Autoware Science & Technology

Co.,Ltd

Instruction Manual
For

The Anti-explosion Distributed

AWZ Batch controller of loading

- 1 -

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 -

- 2 -

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.

2. Features and Functions

The features and functions of AWZ PLC are as follows:
An AWC BCL can time-sharing control 1-4 loadings with crane positions;
It can control the proportioning of the materiel and supplies;
It has the function of temperature compensation with two compensation methods:
artificial set temperature and automatic temperature collection.
Static electrical grounding protection. That is, the loading cant be started up or
stopped immediately if the grounding is not proper.
Oil outflow protection. When receiving the signal from the oil outflow controller, it
closes the valve and stops the pump;
Emergency stopping. It can stop the loading when press the emergency stop in case
of emergency.

- 3 -

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.

3. Important Technical Indicators

Power source
Output 220VAC or 24VDC
Input12VDC24VDC, power value 50W (for external sensor and actuator)
Input signal
Flow ratepulse signal 010kHz
Compensation temperaturedepending on the conditions on the spot (usually
recommend 0100)
Valve open/close signal electrical independent contact (current or voltage
series; specified in the orders)
Liquid level switchelectrical independent contact (current or voltage series;
specified in the orders)
Output signal
Valve control signalcapacity 24VDC, 0.5A / 1A or 220VAC (optional)
Hold time of the control signal198 minutes or forever
Control logicit can control 8 magnet windings and the manner and order of the
valve switch are configurable.
Swiping mode of IC card: Non-contact
Type constraining of IC card: No
Distance of IC card swiping: within 50mm of the controller IC card swiping plane
Display manner
Total LCD and high backlight
Key structure
24 keys (machine with one bit) and 24 joint keys (machine with two keys)
(9) Precision
Accumulated error of the flow rate0.1FS
Display error of the temperature0.5
- 4 -

(10) Set volume

Setting range of the definite quantity 1999999 kilograms (or liters)
Setting range of the density0.00012.0000
Setting range of flow coefficient0.100099999
Setting range of coefficient of expansion0.00001 000.0 10-6/
(11) Operation
Continuous operation
(12) Communication
RS485
MODBUS RTU protocol
Baud rate1200240048009600,19200
Maximum distance1.2km
Ethernet
TCP/IP protocol
Transmission distance reaches up to hundreds of kilometers when transmitted
by optical fiber.
(13) Requirements
Ambient temperature 40 70
Relative humidityno more than 95%
The magnitude of explosion for the gas mixture of the combustible gas or the
flammable liquid is II B.
(14) Storage temperature
4060
(15) Explosion-proof magnitude
EX(d)BT6
(16) Dimension (L W H)
470mm350mm170 mm machine with one bit
500mm400mm200 mm machine with two bits
500mm402mm13800 mm machine with two bits
(17) Weight
15kg (machine with one bit)
18kg (machine with two bits)
35kg (machine with two bits)

4. Operational Principle
(1) Hardware
The hardware of the system consists of intelligent controller module, unitized liquid
- 5 -

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

- 6 -

standard density of the fluid at 20)

(5) Interlock and alarm
The liquid level switch is installed a little higher than the specified liquid level of the
tank. When the loading LL goes beyond the specified LL and reaches the position of the
LL switch, the switch sends out signal and the BCL closes all the valves and alarms.
Meanwhile, the alarm message is displayed on the operation panel.
In order to avoid the fire accident which may be caused by the excessive
accumulation of the static electricity that is produced by the friction between the materials
and supplies and the air, a proper grounding system of tank wagon is then required. When
BCL starts, it first checks the grounding alarm signal. If the signal is greater than the
specified ground resistance, the controller will alarm and refuse to load and the alarm
message is displayed on the operation panel.

