Training Manual 2018
Training Manual 2018
Training Manual 2018
ManuFlo
MANU ELECTRONICS PTY LTD
® TM 41 Carter Road, Brookvale
Sydney NSW 2100 Australia
Ph: +61 2 9938-1425
Flow Measurement Products +61 2 9905-4324
Fax: +61 2 9938-5852
E-mail: [email protected]
web : www.manuelectronics.com.au
V1.09/17
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Contents
1. About Manu Electronics / ManuFlo 8. Shotcrete, Grout, Slurry, Oxides,
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1.
About
Manu Electronics P/L
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About Manu Electronics
• Manu Electronics Pty Ltd was founded in 1965
by Anthony Manu
• Specialises in design/manufacture of
process control and measurement instrumentation,
primarily for the concrete construction chemical additives industry.
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Key Staff
Alex Manu - Managing Director
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Tens of Thousands in Operation …
Manila
Philippines
• Used in over 95% of all pre-mix concrete production plants throughout Australia/NZ
• Exported to regions including the Asia/Pacific, South America, Europe and the Middle-East
• Used in varied liquid measurement applications including concrete admixtures, shotcrete, chemical,
mining, irrigation, food, tradewaste, water and water-usage studies.
Global Admixture manufacturer / supplier companies use ManuFlo products for measurement
and batching of liquids in their production facilities, distribution network and final dispensing at their
customers’ premix concrete production plant.
Selected distributors and end users use ManuFlo products for numerous applications worldwide.
ManuFlo has a global pricelist in AUD$ with quantity discounts, maintaining pricing parity for its
products to all its admixture supplier customers.
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ManuFlo Advantages
Economically priced products, with Australian Quality Control.
Global pricelist.
Free on-going product and application support.
Personal service and phone support.
Simple to use, proven products with overdose or failure safety features.
Direct delivery flow measurement, with no flushing required.
Stock and spare parts available on call.
Up-to-date information at websites www.manuelectronics.com.au
www.manuflo.com
Data Sheets, Installation and Troubleshooting Guides and User Manuals.
Company with 50+ years history.
Ongoing R&D program.
Deal direct with the Manufacturer, Equipment training available.
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2.
Measuring Admixtures.
Production,
Transfer and Use
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2. Measuring Admixtures, Production, Transfer
and Use for Premix Concrete Plants
ManuFlo -
suppliers of
liquid measurement
application
products
since 1965.
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The
Admixtures – Flowmeter Selection Guide Advantage
•
• Simplistic technology easy to operate
• No issues with foaming product
• Most applications no solenoid valves required
• No flushing required
• Suitable for dosing applications
• AS1379 & NMI NSS1671 approved devices
+ New MES20N –compact body/chamber • Easy calibration procedure & no need for
+ New “DSP” Digital Smart Pulse output pulse-head expensive NATA approved personnel
+ provides better performance & Vibration free pulsing. • MM & KMS have on‐board totaliser back up
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The
Advantage
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The
Advantage
ADMIX Dispensing – Specification Requirements
Typical Questions Concerning System ManuFlo Volumetric Flowmeter
Specifications (Comment)
Is system capable of simultaneous batching Yes easily achieved cuts down on batch time therefore
(adding multiple ingredients at same time) allows quicker throughput at the batch plant = more
productivity.
Is system capable of continuous dosing of product Yes easily achieved, liquid can be pumped as fast or as slow
during batch. e.g. shotcrete apps quarries etc) through appropriate meter as required and at the regulated
continuous doserate.
What is involved at design and installation stage From the chemical type and volumetric output required
select a suitable flowmeter using enclosed flowmeter matrix.
Add pumps and box to hold equipment, mount at ground
level if possible.
What is involved for an expansion of the dispensing Modular system simply add pipelines and flowmeters (ex‐
line. stock) as required. (inexpensive and quick).
Comment on ongoing Calibration costs & Calibrations can be performed by trained company
maintenance requirements. employees to AS1379. Issues with flowmeters are
immediately reported via the ME2000 safety system and can
be dealt with by local personnel. If meter needs changing it’s
quick simple and cost effective!
Apart from pumps are there any other instruments Generally simple mechanical check valves are used and on
or requirements for operation of dispensing rare occasions solenoid valves depending on application.
equipment.
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The
Advantage
ADMIX Dispensing – Specification Requirements
(continued)
Typical Questions Concerning System ManuFlo Volumetric Flowmeter
Specifications (Comment)
If a new ADMIX chemical is to be batched does Not necessary.
the system have to be flushed out first?
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The
Advantage
New “DSP” Digital Smart Pulse. Vibration Free Pulseheads
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The
Advantage
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The
Advantage
SUMMARY: ADMIX Dispensing by Flow Measurement
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8 x BOTTLES verses 1 x ME2008
Why settle for this, when all this can be replaced with the one ME2008 or ME995’s.
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3.
Overview:
Admix Batching
with Flow metering
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Overview:
Admix Batching with Flowmetering
ME2008
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Manual Batching
Example for Admixture
closing lid
resets total
Admix
Storage
Tank
Pump
Valve
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Semi-Automatic Batching
Batch Controller
Contactor
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4.
MES Flowmeters
Used for Admixture Measurement
Worldwide
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MES Series Flowmeters Primary admixture
flowmeter used
worldwide since 1995.
• Available in sizes 20, 25, 32, and 40mm.
• Pulse, Digital LCD, Mechanical display and combo options
• Nutating Disc operation allows a long operational life.
• Accuracy un-affected by Specific Gravity changes.
• New MES20N compact body with “DSP” Digital Smart Pulse output pulse-head.
Vibration Free (fr Aug.2018).
MES-series flowmeters are the most commonly used devise for
measurement of admixtures.
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MES Flowmeters -Types
• 20mm range most commonly used with 1000 pulses per litre (1ml./1pulse)
• Operational chamber life up to 20+ years Yellow body
with Ryton chamber
• New MES20N Digital Smart Pulse output pulse-head. (from Aug.2018).
VIBRATION FREE
MES20MR MES20LCD6DP -T
None DC or battery
Reed Switch Reed Switch *
60.6 ppl 60.6 ppl
*
--
Yes
Yes
*Pulserates for –S / -S-T can be from 810 to 1000 PPL must calibration check accordingly
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MES Flowmeters - Types
Pulses per
Litre ppL*
20mm size
A Range of special
sealing gaskets in
Viton or EDPM
and Bases available.
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MES Flowmeter Sizes - Specifications
Now: - with Digital Smart Pulse (DSP).
With DSP – no vibration issues – Pulses factory settable from 1 to 1000 PPL for all sizes).
75 112 185
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MES20 Flowmeter – How it Measures
• Is a Positive Displacement type
o Measures volume of liquid flowing by counting repeatedly the filling and discharging of a known fixed volume.
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MES20 Flowmeter – Installation - Rating IPxxx IP (Ingress Protection) Rating
against solid
against liquid
against mechanical impact (often omitted)
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MES20 Flowmeter – Installation - Location
• Flush out pipes thoroughly before connecting flowmeter.
• Install under cover, in an accessible area for any future service.
• Multiple flowmeters should be grouped together off the ground on a stand.
• Avoid high vibration areas – move, use dampeners, use MES20-R instead
with ME2000, ME3000 or UIC/A.
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MES20 Flowmeter – Installation - Wiring
The shield is internally Earthed at the Batch Controller end only and not at the
flowmeter end. (Earthing both ends would create a ground loop antenna).
Flowmeter Batch Controller
MES Flowmeters now with new “DSP” Digital Smart Pulse. Vibration Free Pulseheads
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MES20 Flowmeter - Operation
• Do not exceed operating specifications as this can damage the
meter Litres/minute
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MES20 Flowmeter – Operational Points
The MES20 (25,32,40mm) are high-resolution flowmeters (MES20 =1000 pulses/Litre). Note: false
counts is usually due to excessive high vibration – either directly due to the meter installation, or in
extreme rare cases from extreme plant vibration of the liquid.
Tap
This can be dealt with by:
• Checking the pulse-head is secured to the body (especially if swapped)
and no free movement, if there is then a simple hammer tap to the
grip wings will be sufficient to better secure the pulse-head tolerance clearances.
• If possible, install flowmeter away from vibration areas; or
• Using rubber dampeners to buffer the flowmeter from vibration
e.g. from a nearby compressor, alternate pumps; or Tap
• Or swap with MES20N Digital Smart Pulse output pulsehead. (from Aug. 2018).
(Bi-Directional intelligent –free of any vibration issues)
Also:
• Counts can result if a Non-Return Valve is faulty, and allows liquid to drain back
(Back-Flow) into the storage tank. Replace the Valve if required.
• Ensure hoses are tied down to avoid unnecessary liquid vibration.
• Failing this the pulse cables may not be shielded.
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MES20 Flowmeter – Head Removal
• Pulsehead is self-contained, and is attached to meter body
via a bayonet turn and lock fitting mechansim.
• Don’t deform the pulsehead copper face
as that could damage internal parts.
Locking pin
• Turn pulsehead anti-clockwise 1/8 turn, then lift pulsehead off. Don’t lose pin.
• To re-attach, reverse sequence, and tap-in locking pin (split end goes in first).
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MES Flowmeters – Body Types
• Body end threads are 25 mm gas metric. • 20mm (3/4”) BSP (male) threaded
• Shipped with 20mm (3/4”) ends.
BSP (male) coupling connectors. • Barrel Union Plastic Connectors
• Couplings are screwed on for Now optionally available
connecting to pipe.
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MES20 Flowmeter – Chamber Access
(1) Rotate or remove meter body from pipe.
(2) Unscrew the 4 base screws
For any body gaskets that swell, replace with EDPM/VITON option.
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MES20 Flowmeter – Service
• Flush the flowmeter with water if the pipe runs dry.
(Admixture dries and crystalizes if in contact with air and seizes the chamber /pumps/valves etc).
• If measuring chamber is blocked, there will be pressure loss on output and loss of flowrate
and possible overdose may occur. Blockage will be detected by ME995, ME2000/2008, ME3000 systems
with warning alarms or messages.
• If flow becomes excessively restricted, or meter is out of calibration or pulsehead stops sending pulses, then:
o Reset the connected controller.
o Remove flowmeter pulse-head.
o Shake pulse-head (MES-P only) left-right to check if there are pulses (counts appear on Batch Controller etc).
• If no pulses:
o Check wiring cable connector and that 12VDC is delivered to pulsehead. If wiring/power OK:
o Switch off connected equipment and replace pulsehead.
• If receiving pulses, then check chamber:
o Access chamber and inspect. Either:
o For minimum service time, use a new chamber (E.G. Order Code: 20-5); or
o Clean chamber parts in warm soapy water or diluted HC-acid (5 water : 1 acid).
After use with chemicals, if MES20 removed from pipeline, always flush out
working chamber with water.
Ensure wobble disc roller pin (20-5D) is in place, shutter plate (20-5B) is refitted
and the square O’ring chamber gasket (20-6) is also positioned.
• Re-insert chamber, secure position with the strainer/locator. Refit or replace body gasket (20-7).
• Re-assemble flowmeter
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MES20 Flowmeter - Maintenance
• Abrasive particles can wear out the chamber and create inaccuracy
over time (detect this through calibration checks).
In Australia, the admixture standard allows ± 5% tolerances. (AS-1379).
• Liquids should be free of particles to increase the accuracy life
of the chamber to 20+ years – use filters if necessary.
(or use a Filter or AMM20 or KMS magflows –no moving parts)
• A calibration check is recommended every 6 to 12 months (admixtures only).
• If calibration is within +/- 3 to 4% there is no need to inspect the working chamber.
• If 5%> then if required, clean chamber parts in warm detergent water or diluted acid 5:1.
• If after cleaning still out, then replace chamber if out by more than 5%.
(or change K-factors on input device).
