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Instruction Manual
For
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Contents
1.GENERAL INSTRUCTION .................................................................................... - 3 2. FEATURES AND FUNCTIONS ............................................................................ - 3 3. IMPORTANT TECHNICAL INDICATORS ............................................................ - 4 4. OPERATIONAL PRINCIPLE................................................................................. - 5 5. OPERATION INSTRUCTION ............................................................................... - 7 5.1 The instruction of BCL panel and keyboard...................................................... - 7 5.2 Operation procedure ......................................................................................... - 9 6STRUCTURE CHART OF LOADING INSTRUMENT HARD WARES ............. - 19 6.1 Wiring diagram of loading instrument terminal ............................................... - 19 SELECTION OF CABLES CONNECTED TO RELATED EQUIPMENTS ...... - 19 7.1 Connection with the flow meter ....................................................................... - 19 7.2 Connection of temperature transmitter ........................................................... - 20 7.3 Valve connection ............................................................................................. - 20 7.4 Electrostatic oil spill protector connection ....................................................... - 22 7.5 Communication cable connection ................................................................... - 22 7.6 Power supply ................................................................................................... - 23 8SELECTION INTRODUCTION.......................................................................... - 26 9. MAINTENANCE .................................................................................................. - 26 9. 1 General Maintenance ..................................................................................... - 26 9.2 Cautions of loading instrument operation ....................................................... - 27 9.3 Fault judgments and treatments of loading instrument................................... - 27 9.4 Other cautions ................................................................................................. - 28 -
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1. General Instruction
The explosion-proof distributed AWZ batch controller of loading (AWZ BCL for short)
is a new type intelligent explosion-proof instrument with an advanced intelligent controller
as its core. Its core components are the intelligent controller and operation terminal of the
world famous brands, combined with the general used IC card configuration software and
the advanced control algorithm. It is easy to maintain and operate with a high control
precision and reliable performance. At the same time, this BCL is equipped with the fully
developed standard MODBUS RTU communication protocol, which is convenient to be
connected with other user management systems. Whats more, with the requirement of
the users, AWZ BCL has wall type and vertical type, so the users can choose their favorite
type; from the management point, it has the controller with or without the interior IC card,
where with the integrated IC card reader inside the BCL it can be explosion-proof to
guarantee the management process of the loading process.
AWZ BCL is universal products which can be used together with all kinds of flow
meter, thermograph, liquid level switch, earthed switch, control valve and master
computer to form a complete distributed quantitative loading control system. The system
can be operated on one machine and supervised by the operator on the spot; or it can be
connected to the computers in the control room by the table, and the computer can carry
out the loading work, collect and transmit the loading conditions on the spot to the control
room to be managed by the computer centralizedly, and display or print the loading
reports.
AWZ BCL applies to the control of the liquid material loading, barrel filling and dosing
in the trades of petroleum, chemical industry and pharmacy.
The Autoware Company provides the users with excellent services and reliable
technical supports. The operators and maintenance staff will be able to operate and do
some basic maintenance after training.
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Two operation styles: remote and on the spot operation, which can be switched over
freely.
Power failure protection. Save the filling over record and the other parameters
which have not been transmitted in case of power failure and continue to fill the loading
according to the record. The parameters can be kept for more than one year;
Self-test. When the loading controller goes wrong, it alarms;
Setting of operation limits. It can set many operation limits and multi-level passwords
to guarantee the safety of data and system;
Open ended protocol. It can communicate with the master computer or other systems
though ethernet protocol or MODBUS RTU protocol;
IC swiping in case of completely explosion-proof case. The controller can either read
data from or write data in the IC, which simplifies the operation process and improves the
production management.
4. Operational Principle
(1) Hardware
The hardware of the system consists of intelligent controller module, unitized liquid
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crystal operation panel, IC card reader, 24V industry power supply, explosion-proof
control box and the well-designed cabinet body.
The intelligent controller carries out the collection, conversion and logical operation of
data as well as the output of the control signals.
