Contrec 515 BR03 User manual

Model 515 Flow Computer
Operation Manual
Application BR03
Batch/Ratio Process Controller
for
Mass Frequency Flowmeters
15 August 2021

Model 515 Flow Computer - Operation Manual
© Contrec Ltd 2021
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]
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: 515-BR03-OM - 15 August 2021

515 BR03 - 15 August 2021 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.
This document must be consulted in all cases where the following “Caution” safety symbol is
used :
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. Refer to section 3 for further information regarding permitted
maintenance operations. The safety of any system incorporating the equipment is the
responsibility of the assembler of the system.
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,
especially during servicing. Once the unit is installed, grounded and interconnected, the chances
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. Operate only in a clean, dry and pollutant-free environment.
Operating & Storage Temperature
Operating: If a heater is being used, DO NOT isolate the instrument in temperatures below
-20°C.
Storage: DO NOT store the equipment below -20°C.
515 BR03 - 15 August 2021

i v 515 BR03 - 15 August 2021
Disconnection Device
When powered from a mains supply this unit requires the provision of a suitable mains isolation
device, capable of interrupting both poles of the supply and meeting your local wiring
regulations, to be suitably located and easily accessible near to the installed instrument. It must
be marked as the disconnecting device for the equipment. It must be suitably rated with respect
to the cross sectional area of the supply conductors.
Instrument Disposal
Contrec instrumentation should not be thrown into the general waste system.
If within EU member states, this instrument should be disposed of according to
the guidelines set by the WEEE (Waste Electrical and Electronic Equipment)
directive 2012/19/EU. If outside of the EU, this equipment should be
responsibly disposed of according to local and national regulations for EEE
(Electrical and Electronic Equipment).
By not discarding of this product along with other house hold waste you are
preserving natural resources and reducing waste sent to landfill and incinerators.
Remove batteries and dispose of separately (see Disposal of Batteries) before disposal of
Contrec instrumentation.
Disposal of Batteries
Batteries have an environmental impact. Safe and responsible disposal should
be undertaken.
In all EU member states, as per Directive 2006/66/EC, batteries must not be
thrown away with general waste. Contact your local environmental authority
for information regarding disposal or recycling of used batteries, alternatively
they can be returned directly to Contrec Ltd. for disposal.
Please Contact Contrec Ltd before returning batteries for disposal.
Explanation of IEC Symbols Used
You should familiarise yourself with the following symbols which are used both within this
manual and on the instrument itself.
This document must be consulted in all cases where the following “Caution” safety
symbol is used.
DC Input (DC).
AC Input (AC).
Protective Earth Terminal.

v
1 Introduction
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Displayed Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Main Menu Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Isolated Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Relay Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Specifications
Specification Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Installation & Maintenance
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cleaning and Decontamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Panel Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Rear Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Terminal Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Terminal Wiring Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Relay Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Mains Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Frequency Input Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Logic Input Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-20 mA Output Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Digital Output Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Control Relays (Alarms) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
RC Network for Interference Suppression . . . . . . . . . . . . . . . . . . . . . . 17
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
COM-1 RS-232 Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
COM-2 RS-485 Port Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
COM-2 Ethernet Port Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Mains Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Earthing and Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Disconnection Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Contents
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Battery Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4 Operation
Front Panel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Default Variable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Front Panel Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Main Menu Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Detail and Basic Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Setting the Batch Preset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Setting the Flow Control Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Data Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Model Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Flow Control Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Tuning the Control Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Batch Operation Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Preset Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
On-Off Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Release Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Batch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Operation Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Safety and Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Starting a Batch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Stopping a Batch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Resetting a Batch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Printing a Delivery Docket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Logic Input Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Batch Flow Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Batch Control Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5 Instrument Calibration
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Calibration View Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Calibration Set Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Changing the Instrument Settings . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Program Backup & Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Backup via 500 Series Program Manager . . . . . . . . . . . . . . . . . . . . . . 43
Printing Configuration Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Upload and Clone of Application Software . . . . . . . . . . . . . . . . . . . . . 43
Calibration Menu Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Instrument Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Units of Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Time Settings and Data Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

515 BR03 - 15 August 2021 vii
General Setup Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Test Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
System Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Warning Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Prompt Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6 Communications
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Hardware Interconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Protocols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Simple ASCII Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Requests Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Instrument Responses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Corrupted or Invalid Requests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Modbus RTU Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
List of Data Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Printer Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Types of Printouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Printer Data Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Appendix A Glossary
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Appendix B Model Numbers
Product Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Custom Version Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Application Information Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Appendix C Ethernet Port & Setup
Ethernet Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Connecting 515 Ethernet to Networks/Routers . . . . . . . . . . . . . . . . . . . . . 94
Connecting DataMod via Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

