pump may cause spurious flow signals which are not attributed to actual flow 3 Inhibit the integration amp registration of flow at input frequencies below what is considered the minimum accurate flow rate of the primary flow element flowmeter Caution If the low frequency cut off is set to any value other than 0 0Hz then the integration of rate and total will cease at frequencies on or below the set frequency value Programming 15 4 8 Display priority The large digits at the top of the display can be programmed to show either flow rate or resettable total When flow rate is selected at the top display the rate key can be used to cycle between rate reset total amp accumulate total in this mode the instrument will default from rate to reset amp accumulative totals after 1 minute external power must be applied if required to display rate at top display continuously 4 9 1 Flow Alarms The RT must be externally powered as per page 12 Two flow alarm FET transistor outputs may be programmed for Low amp High flow alarms An optional plug in alarm board is available having dual SPDT 5 amp electro mechanical contacts 4 9 2 Flow Alarm Deadband An adjustable deadband reset differential provides a trip buffer zone about the set point in order to overcome alarm chattering when the flow rate is fluctuating close to the alarm set point Deadband is ent
43. ble gland entry at base amp rear of the enclosure Overall 85mm diameter x 45mm deep x 175g 0 4Ib B C D Operating temperature 20 C 80 C 4 F 176 F Accumulated amp Resettable totals pre amplifier pulse output amp a scaleable pulse output Low battery indication Flow chart entry of data with English text prompts User selectable 4 digit PIN number program protection Programmable engineering units decimal points and K factors All programmed data protected with the battery Entered as pulses litre gallon b etc Programmable range is 0 001 9 999 999 999 with a floating decimal point during K factor scale factor entry Entered as engineering units pulse Range is 0 1 9999 9 units pulse Selectable Ltr Gal m3 kgs Ibs MLtr amp Mgal or no units of display A Introduction 1 3 Overview The ZOD Z1 series instruments are specifically designed for computing displaying totals from flowmeters with pulse or frequency outputs They are battery powered or can be powered by an external 8 24Vdc regulated or l S certified supply The instrument will display Resettable Total and an Accumulated Total in engineering units as programmed by the user Simple PIN protected flow chart programming with English prompts guide you through the programming routine greatly reducing the need to refer to the manual Special Features Standard PIN Protection Amplified non scaled repeater or scaleable pulse out
44. caled Pulse Alarms Analog Output The resultant Ratio between A B flow rates displayed as an instantaneous Ratio The total of input A The total of input B The Accumulative total of input A The Accumulative total of input B The scaled pulse output relates to input A Alarms are taken relative to the displayed ratio 4 20mA output is proportional to the displayed ratio Note The alarm and analog outputs for the A B function are set in the initial stages of programming in relation to rate units eg setting the analog output range to 4mA 00 000 litres min and 20mA 10 000 litres min the analog output will be proportional to the ratio rate display of 0 000 10 000 eg 4mA 0 000 and 20mA 10 000 The same set up analogy applies to the alarm settings Declaration of Conformance 21 di Declaration of Conformance We KOBOLD Messring GmbH Hofheim Ts Germany declare under our sole responsibility that the product Flow Rate Totaliser Model ZOD Z3K to which this declaration relates is in conformity with the standards noted below Optional for Equipment intended for use in Potentially Explosive Atmospheres ATEX Directive 94 9 EC EN 50014 1997 Amds 1 4 2 Intrinsically Safe Electronics 1 S Optional EN 50020 2002 Intrinsically Safe Electronics 1 S Optional EN 60529 DIN VDE 0470 1 1992 11 I P Ingress Protection Classifications EN 61326 1 2006 10 Electrical equipment for contr
45. e stop 4 8 Automatic overrun compensation AOC 4 9 Missing pulse detection no flow alarm output 4 10 Batch limiting 4 11 Controller network ID number PROGRAMMING FLOW CHART BATCH OPERATING PROCEDURE SECONDARY I O 7 1 Batch status output 7 2 No flow alarm output 71 3 Run inhibit input 7 4 Solid state output logics NPN selection TS Solid state output logics PNP selection BATCH CONTROLLER NETWORKING REFERENCE INFORMATION 9 1 Program detail record 9 2 Error messages 9 3 Back up PIN number ALPHABETICAL INDEX Eh KON a d O OA oo 2 Introduction 1 1 Model number designation Order Details Example ZOD B1KS1F300 Electrical Housing Type connection Supply Voltage Cable gland 1 KS universal mount 3x cable entry F3 8 24 VDC standard M20 Battery 2 3 x cable entry F1 110 VAC KM integral mount 1 2 NPT 8 24 VDC 0 without R 2x Relay PP panel mount 0 FO 220 VAC for ZOD IP20 screw terminal 8 24 VDC B1K order only when retrofitting a pulse meter only possible with ZOD B1PP Mechan ical protect ion 0 without S silicone bezel boot Part No ACCESSORIES FOR ABOVE SERIES Model ERS ZOD stainless steel wall mount kit stainless steel 2 pipe mount kit DOR amp Turbine stem adaptor metric M16 to M20 DOR amp Turbine stem adaptor USA M16 to 1 2 NPT DOR 42 stem 100mm effective height threaded M16 male D
46. er than 40 hz ON DIP switches OO 183 de bounce D in the ON position 40 hz max gnd Vdc l gnd Coil input from turbines or paddle DIP switch 1 in the ON position 5 Khz max Vdc tI L gnd and twisted pair A WO TO Voltage pulse input pulse wire DIP switch 1 in the ON position 2 Khz max Vdc L gnd Screen grounded at amphenol shroud or terminal box and terminal 3 at ZOD Z1 gnd yellow N aster gt 5 a B Installation 9 3 2 Flowmeter connections powered sensors Namur proximity NOTE Voltage not to exceed 13 4 Vdc through an approved barrier if when using input an intrinsically safe NAMUR proximity in a hazardous area EEx la 11C Typically DIP switch 2 in these proximity s are limited to 8 2 Vdc the ON position 250 hz max gnd Vdc l gnd NAMUR Inductive Proximity 8 24Vdc external power Ground screen at 3 Hall effect input NPN open collector DIP switch 1 in the ON position Vdc L gnd NOTE For an input gt 800hz position a Ya watt resistor across terminals 1 4 12Vdc 1Meg Q 24Vdc 2Meg Q gnd EL 1 Hall 8 24Vdc effect external power Modulated current pulse input 4 20mA All DIP switches to be in the OFF position Vdc gnd NOTE Position a 100 oh
47. ered as of each set point value refer to page 17 for an example Programming 16 5 1 Return to top ISSUE 1 0 AccESSED if PIN protected hold Program amp Reset keys for Prog k press Frog key 5 secs to access program mode to step through program levels Nu Pin rESEt ACCUM TOTAL XxXxxxxxx Ltr gal m3 Ibs kgs none Eng unit S FAct 00000 001 99999 999 0 0 0 0 00 0 000 dEc tot PEr SEC min hr dAy 001 999 rESPonSE if incorrect PIN No is entered rEAdonLY 4 Read only S factor K factor is the number of pulses unit volume or unit mass eg 20 465 pulses litre gallon kg etc 0 0 0 0 00 0 000 0 0 0 0 00 0 000 dEc rAtE Response to change in rate see rate dampening 4 6 Low frequency cut off is generally set to 0 0Hz disabled for most applications other than those described at clause 2 4 PuLSE The scaleable pulse output is set as the number of litres Out 0001 0 gallons etc per output pulse see clause 4 8 totAL rAtE toP diSP Continued over Assign resettable total or rate to the large LCD top display see display priority 4 8 of program page Programming 17 Return to top of program XXXXXX Optional alarm outputs Lo FLo 1 Low flow alarm Lo Flo occurs when the flow falls below the set point High flow alarm Hi Flo occurs when the
48. es are made after 4 minutes 14 Programming 5 PROGRAMMING FLOW CH V3 1 HOLD 3 2 1 TESTING DISPLAY 88888888 PROGRAM MODE ENTERED if PIN protected ENTER PIN PIN press Prog key to step through program levels CHANGE PIN No Y N NUPIN Y N YES NO RESET ACCUM TOTALS Y N RESET Y N SET ENGINEERING UNITS ENG UNIT Ltr gal m3 Ibs kgs none ENTER NUMBER PULSES PER Ltr m3 kg gal Ib unit K 0000 001 999999 999 SET DECIMAL POINTS DPt TOTAL 0 0 0 0 00 0 000 DPt ACCUM TOTAL O 0 0 0 00 0 00 SET COUNT DIRECTION COUNT DN UP START DELAY RELAY 2 DELAY 000 999 seconds PRE STOP VALUE RELAY 2 PRE 000 999 AUTOMATIC OVERRUN COMPENSATION AICOMP Y N continued ART CE hold Program amp Stop 6 keys for 5 secs to C stop enter the program if incorrect PIN No is entered INVALID PIN VIEW EXISTING PROGRAM DETAILS ONLY gt K factor scale factor is the number of pulses per unit volume or unit mass eg 20 465 pulses litre gallon kg etc SET MISSING PULSE TIME OUT T OUT 00 99 seconds SET BATCH LIMIT XXXXXXXX NETWORK OPERATION N WORK Y N YES NO SET UNIT ID No ID No X See page 13 NO YES Exit program mode BATCH OPERATING PROCEDURE TO REPEAT BATCH Operating 15 fentcu SEN TO CHANGE A BATCH ENTER BATCH A QTY XXXXXXXX AIDA UM O TO AB
49. ets screws and worm drive clamps seo HAAR e G Optional facia protector 3mm clear polycarbonate plate with access port for keys Order P No 1306067 Horizontal pipe mount 10 Installation 3 2 Flowmeter connections unpowered sensors DIP switch functions Switch 3 ON engages 8200 pull down resister Input Switch 2 ON engages 1 meg pull up resister Switch 1 ON engages 0 01uf capacitor to suppress reed switch bounce 1 Reed switch DIP switch 1 amp 2 are on 2 Flow Input ae gt Ground screen at OV 5 6 8 24Vdc in 2 Voltage Pulse Flow Input 3 Coil Turbine 8 paddle style flowmeters minimum 15mV p p All DIP switches off position switch 1 OV ground ON if unit is effected by line noise Remote reset 03 a d1 OV ground 8 24Vdc in Pulse output Installation 11 3 2 Flowmeter connections powered sensors 4 Hall effect 5 24Vac open collector DIP SW2 pull up is on OV ground Remote reset Signal out J U L A ti pos OW OV ground ime Input Vdc supply m OV ground 8 24Vdc in Ground screen 5 Namur inductive proximity switch DIP SW3 pull down is on Ground screen LF 3 O Flow at terminal 5 As Input NAMUR Inductive Proximity NOTE Limit supply to 8 5Vdc through an approved barrier for intrinsically safe NAMUR proximities 6 Current modulated pulse 4mA to 20mA
