The Micro Series batch controller is a powerful and highly accurate production workhorse in the form of a compact 1/8 DIN panel meter. It can display the current batch total (Item #1), grand total or number of batches (Item #2), and flow rate (Item #3). All displayed values are scaled to engineering units of volume or flow.
The batch controller utilizes the Extended counter main board and FR dual channel signal conditioner board to accept a wide range of pulse signals, in particular those from turbine flowmeters. The same signal is applied in parallel to the A and B channels.
A 8A contact relay serves as the batch relay to control repetitive fill operations. It repeats the batch cycles continually with a programmable delay from 10 ms to 199.99 sec, or based on an external control input. The batch total (Item #1) can be set up to count up from zero to a preset limit, or down from a preset limit to zero. The single-relay board fits in the slot which would otherwise be available for the analog output board.
An optional dual relay board (8A contact or 0.12 A AC/DC solid state relays) is normally used. Either relay can be assigned to the batch total (Item #1) to serve as a pre-warn to slow down filling near the setpoint, to the grand total or number of batches (Item #2), or to flow rate (Item #3).
An optional RS232 or RS485 boardallows the batch controller to transmit Items #1, #2 and #3, as well as peak for #3 (rate). If required, all four items can be displayed simultaneously by augmenting the batch controller with up to three Micro 1/8 DIN remote displays. Each of these can have its own analog output and dual relays for alarm or control.
Fast, High Resolution Measurement
The A and B channels of the FR dual-channel signal conditioner are used independently. Either channel can accept pulse rates from 0.005 Hz to 250 kHz, which exceeds the working range of turbine flow meters.
Channel A is used for totalizing. The measured total is scaled mathematically for control and display in engineering units, such as liters.
Channel B is used for rate. The pulse frequency is determined by timing an integral number of periods over a specified gate time (plus 30 ms and 0-2 periods), and then taking the inverse of period. The inverse period approach allows much greater accuracy and faster update times than conventional rate meters which count signal pulses over a specified time interval. Update times can be as high as 25/sec. Rate in engineering units, such as liters per second, is obtained by multiplying the input by a scale factor.
For either total or rate, displayed values can be up to six digits (999,999) with a selectable decimal point.
Flowmeter Signal Conditioner
The FR dual-channel signal conditioner accepts pulses from all types of turbine flowmeters and most industrial transducers with a pulse output such as proximity switches with PNP or NPN output, TTL or CMOS logic, magnetic pickup pulses down to 12 mV, as well as AC inputs up to 250 Vac. Jumper selections provide optimum operation for different sensor types and noise conditions.
A built-in isolated 5, 10, or 24 Vdc excitation supply can power proximity switches and other sensors, and eliminate the need for an external power supply.
Micro Series batch controller can be powered from 95-240 Vac ±10% and 95-370 Vdc, or optionally from 12-34 Vac and 10-48 Vdc. Any setup functions and front panel keys may be locked out for simplified usage and security. The ability of the Micro batch controller to drive an isolated 4-20 mA or 0-10 V output signal which tracks a total may be unique among batch controllers.
The popular 1/8 DINversionwith 0.56″ high digits is environmentally sealed to NEMA-4X (IP65) from the front when panel mounted, and is available with red or green LEDs. All power and signal connections are via UL / VDE / CSA rated screw clamp plugs, which are standard.
6 digits, 7-segment
Available with 0.56" or 5.0" digits.
High brightness red. Green available with 0.56" digits.
-999999 to +999999, XXXXEX scientific notation beyond 999999
Four LED lamps
Pulses from NPN, PNP transistors, contact closures, magnetic pickups, AC
Common ground for channels A & B
Channel A Frequency
0 Hz to 1 MHz (totalizing), 0.005 Hz to 1 MHz (rate)
Channel B Frequency
0 Hz to 250 kHz (totalizing), 0.005 Hz to 250 kHz (rate)
-12 mV to +12 mV, +30 mV to +60 mV, -30 mV to -20 m),
-150 mV to +150 mV, +350 mV to +600 mV, -600 mV to -350 mV,
-1.15V to +1.15V, +1.25V to +2.1V, -2.1V to -1.25V
Selectable: 1 MHz, 30 kHz or 250 Hz
Selectable: 0, 3, 50 ms
Delay between batches
Selectable 10 ms to 199.99 s
Display Update Time
Same as conversion time
Output Update Time
Same as conversion time
Crystal calibrated to ±2 ppm
±1 ppm/°C (typ)
95-240 Vac ±10% and 95-370 Vdc
12-34 Vac and 10-48 Vdc
DC or 49-440 Hz
Safety-rated to 250 Vac, meter ground to earth ground,
DC to 60 Hz, 4.2 kVp per High Voltage Test
5 Vdc ±5%, 100 mA max
10 Vdc ±5%, 120 mA max
24 Vdc ±5%, 50 mA max
50 Vdc to meter ground
0°C to 60°C
-40°C to 85°C
95% at 40°C, non-condensing
NEMA-4X (IP-65) when panel mounted
Drum Filling Application Utilizing Three Relay Outputs
In this drum filling application, the Micro batch controller utilizes its maximum of three relays to control the pump.
The Prewarn relay slows down the pump near the preset to avoid overshoot. The Batch relay stops the pump at the preset. The Grand Total relay stops the filling operation once a predetermined number of drums have been filled.
Controlling the Mixing of Materials
Multiple Micro batch controllers can be used in combination to control the mixing of materials in the proper ratio. Each feed line is equipped with its own pump, flowmeter, and Micro batch controller.
Controller setup and monitoring of the mixing operation are facilitated by optional serial communications. RS485 allows a single data line to handle multiple controllers.
Up-Counting Batch Control
In up-counting batch control, the Micro batch controller counts up from zero to a preset maximum. A prewarn level is available to slow down filling near the preset to avoid overshoot. A time delay can be programmed from the end of each batch to the start of the next batch.
Down-Counting Batch Control
In down-counting batch control, the Micro batch controller counts down from the preset maximum to zero. A prewarn level is available to slow down filling or emptying near zero. Again, a time delay can be programmed from the end of each batch to the start of the next batch.
Discrete Filling and Batch Counting
The Micro batch controller is ideal for discrete manufacturing as well as repetitive fill operations. In this example, the Micro counts bottles which it then groups into sixpacks. Its Grand Total capability can be used to track bottles or sixpacks.