SCALETRON 1099 Chemical Process Controller

General Description

The Model 1099TM Chemical Process Controller provides a means for weighing chemicals, controlling the processes of batching, filling, emptying containers, and providing “scada friendly” information. This indicator can be used as the first step toward an automated system. The Model 1099TM will monitor up to four scale systems simultaneously and provides the data and ability to record daily usage reports. The large LED display (0.56″ high) provides digital weight. The LCD display is an alphanumeric display that provides 2 lines of 16 characters for the menu and options, which is backlit for easy reading. The electronics are housed in a NEMA 4X, UL approved enclosure. The indicator plugs into a wall power source and operates on 120/240 VAC, at 50/60 Hz. The Model 1099TM can be used with all of our electronic scale bases.

Standard parts
Indicator
Instruction Manual

Available Options
4-20mA signals after the first standard Set Points: a maximum of four available

Specifications

Channel: 1 – 4 Independent weighing channels with independent input / output controls
Input: Up to (16) 350 Ohm load cells on each indicator total
Display Units: pounds, kilograms, gallons, and liters
Range: Maximum Reading: 99,999
LED Display: 0.56” high, indicates the numeric result
LCD Display: alphanumeric display, 2 lines of 16 characters, backlit for easy reading, displays menu and function
Keyboard: 10 Function keys, 10 Numeric keys, Audible and Tactile feedback
Connector: Power cable sealed with plastic strain relief
Enclosure: NEMA 4X, UL Approved Enclosure
Performance: Overall system accuracy 0.1% to 0.25% Full Scale
Power Rating: nominal
Voltage: 120 / 240 VAC
Frequency: 50/60 Hz
Power: 0.10 / 0.05 A
MAINS supply operational range: +/- 10% of Nominal VAC
Battery: Lithium Coin battery (not replaceable in field). Lifespan estimate: 10 years.
Operational Temperature: 0 C – 40 C
Maximum Rated Altitude: 2000 m
Maximum Relative Humidity: 20% to 90% non-condensing
Pollution degree: 2
Weight of Indicator: approximately 7 lbs.
Dimensions of Indicator: 11.31” high, 9.31” wide, 5.43” deep
Recommended Indicator Location: This indicator should be located in a location that protects the indicator from being soaked with liquids or extreme weather locations. If the indicator is to be located outdoors, you must make sure not to exceed the operational temperature range, and it is recommended that you provide a covering to protect the indicator from the elements. Locations inside buildings should be at a height that protects it from chemical splashes and washdown areas, but still allow for easy operation of keypad.

Please note: It is imperative that you read the instructions in the manual. Indicator is fully tested and programmed to the corresponding base at the factory. If you experience a problem with this equipment, please disconnect all accessories to this equipment to isolate the problem. As we have taken great care to be sure your equipment is fully functional within factory specifications before it leaves our facility, it is best to familiarize yourself with the manual for set-up and operation procedures before you begin using this equipment. All safety precautions need to be observed for the safe operation of this equipment. Failure to operate this equipment as instructed can result in damage to the equipment, and can possibly cause

Assembly and Start-up Instructions

Before you begin, please notice the programming sheet that comes in the box with your indicator and instructions. This page tells you the parameters to which your unit has been programmed. Your unit is programmed at the factory as it is ordered. If there are incorrect parameters, please refer to this manual to see how any changes you make will affect the other options, and the calibration of your unit. It is imperative that you correctly set the menus in order for this unit to work. Any changes in the units, decimals, count-by, resolution, and calibration of the unit will affect the output! If you make any changes to the set-up, you must record the menus you alter so that you can inform customer assistance if you call for technical help. Without the changes, our factory will be trying to advise you using the factory set-up!