50. fficient time for the battery change to take place Changing the battery whilst flow is taking place could cause loss of the programmed detail It is advisable to record program details prior to battery change The battery can last 7 10 years depending on application amp environment 2 5 Processor reset button Should the instrument be corrupted by an electrical hit the processor can be reset by pressing the black re boot button located above the red DIP switch block on the input interface board refer page 10 This procedure does not effect totals or programmed data 6 Installation 7 3 INSTALLATION Surface mount footprint 3 1 Mounting Integral meter mounting Use only the 4 special length self tapping screws supplied If using the cable gland supplied carefully drill a 12 5mm 72 hole at the underside or from Noe the inside rear of housing Cable diameter range is 2 9 6 4mm Z8 4 Panel mounting APM adaptor pipe mount kit is suitable for vertical or horizontal pipes If using the cable gland supplied carefully drill a 12 5mm 72 hole at bottom or rear of housing as shown on housing footprint detail on page 7 Cut a 75mm 3 dia hole in panel Existing O ring seals against panel face 8 Installation 3 2 Flowmeter connections un powered sensors Reed switch input Note DIP switch 3 is to be OFF for reed switch input frequencies great
51. frequencies may induce erroneous noise transients onto the signal Run instrument cables in a dedicated low energy low voltage conduit Installation 11 3 3 Wiring connections pulse outputs Current Sinking outputs NPN Current sinking derives its name from the fact that it sinks current from a load The current flows from the load into the appropriate output terminal 5 Driving a logic input The output voltage pulse is typically the internal voltage of the load The load would normally have an internal pull up resistor on its input Driving a coil The NPN style of output is to be used when driving a coil The coil load is obtained by dividing the coil voltage by coil impediance Q is expressed in amps amp is not to exceed 0 1A The coil voltage is connected across 8 must match the ZOD Z1 supply voltage 8 the output 5 m FA TIT J1 in the NPN position scaleable iJ non scaled freq pulse output ai pulse output 8hz max 5Khz max NPN output pulse 8 24Vdc external power Current Sourcing outputs PNP Current sourcing gets its name from the fact that it sources current to a load The current flows from the output terminal 5 into the load When wired as below the output voltage pulse is the supply voltage of the load The load would normally have an internal pull down resistor on its input J1 in the PNP position scaleable iJ nonscaled freq pulse outp
52. gnal Inputs Powering Pulse output Physical Configuration Functions Configuration K factor range Pulse output range Engineering units Introduction 3 5 digit resettable LCD totaliser 7 5mm 0 3 high with second line 8 digit accumulative total display amp text 3 6mm 0 15 high 3 programmable decimal points with both display lines Universal pulse frequency input compatible with Reed switch Hall effect Coil sine 20mV P P min Voltage or current pulse amp Namur proximity detectors Maximum input frequency is 5Khz for coils 2 5Khz for Hall effect amp current pulse inputs 2Khz for voltage pulse devices amp 500Hz for a Namur proximity sensor 3 6Vdc Ultra Lithium battery or l S battery pack supplied life expectancy can be up to 7 10 years Battery life reduces when connected with a coil input from turbine flowmeters The ZOD Z1 may also be externally powered from a regulated 8 24Vdc supply see page 14 for special instructions regarding ghosting Scaleable or non scaleable NPN PNP selectable field effect output Transistor Non scaleable pulse is particularly suitable for pre amplifying pick off coil inputs from turbine meters 5Khz Max The scaleable pulse output has a fixed pulse width of 60ms and therefore has a frequency limit of 8hz Both pulse outputs have a 50mA maximum drive capability A IP66 67 high impact glass reinforced Polyamide enclosure Self drill ca
53. he count down mode will show with a minus sign in front of the overrun value 4 7 Start Delay amp Pre Stop Relay 2 can be programmed to turn on a time period after the run signal is given then turn off again a preset number of litres gallons etc before the end of the batch These operational features provide greater control over the dynamics of the batching process through soft start and or soft stop or phasing of the control valves and or pump control The Start Delay can be set from 0 seconds no delay to 999 seconds The pre stop range is O no pre stop to 999 units of measure litres or gallons etc Programming 13 4 8 Automatic Overrun Compensation AOC Most batching applications will have an inherent end of batch overrun due mainly to the response time of the process valve Overrun can be compensated by closing the valve slightly before the batch value is reached so that the exact batch value is achieved by the time that the system comes to rest ZOD B1 has an Automatic Overrun Compensation feature which when enabled will assess the degree of overrun on previous batches and automatically alters the close timing of the process valve so that the exact batch value is reached This feature should not be enabled on batch processes which are subject to erratic or inconsistent flow conditions 4 9 Missing Pulse Detection When a value other than 00 seconds is set at Time Out T OUT in the program mode ZOD B1 will monitor for
54. hing display Tohave the accum total display latch when key is pressed simply press amp hold the ACCUM TOTAL key for 10 seconds the display will then latch each time the key is pressed Holding the accumulative total key again for 10 seconds will revert this key function back to a momentary action 2 2 Resettable Total also see page 18 for remote reset feature The display toggles between Rate amp Total when the RATE TOTAL key is pressed Pressing the RESET key whilst displaying total will cause the total to reset to Zero 2 3 Rate display When rate is displayed the leading three alpha characters on the left of the display flash the time base for rate eg rate SEC rate MIN rate HR or rate DAY Decimal points float to provide good resolution amp rangeability Ltr SEC litres second The minimum input frequency for rate display is 0 3hz reducing to 0 1hz If the low frequency cut off is set to 0 1Hz see below amp 0 7Hz with NLC enabled 2 4 Low frequency cut off The low frequency cut off is most commonly set to 0 0Hz disabled other than to 1 To display rate for input frequencies below 0 3hz for example setting the cut off at 0 1Hz the rate will continue to display for input frequencies as low as 0 1Hz one pulse every 10 seconds such conditions often apply to flowmeters with low resolution pulse outputs low frequency or flowmeters with a high operational turndown maximum to minimum flow rate 2
55. hreaded weld on fitting threadolet or service saddle Wrap the threads of the flowmeter with PTFE tape or sealing compound 8 screw the unit into the installed fitting page 5 2 3 Height adjustment calculation Calculate the adjustment height A for DOR 42 or AA for the DOR 52 as follows A for DOR 42 175mm 6 9 B C D AA for DOR 52 420mm 16 5 B C D Where B Distance between the top of the pipe 8 the top of the hex adaptor C Pipe wall thickness D Insertion depth pipe ID 8 ALIGNMENT SLOT TO PARRALLEL PIPE Examples of insertion depth D For 40mm pipe ID D 5 0mm For 50mm pipe ID D 6 25 mm For 100mm pipe ID D 12 5 mm For 400mm pipe ID D 50 0 mm Tum the height adjustment nuts 1 as required so that the distance between the top of the hex adaptor 2 and the top of the positioning collar 3 equals your calculated distance A for DOR 42 or AA for model DOR 52 Retighten the height adjustment nuts 1 2 4 Flow direction orientation The unit is bi directional however the paddle must be aligned with the direction of flow Using a 2mm hex key Allen key unlock the locking screw located on the positioning collar 3 then insert the hex key as a lever in the body rotating hole located above the collar turn the body until the alignment slot is parallel with the direction of pipe Retighten the locking screw page page 6 ELECTRICAL CONNECTIONS see page 9 for QP output
56. hz 52 43hz 524hz or 5243hz followed by the input frequency at which the flow alarm is to change status next the deadband is set as a percentage of the frequency switch point Deadband provides a variable trip buffer zone about the set point in order to overcome alarm chattering when the flow is fluctuating close to the set point Deadband is expressed as 0 9 of the set point hz The final setting covers the number of poles NOP of magnetic flux associated with the primary measuring elements for example an Oval PD flowmeter may typically have 1 2 or 4 magnetic poles per revolution a Turbine flowmeter may have from 5 to 20 turbine blades this feature compensates for any inherent cyclic variations in the flux density field of each pole which could otherwise produce an unstable output Setting the NOP or multiples of the NOP for even better stability enables the processor to average the input readings thereby maximizing accuracy and repeatability In run mode the LCD defaults to display the flowmeter input frequency which is used during alarm set point checks Frequency divider A limited divider range of 1 9999 suits most smaller capacity flowmeters having a high resolution pulse output generally in excess of 100 pulses per litre gallon etc often in situations where the output is used for totalising Other applications can include dosing control signals or general output frequency reduction Programming simply requires the setting of the appr
