Training Manual 2018

Admix & Water Batching Equipment
Advanced Training Guide
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
ManuFlo ®™
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(c) Manu Electronics 2018
Contents
1. About Manu Electronics / ManuFlo 8. Shotcrete, Grout, Slurry, Oxides,
2. Measuring Admixtures, Silica-fume flowmeters,

Production, Transfer and Use for Continuous Dosing Measurement
Premix Concrete Plants
9. For Admix Production and Delivery Trucks
3. Overview:
Admix Batching with Flow-metering 10. Water Measurement in Concrete Plants
4. MES Flowmeters & other flowmeters. 11. Other Equipment / Repairs
5. Achieving Faster Delivery Flow Rates 12. Quiz Questions
6. Semi Automatic Batching with 13. General Advice

Batch Controllers
14. ManuFlo Website
7. Interfacing Flowmeters in
Computer controlled Batch Plants; 15. Q & A - Questions
i) Batch Controllers.
ii) ME2008 cards. First to spot Wally wins a prize !
iii) UIC cards.
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1.
About
Manu Electronics P/L
ManuFlo ®
ManuFlo ®™
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About Manu Electronics
• Manu Electronics Pty Ltd was founded in 1965
by Anthony Manu
• From bottle dispenser manufacturer in the 1960’s

to digital equipment manufacturer from the 1970’s
and microprocessor technology from the 2000’s.
• Specialises in design/manufacture of
process control and measurement instrumentation,
primarily for the concrete construction chemical additives industry.
• January 2000 - Moved to new 600m² office and manufacturing facilities

at 41 Carter Road Brookvale Sydney NSW Australia.
• June 2001 - ManuFlo ®™ worldwide trademark
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Key Staff
Alex Manu - Managing Director
Phil King - Sales Engineer
Vicki / Erica - Office Admin. / Accounts / Logistics
Mitch Z. - Electronics Engineer / Technical Support
Bill / Harry - Specialty Product Support
Matine / John - MRP / MRT products
- and the silent team
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Tens of Thousands in Operation …
Manila
Philippines
ManuFlo products are:
• 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
Admixture Production Admixture Delivery Premix Concrete Concrete

Plant Tankers Plant Trucks
And Liquid slurries, Oxides, Grouts, Silca-Fume
ManuFlo -
suppliers of
liquid measurement
application
products
since 1965.
Shotcrete Pug Mill / Dosing

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SELECTION GUIDE Advantage
Flow Metered Measurement for Liquid Admixtures
MES Series Flowmeters

• Available in sizes 20, 25, 32 and 40mm.
• Pulse, Digital LCD, Mechanical display and combo options
• Nutating Disc operation allows a long operational life.
• MES-series flowmeters are the most commonly used devise for
measurement of admixtures (over 40,000)
AMM Series Flowmeters

• Available in sizes 15, 20 and 25mm
KMS & RMS Series Magflows

• Available in sizes 4mm up to 150mm
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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
ADMIX Batch Plant – Instrument Selection Guide
Type of Concrete Plant Typical Dispensing Instrument Description

Instruments Utilised
• Manual Batching / Dosing MESLCD Positive Displacement Flowmeter 20 - 40mm
• Low Volume / Mobile KMS, RMS Electromagnetic Flowmeter 4 – 50mm
• Non computerised
• Semi Automatic Batching ME995 / ME3000 Batch Controllers with safety system
• Print Out ME6008M (optional) Batch Monitor / Logger / Printer Driver (optional)
• Low Volume / Mobile MES20 Positive Displacement Flowmeter 20mm
• Non computerised AMM20
• Automatic Batching ME995 / ME3000 – MC2 or Batch Controller with Computer Interface
• Medium Volume ME2008 Safety Management Interface to Computer
• Computer / PLC Controlled MES20, MES25, MES32 Positive Displacement Flowmeter 20 / 25mm
AMM20 Electromagnetic Flowmeter 20 / 25mm
• Automatic Batching ME2008 / Safety Management Interface to Computer
• High Volume MES20 to MES40 or Positive Displacement Flowmeter (sizes 20-40mm)
• Computer Controlled AMM20/25, MM25, Electromagnetic Flowmeter (depends on volume)
KMS25/KMS40
• Dosing / Bessa Block Plants MM10/15/20/25 Display with Pulse & mA Outputs
• Continuous Shotcrete Apps. KMS25 / KMS40 For Manual or PLC Control
• Quarries RMS series
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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?
Does excessive vibration cause an issue with Possibly if incorrectly installed (MES‐P versions).

measurement? Options are to use –R or‐MR versions (contact
closure switch) which solves phantom pulsing issues.
Or KMS Magflows.
Comment on replacement of equipment, service Stock available at all times with usually same day
and turn around of repairs . Do you have an R&D shipping. Free on‐going product and application
programme. support. Repair turn around within 7 days. Ongoing
R&D programme with new instruments continuously
under development following stringent survey of
industry needs.
How many concrete plants Australia/NZ and We estimate we have 90‐95% of the Australian/NZ
throughout the Pacific Rim use your dispensing market. We also have significant numbers in Malaysia,
systems? Indonesia, Thailand, Nth China, Hong Kong, Vietnam
Singapore, Chile , UK and other countries.
Are there any constraints on Batch Volume Sizes Unlimited. If volume throughput is high simply select
and how quickly a batch can be carried out? large bore MES or Magflow. Batch times are only
restricted by the size of pipes or pumps selected.
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The
Advantage
Flow Metered Measurement for Batching - Points
New “DSP” Digital Smart Pulse. Vibration Free Pulseheads
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The
Advantage
Flow Metered Measurement for Batching - Points
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The
Advantage
SUMMARY: ADMIX Dispensing by Flow Measurement
ManuFlo Flowmetered Systems since 1965.

Long lasting decades of uninterrupted performance....
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The
Advantage
SUMMARY: ADMIX Dispensing by Flow Measurement
ManuFlo Flowmetered Systems since 1965.

Long lasting decades of uninterrupted performance....
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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.
Pictured a batch plant in California -USA ManuFlo ®™

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Bottles vs Flowmetering / ME2008 & Batch Controllers
• Slow discharge time, Double handling.
• Messy, Large & cumbersome, Extra maintenance, Expensive
• Risk: bottles are pressurized - can explode.
• Quick exhaust valves can fail – not completely safe or foolproof.
• Replace your bottles now, save ongoing maintenance costs:

ManuFlo recommends using ME2008 or ME995 (which incorporate
safety features) with MES or AMM flowmeters in lieu of bottles.
New technology wins new customers!!
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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
Flowmeter with display

Rate + Reset Total
e.g. MES20LCD6DP
Quantity determined by: operator

Delivery controlled by: operator
Internal battery powered meter
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Semi-Automatic Batching
Batch Controller
Contactor
optional 3-Way Valve

Gate Valve Outlet line at
(calibration point)
restricts flow same level as
Admix Storage Tank
Storage tank
Non-Return
Valve
Tank Filter Valve Non-Return Valve Solenoid
Pulse Output
Pump Flowmeter
e.g. MES20
Quantity set by: operator

Delivery controlled by: batch controller Or AMM Mag-flowmeter
option
Early models used since 1972 !!
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Automatic Batching via PLC/Computers
ME2008, ME2000
Microprocessor interface batch safety unit.
UIC Interface Card