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i x515 BR03 - 15 August 2021
List of Figures
1 Typical Application Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 500 Series Instrument Panel Mounting . . . . . . . . . . . . . . . . . . . . . . . 9
3 Rear Panel Connections - Original . . . . . . . . . . . . . . . . . . . . . . . . 10
4 Rear Panel Connections - New RS-485 Version . . . . . . . . . . . . . . . . . 10
5 Rear Panel Connections - New Ethernet Version . . . . . . . . . . . . . . . . . 11
6 Logic Inputs Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . 14
7 Output 4-20 mA Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . 15
8 Output Pulse Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . 15
9 Relay Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
10 RS-485 Interface Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
11 Batch Operation with Manual or Automatic Reset . . . . . . . . . . . . . . . . 37
12 Batch Operation with Automatic Restart . . . . . . . . . . . . . . . . . . . . . 38
13 Calibration Menu Tree Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 44
14 Calibration Menu Tree Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 45
15 RS-232 Cable Connections to a Computer . . . . . . . . . . . . . . . . . . . . 69
16 RS-485 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
17 DataMod - Modbus Connection Settings . . . . . . . . . . . . . . . . . . . . . 95

x 515 BR03 - 15 August 2021

1
Chapter 1
Introduction
Features
•Tailored for mass frequency flow inputs
•Single or Dual stage control
•Preset or manual On-Off modes
•Easy access to batch and flow rate presets
•No-flow, leakage and overflow error detection
•Remote RUN/STOP/RESET functions
•Allows for permissive with prompt
•Uses PI Loop Control
•Allows for non-linear correction
•Storage of 1000 transactions with time and date stamp
•Selection of Detail or Basic main menu to suit operator and application
•Selection of second language and user tags
•Pulse width and scaling of pulse output
•4-20 mA retransmission
•Available protocols on communication ports including Printers, Modbus
RTU and TCP/IP
•Front panel adjustment of 8-24 V DC output voltage
•Backlit display with LCD backup
515 BR03 - 15 August 2021

Introduction
2 515 BR03 - 15 August 2021
Overview
The 515 BR03 application is a batching ratio controller for delivery of
preset quantities at preset ratios using mass frequency inputs. Batch control
can operate in preset or on-off modes, while flow control can be set to
various loop control modes.
This application provides the operator with clear local readout including
flowrate deviation 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.
The PI control of the process flow is via a 4-20mA proportional valve or
pump controller. It has integral wind-up protection, a deadband, output hold
and ramp time that can be programmed to reduce wear on valves and
actuators and provide for bumpless operation.
Calculations
There are three types of control modes in which the process flow is
dependent on the main flow. These are RATIO, BLEND-1 and BLEND-2
modes where the relationship between the flows are as follows:
Ratio Control Mode.
The process flow is a ratio of the main flow (0 to 400% range).
Blend Control Modes.
These modes cater for blending points before and after the main flowmeter.
The process flow is a ratio of the net (combined) flow (0 to 80% range).
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
1000 transactions with time and date stamps.
Ratio% Pflow
Mflow
-------------- 100=
Ratio% Pflow
Netflow
------------------ 100=

Introduction
515 BR03 - 15 August 2021 3
Main Menu Variables
* These variables are logged and can be printed but are not shown in main menu.
Units of Measurement
In the 500 Series instruments there is a wide range of available units of
measurement to be selected from. These can be viewed and selected either
during initial Software Configuration via the 500 Series Program Manager
(see below) or from within the instrument’s calibration settings (if access
has been granted) as per Units of Measurement on page 46.
Communications
There are two communication ports available as follows:
•COM-1 RS-232 port
•COM-2 RS-485 port (optional) or Ethernet (optional)
The ports are available for remote data reading, printouts and for initial
application loading of the instrument.
Isolated Outputs
The opto-isolated outputs can retransmit any main menu variable. The type
of output is determined by the nature of the assigned variable. Totals are
output as pulses and rates are output as 4-20 mA signals. One output is
standard, a second output is available as an option.
Main Menu
Variables
Default
Units
Variable
Type
Net Mass kg Total
Net Flowrate kg/m Rate
Main Line Mass kg Total
Main Line Flowrate kg/m Rate
Process Line Mass kg Total
Process Line Flowrate kg/m Rate
Process Mass Ratio % Rate
Process Flowrate Ratio % Rate
Process Control Output % Rate
Process Flowrate Deviation % Rate
Preset Quantity * - - - - - -