Indicator Precautions:

The indicator is sent with a door latch, and the door will have two screws holding the door shut. Those screws are to be removed in order to insert the connections to the various connectors in the box. When connections are complete, and the indicator door is latched closed, you must reinstall the screws that hold the indicator door closed. The power cord is attached at the factory using a liquid tight fitting. Do not modify or restrict the ability to disconnect the power cord from the outlet. Connections for bases using other fittings or conduit must be made in the field. Please take care to not damage the internal components when drilling a hole in the indicator box. All holes drilled MUST be sealed so that gasses and liquids cannot penetrate the box and damage the internal electronics. Do not drill holes where the internal cables are located. If there is a gap or opening in the box that isn’t sealed by the connector, use a silicon caulk to seal the opening from exposure. Please use fittings that are liquid tight fittings and are rated for NEMA 4X conditions. Do not use any type of conduit fitting or other fittings that do not have a tight seal to the indicator. Damage may occur if gasses and liquids have access to the electronics! The mounting location of the indicator should be at operational level, away from the floor. Indicator is a NEMA 4X rated enclosure; however, it is not designed to withstand wash-down procedures, or chemical contact beyond accidental exposure. Please choose a location that will protect the indicator from direct contact with chemicals, or regular soaking of water. Indicator is mounted to wall using the four holes in the tabs on the indicator box. If the indicator is mounted in a way that does not comply to the standards above, the resulting damage will not be considered for warranty repair, and may cause substantial damage to the electronics. If the indicator should require cleaning, a cloth damp with water would be recommended to wipe the display and keypad area, as long as the chemical conditions can allow for it. Due to the fact that the chemical environment in which the 1099TM may be located, can vary greatly, we cannot identify one specific cleaner to maintain the indicator. You must use your own discretion when cleaning with any substances. Mild cleaners should not affect the indicator box. Harsh or abrasive cleaners are NOT recommended for use as they may etch or scratch the finish on the mylar or enclosure.

Indicator Connections:

In order to start the Model 1099™ Chemical Process Controller, you must first install the bases according to their instructions. Please refer to the Base Installation portion of the Instruction Manual found on the front of the manual for the safe installation of your new base(s). The Orientation Diagram on page 23 will illustrate the layout of the area on the interface board where the wires need to be connected for base input, 4-20mA circuit, Set Point connections, and communication circuits, if ordered. If a “Remote Box” option is ordered, there will be instructions included for the wire connections at the remote box, and then to the Model 1099™. If you have multiple bases and channels, you must connect the bases as labeled, to the channels to which they were calibrated. Bases and indicators are clearly marked as to their connection location.
After bases are secured, according to factory instructions, connect them to the indicator as shown on Diagram 1. TB1 is the connection location for Channel #1. If more than one channel has been ordered, the connections are as follows: TB2 is the connection location for Channel #2, TB3 is the connection for Channel #3, and TB4 is the connection location for Channel

4. The wire color code is as follows: R = red, G = green, W = white, B =

black, and S = shield (referring to the wires that come from the base to the indicator. The terminal blocks are labeled with the letters to guide you.
4-20mA Connection:
The 4-20 circuit for the Model 1099™is a LOOP POWERED circuit, or supplied or externally supplied with power. The circuit is designed to work with a supply range of 18-30 VDC, but the nominal supply rating is 24 VDC. The connection for this circuit is found on page 22 of the manual.
The 4-20mA signal connections are located at the connectors labeled: TB9, (and if optional 4-20mA connections are ordered), TB10, TB11, and TB12. The connectors are labeled with positive and negative respectively. TB9 is the connection site for 4-20mA reading at Channel #1, TB10 is the connection site for Channel #2, TB11 is the connection site for Channel

3, and TB12 is the connection site for Channel #4.

Set Point Connections:
The Model 1099™ has an option for up to set point circuits with a relay rated for 5 VDC, 40mA, and coil resistance of 125 Ohms. Relays are SPST- NO + SPST-NC.
The Set Point connections, if ordered as an option, are located at the connectors labeled: TB5, TB6, TB7, and TB8. Set-points may be configured to any of the channels, from one to four on one channel, or any combination limited to four separate set points. Relays may be latching or non-latching, may be set as HI, LO, or Control (no beeping buzzer, but contact closure), or may be deactivated by setting to NONE. When in use, the ACK key can be used to stop the alarm, but this also RESETS the coil and can reactivate the circuit. Please be aware of this when making connections. Printer
Port Connections:
If the printer option is selected, the connection location is at TB13. When connecting an RS 232 printer, the connection is as follows: At TB 13, #1 = Transmit, and #3 = Return. When connecting an RS 485 printer, the connection is as follows: At TB 13, #1 = Receive+, #2 = Receive – , #3 = Shield, #4 = Transmit – , #5 = Transmit+.

