Modbus protocol, universal digital panel meters, counters, timers and transmitters, series 2, now with ethernet (32 pages)
Summary of Contents for YOKOGAWA 800 PLUS
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Plus Universal Digital Counter Series 2 INSTRUCTION MANUAL Now with Ethernet 2 Dart Rd, Newnan, GA 30265, USA Phone: 770-251-8700, Fax: 770-251-2088 http://www.yca.com...
1. ORDERING GUIDE Configure a model number in this format: 850200FR Plus 8 .800 Counter/timer/serial input meter Extended counter Includes screw terminal connectors. Above plus rate and total simultaneously, custom curve linearization, arithmetic func- Processors & Display Color tions (A*B, A/B, A+B, A-B, A/B-1), phase 5 ........
3. PRODUCT INTRODUCTION Our counters are a versatile, cost effective solution to a wide range of monitoring and control applications including frequency, rate, total, period, time, phase, position, and flow. Setup can be via front panel pushbuttons or a PC. Selective lockout of front panel keys protects against accidental or unauthorized setup changes and simplifies meter use.
4. RECEIVING & UPACKING Your meter was carefully tested and inspected prior to shipment. Should the meter be damaged in shipment, notify the freight carrier immediately. In the event the meter is not configured as ordered or the unit is inoperable, return it to the place of purchase for repair or replacement.
6. CONNECTOR WIRING INFORMATION CONNECTORS Connectors for signal and power are U/L rated screw-clamp terminal blocks that plug into mating jacks on the printed circuit board. Communication connectors are a single RJ11 plug for RS232, dual RJ11 or RJ45 plugs for RS485, and RJ45 for Ethernet.
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P3 - SERIAL OMMUNICATIONS RS232 INTERFACE Computer ISO GND P4 – DUAL ANALOG OUTPUT, provides two unipolar connections at pins 1,2,3 and 4,5,6 RS485 INTERFACE - FULL DUPLEX RS485 INTERFACE - HALF DUPLEX ISO GND ISO GND ATX / ARX ATX / ARX BTX / BRX BTX / BRX...
7. MECHANICAL ASSEMBLY REMOVING THE REAR PANEL First remove any connectors. Use one hand to press in the two sides of the rear of the case, and the other hand to press down the two protruding tab releases at the top of the rear panel (see figure below).
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Note: Corresponding main board and option board connectors have the same number of electrical lines. When an option board is correctly installed, the top and bottom edges of the main board and option board are aligned. REASSEMBLING YOUR METER Slide the electronics assembly into the case until the display board is seated flush against the front overlay.
8. FRONT PANEL SETUP KEYS Counter Front Panel There are four front panel keys, which change function for the Run Mode and Menu Mode, effectively becoming eight keys. The keys are labeled with alphanumeric captions (MENU, PEAK, RESET, ALARMS) for the Run Mode and with symbols ( right arrow, right triangle,...
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RESET Key. Pressing RESET with PEAK resets peak and valley values. Pressing RESET with ALARMS resets latched alarms. Pressing RESET with MENU performs a meter reset (same as power on). Pressing and releasing RESET without pressing another key changes the displayed item if the mode has multiple items. For Item 1, the V LED is out.
9. ENABLING & LOCKING OUT MENU ITEMS For security reasons and ease of operation, any and all menu items may be disabled or "locked out" so that they are no longer directly accessible from the front panel. Each function to be enabled is set to "0"...
10. DUAL CHANNEL PULSE OR AC INPUT SIGNAL CONDITIONER The dual channel signal conditioner board is used for the frequency, rate, period, timing, batch control, phase and duty cycle meter functions. The board needs to be configured via jumpers for the input signal type and level. It is recognized by the meter software, which will bring up the applicable menu items.
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Common Jumper Settings Input Type Vmax A0 & B0 A1 & B1 A2 & B2 A3 & B3 A4 & B4 Logic levels 250V NPN open collector PNP open collector Contact closures a or b a, c Line frequency 250V a, c Turbine flow meter 250V...