The unitized liquid crystal operation panel contains keyboard and LCD, which is used
to input data and control the startup and stopover.
The IC card reader reads IC card, then writes in the intelligent controller and finishes
the loading process and the final examination.
(2) The collection and calculation of the flow rate
AWZ PLC can be connected with all kinds of flow meters as required. Generally the
flow meter works in the pulse mode and is trigged by the negative edge. Frequency
domain: 010KHz. Reserve the flow meter interface of 420mA to make it convenient
for the users to choose.
Set the advance coefficient and it can set the timing advance (099 seconds) or the
flow advance (0500 kilograms or liters) to guarantee the accurate delivery of the
materials and supplies.
(3) The control and feedback signals of valve and pump
The extension time of the control switch in the 4 valves (8 valves at most) be input
following the cues on the panel. When the time set comes, BCL will open the valve
automatically; when the loading is over, BCL will close the valve according to the
extension time. Adopt different control manners depending on the control conditions on
the spot.
The control of the startup and stopover of the pump are the same as those of the
valves.
The on or off of the valve and the pump can be real-time displayed on the operation
panel in the form of graph.
(4) The input and compensation of temperature
The BCL uses the signal (420mA) from the unitized temperature sensor to
calculate the automatic temperature compensation of the system. The conversion of the
pipelines volume flow rate at its actual temperature (t ) to the standard volume flow rate
at 20:
Q = q [1 r(t-20)]
Q: the volume flow rate at 20
Q: the volume flow rate at the temperature detected (t )
R: coefficient of expansion
The temperature of the pipelines fluid changes from time to time, so get the
accumulated flow rate of a very short time and calculate the standard volume flow rate in
this time, then the total volume flow rate can be worked out through integral operation.
If calculated in term of weight, the weight of the fluid is W = Q * Db (Db is the
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5. Operation Instruction
AWZ BCL uses all Chinese operation interfaces and is easy to learn use and operate.
Figure 2
In the Key of machine with two bits, the emergency stop and the startup in the left are
the operating keys of the first crane position, while the emergency stop and the startup in
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the right are the operating keys of the second crane position. The rest are the public keys.
Page up, page down: For the cut of screen. Page up is for the previous screen
and page down for the next one;
Start:
For the startup of the loading process. After inputting the set value (it can be
set either on the controller or through the master computer), press this key can activate
the loading control process; this key works only in the Boot Screen;
Emergency stop: For the emergency stop of the loading process. When the key is
pressed, the pump will be turned off and the valve will be closed automatically, then the
current loading process will be stopped; this key works in all the screens and once
pressed, the loading process is in the state of automatic emergency stop.
Shift: For moving the focus of the object on the screen. If there are two digital input
boxs, when the input of the first box is done, move the focus to the second box by shift
and then the input of the second can start;
CancelFor the cancel of the operation. If the enter password screen pops up,
press the cancel, then the screen will disappear. When setting data, press cancel, the
data set will be cancelled. If this key is pressed in reset screen, the reset operation will be
carried out on BCL.
Crane position 1: For the definition of other functions of crane position 1 which can
definite other functions flexibly
Crane position 2: For the definition of other functions of crane position 2 which can
definite other functions flexibly
OK: For the confirmation of the operation. To input the password into the system,
OK must be pressed. Press OK when data is input;
Set: For entering Parameter setting screen. In main menu screen, press set and
input the right password, then can enter Parameter setting screen.
Local/remote: For the switch of loading control mode. In parameter screen, press
this key then the control mode can be switched (local and remote).
Caution:
Dont press the keys with too much force and dont press one of the keys
quickly and frequently.
5.1.2 The card swiping area and operation of IC card
AWZ BCL with IC card can control the loading process and read/write data through
IC card, which is flexible and convenient to use. The users can develop a number of
functions if they need.