• After use with chemicals, if MES20 is removed from pipeline, be sure to flush out working
chamber with water.
• To avoid water damage to electronics, ensure all cable entry glands are secure,
cables are looped downwards and the meters are under cover and not prone to flooding.
• Treat underside of pulseheads with care – do not deform the copper face.
• After any service perform a calibration check of meter.
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MES Flowmeters - Components
Genesis of the MES flow measuring chamber. Part # 20-5 for 20mm size
Original
Ferrite Magnet
(White driver shaft)
Discontinued old
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PRODUCT UPDATE BULLETIN
May 2018
Page 1
New: Digital Smart Pulse “DSP” technology (vibration free) Pulsehead from Sept-2018 as standard
(Added features: Optional bi-directional pulse, forward/reverse pulse, pulse division programmable option e.g. 100ppl).
F.A.Q.
Q) The existing MES20 flowmeters work well why are ManuFlo introducing a new model?
A) The Meter body is lighter weight & chamber section of the flowmeter has been upgraded. Model ‘N’ is a compact improved design with better manufacturing uniformity for mass
production with lower cost spare parts.
Q) Can a current model MES20 be swapped out in their entirety for the new ‘N’ models?
A) Yes this is a like for like exchange, with same threaded connections & insert length so no pipe mods. needed.
Q) What if you want to swap a pulse head or LCD head from the new MES20N to an old MES20/LCD & vice versa?
A) No problem exactly the same pulse head & LCD head is used in the N versions with turn/snap fit coupling.
B) Note: For testing the pulse-head you can no-longer “shake” it to generate pulses (old model), you need a Magnet to activate the internal DSP sensors.
Q) Can I use any of the internal measuring chambers from the new ‘N’ models in an MES20 & vice versa?
A) Generally No, however we will be keeping metering section spares of the existing MES20 for atleast the next 10 yrs.
(Note: Base plate, base and chamber gaskets, chamber base, shutter and roller, S/S screws interchangeable).
PRODUCT UPDATE BULLETIN
May 2018
Page 2
Existing
NEW
68mm
59mm
SAME PULSE
HEAD
Existing
NEW
Existing NEW
PRODUCT UPDATE BULLETIN
May 2018
Page 2
Nutating disc., Roller, Shutter Plate , Filter Spacer, Chamber Gasket, 20-5N complete chamber, Bottom body gasket, Body casting
Existing
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MES20 Flowmeter - Spares
For MES spare parts, the Product Code format is “size-code”
e.g. “20-5” is a spare measuring chamber for a 20mm size MES flowmeter
e.g. “25-5” is a spare measuring chamber for a 25mm size MES flowmeter
Measuring Chamber
20mm size: Part # 20-5
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MES Flowmeters – Summary points
MESLCD MES-P MES20 MES20-N
Resettable Pulse-output
range pictured range pictured
Advantages
Advantages • High resolution PD measurement for
• High resolution PD measurement accurate batching.
• Ideal for admixtures • Accuracy largely un-affected by S.G changes
• Internal Battery powered, • Ideal for admixtures (used worldwide)
no external power required, • Safeties can be added via other equipment
so is ideal in remote sites. e.g. ME Batch Controllers, ME2008,
• Simple and cost effective. PLC/Computer.
• Sizes 20 to 40mm • Simple and cost effective. Sizes 20 to 40mm
• With new DSP Digital Smart Pulse –scalable
• VIRTUALLY VIBRATION FREE
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Flowmeters – Summary Advise
• Never swap LCD display heads between different flowmeter body sizes
(display counts will not represent actual volume as they are pre-
calibrated to the specific size meter).
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Other Flowmeters – Electromagnetic Flowmeters
AMM Series: Admix ManuMag Magflow (budget cost)
• No moving parts, no blockages, virtually maintenance free.
• Ideal for very aggressive chemicals (≥ 20µS/cm)
• Pulses in forward direction only and must be a full pipe at all times
• Very economical. All PVDF/Stainless316 construction
• For liquid conductivity ≥ 20µS/cm.
• +12VDC (or optional 24VDC powered).
AMM15: 15mm bsp-m ( 8mm bore), 1000 pulses/Litre, 1.0 - 50 L/min
AMM20: 20mm bsp-m (12mm bore), 1000 pulses/Litre, 2.0 - 110 L/min
AMM25: 25mm bsp-m (15mm bore), 500 pulses/Litre, 3.0 - 210 L/min
If backflow is a concern install a pneumatic valve
MM Series: Magflows (budget cost -dosing)
• No moving parts or blockages, virtually maintenance free
• Pulses in forward flow direction only and must be full of liquid
• High pressure to 1600Kpa, Compact design all S/S316
• For liquid conductivity ≥ 20µS/cm., BSP-m connection
• 4-digit display to show either flowrate or total
• +24VDC powered
MM15: 15mm connection ( 8mm bore), 100 pulses/Litre, 0.1 - 25 L/min,
MM20: 20mm connection (12mm bore), 100 pulses/Litre, 0.2 - 50 L/min,
MM25: 25mm connection (15mm bore), 100 pulses/Litre, 0.3 - 100 L/min
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Other Flowmeters – Electromagnetic Flowmeters
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Flowmeters –Selection Summary
Use the correct flowmeter for the type of liquid being measured.
• For accuracy and safety in dispensing Admixture use:
o MES series positive-displacement flowmeters.
o MM, AMM series electromagnetic flowmeters (must be 20ms>conductive liquid).
o KMS / RMS electromagnetic flowmeters. (must be 5ms> conductive liquid).
Do NOT use:
Paddlewheel-type, Turbine, Ultrasonic type flowmeters or non positive displacement type
flowmeters. They are not suitable for the accurate dispensing of Admixtures.
Why?
Because the Admixture properties can easily cause the paddle wheel/turbine etc. to drag or
stick, resulting in substantial undetected overdoses. Ultrasonics struggle with repeatability.
Large accuracy changes due to specific gravity properties of liquids other than 1:0 s.g.
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5.
PLUMBING
and achieving Faster Volume
Delivery Flow Rates
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7. Achieving Faster Delivery/Volume Rates
Advantages and Considerations
Advantages
• Faster delivery rates.
• Can upsize MES20 flowmeter to MES25, 32, 40 or 50mm.
• Can use AMM/KMS Electromagnetic Flowmeters
Larger MES flowmeters
(faster max flows, no blockages, virtually maintenance free). volume
Considerations
• Must upsize flowmeter or swap out to magflows or upsize pumps and
upsize pipe diameters. time
► For low flowrates and small batch quantities of liquid (approx < 2000mls),
use ½” diameter pipe or hose (after the flowmeter).
• For faster flow, consider larger flowmeters (MES25, MES32, MES40. or Magflows)
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INJECTION OF ADMIXTURE LINES
1.
Admixtures injected into the waterline –within the flowmetered water batch time cycle.
Admixture lines can be plumbed into the waterline and admixture sequenced to batch during the water dump time cyc
when flowmetered. (Excellent for thoroughly mixing the admix).
Bigger admix flowmeters MES or MAGS sometimes required to batch with say 30 seconds.
Must use pneumatic solenoid valve sat end of line near injection point to avoid syphoning issues.
Or admixture can be batched into the weighed water hopper within the required time cycle.
2.
Admixture lines plumbed direct to the Sok (loading point chute) of truck inlet barrel.
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Pump Selection -Admixtures
► When 20mm MES20 flowmeters are used with fluids of specific gravity 1 - 1.25, then
use centrifuge pumps of 0.5 - 1 horse power (e.g. 1" Onga 413 or Davey SJ35-04
pumps. When using larger capacity flowmeters, a proportionally larger pump will apply).
A flowrate upto 1.0 Litre per second can be achieved, depending on head height. You
can restrict pump speed without damage to these type of pumps.
► For higher density fluids, positive displacement (PD) pumps or other types of positive
displacement pumps (e.g. Mono) are more suitable. Because of the pressures
generated by PD pumps, the flow is best controlled by using an inlet-to-outlet bypass
flow valve to recirculate the flow line. (can push air)
outlet
inlet
PUMP
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Plumbing Install Guide (Admixtures)
Typical admixure dispensing system setup with MES flowmeters
If the outlet point is above the top of the storage tank (the most commonly used setup),
you will at least require the following equipment:
• A pump,
• Non-return valves or spring loaded check valves (12psi),
• Flow restriction gate or ball valve, a flowmeter with pulse output and,
optionally:
A solenoid valve (air-assisted ball valve type) for instant shut off of flow, recommended to prevent
the Venturi effect when injecting into water lines, but may not be required if the installation has
reasonable head height.
A 3-Way Valve to provide an easily accessible calibration point.
ADMIX
tank Non-Return
STORAGE Valve Filter Gate Valve Flowmeter Non-Return Valve
Valve
TANK restricts flow
PUMP
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Plumbing Install Guide (Admixtures)
If the outlet point is below the level of the storage tank, then the equipment you will at least require is:
• a flow control solenoid valve,
• a flow restriction gate or ball valve, and
• a flowmeter with pulse output.
outlet line
be low level of Batch
Contr oller
Storage Tank
an optiona l pu mp
AD MIX tank may be used to Gate V alve
STOR AGE V alve speed up f low rate restricts f low Filt er
T ANK PUMP
Flow mete r
Soleno id
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Operational Issues - Piping
Common causes of batch overrun:
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6.
Semi-Automatic Batching
with Batch Controllers
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Semi-Automatic Batching
Batch Controller starts and stops
Batch Controller flow so that a requested quantity
00.0 is accurately dispensed.
Contactor
In use in various
countries.
e.g. Asia-Pacific,
Quantity set by: operator South America,
Middle-East
Delivery controlled by: batch controller
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Semi-Automatic Batching
(1) Operator sets
batch quantity Batch Controller
00.0
Contactor
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Semi-Automatic Batching
00.1
All
LEDs off.
Batch
Contactor
Controller
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Semi-Automatic Batching
(3) Batch Controller
starts pump / opens solenoid
to start flow.
02.1
Contact Drive
LED goes on.
Batch
Contactor
Controller
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Semi-Automatic Batching
(4) Batch Controller monitors
pulses from flowmeter to
determine quantity delivered.
03.4
Batch
Contactor Controller
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Semi-Automatic Batching
(5) When desired quantity dispensed,
Batch Controller stops pump /
Batch Target was 9.2 litres closes solenoid to stop flow.
09.2
CD, then FL
LED, go off.
Batch
Contactor
Controller
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ME995 Series Batch Controllers - Safety Features
• LIMIT (LM) LED - illuminates if:
• batch cycle reaches locked internal maximum limit, or
• circuit diagnostics detect internal chip problem, with subsequent
automatic shutoff of voltage contact drive.
• PULSE FAIL (PF) LED - activates if:
• no flowmeter pulses arrive within initial 1.5 seconds (variable), or
• pulses are interrupted or intermittent during batch cycle (fall below variable pulse
scanning time, typical 30 Hz) with subsequent automatic shutoff of voltage drive to pump.
• FLOW (FL) LED - indicates pulses coming from field flowmeter, or if test is used.
• CONTACT DRIVE (CD) LED - output drive activated to pump or solenoid.
00.0
Audible ALARM sounds:
• momentarily upon completion of batch cycle,
• continuously if PULSE FAIL or LIMIT occurs LEDs are activated or
if overflow runs 1000 ml (variable) past selected batch quantity.
Warning: If Contact or Flow LED indicators are on,
but contoller is not counting, discontinue use and call for service.
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Batch Controllers – Selection Questions
(1) What is the minimum & maximum batch quantity volumes ?
(2) What is size of the intended connected flowmeter ?
(3) What batch quantity resolution units do you require ?
(4) Is a PLC/computer system being connected to the system ?
(5) What is the display to show – total dose, or delivered batch quantity ?
