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