In this instruction manual, IC card is used only to control the loading process. The
specific operation is as follows:
When the tank wagon comes to a loading position, enter the monitor screen of card
swiping, and then put IC card in the card swiping area. At this time, press set (means
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swiping once) on the controller if it is a machine with one bit. In case of machine with two
bits, if the wagon comes to the crane position 1, press the function key 1; if the wagon
comes to crane position 2, press 2. When the monitor screen of card swiping on the
machine with one bit shows pass, loading begins!, the screen will be cut to the startup
screen automatically; when the monitor screen shows pass, no loading begins!, it
refuses to load in this crane position; when there isnt any indications, it means a card
swiping failure. In case of machine with two bits, the screen shows crane position 1
passes and loading begins, and then it will be cut to the monitor screen automatically.
Cautions:
1. IC card should be put in the card swiping area;
2. IC card should be within 50 mm of the card swiping area,
3. Press OK or the function key 1, or the card reader doesnt work, which is
designed to restrict some random and useless card swiping, so dont swipe the card if
there is no need to do so. When swiping the card on the machine with two bits, press the
function key according to the crane position. The reader doesnt work if the wrong key is
pressed.
5.2 Operation procedure
welcome
Boot screen
Shenzhen Autoware Technology
The leisure screen will appear in three seconds:
AWZ
Quantitative
loading
controller
Shenzhen Autoware Technology
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Leisure
leisure screen
screen
Password = ********
Password
box
When the password has been input, press OK. If the password is right, it will be
switched to the screen below:
Main menu
Loading control code
Local
The main menu screen is to show the loading control mode and enter the parameter
screen and the loading control screen; to enter the parameter screen; the second level
password is needed: Press set, then the password box will pop up and only a right one
can ensure you enter the parameter setup screen:
The parameter setup screen is to set the flow coefficient of BCL and the preact of
closing valve as well as the loading mode.
1. Flow coefficient is the measurement standard of loading. Because the loading
system is measured by receiving and accumulating the pulse from the flow meter, so each
pulse corresponding flow unit (That is, how many liters or kilos each pulse is) must be
determined previously before the loading, which is called flow coefficient. During the
loading process, set a volume in advance for the first section of closing valve because the
control of valve is through multi-sections of closing valve and when the accumulative
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volume is greater than it, close the valve by the first section of closing valve. This is the
function of the preact of closing valve.
2. There are two kinds of loading modes: local loading and remote loading. The
former is to directly set on the loading instrument; the latter is to set on the master
computer and then start loading by inputting the bill of lading password on the instrument
locally.
To enter the loading control screen, press page down in the main menu screen. If it
is the local control mode, it will enter the local loading setup screen:
Press set
The local loading setup screen is to set the loading volume in the loading process
under the local mode; the set volume should be round number with 5digits;
If it is a remote control mode, when pressing page down in the main menu screen or
the master computer has been placed an order, it will enter the number of the bill of lading
input screen:
without IC card
When the loading mode is switched to the remote control, the master computer will
place an order, which has the loading set volume and crane position password (bill
number), to the designated crane position. When the operator input a wrong bill number
into the loading instrument, it means that the loading bill isnt for this crane position and no
loading will begin at this position!
The bill number is the actual date plus a three-digit number. For instance, 15001 is
the first loading bill on 15th.
If it is a remote control mode, when pressing page down in the main menu screen or
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the master computer has been placed an order, it will enter the number of the bill of lading
input screen:
Bill number
Local CP number
CP number
Read
Pass
OK
Bill number input screenwith IC cardreads out the bill number by swiping the card.
Put IC card in the card swiping area of the loading instrument and press set, then the
card reader will read out data from IC card. If data is the same as that of the instrument, it
will show pass and enter the boot screen.
If there are no problems with the operations carried out on the local loading setup
screen or the bill number input screen, it will enter the boot screen:
Set volume
Loaded volume
State Loading
Boot screen
The boot screen is to start and monitor the loading process. Whether it is a local or a
remote control, the startup control of the loading must be carried out on this screen. Only
press start in this screen can it start the loading process and once started, the screen will
real-time monitor the loading volume and the loading state: loading, free, emergency
stopping.