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DISPLAY 0-50.00 RATE FROM 1-10 kHz INPUT, COORDINATES OF 2 POINTS METHOD Application: Display 0-50.00 (with two decimal places) for 1-10 kHz input. Use coordinates of 2 points scaling method. Solution: Set Input to “Rate A Only.” Select “coordinates of 2 points” scaling method under Setup.
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• RATE A, TOTAL B (A_btot) (Extended counter) displays Rate for Channel A as Item #1 and Total for Channel B as Item #2. • RATES A+B, A-B, AxB, A/B, A/B-1 (Extended counter) display arithmetic combinations of Rates A and B as Item #1, Rate A as Item #2, and Rate B as Item #3. With rates A and B scaled to produce a ratio close to 1 and an offset of -1, the special combination A/B-1, called “Draw,”...
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DISPLAY TOTAL VOLUME BY ADDING TWO TURBINE FLOW METER CHANNELS Application: Display total liquid volume in gallons to two decimal places from 2 pipes dispensing liquids into the same tank. Flow meter A is calibrated to 36.67 pulses/gal- lon, flow meter B to 58.12 pulses/gallon. Solution: Arithmetic operations require the Extended counter.
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• TOTAL A B INHIBIT (A_bInH) (Extended counter) displays Total A as Item #1, where counting may be inhibited by a control input on Channel B. If the menu item SLOPE is set to 0 for Channel B (digit 6), a low input level on B allows counting, and a high input level inhibits counting.
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• In batch control mode with external resets, pushing the RESET key initiates cycling. Grounding an external Gate input for a minimum of 3.33 ms then starts each new fill cycle by energizing Relay #1 and resetting the Batch Total. Gate time is not used. Three values are tracked and can be separately displayed by pressing the RESET key: Item #1, the Batch Total;...
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STOPWATCH TIMING, CLOSING TIME OF A RELAY TO 0.001 MSEC RESOLUTION Application: Measure the closing time of a relay in msec to 0.001 msec resolution. Solution: To close the relay, apply the same positive voltage to the relay coil and to meter Channel A.
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• INVERSE STOPWATCH TIME A TO A & A TO B (__1/AA & 1/AB) (Extended counter) Takes the inverse of stopwatch time for a reading in /second. For example, if the travel time for an object to travel from point A to point B is 5 seconds, the inverse stopwatch time interval would be 0.2/sec.
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POWER FACTOR MODE (PHASE) (Extended counter) The power factor of an AC power system is the ratio of real power in watts (W) divided by apparent power in volt-amperes (VA). For sinusoidal signals differing by a phase angle θ, power factor will be cos(θ), which is how the meter computes power factor. Power Factor readings can range from 1.000 to 0.000 with three decimal places and an accuracy of 0.1% for sinusoidal signals at 50/60 Hz AC line frequency.
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Example of Using OCV of 0 to 2.000 for setting Analog Output 4 mA output is desired for Power Factor of -0.4 (OCV = 0.400). 20 mA output is desired for Power Factor of +0.4 (OCV = 2.000 - 0.4 = 1.600). Set up as follows: deC.Pt to 111.111, AnSEt to 21, An_Lo to +0.400 (4 mA point), An_Hi to +1.600 (20 mA point), dEC.Pt as desired to 111.111, 1111.11 or 11111.1 Example of Using OCV of 0 to 2.000 for setting the Alarm Setpoints...
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SETUP OF COUNTERS WITH DUAL CHANNEL PULSE SIGNAL CONDITIONER If the MENU key does not work, see Section 9 “Enabling & Locking Out Menu Items.” Menus are dynamic. Menu items will only appear if appropriate for previously made menu selections. For example, Batch menu items will only appear if “Batch” was selected under “Rate.”...
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Press Press Digit Press Value Select Menu Select Key _InPut _totAL. A__b__ Total for Channel A (Item #1). Total for (continued) Total modes Channel B (Item #2). A_OnLy Total for Channel A only (Item #1). A-b_Ud. Running total (Item #1) of counts on Channel A minus counts on Channel B.
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Press Press Digit Press Value Select Menu Select Key _InPut PHASE _0-360. Span from 0° to 360°. Select for phase (continued) Phase angle modes angles centered around 180° (Item #1). _-180+. Span from -180° to +180°. Select for phase angles centered around 0° (Item #1). duty_C A_to_b On or Off period of square waves as a...