(6) Is Variable Dosage required ? If so:
(7) What dose units do you want ? (Kg’s or m3)
(8) What is the maximum dose-rate ?
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Batch Controllers
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Older Model Batch Controllers – ME188 Series
ME188 Built 1982 to 1994 ME995 Built 1995 to present
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ME995-2 Batch Controller - Use
• For use with Manu AMM15, MES20 and other 1000 ppL flowmeters
• Mainly used in computer/PLC controlled batch plants DOSAGE 35 x 10 mls per m3.
• Set on maximum permitted batch limits = 350 mls per cubic metre selected
700
Shows
delivered
Dose in ML
MILLILITRES
Batch Quantity
up to 9.0,
increment 0.1
e.g. 2.0 cubic metres
Formula is: 350mls dosage rate x 2.0 m3 load of concrete = 700mls in liquid delivered and shown on display
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ME995-2C Batch Controller - Use
• For use with Manu MES20 and other 1000 ppl flowmeters.
• Mainly used in manual batch plants DOSAGE 35 x 10 mls per m3.
= 350 mls per cubic metre selected
2.0
Shows delivered
Batch Quantity
in cubic metres
selected
Batch Quantity
up to 9.0,
increment 0.1 e.g.
2.0 cubic metres
Formula is: 350mls dosage rate x 2.0 m3 load of concrete = 700mls in liquid delivered, and shown in m3 selected on display
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ME995-3 Batch Controller
Ideal for Computer plants to compare volumetric display in MLs.
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ME995-3 Batch Controller - Use
For use with Manu MES20 and AMM20 1000 ppl flowmeters
• Mainly used in computer/PLC controlled batch plants DOSERATE
• Set on maximum permitted batch limit Max 99 x10
e.g. 20 x 10ml/100kg
Shows
delivered
Dose in ML 2000
Batch Quantity
up to 9000,
increment 10
e.g. 1000 kg
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ME995-3K Batch Controller - Features
• Variable doserate blending preset batch controller
• Rotary knob selector switches, for easy select of:
o Doserate (top 2 selectors)
o Batch Quantity (bottom 4 selectors)
• 4 Digit LED display - Display counts upward in 10 kg lots to kilograms of cement selected
• 4 x LED status indicators.
MLs x 10 per 100KG
• Preact (overflow deduct) function Max. Setting: 99x10
• Preset maximum batch limit
Shows Batch
• Missing pulse detection safeties Quantity in KG
• Contact output drive is via 1 (or optionally 2) relays
• For use with Manu MES20 20mm 1000 ppl flowmeters
• Optional PLC and computer interface
• Mainly used in manual batch plants
Batch Quantity
up to 9000, increment 10
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ME995-3K Batch Controller - Use
For use with ManuFlo AMM20 and MES20
1000 ppL flowmeters (mainly used manual batch plants) DOSAGE: 20 x 10 mls.
e.g. = 200mls./100kg
Shows delivered
Batch Quantity
in kg 1000
Batch Quantity
up to 9000,
increment 10
e.g. 1000 kg cement.
Formula = 200mls dosage rate x (10 lots of 100KGs) load of cement = 2000mls in liquid delivered, shown in KG selected
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ME995-4 Batch Controller - Use
For use with Manu MES20 and AMM20 1000 ppl flowmeters
Shows delivered
Batch Quantity
in Litres 03.000
Batch Quantity
up to 99.990,
increment 0.01 L
e.g. 3.000 Litres
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ME995-6 Batch Controller
For use with ManuFlo AMM20 and MES20 1000 ppl flowmeters
01.0
Shows delivered
Batch Quantity
in Litres
Batch Quantity
up to 99.9,
increment 0.1 L
e.g. 1.0 Litres
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ME995-7D-S / ME995-7D / ME995-7 Batch Controllers
( with x1 input ) K-Factor calibration adjustment precision option.
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Batch Controller Pre-act Explained
PREACT: Calibrating inflight overflow deduct:
• Is via two rotary knobs marked (on ME995-3K) “HUNDREDS” and “TENS" of mls
located at the rear of the Batch Controller.
• As the batch display will indicate total kilograms of cement at the selected doserate,
a calculation must be performed to convert the overrun displayed
into actual overflow millilitres of dose.
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Batch Controller Pre-act
Total Quantity
target Overrun
Time
Total Quantity
target
Preact
Time
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Batch Controller Preact
ME995-6, Example 1
• The flat shaft with notch is griped and turned to point of desired setting.
ME995-6 ME995-1A, -1
MILLILITRES PREACT
HUNDREDS TENS
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Batch Controller Preact
ME995-3K, Example 1
• Doserate was 10 x 10 mls/100kg (i.e. 100 mls/100 kg,
• Total kgs cement load selected was 2000kg,
• Actual quantity delivered shown on display was 2060kg (60 kgs over at the selected doserate).
overbatch x Doserate
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Batch Controller Preact
ME995-3K, Example 2
• Doserate was 27 x 10 mls/100kg (i.e. 270 mls/100 kg),
• Total kgs cement load selected was 2000kg,
• Actual quantity delivered shown on display was 2060kg (60 kgs over at the selected doserate).
overbatch x Doserate
Dose Overflow = 60 kg x 27x10 mls = 60 x 270 mls = 162 mls = ~ 160 mls overflow
100 kg 100
Set the preact to HUNDREDS=1 and TENS=6 (1x100 + 6x10 = 100 + 60 = 160 mls)
MILLILITRES PREACT
HUNDREDS TENS
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Batch Controller Preact
ME995-3K, Example 3
• Doserate 38 x 10 mls/100kg.
• Total kgs cement load selected was 3150 kg.
• Actual quantity delivered shown on display was 3290 kg.
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Batch Controller Preact
ME995-3K, Example 3
• Doserate 38 x 10 mls/100kg.
• Total kgs cement load selected was 3150 kg.
• actual quantity delivered shown on display was 3290 kg (i.e. overran 140 kg).
Dose Overflow = 140 kg x 38x10 mls = 140 x 380 mls = 532 mls = ~ 530 mls overflow
100 kg 100
Set the preact to HUNDREDS=5 and TENS=3 (5x100 + 3x10 = 500 + 30 = 530 mls)
MILLILITRES PREACT
HUNDREDS TENS
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Batch Controller - Service Adjustments to Safety Timings and Limits for ME995
INITIAL START (T2):
• Once start toggle is pressed, controller allows 1.5 seconds for pulses to arrive from the flowmeter. CAUTION
• If there are no pulses within the 1.5 second time period, controller will shut down the output voltage drive, and will turn on the pulse fail LED and alarm warnings.
• In some applications, the 1.5 second delay may not be long enough, due to slow opening solenoids or slow pressure buildup pumps etc.
• The initial start time period can be increased by soldering a tantalum capacitor in parallel with the standard capacitor value, found on the rear of the PCB.
FLOWRATE (T1):
• If pulses do arrive within the allocated initial start time, the controller then locks in pulserate safety.
• Most ManuFlo Batch Controllers have a standard 30 counts per second (30Hz) pulserate safety setting.
• If the pulses from the flowmeter drop below the 30Hz, the controller will shut down the output voltage drive, and turn on the Pulse Fail LED and alarm warnings.
• The 30Hz standard setting is typical with concrete admixture dispensing systems using MES20 (1ml/1 pulse) flowmeters, where if the flowrate drops below 30 millilitres per second the pulse
fail safety will activate. T
• The flowrate (frequency) minimum setting can be adjusted by soldering a capacitor in parallel with the standard capacitor found on the PCB.
Physical mods not
needed for ME3000
Note: The flowrate safety timing is changed if required:
• because of viscosity changes due to seasonal temperatures, or (is programmable).
• by very low flowrate applications, or
• when using flowmeters other than the most commonly used (MES20 20mm 1 pulse/1ml output flowmeter) with Batch Controllers that have K-factor (ppl) calibration.
When controller/flowmeter systems are ordered, we supply the safety timing setting to suit your chosen flowmeter, thus always providing the safest possible watchdog system.
LM limit wire
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Batch Controller – T2 (Initial Start) and T1 (Flowrate) Timing CAUTION
Factory
capacitor is
+ +
on other
side of
PCB.
Standard factory set values are T2: 1 µF capacitor, T1: 0.02 µF.
Use the following tables to change factory set values.
Table 1. INITIAL START TIMING (T2) Table 2. FLOWRATE TIMING (T1)
Extra Capacitor value Extra timing Total Capacitor value Frequency Hz (pulses per second)
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Batch Controller – DRLM Dose Rate Limit (Doserate Models Only)
To change doserate limit, move this end of the DRLM limit wire to a new pad on the rotary.
Physical mods Doserate Limit Values, According to DRLM Limit Wire Position
not needed for
ME3000 (is
programmable).
0 0
1 0
2 9
3 8
4 7
5 6
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Batch Controller – LM Batch Limit CAUTION
0
1 0
2 9
3 8
Batch Limit wire is connected to 7
Physical mods
the right-most installed batch dial
4
not needed for
(as seen on this view).
5 6
ME3000 (is
programmable). To change batch limit, move this end of the LM limit wire to a new pad on the rotary.
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ME995-7 or -7D
For use with various unity or high pulse flowmeters e.g. MES20 / 25 etc
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Batch Controller Housing Boxes
• The SHB/DHB housing boxes are for wall or bench
mounting ME995 Batch Controllers.
• Metal black powder-coated paint finish.
• These boxes are also available fully wired with 110
or 240vac 15amp industrial contactors, pump plug-
SHB - SINGLE HOUSING BOX
SHB1 - SINGLE BOX WIRED in 240vac power entries, power cord and 10-pin
Weidmuller mating plug.
• Also available in a terminal strip entry version.
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Batch Controller Housing Box - Use
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ME995 Series Batch Controllers - Connections
Calibration knobs HTU (only on ME995-7, ME995-7D & -7DS),
to set to flowmeter’s K-Factor (the pulses/Litre). Rear connector insulator cover
New
Weidmuller 10-pin recepticle –
changeover and replacement is instant
with no rewiring necessary. REAR VIEW
SPECIFICATIONS
Power supply 220-260 vac (optional 110 vac or 12-24 VDC)
Output to flowmeter 12 VDC up to 100mA
Relay outputs Max. 240 vac, 30 VDC 1 Amp
Frequency input 5 KHz: x1 input, 340 Hz: x17 inputs
Display 7 segment LED (14mm H)
Connection 10-pin Weidmuller mating plug and socket
Fuse 1 Amp (5 x 20mm case)
Batch selection Visual rotary select switches
Batch commands Push toggle switches
Mounting Panel mount Serial No.
Instrument housing ABS hi-impact case
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Batch Controller/Housing Box: 240vac re-labelling
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Batch Controller Wiring - Guide
• Remove the detachable Weidmuller 10-pin plug from the rear of Batch Controller.
• Connect the flowmeter signal cable into the 10pin Weidmuller plug. When wiring the
flowmeter, use 2-core shielded cable (use more cores if wiring more flowmeters) - this will
supply the flowmeter with 12VDC from the Manu Batch controller.
• Wire the 240VAC supply cables.
• Wire the Active/contact drive, Neutral and Earth from the solenoid valve or return from
the external contactor if driving a pump. If starting a pump, make sure the contactor is of
sufficient amperage rating to handle the pump current draw (e.g. 10 Amps for Onga413
pump).
• Don’t use cheap plug-in relays in your installation –
they cannot handle pump surge currents and can stick/fuse.
Must have industrial grade contactors
(available from ManuFlo: Order Code C240, rated 3kW 1.5hp).
• Consider wiring an override button (N.O. with spring return) for manual batching or top-up
of admix, which will be counted by the controller display.
Power up the system. Reset and start a number of times to prime the system, until fluid
appears at the outlet line and the Batch Controller digits begin counting.