The next screen is the loading process monitor screen. Press page down on the
boot screen, it will enter the monitor screen:
Transient flow
5000
Monitor screen
Valve state
On the monitor screen it can real-time monitor the transient flow, valve and static
electricity oil spill and so on.
Valve state:
Static electricity:
indicates no grounding.
indicates that oil switch is normal,
alarms.
The next screen is loading process reset screen. The first level password is needed
to input to enter reset screen and only a right password can it carry out a reset operation.
Press page down on the monitor screen, it will pop up password box. Input the right
password and enter another reset screen:
Order placed
The reset screen is used to reset to continue the loading state in case of
misoperations (the master computer places a wrong order or a wrong volume is set in the
local loading) or breakdowns during the loading process.
First reset in the next loading if the loading process is not completed normally or the
loading instrument is in the state of emergency stop.
Cautions: If the loading instrument is in the norm loading process, better not
reset. When to reset, manual record of the loaded volume will be needed. First reset
in the next loading if the loading process is not completed normally or the loading
instrument is in the state of emergency stop, or data cant be written into the
database.
5.2.1.2 Screen introduction of machine with one bit
After the system is on, boot screen is shown as:
welcome
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AWZ BCL
Shenzhen Autoware Technology
Boot screen
Leisure screen
Password = ********
Password
box
When the password has been input, press OK. If the password is right, it will be
switched to the screen below:
Main
Loading control mode
Local
Menu
The main menu screen is to show the loading control mode and enter the
parameter screen and the loading control screen; to enter the parameter screen;
the second level password is needed: Press set, then the password box will pop
up and only a right one can ensure you enter the parameter setup screen:
Crane position 1
Local
Flow coefficient
Preact of closing valve:
Crane position 2
Flow coefficient
Preact of closing valve:
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The parameter setup screen is to set the flow coefficient of BCL and the preact of
closing valve as well as the loading mode.
1. Flow coefficient is the measurement standard of loading. Because the loading
system is measured by receiving and accumulating the pulse from the flow meter, so each
pulse corresponding flow unit (That is, how many liters or kilos each pulse is) must be
determined previously before the loading, which is called flow coefficient. During the
loading process, set a volume in advance for the first section of closing valve because the
control of valve is through multi-sections of closing valve and when the accumulative
volume is greater than it, close the valve by the first section of closing valve. This is the
function of the preact of closing valve.
2. There are two kinds of loading modes: local loading and remote loading. The
former is to directly set on the loading instrument; the latter is to set on the master
computer and then start loading by inputting the bill of lading password on the instrument
locally.
You should press switch to set the two parameters. For example, if you want
to set the preact of closing valve after setting the flow system, press switch, to
switch the input focus to input box of closing valve setting, and then you can set
the preact of closing valve.
To enter the loading control screen, press page down in the main menu screen. If it
is the local control mode, it will enter the local loading setup screen:
Monitor screen is to monitor the loading volume set, the process of starting loading,
and the process of emergency stop, reset loading, as follows:
1) Setting the set volume of each crane position, if you want to use the loading of
crane position 1, press the key switch, move the input focus to the input box of the right
of crane position 1 set volume, directly input figures on keyboard, then can set the loading
capacity. If you want to use the loading of crane position 2, press the key switch, move
the input focus to the input box of the right of crane position 2 set volume, directly input
figures on keyboard, then can set the loading capacity. Set volume must be a round
number of 5 digits;
2) Starting the loading process, whether local or remote loading, press the key start,
can only function on monitor screen. That is on the screen, press the left key start, then
start the loading process of crane position 1, press the right key start, then start the
loading process of crane position 2; If you press the key start on other screens, can not
start the loading process;
3) Stopping the loading process urgently, of all the emergency stop keys on the
loading instrument, no matter on which screen, press the left key emergency stop, the
loading process of crane position 1 will stop urgently, press the right key emergency stop,
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Static electricity:
5When resetting on loading monitor screen, you must input the first level password,
the main function of resetting is to reset some disoperation and failures during loading
process to loading leisure state. Misoperations mainly include master computer places an
order wrongly, set the volume wrongly during local loading, and so on. If you want to reset
the crane position 1, please press the key crane position 1 on loading monitor screen,
which will be reset after inputting the correct password. If you want to reset the crane
position 2, please press the key crane position 2 on loading monitor screen, which will
be reset after inputting the correct password.