57. ically Safe Electronics 1 S Optional EN 50020 2002 Intrinsically Safe Electronics 1 S Optional EN 60529 DIN VDE 0470 1 I P Ingress Protection Classifications EN 61326 1 2006 10 Electrical equipment for control instrumentation technology and laboratory use EMC requirements Industrial area EN 61010 1 2002 08 Safety requirements for electrical equipment for measurement control and laboratory USE 2008 35 EC Waste Electrical amp Electronic Equipment WEEE Also the following EEC guidelines are fulfilled 2004 108EC EMC Directive 2006 95 EC Low Voltage Directive General Manager Hofheim 18 Oct 2010 8 ALPHABETICAL INDEX Accumulative total Battery condition indicator Battery replacement Battery jumper D DC power powering Decimal points Displays El Engineering units External DC powering F Flowmeter connections 1 Input signal Interface board Installation K Keypad functions K factor scale factor LCD display M Model number designation Mounting options 0 11 12 14 N NPN pulse output o Operation Overview amp Options P PIN number protection PNP pulse output Processor reset button Programming Program detail record Pulse output R Resettable total Index Resetting accumulative total 5 Resetting the processor s Scale factor K factor Scaleable pulse output Specifications Terminal designation
58. imum 10xd upstream 5xd downstream Optimal 25xd upstream 10xd downstream approx without electronics 1 6 kg DOR 4 2 5 kg DOR 5 page 4 2 0 INSTALLATION 2 1 Meter location Choose an appropriate section of horizontal or vertical pipe as per the guidelines below With vertical pipe installations the media should be pumped up through the pipe past the flow sensor so that any entrained air will pass freely The DOR flow sensor requires a fully developed turbulent flow profile to ensure maximum measurement accuracy and repeatability This can be achieved by installing the DOR in a straight run of pipe We recommend at least 10 but ideally 25 straight pipe diameters upstream amp at least 5 but ideally 10 pipe diameters downstream of the flowmeter Major obstructions such as pumps valves or strainers will require longer straight runs before and after the flowmeter Major obstructions such as pumps valves reducers or strainers to be kept well outside the straight run pipe sections 10 pipe dia minimum 25 pipe dia prefered 5 pipe dia min 10 pipe dia prefered 2 2 Meter installation amp orientation Cut a 40mm diameter hole 1 6 on either the 2 10 or 12 o clock positions of the pipe If there is any likelihood of air entrainment in a horizontal pipe do not locate the flow transducer in the 12 o clock position mon mi an Other positions around the pipe are acceptable Install a female t
59. ing a logic input The output voltage pulse is typically the internal voltage of the load The load would normally have an internal pull up resistor on its input as shown Driving a coil The NPN style of output is to be used when diving a coil The coil load is obtained by dividing the coil voltage by coil impediance Q is expressed in amps amp is not to exceed 0 1A The coil voltage is connected across amp must match the ZOD Z3 supply voltage amp the output 7 13 amp 14 LAS scaled pulse PNP Set jumper s REP repeater pulse A A NEN lt to NPN TA 13 14 High flow alarm Low flow alarm OV ground 8 24Vac in Pulse output OV ground 7B 0 ojo set jumper i E 8 NPN PNP to NPN ee a ea O tase er oe Se er es SS ee aaa Ss ae a a a Y SS a Se ee SS Sa a Current Sourcing outputs PNP Current sourcing gets its name from the fact that it sources current to a load When activated the current flows from the output 7 13 amp 14 into the load When wired as below the output voltage pulse is the supply voltage of the load The load would normally have an internal pull down resistor on its input as shown LAS scaled pulse PNP D Set jumper s REP repeater pulse Jo Lo NPN to PNP TA 13 14 High flow alarm Low flow alarm 5 OV ground Ss 8 24Vdc in Pulse output OV ground Do not tie O volts of the l logic input to O volt
60. ion 4 2 Resetting accumulative total 43 Engineering units 4 4 K factor flow input scale factor 4 5 Rate conversion factor 4 6 Rate dampening see response graph page 19 4 7 Low frequency cut off refer clause 2 4 page 5 4 8 Pulse outputs scaleable or non scaleable 49 Non linearity correction NLC Linearisation 4 10 Presetting battery power levels ADDITIONAL PROGRAM PARAMETERS 9 1 Analog output 9 2 Flow alarms 9 3 Flow alarm deadband 9 4 Dual flow inputs PROGRAMMING 6 1 Program levels 1 7 Program levels 8 13 6 2 Program levels 14 24 6 3 Program detail record TERMINAL LAYOUT SELECTION LINKS amp REMOTE SWITCHES DECLARATION OF CONFORMANCE ALPHABETICAL INDEX A B Po Ooo ooo Introduction 2 1 1 Model number designation Electrical connection Housing Type Cable gland Supply Voltage Mechanical protection KS universal mount 1 3 x cable entry F3 8 24 VDC standard M20 Battery 0 without 0 without F1 110 VAC ZOD 2 3 x cable entry 8 24 R 2 x Relay Z3 KM integral mount 1 2 NPT VDC for ZOD Z3K F0 220 VAC PP panel mount 8 24 S IP20 02 screw terminal VDC E EExia IIB T4 silicone bezel boot Yorder only when retrofitting a pulse meter only possible with ZOD Z3PP Donk possbk with ZOD Z3K Optons R and E cannotbe com binned Part No ACCESSORIES FOR ABOVE SERIES ERS ZOD 1522001 stainless steel wall mount
61. l cause the large 5 digit total to reset to zero The reset function is possible at any time during counting 2 2 Accumulative Total There are 8 digits in the accumulative total display these can only be reset in the program mode or can be protected by enabling the PIN protection feature at the front end of program mode 2 3 Keypad functions Resets the 8 digit accumulative total display to zero Resets internal K factor scale factor to zero Resets the 5 digit resettable total display to zero 1 Pressing the Program amp Reset keys for 5 1 Each press steps you through each level of seconds enters you into the program mode the program chart 2 Holding for 3 seconds fast tracks to the END 2 Displays model amp software revision No of the program from any program level Selects the digit to be set the selected digit will be flashing indicating that it can be incremented No function Increments the selected digit each time No function that it is pressed 2 4 Battery replacement The instrument draws very little power and will run for many years without the need to replace the battery A battery condition indicator on the LCD display will appear when the battery is low if the low battery is not replaced the programmed detail amp totals will be lost When changing the battery a small capacitor within the instrument will maintain the programmed detail amp totals in memory for up to 10 seconds providing su
62. loss of flowmeter input signal at all times when either of the control relays 1 8 2 are energised If no pulses are received within the time out period 0 99 sec the controller will de energise both control relays and scroll a NO INPUT message across the LCD display at the same time it will turn on the no flow alarm output at terminal 7 see page 17 for flow alarm connection detail At NO INPUT the user must acknowledge the alarm condition by pressing the STOP key once the operator then has the option of continuing the batch by pressing the RUN key or aborting the batch by pressing the RESET key which will return the controller to the original batch set value 4 10 Batch Limit To avoid entering excessive batch quantities a maximum batch limit can be set at the program level ZOD B1 will not accept a batch value which exceeds the batch limit on rejecting an excessive batch value the controller will scroll the message BATCH VALUE EXCEEDS BATCH LIMIT and default to the batch limit on entry batch set 4 11 Controller networking ID number Each controller can be given a networking ID number in the range of 1 9 Allocating an ID number other than 0 is only necessary when a number of controllers are to be networked together for interlocking purposes see page 18 for Controller Networking Setting the ID number to zero inhibits this function Note The instrument defaults out of the program mode if no program entri
63. m Ya watt resistor across terminals 1 8 3 as shown gnd Coil with pre amp B current modulated A 8 24Vdc RECTO si exte rnal Ground screen at 3 power 10 Installation 3 3 Wiring connections Terminal designation I P Flow input pulse signal Vref Flow input coils amp voltage type inputs gnd GND Flowinput pulse type inputs Ef O P Output pulse J1 amp J3 selectable 1 2 3 4 Vdc Vdc External power 8 24Vdc see P14 5 6 gnd GND External power Interface board layout Battery jumper battery engaged Processor reset button battery isolated o F O ol P O Input DIP switches 1 1MO pull up resistor 2 8200 pull down resistor 3 0 01uf de bounce amp noise capacitor limits max input freq to 40hz Output jumpers J1 NPN PNP selection J3 Output pulse selection F O non scaled frequency P O scaleable pulse Wiring practice Use multi core screened twisted pair instrument cable 0 5mm for electrical connection between the instrument and any remote flowmeter or receiving instrument The screen needs to be earthed to the signal ground or the receiving instrument this is to protect the transmitted signal from mutual inductive interference Do not earth the screen at both ends of the cable Instrument cabling is not be run in a common conduit or parallel with power and high inductive load carrying cables power surges 8 power line