Admix Flowmeter
measures
flow
Admix pulse/voltage scaling
Pump Storage
Tank
Direct Flowmeter Pulses
via interface plugs –MC2
Batch Controller ME5IC i/f Card

controls batch delivery i/o scaling and comms i/f
Batching computer
Quantity set by: Computer/PLC sets/controls/records
Delivery controlled by: Batch Controller/MES2000/Computer/PLC batches
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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
Black Teflon coated body

with Ryton chamber
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
Heads Digital Smart Reed Switch LCD Resettable Non-resettable

Pulse 1000 ppL* Pulse 60.6 ppL* Litres dec.pt Mechanical Totaliser
For 20mm (Round J-Box) (square & grey/green) +Rate Display & Pulse Output 60.6 ppL
WARNING: Pulse output value (PPL) changes for the fitted body size. WARNING: Use correct LCD head (size is on lid) for body size.
Now with Vibration Free technology -DSP
A Range of special
sealing gaskets in
Viton or EDPM
and Bases available.
New Compact Standard Standard or Ryton

Body –MES20N (gunmetal) Chamber + Teflon Coating
for Acidic liquids (black) Various Body Sizes
for 20, 25, 32, and 40mm Ø pipes
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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.
• Measuring chamber with nutating (wobbling) disk

o Has a chamber that has inside it a nutating (wobbling) disk that creates fixed-volume discrete “parcels” from the passing liquid.
• Chamber is magnetically coupled to the pulsehead

o The volume of the liquid that passes the chamber is found by counting the number of “parcels” (i.e. the number of revolutions of the
nutating disk).
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MES20 Flowmeter – Installation - Rating IPxxx IP (Ingress Protection) Rating
against solid
against liquid
against mechanical impact (often omitted)
Protection Interpretation Protection Interpretation

rating against rating against
solids liquids
X No specific protection X No specific protection
0 Inherent degree of protection 0 Inherent degree of protection
1 Protected against solid objects larger than 1 Protected against drops of water
50mm. (eg. accidental contact with the falling vertically.
hand)
2 Protected against solid objects larger than 2 Protected against water drops falling
12mm. (eg. accidental contact with finger) at up to 15 degrees from vertical.
3 Protected against solid objects larger than 3 Protected against water drops falling
2.5mm. (eg. tools and wires) at up to 60 degrees from the vertical.
4 Protected against solid objects larger than 4 Protected against splashing water
1mm. (eg. fine tools and wires) from all directions.
5 Protected against quantities of dust that 5 Protected against jets of water from all
could interfere with satisfactory operation directions
6 Completely protected against dust 6 Protected against jets of water of
similar force to heavy seas.
- - 7 Protected against the effects of
immersion.
- - 8 Protected against the effects of
submersion.
http://www.greenhouse.gov.au/lgmodules/wep/toolkit/streetlighting/street_ip.html
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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.
• Direction: Arrow on meter body must coincide with flow direction.

• Orientation: in any plane, except upside down
(to avoid deposits in chamber magnetic drive section).
• Filter: can pass small impurities & has internal strainer,

but if liquid contains granules or many impurities, a filter box or strainer may be
fitted before the flowmeter (800 micron cartridge filter recommended).
• Install any regulation valve preferably before the flowmeter.
• If injecting into water line, a solenoid may be needed at the discharge point
to avoid syphoning.
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MES20 Flowmeter – Installation - Wiring
• To avoid water ingress into electronics, ensure To Wire:
• Remove colour cap
cable entry glands are secure and loop cable down. • Open Junction Box lid
• Pass cable through
cable gland
• Strip cable ends
• Fit to terminal connector
• Check wiring
• Tighten gland
• Electrical connections: • Close Junction Box
For PNP input (12 – 24 VDC) Current limiting resistor

fit a 1.5 – 1.8K resistor and debounce capacitor
(value depends on input impedence). are fitted.
• Interface cards are available to scale output pulses.

• To avoid interference, use only shielded cable.
• Ensure only regulated DC voltages used (when using external power).
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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
Pulse Shielded Cable Pulse

+12VDC +12VDC
shield (-) shield
Do not Earth shield at flowmeter Shield goes to Earth internally
Flowmeter Batch Controller
Pulse Aluminium sheath Pulse

+12VDC +12VDC
(-) shield bleed wire Earth touches the aluminium sheath which then
(-) shield
acts as a shield.
Do not Earth this end Shield goes to Earth internally

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MES Flowmeter – Installation -Multiple
Multiple wiring and plumbing MES20 installation examples
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
• Don’t exceed recommended maximum flowrate*

(75 Litres/min for MES20) - damage/overdose can occur.
• Must have full pipe at all times: Flow direction arrow
o For accurate measurement,

o To avoid dry chemical deposits (through exposure to air)
o Fouling meter chamber
• A calibration check is recommended every 6 to 12 months.

• Replace chamber if accuracy out by > 5% (low replacement cost).
* Note: The higher the Specific Gravity of the liquid, proportionally the lower the maximum flowrate.
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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)
Available as a complete flowmeter, or pulse-head only

(which is interchangeable with the MES20 / MES20-N pulse-head).
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.
• Push in the locking pin with a screwdriver.
Locking pin
MES20 Body Types MES20-N

V1,V2,V3 V1 from
fr. June.2018
• 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
Old Body Current Body New Body
20mm v1, body discontinued.

Couplings and Gaskets
still available. V2, V3 V1-new(compact fr. June.2018)
• 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
(3) Remove baseplate and base seal ring.

(4) Using long nose pliers, pry and pull out white strainer/
locator, so unlocking the measuring chamber assembly.
*Note: Don’t lose strainer, as it also acts as a spacer/positioning
element.
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
• Always perform a calibration check of the flowmeter after any service.
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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
Ceramic Magnet (-CSM) Ceramic-Barium Magnet c/w MES20-N compact profile

(Black driver shaft) Plastic Shroud (White driver shaft) flowmeter chamber with
For upgrade of old chambers Supplied as standard issue Ceramic-Barium Magnet Shroud.
Over the last 50 years ingredient composition of liquid chemical admixtures have changed.
ManuFlo as a result have also introduced improvements in material technology to maintain New
compatibility and suitability of use.
From 1st July 2016: MES20 flowmeters measurement chambers are fitted with
Ceramic-Barium Magnet Plastic Shroud magnet, the latest magnet technology to cater for
many liquid additives. Standard ferrite magnet types can be upgraded with the Ceramic magnet with
black glass/nylon driver on the measurement chamber which provides higher resistance to the
newer chemicals that may affect the standard magnet.
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PRODUCT UPDATE BULLETIN
May 2018
Page 1
MES20– Introducing Upgraded Flowmeters MES20N

Specification Parameter Original Models New Models Difference Inter‐changeable
MES20 (since 1995) MES20N (from May 2018) MES20 MES20N
Insertion length end to end 191 mm 191 mm None Yes
Connection thread ¾” BSP ¾” BSP None Yes
Pulse Head & resolution Transistor, 1000 PPL DIGITAL‐DSP, 1000 PPL None Yes (same pulse head)

LCD head Reset Total &/or Flow Rate Reset Total &/or Flow Rate None Yes (same LCD head)
Performance (Full range) Acc. +/‐ 1.5%, Rate:+/‐0.2% Acc. +/‐ 1.5%, Rate +/‐ 0.2% None Yes
Measuring chamber type Nutating disc with Nutating disc with Slightly lower dome height No

shrouded mag. shrouded mag. but with
Improved chamber Faster Flowrates
Meter body / base plate / base Gun metal / nylon / Gun metal / nylon / Slightly lower height size, (YES – for some parts)
sealer gasket ring NBR rubber NBR rubber lighter weight.
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).
May 2018
Page 2
MES20 flowmeters – Introducing new improved model MES20N-(DSP)
- with new “Digital Smart pulse” SAME PHYSICAL

