FLOW TRANSMITTERS ELECTRONICS FOR INSTRUMENTATION EMO-1005 Flow Computer Operation Manual Rev. 1a 8809 Industrial Drive, Franksville, WI 53126-9337 Tel: 262-884-9800 Fax: 262-884-9810 E-Mail: awinfo@aw-lake.com Web: http://www.awgearmeters.
Table of Contents Introduction 2 Using the EMO-1005 Unit Installation Screen Manipulation Display Mode Selection Rate Display Total Display Simple Ratio Display Peak Ratio Display Status Display Mode 4 5 6 6 7 7 8 8 9 Programming the EMO-1005 Rate Scaling Totalizer Scaling - KFT Limits Programming Rate Limit Total Limit Analog Gain - KFA Offset Analog Out Sample Amount Cutoff Frequency Analog In Gain 10 12 13 15 16 16 17 18 18 19 19 Channel Mode Selection Monitor Mode PID Operations Transparent PI Con
INTRODUCTION The EMO-1005 is a multi channel indicating, computing and signal processing system, applicable in single channel use and expandable to systems with as many as 250 independently operating channels. All its functions can be programmed through the programming keyboard in the front panel or optionally, by a host computer through a RS 422 (RS 232 option) serial port. There are 5 selectable modes of operation (see page 19); the most popular are either MONITOR or PID (closed loop).
Typical applications for the EMO-1005 unit: - Rate and total indicator for flow meters, tachometers, parts counters, etc. - Processing unit for batch operations. - Closed loop controller for flow rate, speed, etc. - In applications with non-linear transmitters (frequency output not directly proportional w/flow or speed). - Operations requiring limit outputs.
USING THE EMO-1005 FLO 7 TOT 5 SPC 9 CHA A/B 4 5 RAO 6 LIM A+B 1 A 2 B 3 KFR 0 DP . ENT KFA The EMO-1005 Keyboard The keyboard has membrane type switches. There is no "click" heard or felt when pressing a key. The press on the key must be very firm to activate the switch. This type of keyboard was selected to avoid the likelihood of accidental programming.
UNIT INITIALIZATION When powering up the EMO-1005 unit, the following sequence will display system hardware and software information. LINE 1 Ram Test ................. LINE 2 Ram and no Bat Ram test ..................... or Ram and battery Line one indicates the RAM memory is being tested. Line two indicates whether the RAM memory battery back-up is installed and operational.
QUICK START The EMO-1005 has several default values programmed in at the factory. This means you can hook it up and test it out before any serious programming is necessary. The unit comes up in Monitor mode as a default. The default rate scaling is 100 and the engineering units is Hertz (Hz). This means that a 100 Hz signal input on pin 4 will be displayed as 100 Hz on line 1. And the totalizer will display impulses (Imp) on line 2.
RATE FLO To display the rate press the FLO key. The Rate Mode displays the current incoming frequency for the channel selected on line 1. The displayed frequency is initially displayed in Hz. But the display can be programmed to any of the 28 familiar engineering units. For further information see the Programming section, page 11. The rate will be displayed in the following form: LINE 1 01:XXXXX.XXXzzzz LINE 2 where, 01: is the channel number XXXXX.
SIMPLE RATIO RAO There are two ratios available on the EMO-1005: the Simple Ratio and the Complex Ratio. The Complex Ratio is a channel mode selection. This ratio changes the inputs and outputs on the channel designated to be in the Complex Ratio Mode. The Simple Ratio Mode however, does not affect anything on the unit but the display screen. When the RAO key is pressed, the channel being displayed on line 1 is changed to show a ratio of channel 1 divided by the channel on line 1.
STATUS DISPLAY MODE Press the following key sequence: CHA -> DP -> ENT -> KFR The status display will be displayed in the following form: LINE 1 LINE 2 SDxx:XXXXPO/YYYY AOzzzzAIyyyLOOIO where, xx: is the channel selected in line 1 XXXX is the input rate (frequency) in Hz P indicates the mode: P = PID R = Complex Ratio M = Monitor T = Transparent G = Gun-On C = Closed Loop Control O / YYYY AO zzzz AI yyy L OOIO ^.. ^... ^.... ^.....
