Contrec 505 BC01 User manual

Model 505 Flow Computer
Operation Manual
Application BC01
Dual Stage Batch Controller
for
Volumetric Frequency Flowmeters
17 June 2017

Model 505 Flow Computer - Operation Manual
© Contrec Ltd 2017
The instructions given herein cover the general description, installation, operation and maintenance of the subject
equipment. Contrec Ltd reserves the right, without prior notice, to make engineering refinements that may not be
reflected in this manual.
Should any questions arise which cannot be answered specifically by this manual, they should be directed to
Contrec Ltd for further detailed information and technical assistance.
Contrec Ltd will not accept any liability for either direct or consequential damages resulting from the use or
misapplication of the contents of this manual.
Part of the software embedded in this product is eCos - Embedded Configurable Operating System, a trademark of
Red Hat. Portions created by Red Hat are Copyright © 1998, 1999, 2000 Red Hat, Inc.
(http://www.redhat.com). All rights reserved
The software in this product was in part provided by Red Hat and any express or implied warranties, including, but
not limited to, the implied warranties of merchantability and fitness for a particular purpose are disclaimed. In no
event shall the author be liable for any direct, indirect, incidental, special, exemplary, or consequential damages
(including, but not limited to, procurement of substitute goods or services; loss of use, data, or profits; or business
interruption) however caused and on any theory of liability, whether in contract, strict liability, or tort (including
negligence or otherwise) arising in any way out of the use of this software, even if advised of the possibility of such
damage. Contrec Ltd
Riverside, Canal Road, Sowerby Bridge,
West Yorkshire HX6 2AY UNITED KINGDOM
Tel: [phone] Fax: [phone]
Email: [email protected]
Website: www.contrec.co.uk
Contrec Systems Pty Ltd
5 Norfolk Avenue Ringwood, Melbourne 3134 AUSTRALIA
Tel: [phone]
Email: [email protected]
Contrec - USA, LLC
916 Belcher Drive Pelham AL 35124 USA
Tel: [phone] Fax: [phone]
Email: [email protected]
Publication No: 505-BC01-OM - 17 June 2017

505 BC01 - 17 June 2017 iii
Safety Notice
The information in this safety notice is for the prevention of injury to personnel and
damage to the instrument.
The manufacturer assumes no liability for injury or damage caused by misuse of the
instrument or for modifications made to the instrument.
Qualified Personnel
The instrument must be installed, operated and serviced by persons who have been properly
trained and authorised. Personnel must read and understand this manual prior to installation and
operation of the instrument.
Static Hazard
The 500 series flow computer uses high speed CMOS circuitry which is sensitive to static
damage. The user should observe accepted safety practices for handling electronic devices,
especiallyduringservicing.Oncetheunitisinstalled,groundedandinterconnected,thechances
of static damage are greatly reduced.
Voltage Hazard
Before connecting power to the instrument, ensure that the supply voltage for the AC or DC
input is suitable. The AC voltage rating is as stated on the instrument rating plate. Personnel
should take all due care to avoid electric shock. For safe operation it is essential to connect a
mains safety earth to the A.C. power inlet. Do not operate at altitudes above 2000m.
Welding Hazard
Do not perform electric welding in close proximity to the instrument or its interconnecting
cables. If welding in these areas must be performed, disconnect all cables from the instrument.
Failure to do so may result in damage to the unit.
Moisture Hazard
To avoid electrical faults and corrosion of the instrument, do not allow moisture to remain in
contact with the instrument.
Disconnection Device
When powered from a mains supply this unit requires the provision of a suitable mains isolation
device to be accessible near to the installed instrument.
505 BC01 - 17 June 2017