After these connections have been made, double check to be sure that the correct wires are connected in the correct location to prevent electrical damage to the scale and its components.

Now you are ready to plug the Model 1099TM indicator into the wall power supply source. When you plug in the indicator, you will see the LED display show a number, and the LCD display flash a message of the version number of the software, then it will show a reading “SCALE X (UNIT) NET WEIGHT”. In order to view the other channels (if activated) press the key.

General Operation Keys:

The following instructions are IMPORTANT FOR THE GENERAL OPERATION OF THE MODEL 1099™. These are general rules that apply to the navigation of the menus and sub-menus. The term: COMMON DISPLAY SCREEN refers to the screen that you see upon start-up. It is the screen that says Total, or Scale X (where x represents a channel number between 1-4) “Net Weight”. This screen may always be returned to by pressing the Esc key from any menu, but be aware that if you are making changes to any sub-menu that has not been completed, and you press ESC, you will erase your most recent changes! Make sure to “complete” a sub- menu by returning to the first screen of that sub-menu. For example, the “first screen” of the Zero a Scale sub-menu shows the following: “Zero A Scale “. Please refer to the Pro Gram™ Guide for a pictorial illustration of this concept. The Pro-Gram™ Guide makes this concept very obvious. It is the best tool for helping you to navigate the options!

1. The ESC key is used to escape from any state (color code red on Pro-Gram™ Guide):
   a. If in Operator’s Menu:
   1] If in a sub-menu of the Operator’s menu, and ESC is pressed, the changes of that specific sub-menu will be erased. The screen will return to the head of that sub-menu first. Pressing ESC again returns the user to the Common Display Screen.
   2] If at the head of a sub-menu, changes are not discarded. User will return to the Common Display Screen.
   b. If in Set-up Menu:
   1] If currently in the Set-up menu, at the head of a sub-menu, return to the Operator’s menu screen that says “GO TO SETUP
   MENU ”. Pressing ESC a second time returns the user to the Common Display Screen. 2] If currently in a sub-menu of the Set-up menu, pressing the ESC key will return you to the head of the sub-menu, erasing the data you have just changed in that sub-menu. Pressing ESC again returns user to the Operator’s Menu at the “GO TO SETUP MENU” screen. Pressing ESC a third time returns you to the Common Display Screen.

2. is a prompt to press the ENTER key (color code blue on the ProGram™ Guide).

3. is a prompt to press the ESC key (color code red on the Pro-Gram™ Guide)

4. is a prompt to press the DELETE key (color code purple in the ProGram ™ Guide).

5. A blinking entry point indicates that a value is to be entered.
   a. The symbols , indicate to use the “Menu ” ,, or “Menu  ” key to cycle through a circular list of values, then .
   b. An “=” sign, (with no present) means that the user will enter a number using the keypad, followed by the ENTER key.

6. In the OPERATOR’S MODE only:
   a. the SCALE SELECT key scrolls through the available scales, including the TOTAL for all scaies when appropriate.
   b. the DISPLAY SELECT key scrolls down through the list of display screen types, wrapping back to the top of the list.
   c. “….” On the LED display indicates that the LED display is not used for this function.

7. In the SET-UP MODE only:
   a. On the OPERATOR’S MENU screen, you can key in and a step number directly,
   or
   b. Use the MENU , or MENU   key to scroll up and down through the numbered primary menus (head of the sub-menu).
   c. In the sub-menus, the symbol indicates to use the MENU  , or
   MENU key to cycle through a circular list of values, then press to select.