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Press Press Digit Select Press Value Select Menu ConFiG __0000 Normal, overload to exponential format Configu- Display mode Normal, overload to 999999 ration 1 right-hand dummy zero 2 right-hand dummy zeros Time display in seconds Time display in HH.MM.SS format Remote display (H, K, L commands) Single-value remote display Show 1...
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Press Press Digit Select Press Value Select Menu bAtCH _00000 Make Item #2 the Grand Total of all batches. (continued) Definition of Item #2 Make Item #2 the Total Number of batches. _00000 Display “rEAdy.” RESET key starts batching. Action after Meter Reset Start batching upon Meter Reset.
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Press Press Digit Select Press Value Select Menu Coordinates of 2 points scaling method if selected under SEtuP .Lo_In1. 000000 000000 000000 Select thru for flashing first digit and thru Low signal other flashing digits. Move decimal point location 000000 000000 000000 input 1.
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Scale multiplier for combinations of two channels (e.g., AxB, A/B) if selected under _InPut rESoLn. Flashing 6-digit number Press to select. This is a multiplier R to avoid Resolution in decade steps from overflow or underflow of arithmetic combinations of 0.00001 100000 Channels A and B.
11. PROCESS RECEIVER & TOTALIZER SIGNAL CONDITIONER This signal conditioner board converts 0-1 mA, 4-20 mA or 0-10 V analog process signals to a frequency signal, which is then read by the counter main board and processed mathematically for display of rate, total (time x rate), time based on rate, or batch control. The board needs to be configured via jumpers for the input signal range.
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noise filtering. Moving average filtering is also available. Square root extraction is selectable for use with differential pressure flow transducers. Custom curve linearization is available with the Extended counter. RATE & TOTAL MODE (Basic Counter) TOTAL FROM A 4-20 mA OUTPUT FLOW METER Application: Display Total from a 4-20 mA flow Solution: Set Input to “VF420 A A Total,”...
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• In batch control mode with “external gate”, the meter waits a the end of every cycle until an external gate input is grounded for a minimum of 3.33 ms. This starts a new fill cycle by energizing Relay #1 and resetting the Batch Total. Gate time is not used. Three values are tracked and can be separately displayed by pressing the RESET key: Item #1, the Batch Total;...
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KEYSTROKES FOR SETUP If the MENU key does not work, see Section 9 “Enabling & Locking Out Menu Items.” Menus are dynamic. Menu items will only appear if appropriate for previously made menu selections. For example, Batch menu items will only appear if “Batch” was selected under “Rate.”...
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Press Press Digit Press Value Select Menu Select Key ConFiG __0000 Normal, overload to exponential format Configura- Display mode Normal, overload to 999999 tion 1 right-hand dummy zero 2 right-hand dummy zeros Time display in seconds Time display in HH.MM.SS format Remote display (H, K, L commands) Single-value remote display Show 1...
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Press Press Digit Press Value Select Menu Select Key bAtCH _00000 & _00000 Not used with VF Batch. Set to 0. Batch setup _00000 Use gate time* as delay between batches. Batch triggering Use External Input B to start each new batch. _00000 Make Item #2 the Grand Total of all batches.
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Press Press Digit Press Value Select Menu Select Key Coordinates of 2 points scaling method if selected under SEtuP .Lo_In1. 000000 000000 000000 Select thru for flashing first digit and thru Low signal for other flashing digits. Move decimal point location 000000 000000 000000 input 1.
12. QUADRATURE SIGNAL CONDITIONER Our quadrature signal conditioner board can be used for quadrature position (with Basic or Extended main board) or for quadrature rate (with Extended main board). Two quadrature signals, which are 90º out of phase, are applied to the Channel A and B inputs. Their phase relationship determines whether the count is up (+) or down (-).
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Jumper Settings Note: Letters indicate jumper position. Jumpers are installed on pins adjacent to letters. Input Type Single-ended (signal & return) a, c a, c a, c Differential Differential (with excitation and no zero index) b, d Input Termination (for differential inputs only) For long cable runs For short cable runs none...