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ME995 Batch Controller Wiring - 240vac i/o standard
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Batch Controller Calibration Test
Volumetric Calibration Test should be performed when commissioning installation:
• place a calibrated vessel at the discharge point
• on the Batch Controller, select an amount of liquid e.g. 1000 mls.
• press Reset, then Start to batch the quantity
• at the calibrated container, check that the amount dispensed is as requested.
An overflow may occur due to the inability of the pump to stop instantly. The amount of overflow will
depend on how fast the liquid is being dispensed and/or the closing time of the solenoid valve. The
Batch Controller will count the overflow as part of the displayed total dispensed.
• if the system is totally controlled via PLC/Computer, overflow will be adjusted by the computer;
otherwise,
• where a ME995 series Batch Controller is fitted with a Preact, simply set the Preact to the amount of
overflow i.e
overflow = (actual amount dispensed, as shown on the Batch Controller display) minus
(amount requested).
If required:
• slow down flow velocity by using a restriction gate valve;
• avoid over-batching by using the Preact function, or installing a quick-acting solenoid valve.
Note: If the flow is restricted excessively, Batch Controller Pulse Fail circuitry will shut down the
system for safety reasons, in which case open up the restriction gate valve.
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Batch Controllers - Maintenance
• A calibration check should be performed periodically
(say every 6-12 months).
• Return for service after 5-10 years, especially for manual plants.
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Batch Controllers – Troubleshooting
IMPORTANT
•If batcher gets Low Flow Alarm on two successive attempts at batching, then:
MOVE THE TRUCK MIXER AWAY FROM THE LOADING POINT
stop using the Controller; as each attempt doses 2 seconds worth of chemical into the mix.
record the quantity displayed on the ME995; and
ring your local admixture supplier or service agent for advise/service (or attempt to address).
THIS WARNING GUIDE SHOULD BE DISPLAYED AT PREMIX PLANT FOR THE BATCHER / OPERATOR !!
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Batch Controllers – Safeguards
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Batch Controllers – Troubleshooting
Incorrect Batching from
Selected to LED display
1. The selector knob number dials on the Batch Controller may not be aligned correctly, and therefore do not
correspond to the rotary switch numeric values.
2. To test, set all numbered dials to the zero position, then press the RESET toggle. The alarm should beep
momentarily. This will indicate correct alignment of dials. If alarm does not beep, this indicates incorrect
alignment of numbered dials.
• To rectify, remove the grey-colored cap from each dial, the grip nut is now exposed, un-tighten and the
knob grip will release from switch shaft and pull off knob.
• Check that the exposed switch shaft flat side notch is in horizontal. If not, turn shafts to horizontal as
pictured above and refit the numbered dial knob to the zero number setting.
• For dosage switches, position to zero and push up hold the TEST button. Digits should not count
(except in the ME995-3 model). If digits count, then remove grey knob and check the numbered dial
alignment –same procedure as above.
3. If batch controller is tested and found to be operating correctly, then proceed to checking and testing
flowmeter components.
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Batch Controllers – Troubleshooting
PROBLEM POSSIBLE CAUSE SUGGESTED SOLUTION
o No power to batch controller, displays o Blown fuse or holder not tight o Check fuse, tighten fuse holder (at rear
not on o +12vdc and O.V. shorted of controller)
o No main power supply o Check wiring, rear of controller & at
flowmeters, replace cables.
o Check power supply, check wiring
o Pulse fails at start of batch o Air pocket o Prime line by shorting output drive
o Restriction gate valve closed (C=Contact & A=Active)
o Empty liquid tank o Open gate valve
o Pump not turning o Check liquid level
o Solenoid valve not opening o Check and service pump
o Seized flowmeter chamber o Check and service solenoid valve or non
o Flowmeter pulsehead faulty return valve stuck closed
o Signal cable cut or bad joint o Service and clean flowmeter chamber,
replace if required
o Replace with new pulsehead, or
connections corroded.
o Check signal cable
WARNING: In any pulse-fail or repeat malfunction condition, remove the truck mixer from the sock loading point.
NOTE: In winter, liquid may flow slower causing Pulse Fail. We recommend:
• Opening up the restriction valve
or
• Fitting the capacitor to change Batch Controller T1 timing
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Batch Controllers – Troubleshooting
PROBLEM POSSIBLE CAUSE SUGGESTED SOLUTION
o Pulse fails during batch cycle o Flowrate too slow o Open restriction gate valve or increase flowrate
o Flowrate too fast pulse fail timing capacitor (see service guide).
o Blocked filter restricting flow o Chamber clutching, slow down flowrate via
o Measuring chamber clutching restrictor valve. Check flowmeter specs for
performance operating range
o Cleanout filter
o Cleanout chamber or replace
o Clean, service or replace
o Display digits count slowly after batch complete o Non return valve faulty (jammed open) o Clean, service or replace
o Batch target display counter above batch o Flowrate too fast, excessive overflow o Turn down gate valve to restrict flowrate or set
selection preact (overflow deduct) function to compensate
(ME995 models)
o Reduce delivery pipe diameter
o During calibration test more admix collected than o Flowmeter chamber part missing o Check flow chamber, check O rings are seated
indicated o Chamber excessively worn, liquid is slipping correctly (MEK20/MES20 roller bush or O ring)
through without registration o Replace with new chamber, recheck calibration
o S.G. below 1.0 o Replace chamber and restrict flowrate or
o MES20 under excessive pressure with AEA recalibrate via controller (certain models only) or
slippery admix recalibrate via card
o Place restriction valve after pump and prior to
flowmeter
NOTE: After servicing any flowmeter, always perform a volumetric calibration test. Make sure glands are sealed, pulse cable is lopped downward, and
meters are under cover and protected from water ingress.
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Batch Controllers – Troubleshooting
PROBLEM POSSIBLE CAUSE SUGGESTED SOLUTION
o Less admix collected than displayed o Possible syphoning effect if fed (mixing) into o Fit ball valve solenoid or do not feed into flowing
flowing water line water line, or check valve
o Liquid flows backward after batches o Non-return valve faulty, service or replace
o Controller starts counting when power switched o Active and contact power drive short circuited o Short circuit on PCB, check PCB or replace
on, does not stop at batch complete o Contactor sticky or fused o External pump contractor relay fused or need
higher ampere rating, replace contractor
o Controller not counting but flow and/or contact o Controller malfunction, IC failure o Replace controller, ring ManuFlo for urgent
drive LED’s are on advice
o Controller counts although pump off (contact o Dried out main electro capacitor o Replace electrolytic capacitor (Pre ME995 units)
drive LED off)
o Controller counts up a batch cycle but no o Flowmeter (MES) measuring air o Can occur with positive displacement pumps. Fit
admixture delivered a recirculation line on inlet/outlet of pump. See
install guide brochure.
o Controller Limit “LM” LED light triggers disabling o Spike caused by 240vac contactor coil o Fit a 0.1uF 275vac> mains capacitor across the
controller or spike of counts appears on display coil to filter initial start spikes
counts suddenly when engaging start toggle
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CAREFULL – some ME995 Models
No x10 Scaling on Doser Dials (HANSON –NSW-VIC ??)
ME995-2CS ME995-3KS
Introduced due to some batchers miscalculating with the doserate mls x 10 option.
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ME3000 – programable ManuFlo Batch Controller
Displays Configuration
• Set/Run • Calibration I/P
• Flowrate • Output Pulse
• Backflow • Max output rate
• Grand Total (resetable) • Max. batch limit
• Batch Id (resetable)
• Max. backflow
• 6 digits
• Min. flow alarm level
Alarms Features • Max. flow alarm level
• Batch Limit • Event log (500 batches) • Start delay
• Max Flow Limit • Run/flow/output indicator LEDs • Stop delay
• Min Flow Limit • 4-20 mA current o/p
Features (Optional)
• Backflow • Preact overrun
• Computer control interface
• Output Rate • Time & date
• RS232 interface for printing batch
• Overbatch • Date last calibrated
tickets and/or downloading event log
• Front Port RS232 for easy access
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ME995/ME3000
NEW Configuration Updates Optional batch override/topup
momentary push button switch
SHIELD (0 v)
liquid
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Portable Trolley - Manual Auto
Admix Batch
Flowmeter Systems
TYPICAL CONFIGURATIONS:
Type: Manual or Automatic
Pump options: Centrifugal or Positive Displacement
Controller: ME995 series or ME3000
Flowmeter: MES disc flowmeter or MM magnetic
flowmeter, Size 20mm or 25mm.
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7.
Interfacing Flowmeters to
PLC/Computer Controlled
Batch Plants
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7. Automatic Batching via PLC/Computers
ME2008, ME2000
Microprocessor interface batch safety unit.
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Batching Computers
• Types of Batching Computers include:
• Command-Batch Eagle/Alkon (see http://www.commandalkon.com)
• Jonel-Archer (see http://www.jonel.com/readyMixBatch.htm)
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Computer/Batch Controller Interface
Considerations
When interfacing a Computer with a Batch Controller, ME2008, UIC
or just our flowmeters, consider the Computers:-
• I/O:
Supply voltage
Command voltages
AC or DC pulses?
DC sink or source pulses?
• Maximum input frequency
• Scan time (width of pulse read)
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Computer/Batch Controller Interface - Common Issues
• With AC voltage I/O PLC/computers, AC pulse input frequency limit is 15 Hz.
Ensure the AC input frequency from the interface card and or flowmeter to the computer is not
exceeded, else overdose could occur!
Be particularly careful when using AEA at 10 mls/pulse – speeding up the flow can cause computer to lose pulses.
DC pulse inputs are higher speed at 35 Hz. (PC based systems with DC can be 1000’s Hz).
• Why do they use AC inputs ? Better isolation from lightning strikes, less industrial noise issues.
scale input to the computer by using ManuFlo:
• UIC – Universal Interface Card with pulse scaling
• ME2008 – Microprocessor Interface Batch safety Unit
• ME5IC – interface card with pulse dividers (via ME995 batch controllers)
• MC2 -- interface plugs
• Direct -- scaled output from flowmeters (e.g. scaled Magflows)
• NOTE: FOR HIGH SPEED DIGITAL INPUT PLC CARDS THERE IS NO ISSUE
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i) Interfacing with ME995 Batch Controllers
•Having Batch Controller incorporates safeties e.g. Batch Limit, Pulse Fail.
•Batch Controller provides manual control should Computer/PLC fail.
Flowmeter
measures
flow In use in various countries.
Admix e.g. Australasia-Pacific,
Pump Storage Sth America, Middle-East
Tank
Batch Controller
controls batch delivery
Batching computer
sets/records
batch
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(A) Interfacing to PLC using – MC2
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(A) Interfacing to PLC using – MC2
Model Defaults:
1ml./p = -1 to -6
0.1ltr/p = -7D, -7DS
1ltr/p = -7
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(A) Interfacing to PLC using – MC2
-MC option
For interfacing a
Batch Controller to 2-pin plug with
PC-based, low-voltage 4-pin PLC
C E OPTO 4N33
command
DC input Computers e.g. plug (volt free) :
open collector
CompuBatch Systems, pulse output
start, stop, rest.
Dickinson Autocon, United 1 or 10ml / pulse
Weighing etc
-MC2 plugset option
-MC2 for Dickinson Autocon computers (sink) , and others.
-Sn option, combined with MC2, for 10, 20, 50 or 100 ml/pulse output
(where n is the pulse value required) depending on the PLC input rate.
Note: On ME3000 Batch Controllers, the pulse o/p is scaleable via software.
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(B) Interfacing PLCs – with ME5IC Superseded by ME2008.
1 pulse = 1 ml
-5P interface
ME5IC:
• Interface card (1 to 5 channel options)
• Enables incorporation of the Batch Controllers and their safeties to the Computer/PLC batch
system, and provides an independent backup batch facility.