General Usage:

There are two separate menus that are available to the operator. The first menu is the “Setup Menu” which is where your options will be selected and locked, by the use of a password. If the factory is given all of the required information, the indicator can be programmed at the factory. We will assign a password and give it to you, if you wish, so that you may access the set-up menu if changes need to be made. This password can be changed at a later date, but should be kept on file in a secure location. This will prevent the data and output from being altered. This menu is accessible through the Operator’s menu. The Operator’s menu allows for easy access to the operational type information, while keeping it separate from the set-up of the indicator. Some of the options accessible in the Operator’s Menu include the ability to zero a scale, load scale, enter net or tare weight, and select different channels. Also, you may read amount used, the last time the scale was cleared, daily usage, and days until empty, and gross weight.

For specific information on the set up and operation of this scale, you may refer to this manual and to the Pro-GramTM Guide Flow Chart that provides a visual, step by step guide to the use of your new Model 1099TM Chemical Process Controller. The Model 1099TM Chemical Process Controller is designed for ease of use. Please follow the directions following, and use the flow chart as a reminder of how to operate the scales and indicator. The chart may be mounted on a wall near the indicator, and is laminated for your convenience . Please refer to the Pro-GramTM Guide for a helpful visual representation of the menus and sub-menus**** The following instructions are IMPORTANT FOR THE GENERAL OPERATION OF THE MODEL 1099TM. These are general rules that apply to the navigation of the menus and sub-menus.

The following instructions describe the general operation of the Model 1099TM Chemical Process Controller. The individual needs of the user may dictate an adjustment to this procedure. All users, regardless of the Tank Mode selected, must navigate the “Load Tank” or “Fill Tank” menu in the “Operator’s Menu”. This can be achieved by beginning at the Net Weight Screen, and pressing “Display Select” button once. If you have chosen the Load Tank (Net), or Load Tank (Tare) modes, you will be removing the empty cylinder. If you are set up to “Fill Tank”, you will not remove the empty tank. Please refer to the laminated Pro-GramTM Guide for pictorial illustration of these menus. Each time there is a cylinder change, this sub menu must be entirely completed in order to register a correct amount used. (You will know this has happened once the LCD prompt is showing the screen at the “top” of the sub-menu, according to the Pro-GramTM Guide.) If there is more than one base attached to any one channel, all cylinders / tanks on that channel must be removed simultaneously when loading a new cylinder/tank, even if only one will be replaced. (Multiple bases on one channel only have one signal going into indicator, therefore any channel with multiple bases per channel must have all bases on that channel cleared off when scale prompts user to “Remove Empty” and press enter!) Please see appropriate instructions below according to your custom set-up.

The first time that this scale is put into operation, all channels must be zeroed completely. If you are operating in “FILL” mode, then you will prepare scale base, mount and center the EMPTY, permanent tank on the base, and complete the “Zero a Scale” menu. If you are in “TARE or NET” mode, you will zero the empty base. This is accomplished by completing the “Zero a Tank” sub- menu in the Operator’s Menu. This may be reached from the main screen by pressing “Display Select” key two times. The heading reads: “Zero a Scale”. Complete this sub-menu and return to the main screen. If there are any readings on any channel at this point, you may have a residual net weight stored in the unit from when it was tested. If this is the case, you must complete the “Load a Tank” menu in a special way in order to clear out the net weight. From the Common Display Screen (Net Weight Screen), press Display Select key once. The sub menu will say, “Load a Tank” in whatever mode you are operating in (Tare, or Net). Press Enter key to access this sub-menu. The LCD will read: Enter Scale # (Use ) X” (Where X represents the channel that you are choosing). Press the Menu keys to choose channel, and press Enter to accept that choice. The menu will now read: Remove Empty and Press Enter. Press Enter to see: Load A Tank And Press Enter. Press Enter. Now the LCD will read: Enter (Net or Tare) Wt. = X Lbs. At this point ­ DO NOT LOAD THE TANK ON TO THE BASE! You will type in the number “0” and Press Enter. LCD will read: Are You Sure? You will press Enter. You will now be seeing the top of this sub-menu, which means you have successfully completed this sub-menu. You may press the Esc key one time to get back to the Common Display Screen. Your Net Weight readings should say “0”. Make sure this procedure is completed for each channel activated!