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PRINCIPLE OF OPERATION The quadrature decoder board generates up (+) and down (-) counts that are arithmetically totalized on the main counter board and are then displayed. The decoder board has input circuitry that may be jumpered for single-ended input signals or balanced line driver signals. It accepts normal A &...
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The zero index channel has the same digital filtering as the A & B channels. It contains a Polarity jumper that allows selection of either a positive or negative zero index signal. It also contains two Control inputs, C1 and C2 that control the ANDing of the zero index signal with the Channel A and Channel B signals.
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ZERO INDEX SETUP The relationship between the zero index correction signal and the Channel A & B signals varies by encoder model and by manufacturer. To accommodate this variation, the Quadra- ture board has control jumpers and selectable outputs that provide ANDing of the zero index signal with all possible combinations of the Channel A &...
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By ANDing the zero index signal with the A & B channels, there is no regional discrepancy between counting up and counting down. There are 2 control signals, C1 and C2, and 3 outputs, ZI, ZIX and ZIY. These may be jumpered to provide 8 selections of ANDed signals or the zero index signal without ANDing.
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8. Rotate the optical encoder past the zero index point to set the internal correction. 9. Return to the desired zero mechanical position and verify a zero reading. This completes the procedure. If the encoder is rotated back to mechanical zero, it should read zero.
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WAVESHAPE EXAMPLES BY ENCODER MANUFACTURER A Channel B Channel Zero Index Allen Bradley: current sink, open collector & line driver, CCW rotation A Channel B Channel Zero Index Allen Bradley: current source, CCW rotation. A Channel B Channel Zero Index Zero Index (gated) BEI: Models H25, L25, E25, MOD5500, MOD5600,CCW rotation A Channel...
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A Channel B Channel Zero Index Bourns: EN Series . A Channel B Channel 90-270 deg Zero Index Computer Optical Products Models CP-350, CP-360, CP-370, CP-850, CP870,CCW rotation. A Channel B Channel Zero Index Encoder Prod: Models H25, L25, E25, MOD5500, MOD5600,CCW rotation A Channel B Channel Grayhill &...
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PROGRAMMING EXAMPLE FOR QUADRATURE TOTAL: DISPLAY DISTANCE TO 0.001 FT FROM A 1024 PULSE/REV QUADRATURE ENCODER Application: Display distance in feet with 3 decimal points using a 1024 pulse/revolution quadrature encoder tied to a roller with 1.782 ft circumference. Solution: Set Input to “Quadrature Total.” Set Gate Time to 0.01 sec for fast display updates.
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1 = Display Blank, 2 = External Gate* 1 = Display Item #2, 2 = Display Item #3 With 1 and 2 at 5V or open, Display Item #1. ------------------------------------------------------------------- 1 & 2 both at 0V = Meter Reset (can restore totals).
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Press Press Digit Press Value Select Menu Select Key Coordinates of 2 points scaling method if selected under SEtuP .Lo_In1. 000000 000000 000000 Select thru for flashing first digit and thru Low signal other flashing digits. Move decimal point location 000000 000000 000000 input 1.
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PROGRAMMING EXAMPLE FOR QUADRATURE RATE: DISPLAY RATE TO 0.001 FT/SEC FROM A 1024 PULSE/REV QUADRATURE ENCODER Application: Display rate in feet/sec with 3 decimal points using a 1024 pulse/revolution quadrature encoder tied to a roller with 1.782 ft circumference. Have 4 display updates per second.
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KEYSTROKES FOR SETUP OF QUADRATURE RATE If the MENU key does not work, see Section 9 “Enabling & Locking Out Menu Items.” Press Press Digit Press Value Select Menu Select Key _InPut _quAdr Basic meter _totAL Quadrature total Input Quadrature Extended _rAtE_ Quadrature rate...
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Press Press Digit Press Value Select Menu Select Key dSPyno ____01 PEAK key action Display Peak Display Valley Display # Peak (1 push), Valley (2 push) ____01 Item to display Item #1* (Quadrature Rate = Rate A - Rate B) after Meter Reset Item #2* (Rate A) Item #3* (Rate B)
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Coordinates of 2 points scaling method if selected under SEtuP .Lo_In1. 000000 000000 000000 Select thru for flashing first digit and thru Low signal other flashing digits. Move decimal point location 000000 000000 000000 input 1. when flashing. Select digit to flash. 000000 000000 000000 Select thru...