PROGRAMMING THE EMO-1005 To enter the programming mode press the following key sequence: CHA -> DP -> ENT -> KFA Now the display will show: LINE 1 LINE 2 PROGRAMMING 0 = NO 1 = YES If this screen did not come up then try the key sequence once more (press slowly and firmly on the keys). If you would like to program press the 1 key; if not, press the 0 key. Pressing the 0 key returns the unit to the normal operating mode.
In the following lines the menu questions are listed in the order they appear while in programming mode: QUESTION: ANSWER: Display 1 RATE SCALING ? 0 = NO and 1 = YES 0 or 1 ENTER Display 2 TOTALIZER SCALE? 0 = NO and 1 = YES 0 or 1 ENTER Display 3 LIMITS? (none=0) RATE=1 TOTAL=2 0, 1 or 2 ENTER Display 4 ANALOG GAIN (KFA) CURRENT=00000167 Enter new KFA ENT alone is no change (167 is default) Display 5 OFFSET ANALOGOUT CURRENT=00000205 Enter new number ENT alone is no change (205 is defa
RATE SCALING - KFR (Display 1) By answering with a 0 the scaling will be skipped. By answering with a 1 the following display appears: CURRENT KFR/UNIT XXXXXXXX.X YYYY where, XXXXXXX.X is the current rate scaling YYYY is the selected engineering units The EMO-1005 is programmed, at the factory, to calculate the incoming frequency in Hertz (Hz). In order to make the EMO-1005 show a more convenient engineering unit, such as GPM, an appropriate scaling factor must be applied.
Decimal Point Location In order to change the scaling just enter the number, and change the decimal point location by pressing the DP key. After having the desired number in the display press the ENT key once. Engineering Units Now by pressing the SPC key the unit display can be changed to one of the following engineering units: Hz, GPM, li/m, ci/m, cc/m, lb/m, lb/s, lb/h, gr/s, kg/m, gr/m, mm/s, cm/m, in/m, ft/m, oz/m, Volt, mV, Amp, mA, PSI, Bar, F, C, RPM, SSU, cSt, cPs.
In order to make the EMO-1005 display show the desired engineering units, the most important thing to know is the K-factor of the transmitter that is being monitored. The K-factor is the relationship between the amount of impulses and the engineering unit. To change the scaling just enter the number, (zero the display first) and to change the decimal point location press the DP key. After having the decimal point in the correct location press the ENT key once.
LIMITS PROGRAMMING (Display 3) LIMITS? RATE=1 (none=0) TOTAL=2 By answering with a 0 the scaling will be skipped By answering with a 2 go to the next section There are a total of 4 limits per channel. Each of the limits can be a totalizer or rate limit. If the limit has been programmed for total and rate, the output will respond to the one that occurs first. This can produce unexpected limit initiation therefore you should be careful to avoid this type of programming duplication.
RATE LIMIT By answering with a 1 the following display appears: RATE LIMIT NO ENTER 1 ........4 ? Select the rate limit that needs to be changed. Do this by pressing a number 1...4 Now the display will show the selected limit in the following fashion: CURRENT RATE Y LIMIT XXXXXX.XX where, Y indicates the limit number selected XXXXXX.XX indicates the current rate limit in Hertz To change the limit enter the right number and press ENT After entering the number the display returns to the Limit Main Menu.
ANALOG GAIN - KFA (Display 4) The Analog Gain (KFA) is the scaling between the frequency input and the analog output. This is only valid in Monitor Mode -- in PID Mode, KFA controls the closed loop reaction time (P21). This should not be confused with the KFR factor ANALOG GAIN (KFA) CURRENT=XXXXXXXX The formula that describes the relation is as follows: Frequency when Eng.
OFFSET ANALOG OUT (Display 5) OFFSET ANALOG OUT CURRENT=XXXXXXXX This display takes care of the Analog Offset adjustment. The full voltage span goes from 0 to 5V (0-20mA). Some applications however require a base voltage of 1 Volt (4mA). This base voltage can be programmed in the Offset Voltage. The EMO-1005 unit uses a 10 bit D/A converter for the Analog Output, where 0 Volt relates to a count of 0000 and 5 Volt is 1023. The offset is a number between 000 and 255 (0V to approximately 1.24V).
CUTOFF FREQUENCY (Display 7) CUTOFF FREQ. CURRENT=XXXXXXXX The cutoff frequency can be entered in this display. The cutoff frequency is used to remove a slowly decreasing rate being displayed when the flow is shut off - this is a display function only and pulses are not being counted. When actual flow stops, however, the unit will momentarily look for the next pulse and for a very short period, the displayed flow rate will tail away to zero.