When you are ready to begin using the contents of the tank, you must start by entering the LOAD TANK (or FILL TANK) menu. Follow the instructions as prompted on the LCD. Do not load tank (or fill) until you are prompted to. Make sure you follow each step in the correct order. Doing steps out of order will register incorrect values into memory. Please choose the correct set of instructions below for your machine’s set-up.

Load Tank (Net):

From main screen (NET WEIGHT), press Display Select one time. You will see “Load Tank (Net)” on the LCD. Press ENTER to gain access to this Sub Menu. Your LCD will read “Enter Scale #1” with two up/down arrows. If you have only one channel activated, you will not change this screen by pressing the Menu ab keys. If you have more than one channel activated, you will be able to scroll through the different “scales”, or channels, that are active. Choose the “scale” or channel you wish to reload by pressing the ENTER key. Your LCD will read, “REMOVE EMPTY AND PRESS ENTER”. At this time, you must remove all cylinders/tanks that are on bases hooked to this channel before pressing anything! When scale base(s) are empty, proceed by pressing ENTER. Your LCD will read, “LOAD TANK AND PRESS ENTER”. You must load all cylinders on at this time (even if some are not full) before pressing anything. Please note: if you have a partially used cylinder that you are reloading on a base hooked to this channel, you must know the NET weight (the contents in the cylinder/tank) and add the Net Weights of all cylinders/tanks that are connected to this channel. Add the Net weight of all cylinders/tanks on this channel and type that number in, using the keypad. (It is wise to allow the contents to settle if possible, for 15 minutes before pressing enter.) When ready, press enter. The LCD will ask you: Are you sure? You will press ENTER for yes. This is now complete. Press ESC one time to see the Net Weight screen, which will now reflect the Net weight of the cylinders/tanks you have reloaded.

( Example: Two Ton bases are connected to channel one. You are loading on a new Ton cylinder with 2000 lbs of contents, and you have 1150 lbs. of contents in the second Ton cylinder. (You replace the empty tank with a full one, and load on the partially full tank as you proceed through the “LOAD TANK (NET) menu.) When the scale prompts to remove empties, you must clear off all bases. Then you are prompted to load new cylinders. Both cylinders are re- loaded, and you press enter. The next screen asks you to enter the net weight. ADD the NET weights of both cylinders you will have re-loaded, and type that number in using the keypad. Your combined net weight is: 3150. You type in 3-1-5-0- and press ENTER. The screen will ask: Are you sure? And you will press ENTER to say Yes. The screen will return to the head of the sub menu. At this time you know that you have completed this function. Press the ESC key to return to the main, “Net Weight” screen. Begin using the contents.)

Load a Tank (Tare):

From main screen (NET WEIGHT), press Display Select one time. You will see “Load Tank (Tare)” on the LCD. Press ENTER to gain access to this Sub Menu. Your LCD will read “Enter Scale #1” with two up/down arrows. If you have only one channel activated, you will not change this screen by pressing the Menu keys. If you have more than one channel activated, you will be able to scroll through the different “scales”, or channels, that are active. Choose the “scale” or channel you wish to reload by pressing the ENTER key. Your LCD will read, “REMOVE EMPTY AND PRESS ENTER”. At this time, you must remove all cylinders/tanks that are on bases hooked to this channel before pressing anything! When scale base(s) are empty, proceed by pressing ENTER. Your LCD will read, “LOAD TANK AND PRESS ENTER”. You must load all cylinders on at this time (even if some are not full) before pressing anything. Please note: if you have a partially used cylinder that you are reloading on a base hooked to this channel, you must know the TARE weight (the weight of the cylinder/tank) and add the Tare Weights of all cylinders/tanks that are connected to this channel. Add the Tare weight of all cylinders/tanks on this channel and type that number in, using the keypad. (It is wise to allow the contents to settle if possible, for 15 minutes before pressing enter.) When ready, press enter. The LCD will ask you: Are you sure? You will press ENTER for yes. This is now complete. Press ESC one time to see the Net Weight screen, which will now reflect the Net weight of the cylinders/tanks you have reloaded.