• Batch Controller must be fitted with the “–5P” 5-pin interface plug option.
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Slowly Superseded by
(B) Interface Cards – with ME5IC ME2008.
1 pulse = 1 ml
-5P interface
ME5IC enables:
• PLC/computer to control the ManuFlo Batch Controller, and
• PLC/computer to accept input from MES20 flowmeter (1ml/1pulse output) that is
• opto isolated, and
• in divided pulse form. Superseded by ME2000/8
ME5IC-1W 1 channel interface card, for WATER e.g. use with ME995-7.
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Superseded by ME2008.
(1)
-5P interface
(4)
(3)
Batch Controller ME5IC-5 Computer/PLC
MES20 Flow meter
(2)
Pump
(2) Batch Controller starts : activates 240vac drive to pump and/or solenoid.
(3) Once liquid flow begins, flowmeter will pulse to the Batch Controller.
(4) Scaled pulses sent to computer input.
(5) When desired pulses arrive to PLC, start drive disenages , STOP pulse generated
by ME5IC card to batch controller.
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Superseded by ME2008.
(B) Interface Cards – ME5IC-1
-5P Plug on
Batch Controller
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ME995 series Batch Controllers, –5P Interface option
CONT. 1
SHIELD
+12 VDC
PULSE
A
N
EARTH
240vac
F US
E
-5P Interface
Superseded by
• Optional 5-pin socket and locking plug. ME2008.
• Socket fitted to rear of ME995-series Batch Controller.
• Suitable for external PLC/remote command control (via volt-free contacts).
• Suitable for Jonel/Eagle computer system control of ME995 Batch Controllers
(via ME5IC interface cards for high voltage I/Os). Sends 1 pulse/ml to be divided by ME5IC
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Superseded by
Symptom Solution
1. Computer continues batching on after batch target. Optos when switching off, can have residual leakage voltage, high enough to keep relay coil of ME5IC
in on-state, driving Batch Controller and pump until it reaches its setting on front dials. Measure
between Neutral and Active of Opto, if above 50vac in off-state, fit a 10-15K 10watt resistor to drain
leakage to neutral. Generally in this situation, batch will run to setting on ManuFlo controller. If running
past settings, contactor coil may be stuck on (i.e. is faulty). Turn off power and replace contactor.
2. Computer display and ME995 display not matching. Check that the divided pulse value on ME5IC and computer pulse input value are matched
e.g. 10mls/pulse. Note: Preferably use ME995 controllers that display in total millilitres or litres
dispensed.
3. Calibrated collected quantity matches ME995 display but not computer display quantity. Computer Check pulse divider value on ME5IC card, check computer input value. Pulses to AC computer inputs
misses pulses. must not exceed 15HZ or max. scanning time. Check pulse dividers and compter input (Admix
Flowspeed mls/sec) divided by (divided pulse value) =< 15HZ. E.g. AEA flowing at 160ml/sec through
divider of 10ml/pulse = 16HZ. Means computer i/p will miss pulses, and overdose will occur. So, restrict
flow or increase divider to 20mls/pulse.
4. Reset, start or stop function to ME995 not working. ME995 counts but no counts to ME5IC (LED Check 5-pin (-5P) interface plug at rear of ME995 Batch Controller, may not be properly secured and
pulse not blinking). locked (intermittent contact), or wire broken inside plug. Open plug and inspect wiring joints. Inspect
connections from cable entering ME5IC interface plug. Wire may be shorted – inspect.
5. ME995 Batch Controller stops under batch target. Front dial batch settings below computer batch targets. Select to higher value. Pulsefail LED activated,
flowmeter blockage/problem, check flowmeter.
6. ME995 alarm condition This indicates batch has been interrupted, or overbatched. Before releasing truck load, check ME995
and computer displays. If discrepancy, dump load or compensate. Call for service. Refer to
ME995/MES20 troubleshooting/maintenance guides.
7. After above checks, ME5IC still appears defective. After consultation with installer/admix supplier or ManuFlo, replace ME5IC card or ME995 controller or
Flowmeter or OPTO. Check operation guides for each product.
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ii) Batch Safety Interface
with ME2000/2008 The
Advantage
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ii) Interfacing with ME2000/2008
ME2008, ME2000 (or ME697)
Microprocessor interface batch safety unit.
up to 8 flowmeters
Flowmeter
measures
flow
Admix
Pump Storage
Tank
Batching computer
sets/records
batch
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Interface – ME2000/2008
Pump
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Interface – ME2000/2008
• All parameters and entries are fully programmable
via a plug-in hand held keypad.
• Dual-Channel Modules (mount up to 4) on motherboard,
for creation of 2, 4, 6 or 8 channel unit.
Optional Pulse Comparator for Dual Flowmeter system.
Optional Dual Display Counters for each channel
(for Comparator function).
Input Pulse scalable for use with most types of Flowmeters.
All display readouts in Litres to 3 decimal places, with
instantaneous flowrate display reading.
Accumulated batch totals (grand totals) for inventory records.
Initial Start and Pulsefail Safety.
Low and High Flow range settings. Pulsefail Safety
safeguards against exceeding flowmeter operating ranges.
Maximum pulse output frequency alarm, for PLC input safety.
Maximum Batch Limit Safety.
Output Pulse Division to PLC/Computer scalable.
24-240 vac or 5-25 VDC pulse switching.
Input/Output control with optional voltages.
Manual Batch facility, with Disable option.
Master Audible alarm function
Alarm condition for leaky check valves (back flow).
• Can be used for water channels e.g. RPFS-P paddlewheel.
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Interface - ME2000/ME2008 - Displays
• Switch on power to the ME2000 interface safety unit.
• Scroll through the settings by pressing SELECT.
• Go to the desired display to change a parameter via re-programming.
• Current Software version: V1.8
• Use at least V1.7
• Versions 1.6, 1.5, 1.4 V1.8
•should be upgraded
Channel 1 Channel 2
Flowmeter A Flowmeter A
Flowmeter B Flowmeter B
New option to
enable/disable
comparator
function
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Interface - ME2000/2008 - Displays
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Interface - ME2000/2008 – Displays
15Hz for AC
35Hz for DC
AC = 15 Hz
DC = 40 Hz
Latest is V1.8
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Interface – ME2000/2008 Order Codes
e.g.
for Command/Batch,Eagle PLC, AC i/o - order ME2008-8-1A-2A-3A, NEW MODEL OPTION:-
For Command Batch PLC, DC i/o - order ME20008-8-1D-2D-3C ME2000-2-CV
for Jonel-Archer computer, - order ME2008-8-1A-2A-3C, 2 channel only
compact version
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Interface – ME2000/2008 - Programming
4-way
New 8CAT5E
with
included
HP-CAT5E
programmer
Old
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Interface – ME2000/2008 - Programming
Data entry is via a 4-button keypad programmer that is plugged into
the 5-pin inline plug rail located on each 2-channel module.
Programming socket is keyed. Or via the later CAT5-E external entry panel
Old
New board
NEW
Reprogrammer access via external panel:
• 6CAT5E: 3-way panel for 6-channel ME2000.
• 8CAT5E: 4-way panel for 8-channel ME2008.
• HP-CAT5E: Programmmer with Cat5E plug.
Upgrade with
kit now
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ME2000/2008 – Able or Disable Dual Display on Ch.
Channel 1 Channel 2
Flowmeter A Flowmeter A
Flowmeter B Flowmeter B
additional
configuration
menu
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Computer Resolution display gradients
• Resolution as fine as 1 millilitre is available when using a MES20 20mm 1000ppl flowmeter or with ManuFlo’s electromagnetic
flowmetering options.
• The resolution of the system is totally dependant on capability of the Computer / PLC input specifications, that is the scanning
time / speed capability of the computers PLC input card.
• High speed PLC based systems can provide accuracy down to measuring 1 millilitre per 1 pulse gradients
(or better) with upto 10,000 Hz counting speed capability.
• To our knowledge current Command Batch / Jonel‐Archer and other USA based batching systems are using PLC solid state
digital inputs with the following Opto input capability;
i) AC inputs capable of speeds upto 15Hz (15 counts per second).
ii) DC inputs capable of speeds upto 40Hz (40 counts per second).
• If Batch Systems use high speed PLC input cards there would be no need to divide or slow down the pulse resolutions from the
ManuFlo flowmeters.
• In the early 1980’s when Boral Concrete and others were converting Concrete Batch Plants to computer control using the
Australian Compu‐Batch C2000 PC based system they used high speed inputs where 1ml/1pulse resolution was a standard.
• SEE BELOW TABLE FOR CURRENT BEST SAFE MODE SETTINGS WITH CURRENT COMMAND‐BATCH SOLID STATE INPUTS;
Max Safe Flowrate not to exceed computers
Model Size Pulse Output value Current DC digital input count limit speed of 35Hz
(& flowmeter max) (set in Max. Out Rate)
NOTE: ME2000 can emit 1mls/1 pulse if PLC computer input cards have high speed input capability
(Output overrun is set to 35Hz to safeguard the system settings).
FOR OTHER FLOWMETERED OPTIONS : CONSULT MANUFLO e.g. MAGFLOWS
Max Safe Flowrate not to exceed computers
Model Size Pulse Output value Current AC digital input count limit speed of 14Hz
(set in Max. Out Rate)
NOTE: (Output overrun is set to 14Hz to safeguard the system settings).
FOR OTHER FLOWMETERED OPTIONS : CONSULT MANUFLO e.g. MAGFLOWS
Most practical safe setting for MES20 is 50mls per pulse output for current AC inputs.
(Allows 42 litres/min. ME2000/2008 flowrate display will indicate)
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ME2008 ‐ Typical Settings – MES P.D.meters
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ME2008 – Typical Settings – AMM mags
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ME2008 ‐ Typical Settings ‐ KMS/RMS mags
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ME2008 ‐ Typical Settings – WATER CHANNEL
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Interface - ME2000/2008 – Default settings
ME2008 - Program Record Sheet Channel
DEFAULT –Software settings 1 2 3 4 5 6 7 8
Flowmeter Model (part no.)
K‐FACTOR (CALIBRATION)
If not known: Set input parameter to 1, then run
liquid, divide volume by count = pulses per unit.
Input Pulses per Litre
PULSE OUTPUT VOLUME VALUE TO PLC
Output Pulses Litres/pulse
* MINIMUM FLOWRATE CUTOFF
Min. flow Litres/sec
MAXIMUM FLOWRATE CUTOFF Sample –
Max. flow Litres/sec entered final software
MAXIMUM BATCH LIMIT
Dose Limit total Litres setting parameters
MAXIMUM BACKFLOW Record sheet
Litres
Comparator difference %
Start Delay (seconds)
Stop Delay (seconds)
Max Output Rate (Hz)
Date Programmed : Date Commissioned:
By : By:
Comments :
* Change to higher value, except for AEA Serial Number : Date :
Note: default values, you must change ME2008 Part
No. Config
: Software
Version
:
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ME2008 - Troubleshooting Guide -Summary
Text on the LCD display/Alarm Possible Cause Remedy
“Low Flow” -Flow Rate below setting -Check “Min. flow” value
-Pulse Fail due to flowmeter failure -Check flowmeter, and pulse cable wiring
-Airlock in flowline -Check delivery line
-Check for line restriction
“High Flow” -Flow Rate above Max.-Flow setting -Check “Max. flow” value, has been exceeded
-Check gate valve, restrict if necessary
“Output Overrun” -Higher pulse rate than pulse out Hz -Check “Max Out Rate” value
(frequency) maximum setting -Adjust pulse output value resolution
(AC=15Hz, DC=35Hz). -Check Flow Rate, restrict the gate valve.
“Over Dose” -Dose Limit exceeded during batch -Check “Dose Limit” (batch limit) value
-Check PLC/Computer Settings
“Back Flow” -Backflow of liquid after batch complete -Check Non-return valve, clean or replace.