INSERTION LENGTH
SAME LCD HEAD
Existing
NEW
68mm
59mm
SAME PULSE
HEAD
Existing
NEW
Existing NEW
May 2018
Page 2
MES20 flowmeters – Introducing new model MES20N - parts disected
Nutating disc., Roller, Shutter Plate , Filter Spacer, Chamber Gasket, 20-5N complete chamber, Bottom body gasket, Body casting
Existing
Chamber bottom ½ Chamber Top ½

Base Plate, S/S310 /316 screws x4
20-5N CHAMBER PARTS MES20-N dis-assembled

MES Flowmeters - Components
Or USE MAGFLOWS
MES Ryton-MTL Chamber (-S)

Order Code: 20-5-S (for 20mm flowmeter only)
For highly aggressive-chemical/Petroleum-resistant AMM 15/20/25mm KMS 004-150mm
measuring chamber and seals.
(Dark brown in color)
MES-CSM Higher Chemical Resistant Magnet - Conversions

Old MES standard chambers can be optionally returned for cleaning / upgrading and be fitted with
Ceramic magnet with black glass/nylon driver fitted on the measurement chamber which allows
higher resistance to chemicals that may affect old standard magnets. The flowmeter order code with
the ceramic magnet option for 20mm is 20-CSM.
(NOTE: CSM Chambers with red/yellow drivers should be returned for upgrade to stronger black
glass filled nylon driver shafts (part # 20-DST).
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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
NEW Compact Chamber

20mm size: Part # 20-5-N
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
• Always perform a calibration check after any service.

• For admixtures we recommend a calibration test in 1 year cycles.
• MES pulseheads can be swapped between different flowmeter body
sizes provided the Pulses per Litre setting is changed accordingly in the
ME2000 / ME2008 / ME3000 / ME995-7 / UIC or other scalable devices.
• All ME995 Batch Controllers (except ME995-7 and ME3000)
are only for use with MES20 / AMM15-20 / or other 1000ppl flowmeters
(because of the fixed 1 pulse/1ml. input needed to Batch Controller).
• 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).
• If in doubt, call ManuFlo.
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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
KMS K-Mags New

• No moving parts.
• No blockages.
•Ideal for high volume batch . plants
• Virtually and or aggressive liquid batching
applications
maintenance free. •e.g. Colour Oxides, Slurries,
Silica-Fume, Grout mixes.
•Sizes: 15 – 150mm.
KMS100 series KMS300 series
•Series flow range: 0.5 – 10,000 LPM
• Displays Flowrate & resettable total.
•Pulse & 4-20mA output.
•Dual Forward and Reverse Pulse
•Empty pipe detection
•Many other logic outputs
. •For liquid conductivity ≥ 5µS/cm.
•AC or DC powered.
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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.
NOTE: If unsure send a liquid sample to ManuFlo for suitability testing.
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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
• Increased costs incurred

• Possible lower resolution - flowmeter pulse may represent a larger liquid unit quantity
e.g. MES20 = 1000 pulse/Litre, MES25 =555 pulses/Litre.
• Accuracy can suffer if small quantities are attempted batched quickly.
• Not suitable with standard Batch Controllers models ME995-1 to ME995-6
(they are for MES20 1000ppl flowmeters). For larger flowmeters, use only
Batch Controllers ME995-7, ME995-7D, ME995-7D-S or ME3000 with K-factor calibration
adjustment, or use ME2000, or UIC Interface cards to interface to computer.
• If injecting into water line, flowmeter selected must deliver the admix within the time
cycle prior to end of water batch cycle ManuFlo ®™ 56
Plumbing Install Guide (Admixtures)
Selection of Pipeline Diameters
► For low flowrates and small batch quantities of liquid (approx < 2000mls),
use ½” diameter pipe or hose (after the flowmeter).
► For medium to high flowrates, use ¾” to 1” diameter pipe.
► For very high flowrates, use 1¼”.
NOTE: Pipeline can be

• Flexible reinforced hose (NOT flexible expandable soft hose)
• Rigid PVC
• Metallic
• For higher density chemicals, higher head requirements or injecting into water lines,
consider positive displacement pumps to maintain or increase flowrates.
• 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.
DRAFT PAGE ONLY TO BE COMPLETED.
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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
Note: This method of restriction of flow eliminates air being counted by

MES flowmeters when admix storage tank is empty.
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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.
outlet line optional Solenoid – to

Batch
above level of Controller
prevent Venturi effect
Storage Tank when injecting into
optional 3-W ay Valve water lines.
(most common)
Contactor (calibration point)
ADMIX
tank Non-Return
STORAGE Valve Filter Gate Valve Flowmeter Non-Return Valve
Valve
TANK restricts flow
PUMP
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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:
• Flowmeter is clutching, or chamber is worn out.

Clutching can cause more liquid to be dispensed than is measured, but if significant
then the ME995 or ME2008 Systems will Pulse Fail consistently.
 clean or replace chamber.
• After flowmeter, any restriction (e.g. valve) at end of flexible hose will
allow expansion of hose line in hot conditions, introducing a
contraction/expansion “squeegee” effect that affects the amount
dispensed at the end of a batch.
 move restriction to before flowmeter;
valve
 use rigid/reinforced hose/pipe.
• Fluid particles block meter.
flowmeter flexible hose
 clean measuring chamber;
 install filter prior to flowmeter (800 – 1000 micron recommended).
 or replace with MAGFLOWS
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6.
with Batch Controllers
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Batch Controller starts and stops
Batch Controller flow so that a requested quantity
00.0 is accurately dispensed.
Contactor

Gate Valve outlet line at
(calibration point)
Admix Storage Tank
Storage tank
Non-Return
Valve
Tank Filter Valve Non-Return Valve Solenoid (OPTIONAL)
Pulse Output
Pump Flowmeter
e.g. MES20
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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(1) Operator sets
batch quantity Batch Controller
00.0
Contactor

Gate Valve Outlet line at
(calibration point)
Admix Storage Tank
Storage tank
Non-Return
Valve
Pulse Output
Pump Flowmeter
e.g. MES20
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(2) Operator presses RESET,

then STARTs batch.
00.1
All
LEDs off.
Batch
Contactor
Controller

(calibration point)
same level as
Admix restricts flow
Storage Tank
Storage tank
Non-Return
Valve
Pulse Output
Pump Flowmeter
e.g. MES20
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(3) Batch Controller
starts pump / opens solenoid
to start flow.
02.1
Contact Drive
LED goes on.
Batch
Contactor
Controller

(calibration point)
same level as
Storage Tank
Storage tank
Non-Return
Valve
Pulse Output
Pump Flowmeter
e.g. MES20
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(4) Batch Controller monitors
pulses from flowmeter to
determine quantity delivered.
03.4
Contact Drive & FLow

LEDs on.
Batch
Contactor Controller

(calibration point)
same level as
Storage Tank
Storage tank
Non-Return
Valve
Pulse Output
Pump Flowmeter
e.g. MES20
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(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

(calibration point)
same level as
Storage Tank
Storage tank
Non-Return
Valve
Pulse Output
Flowmeter
Pump e.g. MES20
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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
NEW MODELS: ME999 - MLS./LITRES Multi‐role programmable batch controller (with USB log) New