If you only have one base per channel, you will only have to lift the cylinder/tank for that channel. Follow the same directions as written above, or see example below.

(Example: Two Ton bases are connected to channel one. You are loading on a new Ton cylinder with 1200 lbs tare weight (stamped on cylinder), and you have 1100 lbs. tare stamped on the second Ton cylinder. You replace the empty tank with a full one, and load on the partially full tank, and proceed through the “LOAD TANK (TARE) menu by pressing ENTER. When the scale prompts to remove empties, you have cleared off all bases. Then you are prompted to load new cylinders. Both cylinders are re-loaded, and you press enter. The next screen asks you to enter the net weight. ADD the TARE weights of both cylinders you will have re-loaded, and type that number in using the keypad. Your combined tare weight is: 2300. You type 2-3-0-0- and press ENTER. The screen will ask: “Are you sure?” and you will press ENTER to say Yes. The screen will return to the head of the sub menu. At this time you know that you have completed this function. Press the ESC key to return to the main, “Net Weight” screen. Begin using the contents.)

Fill Tank:

When operating in Fill Tank Mode, there are a few things done for the first use of the tank that are not repeated. It is imperative that these things be done in the correct order to assure proper readings of the weight.

For use the FIRST time: User should place the scale into its permanent position, level the scale if needed, and connect all wires accordingly. Once scale base is properly installed and the empty tank is loaded, the scale should be zeroed. This is accomplished by the following: From the NET WEIGHT (main screen), press Display Select key twice. The LCD will read: “ZERO A SCALE”. Press ENTER. The LCD will read: “ENTER SCALE #1 “. If there is more than one channel activated, you must zero each channel by going through the menu completely for each channel. Choose the “Scale” or channel, by pressing ENTER. (AT THIS TIME, BASE(S) LOADED WITH A COMPLETELY EMPTY TANK.) The LCD will ask “ARE YOU SURE?” and you will press ENTER to say Yes. Do this for each active channel. When each channel has been zeroed, return to the Net Weight Screen by pressing the ESC key. This should display a “0” for each channel activated. DO NOT ZERO THESE BASES AGAIN WHILE A CYLINDER/TANK IS IN USE! You must now proceed to the “FILL TANK” sub-menu by pressing the Display Select key one time. With the tank empty, press ENTER to navigate the Fill Tank submenu. This will be the process that is completed EACH TIME you are finished with a tank and need to refill that tank. The LCD will say, “ENTER SCALE #1” and you will use the Menu keys to choose the correct channel. Press ENTER to select that channel. The LCD will prompt you to “FILL TANK AND PRESS ENTER.” Be sure to completely finish filling this tank before pressing enter! When tank is full, press ENTER. The LCD will ask, ARE YOU SURE? Press ENTER to say Yes. This procedure must be followed each time a tank is filled so that a proper record of amount used will be registered. Failure to follow these steps may result in an inaccurate weight reading.

** All methods of use: The rest of the Operator’s Menu will provide information about usage of your material, and can be accessed by pressing the Display Select key. Please refer to the Operator’s menu instructions for more details.

Operator’s Menu:

In order to move through the Operator’s Menu, press the Display Select key.

LOAD A SCALE:

Depending on your selections in the Set-up menu for #15 ­ Tank Load Mode ­ your sub-menu options will vary to one of the following choices:

LOAD TANK (NET):

The LED Display shows “….” and the LCD Display shows “LOAD TANK (NET)” “”. In this case, leads to “ENTER SCALE # (USE ) 1″ This screen is prompting you to use the Menu up and down keys to choose the number of the scale, or channel, you want to work on. Press the key to continue. If there is nothing on the scale base, then press at the screen that says “REMOVE EMPTY AND PRESS ”. If there is something on the scale, remove it, and then press . The LCD screen will read: “LOAD TANK AND PRESS