A. Product Overview

The iTherm BL Series is a range of programmable industrial counters developed for applications where machines need to count products, measure material length, monitor production quantity or operate equipment according to a preset count.

The controller can be configured for three primary functions:

Batch Counter: Counts products, cycles, pulses or machine operations and can operate an output when the programmed batch quantity is reached.

Length Counter: Measures material length and can also display material speed in metres per minute. The material diameter can be programmed from 0.01 to 9999.99 mm.

Preset Counter: Counts incoming pulses against a programmed target and can display RPM in preset mode.

The BL Series provides a counting range from 0 to 999999 counts and selectable count frequencies of 3 Hz, 30 Hz, 100 Hz, 1 kHz and 2.5 kHz, allowing it to work with different machine speeds and counting applications.

The available models documented by iTherm are:

BL-77: Dual display model with upper and lower LED indication

BL-886: Single display configuration within the BL Series

BL-99: Larger dual display model

The BL Series also provides two independent outputs. Depending on factory configuration, the outputs can be Relay or SSR Drive. Relay output is rated at 5 A at 250 VAC or 30 VDC, while the SSR Drive output is 12 VDC at 30 mA.

The standard operating supply is 90 to 270 VAC, with 24 VDC available on request.

B. Working Principle

The iTherm BL Series works by receiving pulses from a compatible machine sensor or counting source. Each pulse represents an event such as one product passing a sensor, one machine cycle, one shaft rotation or a defined amount of material movement.

The basic working process is:

Sensor or Pulse Source → BL Series Counter → Pulse Processing → Displayed Count or Length → Output Action

In Batch Counter Mode

A sensor generates pulses as products or machine cycles are detected.

The BL Series counts these pulses and continuously displays the accumulated quantity.

When the programmed batch quantity is reached, the configured output can operate. Depending on the programmed settings, the output can work in latch, auto reset or offset count mode.

This makes the counter useful when a machine needs to process a specific number of pieces before stopping, activating another device or starting another production cycle.

In Length Counter Mode

The instrument calculates material length according to the incoming pulses and the programmed diameter value.

The diameter can be configured from 0.01 to 9999.99 mm. The instrument can also show the operating speed in metres per minute while working in length mode.

This is useful when continuous material such as wire, cable, sheet, film, fabric or other moving material needs to be measured.

In Preset Counter Mode

The operator enters the required preset count through the keyboard.

The instrument monitors incoming pulses and compares the actual count with the programmed value. The counter can operate an output when the required value is reached.

The BL Series can also display the RPM value in preset mode.

C. Why is the BL Series Used?

The iTherm BL Series is used when an industrial machine or process requires reliable counting, batching, length measurement or preset based operation.

A manual counting process can become difficult or inaccurate when production speeds increase. An industrial digital counter automatically receives sensor pulses and maintains the count during machine operation.

One important feature of the BL Series is count retention during power failure. If electrical power is interrupted, the stored count can be retained instead of requiring the production quantity to be counted again from zero.

Typical applications can include:

Product counting

Production quantity monitoring

Batch counting

Packing machine counting

Length measurement

Cable length measurement

Wire length measurement

Fabric and textile length measurement

Sheet and film measurement

Machine cycle counting

Preset production counting

RPM monitoring

Speed monitoring

Conveyor counting

Cut to length applications

Industrial automation machinery

The two independent outputs can also be useful where one counting operation needs to trigger external equipment or provide separate control actions.

D. Suitable Buyers

The iTherm BL Series Batch and Length Counter can be suitable for businesses and engineers working with automated production, material measurement and industrial counting systems.

Machine Manufacturers and OEMs

OEMs manufacturing packaging machines, cutting machines, winding machines, conveyor systems and production equipment can use the BL Series where automatic counting or length measurement is required.

Panel Builders

Control panel manufacturers can use BL Series counters when a machine control panel requires production counting, preset counting or length indication.

Automation System Integrators

System integrators can use the BL Series with industrial sensors as part of automatic counting and monitoring systems.

Packaging Industries

Packaging machines frequently require a preset number of products, packets, bottles or cycles to be counted before the next machine operation.

Wire and Cable Industries

Length Counter mode can be useful for measuring continuous wire and cable during production, winding or cutting operations.

Textile and Fabric Industries

The Length Counter function can be applied where fabric, textile or other continuous material length needs to be measured.

Printing, Film and Packaging Material Manufacturers

Companies handling continuous sheet, film or similar materials can use length measurement and speed indication functions for process monitoring.

Production and Maintenance Departments

Production teams can use the counter for monitoring output quantities, while maintenance teams can use counting information for machine cycle monitoring and related industrial applications.

Frequently Asked Questions

1. What is the iTherm BL Series?

The iTherm BL Series is a programmable industrial counter designed for batch counting, length measurement and preset counting applications.

2. Which models are available in the BL Series?

The current iTherm technical documentation lists BL-77, BL-886 and BL-99 under the BL Series.

3. What is the maximum counting range?

The BL Series supports a counting range from 0 to 999999 counts.

4. Can the BL Series be used as a batch counter?

Yes. Batch counting is one of the programmable operating functions of the BL Series.

5. Can it measure material length?

Yes. The BL Series provides a dedicated Length Counter mode and allows programmable diameter settings from 0.01 to 9999.99 mm.

6. Can it display material speed?

Yes. In Length Mode, the BL Series can display material speed in metres per minute.

7. Can the BL Series display RPM?

Yes. RPM value can be displayed when the instrument operates in Preset Mode.

8. Does the counter retain the reading during a power failure?

Yes. Count retention at power failure is listed as a BL Series feature.

9. How many outputs does the BL Series have?

The BL Series provides two independent outputs. Output 1 and Output 2 can be configured as Relay or SSR Drive depending on the factory configuration.

10. What output modes are available?

Output 1 supports Latch Output, Auto Reset and Offset Count modes. Output 2 can be configured for Auxiliary Contact, Batch Mode, Independent Set Point or Off operation.

11. What counting frequencies are supported?

The available count frequencies are 3 Hz, 30 Hz, 100 Hz, 1 kHz and 2.5 kHz.

12. What is the power supply requirement?

The standard power supply is 90 to 270 VAC. A 24 VDC supply version is available on request according to iTherm.

13. Can the BL Series be used for production counting?

Yes. It can count incoming pulses from a machine or sensor, making it suitable for production quantity and machine cycle counting applications.

14. Can it be used for wire, cable or fabric length measurement?

Yes, provided the machine and sensor arrangement generates the required counting pulses. The Length Counter function is specifically designed for applications where material length and speed need to be measured.

15. Does the counter have programmable settings?

Yes. Count settings and operating parameters can be configured through the instrument keyboard.