64. m view remain functional 4 5 Pulse output The pulse output is NPN PNP link selectable via jumper J1 It is also selected at jumper J3 to act as a non scaled pre amplified pulse output or scaleable pulse output maximum load is 50mA Non scaled pulse output The un scaled repeater pulse output represents one pulse out for each input pulse from the primary measuring element flowmeter This output acts as an input signal pre amplifier particularly suitable for pick up coil inputs up to 5Khz The duty cycle of the output adopts the duty cycle of the input The ZOD Z1 needs to be externally powered for this feature to operate see page 11 Scaleable pulse output The fully scaleable pulse output is programmable as the number of litres gallons etc per output pulse Eg 0 1 litres pulse 10 litres pulse 100 gallons pulse Range is 0 1 9999 9 Eng unit pulse The ZOD Z1 needs to be externally powered for this feature to operate p11 The scaleable pulse output is suitable only for remote integration due to the spasmodic nature of its output frequency it is limited to 8hz Should the potential incidence of this output exceed 8hz it can continue to count after flow has stopped until such time as the processor buffer has completed integration Most scaleable pulse output requirements are low frequency due to down scaling and therefore not effected by the buffer count effect Programming 13 9 PROGRAMMING FLOW CHART hold P
65. n No s press 8 hold program key Replacement Batteries Non l S battery P No 1312007 3 6V x 2 4Ah AA Lithium Thionyl Chloride non rechargeable cell R S Components Farnell Components Stock No 596 602 Order code 206 532 TABLE OF CONTENTS 1 INTRODUCTION 1 1 Model number designation 1 2 Specifications 1 3 Overview 1 4 LCD displays 2 OPERATION 2 1 Resettable total 2 2 Accumulative total 2 3 Keypad function matrix 2 4 Battery replacement 2 5 Processor reset button 3 INSTALLATION 3 1 Mounting integral meter mounting panel mounting wall surface mounting pipe mounting 3 2 Flowmeter connections un powered sensors powered sensors 3 3 Wiring connections Terminal designation Interface board layout Wiring practice NPN pulse output PNP pulse output 4 PROGRAM PARAMETERS 4 1 PIN number protection 4 2 Resetting accumulative total 4 3 Engineering units 4 4 K factor scale factor 4 5 Pulse output 5 PROGRAMMING FLOW CHART 5 1 Program detail record 6 TROUBLESHOOTING 7 Declaration of Conformance 8 ALPHABETICAL INDEX Page 1 E KON ooo O1 Ol 14 16 17 2 1 Introduction INTRODUCTION Housing Type Electrical connection Supply Voltage Mechanical Cable gland protection KS universal mount standard KM integral mount order only when retrofitting a pulse meter 0 cable gland supplied suits 3 6 mm cables 1 2 Specifications Display Si
66. n factor is the number needed to convert to the required rate unit some examples are Total unit Cubic metres Litres 1000 000 US Barrels USgal 42 000 Imp gallons Litres 4 546 continued N program return 15 Programming 6 1 Program levels 8 13 L8 SET RATE DAMPENING DAMP 00 99 RATE L10 OUTPUT PULSE REQUIRED Y N PULSE Y N YES NO L11 ENTER No OF gal litres etc PER OUTPUT PULSE OP XXXX X L12 NON LINEAR CORRECTION NLC Y N YES NO OF 0000 0 set output freq at point 0 000000 000 set K factor at point 0 1F 0000 0 set output freq at point 1 000000 000 set K factor at point 1 10 points from OF up to 9F 9F 0000 0 set output freq at point 9 000000 000 set K factor at point 9 L13 CHANGE POWER MODE Y N CHANGE Y N applicable under battery only YES NO 1 ULTRA POWER SAVE 2 STANDBY 3 CONTINUOUS refer clause 4 10 L9 SET LOW FREQUENCY CUT OFF HERTZ 0 0 9 9 Low frequency cut off The low frequency cut off is generally set to 0 0Hz disabled for most applications other than those described at clause 2 4 on page 5 Non linear correction NLC overrides K factor set at L4 1 Any number up to 10 frequency points of non linearity can be programmed with point OF being the pulse output frequency at the lowest flow rate 2 If any frequency point is set to zero Hz then all remaining NLC points up to p
67. nction of A B to give instantaneous ratio Note When using A 8 B inputs the functions of Scaled Pulse output Alarm set points and the Analog output are relevant to resultant computation between A 8 B The analog output of function A B can be used as an input for ratio control 6 PROGRAMMING 6 1 Program levels 1 7 V3 2 HOLD 3 2 1 TESTING DISPLAY 88888888 tt PROGRAM MODE ENTERED if PIN protected ENTER PIN L1 CHANGE PIN No Y N NUPIN Y N YES NO L2 RESET ACCUM TOTAL Y N RESET Y N L3 SET ENGINEERING UNITS ENG UNIT Ltr gal m3 Ibs kgs none press Prog key to step through program levels L4 ENTER NUMBER PULSES PER Ltr m3 kg gal Ib unit of measure 0000000 001 9999999 999 L6 RATE CONVERSION Y N RATECON Y N L7 SET TIME BASE FOR RATE Ltr gal etc SEC MIN HR or DAY NO Saves amp exits program YES YES Programming 14 eS you hold Program amp Rate keys for 5 secs to enter the program if incorrect PIN No is entered INVALID PIN VIEW EXISTING PROGRAM DETAILS ONLY Mit ia gt K factor scale factor is the number of pulses per unit volume or unit mass eg 20 465 pulses litre gallon kg etc R 0000 001 9999 999 WARNING on rate conversion factor RCF This feature need only be programmed when the total amp rate engineering units are to be different eg m3 for total and litres for rate The conversio
68. nformance O O oO amp NNNN 15 16 20 22 4 Introduction Introduction 5 1 1 Order Details Housing Type Electrical connection Supply Voltage Mechanical Cable gland protection 1 2 Specifications KS n es ak moun 0 without Display Large backlit 6 digit numeric display with LCD characters 17mm 0 67 high second line 2 3 x cable gland entry 1 2 NPT F3 8 24 Voc 0 without se ae a i ap dat ee a standard 3 3 x cable gland entry M16 R 2xRelays P display of 8 digits x 7mm high totalising plus 5 digits of rate indication Programmable 0 3 decimal KM integral mount protection plate f Il displ order only when retrofitting a pulse meter places tor all displays Signal Input Universal pulse frequency input compatible with Reed switch Hall effect Namur proximity detectors voltage current amp Coil 15mV P P min Max input frequency 5Khz Minimum input frequency for rate display is 0 1hz with low frequency cut off feature enabled totals have no minimum input frequency when low frequency cut off is set to zero Battery power The unit draws about 70UA under battery life expectancy is generally 3 years Battery life reduces when rate is more often displayed amp there is no external power connected Rate display defaults to total display 1 minute after pressing the rate key in order to conserve battery power reverse polarity protected Battery condition is continuously monitored internally
69. ns K factor scale factor LCD displays Low frequency cut off Model number designation Mounting options Operation Overview 15 12 17 11 15 8 13 10 14 14 11 P PIN number protection Programming Program detail record Pulse output Rate response Rate display Rate time base Remote reset input Resettable total Resetting accumulative total Scale factor K factor Scaled pulse output Specifications Wiring of flowmeter inputs Wiring of pulse output Wiring to external power Wiring requirements 14 16 14 15 16 13 14 15 7 15 7 15 12 14 15 13 5 10 11 13 12 12 89 6 mm Panel mount template 19 3 53 PANNEL CUT OUT 71mm high x 83mm wide 2 8 x 3 3 Tapping Drill amp tap 4 x M4 holes where indicated Tapping drills 3 4mm 1 8 or 30 drill Clearance drills Clearance drills 4 7mm 3 16 or 13 drill gt 68 0 mm 2 68 20 Supplement 8 Instruction manual supplement for ELECTRONICS ZOD Z3 ZOD Z5 amp ZOD B1 WITH OPTIONAL RELAY OUTPUT BOARD 1 Overview The Relay Control Output boards are an option for the flow rate totalisers and batch controller they have two electro mechanical SPCO relays instead of the solid state outputs of either instrument The relays will switch higher loads 5 amps max to that of the solid state relays and provide electrical is
70. oad would normally have an internal pull up resistor on its input as shown Driving a coil The coil load is obtained by dividing the coil voltage by coil impediance Q is expressed in amps amp is not to exceed 0 1A The coil voltage is connected across amp must match the RT supply voltage amp the output 7 13 amp 14 14 Programming 4 PROGRAM PARAMETERS Note The instrument defaults out of the program mode if no programming entries are made after 4 minutes 4 1 PIN No Program Protection Any user defined PIN number other than 0000 will engage the program protection feature failure to input the correct PIN number will deny the ability to change any of the program parameters but will allow the user to step through and view the existing program parameters Only one PIN number may be set but this can be changed at any time after gaining access through PIN entry A second back up PIN number is installed at the factory should the programmed PIN be lost or forgotten refer bottom of page 16 for the back up PIN No 4 2 Resetting Accumulated Total Resetting the accumulated total can only be done in the program mode 4 3 Engineering Units Select from available Engineering units to right of the display refer clause 1 4 for other engineering units set display to show no engineering units amp program a suitable K factor 4 4 K factor scale factor Enter K factor at S Fact up to 5 whole numbers amp 3 decimal n
