Contrec 515 User manual

Model 515 Flow Computer
Operation Manual
Application BS03
Secure Dual Stage Batch Controller
for
Mass Frequency Flowmeters
2 April 2017

Model 515 Flow Computer - Operation Manual
© Contrec Limited 2017
The instructions given herein cover the general description, installation, operation and maintenance of the subject
equipment. Contrec Limited. 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 Limited for further detailed information and technical assistance.
Contrec Limited 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 Limited
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: 515-BS03-OM - 2 April 2017

515 BS03 - 2 April 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.
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.
515 BS03 - 2 April 2017

iv 515 BS03 - 2 April 2017

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
Specialised Uses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Specifications
Specification Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Installation
Panel Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Rear Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Terminal Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Frequency Input Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Logic Input Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-20mA Output Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Digital Output Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Control Relays (Alarms) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
RC Network for Interference Suppression . . . . . . . . . . . . . . . . . . . . . . 14
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
RS-232 Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
RS-485 Port (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Earthing and Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4 Operation
Front Panel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Default Variable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Front Panel Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Main Menu Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Setting the Batch Preset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Data Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Contents
515 BS03 - 2 April 2017

vi 515 BS03 - 2 April 2017
Model Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Batch Operation Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Preset Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
On-Off Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Unload Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Batch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Safety and Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Starting a Batch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Stopping a Batch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Resetting a Batch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Printing a Delivery Docket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Logic Input Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Batch Flow Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Batch Control Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5 Instrument Calibration
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Calibration View Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Calibration Set Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Changing the Instrument Settings . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Calibration Menu Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Instrument Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Units of Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Time Settings and Data Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
General Setup Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Test Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
System Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Warning Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Prompt Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6 Communications
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Hardware Interconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Protocols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Simple ASCII Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Requests Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Instrument Responses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Corrupted or Invalid Requests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Modbus RTU Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
List of Data Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
iButton ID Tag Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Printer Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

515 BS03 - 2 April 2017 vii
Types of Printouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Printer Data Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Appendix A Glossary
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Appendix B Model Numbers
Product Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Custom Version Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Application Information Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Appendix C Units of Measurement
Available Units of Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

viii 515 BS03 - 2 April 2017

ix515 BS03 - 2 April 2017
List of Figures
1 Typical Application Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 500 Series Instrument Panel Mounting . . . . . . . . . . . . . . . . . . . . . . . 9
3 Rear Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4 Logic Inputs Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . 12
5 Output 4-20mA Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . 13
6 Output Pulse Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . 13
7 Relay Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
8 RS-485 Interface Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
9 Batch Operation with Manual or Automatic Reset . . . . . . . . . . . . . . . . 27
10 Batch Operation with Automatic Restart . . . . . . . . . . . . . . . . . . . . . 28
11 Calibration Menu Tree Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 32
12 Calibration Menu Tree Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 33
13 RS-232 Cable Connections to a Computer . . . . . . . . . . . . . . . . . . . . 56
14 RS-485 Connections
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

x 515 BS03 - 2 April 2017