CHANNEL MODE SELECTION Each channel card installed in an EMO-1005 is a separate microprocessor controlled system. Each channel card has the option to designated as a Monitor, PI Controller, Closed Loop Controller (CLC) or a Complex Ratio System.
THE EMO-1005 PID OPERATIONS (Select 4) When a 4 is selected in the previous screen, the channel card will be designated as a PI Controller with the Transparent option. The PI Controller with the Transparent option works the same as the standard PI - controller except that the mode, when activated, takes the Analog Input and diverts it to the Analog Output. This feature even overrides the HOLD signal. By doing this the EMO-1005 channel card becomes transparent.
The limits in monitor mode have no validity in PID mode, the following table shows their revised functions and programming locations. MONITOR MODE Rate Limit 1 (Hz) Rate Limit 2 (Hz) Rate Limit 3 (Hz) Rate Limit 4 (Hz) Total Limit 1 (Impulses) Total Limit 2 (Impulses) Total Limit 3 (Impulses) Total Limit 4 (Impulses) Totalizer Reset (Pin 9) CLOSED LOOP (PID) Set Value 1 (Pg. 20) Set Value 2 (Pg. 20) Initial Kick (Pg. 22) Integral Adder for I-Part (Pg. 21) Initial Kick Threshold (Pg.
Initial Kick The PI-controller will output the value in total limit 2 (P. 21) if there is a set value and nothing is being received from the feedback loop. This is called the initial kick and is meant to >kick start= some fluid regulators, which will resist an initial opening when starting from a zero flow condition. The initial kick can be programmed from 0000 to 1023 (where 0000=omA and 1023=20mA). In units prior to AUGUST 1987, the initial kick could be programmed only from 000 to 255.
EMO-1005 SOFTWARE CHANGE A new programmable feature has been added to the EMO-1005 software. It is a Programmable Threshold for the initial kick value used in PI and Closed Loop Mode. (See Initial Kick, pg. 22). While most good fluid regulators are supposed to crack open at 4mA, there is much inconsistency to be found. The earlier threshold value was fixed at 5.0 mA -this is now user programmable. If nothing is programmed here (0000), a threshold default value of 5.0 mA (256) is still used.
GUN-ON PI CONTROLLER (Select 3) When a 3 is selected in the previous screen, the channel card will be designated as a PI Controller with the Gun-On option. The only difference between this and the standard PI Controller is the Gun-On feature which makes the Analog Output increase until the EMO-1005 starts to see a feedback frequency. When the EMO-1005 is in this mode, the initial kick has no affect on the Analog Output.
CLOSED LOOP CONTROL MODE (CLC) The CLC mode has been adapted to the EMO-1005 for extremely slow closed loop applications. In some applications (fluid) where the distance between the I/P converter and the regulator is more than 40 feet and the pneumatic system is not quick enough in response, the standard PI loop will not do the job. The CLC mode has one major difference to the standard PI mode in that the corrections are done by a percentage to the error rather than proportionally.
THE EMO-1005 LINEARIZER Some systems have un-linear transducers for the rate or frequency. To solve this problem the EMO-1005 was developed with a ten point Linearizer that can be programmed with an error of +/12.7%. USING THE LINEARIZER The Emo-1005 Linearizer can be used with any of the channel mode selections listed. This means that the unit can linearize the feedback frequency of a PID controlled system or correct for error of one component in a two component ratio system.
PROGRAMMING THE LINEARIZER To enter the Linearizer mode press the following key sequence: CHA -> DP -> ENT -> DP Now the display shows: LINEARIZER !!! 1=CL 2=AC 3=DEAC By pressing the 1 key the Linearizer will be cleared. This means all error values are set to +12.7% and all frequency points are set to zero. By pressing the 2 key the Linearizer will be activated. By pressing the 3 key the Linearizer will de deactivated.
THE EMO-1005 SERIAL PORT The standard EMO-1005 has a RS-422 serial port. AW-Company decided to use the RS-422 as a standard because of higher noise immunity and better acceptance in industrial applications. General characteristics for the EMO-1005 serial port.