-Or excessive vibration at flowmeter -Eliminate vibration source or use MES-R contact closure flowmeters.
install *see also Troubleshooting-Backflow on next page
-Stuck external contactor/pump. -rare case continuous backflow is external stuck contactor/pump running.
kill power, replace contactor/pump or ME2000 drive relay stuck.
ME2020 when introduced should differentiate.
To re‐enable the module showing “settings lost”, proceed as follows:
Plug the hand‐held Programmer into the Dual Channel Module;
Or short
the 2 pins
To restore the default settings (which are input calibration 1000 pulses/Litre,
as shown divided pulse output 10mls/pulse), push 2 buttons simultaneously on the
Programmer, being either the 2 arrow buttons or the DOWN and UP buttons;
Re‐enter parameters (via the Programmer) and refer to program sheet
settings.
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ME2008 - LATEST UNIT UPGRADES
Power Supply to ME2008
The power supply must come from the PLC/Computer or dedicated power supply, which should have
lightning arrestors / power surge protection already fitted to its Uninterruptable Power Supply (UPS).
Software Upgrade
Software version V1.8 should now be used (shown on Menu display start up or marked on channel IC).
• Due to extra current drawn on the units, Fuses should be upgraded to 2 to 2.5 amps..
Fuse RHS rear of PCB)
• DC powered units should be returned for upgrade / install & modification with
the latest technology high efficiency DC voltage converter now available.
DC
NOTE: Units built or reconditioned after 20th April 2018 have the latest enhancement pre-fitted as standard.
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ME2008 Troubleshooting - Backflow
In some installations with standard MES flowmeters, the ME2008 may count without batching being in
progress, causing a “Back Flow” alarm.
1 Usually, this is due to the Non-Return Valve not closing, thus allowing backflow which results in counts as the liquid runs back thru the
flowmeter (PD types).
Ensure that the Non-Return Valve is clean (spring or flap type) and operating correctly or replace with pneumatic controlled type.
The counts will be at a slow rate due to liquid tricking backwards.
2 If Non-Return Valve is OK, then ensure that shielded cable is used. If cable is not shielded, then interference may be picked up and
transmitted to the ME2008 which will interpret it as backflow.
3 If shielding is OK, then possible cause is vibration in plant near MES meters. Install flowmeters away from vibration causes, or anchor meters
with rubber mounts. Or tap the grip wings on the flowmeter body to better secure the pulsehead –see page 38.
4 If after batch complete and the shut off solenoid valve fails to close, then “backflow” alarm will engage. (lower loading points or syphoning)
5 If vibration is still prevalent, then using MES-R Reed Switch flowmeter pulseheads is recommended.
The MES-R pulsehead is GREEN in colour with a square junction box (2 wire connection) - this distinguishes them from the ordinary
MES black/white round junction pulseheads.
The MES-R pulsehead is much less sensitive to vibration, having much higher hysteresis.
Or use NEW MES20-DSP Special digital smart pulse pulsehead
WARNING:
If the blackflow alarm/counts rapidly and does not stop within 1-2 litres; then in extreme rare
circumstances the contactor/pump drive is stuck on, CUT POWER to system.
Wire a neon/globe
across coil of MES-R pulse-head
suspect contactors
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ME2008 now use MES-DSP “Digital Smart Pulse”
Installation and Programming
For excessively high Vibration Plants
A. Replace MES pulsehead with new MES20-N Digital smart pulse pulsehead.s
B. Wire “Shield” and “Pulse” connections only. This is a 2-wire connection only - DO NOT wire +12v into pulsehead.
D. VERY IMPORTANT
After replacement and programming of pulsehead, take a calibration test before you leave the plant.
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ME2008 – On Alarm condition
ALARMS
• If any of the safety features are triggered, the relevant alarm will come on.
• The Display will indicate status of the channel that is in alarm condition,
in which case, as a precaution the ME2008 will shut down pump drive of the faulty
channel only, allowing for further examination of the problem.
• If the alarm comes on, DO NOT push RESET immediately - observe display and take note
of the batch readings and the alarm message.
• WAIT for other channels to complete batch,
then push RESET to be ready for the next batch.
• If batcher gets Low Flow Alarm on two successive attempts at batching, then:
• MOVE THE TRUCK MIXER AWAY FROM THE LOADING POINT
• stop using that chemical channel; as each attempt doses 2 seconds worth of chemical into the mix.
• record the quantity displayed on the ME2008 and the batch computer; and
• ring your local admixture supplier or service agent for advise/service (or attempt to address).
• THIS WARNING GUIDE SHOULD BE DISPLAYED AT PREMIX PLANT FOR THE BATCHER / OPERATOR !!
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ME2008 Low and High Flow Limits
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ME2000/2008 – Programming
Bulletin 30 Jan 2004
Improved Safety Margin of Operation
• Low Flow setting – 25% of the usual flow rate of that channel.
• High Flow setting - 90% of maximum flowrate of channel’s flowmeter.
25% 90%
of o f fl o wm e te r
us ual m ax im um
fl o w ra te fl o w ra te
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ME2008 Output Over-run explained
Max Out Rate (Hz) Max Out Rate is the maximum allowed rate of output pulses to the
computer. If the maximum is exceeded, then the pump stops and the
ME2008 memory sends the extra pulses to the PLC/Computer’s DC Optos
0035 (under the 35 Hz max. input rate) or low scan rate systems.
Extra pulses received (above the allowed rate) represent actual extra
volume measured by the flowmeter and ME2008, but which would have
otherwise not been fully counted by the PLC/Computer system. (This
situation is different to actual “inflight overflow”, where a DEDUCT value
IMPORTANT: PLC/Computers with White Opto DC inputs have a pulse input
must be programmed in the computer system to stop the pump earlier).
frequency limit of 35 Hz, so for the ME2008 to protect such systems and
prevent overdose, set values in the ME2008:
IMPORTANT: PLC/Computers with White Opto DC inputs have a pulse
Industrial Grade
* MAX OUT RATE to 35Hz or less; and
input frequency limit of 35 Hz, so for the ME2008 to protect such systems
* OUTPUT (LITRES/PULSE) to a value so that, at your maximum operating
Input OPTO’s count speed: and prevent overdose, set values in the ME2008:
flowrate, pulses to PLC/Computer input will not excee35Hz
* MAX OUT RATE to 35Hz or less; and
e.g. If your maximum operating flowrate is 40 Litres/minute
(Max Flow = 0.67 l/s) and pulse output is 20 mls/pulse
* OUTPUT (LITRES/PULSE) to a value so that, at your maximum operating
DC White Optos : 35Hz
(Output=00.020 l/p), the ME2008 will output 33.3 pulses/second (i.e. <
flowrate, pulses to PLC/Computer input will not exceed 35Hz
35Hz) to the PLC/Computer when flow is 40 Litres/minute.
e.g. If your maximum operating flowrate is 40 Litres/minute
AC Black Optos: 15Hz
(Max Flow = 0.67 l/s) and pulse output is 20 mls/pulse
Output Rate (Hz) = Maximum flowrate (l/s) / Pulse output (l/p)
(Output=00.020 l/p), the ME2008 will output 33.3 pulses/second (i.e. <
35Hz) to the PLC/Computer when flow is 40 Litres/minute.
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ME2008 – converting the Pulse output from AC to DC (& visa versa)
For 24-240 VAC pulse output: insert MOC3043 ICs into U1 and U2 (remove U3,U4 IC’s) pin 1 .
For 5-30 VDC pulse output: insert 4N33 ICs into U3 and U4 (remove U1,U2 IC’s)
______________________________________________________________________________________________________________
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240 vac Computer Active
ME2000/ME2008
Black OPTO
Black OPTO
Black OPTO
external
6-way black
240 vac connector
Active line 240 vac Start 1
CONTACTOR S1
Run 1
R1
0.03 – 0.1 uF, 250vac Output 1
Suppression Capacitor O1
PUMP
Start 2
N S2
Run 2
Wire a neon/globe R2
0.03 – 0.1 uF, 250vac Output 2
across coil of Suppression Capacitor
O2
PUMP
suspect contactors 2-channel module
N
152
INDUSTRY BULLETIN 14/1
Benefit: Detection of pumping air via PD pumps.
Product: ME2008, Microprocessor Interface Controller Safety Card
Feature: Batching computer, ME2008 settings, batching procedure.
Date: 25th August 2014
To safeguard against possible pumping and recording of air if admixture chemical storage tanks run out (empty) and positive displacement pumps push air
through MES pulse flowmeters causing false counting of air miss-interpreted as liquid chemical;
(1) Field Report
A majority of admixture dispensing installations in premix concrete plants are using centrifuge pumps. These type of pumps do not pump/push air in
significant capacity.
We were advised that a positive displacement pump was installed in an installation with an MES20 positive displacement pulse flowmeter and ME2008
system. The chemical storage tank ran empty of liquid and the pump continued to push air through the MES flowmeter. The flowmeter continued to
transmit pulses to the ME2008. The system interpreted this as liquid whereas it was air, causing under dose of liquid.
(2) ManuFlo factory test
The same installation and equipment conditions were setup at ManuFlo. We found that pumping air registration occurs in a fluctuating manner from 0.06 to
0.340 litres/sec. (60 to 340 millilitres/sec).
(3) Recommendation Setting for the ME2000 / ME2008
To improve the ability of the ME2000/08 to detect a problem if tanks empty and a positive displacement pump pushes air and the MES flowmeter
transmits pulses, the settings for Low Flow {menu:6 of the display screen [min.flow (l/s)] } should be set to 000.100 , this equates to 0.1 litres/sec, or
100mls/sec or 6 litres/min. The value is changed via the hand held programmer.
As general guide, to fully utilize the safety management system of the ME2000/08:
•the Low Flow setting should be set at 20%* of the usual flow rate (or 000.100 which ever is the greater)* of that channel; and
•the High Flow setting should be set at 90% of the specified operational maximum flowrate of the flowmeter on that channel.
(4) When Batching
MOST IMPORTANT
If a batcher gets a Low Flow Alarm on two successive attempts at
Or use KMS batching, then the batcher must:
Magflows
With empty pipe
detection ! o stop using that channel; and
o record the quantity displayed on the ME2000/08 and the batch
computer; and
o ring your local admixture supplier or ManuFlo for service.
Note: ManuFlo has an advanced training course available for relevant personnel.
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INDUSTRY BULLETIN 16/8
Benefit: DETECTION AND RECORDING OVER BATCHES
Product: ME2008 /ME2000, Microprocessor Interface Controller Safety Card
Feature: Batching computer with ME2008 over‐batch DOSE‐LIMIT alarm.
Date: 4th August 2016
The following is an explanation of the functionality of the ME2008/ME2000 logic in conjunction with the PLC/computer system during an over-batch “Over Dose” alarm
being triggered due to:
Malfunction of PLC/computer START Opto drive ( seized ON-state ).
Oversized recipe or quantity request of the PLC/computer software batch load operator.
- ( PLC/Computer Set Quantity ≥ ME2008/ME2000 Set “Dose Limit” Quantity )
THE SEQUENCE & LOGIC OF THE SAFETY SYSTEM SCENARIOS EXPLAINED;
I. The PLC/Computer provides a continuous START drive from its Opto’s to the ME2008.
II. The ME2008 then provides a continuous RUN drive to the external contactor/solenoid to start the flow of admixture/liquid.
III. The ME2008 allows 2 seconds (adjustable “Start Delay”) for pulse signals from flowmeters to arrive.
IV. The ME2008 software now counts then totalise the incoming pulses received and continuously monitor (watchdog safety mode) if no safety setting is being breach
( e.g Minimum/Maximum Flow, Dose Limit and Max Out Rate settings ).