2018
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Older Model Batch Controllers – ME188 Series
ME188 Built 1982 to 1994 ME995 Built 1995 to present
ME188-1 superseded by ME995-1A
ME188-2 superseded by ME995-2C
ME188-3 superseded by ME995-3K
ME188-6 superseded by ME995-6
ME188-7 superseded by ME995-7
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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.
• 5 Digit LED display.
• 4 x LED status indicators. *
• Variable doserate selection. Doserate

mls x 10 per 100kg
• Display counts in total millilitres of dosage. max 99 x 10
• Preact function and preset maximum limit
Shows Total
• Missing pulse detection Dosage in ML
• Interchangeable with earlier ME188 models
• For use with Manu MES20, MEA15 1000 ppl flowmeters.
• Optional PLC and computer interface. Batch Quantity

up to 9000, increment 10
• Mainly used in computer/PLC controlled batch plants
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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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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.
For use with ManuFlo MES20-S, MES20-S-T, MES25, AMM25 etc

and other flowmeters where pulse output values are NOT 1000 ppl.
K-Factor adjustment U,T,H 90.0

(units/tens/hundreds)
Turn the flat shaft pointer
to the desired calibration
Setting value.
ME995-7D-S 3 dial to 90.0 Litres
e.g. MES-S-T
UTH = 580 (HTU=085)
i.e. 85 pulses per 0.1 litre.
900.0
Pre-act (overflow deduct)

Final Calibration:
•If the liquid collected is higher than value shown on display, then decrease the calibration input set
value (K-factor) by the same % difference.
•If the liquid collected is less than value shown on display, then increase the calibration input set value ME995-7D 4 dial to 900.0 Litres
(K-factor) by the same % difference
•Note: Finally then set the Pre-Act to compensate for ant overrun from batch target..
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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.
PREACT KNOBS at rear of batch controller
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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
• Total Litres selected was 11.2 Litres

• Actual quantity delivered shown on display was 11.4 litres
• Overflow is 0.2 Litres
• Set the Preact to TENS=0 and UNITS=2
• 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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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
Dose Overflow = 60 kg x 10 x 10 mls = 60 x 100 mls = 60 mls = 60 mls overflow

100 kg 100
Set the preact to HUNDREDS=0 and TENS=6 (0x100 + 6x10 = 0 + 60 = 60 mls)
MILLILITRES PREACT For pure volumetric selection controllers:

HUNDREDS TENS Models: ME995-1, -4, -6 and -7 simply
if you selected 1000 mls but at
batch complete the display shows
1110 mls, then simply set the rear
pre-act knobs to 110mls.
(Hundreds = 1 & Tens = 0).
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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
MILLILITRES PREACT
HUNDREDS TENS
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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.
What should preact be set to?
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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
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.
BATCH LIMIT (LM): DOSERATE LIMIT (DRLM), on Doserate models only:

• The maximum permissible batch is determined by the internal limit value. • The maximum permissible doserate is determined by the internal limit value.
• The factory setting is always at the maximum value. • The factory setting is always at the maximum value.
• The limit setting can be reduced by simply desoldering the limit lead wire (connected • The limit setting can be reduced by simply repositioning the limit wire at the rear of
to the rear of the rotary switch solder pads) and resoldering to set the desired quantity. the rotary switch solder pads.
DRLM limit wire (on Doserate models only)

T2 initial start cap
T1 flowrate cap.
LM limit wire
Note: Setting are

programmable
in the ME3000. To access PCB, unscrew 6x screws
located at rear of controller case.
Rear view of ME995 PCB
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Batch Controller – T2 (Initial Start) and T1 (Flowrate) Timing CAUTION
Factory
capacitor is
+ +
on other
side of
PCB.
Physical mods not

needed for ME3000
Initial Start capacitor T2. T1 flowrate capacitor.
(is programmable). Add Tantalum capacitor in parallel to adjust. Add capacitor in parallel to adjust.
Standard factory set values are T2: 1 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)
1 µF 1.5 seconds 0.01 µF 30 Hz

2 µF 3.0 seconds 0.02 µF 25 Hz
3.3 µF 4.1 seconds 0.03 µF 20 Hz (low flowrate MES20)
4.7 µF 5.8 seconds 0.1 µF 07 Hz
0.2 µF 03 Hz
1.0 µF 0.2 Hz (PSM20-T flowmeters)
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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.
Doserate Limit wire is connected to

the right-most installed Doserate dial
(as seen on this view). 1N4148 signal diode
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
Start pad of Limit Wire is marked LM
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.
Batch Limit Values, According to LM Limit Wire Position
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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.
DHB - DUAL HOUSING BOX

DHB2 - DUAL HOUSING BOX
Order Code Description

SHB Single metal box (houses one ME995)
SHB1 Single, with contactor, pump outlet
SHB2 Single, with 2 contactors, 2 pump outlets
DHB Dual metal box (houses two ME995s) HB2500/2510 - WATERPROOF ENCLOSURES
DHB2 Dual, with 2 contactors, 2 pump outlets Order Code
DHB3 Dual, with 3 contactors, 3 pump outlets HB2510 IP65 Enclosure with S/S316 hinges
-T Terminal strip entry (in lieu of outlets) Options
-SSR Start/Stop/Reset command buttons.
-C240 Contactor, internally wired. 15 Amp, 240vac, 1phase.
Select a good viewing AND operating position for the Batch Controller.
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Batch Controller Housing Box - Use
Do not install ME995 / ME3000 with

SHB/DHB metal boxes in areas exposed to
rain or wash-down areas. If so use the
HB2510 IP65 waterproof/dust proof box
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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
External dimensions 206 L, 130 H, 90 D mm

Fuse Preact knobs -
Panel cutout 190 L, 122 H mm to adjust for overrun.
Weight 1 kg
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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.
• In winter, liquid can thicken because of

the cold, and so can flow slower.
If Pulse Fail continually occurs in winter
on a ME995 series Batch Controllers
(Even ME2008’s),
THROTTLE UP PUMP SPEED or
adjust the pulsefail flowrate timing (T1).
Note: The ME3000 Batch Controller (and ME2008) are
programmable, so do not require any hardware modifications.
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Batch Controllers – Troubleshooting
IMPORTANT
Questions to ask the batcher upon a batching problem:
• Which LEDs are on?

• Describe what faults are evident?
•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 !!
ManuFlo ®™ 10
(c) Manu Electronics 2015 3
Batch Controllers – Safeguards
THIS WARNING GUIDE SHOULD

LAMINATED AND BE DISPLAYED AT
PREMIX PLANT FOR THE BATCHER /
OPERATOR !!
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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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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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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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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
Straight mls /m3 selection Straight mls /100kg selection
o 3 dials for direct selection of doserate

o No longer mls x10 calculation required
o First dial is fixed at zero
Introduced due to some batchers miscalculating with the doserate mls x 10 option.
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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
+DC, or ACTIVE CONTACT

Open Contact
Output Drive CONTACT 1
ACTIVE 0v , or NEUTRAL
Rear
+VDC +VDC ME3000
12 – 24
VDC supply
EARTH 0v
(GROUND)
SHIELD (0 v)
Now available with:

TWIN
SHIELDED
PULSE
CABLE
at rear of
-- + Batch
Controller
liquid
Gate Valve Flowmeter Solenoid

(ac or DC)
• 24Vac or 24VDC powered options

• With open contact output drive (to drive any voltage)
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Portable Kits - Batch Controller / Flowmeter Systems
5. Concrete Batch Plant Admix System Kit
 Batch Controller:‐
 order ME995 model of your choice, to suit,
 Batch Controller Housing Box: order housing SHB, DHB, HB2500 options to suit.
 Flowmeters: ‐
 order MES or MM flowmeter to suit.
 Pump:‐
 order pump to suit
 Ancillary Kit:‐
with filter, gate valve, non‐return valve, elbows & camlocks.
Cable:‐
order length of cable from flowmeter to Batch Controller.
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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.
……………… Fitted out complete ready to go.
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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
UIC Interface Card