5. Operation Instruction
AWZ BCL uses all Chinese operation interfaces and is easy to learn use and operate.

5.1 The instruction of BCL panel and keyboard

Figure 2

The operation panel and keyboard

Key functions description as below:

5.1.1 Key of machine with two bits

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
- 7 -

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

- 8 -

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

5.2.1 Screen instruction

The following screens are the unified screens before leaving the factory. The screens
leaving the factory depend on the specific configuration and may differ from the followings
because of the difference of projects.
5.2.1.1 Screen instruction of machine with one bit
When turning on the system, the boot screens are as following:

welcome
Boot screen
Shenzhen Autoware Technology
The leisure screen will appear in three seconds:

AWZ

Quantitative

loading

controller
Shenzhen Autoware Technology
- 9 -

Leisure
leisure screen
screen

The leisure screen, working as a screensaver, usually comes when there is no

loading. To enter the loading system, input the password: press page down, and input
the first level password when the box pops up. If the password is right, the main menu
screen will shows itself

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

Press set to setup parameters

Main menu screen

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:

Setup of flow coefficient

Setup of preact of closing valve

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
- 10 -

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:

Please input the set volume

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:

Please input the bill number

Bill number input screen

A right number can enter boot 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
- 11 -

the master computer has been placed an order, it will enter the number of the bill of lading
input screen:

Bill number input screen

with IC card

Local bill number

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

static electricity oil

spill
- 12 -

On the monitor screen it can real-time monitor the transient flow, valve and static
electricity oil spill and so on.
Valve state:

indicates a proper closing,

Static electricity:

indicates a proper open;

indicates a proper grounding. If there is no match display, it

indicates no grounding.
indicates that oil switch is normal,

indicates that oil spill switch

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

Loading emergency stopping

Please press set to reset

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
- 13 -

Shenzhen Autoware Technology

The leisure screen will appear in three seconds:

AWZ BCL
Shenzhen Autoware Technology

Boot screen

Leisure screen

The leisure screen, working as a screensaver, usually comes when there is no

loading. To enter the loading system, input the password: press page down, and input
the first level password when the box pops up. If the password is right, the main menu
screen will shows itself

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

Main menu screen

Loading Instrument parameter settingsPress set

Loading Instrument Monitor screenPress page down

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:

Parameter setting screen

Crane position 2

Flow coefficient
Preact of closing valve:

- 14 -

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,
- 15 -

the loading process of crane position 2 will stop urgently;

4) Monitoring several major equipments of the two crane positions loading processes,
mainly includes loaded volume, loading state, valve, electrostatic switch, oil spill switch,
and so on.
Loading states: loadingleisure, emergency stop, placed an order;
Valve state:

indicates a proper closing,

Static electricity:

indicates a proper open;

indicates a proper grounding. If there is no match display, it

indicates no grounding.

indicates that oil switch is normal,

indicates that oil spill switch alarms.

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

Input the correct number, and then enter the

boot screen automatically
The main function of input screen of bill No. is to input the No. printed by master
computer on loading instrument which has placed orders, to ensure that the tanker can
load in correct crane position;
If the No. you entered is the bill No. reserved by loading instrument, you can enter the

- 16 -

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:

Local bill number

CP1

Bill number
Local CP number

Bill number input screen

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:

5.2.3 Loading Instrument operation process with 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 with IC card:

- 17 -

Make out an bill in business office

input relative parameters into database)
Draws bill, exchanges bill and issues oil payment bill in control room (enter user
name, bill number, delivery capacity and other parameters into relational database;
at the same time write loading data in control device and IC card)

Drives tanker to one crane position

Operator puts in crane pipe, and turns on the

electrostatic switch
Customer or driver punches the IC card

NO
Validates if the data

NO

is correct

YES

If can send out oil in

the crane position?

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

- 18 -

6Structure chart of loading instrument hard wares

Quantitative loading control device

Central processing unit
Communication interface

power interface

LCD Interface
Keyboard interface

Input/output interface

Terminal blocks

Communication signal

Alarm output signal

Static grounding signal input

Spill switch input signal

Pump control output signal

Valve input and output signals

Temperature signal input

Flowmeter signal input

Power output

Power input

Figure 3 Internal structure chart of loading instrument

6.1 Wiring diagram of loading instrument terminal

The wiring diagram is printed separately according to the requirement of each project before
loading instrument leaves the factory, and is bound together with the manual!

Selection of cables connected to related equipments

7.1 Connection with the flow meter
7.1.1 Flow meter transmitter selection
AWZ quantitative loading instrument can be connected with various types of flow
meters which measure pulse volume output. To ensure the success of connection,
commissioning and operation, the flow meter transmitter selected must have the following
electrical characteristics:
22.