Cautions: If the loading instrument is in the norm loading process, better not
reset. When to reset, manual record of the loaded volume will be needed. First reset
in the next loading if the loading process is not completed normally or the loading
instrument is in the state of emergency stop, or data cant be written into the
database.
If it is remote control mode, press the key crane position 1, then enters the input
screen of bill No.:
No bill
Bill
Bill No.
position 1
of
crane
No.
input
screen
without IC card
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loading monitor screen, then press the key on corresponding crane position, to start
loading. If the No. is wrong, the screen will keep static until you enter the correct No.;
Bill No. is composed by date of the day and 3 numbers, for example, 15001 means
the first loading bill on 15th.
If it is remote control mode, and press the key crane position 1 or crane position 2
on main menu screen, or master computer has placed orders, then enter the slot card
screen of bill:
CP1
Bill number
Local CP number
CP number
Read
Pass
with IC card
OK
On input screen of bill with IC card, the No. is read by slotting the card. If you want to
slot the card of crane position 1, put the IC card in card area of loading instrument, press
the key crane position 1, then internal card reader of loading instrument read the data
from the IC card. If the read number is in accord with the internal number of the native
machine, then prompts the success of slotting card, and you can enter boot screen
directly.
The above is loading system screen, the loading instrument can also add new
operation windows and screen functions according to practical situations and customers
requirements.
5.2.2 Loading Instrument operation process without IC card
The operation process is general process of loading, specific operation process
should be depended on the condition of the site. The following diagram is the loading
process without IC card:
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NO
Validates if the data
NO
is correct
YES
YES
Field operation is ready, presses the key start to send out oil
Sends out oil in the field, and monitors the process in control room
NO
Send out oil to the
volume?
YES
Closes the valve and pump, operator takes out crane pipe and removes the electrostatic switch
Central control room automatically records the data of this operation, forming database records
Customer or driver takes back oil payment bill, punches the card and drives out the vehicle
The end
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power interface
LCD Interface
Keyboard interface
Input/output interface
Terminal blocks
Communication signal
Power output
Power input
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Signal model:
24.
Signal type:
25.
Signal amplitude
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quantitative loading control device provides control output for customers, can be
connected with various configuration plans and various types of valves, to meet the
different loading processes of customers.
29. Valve configuration: 1 to 2 sets of main control valve (required), oil select valve
(optional), blow-down valve (optional), reflux valve (optional), gas valve (optional), and
so on.
30. Valve selection: solenoid valve, electronically controlled pneumatic gate valve,
electronically controlled pneumatic ball valve, two-stage solenoid valve, multi-stage
solenoid valve, motorized valve, dual control valve, single control valve,
electro-hydraulic valve, and so on.
31. Adaptability requirements of different valves for AWZ quantitative loading instrument:
i) Load requirements of control output are different (For example, solenoid
valve normally takes power 20W, electronically controlled pneumatic valve
only takes power 12W).
ii) Hold-up time of control output effective signal are different (For example,
single control valve must remain effective throughout the whole action
period, generally dual control valve only requires effective pulse of
second-class action time).
iii) Interdependence degree and interdependence feature of adjacent signals
are different(For example,
only has simple open/close control, but the relationship between 2 control
signals of multi-stage valve is very complex.
iv) Direct and indirect control(Valves are generally 24V power supply, can be
controlled directly by output of AWZ quantitative loading instrument.
Some multi-stage valves and motorized valves require 220V power
supply, can be controlled only through intermediate relay).
v) Have or not valve echo device (For example, electronically controlled
pneumatic valve always be equipped with echo device, but generally
multi-stage valve not be equipped with).
vi) Types of echo signals are different (There are dry contact type, current
type of two-wire or three-wire).