Flowmeter
measures
flow
Admix pulse/voltage scaling
Pump Storage
Tank
via interface plugs –MC2
Batch Controller ME5IC i/f Card

controls batch delivery i/o scaling and comms i/f
Batching computer
Quantity set by: Computer/PLC sets/records
Delivery controlled by: Batch Controller/MES2000/Computer/PLC batch
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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)
• PC based systems include CompuBatch C500, Axion, Eagle by IPE,

Batch-Tec, Matcon-Matic, United-Software and others
• ManuFlo do not supply Batching Computers but our equipment &

or flowmeters interface with computers in customer installations.
• Call ManuFlo if you are unsure as to the interface required.
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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)
Please consult with ManuFlo if you have any interfacing questions.
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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
Kowloon Hong Kong
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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
MC2 via interface plugs
Batch Controller
controls batch delivery
Batching computer
sets/records
batch
Quantity set by: Computer/PLC

Delivery controlled by: Batch Controller/Computer/PLC In many cases
superseded by ME2008
Eliminates Bottle Requirement
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(A) Interfacing to PLC using – MC2
With PLCs, ME995 or

ME3000 used as a
Set Point Controller, or for
added safety. Located at rear of ME995 /ME3000
(4pin and 2 pin plugs
For safety, when using ManuFlo Batch Controllers in a system controlled by a

PLC/Computer with batch recipe software: on the Batch Controller use the front
selector switches to set the maximum batch limit and/or doserate. Thereafter, in
the event of a flowmeter or PLC malfunction, the Batch Controller will override the
computer and stop the batch.
If unsure about any aspect of installation, please check

the appropriate wiring diagram, product brochure and
trouble shooting guide.
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Model Defaults:
1ml./p = -1 to -6
0.1ltr/p = -7D, -7DS
1ltr/p = -7
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-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.
Inside Batch Controller

Inside Batch Controller
The 2-pin plug provides opto-isolated

The 4-pin plug allows an external PLC to command a
open collector 5-25VDC
Batch Controller (to start/stop/reset the Batch Controller) via
(maximum 120mA via the internal 4N33 opto)
a volt-free momentary (minimum 0.5 second) contact that actuates the
pulse output to the PLC inputs.
internal 12 VDC of the Controller’s Start/Stop/Reset signal.
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(B) Interfacing PLCs – with ME5IC Superseded by ME2008.
1 pulse = 1 ml
-5P interface
MES20 Flowmeter Batch Controller ME5IC Computer/PLC
ME5IC:
• Interface card (1 to 5 channel options)
• Provides interfacing of ManuFlo Batch Controllers to Computer / PLC.

Primarily designed for interfacing to American Command-Batch, Eagle, Alcon and Jonel industrial
computer batching systems (which only have a PLC Start & Hold batch active drive – no stop signal).
• Enables incorporation of the Batch Controllers and their safeties to the Computer/PLC batch
system, and provides an independent backup batch facility.
• Used with ME995 Batch Controllers only. (not ME3000)
• Batch Controller must be fitted with the “–5P” 5-pin interface plug option.
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123
Slowly Superseded by
(B) Interface Cards – with ME5IC ME2008.
1 pulse = 1 ml
-5P interface
MES20 Flowmeter Batch Controller ME5IC Computer/PLC
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-5 5 channel INTERFACE CARD e.g. ME995-controller/MES20 to Computer PLC,

with pulse dividers, 240vac triac optos, start relays, reset relay, 2metres wired
comms cable, and 5 pin interface plug (Suits Eagle or computers using Opto22
yellow case inputs & black case outputs).
Note: Batch Controller requires the ‘-5P’ plug option to connect to ME5IC-5.
ME5IC-5
ME5IC-4 As for ME5IC-5 above, but 4 channels only (4 admixtures).
ME5IC-2 As for ME5IC-5 above, but 2 channels only (2 admixtures).
ME5IC-1 1 channel interface card, for 1 admixture. ME5IC-1
ME5IC-1W 1 channel interface card, for WATER e.g. use with ME995-7.
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124
Superseded by ME2008.
(B) Interfacing – with ME5IC-5 – Operation

(e.g. 240vac Eagle – 5 channel Admixtures)
(1)
-5P interface
(4)
(3)
Batch Controller ME5IC-5 Computer/PLC
MES20 Flow meter
(2)
Pump
(1) The computer ‘start’ command is via Computer’s Black Opto22.

The Opto stays on for the duration of computer batch cycle.
The start voltage to Batch Controller must be on for at least 0.5 seconds
(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
ME5IC-1 Single channel Card Schematic

5-24 VDC pulse option:
C (Collector)  : connect to Computer pulse input line OPTO (White),
E (Emitter)  : connect to 0.V. input line.
24-240 vac pulse option:
C  : Active line from Computer supply line
E  : 24-240 vac pulse to Computer input pulse OPTO (Yellow).
VARIOUS: Command Voltage start drives 24, 110 or 240VAC or 24VDC
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126
ME995 series Batch Controllers, –5P Interface option
CONT. 1
SHIELD
+12 VDC
PULSE
A
N
EARTH
240vac
F US
E
matching 5-pin plug

(supplied if not using the
ME5IC interface card).
-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
ManuFlo ®™
127
Superseded by
(B) Interface Cards – ME5IC – Troubleshooting ME2008.
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.
ManuFlo ®™
128
ii) Batch Safety Interface
with ME2000/2008 The
Advantage
ME2000 ME2008 ME2000-CV

2, 4 or 6 channel 2, 4, 6 or 8 channel 2 channel Compact
ManuFlo ®™
129
ii) Interfacing with ME2000/2008
ME2008, ME2000 (or ME697)
up to 8 flowmeters
Flowmeter
measures
flow
Admix
Pump Storage
Tank
Batching computer
sets/records
batch
Eliminates Bottle Requirement

In use in Australia,
NZ, HK, Nth China
Safest form of Admix batching

Delivery controlled by: MES2000/Computer/PLC
in computer controlled plants
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130
Interface – ME2000/2008
Flow meter ME2000 Contactor Computer/PLC
Pump
• The ME2000 and ME2008 are microprocessor-based batch safety interface

units for management of flowmetering admixture liquids in the concrete
production industries.
• Designed at the request and requirement of suppliers/producers/users of
construction chemical products.
• A sophisticated safety management watches for any malfunction in the
flowmeter or batch Computer during the batch cycle. If a fault is detected, the
ME2000/2008 will override and shutdown the faulty channel, and will alarm with
a message on the display.
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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
ManuFlo ®™
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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
New Option: -1D 24VDC powered
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
ManuFlo ®™
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Interface – ME2000/2008 - Programming
4-way
New 8CAT5E
with
included
HP-CAT5E
programmer
Old
• Each 2-channel module is programmed one at a time.