Power supply mode: DC power supply, supply voltage DC +24 V or DC

- 19 -

+12 V, supply current is less than 100mA.

23.

Signal model:

010kHz pulse signalsquare wave or sine wave.

24.

Signal type:

25.

Signal amplitude

Power level or power current signal.

Power level 024VDCpower supply voltage

Power currentSpecifically declared and provide specific

technical parameters.
26.

Transmitter type: Normally two-wire system is suitable;

7.1.2 Cable selection

Generally select KVVRP 31.0or 1.5or KVVP 31.0or 1.5, KVVRP is flexible
control cable with shieldKVVP is rigid control cable with shield; Control cable with shield
possesses strong anti-jamming capability, which is suitable for flow meter.
If select RVVP 31.0or1.5or RVV 31.0or 1.5,the thickness of sheath is only
0.8mm, can only be suitable for installation through pipes.
7.1.3 Wire splice
Splice the flow meter and terminal block of AWZ quantitative loading instrument
junction box with selected cable. If you select cable with shield, splice the shielding layer
and ground pile of junction box.
7.2 Connection of temperature transmitter
721 Quantitative loading instrument and temperature detection
Main functions: Real-time compensate temperature for volume flow value adopted by
flow meter, convert the volume flow of pipeline actual temperature t into standard
volume flow of temperature 20.
Temperature measurement range:50 100 or higher (Please specify when
you order it).
7.2.2 Temperature transmitter selection
27. Temperature detection transmitter: Integrated temperature transmitter;
28. Connection type: two-wire system4-20mA.
7.2.3 Cable selection
Select KVVRP 31.0or 1.5or KVVP 31.0or 1.5, control cable with shield
possesses strong anti-jamming capability.
If select RVVP 31.0or1.5or RVV 31.0or 1.5,the thickness of sheath is only
0.8mm, can only be suitable for installation through pipes.

7.3 Valve connection

7.3.1 Valve configuration and selection
Valve and configuration and selection are determined by loading process, AWZ

- 20 -

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,

electronically controlled pneumatic valve

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

- 21 -

wire number of cable properly.

7.4 Electrostatic oil spill protector connection

With the continuous improvement of automation instrumentation, there are some
related products which can achieve the functions of electrostatic and oil spill
simultaneously. Because they achieve the two functions as a whole, so the cable
selection is the same as single electrostatic protector, as the following:
Generally use KVV 41.0or 1.5or KVVR41.0 (or 1.5 control cable without shield,
R means that the lead is multi-core flexible wire.
If select RVV 21.0or 1.5, the thickness of sheath is only 0.8mm, can only be
suitable for installation through pipes.

7.5 Communication cable connection

7.5.1 Communication port of AWZ quantitative loading instrument
Monitor Computer located in main control room connects the AWZ quantitative
loading instrument distributed in the scene, via RS485 data communication bus, to
compose a distributed quantitative loading monitor system of decentralized control and
centralized management. And each communication wire is allowed to connect up to 25
units of AWZ quantitative loading instruments.
AWZ quantitative loading instrument has an independent communication port, which
is used for communication.

7.5.2 Communication cable selection

Should select twisted-pair communication cable special for communication, such as
pair twisted insulated PVC sheathed copper wrapped shielded cable for computer, it is
best not less than two cores according to the situation.
The thickness of outer sheath must be noticed when making selection, to meet the
requirements of explosion-proof installation.

7.5.3 Wire splice

Communication cable connected monitor computer and AWZ quantitative loading
instrument must apply cascade connection. For specific schematic diagram of wire splice,
see the following figure.
Cautions:
Communication wire must be designed as cascade connection, if wiring in normal
power distribution methods, and arranging cable joints in the scene at random, which will
increase communication errors, even make not to communicate!

- 22 -

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!

7.5.4 Maximum transmission range

According to the specification of RS-485 bus standard, the maximum length of
communication cable is related with the baud rate of communication signals, the higher
the signal baud rate is, the shorter the allowable length of communication cable is.

7.6 Power supply

i.