71. oint 9F will automatically assume the last entered NLC K factor and the program will advance to the next level This feature simplifies programming when not all points of correction are used 3 Linear interpolation is used between frequency points except above the last entered frequency where the last entered NLC K factor is applied continued _ _ _ _ gt p gt eg program return e Programming 16 6 2 Program levels 14 24 L14 ANALOG OUTPUT REQUIRED Y N 4 20mA Y N YES NO L15 ENTER FLOW RATE AT 4mA TIP holding the prog key for 3 sec s fast tracks to the END of the program XXXXX XXX LOW L16 ENTER FLOW RATE AT 20mA XXXXX XXX HIGH L17 ALARM OUTPUTS REQUIRED Y N ALARMS Y N Alarm outputs YES NO 1 Low flow alarm occurs when the flow falls below the set point High flow alarm occurs when the flow goes above the set point XXXXX XXX LOW 2 Deadband Reset Differential provides a buffer zone about the alarm set point in order to avoid alarm output chattering on amp off L19 ENTER LOW ALARM DEADBAND when the flow rate is hovering about an alarm set point BAND XX LOW The deadband applies above the Low set point and below the High set point Deadband L20 ENTER FLOW RATE HIGH ALARM is setas a percentage of each set point XXXXX XXX HIGH Eg 5 deadband at a low alarm set point of 100 L hr will cause a low alarm when the flow drops to 100
72. ol instrumentation technology and laboratory use EMC requirements Industrial area EN 61010 1 2002 08 Safety requirements for electrical equipment for measurement control and laboratory use 2008 35 EC Waste Electrical amp Electronic Equipment WEEE Also the following EEC guidelines are fulfilled 2004 108EC EMC Directive 2006 95 EC Low Voltage Directive AE VO J Hofheim 18 Oct 2010 H Peters M Wenzel General Manager Proxy Holder 8 5 ALPHABETICAL INDEX Accumulative total Alarm deadband Alarm outputs Analog output Battery power levels DC power Decimal point Displays Dual flow inputs Engineering units External DC powering Flowmeter connections Flow rate Inhibit totals Installation Input signals Keypad functions K factor scale factor LCD displays Loop powering Link selectors for outputs Low frequency cut off Model number designation Mounting options 11 13 12 13 13 13 13 10 14 20 12 10 14 10 18 N 22 Index Non linear correction o Operation P Output selector links Overview PIN number protection Presetting battery power levels 13 Programming Program detail record Pulse outputs Rate conversion factor Rate dampening Rate display Rate time base Remote switch inputs Resettable total Resetting accumulative total Scale factor K factor Scaled pulse output Specifications Terminal designation
73. olation between the switched output and the instruments circuitry This option cannot be used in Intrinsically Safe environs Once plugged into the 16 pin socket ZOD Z3 amp ZOD B1 or 20 pin socket ZOD Z5 the solid state outputs at terminals 13 amp 14 then cannot be used the installer must make his control terminations at the relay board terminals marked NO normally open C common amp NC normally closed DC amp AC voltages may be switched at these terminals generally the active is switched 2 Installing relay board First check and set if necessary the positions of the flow input DIP switches adjacent terminals 1 4 on the instrument PC board see pages 9 10 in the relevant instrument instruction manual for setting options As the relay control output board requires external DC power 12 24Vdc at terminals 5 amp 6 the instrument battery is no longer required With no external power applied remove the battery to enable the relay board to be plugged into place using the battery cradle as the retaining mechanism apply slight pressure to the board as you spread the battery cradle clips to embrace the relay PC board The assembly is now ready to be wired 3 Operation The relay board has a voltage dropping circuit which limits the relay coil drive voltage to 12Vdc irrespective of the external supply to the instrument When the external supply exceeds 12Vdc the largest component of this circuit will become hot to touch this is
74. opriate divisor number between 0001 amp 9999 The divided pulse output is limited to 25hz The output is current modulated between 4mA and 20mA In run mode the LCD defaults to function as an output totaliser amp may be reset at any time Operation 3 LCD contrast has 4 settings 0 3 Press A for best contrast KA GND E GE YA PROGRAM Touch key matrix Displays set function Press amp hold to enter program Adjusts LCD contrast Selects digit to be set Shows set point divide factor or resets total Changes value of selected digit Touch key operation The 3 touch keys need to be operated slowly with deliberate action as the processor cyclic routine is some what slow amp at times may miss a sharp key action this is not to be interpreted as an intermittent fault Testing output with a multimeter Wire in accordance with the diagram shown Test output in proportion to frequency input for the 16mA span 4 20mA 16mA span 20mA being full scale FS range for example if 100hz were to produce 20mA then 50hz should produce 12mA 25hz should produce 8mA amp 10hz 5 6mA NOTE Include a 250 load resistor in circuit to protect output from overload K VA GND x ieee YA JD D PROGRAM 4 Analog output Programming 5 Programming chart Electrical connections Press amp hold PROGRAM Twisted pair low capacitance shielded instrument cable
75. put NPN PNP selectable pulse output Optional Display backlighting needs external dc power for this option to illuminate Intrinsic Safety Certification to IECex scheme and ATEX directive Environments The ZOD Z1 series is designed to suit harsh indoor and outdoor industrial and marine environments The robust housing is weatherproof to IP676 IP67 standards UV resistant glass reinforced Polyamide with stainless steel screws amp FKM O ring seals Installation Specifically engineered to be directly mounted on a variety of flowmeters wall surface or pipe mounted in the field or control room Various mounting kits are available The instrument is self powered using one 3 6Vdc lithium battery or I S battery pack the pulse output option requires 8 24Vdc 1 4 LCD display Full LCD display test feature illuminates all characters and script text displays for 5 seconds when entering the program mode The 5 digit Total display is front panel resettable and can be programmed for up to 3 decimal places Engineering units are selected during the initial programming routine Battery condition indicator shows only when battery is low battery life can last up to 7 10 years The 8 digit Accumulative Total display can be programmed for up to 3 decimal places Reset is only possible when in the program mode which can be PIN protected for security Operation 5 2 OPERATION 2 1 Resettable Total Pressing the RESET key wil
76. r 3 seconds fast tracks to the end of the program from any program level Selects the digit to be set the selected digit will be flashing indicating that it can be incremented Increments the selected digit each time that it is pressed Surface mount footprint 426mm N Z use 4 screws supplied i Wall mount using optional 3 bracket set ERS ZOD 1522001 96 mm 3 8 i 7 Installation 3 1 Remote Mounting continued Vertical pipe mount order Pipe mount kit PANO ERS ZOD 152202 comprising two brackets screws and worm drive clamps Panel mount Horizontal Po pipe mount 1 Conduit entries have an integral moulded seal to remove break seal out using suitable lever eg screwdriver or rod Cut a 106 5mm 4 2 diameter hole in panel Installation 8 3 2 Flowmeter connections unpowered sensors for l S installations refer to l S supplement Flow input A 8 B switch functions Gen Flow Terminals 1 28 5 replicate terminals 3 4 amp 5 for dual flow inputs Ny 1 Input B Switch 1 ON engages 0 01uf capacitor to suppress reed switch bounce guns Flow Switch 2 ON engages 1 meg Q pull up resister NE 4 nputA Switch 3 ON engages 8200 pull down resister 1 Reed switch 200hz max DIP switch 1 4 2 are on gan Flow High flow alarm Ny 1 Input B Low flow alarm Flow 4 20mA output InputA _4 20mA output 3 ground not used Pani gt
77. rogram amp Reset Cros keys for 5 seconds to enter the program mode if PIN protected press Program key to advance through each program level Use arrowed keys to enter parameters if incorrect PIN No is entered Note The ZOD Z1 will default out of the program mode if no entries are made within 4 mins __ View program details only wo l p K factor scale factor is the number of pulses per unit volume or unit mass eg 20 465 pulses litre gal kg etc NO Important record program details overleaf 14 Programming flow chart 5 1 Program detail record If not powered for more than 10 seconds the programmed detail amp Accumulated Total will be lost from the processor memory it is advisable to record your programmed detail below Specific instructions on changing the battery without loss of program detail are given at clause 2 4 page 5 Pencil your program details here po 0001 0 Factory default settings 6 TROUBLESHOOTING No display Check position of the battery jumper J2 see interface board layout page 10 amp check battery contact connections Replace battery Display ghosting under external power The LCD display will ghost when the instrument is powered from an external 24Vdc power supply this is corrected by including two watt resistors 1 2K amp 3 3K on the input power source as shown below omy ZOD Z1 Vdc tI Ll gnd 3 gnd
78. rom the flowmeters known K factor these are in most cases available from the respective flowmeters calibration sheet or given as a nominal with some inferential style flowmeters such as insertion paddle wheel meters Some programming examples for each function are shown below Programming examples 30 litres hr 23 47 hz 282 or 2816 23 47 hz Flowmeter K factor from calibration report or established tests Flow rate for 20mA full scale output no decimal position above 99 9 hz Minimum divisor depends on acceptable error levels by the user 2 Configuration Input configurations The processor board is produced in two configurations the most common is supplied fitted with a loop powered Hall Effect pick up this model is typically supplied with positive displacement flowmeters The second configuration board does not have a Hall Effect device but has the facility to accept either a reed switch coil or pulse wire input via hard wire solder pad connection Unless otherwise requested at time of order placement the unit is pre programmed at the factory to produce 20mA at the maximum flow rate of the associated flowmeter Function configuration Frequency to current F I Produces 4 20mA analog output proportional to flow rate Programming requires the setting of a decimal point for frequency resolution eg 1 000hz 10 00hz 100hz or 1000hz followed by the full scale frequency to produce 20mA output then finally a respon