After pressing 1 or 0 the EMO-1005 unit goes into the Receiver/Transmitter display mode and the beginning usually looks as follows: RXXXXXXXXXXXXXXX TXXXXXXXXXXXXXXX If left in this mode the serial communication can be viewed. The Receiver is on the upper line and the Transmitter on the lower line. If the text ORFE is right after the R it means that the unit has an over run/framing error. This error usually occurs when there is nothing hooked up to the serial port or when the baud rate is not right.
SERIAL PORT CONNECTION WIRING The serial port connection is established through the 9 pin D-sub connector on the back panel of the unit.
Writing with the host computer: >01J03340F6587XXcr ^....................... start of text always > sign ^^.................... channel number that should be written to ^................... J = writing into channel (K = read) ^^^^........... address to write to ^^......... byte written to 0334 ^^...... byte written to 0335 ^^... byte written to 0336 ^^.. checksum for string 01J03340F6558 ^^.
These are the ASCII characters needed when working with the EMO-1005 ASCII 0 1 2 3 4 5 6 7 8 9 Decimal 48 49 50 51 52 53 54 55 56 57 ASCII A B C D E F J K Decimal 65 66 67 68 69 70 74 75 BASIC PROGRAM FOR TESTING THE SERIAL PORT. The BASIC program below will help test the communication port with a IBM PC compatible computer. The program can be used in connection with BASIC, BASICA, GWBASIC or any other reasonably standard PC BASIC.
IMPORTANT ADDRESSES WARNING --- IMPORTANT --- WARNING --- IMPORTANT --- WARNING The communication port does not discriminate any addresses. This means that any address can be written to as well read from. Certain addresses will change the operation of the EMO-1005 drastically. Caution is recommended. Double check your programming. The bytes are always arranged such that the low byte is first and then the more significant byte.
These addresses are located in every channel.. Example: >03K006304XXcr >01K006304XXcr Reads channel 03 totalizer Reads channel 01 totalizer The next information is battery backed in Channel 01 even though it concerns channel 01 through FF. Below is a table where to find this information located in the Channel 1 memory. in HEX Address for Ch1 Ch2 Ch3 Ch4 Ch5 .............. Description 0552 05D2 0652 06D2 0752 ............ Display KFT factor, 2 bytes 0554 05D4 0654 06D4 0754 ..........
HARDWARE HINTS The EMO-1005 internally has 1-5 microprocessors therefore, it is very important to pay attention to proper signal wiring and shielding. SIGNALS AND SHIELDING The standard EMO-1005 is delivered with two frequency inputs. Pin 4 of any channel card is an opto-coupler input where 5-30Volts turn on the opto-coupler. This input is used mainly for the ZHM series flowmeters distributed by the AW Company. The frequency return from a ZHM meter can be directly connected to this input.
BACK PANEL DETAILS Before hooking up the EMO-1005 it would be advisable to read this complete section. The EMO-1005 consists of a POWER SUPPLY CARD and at least one CHANNEL CARD. The regular EMO-1005 could be equipped to hold 4 CHANNEL CARDS. In the expanded chassis model the case can hold as many as 14 Channel cards. The 5" units holds up to 4 channels, the 10" unit up to 12 channels, and the 15" unit up to 14 (15) channels.
EMO-1005 TROUBLESHOOTING CAUTION!!! The Power-supply card has live 110 VAC on the card. Disconnect the power cord before opening the EMO-1005. Symptom Possible Cause Correction No display at all.
One of the Limits output is not working External Wiring Wrong Faulty Opto-coupler If Status display is OK Check external wiring If Status display and wiring is OK, return to AW Company Random number comes up when a number is entered in programming mode. The number entered is too large. Check programming section for maximum allowable number. Serial communication does not work. If only ONE EMO-1005 is used and an offset value has been programmed.
LIMITED WARRANTY AW Company warrants the EMO-1005 flow computer to be in good working order for a period of 1 (one) year from the date of purchase from AW Company or an authorized AW Company distributor. Should the EMO-1005 fail to be in good working order at any time during this 1 year warranty period, AW Company will, at its option, repair or replace the EMO-1005, at no additional charge except as set forth below.
QUICK REFERENCE KEY SEQUENCES STATUS DISPLAY MODE CHA CHA -> DP -> ENT -> KFR -> 01, 02, etc = Channel Number PROGRAMMING CHA -> DP -> ENT SPC = Engineering Units DP = Decimal Point -> KF A -> LIM -> DP -> 1 CHANNEL MODE SELECTION CHA -> DP -> ENT PROGRAMMING THE LINEARIZER CHA -> DP -> ENT SERIAL PORT PROGRAMMING CHA -> DP -> ENT APPENDIX A AW-Lake Company 8809 Industrial Drive, Franksville, WI 53126 web: www.awgearmeters.