Power-supply system of AWZ quantitative loading instrument

1. Power supplydirect current 220V-15%5%

2. Working power
Group 1

24V direct current switching power

direct current 24V1.5AMain circuit working power,

communication line

Group 2

direct current +24V/1 1.5A Field Instrument and

equipment, valve control and echo detection

7.6.2 Power cable selection

1. Cable type:
KVV or KVVR control cable without shield, R means that the lead is multi-core
flexible wire. If you select RVV, the thickness of sheath is only 0.8mm, can only be
suitable for installation through pipes.
2. Cable wire diameter:
Wire diameter should be selected based on field devices, the size of required
current, the length of power cable, the mode of power supply wiring, allowable loss
of cable and other factors of AWZ quantitative loading instrument.
32. Required

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

- 23 -

loading

35. Flow meter0.53W24V 150mA

36. Valve control and detection150W24V 40mA2A
37. Total1060W24V 400mA2.5A
Of the total required current, current of the valve control be greatest influenced,
electronically controlled pneumatic valve only needs tens mA of current for a moment,
but solenoid valve needs holding current of 12A in the whole effective action,
difference between them are dozens of times.
38.

Allowable voltage loss of cableV15%24V 95%15%3V

39.

cable resistance RisectionS1mm2 Copper cable each km

resistance is18

7.6.3 Calculation example of wire diameter selection

When using the electronic controlled pneumatic valve and solenoid valve systems,
the maximum allowable distance of cables of 1.5 and 2.5mm2 is given, represented by L.
LVIRiSVRiS
Table 3 Maximum connection distance of certain wire diameter power cables under
different load

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

- 24 -

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.

- 25 -

8Selection introduction

AWZ
1 LED

large

screen

without

anti-explosion
1.

LED large screen with anti-explosion

1. Alarm without anti-explosion sound and light

2. alarm with anti-explosion sound and light

2.

Alarm without level

3.

Alarm with floating ball liquid level

3.

Alarm with tuning fork liquid level

4.

Protector without electrostatic

5.

Protector with electrostatic

1.

Pneumatic ball valve

2.

Electro-hydraulic valve

3.

Control Valve

4.

Electric switch valve

1.

Mass flow meter

5.

Dual rotor flow meter

3.

Other

1. Wall mounting type

2. Rack mount type

1. Machine with one bit

6.

Machine with two bits

1. Without IC card
2. With IC card

Batch controller of loading

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
- 26 -

they have the above situations.

3) For the field that use wire installation through pipes,pay attention to check the
insulation resistance of inlet and outlet wires and metal conduit for protection,
especially for valve control, check the insulation resistance of power line and
conduit of field instrument, to avoid fault and damage caused by short circuit.
40. As there is a lot of dust in the field, control cabinet surface and glass surface of display
should be cleaned regularly, to avoid damage to their surfaces.
41.
9.2 Cautions of loading instrument operation
1) The loading will be completed by loading instrument automatically if there is no
fault or damage in the loading process, operators can not randomly make any
unrelated operation to stop loading; Must not loose the switch of electrostatic
grounding clip and oil spill, must not press the key emergency stop without
abnormalities;
2) If there is fault of valve, flow meter and other equipments (except for electrostatic
oil spill protection) in the loading process, can press the key emergency stop, the
loading will be stopped by loading instrument automatically. After fault handling
and all equipments return to normal, press the key start on loading instrument,
the loading will be continued from installed volume at emergency stop until
completed by set volume;
3) If there is fault of electrostatic grounding clip in loading process, the loading will be
stopped by loading instrument automatically, which is equivalent to press the key
emergency stop. After electrostatic grounding clip returns to normal, press the
key start on loading instrument, the loading will be continued from installed
volume at emergency stop until completed by set volume;
9.3 Fault judgments and treatments of loading instrument
1) Judgment methods of loading instrument and treatments
See if the screen of loading instrument can be normally switched, if not, it means
that there is something wrong in internal loading instrument. The treatment is to power
off the loading instrument firstly, and then re-power. If the screen also can not be
normally switched, maybe there is something wrong with the internal equipment of
loading instrument. The treatment is to open the cover and to check the running
- 27 -

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.

Autoware Science & Technology Co., Ltd.

- 28 -