V. Once the computer has received its desired pulse target quantity the START drive dis-engages and the ME2008 RUN drive dis-engage also at the same time.
VI. A MASTER RESET command from the PLC/computer will then reset the ME2008 totalisers and ready for the next batch.
Scene 1: Malfunction of PLC/computer START Opto drive
If the PLC/computer START Opto drive is stuck-on then the ME2008 will count continuously to the Dose Limit setting and will continue to record and send the incoming
pulses from the flowmeter on the ME2008 display to the PLC/computer.
MASTER RESET command will be received by the ME2008 totalisers if the set batch quantity has been met by the PLC/Computer, at this point if the PLC/computer
channel inputs close off, it may or may not be live to register further incoming pulses (software dependent), the ME2008 will not accept any RESET command while the
START and RUN drive is still active due to START Opto drive malfunction so the total count will not be reset and will continue to transmit pulses to the computer until the
Dose Limit quantity is reached and “Over Dose” alarm safety and function will be activated.
Scene 2: Oversized recipe or quantity request of the PLC/computer software batch load operator.
If the PLC/Computer Set Quantity is equal or more than the ME2008 Set “Dose Limit” Quantity, then the PLC/computer will provide a continuous START drive to the
ME2008 until a desired pulse target quantity is achieved but the ME2008 is also continuously monitoring the total quantity being delivered and must not reach the Dose
Limit amount setting otherwise “Over Dose” alarm safety and function will be activated.
Note: No MASTER RESET command will be received by the ME2008 totalisers if the batch size has not been met by the PLC/Computer.
Alarm safety and function: “Over Dose”
If “Over Dose” alarm is activated, the ME2008 will override the PLC/computer START drive and disengage the RUN drive to the contactor/solenoids to stop the flow and
. at the same time will raise a visual and audible “Over Dose” Alarm to notify the operator.
avoid over dosing of admixture/liquid, and
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ME2000/08 calibration adjustment guide
A volumetric calibration test is performed when commissioning a new installation and periodic follow-up tests.
To calibrate a vessel is placed near the sock or by-pass port, a selected batch quantity set on computer,
and batched. Or can be manually batched by over-riding the pump drive.
Final Calibration:
• If the liquid collected is more than pulse value shown on computer screen or volumetric amount on display,
then decrease the calibration input set value (K-factor) by the same % difference
• If the liquid collected is less than pulse value shown on computer screen or volumetric amount on display,
then increase the calibration input set value (K-factor) by the same % difference
• Note: Final calibration can also be performed via computer software scaling.
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ME2020 under development
•
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iii) Interface Cards
UIC
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iii) With UIC Interface Card
The UIC Universal Interface Card provides: signal scaling and an isolation interface
to pulse flowmeter outputs, and re-transmits to PLC/computer inputs. Models available:
UIC/A2 = 24-240vac switching or UIC/D = 5-30vdc switching.
Batching computer
sets/records batch
or AMM Flowmeter
In use in Thailand, Indonesia,
New! Philippines, Malaysia, HK,
Vietnam, Nth China, Singapore
and elsewhere.
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UIC Interface Card - Configurations
UIC/A2 • switches 220-240vac, 5-12 VDC powered UIC/A1 • switches 110-240vac, 5-12 VDC powered
white IC,
ASO241 AC-triac MOC3041-triac
no IC labelled “AC”
7 pos.term.blk
no regulator
Regulator
6pin 4n33 wh/blk
6pin 4n33 IC opto
IC opto
(Wht/Blk)
no triac
160
0901/1
Interface Cards – UIC for Admixtures
Flowmeter UIC Computer/PLC
Usually used
with
Bottle Systems
Mainly in Asia.
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Interface Cards - UIC
2 mounting holes,
for fixing to panels,
enclosures etc. all scaled output pulses
are indicated by a LED
VOLATGE SUPPLY
• Requires strictly regulated supply of 5 to 12VDC, which in turn supplies flowmeter.
If only 24 VDC available, an optional voltage regulator is pre-fitted on card (-24DC).
input
• Schmitt trigger input filters possible industrial noise.
output
• produces low voltage 5-12 VDC NPN (sinking) scaled output pulse (proportional
to supply voltage), which can be used for connection to counters or other devices.
• output pulses feeding PLC input have 50% duty cycle (square wave).
50% 50%
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Interface Cards - UIC – Wiring for AC
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Interface Cards - UIC – Wiring for DC
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Interface Cards - UIC – Installation
• Mount UIC interface cards on a suitable panel or inside an enclosure near the Computer/PLC
input panel.
• When wiring the flowmeter, use shielded cable.
For example, when wiring 4 flowmeters in the one installation, use at least 6-core shielded cable:
4 cores for each pulse wire and at least one core for the positive DC voltage supply linked to each
UIC card and the flowmeters, and one core coupled with the shield as O.V.
• Wire the Pulse Output and return line from the dual (white) terminal to the computer/PLC pulse
input(s).
• Wire the external power supply (also available from ManuFlo), to the UIC card which in turn
supplies voltage to flowmeter(s).
Power supply must be stricktly regulated +5 to 12 VDC only, noting each UIC
card/flowmeter can draw up to 25mA each.
Or 24VDC if UIC-24VDC input powered option is installed.
• Select the appropriate calibration pulse ratio setting via the 3 decade rotary pots, marked
Hundreds(H) Tens(T) and Units(U).
• Power up the system.
• Prime the admix line, until liquid appears at outlet line, UIC card’s pulse LED is blinking and the
computer screen is counting.
• A volumetric calibration test must be performed when commissioning a new installation, and a
follow-up quarterly test: a calibrated vessel is placed near the sock, a selected batch quantity set
on computer, and batched.
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Interface Cards - UIC - Scaling
Calibrating or scaling of pulse output signals is via
3 rotary select switches (numbered 0-9) marked Hundreds (H),
Tens (T) and Units (U).
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Interface Cards - UIC - Scaling
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Interface Cards - UIC - Calibration
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Interface Cards - UIC - Calibration
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Interface Cards - UIC – Pulse Trouble Shoot
• If there is no pulse output or it is erratic from the UIC
1. Check that the HTU settings on the UIC card are not set to H=0 T=0 U=0, and are
correct for your application.
2. Turn off power to the UIC, NOW SET a VALUE e.g. HTU=100, then turn the power
on again.
3. Run some fluid through the flowmeter (or simulate flow by inputting pulses to the
UIC card).
4. Observe if the UIC’s output LED blinks at the rate expected for the divided output
pulse rate.
5. If the problem still exists, repeat steps 1 to 4 (2‐3 times) until the UIC card
autocorrects itself.
6. If the UIC does not autocorrect, then return the suspect UIC card to ManuFlo for
further checking or repair.
H
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Interface Cards – with ME697 / ME693N
In use in Australia, ME697
NZ, HK, Nth China
Computer
+12VDC
start drives
drives
ME693N
Still in use in NZ,
Indonesia Computer
+12VDC
drives
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Interface Cards – ME697
ME697
Computer
+12VDC
Pump
MES20 Flow meter
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Interface Cards - ME697 - settings
Pulse inputs to ME697 are 1 pulse = 1 ml and are counted on the LCD displays.
(1) Using the red 4 way DIP switches, select the (2) Using the blue 4 way DIP
appropriate divider pulse ratio setting for each switches, select the override
channel. (Make sure the divided pulse value limit settings
corresponds with the computer software input
parameter e.g. divide by 100 is 100 mls per
Computer input count.
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Interface Cards – ME697
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8.
Flowmeters for
Admix Shotcrete, Grout Mix,
Slurry and oxides.
Continuous-Dosing
Measurement
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Admix Shotcrete / Grout, Slurry, Oxide,
SilicaFume Flowmeters
K-Mag & RMS-Mag
• Ideal for shotcrete chemical applications.
• 15mm electromagnetic flowmeter. (upto 150mm)
RMS Integral
• Obstructionless bore – nothing to block.
• Pulse & 4-20mA output.
• LCD backlit display shows
Flowrate and optionally resetableTotal.
• ANSI-150 flanged, PTFE liner, for sizes ≥15mm;
• RMS8711 WAFER for high pressure GROUT
to 740psi.
• Hastelloy-C4 electrodes.
• IP65 sensor and transmitter.
Sensor potable to IP68 protection.
• Accuracy to @ ±0.2%
• For liquid conductivity ≥ 5µS/cm.
• 11 – 30 VDC powered
(also available as 90 - 250 vac version).
FLANGE KITS available Shotcrete Spray Rig
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Admix Shotcrete Flowmeters
MES20LCD6DP
For a resetable total
+ flowrate remote series for
larger display screen Shotcrete
use with
chemicals only
SCS-AMM15
Complete package wired
with S/S316 box
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Continuous Dosing
Admix
Storage
Tank Pump
Valve
Instantaneous
Flowrate display
Manually operated - visual e.g. MES20LCD5DP-F
FRT303-E with MES20
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9.
for Delivery Trucks
and
Admix Production
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TMP – Truck Mounted Batching Printer System
• Batch Controller and Printer for automatic ticketing.
• Ideal for admixture delivery trucks or loading and discharge locations
where custody transfer docket is required.
• Prints Batch ID, quantity, time and date.
• Paper easily changed.
• Rugged IP64 hinged enclosure, with key lock.
• contains wired and mounted ME3000-SC Batch Controller
and APM-n93XS printer.
Batch Ticket
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TMP1 – Truck Mounted Batch Monitor
Ticket Printer System
TMP-1
Batch Ticket
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Use with KMS Electromagnetic Flowmeter
• Unsurpassed accuracy to ± 0.2 %
• Virtually unaffected by varying viscocities
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Flowmeters for Admix Production
For the batching & blending in
production plant
Tanks production
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10.
Equipment for Water
Measurement
in Concrete Plants
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BATCH ROOM
Water Supply Batch Monitor Batch Controllers Resettable Totaliser Slumpstand
OR MRTU4‐GAL25‐T2
(standalone or dual display (‐
P) slumpstand flowmeter)
S Reconditioning
Service Available
Overhead Tank Save $$$ !!!
(Fresh water / Solenoid
Mains ) Flowsensor Operated Water Discharge
OR RPFS Valve
Pump
Ground Pit Paddlewheel type
(Fresh water/Mains)
(Recycled water)
MRTU4 ManuFlo
Resettable Battery MRP20-T2 also supplies
Powered Flowmeter For adding equipment for:
(MANUAL e.g B50 water Grout mix
BATCHING) 50mm Butterfly valve (mounted at the Shotcrete
KMS RMS Size: 25-100mm back of agitator/ Admixtures
Electromagnetic Flowmeter mixer truck) Tradewaste
(Fresh /Recycled water) MRT20-T2
ManuFlo
MANU ELECTRONICS PTY LTD
41 Carter Rd, Brookvale
7
Flow Measurement & Control Products Sydney NSW 2100 Australia
Web: www.manuelectronics.com.au a division of Ph: + 61 2 9905-4324, 9938-1425
Email: [email protected] Fax: + 61 2 9938-5852
ME995-7 Preset Batch RPFS‐P Flow Sensor
Controller • Paddlewheel type.
• 9999 Litres Preset Batch Controller. MRP20-T2 & MRT20-T2 • For fresh/mains water.
• 4 Digit LED display. • 20mm LCD Resetable • Fits into pipe adapters of various types
• Counts in Litres up to 9999. Counter Flowmeter. and sizes 20‐200mm.
• 4 x LED status indicators. • Screwed & Slip insertion types
• Preact function.
• Custom designed and built primarily e.g SS25
• Preset maximum limit.
• Missing pulse detection.
for use on Concrete Transit Mixers. 25mm Stainless
• Optional PLC & computer interface. • 4 digit counts in LITRES. Steel pipe
• K-factor (calibration) adjustment. • (-P) for pulse output option. adapter
• Compatibility with most flowmeters.