PROGRAMMABLE PARAMETERS PARAMETER DEFAULT RATE SCALING (KFR) 0000100.0 TOTALIZER SCALING 00010000 RATE LIMIT 1 00000000 RATE LIMIT 2 00000000 RATE LIMIT 3 00000000 RATE LIMIT 4 00000000 TOTAL LIMIT 1 00000000 TOTAL LIMIT 2 00000000 TOTAL LIMIT 3 00000000 TOTAL LIMIT 4 00000000 ANALOG GAIN (KFA) 00000167 OFFSET ANALOG OUT 00000205 SAMPLE AMOUNT 00000008 CUTOFF FREQUENCY 00000050 ANALOG IN GAIN 00000000 LINEARIZER ERR. POINT 01 0000012.7 LINEARIZER POI.
AW-Lake Company 8809 Industrial Drive, Franksville, WI 53126 web: www.awgearmeters.com Tel: 262-884-9800 Fax: 262-884-9810 Email: awinfo@aw-lake.com REV. 1a 05/98 EMO-1005 Manual.
AW-Lake Company 8809 Industrial Drive, Franksville, WI 53126 web: www.awgearmeters.com Tel: 262-884-9800 Fax: 262-884-9810 Email: awinfo@aw-lake.com REV. 1a 05/98 EMO-1005 Manual.
AW-Lake Company 8809 Industrial Drive, Franksville, WI 53126 web: www.awgearmeters.com Tel: 262-884-9800 Fax: 262-884-9810 Email: awinfo@aw-lake.com REV. 1a 05/98 EMO-1005 Manual.
AW-Lake Company 8809 Industrial Drive, Franksville, WI 53126 web: www.awgearmeters.com Tel: 262-884-9800 Fax: 262-884-9810 Email: awinfo@aw-lake.com REV. 1a 05/98 EMO-1005 Manual.
AW-Lake Company 8809 Industrial Drive, Franksville, WI 53126 web: www.awgearmeters.com Tel: 262-884-9800 Fax: 262-884-9810 Email: awinfo@aw-lake.com REV. 1a 05/98 EMO-1005 Manual.
AW-Lake Company 8809 Industrial Drive, Franksville, WI 53126 web: www.awgearmeters.com Tel: 262-884-9800 Fax: 262-884-9810 Email: awinfo@aw-lake.com REV. 1a 05/98 EMO-1005 Manual.
AW-Lake Company 8809 Industrial Drive, Franksville, WI 53126 web: www.awgearmeters.com Tel: 262-884-9800 Fax: 262-884-9810 Email: awinfo@aw-lake.com REV. 1a 05/98 EMO-1005 Manual.
AW-Lake Company 8809 Industrial Drive, Franksville, WI 53126 web: www.awgearmeters.com Tel: 262-884-9800 Fax: 262-884-9810 Email: awinfo@aw-lake.com REV. 1a 05/98 EMO-1005 Manual.
AW-Lake Company 8809 Industrial Drive, Franksville, WI 53126 web: www.awgearmeters.com Tel: 262-884-9800 Fax: 262-884-9810 Email: awinfo@aw-lake.com REV. 1a 05/98 EMO-1005 Manual.
AW-Lake Company 8809 Industrial Drive, Franksville, WI 53126 web: www.awgearmeters.com Tel: 262-884-9800 Fax: 262-884-9810 Email: awinfo@aw-lake.com REV. 1a 05/98 EMO-1005 Manual.
APPENDIX L: EMO-1005 WITH BUILT-IN PNAO When the EMO-1005 is modified to have a built-in PNAO module, the following items need to be taken into consideration. The PNAO modification allows the EMO-1005 to receive quadrature input flow-meter signals and provide a ± 5 volt output depending on flow direction. The voltage output is scaled using the KFA. When calculating the KFA, assume +5 volts for maximum forward flow over a flow range of 0-5 volts.
AW-Lake Company 8809 Industrial Drive, Franksville, WI 53126 web: www.awgearmeters.com Tel: 262-884-9800 Fax: 262-884-9810 Email: awinfo@aw-lake.com REV. 1a 05/98 EMO-1005 Manual.
