X.0501-C INSTRUCTIONS Issued User's Manual for the PetroCount® IMS Control Unit Model 0501 Electronic Preset Batch Controller Warning Caution This instrument is designed for use in Itisrecommended tha this publication be read inits entirety hazardous areas. Do notremovecovers before performingany operation. Should thisequipment require before first disconiecting all sources of repair or adjustment, contact the nearest Sales Off power. FRiluretodoso may Itisimportantthatservieingbe performed only by trained and explosion resulting in serious qualifiedservice personnel. Personnel must begrounded, via personalinjury or death. wriststrap or othersafe,suitablemeansbeforeany printed ircuitboard or other internal deviceisinstalled removed or adjusted, Failure tounderstand and follow these instructions ‘could resultin damage totheequipment. DANIEL’:Contents Table of Contents Section 1 Introduction Section 2 Installation Section 3 Startup Section 4 . Software Configuration Using This Manual Manual Organization Control Unit Overview Design Overview Introduction Operations Planning Selection Environmental Considerations Configuration Considerations Installation Tasks Receipt of Equipment Control Unit Mounting Conwol Unit Hardware Configuration Control Unit Wiring Power and Ground Field Signal Data Communication Installation Checkout Installation Checklist Introduction Startup Procedure Energizing the Control Ur Perform On Board Diagnostics Verify Parameter Setting Control Valve Adjustments ‘Two-Stage Control Valves Digital Coatrol Valves Meter Proving RID Setup (Optional) Securing the Coatrol Unit Introduction Accessing the Program Mode Programming the Control Unit Weights and Measures Setup Category Delivery Group Factors Group Alarms Group VO Configuration Group Operatce View Group Ld 12 110 34 Ba Ba 3.2 39 340 340 3.13 315 316 318 41 41 41 42 42 44 417 428 431 4-88 11/15/91 Rev. CiPetroCount® IMS Control Unit User's Manual Section 4 Software Configuration (cont'd) Section 5 Operations ‘Temperature and Pressure Compensation Group Blending Group Data Communications Group Status Category Archive Category Introduction Site Engineer Considerations Input and Output Configuration Meter Signal Input Flowrate Control Calibration Factors Temperature and Pressure Compensation Features ‘Temperature and Pressure Compensation Configuration Data Communications Interface ‘Access Security Loading Arm Position Auxiliary Data Archival Storage Data Logging Batch Blending Weights and Measures Audit Trail Additive Totalization AC Permissive ‘Tesminal Manager Considerations Accessing Secured Parameters Adjusting the Delivery Profile Valve Control Response Setting Preset Limits Using the Operator View Feature Changing Additive Factors Acknowledging Lock Type Alarms Changing K-Factors and Meter Factors Adjusting Blend Recipes Operator Tasks Starting Delivery Method 1 Method 2 Method 3 Method 4 ‘Stopping Delivery Restarting Delivery Acknowledging Alarms 450 455 478 481 493 ii Rev. C 06/27/91Contents Section 6 Troubleshooting General System Troubleshooting 6a Control Unit Troubleshooting 6-4 Appendix A Specification and Reference Data Electrical Specifications AL Environmental Specifications A3 Appendix B Control Unit Replacement Parts List BA Appendix C Parameter Tables C1 Delivery Parameters cr C2 Factor Parameters ca C3 Alarm Parameters GH C4 1/0 Configuration Parameters cal CS Operator View Parameters C51 C6 Temperature and Pressure Compensation Parameters Cot C7 Blending Parameters cr €8 Data Communication Parameters cet C9 Status Category Parameters ol C10 Archive Category Parameters 10-1 Appendix D Control Unit X-Command Summary DA 06/27/91 Rev. C iiiPetroCount® IMS Control Unit User's Manual List of Figures and Illustrations Section 1 Introduction 1.1 Explosion-Proof Control Unit 1.2. Explosion-Proof Interior 1.3. Explosion-Proof Card Location 14 Division 2 Control Unit 13 Division 2 Interior 1.6 Rackmount Control Unit 1.7 Controt Unit Block Diagram 1.8 Control Unit Modet Number Breakdown Section 2 Installation 2.1 Basic System Components 22 Control Unit Mounting Height 2.3 Rackmount Dimensional Drawing 2.4 Explosion-Proof