Introduction
4 515 BR03 - 15 August 2021
Relay Outputs
The relay outputs 1 and 2 are used to control the flow of product for each
delivery. These contacts are normally open and can be used to drive external
relays, valves, pump circuits etc. The advanced option provides another two
relays that can be used as fully programmable alarms for any rate type
variable.
Software Configuration
The instrument can be programmed to suit the particular application needs
and the flexible I/O can be assigned as required. Program settings can be
changed either via the front panel (depending on assigned access levels) or
via the 500 Series Program Manager (500-PM software).
The 500-PM software is a free comprehensive configuration tool and
resource centre that can be used to further tailor an instrument to suit
specific application needs including units of measurement, custom tags and
text, access levels and more.
The software is a Windows based program that is freely available from the
download section of the Contrec website. The program can be used to create
a custom version of an existing application to be saved for backup purposes
and/or to generate a PDF of configuration report for record keeping.
The instrument stores all set-up parameters, totals and logged data in non-
volatile memory with at least 30 years retention.
Figure 1 Typical Application Diagram
Main Flow
Proportional
Control Valve
Frequency
Input 1
Process Flow
Flowmeters
Analog
Output 1
Frequency
Input 2
Example of
Batch/Blend-1
Configuration
Relay 1
On-Off
Valve
Net Flow

Introduction
515 BR03 - 15 August 2021 5
Approvals
This instrument conforms to the EMC-Directive of the Council of
European Communities 2014/30/EU, the LVD safety directive 2014/35/EU
and the following standards:
•EN61326:2013 Electrical equipment for measurement, control and
laboratory use – EMC requirements: Industrial Environment.
•EN61010:2010 Safety requirements for electrical equipment for
measurement, control, and laboratory use.
In order to comply with these standards, the wiring instructions in Chapter
3 - Installation & Maintenance must be followed.
FCC Declaration
This equipment has been tested and found to comply with the limits for a
Class A digital device, pursuant to Part 15 of the FCC Rules. These limits
are designed to provide reasonable protection against harmful interference
when the equipment is operated in a commercial environment. This
equipment generates, uses, and can radiate radio frequency energy and, if
not installed and used in accordance with the instruction manual, might
cause harmful interference to radio communications. Operation of this
equipment in a residential area is likely to cause harmful interference, in
which case the user will be required to correct the interference at his own
expense.
Properly shielded and grounded cables and connectors must be used in order
to meet FCC emission limits. Contrec Ltd is not responsible for any radio or
television interference caused by using other than recommended cables and
connectors or by unauthorized changes or modifications to this equipment.
Unauthorized changes or modifications could void the user's authority to
operate the equipment.
This device complies with Part 15 of the FCC Rules. Operation is subject to
the following two conditions: (1) this device might not cause harmful
interference, and (2) this device must accept any interference received,
including interference that might cause undesired operation.