79. rsion feature is available amp is explained at level 6 in the program chart page 14 When enabled the analog output under rate conversion needs to be programmed in relation to the TOTAL engineering units 4 6 Rate dampening Dampening is available to smooth out fluctuating flow input signals in order to provide a stable rate display amp analog output Most input signal are reasonably stable and need only a low setting value of 40 to 70 see response graph on page 19 4 7 Low frequency cut off This feature is explained in clause 2 4 page 5 4 8 Pulse Outputs for this feature the ZOD Z3 must be externally powered as per page 10 The pulse output is link selectable as a scaleable pulse or non scaled repeater pulse amp NPN current sinking or PNP current sourcing style pulse capable of switching up to 1 amp Pulse scaling when selected is set as the number of litres gallons etc per output pulse Eg 0 1 litres pulse 10 litres pulse 100 gallons pulse Range is 0 1 9999 9 Eng unit pulse The totalising display visually slows to two updates sec if the scaled pulse output is selected The pulse width pulse duration 1 1 automatically adjusts to the output frequency defaulting to a maximum pulse width of 300 milliseconds at frequencies below 1 66hz To calculate pulse width at higher frequencies use 1000 hz x 2 pulse width in milliseconds 4 9 Non Linearity Correction NLC Linearisation Linearisation enables the inst
80. rument to correct for known inaccuracies in a flowmeter thereby improving the overall accuracy and in many cases increasing the effective flow range turndown of the flowmeter Refer to program level L12 page 15 for setting NLC points NLC can be used without external power however battery life is reduced according to usage 13 Programming 4 10 Presetting battery power levels When the instrument is operated under battery power only a special Power Mode program option will appear at level 13 within the programming routine A choice of three battery power modes enable maximisation of the battery life according to operational requirements Ultra Power Save Typically selected if reading the register infrequently The display scrolls a Prompt PRESS ANY KEY when a key is pressed display wakes up for 4 minutes then returns to sleep mode greatly extending the battery life otandby Display becomes active whenever a key is pressed or product flows through the flowmeter Display returns to sleep mode after 4 minutes of no flow input or key actions prompt then returns to PRESS ANY KEY Continuous Display is active at all times resulting in reduced battery life Display reverts from Rate to Total after 4 minutes to reduce battery draw In sleep mode and programming mode flow is always continually totalised When the battery voltage is low a battery low indicator will appear on the display J ADDITIONAL PROGRAM PARAMETER
81. s 3 0 DIT k ALALLAAN LLANTA 3 2 5 Hot tap installation Yellow Green REED SWITCH OUTPUT al F Wo De o sla 8 T g Wy amp To Q s 3 a as 3 2 SE 2 5 g 22 8 L L gt ol O 5 we o 5 Ows5 WO gt Q O5 gt Gs 622 or S gt IS Et TE agi 5 2 si 2 lt Ss gt sone A AME N oo q SMES m ole E D D KOBOLD OQ Lock ALO sensor and high temperature output options Terminal box option terminal connections Conductor color coding also applies to the Non magnetic Positioning collar bang 2 Do v o D P Shs E O a ko O JAN lt D 7 23068 os Q o2 HL 8 35 x n 05 e n oo aj ocg os OF Y lt 58 7 W ep 2 E Ss5x 3 Mo 1 22D Qu De D Q O Lo lt 2 28 2S SCS G ws Na e O gt T o a Oy en B pLa gt cos A A oc Oo OL s O BULLE LL x A 12 258 Eg 522 p f 2 EZEKZEZ s 532 lt SP OL wew Ye E Pop c N 2s ROET a gfo Lo O q pa oS amp o gt n oN u a lt fe f E 5 lt ey 3 Sd E SA fo sheas N GOTTODE LSDESE Vw AY 500 aw go o ANZ O a W uNnNSo230 2 0 D D 5 su X O WoJ20ES2 lt p ou jo o YSsuU Ro S5SLeD a T 2 O x to ZoaLlis SD gt an f DEBOBEZNEOOQ gt 8 0 3 2 Fz OF wy a DOocr a O eD ZEDZ 6 E Q O ONE BL otis 38 O O 2 Oo oO ao as oq YE 0 SUE 9 2 OS we D D gt Clo co
82. s fitted with the QP output option quadrature pulse output may be interfaced with the Pulse Discriminator Module PD2 The PD2 accepts the Quadrature pulse inputs amp from these will discriminate between forward amp reverse flow Two individual amp proportional pulse outputs can then be sent to appropriate totalising registers or an Z3 add and subtract flow rate totaliser It is important to note that the Quadrature Pulse option has the same pulse resolution pulses unit volume as a standard flowmeter for both forward amp reverse outputs Flowmeter with QP outputs 5 24Vdc maximum Forward flow Sig Output signals Reverse flow Sig page 10 3 7 Voltage Pulse Connection to family instruments Flow instruments or a terminal box can be directly mounted to the flowmeter using ST4 for DOR 42 or ST5 DOR 52 mounting stem kits Note For other output styles see receiving instrument manual Z3 8 B1 SERIES INSTRUMENTS I E B3 Allflow DIP C12 switches in the LITI OFF position OV ground ZO Screen Z1 TOTALISER DIP switch 1 in the ON position 2 Khz max yellow The flowmeter cable should not be run with other high energy cables clause 3 3 page 11 4 0 K FACTORS calibration factors for meter The K factor pulses litre gallon etc will vary in relation to the bore size of the pipe in which the flowmeter is installed The K fac
83. s of 7B gt Set jumper the RT when wired in NPN PNP to PNP PNP configuration Programming 12 4 PROGRAM PARAMETERS Note The ZOD Z3 defaults out of the program mode if no programming entries are made after 4 minutes 4 1 PIN No Program Protection Any user defined PIN number other than 0000 will engage the program protection feature failure to input the correct PIN number will deny the ability to change any of the program parameters but will allow the user to step through and view the existing program parameters Only one PIN number may be set but this can be changed at any time after gaining access through PIN entry A second back up PIN number is installed at the factory should the programmed PIN be lost or forgotten refer bottom of page 17 for the back up PIN No 4 2 Resetting Accumulated Total Resetting the accumulated total can only be done at level 2 L2 in the program mode 4 3 Engineering Units refer clause 1 4 select from available Engineering units to right of the display For other engineering units set display to show no engineering units amp program a suitable K factor 4 4 K factor scale factor Enter K factor starting with the most significant number up to 7 whole numbers amp 3 decimal numbers can be entered Trailing decimal numbers move into view as digits to the right are progressively selected any significant digits which may move from view remain functional 4 5 Rate conversion factor A rate conve
84. se time in seconds The response time is used to smooth out fluctuating flow rate in order to provide a stable current output Most input signals are reasonably stable and only need a low setting value of 1 to 3 seconds 9 sec is maximum these are step changes to the analog output signal for example a response setting of 2 seconds would cause the processor to update the output every 2 seconds The final setting covers the number of poles NOP of magnetic flux associated with the primary measuring elements for example an Oval PD flowmeter may typically have 1 2 or 4 magnetic poles per revolution a Turbine flowmeter may have from 5 to 20 turbine blades this feature compensates for any inherent cyclic variations in the flux density field of each pole which could otherwise produce an unstable output Setting the NOP or multiples of the NOP for even better stability enables the processor to average the input readings thereby maximizing accuracy and repeatability of the output The span adjustment 20m4 is preset at the factory and should have no need to be adjusted there after In run mode the LCD defaults to display the flowmeter input frequency which is used during calibration Frequency flow rate alarm Output is current modulated between 4mA no alarm condition and 20ma flow rate alarm condition when the input frequency reaches the alarm set point frequency Programming requires the setting of a decimal point for frequency resolution eg 5 243
85. selected engineering units batch status and has scrolling English prompts to make programming easy Two independent output relays the second with programmable start delay and pre stop enable pump and valve control or 2 stage flow phasing at the start and end of each batch Precise batching is aided by Automatic Overrun Compensation which when enabled automatically manages variations in system time lags which could otherwise lead to discrepancies in dispensed quantity Safety features includes for an alarm output and automatic cessation of batching if no flow input is detected and programmable batch limiting protects against setting an oversize batch quantity Scrolling messages on the LCD annunciate any alarm fault conditions Control features include batch count up or down remote operational switch interface run inhibit interlock and batch status output The ZOD B1 is capable of networking with up to 9 batch controllers using one common flowmeter Environments The ZOD B1 is designed to suit harsh indoor and outdoor industrial environments amp conforms to EMC directives The housing is weatherproof to IP66 67 Nema 4X standards UV resistant robust glass re enforced plastic with stainless steel screws amp FKM O ring seals ZOD B1 can be mounted on a variety of flowmeters or as a stand alone instrument for wall surface pipe or panel mount Various mounting kits are available 1 4 LCD displays PAVIA ZN VAN AN ZN Y AN RUN AC
