Contrec 515 CB01 Installation manual

Model 515 Flow Computer
Operation Manual
Application CB01
Blending Controller
for
Volumetric Frequency Flowmeters
18 May 2007

Model 515 Flow Computer - Operation Manual
© Contrec Pty Ltd 2006
The instructions given herein cover the general description, installation, operation and maintenance of the subject
equipment. Contrec Pty. 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 Pty Ltd for further detailed information and technical assistance.
Contrec Pty. 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 Pty Ltd
22 Hall Street Hawthorn East, Melbourne 3123 AUSTRALIA
Tel: [phone] Fax: [phone]
Email: [email protected]
Contrec - USA, LLC
916 Belcher Drive Pelham AL 35124 USA
Tel: [phone] Fax: [phone]
Email: [email protected]
Contrec Europe Limited
PO Box 436 Sowerby Bridge, West Yorkshire HX6 3YA, UK
Tel: [phone] Fax: [phone]
Email: [email protected]
Website: www.contrec.com.au
Publication No: 515-CB01-OM - 18 May 2007

515 CB01 - 18 May 2007 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.Oncetheunitis 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 serial number plate. Personnel should
take all due care to avoid electric shock.
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.
515 CB01 - 18 May 2007

iv 515 CB01 - 18 May 2007

v
1 Introduction
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Displayed Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Main Menu Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Isolated Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Relay Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Specifications
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
Pulse Output Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Control Relays (Alarms) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
RC Network for Interference Suppression . . . . . . . . . . . . . . . . . . . . . . 12
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
RS-232 Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Infra-red Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
RS-485 Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Earthing and Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4 Operation
Normal Operation Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Default Variable & Total . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Status Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Contents
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vi 515 CB01- 18 May 2007
Front Panel Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Main Menu Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Peak Flowrates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Setting the Batch Preset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Data Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Model Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Blending Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
ON-OFF Mode of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
PRESET Mode of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Typical Blending Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Resetting Totals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Logic Input Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Digital Control Valve Connection . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Blending Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5 Instrument Calibration
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Calibration View Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Calibration Set Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Changing the Instrument Settings . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Calibration Menu Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Instrument Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Units of Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Time Settings and Data Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
General Setup Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Test Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
System Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Warning Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6 Communications
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Hardware Interconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Protocols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Simple ASCII Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Requests Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Instrument Responses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Corrupted or Invalid Requests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Modbus RTU Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
List of Data Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

515 CB01- 18 May 2007 vii
Printer Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Types of Printouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Printer Data Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Appendix A Glossary
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Appendix B Model Numbers
Product Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Custom Version Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Application Information Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Appendix C Units of Measurement
Available Units of Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

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ix515 CB01- 18 May 2007
List of Figures
1 Typical Application Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 500 Series Instrument Panel Mounting . . . . . . . . . . . . . . . . . . . . . . . 7
3 Rear Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Logic Inputs Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . 10
5 Output 4-20mA Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . 11
6 Output Pulse Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . 11
7 Relay Connection Diagram
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
8 RS-485 Interface Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
9 Blending Operation in ON-OFF Mode . . . . . . . . . . . . . . . . . . . . . . 21
10 Blending Operation in PRESET Mode . . . . . . . . . . . . . . . . . . . . . . 22
11 Calibration Menu Tree Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 28
12 Calibration Menu Tree Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 29
13 RS-232 Cable Connections to a Computer . . . . . . . . . . . . . . . . . . . . 48
14 RS-485 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

x515 CB01- 18 May 2007