13. SERIAL INPUT METER / REMOTE DISPLAY OPERATION With a Basic counter main board and a serial interface board, the counter can operate as a 6-digit serial input meter (or remote display) to display serial data received from a computer or PLC, or act as a slave display to another meter, counter or timer with a serial output.
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Additional programmable features of the serial input meter are detailed in the “Command Mode for Remote Display Operation of Counter / Timer” and “Data Formats” sections of the Custom ASCII Protocol Serial Communications Manual. In particular, Mode 12 (hex C), which is invoked by setting the first digit under ConFIG to C, allows extraction of data from an ASCII string that contains multiple data values or non-numeric characters.
14. DUAL & QUAD RELAY OUTPUT OPTIONS An optional relay board may be installed in the meter main board at plug position P2, adjacent to the power supply board. Four board versions are available: 2 or 4 relays, contact or solid state. Once installed, the relay board is recognized by the meter software or PC-based Instrument Set- up software, which will bring up the appropriate...
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KEYSTROKES FOR SETUP If the MENU key does not work, see Section 9 “Enabling & Locking Out Menu Items.” Press Press Digit Press Value Select Menu Select Key SourcE 0000 Filtered item Item #2 Source to com- Setpoint 1 compared to: Item #1 Item #3 pare to setpoint...
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Press Press Digit Press Value Select Menu Select Key ALS 34 00000 Relay 3 active on Relay 4 active on Alarm Setup Relay alarm state when Relay 3 active off Relay 4 active on for relays 3 & 4 alarm is active. Relay 3 active on Relay 4 active off if detected.
15. SINGLE & DUAL ANALOG OUTPUT OPTIONS Two versions of an analog board may be installed in the meter at rear panel jack position J4, adjacent to the signal conditioner board. Once installed, this board is recognized by the meter, which will bring up the appropriate menu items for it.
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KEYSTROKES FOR SETUP OF DUAL ANALOG OUTPUT BOARD If the MENU key does not work, see Section 9 “Enabling & Locking Out Menu Items.” Press Menu Press Digit Select Press Value Select An_SEt 0000 0-20 mA current output Analog Output Setup. Scaling of analog output 2 0-10V voltage output Press...
16. SERIAL COMMUNICATIONS OPTIONS A serial communications board may be connected to the meter main board at plug position P13 (middle position). Available boards are RS232, RS485 (with dual RJ11 connectors), RS485 Modbus (with dual RJ45 connectors), USB, USB-to-RS485 converter, Ethernet, and Ethernet-to-RS485 converter.
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Basic Ethernet Board No jumpers needed. RS232 Board e - Normal operation. f - Slave display to RS232 from another meter. g - Pull-up resistor on RTS line. Note: Board is shipped with jumpers e and g installed RS485 Board, Full Duplex Operation b &...
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KEYSTROKES FOR SETUP If the MENU key does not work, see Section 9 “Enabling & Locking Out Menu Items.” Press Menu Press Digit Select Press Value Select .Ser ___000 Send unfiltered signal Serial Setup 1. Output filtering Send filtered signal Press until ___000U...
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Press Menu Press Digit Select Press Value Select .Ser _00000U Half or full duplex Full duplex Half duplex Serial Setup 3 _00000U * (asterisk) is recognition character. Recognition characters, No start & stop characters. start & stop characters. Custom recognition character. No start &...
17. EXCITATION OUTPUT & POWER SUPPLY Three isolated transducer excitation output levels are available from the power supply board. These are selectable via jumpers b, c, d, e, f in the upper right of the board, as illustrated. In addition, the board provides three jumper positions for special features. The same jumper locations apply to the universal power supply (85-264 Vac or 90-300 Vdc) and to the low voltage power supply (12-32 Vac or 10-48 Vdc).
18. INSTRUMENT SETUP VIA PC Instrument Setup software is a PC program which is much easier to learn than front panel programming. It is of benefit whether or not the meter is connected to a PC. With the meter connected to a PC, it allows uploading, editing and downloading of setup data, execution of commands under computer control, listing, plotting and graphing of data, and computer prompted calibration.