• To start programming, push either arrow button (   ), cursor (digit) will flash.
• Push UP or DOWN to change numeric values.
• Push arrows to scroll through the individual numeric settings.
• Once programming is completed, push either arrow button (   ) until no
digits are blinking, data is now entered into memory.
• Unplug keypad, then plug in to next module or CAT5E entry point and repeat
data entry to programme another module.
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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 B Flowmeter B
SINGLE COUNTING CHANNEL

Customer feedback is that some confusion can result due to the comparator function (which is
commonly used in Asia) i.e.
* double display of count per channel; and
* the need to have a wire link to short Flowmeter A and B inputs for each channel.
We are now able to offer the ME2000 / ME2008 with:
* count displayed only for Flowmeter A on each channel (Flowmeter B count is blank); and
* no need for wire link to short Flowmeter A and B inputs.
Channel 1 Channel 2
Flowmeter B With Software Version V1.8
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;
ManuFlo ®™ Manu Electronics 2016

135
Pulse Output Resolution Guide (DC input)
BEST OUTPUT PULSE RESOLUTION VALUES
with MES flowmeters to DC input CommandBatch Computers
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) 
MES20 20mm 10 mls per pulse 0.35 litres/sec. 21 litres/min. 35hz

" " 20 mls per pulse 0.70 litres/sec 42 litres/min. 35hz
" " 30 mls per pulse 1.05 litres/sec 63 litres/min 35hz
" " 40 mls per pulse 1.40 litres/sec 84 litres/min 35hz
“ “ 50 mls per pulse 1.40 litres/sec 84 litres/min 35hz
MES25 25mm 40 mls per pulse 1.40 litres/sec 84 litres/min. 35hz
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
ManuFlo ™ Manu Electronics. 2017

136
Pulse Output Resolution Guide (AC input)
BEST OUTPUT PULSE RESOLUTION VALUES
with MES flowmeters to AC input CommandBatch/Eagle Computers
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) 
MES20 20mm 10 mls per pulse 0.14 litres/sec. 8.4 litres/min. 14hz

" " 20 mls per pulse 0.28 litres/sec 16.8 litres/min. 14hz
" " 30 mls per pulse 0.42 litres/sec 25.2 litres/min 14hz
14hz
" " 100 mls per pulse 1.40 litres/sec 84.0 litres/min
MES25 25mm 100 mls per pulse 1.40 litres/sec 84.0 litres/min. 14hz
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)
ManuFlo ™ Manu Electronics. 2017

137
ME2008 ‐ Typical Settings ‐ MES
ManuFlo ®™
143
ME2008 ‐ Typical Settings – MES P.D.meters
ManuFlo ®™
144
ME2008 – Typical Settings – AMM mags
ManuFlo ®™
145
ME2008 ‐ Typical Settings ‐ KMS/RMS mags
ManuFlo ®™
146
ME2008 ‐ Typical Settings – WATER CHANNEL
ManuFlo ®™
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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
:
onsite to match app./flowmeter. Voltages :
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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.
“Diff Flow” (where used) -Flowmeter Percent difference 5% -Check flowmeters

exceeded (when comparator function is (see comparator function explained)
used)
“Setting Lost” -Power Surge or major power loss to -Check power supply/source
systems -Use handheld programmer to reset the system and re-enter the parameters.
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.
ManuFlo ®™ 145
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).
Fuses and Hardware upgrades

With the advent of 24VDC I/O + powered units becoming the preferred industry standard, coupled with the
Increased number of admixtures simultaneously batched in a load;
• 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
• AC powered units should be returned for upgrade/install & Modification

with an enhanced more powerful 240vac Toriod Transformer.
AC
Alarm outs or non-operation due to excessive current draw
Due to higher current draw, (possible leakage/short of signal cables)
or 5+ admixes batched simultaneously.
Stage the starts drives from PLC with 0.5 - 1 sec start sequential duration,
BUT return the units for upgrade of the regulator for DC units
and the transformer for AC units.
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
ManuFlo ®™ 144
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.
C. Program the ME2008 Input Pulse to following factors:

for MES20-R 20mm : 0061.00 pulses/Litre for new MES20-N DIGITAL SMART PULSE -NO CHANGE still 1000ppl
for MES25-R 25mm : 0034.00 pulses/Litre and same pulse value for 25, 32 and 40mm sizes –NO CHANGE
All other program factors remain unchanged.
D. VERY IMPORTANT
After replacement and programming of pulsehead, take a calibration test before you leave the plant.
If in doubt, phone ManuFlo on +61 2 9938 1425 or +61 2 9905 4324.
ManuFlo ®™ 146
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 !!
ManuFlo ®™
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ME2008 Low and High Flow Limits
Setting the ME2008

To improve the ability of the ME2008 to detect a problem should a batch error occur due to measurement
malfunction, the settings for Low and High Flow must give a narrow operating window, especially with
mechanical flowmeters. ME2008s are programmed according to the conditions of each plant e.g. according to
flowrates and maximum batch quantities.
On each channel of the ME2008:
•the Low Flow setting must be set at 25% of the usual flow rate of that channel; and
•the High Flow setting must be set at 90% of the specified maximum flowrate of the flowmeter on that
channel.
Also, the pump start period should be programmed to atleast 2 seconds according to how quick the flow
stabilizes.
Whilst Batching - Most Important

If a batcher gets a Low Flow Alarm on two successive
attempts at batching, then the batcher must:
o Stop using that channel; and
o Record the quantity displayed on the ME2008 and the
batch computer; and
o Ring your local service provider for assistance.
ManuFlo ®™ 148
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
0.125 L/s e .g. 0.5 L/s 0.975 L/s 1.08 L/s

u s u a l fl o w ra te Fl o wm e te r
o f th e i n s ta l a ti o n. m a x . fl o w ra
LOW HIGH
FLOW FLOW
ENTRY ENTRY
NOTE: Example only. Set the Low Flow setting
in accordance with your site environment.
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155
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.
•14. Push Select: Output Rate (Hz) = Maximum flowrate (l/s) / Pulse output (l/p)
Is a pulse data storage buffer
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156
ME2008 – converting the Pulse output from AC to DC (& visa versa)
DCPM software chip

Can be upgraded by removing
from IC socket.
Gently with a flat blade pry out slightly
each end repeatedly until it comes away
from the socket –Note: polarity
Note polarity on ICs
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)
______________________________________________________________________________________________________________
ME2008 – Disabling manual push button pumps starts

To disable the front manual batch push buttons,
Warning: remove (with pliers) link (jumper) LK1 located on
Turn off power. motherboard near the Alarm buzzer & Capacitor rear
Live 240vac at rear bottom of PCB. This will avoid misuse of manual starts.
where applicable.
Plug-in LK1 to re-activate manual batch functions.
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151
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
For each contactor,

fit a Suppression Capacitor 2-channel module
across the contactor coil
MASTER RESET RST
For 240 vac I/O versions of ME2000/ME2008, as
a precaution against excessive industrial noise, N
N
Suppression Capacitors are supplied, A
to be fitted by the customer across the coil
X1
of each contactor in the field.
ManuFlo ®TM Installer Note: ME2008 – 240v AC I/O considerations

Flow Measurement & Control Products
Please see our website http://www.manuelectronics.com.au/data_sheets.html for full specifications and other products.
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.
ManuFlo ®™
159
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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160
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.
Now compare volume displayed on ME2008 Display and that collected.

If incorrect check flowmeter specification pulse value which must match the input Pulses per Litre (PPL).
Then divided output pulse must match the computer input pulse value e.g. 1 count = 100mls.
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.
UIC Interface Card

MES Flowmeter
measures
flow
Admix pulse/voltage
Pump Storage scaling
Tank
Batching computer
sets/records batch
or AMM Flowmeter
In use in Thailand, Indonesia,
New! Philippines, Malaysia, HK,
Vietnam, Nth China, Singapore
and elsewhere.