Introduction
6 515 BR03 - 15 August 2021

7
Chapter 2
Specifications
Specification Table
Operating Environment
Temperature +5 °C to +40 °C (standard - no coating)
-20 °C to +60 °C (with conformal coating)
-30 °C to +60 °C (ExD housing with heater)
Humidity 0 to 95% non condensing (conformal
coating)
5% to 85% non condensing (no coating)
Power Supply 100-240 V AC (+/-10%) 50-60 Hz (+/-
10%) or 12-28 V DC
Consumption 10 W (max) Overvoltage category II
Protection Sealed to IP65 (Nema 4X) when panel
mounted
Dimensions
(panel option)
147 mm (5.8") width
74 mm (2.9") height
170 mm (6.6") depth (behind the panel)
Display
Type Backlit LCD with 7-digit numeric display
and 11-character alphanumeric display
Digits 15.5 mm (0.6") high
Characters 6 mm (0.24") high
LCD Backup Last data visible for 15 min after power
down
Update Rate 0.3 second
Non-volatile Memory
Retention > 30 years
Data Stored Setup, Totals and Logs
Approvals
Interference compliance
Enclosure IECEx, ATEX and CSA approved
enclosures available for hazardous areas
Real Time Clock (Optional)
Battery Type 3 volts Lithium button cell
- For Issue 7 option card, type CR2450N
manufactured by Renata only
- For conformal coated ‘C’ version, type
BR2032 manufactured by Panasonic only
- For non-conformal coated versions, type
BR2032 and CR2032 manufactured by
Panasonic or Sony
Battery Life 5 years (typical)
Frequency Input (General)
Range 0 to 10 kHz for Pulse input type
0 to 5 kHz for Coil & NPS input types
Overvoltage 30 V maximum
Update Time 0.3 sec
Cutoff frequency Programmable
Configuration Pulse, coil or NPS input
Non-linearity Up to 10 correction points
Pulse
Signal Type CMOS, TTL, open collector, reed switch
Threshold Signals switch below 1.3 & above 2 volts
Coil
Signal Type Turbine and sine wave
Sensitivity 15 mV minimum amplitude (typical)
NPS
Signal Type NPS sensor to Namur standard
Logic Inputs
Signal Type CMOS, TTL, open collector, reed switch
Overvoltage 30V maximum
Relay Output
No. of Outputs 2 relays plus 2 optional relays
Voltage 250 volts AC, 30 volts DC maximum
(solid state relays use AC only)
Current 3A maximum - mechanical relays
1.5A maximum - solid state relays
Communication Ports
Ports COM-1 RS-232 port
COM-2 RS-485 or Ethernet port (optional)
Baud Rate 2400 to 19200 baud
Parity Odd, even or none
Stop Bits 1 or 2
Data Bits 8
Protocols ASCII, Modbus RTU, Modbus TCP/IP
(Ethernet Port), Printer
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Specifications
8 515 BR03 - 15 August 2021
Important: Specifications are subject to change without notice.
Transducer Supply
Voltage 8 to 24 volts DC, programmable
Current 70 mA @ 24 V, 120 mA @ 12 V maximum
Protection Power limited output
Isolated Output
No. of Outputs 2 configurable outputs
Configuration Pulse/Digital or 4-20 mA output
Pulse/Digital Output
Signal Type Open collector
Switching 200 mA, 30 volts DC maximum
Saturation 0.8 volts maximum
Pulse Width Programmable: 10 , 20, 50, 100, 200 or
500ms
4-20 mA Output
Supply 9 to 30 volts DC external
Resolution 0.05% full scale
Accuracy 0.05% full scale (20C)
0.1% (full temperature range, typical)

9
Chapter 3
Installation & Maintenance
Installation Instructions
The safety of any system incorporating the equipment is the responsibility
of the assembler of the system and should be installed such that there is no
risk of impact damage.
This instrument is intended for fixed installation only, e.g. within a panel or
cabinet, and is not intended for desktop use. It is not suitable for outdoor use
unless fitted into an appropriate outdoor enclosure with a minimum type 3,
IP54, rating. The instrument has a ‘Pollution degree II’ rating.
Cleaning and Decontamination
For general maintenance or to clean an instrument suitable for return to a
service centre for repair or inspection, use only a damp cloth and mild
detergent. Do not use abrasive cleaners or high pressure water jets. An
instrument must be decontaminated before returning. The marking label can
be cleaned with 35% Isopropanol or mild detergent.
Panel Mounting
The instrument should be located in an area with a clean, dry atmosphere
that is also relatively free of shock and vibration.
The standard mounting procedure is panel mounting in a cutout that is
139 mm wide by 67 mm high. Two side clips secure the unit into the panel.
Figure 2 shows the panel mounting requirements for the 515 instrument.
Figure 2 500 Series Instrument Panel Mounting
145 mm
Side View
22 mm
70 mm
67 mm
139 mm
25 mm
66 mm
Min. 189 mm
Panel Cut-out
Front
Panel
74 mm
Mounting Clip
138 mm
147 mm
Rear Connectors Top View RS232
Port
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Installation & Maintenance
1 0 515 BR03 - 15 August 2021
Electrical Connection
Rear Panel Connections
Note: Depending on the specification and age of the instrument,
there are different versions of the upper option card. Ensure the instrument
is wired as per the correct terminal designation printed on the rear of the
instrument bezel and below.
Figure 3 shows the connections on the original rear panel of the instrument
where relays 1 to 4 (terminals 32-35) share a single Relay Common
(terminal 31). Note: The 5 way relay terminal block is GREEN.
Figure 3 Rear Panel Connections - Original
On the newer rear panel option cards the instrument relays 1 and 2
(terminals 32-33) share Relay Common 1-2 (terminal 31) and relays 3 and
4 (terminals 34-35) share Relay Common 3-4 (terminal 36).
Note: On these option cards the 6 way relay terminal block is ORANGE.
Figure 4 shows the new option card with the RS-485 port (terminals 19-21).
Figure 4 Rear Panel Connections - New RS-485 Version