7.3.2 Cable selection
For dual control valve and control valve with echo device, generally select KVVR
71.0or 1.5or KVV 71.0or 1.5control cable without shield, R means that the lead
is multi-core flexible wire.
If select RVV 71.0or 1.5, the thickness of sheath is only 0.8mm, can only be
suitable for installation through pipes.
For single control valve and control valve without echo device, can reduce the core
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Cascade connection of cable should also include connection of cable shield. Cable
shield of each cable should be connected, and be earthed at one point of monitor
computer! (It is determined according to the situation of the scene!)
Make a parallel connection resistance of about 250 between communications
contacts DATA+ and DATA- of the last AWZ quantitative loading instrument, as the
terminal termination resistance (matched resistance), to improve the accuracy of signal
transmission and transmission distance.
Communication cable must go through pipe separately, can not use the same
pipeline with the other power supply cables!
Group 2
power
flow
power
consumption
of
AWZ
quantitative
instrument7W24V 300mA
33. Anti-oil spill, electrostatic protection device0.10.75W24V 30mA
34. Integrated temperature transmitter0.2W24V 10mA
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loading
39.
Cable
section
mm
power
Allowable
Selected
Total
Working
The maximum
supply
voltage loss
valve
power
current
length of cable
voltage
consu
km
10
0.4
0.3
Solenoid valve
50
0.06
Electronically
10
0.2
0.6
Solenoid valve
50
0.12
Electronically
10
0.4
0.5
Solenoid valve
50
0.1
Electronically
10
0.2
mption
W
1.5
24
Electronically
Controlled
Pneumatic Valve
48
Controlled
Pneumatic Valve
2.5
24
Controlled
Pneumatic Valve
48
Controlled
Pneumatic Valve
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Solenoid valve
50
0.2
If the length of supply cable is given, the cross-sectional area of cable S can also be
calculated.
SL2RiIVL2RiWVV
1 power supply wiring of system
Recommend to supply power for AWZ quantitative loading instrument in the field
station by station in main control room, through power distributor.
Power distributor provides fuse, switch and status indicator for each supply cable,
and the power of each AWZ quantitative loading instrument can be arbitrarily cut off in the
control room, without affecting other AWZ quantitative loading instruments work in the
field, which is easy to commissioning and maintenance.
Power supply and distribution are shown in Figure 4.
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8Selection introduction
AWZ
1 LED
large
screen
without
anti-explosion
1.
2.
3.
3.
4.
5.
1.
2.
Electro-hydraulic valve
3.
Control Valve
4.
1.
5.
3.
Other
1. Without IC card
2. With IC card
9. Maintenance
9.1 General Maintenance
1) Open the cover to overhaul while the power is on is strictly prohibited; you must
restore it after overhaul.
2) Regularly check the screws of loading instrument anti-explosive cover, to see if
they are loose or missing. To ensure safety, please screw on or make up timely if
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condition of internal equipment. If it also can not be solved, please contact the factory!
2) In loading process, if there is no liquid outflow in the case of pipe smooth after
pressing the key start, firstly check if the control valve has movement, if not,
firstly check if the loading instrument has output signal, and then check if there is
something wrong with the control valve.
3) In loading process, if there is no flow accumulation after pressing the key start,
but the control valve is open and liquid flow out, firstly check if there is something
wrong with the parameter of loading instrument. In the case of it has no problem,
open the flow meter, to check if flow meter has signal output. If has, open the
loading instrument to check the signal input terminal.
9.4 Other cautions
1) Use flexible carton for packaging, storing and transporting loading instrument.
Field installation also should be done in moisture proof and ventilated zone,
storage temperature is 40 70, transportation condition meets the
three-level.
2) Ordering information
Customers provide the existing or required equipment conditions of loading
process, including the necessary technical parameters of selected valve, flow
meter, temperature sensor and other equipments.
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