86. smitted signal from mutual inductive interference Instrument cabling should not be run in a common conduit or parallel with power and high inductive load carrying cables power surges amp power line frequencies may induce erroneous noise transients onto the signal Run instrument cables in a separate conduit or with other instrument cables Installation 13 3 3 Wiring connections continued Pulse amp Alarm Output for this feature the instrument must be externally powered as per page 12 The scaled pulse output is in the form of an NPN current sinking style pulse capable of switching up to 100mA Current sinking derives its name from the fact that it sinks current from a load When activated the current flows from the load into the appropriate output terminals 7 13 amp 14 Pulse scaling is set as the number of litres gallons etc per output pulse Eg 0 1 litres pulse 10 litres pulse 100 gallons pulse Range is 0 1 9999 9 Eng unit pulse The pulse width pulse duration of the output pulse automatically mirrors the cyclic width of the incoming pulse for example 5HZ input frequency would produce a scaled pulse output with a duration lt 200ms for 100Hz input the output pulse duration would be lt 10ms E 5 OV ground cabana gt 8 24Vdc Low flow alarm 1 A Pulse out High flow alarm 1 g Driving a logic input The output voltage pulse is typically the internal voltage of the load The l
87. ss control valve Networking takes place when any one controller is started at this point the flowmeter input count is restricted to the controller in use all other controllers will not count and their start function will be inhibited and an ENGAGED will scroll across the LCD display showing the ID number of the controller in use Batch entries can be made whilst individual batch controllers are inhibited locked out but they cannot be started until the controller in operation has completed its batch cycle eee deeds TER OE ey OI OR TRO ja E For the network feature to work the network DIP switches must be set as shown amp each batch controller MUST be programmed with an individual ID number other than 0 zero Network loop wiring ZOD B1 1 ZOD B1 3 Multi product batching 0 A3 Network High relay 2 0_23 Network High relay 2 NA 2 DIP switch my kl eee D1 settings Low relay 1 D1 settings Low relay 1 Product 2 ee ee Flow Batch status input DIP switches OV ground 8 Flow Batch status input DIP switches Alarm output OV ground EA ZOD B1 2 ZOD B1 4 03 Network High relay 2 14 C13 Network High relay 2 14 a joi ewitche AA 14 On 2 DIP switch 919a 14 D1 settings Low relay 1 D1 settings Low relay 1 Flow Batch status input DIP switches Alarm output OV ground ES Flow Batch status input DIP
88. standards include EN 61326 immunity in industrial locations EN 62326 emissions in industrial locations EN 60529 degrees of protection IP Installation specifically engineered to be directly mounted on a variety of flowmeters wall or surface mounted pipe or panel mounted Various mounting kits are available The instrument can be self powered or may be powered by an external dc supply or two wire loop powered 1 4 LCD displays Full LCD display test feature illuminates all display N VIN VN VIN VIN VIN VA segments and script text displays for 5 seconds when RUN ACCUM TOTAL STOP BAT LOW HIGH RATE entering the program mode Rate display has flashing SEC MIN HR or DAY followed by up to 5 digits of rate programmable for up to 3 floating decimal places The 8 digit Total display is push button or remote resettable and can be programmed for up to 3 decimal places pann The 8 digit Accumulative Total display can be L aJ L AL AN gal programmed for up to 3 decimal places Reset is only E al J k ja Ji possible when in the program mode which can be PIN ACCUM TOTAL protected for security 5 Operation 2 OPERATION 2 1 Accumulative Total Accumulative total can be reset at L2 in the program mode The accumulative total can be displayed momentarily or continuously through use of the front panel ACCUM TOTAL key Momentary display Accumulative total is displayed only whilst the key is held pressed Latc
89. t contact is made whilst a batch is running the batch will be paused When the run function is inhibited it is still possible to enter a new batch quantity or review the accumulated totals but it will not allow the operator to RUN or re start the batch until the inhibit input is released An example of this feature in practice is where a batch should not be allowed to RUN whilst a valve at another location is open Solid state output logics 17 7 4 Current Sinking outputs NPN Current sinking derives its name from the fact that it sinks current from a load When activated the current flows from the load into the appropriate output terminals 7 12 13 amp 14 NPN is the factory default configuration for the outputs Refer to pages 10 amp 11 for wiring control outputs Driving a logic input The output voltage pulse is typically the internal voltage of the load The load would normally have an internal pull up resistor on its input as shown Driving a coil The NPN style of output is to be used when driving a coil The coil load is obtained by dividing the coil voltage by coil impediance Q is expressed in amps amp is not to exceed 100mA at terminals 7 8 12 or 1A at terminals 13 amp 14 The coil voltage is connected across 8 must match the ZOD B1 supply voltage amp the appropriate output terminals 7 12 13 8 14 L spo no flow alarm a 0I PNP Set jumper s O REP repeater pulse A A NPN lt to NPN TA 13
90. t change Relay 2 high Relay 1 low Batch status Not used Not used Inhibit input a OV ground 8 9 10 Installation 3 3 Wiring connections Powering 8 Remote switches remote keys use momentary contact Network loop Relay 2 high Relay 1 low Flow Batch status Input not used 11 OV ground not used 8 24Vdc in Run inhibit 9 No flow alarm OV ground sp Remote keys spe Ne clit Reg Vdc cm STOP 15 16 17 18 19 remote switches only m RUN Wiring requirements Use multi core screened twisted pair instrument cable 0 25 0 5mm for electrical connection between the ZOD B1 and any flowmeter or remote switch input The screen needs to be grounded at OV terminal 8 this is to protect the transmitted signal from mutual inductive interference Instrument cabling should not be run in a common conduit or parallel with power or high inductive load cables Power surges amp power line frequencies may induce erroneous noise transients onto the signal Run instrument cables in a separate conduit or with other instrument cables Single Stage Control use relay 1 or 2 relay 2 has pre stop programming capability Network Relay 2 high Relay 1 low Flow Batch status Input not used 11 OV ground not used 8 24Vdc in Run inhibit 9 No flow alarm OV ground a ke A n e e e A A A A A ee y Ma Mu Mu Mu Mu Mu Mu amu Mu Mu e Mu e Mu
91. tancy can be up to 5 10 years when programmed with the unique Ultra Power Save sleep cycle Battery life reduces when connected with a coil input from turbine flowmeters Rate display defaults to total display 4 minutes after pressing the rate key in order to conserve battery power reverse polarity protected Regulated 8 24Vdc x 150mA or 4 20mA loop powered All programmed amp accumulated data is stored permanently in non volatile memory NPN PNP transistor scaleable 50hz max or non scaleable 5000hz max 1A maximum drive capability Two wire loop powered 12 28Vdc into 100 9000 loop load accuracy 0 25 FS key entry programming of Zero amp Span Alarm outputs Two NPN PNP selectable FET transistors programmable low 8 high flow alarm with Physical Configuring K factor range adjustable deadband reset differential Maximum drive 100mA resistive load 24Vdc max A IP66 67 high impact glass reinforced Polyamide enclosure B 3 x M20 or 2 NPT female conduit entries C 125mm diameter 5 x 64mm deep 2 5 x 400g 0 9lb D Temperature range from 20 C to 80 C 4 F to 1 6 F PIN protected data entry with scrolling English text prompts Eg Pulses litre gallon lb etc Programmable range is 0 001 9999999 999 with a floating decimal point during K factor entry Engineering units Selectable Ltr gal m3 kgs Ibs total sec min hr or day rate Rate conversion Enables the ra
92. te to be displayed in different engineering units to that of the totals Battery modes eg totals in barrels oil amp rate in US gallons Ultra power save standby or continuous display selectable Dual Input option Programmable for computations of A B A B or A B ratio Introduction 4 1 3 Overview The ZOD Z3 is specifically designed for computing displaying and transmitting totals and flowrate from flowmeters with pulse or frequency outputs The instrument will display Flow Rate Resettable Total and an Accumulated Total in engineering units as programmed by the user Simple flow chart programming with scrolling English prompts guide you through the programming routine greatly reducing the need to refer to the instruction manual All user program data is retained if the battery is removed Environments The ZOD Z3 is weatherproof to IP66 67 Nema 4X standards UV resistant glass reinforced Polyamide with Stainless screws amp FKM O ring seals The instrument suits harsh indoor and outdoor environments amp conforms to EMC directive 89 336 EEC Electro Magnetic Compatibility Features 10 point Linearisation PIN Protection NPN PNP selectable autoranging pulse outputs scaled or un scaled Low frequency cut off Battery conservation mode 4 20mA output High Low flow alarms with adjustable deadbands Dual inputs Optional l S certification to ATEX directive for conforming standards refer to l S supplement Conforming