iv 505 BC01 - 17 June 2017

v
1 Introduction
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Displayed Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Main Menu Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Retransmission & Control Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Relay Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Specifications
Specification Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Installation
Panel Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Rear Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Terminal Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Frequency Input Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Logic Input Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-20mA Output Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Digital Output Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Control Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
RC Network for Interference Suppression . . . . . . . . . . . . . . . . . . . . . . 12
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
RS-232 Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
RS-485 Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Earthing and Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4 Operation
Front Panel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Default Variable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Front Panel Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Main Menu Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Setting the Batch Preset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Data Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Model Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Batch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Starting a Batch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Stopping a Batch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Resetting a Batch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Contents
505 BC01 - 17 June 2017

vi 505 BC01 - 17 June 2017
Logic Input Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Batch Flow Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Batch Control Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5 Instrument Calibration
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Calibration View Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Calibration Set Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Changing the Instrument Settings . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Calibration Menu Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Instrument Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Units of Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Time Settings and Data Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
General Setup Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Test Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
System Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Warning Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6 Communications
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Hardware Interconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Protocols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Modbus RTU Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
List of Data Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Printer Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Types of Printouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Printer Data Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Appendix A Model Numbers
Product Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Custom Version Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Application Information Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Appendix B Units of Measurement
Available Units of Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

vii505 BC01 - 17 June 2017
List of Figures
1 Typical Application Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 500 Series Instrument Panel Mounting . . . . . . . . . . . . . . . . . . . . . . . 7
3 Rear Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Logic Input Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 10
5 Signal Input Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 10
6 Output 4-20mA Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . 11
7 Output Pulse Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . 11
8 Relay Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
9 RS-485 Interface Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
10 Batch Operation with Manual or Automatic Reset . . . . . . . . . . . . . . . . 22
11 Batch Operation with Automatic Restart . . . . . . . . . . . . . . . . . . . . . 22
12 Calibration Menu Tree Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 26
13 Calibration Menu Tree Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 27
14 RS-232 Cable Connections to a Computer . . . . . . . . . . . . . . . . . . . . 46
15 RS-485 Connections
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

viii 505 BC01 - 17 June 2017

1
Chapter 1
Introduction
Features •Tailored for volumetric frequency flow input
•Single or Dual stage control
•Quick access to common batch quantities
•No-flow, leakage and overflow error detection
•Remote RUN/STOP/RESET
•Allows for non-linear correction
•Storage of 100 transactions with time and date stamp
•Selection of second language and user tags
•Pulse width and scaling of pulse output
•4-20mA retransmission
•Selectable protocols on serial ports including Modbus RTU and Printer
output
•Front panel adjustment of 8-24V DC output voltage
•Backlit display with LCD backup
Overview
The 505 BC01 application is a dual stage batch controller for reliable
measurement of preset quantities using a volumetric frequency input. Used
as a single or dual stage controller it is suitable for fast batch applications.
It provides the operator with clear local readout and can be controlled via
communications in more automated systems. There is quick access to
commonly used preset values directly from the front panel if access has
been authorized. Automatic overrun compensation caters for system delays
such as valve closure for precise volumes.
The instrument is compatible with a wide range of flowmeter frequency
outputs, including millivolt signals, reed switches, Namur proximity
switches and pulse trains via its smart front-panel program selection.
505 BC01 - 17 June 2017

Introduction
2 505 BC01 - 17 June 2017
Calculations
The total and flowrate are derived from accurately measured frequency and
the number of received pulses.
volume = pulses / k-factor
volume flow = frequency / k-factor
Automatic overrun compensation calculates the new valve closure point to
ensure correct delivery by averaging the overrun amount from the last three
complete batches.
Theoverruncompensationvalue is valid for a new preset value provided the
stored overrun is less than 20% of the new preset.
Displayed Information
The front panel display shows the current values of the input variables and
the results of the calculations.
The instrument can be supplied with a real-time clock for storage of up to
100 transactions with time and date stamps.
Main Menu Variables
Refer to Available Units of Measurement on page 62 for the list of
available units.
Communications
There are two communication ports available as follows:
•RS-232 port
•RS-485 port
The ports are available for remote data reading, printouts and for initial
application loading of the instrument.
Main Menu
Variables Default Units Variable Type
Volume L Total
Volume Flowrate L/min Rate