Delivery controlled by: Computer/PLC • Usually used for bottle systems in Asia with Computers
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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”
Code: -24DC for 24VDC powered
• switches 5-30VDC, 5-12 VDC powered

UIC/D UIC/D-24DC • switches 5-30VDC, 24 VDC powered
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.
The UIC Universal Interface Card provides:

• signal scaling and
• an isolation interface
1) UIC/A1 : 110-240 vac pulse switching via a triac opto
2) UIC/A2 : 24-250 vac pulse switching via a heavy duty triac opto
3) UIC/D : 5- 30 VDC NPN/PNP (sink/source) pulse switching via a 4N33 opto
4) -24DC : for 24VDC powered option
UIC/A1 UIC/A2 UIC/D
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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).
Use small flat-bladed screwdriver,

insert into switch slot and
turn arrow to desired number.
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Interface Cards - UIC - Scaling
For batching with concrete admixtures, the

Rotary
MES20/MES20S 20mm pulse flowmeters are
decade value
primarily used. Scaling values (x10 input card
HTU Pulse output
standard) :
rate
Final Calibration:
• If the liquid collected is more than pulse value shown 025 5 mls/pulse
on computer screen, then decrease the rotary decade 050 10 mls/pulse
set value by the same % difference. 100 20 mls/pulse
• If the liquid collected is less than pulse value shown on 150 30 mls/pulse
computer screen, then increase the rotary decade set
250 50 mls/pulse
value by the same % difference.
• Note: Final calibration can also be performed via 500 100 mls/pulse
computer software scaling. 999 200 mls/pulse
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Interface Cards - UIC - Calibration
Volumetric Calibration example:

• MES20 flowmeter used.
• 10.1 Litres called on batch computer program.
• 100 mls/pulse set on UIC (HTU=500)
• 10.1 Litres of admixture collected in container.
• 101 counts on computer.
101 x100mls/count =10.1 litres = CORRECT RESULT.
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Interface Cards - UIC - Calibration
Volumetric Calibration Example:

• MES20 flowmeter used.
• 10.1 Litres called on batch computer program.
• 100 mls/pulse set on UIC (HTU=500)
• 10.3 Litres of admixture collected in container.
• 101 counts on computer.
INCORRECT RESULT. This is

10.3
------ = 102% or 2% excess admix, so
10.1
• subtract 2% from the current HTU=500 setting i.e. set HTU= 500-10 = 490.
• Batch again, result should BE CORRECT.
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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
1 pulse = 1 ml divided pulses
+12VDC
start drives
drives
Pump This setup is

superseded by ME2008
MES20 Flow meter
ME693N
Still in use in NZ,
Indonesia Computer
+12VDC
drives
Pump This setup is now

only used in Indonesia & NZ
MES20 Flow meter
ManuFlo ®™
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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.
Limits x Divided pulse

4 = 64 x PulseDiv
3 = 128 x PulseDiv
2 = 256 x PulseDiv
1 = 512 x PulseDiv
PCB is fitted to lid cover.
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Interface Cards – ME697
Limit x Divided pulse
1 ON only = / 10 ( 10 mls per pulse) 4 = 64 x PulseDiv

4 ON only = /100 (100 mls per pulse) 1 = 512 x PulseDiv
(1) Pulse Division setting (2) Limit x Divided Pulse
Pulse Division = 10 mls per pulse Limit = 128 x Pulse Division

= 128 x 10 mls
= 1280 mls
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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%
• 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
• 20mm resetable flowmeter.

FRT303 Indicator • Ideal for batching.
MM15 • LCD shows Flowrate, • 5-digit LCD shows total Litres
• or shotcrete applications. resetable Total and to 1 decimal place +Rate.
• All S/S316 construction, pressure to 16bar. Grand Total. • Closing lid resets Litres count.
• Very compact. Light weight. IP67. • Programmable. • Flowrange @ ±1.5% accuracy:
• 10mm bore, • DC or AC powered 1.5 - 75 Litres/min.
15mm BSP (male) threaded ends. • Pulse & 4-20mA outputs • Nutating-disc type replaceable
• Flowrange: 0.1 - 25 Litres/min. • IP65 enclosure. measuring chamber.
• 100 pulses/Litre.
• Internal Lithium battery powered
• Other sizes available 20, 25mm. • Options:
* Teflon-coated body.
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
Use a range of flowmeters for

PLC operated PLC Batching manual or instruments with
4-20mA output for PLC /
Dosing pump or control valve computer computer control. Bore sizes to
requirement dependant on
installation setup suit flowrate application range.
4-20mA output 4-20mA output 4-20mA output
Admix Power 4‐20mA RMS004 or

Storage control valve other
Tank magflows
Dosing Pump
ManuFlo ®™
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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
ManuFlo ®™
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Use with KMS Electromagnetic Flowmeter
• Unsurpassed accuracy to ± 0.2 %
• Virtually unaffected by varying viscocities
• Sizes from 15 to 150 mm, widest possible flow ranges.
• Handles widest range of aggressive liquids.

• Hasteloy-C4 electrodes (Platinum-Irridium for HCL)
• Virtually maintenance free with no moving parts.

Robust construction for industrial use.
• Eliminates headlosses and need for filters.
• Multi-function display shows Flowrate & Resetable Total.

• Frequency (Pulse), analogue and alarm outputs.
Ideal for:
• Empty pipe detection. Fully programmable via display.
• Manual and automatic-batching
• Fully bi-directional operation.
of aggressive/high-volume
admixtures
• Power: standard 85-265 vac, or optional 11-30 VDC
• Use on truck tankers with TMP System
• Use in Admix production plants
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Flowmeters for Admix Production
For the batching & blending in
production plant
Tanks production
For the tank farm

and admix truck
Admix plant in Singapore
loading point
Portable trolley for
filling IBCs with
Magflow’s
Admix plant in Sydney
Locations include: Dubai,

Egypt, Saudi Arabia, Bahrain,
Indonesia, Malaysia,
Philippines, Vietnam, Thailand,
Laos, Burma, China, HK,
Singapore, Australia, NZ, Chile
and many other sites.
ManuFlo ®™
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10.
Equipment for Water
Measurement
in Concrete Plants
ManuFlo ®™
189
BATCH ROOM
Water Supply Batch Monitor Batch Controllers Resettable Totaliser Slumpstand
OR MRTU4‐GAL25‐T2
(standalone or dual display (‐
P) slumpstand flowmeter)
ME6008M ME3000 ME995-7 ME5‐T‐A

(8 Channel Monitor) (Keypad Version) (Rotary Switch Version) (Dual display slumpstand)
Start/Stop Pulses Open/Close
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  
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
ManuFlo  
NEW MRTU Series ‐ slip insertion flowmeters
__________________________________________________________________________________________________________________________________________________________________________________________
__
Ideal for Slumpstands new
• 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
• Simpler/Easier removal from pipe fitting

• NFC reprogramming feature
• Easy access to recalibrate
• New robust lid design
• With pulse output option
• NEW Larger Easy Read 4 digit LCD display
Replaces the
MRPU5 series
50mm for plant water

ManuFlo ®™
Slumpstand To Batchroom Full Options
SLUMP STAND BATCH ROOM
UIC/A
AC pulse converter interface card
5-12 VDC, or 24VDC powered versions
AC
computer
MRPU5 input
resetable
flowmeter
ME5 Batchroom Counter:

-P MRTU4-GAL25-T2
pulse ME5-T-D
5-25VDC powered
output
option
new with DC pulse output
or
ME5-T-A
GAL25M (a) Hardwired -up to 250mtrs. 240 VAC powered
with DC pulse output
pipe
adapter
(only if computer input
is high speed)
DC
computer
input
Power (b) Wireless – to 150mtrs
Supply
(i) 12-24 VDC

powered
- 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
• These units resist severe water hammer “-P” pulse option

• Can be run and max. flows speeds For logging
• Impervious to sudden pressure air blasts MRP20-T2 MRT20-T2 data collection
• Clean/bore/grey water no problem 1/1ltr output.
• No filters required
Update your concrete
delivery truck or with a
MRP or MRT reset
flowmeter.
ManuFlo ®™
194
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.
LCD in Normal Mode

Shows Total
1234.5
SET SET
(1) Press SET to enter (4) Press SET again to
Calibration Mode. return to Normal Mode.
LCD in Calibration Mode

Shows Calibration Value C : 0200
Calibration Value
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).
ManuFlo ®™
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Heavy Recycled Water - Measurement - Solution
BATCH ROOM
Batch Controller
Plant Open/close
Recycled feed Computer OR
UIC/D for Heavy Recycled Water

replace RPFS with
Magflows from ManuFlo
Start/Stop Pulses
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
Moving Parts No Moving Parts
ManuFlo  
MANU ELECTRONICS
PTY LTD

23/04/18R1-PK
OPTIONS:- Flow Metered Plant Water
Batching via PLC/Computer Control
1/ RPFS-P Paddlewheels for fresh water Optionally incorporated into a
ME2008-8 Interface ADMIX unit
2/ KMS or RMS Magflows for fresh & recycle / slurry water
NEW !
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
ManuFlo ®™
197
Interface Cards – UIC for Water Batching
Flowmeter UIC Computer/PLC
The UIC Universal Interface Card provides:

• signal scaling and
• an isolation interface
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 ®™
198
Interface Cards - UIC – scaling for Water Batching
• interface cards are available to scale output pulses.

• to avoid interference, use only shielded cable.
• make sure only pure regulated supply DC voltages used.
• For AC pulse inputs the 15Hz maximum pulse
speed rule applies.
• For DC inputs 40Hz or high speed with some PLC’s
For batching with water lines, the RPFS Rotary

paddlewheel and Magflow flowmeters are decade value
primarily used. Scaling values (x10 input card HTU Pulse output
standard) : rate
Magflow with10ppl
Final Calibration:
• If the liquid collected is more than pulse value shown
on computer screen, then decrease the rotary decade 050 DC 1 Litre /pulse
set value by the same % difference. 100 AC 2 Litres/pulse
• If the liquid collected is less than pulse value shown on 200 4 Litres/pulse
computer screen, then increase the rotary decade set
250 5 Litres/pulse
value by the same % difference.
• Note: Final calibration can also be performed via 500 10 Litres/pulse
computer software scaling.
ManuFlo ®™
199
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
Large range of pipe adaptor fittings
For Fresh, Mild Recycle

and Hot Water applications
ManuFlo ®™
200
11.
Other Equipment
ManuFlo ®™
201
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)
ManuFlo ®™
202
Other Equipment
ME6008M Batch Monitor Printer Driver Unit
ME6008M Connection Diagram
ManuFlo ®™
203
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.
ManuFlo ®™ 145
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
ManuFlo ®™
205
11a.
YES WE REPAIR ITEMS
& Supply spare parts
• Batch Controller reconditioning
upgrades and modifications
• Flowmeters reco’s
• ME2000/08 upgrades
• In‐house calibration tests
ManuFlo ®™
206
12. QUIZ / QUESTIONAIRE COMP.
• 10 Questions for a Prize
. .
ManuFlo ®™
207
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 8 ‐ If the none return valve after the flowmeter is faulty what alarm might you expect on the ME2008? (1 pt)
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 pt)
Question 10 ‐ When would you consider using an alternative flowmeter such as an electro‐magnetic? (1pt)
ManuFlo ®™
208
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)
ManuFlo ®™
209
13.
General Advice
If unsure contact ManuFlo
for advice or obtain datsheets
on our website.
ManuFlo ®™
210
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.
ONLINE TECHICAL SUPPORT GUIDES / DATASHEETS:-

http://www.manuelectronics.com.au/technical.html
ManuFlo ®™
211
15.
Questions
• Questions?
• Improvements?
• Product design suggestions?
CapMag. ME999 ME2020
ManuFlo ®™
212
ManuFlo
® TM
Flow Measurement Products
a division of

41 Carter Road, Brookvale
Sydney NSW 2100 Australia
Ph: +61 2 9938-1425
+61 2 9905-4324
Fax: +61 2 9938-5852
E-mail: sales@ manuelectronics.com.au

web : www.manuelectronics.com.au
www.manuflo.com
ManuFlo ®™
213

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Admix & Water Batching Equipment

Advanced Training Guide

2. Measuring Admixtures, Silica-fume flowmeters,

4. MES Flowmeters & other flowmeters. 11. Other Equipment / Repairs

5. Achieving Faster Delivery Flow Rates 12. Quiz Questions

6. Semi Automatic Batching with 13. General Advice

• From bottle dispenser manufacturer in the 1960’s

• January 2000 - Moved to new 600m² office and manufacturing facilities

• June 2001 - ManuFlo ®™ worldwide trademark

Phil King - Sales Engineer

Vicki / Erica - Office Admin. / Accounts / Logistics

Mitch Z. - Electronics Engineer / Technical Support

Bill / Harry - Specialty Product Support

Matine / John - MRP / MRT products

- and the silent team

ManuFlo products are:

Admixture Production Admixture Delivery Premix Concrete Concrete

And Liquid slurries, Oxides, Grouts, Silca-Fume

Shotcrete Pug Mill / Dosing

Flow Metered Measurement for Liquid Admixtures

MES Series Flowmeters

AMM Series Flowmeters

KMS & RMS Series Magflows

ADMIX Batch Plant – Instrument Selection Guide

Type of Concrete Plant Typical Dispensing Instrument Description

Does excessive vibration cause an issue with Possibly if incorrectly installed (MES‐P versions).

Flow Metered Measurement for Batching - Points

Flow Metered Measurement for Batching - Points

ManuFlo Flowmetered Systems since 1965.

ManuFlo Flowmetered Systems since 1965.

Pictured a batch plant in California -USA ManuFlo ®™

• Slow discharge time, Double handling.

• Messy, Large & cumbersome, Extra maintenance, Expensive

• Risk: bottles are pressurized - can explode.

• Quick exhaust valves can fail – not completely safe or foolproof.

• Replace your bottles now, save ongoing maintenance costs:

Flowmeter with display

Quantity determined by: operator

optional 3-Way Valve

Quantity set by: operator

UIC Interface Card

Direct Flowmeter Pulses

via interface plugs –MC2

Batch Controller ME5IC i/f Card

Black Teflon coated body

Heads Digital Smart Reed Switch LCD Resettable Non-resettable

Now with Vibration Free technology -DSP

New Compact Standard Standard or Ryton

• Measuring chamber with nutating (wobbling) disk

• Chamber is magnetically coupled to the pulsehead

Protection Interpretation Protection Interpretation

• Direction: Arrow on meter body must coincide with flow direction.

• Filter: can pass small impurities & has internal strainer,

• Electrical connections: • Close Junction Box

For PNP input (12 – 24 VDC) Current limiting resistor

• Interface cards are available to scale output pulses.

Pulse Shielded Cable Pulse

Do not Earth shield at flowmeter Shield goes to Earth internally

Flowmeter Batch Controller