ME3000 Preset Batch DSSS-1 Dual Display Slump Stand / Batch Room KMS RMS
Controller water measurement system package
• 6 digit LCD Microprocessor
Batch Controller. Panel mount
type.
• Front keypad. IP64. KMS or RMS Electromagnetic Flowmeters
• Displays batch in ml / Litres • In sizes from 4‐250mm.
• Flowrate display. • No moving parts.
• Fully programmable. • Virtually maintenance free.
• Batching safety features. • For heavy recycled water.
• With logic, pulse, and current • Optional connection kits available in PVC or Gal.
output options.
ME6008M Batch Monitor MRTU4‐GAL25‐T2 Solenoid Valves
• Monitors up to 8 channels. • 25mm slump stand meter. • Fast acting solenoid valves.
• For manual batch plants that need • 4‐digit LCD shows total Litres. • For water.
QA printout of flowmetered • Closing lid resets Litres count. • In various types and sizes.
additives or water. • Flowrange: 18‐235 Litres/min. • With or without air assist.
• Automatic end-of-batch printing
• Available in larger sizes for
and datalogging. Used with serial
printers LX-300+II or DP8340. manual batching of plant water
• Optional: 1 channel also e.g. 50mm MRTU6‐GAL50M.
available ME600M1
182
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MANU ELECTRONICS PTY LTD
41 Carter Rd, Brookvale
Flow Measurement & Control Products Sydney NSW 2100 Australia
Web: www.manuelectronics.com.au a division of Ph: + 61 2 9905-4324, 9938-1425
Email: [email protected] Fax: + 61 2 9938-5852
NEW MRTU Series ‐ slip insertion flowmeters
__________________________________________________________________________________________________________________________________________________________________________________________
__
• MRTU4‐GAL25‐T2
• 25mm slump stand meter.
• 4‐digit LCD shows total Litres + Flowrate.
• Closing lid resets Litres count.
• Flowrange: 18‐235 Litres/min.
• Available in larger sizes for manual batching of plant water 25mm slump water
Replaces the
MRPU5 series
AC
computer
MRPU5 input
resetable
flowmeter
DC
computer
input
Power (b) Wireless – to 150mtrs
Supply
- or -
240 VAC UIC/D or UIC/D-24
(ii) to 12 VDC 12 VDC DC pulse converter
converter powered WPTR-T WPTR-R interface card
single channel 1 channel pulse receiver 5-12 VDC, or 24VDC
pulse transmitter (optional 4-channel receiver) powered versions
(5 Hz max,150 metre range) 12-24 VDC powered
a division of
MANU ELECTRONICS PTY LTD Ph: + 61 2 9938 1425, +61 2 9905 4324
41 Carter Road, Brookvale Fax: + 61 2 9938 5852
slumpstand_options.ppt, 1401/1 Sydney NSW 2100 Australia Web: www.manuelectronics.com.au
MRP20-T2 / MRT20-T2 LCD reset flowmeters - for Concrete Truck Mixers.
• Custom designed for the concrete industry cement trucks
• Built to last to endure harsh conditions -gunmetal flowtube
• Durable alloy paddlewheel design
• Pulse output option for logging (-P)
• New large 4 digit LCD display 10+ yr battery life
• Calibration certificate supplied
• Australian built & supported
• Can be returned for reconditioning
• In use for over 20 years… Proven results
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MRP20: calibration (new PCB)
• in newer 5 digit version, to change calibration setting:
• Turn metal locking ring anticlockwise to remove, and remove tempered glass window.
• Adjust 3 calibration using the 3 buttons: UP, LEFT and SET.
LEFT/UP SET
(2) To change the calibration value, use as required: (3) Press SET to lock
• the LEFT pushbutton, to select the next digit to the left, in the changed UP LEFT SET
which will flash), and calibration value
• the UP pushbutton, to change the flashing digit (no digit is flashing).
(digit value will cycle through 0-9).
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Heavy Recycled Water - Measurement - Solution
BATCH ROOM
Batch Controller
Plant Open/close
Recycled feed Computer OR
Magnetic
Flowsensor Flowmeter
no moving parts!
RPFS
Paddlewheel
S
Overhead
Gravity Tank
Valve
(Fresh /Recycled water) Water Discharge
and / or
Ground Pit
Paddle Wheel Magnetic Flowmeter
(Recycled water)
Pump
ManuFlo
MANU ELECTRONICS
41 Carter Rd, Brookvale
PTY LTD
PUMP/
WATER UIC
ME2002-CV-W
VALVE TANK Interface Card
Flowmeter pulse/voltage scaling
measures
flow.
ME2002-CV-W
RPFS
(for clean water)
or via interface –MC2
RMS
(for slurry water)
ME5IC
Batch Controller Interface Card Batching computer
controls i/o scaling sets/records
batch delivery and comms i/f batch
ME995-7 or ME3000
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Interface Cards – UIC for Water Batching
Flowmeter UIC Computer/PLC
1) UIC/A2 : 24-250 vac pulse switching via a heavy duty triac opto
2) UIC/D : 5 - 25 VDC NPN/PNP (sink/source) pulse switching via a 4N33 opto
3) -24 : As above but 24VDC supply input as opposed to the standard 5-12VDC supply to card
UIC/A2 UIC/D -24 with /A2 or /D option
triac ManuFlo ®™
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Interface Cards - UIC – scaling for Water Batching
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RPFS – Rota Pulse Insertion Paddlewheel Flowmeter
RPFS-P to 50C RPFS-H to 120C Black Blue Black Since 1984
(Pulse) (Ground) (Pulse)
Brown
Brown (5-30 VDC)
(5-30 VDC) looking at looking at
plug on socket on
RPFS-P sensor RPFS-P cable
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11.
Other Equipment
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ME6008M Batch Monitor Printer Driver Unit New!
M WIDE COMPACT
dot matrix tractor feed
+
dot matrix paper roll
LX300+II printer
204mm wide printout or DP8340 printer
84mm wide printout
80 characters 40 characters
USB
connection
to your
laptop/PC
Provides multi-channel batch log/printout for manual premix concrete batch plants.
Monitors/prints up to 8 channels of admixture or water.
Provides an automatic QA end-of-batch printout, for use in concrete batch plants. Batch Log
Internally logs at least 500 batch events, downloadable to your laptop/PC
now via optional front-access DB9 RS232 connector (comes with RS232-to-USB adapter).
All records are time stamped from the unit’s Real Time Clock, and have a Batch Number ID, time and date.
Simply parallel flowmeter pulses and connect to the ME6008M, which then connects to a serial printer or PC.
Grand Totals and the Batch History can also be printed(or dumped to a PC) on demand.
Fully programmable, and the user can set parameters including K-Factors (PPL).
Simple to install - same size as the ME995-series Batch Controllers, with same cutout.
New features:
• Extra RS232 connector on front, for easy access to download log to laptop.
• Units (mL or L) indicated in printout.
• NEW “-E” version for remote PLC command functionality (from ANMAR)
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Other Equipment
ME6008M Batch Monitor Printer Driver Unit
ME6008M Connection Diagram
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General other - Troubleshooting Guide
PROBLEM PROBABLE ISSUE SOLUTION
RPFS-P paddlewheel or Valves are installed too close to the RPFS paddlewheels sensors
Magflow is not accurate as sensors. The straight pipe requirements 10 x.Dia before, 5 x Dia after.
per sepcification before and after the sensor / pipe MAGFLOWS
adaptor fittings have not been met. 5 x.Dia before, 3 x Dia after.
Fix the install according to solution The more straight pipe better.
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11. Other Equipment
Generic items
can be sourced
locally or from
ManuFlo. Power converters
Filters
Solenoid valves
Contactors
Cables
Butterfly valves
TANK Level Warning probes
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11a.
YES WE REPAIR ITEMS
& Supply spare parts
• Batch Controller reconditioning
upgrades and modifications
• Flowmeters reco’s
• ME2000/08 upgrades
• In‐house calibration tests
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12. QUIZ / QUESTIONAIRE COMP.
• 10 Questions for a Prize
. .
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Training Quiz:
Question 1 ‐ What is the standard pulse output (resolution per Litre) from the MES20 flowmeters? (1 pt)
Question 2 ‐ After carrying out a calibration on an MES20 the accuracy is 4%, should it be replaced? (1 pt)
Question 3 – What are the implication of changing from a MES20 20mm to a MES25 25mm ? (1 pt)
Question 4 ‐ If a standard MES20 flowmeter is suffering from false (phantom) counts what is the likely cause (1 pt)
and what options are available to resolve this problem? (1 pt)
Question 5 ‐ When programming the ME2008 What is the recommended High and Low MES20 flow settings (%)?
(2 pt)
Question 6 ‐ If a batch operator gets two consecutive ‘Low Flow’ alarms on the ME2008 what should be his
‘Immediate’ course of action? (1 point) ‐ what’s the consequence if he keeps trying to batch? (1 pt)
Question 7 ‐ With AC Voltage I/O computers what is the AC pulse input frequency limit?...... and for DC ? (1 pt)
Question 10 ‐ When would you consider using an alternative flowmeter such as an electro‐magnetic? (1pt)
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Training Quiz: (Answers)
Question 1 ‐ What is the standard pulse output (resolution per Litre) from the MES20 flowmeters? (1 point)
Answer: 1000 (slide 28, 29 & 30)
Question 2 ‐ After carrying out a calibration on an MES20 the accuracy is 4%, should it be replaced? (1 point)
Answer: No only at 5% accuracy should the meter be replaced as per the Australian standard (slide 43)
Question 3 ‐ What are the implications of changing from MES20, 20mm to MES25, 25mm?
Answer: Higher flow rate capability (slide 30) and pulse changes from 1000 to 555 ppl (slide 53).
Question 4 ‐ If a standard MES20 flowmeter is suffering from false (phantom) counts what is the likely cause (1 point)
and what options are available to resolve this problem? (1 point)
Answer: Vibration, install away from vibration, install rubber dampeners, replace MES20 with MES20R. (slide 38)
Question 5 ‐ When programming the ME2008 What is the recommended High and Low MES20 flow settings (%)?
Answer: Low is 25%, High is 90% (slide 149 & 150) (2 points)
Question 6 ‐ If a batch operator gets two consecutive ‘Low Flow’ alarms on the ME2008 what should be his
‘Immediate’ course of action? (1 point) ‐ what’s the consequence if he keeps trying to batch? (1 point)
Answer: Stop using chemical and move truck away from loading point, record amount displayed on ME2008 and
batch controller. The consequence if keep batching is potential overdose of chemical as you dose 2 secs .
volume every time. (slide 148)
Question 7 ‐ With AC Voltage I/O computers what is the AC pulse input frequency limit?...... and for DC ? (1 point)
Answer: 35Hz for DC, 15 Hz for AC (slide 135)
Question 8 ‐ If the none return valve after the flowmeter is faulty what alarm might you expect on the ME2008?
Answer: ‘Back flow’ (slide 140) (1 point)
Question 9 ‐ If the liquid collected is more than pulse value shown on ME2008 display, should you increase or
decrease the calibration input set value (K‐factor) by the same %? (1 point)
Answer: Decrease. (slide 156)
Question 10 ‐ When would you consider using an alternative flowmeter such as an electro‐magnetic? (1 point)
Answer: High volume and/or aggressive/oxide/slurry type ADMIX chemicals (slide 178)
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13.
General Advice
If unsure contact ManuFlo
for advice or obtain datsheets
on our website.
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14.
ManuFlo Website
www.manuelectronics.com.au
www.manuflo.com There is an abundance of
information and resources
available on the ManuFlo
website. If you still have any
queries however, please feel
free to call us for application
advice, product
recommendations, calibrations,
equipment servicing, etc.
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15.
Questions
• Questions?
• Improvements?
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ManuFlo
® TM
a division of
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