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SETUP OF CONNECTED METER A setup file can be retrieved from the meter (Counter => Get Setup), be edited (View => Setup), be saved to disk (File => Save Setup), be retrieved from disk (File => Open Setup), and be downloaded into one or multiple meters (Counter => Put Setup). Downloading of setup files from a PC can be a major time saving when multiple counters have to be set up in the same way.
• The Readings pull-down menu provides three formats to display meter data on the PC monitor. Use the Pause and Continue buttons to control the timing of data collection, then press Print for a hardcopy record on your PC printer. - List presents the latest readings in a 20-row by 10-column table.
19. CUSTOM CURVE LINEARIZATION Curve.exe is a DOS-based, executable PC program used to set up an Extended meter so that the readings have a user-defined, non-linear relationship with the input signal. For example, it allows a meter to correct for non-linearity of transducers, or to display volume from pressure at the bottom of an irregularly shaped tank.
4) Equation entry mode, where the coefficients of a polynomial Y = K1X^P1 + K2X^P2 + K3*X^P3 + are entered. Up to 20 terms are allowed. And offset can be built into X. REQUIRED USER INPUTS • Select CTR • You will be asked to supply the following: LOW X-COORDINATE VALUE >...
21. SPECIFICATIONS DISPLAY Type ..........6 LED digits, 7-segment, 14.2mm, plus 4 LED indicators Digit Color ......................Red or green Display Range ..................-999999 to +999999 CONVERSION (FREQUENCY INPUT) Conversion Technique ....................1/period Conversion Rate ..........Gate Time + 30 ms + 2 signal periods (max) Gate Time ..................
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Conversion Technique for Rate ................... 1/period Conversion Time for Rate .......... Gate time + 30 ms + 0-2 signal periods Time Before Zero Output for Rate ..........0 to 199.99 sec (selectable) Zero Wait Time for Rate ............... 0 to 199.99 sec (selectable) Output &...
ANALOG OUTPUT OPTION Power to Analog Output Option ..............Powered by meter Output Levels, Single Analog Output Option ....0-20 mA, 4-20 mA, 0-10V, -10 to +10V Output Levels, Dual Analog Output Option ........0-20 mA, 4-20 mA, 0-10V Voltage Compliance, 0-20 mA Output ..........12V (0-600 Ohm load) Current Compliance, 0-10V Output ...........
22. GLOSSARY OF TERMS Adaptive filter threshold A threshold which causes an adaptive moving average filter to be reset to the latest reading when the accumulated difference between individual readings and the filtered reading exceeds that threshold. Adaptive moving average filter- ing allows a meter to respond rapidly to actual changes in signal while filtering out normal noise.
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Custom ASCII protocol A simplified, short protocol for use with panel meters, counters and timers. It allows 31 digital addresses. Not an industry-standard protocol, like the more complex Modbus protocol, which is also offered with these instruments. Custom curve A user-specified nonlinear relationship between the input signal and displayed reading.
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produces a more stable reading as more cycles are averaged, but slows down the update rate. At very low frequencies, the update rate of the meter is controlled by the period. In totalizing mode, the gate is always open, but the gate time setting still determines the update rate of the meter.
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more dynamic range with no loss of resolution than could be achieved with a 6- digit scale factor only. Offset A constant adder to the displayed reading. This may be any value from -999,999 to 999,99. The offset may be used as a preset in the totalize mode, where the total can be counted down from the preset to zero.
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RS485 half duplex Serial communications implemented with two wires, allowing data transmission in both directions, but not simultaneously. RS485 full duplex Serial communications implemented with four wires, allowing data transmission in two directions simultaneously. Run Mode The normal operating mode of the meter, where readings are taken, as opposed to the menu mode.
In the event of a defect during the warranty period, the unit should be returned, freight prepaid (and all duties and taxes) by the Buyer, to the authorized Yokogawa distributor where the unit was purchased. The distributor, at its option, will repair or replace the defective unit. The unit will be returned to the buyer with freight charges prepaid by the distributor.