Dimensional Drawing 25. Division 2 Dimensional Drawing 2.6 Exploded View of Retrofit Kit 2.7 Retrofit Kit Installation 28 Meter Pulse Interface Options 29 Data Communications Interface Options 2.10 Recommended 1/0 Configuration Assignments 2.11 Revrofit Wiring Table 2.12 Explosion-Proof TB1 Wiring Table 2.13 Explosion-Proof TB2 Wiring Table 2.14 Explosion-Proof TB3 Wiring Table 2.15 Explosion-Proof TB4 Wiring Table 2.16 Explosion-Proof TBS Wiring Table 2.17 Explosion-Proof TB6 Wiring Table 2.18 Rackmount TBI Wiring Table 2.19 Rackmount TB2 Wiring Table 2.20 Rackmount TB3 Wiring Table 2.21 Rackmount TB4 Wiring Table 2.22 Rackmount TBS Wiring Table 2.23 Rackmount TB6 Wiring Table 2.24 AC Input Voltage Selection 2.25 AC Power Circuit Schematic 2.26 Control Valve Wiring - Digital 2.27 Control Valve Wiring - Low Flow Stop 2.28 Conirol Valve Wiring - Low Flow Start/Stop 2.29 Control Contact States - Valve Opening 2.30 Control Contact States - Valve Lock 2.31 Control Contact States - Valve Closing 2.32 Control Contact States - Final Stop 2.33 Control contact Wiring (Pump, Additive, Auxiliary) 2.34 Sequential Blend Wiring 2.35 Digital Input/Output Wiring 2.36 Meter, Temp,, Pressure, Density Transmitter Wising 2.37 Data Communications Wiring 2.38 Data communications Wiring 2.39 ‘Typical PetroCount IMS Wiring Diagram (115 Voc) 13 14 Ld 16 12 113, 2-86 247 2.48 iv Rev. C 11/15/91Contents List of Figures and Illustrations (cont'd) Section 3 Startup 3.1 Valve Position Indicator Microswitch 342 3.2 Digital Valve Adjustments Bud 3.3, Recommended Digital Valve Settings 343 Section 4 Software configuration 4.1 Parameter Group Structure 43 Section 5 Operations 5.1 Flow Profile Diagram s4 5.2. K-Factor Linearization 35 5.3 API Table Ranges 5:16 5.4 Division 2 Security Jumper 5:30 5.5. Rackmount Security Jumper 530 06/27/91 Rev. CvIntroduction Section 1 Introduction Using this manual Manual organization “This manual is designed to assist inthe installation, programming and operation of the PetroCount® IMS Control Unit. Fach of the following sections covers a specific area, but the organization of the information is such that each section leads naturally into the next. To insure proper understanding of the Control Unit, itis recommended that all sections be read in the order of appearance at least once, Below is a list of the sections and a brief description of their ‘contents. Section 1 - Introduction furnishes an overview of the Control Unit and it's User's Manual. Section 2. - Installation details the sequence for the installation of the Control Unit, ‘These tasks start with the selection of an appropriate site and ‘conclude with a task checklist and startup procedures. Section 3 - Start-up details the step by step procedures used in bringing the Control Unit on line Section 4 - Software Configuration includes a brief explanation of each, available parameter and a sample display screen for cach. Section 5 - Operations describes task responsibilities and procedures for the ‘Terminal Manager, the Site Engineer and all Operators. Section 6 - Troubleshooting details, in check list format, the steps to follow in correcting the more frequently found trouble spots. Appendix A - Specification and Reference Data lists all the relevant technical details of the Control Unit. Appendix B - Spare Parts List indicates which parts are recommended for having on band. Appendix C - Parameter Tables contains tables for each category or group of parameter. Each table lists parameter specifics including the User's Manual ‘page numbers for more information. Appendix D - Execute Command Summary contains alist of all the Execute ‘Commands. ‘The PetroCount* IMS Control Unit is a self-contained device and is capable of performing its function without outside supervisory control. The Control Unit cean also be part of a system which could include a customer computer and/or the PetroCount® IMS Remote Access Unit, Where necessary, this User's Manual includes details relevant to these connections, but more detailed information can be found in the Remote Access User's Manual and in the PetroCount® IMS System Manual. 06/27/91 Rev.C 1-1