93. ter refer page 5 4 Electrical Installation depends on the model you have purchased If the dualpulse is fitted or supplied with a receiving instrument such as a totaliser or rate totaliser please refer to the appropriate manual and page 10 of this manual For pulse output meters select the appropriate output and wire to your receiving device refer pages 7 to 9 5 Calculate the flowmeter K scale factor to suit the installation For ideal installations refer to page 11 or 12 or 13 of the flowmeter Manual For non ideal installations the K factor may be calculated by performing an in situ calibration Enter the appropriate K factor into your receiving instrument CONTENTS 1 0 INTRODUCTION 1 1 Model number designation 1 2 Overview 1 3 Operating principal 1 4 Specifications 2 0 INSTALLATION 2 1 Meter location 2 2 Meter installation amp orientation 2 3 Height adjustment 2 4 Flow direction orientation 2 5 Hot tap installations 3 0 ELECTRICAL CONNECTIONS 3 1 Standard outputs 3 2 Optional Reed switch output 30 Instrument cable installation requirements 3 4 Pulse output selection standard outputs 3 5 QP Quadrature pulse output option 3 6 Bi directional flow using QP option 3 7 Connection to family instruments 4 0 K FACTOR calibration factor for meter 5 0 K factors for common pipe ID sizes lt 575mm K factors for large pipe ID gt 460mm Calculating K factors metric units litres or M3 Calculating K factors U
94. the ability to change any of the program parameters but will allow the user to step through and view the existing program parameters Only one PIN number may be set but this can be changed at any time after gaining access through PIN entry A second back up PIN number is installed at the factory should the programmed PIN be lost or forgotten refer bottom of page 19 for the back up PIN No 4 2 Resetting Accumulated Total amp Total Number of Batches TNB Resetting the Accumulated Total 8 Total Number of Batches TNB is done at RESET ACCUMULATIVE TOTALS in the program mode Both Accumulated Total amp TNB are reset if you select YES at this program level 4 3 Engineering Units refer clause 1 4 Select from available Engineering units to right of the display No engineering units denote NIL set allowing the user to set up the instrument with other units of measure which are not available on the ZOD B1 LCD display 4 4 K factor scale factor Enter K factor starting with the most significant number up to 7 prime numbers amp 3 decimal numbers can be entered Trailing decimal numbers move into view as digits to the right are progressively selected any significant digits which may move from view remain functional 4 5 Decimal Points Up to three decimals points can be selected for Batch Total or Accumulative Total 4 6 Count Direction B1 can be programmed to count DOWN from a preset quantity or UP from zero Overruns in t
95. tors and formula shown are a result of factory testing using smooth bore piping under ideal conditions Variations to the given K factors may occur when using rough bore piping or inadequate flow conditioning on either side of the flow transducer refer clause 2 1 In these instances on site calibration may be used to determine the K factor 4 1 Flow transducer K factors for common pipe sizes Pipe detail K factors standard K factors for voltage 8 square wave outputs NB ID 40 Schedule 40 pipe 40 Schedule 80 pipe 80 For other pipe sizes below 610mm 24 not listed above use the graphs and apply the formula on the following pages 12 8 13 4 2 K factors for large pipes 460mm ID 18 and above use Pulses per litre 28647 pipe ID mm Pulses per M 28647000 pipe ID mm Pulses per US gallon 168 14 pipe ID inches Pulses per Imp gallon 201 94 pipe ID inches NOTE K factors for Reed Switch output option are 1 3 the standard factors of voltage pulse output page 12 4 3 Calculating K factors litres or m 25 24 5 y 24 Pipe ID 450mm amp above A 22 5 A 23 5 23 See example a 22 5
96. um input frequency for rate display is 0 25hz reducing to 0 1hz If the low frequency cut off is set to 0 1Hz see clause 4 7 2 4 Keypad function matrix Displays Accumulative Total No function when pressed Increments the selected digit each time No function that it is pressed Resets the accumulative total Resets the resettable total display to zero when pressed for 1 2 seconds display to zero 1 Pressing the Prog amp Reset keys for 5 PROGRAM seconds enters you into the program mode Each press steps you through each level of the program 2 Displays model amp software revision No Selects the digit to be set the selected digit will be flashing indicating that it can be incremented Displays flow rate when pressed 8 3 Installation INSTALLATION 3 1 Remote Mounting Surface mount footprint use 4 x M3 screws supplied Wall mount bracket en Optional P No AWM 6 5 x 19mm 42 6 mm l t sou HARARE tro LI 1 67 meri la 96 mm 38 Panel mount options Cut a 71mm x 83mm 2 8 x 3 3 opening in panel Drill 4 holes to take M4 screws on a 68 0 x 89 6mm pitch 2 68 x 3 53 See panel mount tem Mount using 4 x M4 nuts amp washers tap panel or use rear case as shown 3 x M16 conduit entries 30mm pitch Installation 9 3 1 Remote Mounting continued Pipe mount order Pipe mount kit P No APM comprising two brack
97. umbers can be entered using the arrowed keys 4 6 Rate response Adjustable response rate dampening is available to smooth out fluctuating flow input signals in order to provide a Stable rate display Most input signal are reasonably stable and need only a low setting value of 001 to 004 The response number ranged 001 999 represents the number of pulse intervals duration between each pulse that the processor averages and displays the rate as calculated As a general rule it would be best to apply a response number which is a multiple of the number of pulses a meter produces for each cycle of its primary measuring element for example a rotating element may produce 4 pulses per revolution so 004 008 012 or 016 would be ideal response settings whereas a turbine meters with high resolution pulse outputs would require response settings like 050 100 200 or in some cases involving high frequency pulse outputs eg 500hz the response number would be set to say 999 4 7 Low frequency cut off The low frequency cut off is most commonly set to 0 0Hz disabled other than to 1 To display rate for input frequencies below 0 25hz for example setting the cut off at 0 1Hz the rate will continue to display for input frequencies as low as 0 1Hz one pulse every 10 seconds such conditions often apply to flowmeters with low frequency pulse outputs 2 Inhibit the integration amp registration of apparent flow which at times may be encountered on mo
98. ur back up 4 digit PIN number is 0502 10 E ALPHABETICAL INDEX Accumulative total 5 Alarm output 16 Automatic Overrun Comp 13 Batch RUN 5 Batch SET 5 Batch STOP 5 Batch total 5 Batch limit 13 Batch operating procedure 15 Batch status 16 Back up PIN number 20 Battery 4 Controller ID number 13 Controller networking 18 19 Count direction 12 Decimal points 12 Engineering units 3 12 End of batch batch status 11 16 amp 17 Error messages 20 External DC powering 10 Flow alarm output 18 Flowmeter connections 8 9 ID numbering 13 Inhibit input 16 Keypad functions 5 K factor scale factor 12 14 Index LCD display M Model number designation Missing pulse detection Mounting options N Networking o Operation Overrun compensation Overview P PIN number protection Pre stop Programming Program detail record Programming flow chart R Relay control logic Remote operating keys Resetting totals Run inhibit input s Scale factor K factor Single stage control Specifications Start delay Total Number of Batches Two stage control Wiring connections Wiring requirements 18 12 12 10 21 12 12 13 20 14 11 10 12 16 11 10 KO1 1010 Manufactured and sold by Kobold Messring GmbH Nordring 22 24 D 65719 Hofheim Tel 49 0 6192 2990 Fax 49 0 6192 23398 Universal Mount Series ZOD ZI BATTERY TOTAUSER INSTRUCTION MANUAL To review software versio
99. ut pulse output 8hz max 5Khz max PNP output pulse 50mA max 8 24Vdc external power load 12 Programming 4 PROGRAM PARAMETERS 4 1 PIN No Program Protection The option exists to protect the programmed detail amp Accum Total with a user selected four digit PIN No 0000 represents no PIN protection f activated the user must input the correct PIN No failure to do so will deny access to change any of the program parameters or reset the Accumulative Total but will allow the user to step through and view the program details Only one PIN number may be set but this can be changed at any time after gaining access through PIN entry A second back up PIN number is installed at the factory should the programmed PIN be lost or forgotten refer page 14 for the back up PIN No 4 2 Resetting Accumulated Total Resetting the accumulated total can only be done within the program mode 4 3 Engineering Units refer clause 1 4 Select from available Eng units to right of the display The ZOD Z1 can display in engineering units not available on the LCD display by programming to no eng units and a suitable K factor 4 4 K factor scale factor Enter K factor starting with the most significant number up to 8 prime numbers amp 3 decimal numbers can be entered Trailing decimal numbers move into view as digits to the right are progressively selected any significant digits which may move fro

Kobold DOR Series Paddle Wheel Flow Meter Manual

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