Contrec 505 Series User manual

Model 505 Flow Computer
Operation Manual
Application LM01
Single Tank Level Monitor
for
Analog Level Sensors
17 June 2017

Model 505 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: 505-LM01-OM - 17 June 2017

505 LM01 - 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 LM01 - 17 June 2017

iv 505 LM01 - 17 June 2017

v
1 Introduction
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Displayed Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Main Menu Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Retransmission & Control Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Relay Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Limitations of Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Specifications
Specification Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Installation
Panel Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Rear Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Terminal Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Analog Input Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Logic Input Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-20mA Output Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Logic Output Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Control Relays (Alarms) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
RC Network for Interference Suppression . . . . . . . . . . . . . . . . . . . . . . 14
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
RS-232 Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
RS-485 Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Earthing and Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4 Operation
Normal Operation Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Default Variable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Front Panel Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Main Menu Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Data Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Model Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Alarms Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Operation of Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Contents
505 LM01 - 17 June 2017

vi 505 LM01 - 17 June 2017
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Time Settings and Data Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
General Setup Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Test Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
System Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Warning Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Alarm Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6 Communications
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Hardware Interconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Protocols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Modbus RTU Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
List of Data Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Printer Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Types of Printouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Printer Data Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Appendix A Model Numbers
Product Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Custom Version Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Application Information Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Appendix B Units of Measurement
Available Units of Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

vii505 LM01 - 17 June 2017
List of Figures
1 Typical Application Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Rear Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3 Externally Powered Current Loop . . . . . . . . . . . . . . . . . . . . . . . . . 11
4 Internally Powered Current Loop . . . . . . . . . . . . . . . . . . . . . . . . . 11
5 Logic Input Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 12
6 Output 4-20mA Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . 12
7 Output Logic Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . 13
8 Relay Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
9 RS-485 Interface Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
10 Logged Data Display Methods . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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

viii 505 LM01 - 17 June 2017

1
Chapter 1
Introduction
Features •20 point level to volume strapping table
•Level control output
•Accepts level and pressure (product head) sensors
•Density correction available for pressure level sensors
•Provides volume to mass conversion via density value
•Freely assignable alarms for high or low levels
•Selection of second language and user tags
•RTC logging with up to 100 entries at user-specified scheduled times
•4-20mA retransmission
•RS-232 and RS-485 (optional) serial ports
•Modbus RTU, Printer and other serial port protocols
•Front panel adjustment of 8-24V DC output voltage
•Backlit display
Overview
The 505 LM01 application monitors and measures the level of product in a
single tank. The instrument uses the 4-20mA signal from a wide range of
level sensors, including pressure transmitters, ultrasonic sensors and
capacitance probes.
The level monitor provides a 20 point strapping table and product density
for level to volume and volume to mass conversions. The instrument can
display Volume, Percentage Full and Mass as well as Level. Relay alarms
are freely assignable as high or low alarms and an open collector output is
provided for programmable level control.
A sub-menu gives full details of alarm status and can offer direct access to
change the alarm setpoints. The instrument also has density correction
available for pressure level sensors to cater for a deviation in product
density.
505 LM01 - 17 June 2017

Introduction
2 505 LM01 - 17 June 2017
Calculations
The following equations identify the derivation of some of the displayed
variables. If your interest is more in the operation of the instrument, you can
skip this section and allow the instrument to take care of the calculations.
Calculations are based on the analog input signal representing the product
level in the tank.
level = (Lmax-Lmin) A + Lmin
volume = (Vmax - Vmin) A* + Vmin
mass = volume density
where:
A = normalised input signal with
density correction.
A* = Afor linear tanks.
A* = f(A) for non-linear tanks.
f(A) = level to volume normalised
strapping table.
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 data logging of up
to 100 entries of the variables as displayed on the main menu.
Main Menu Variables
Refer to Available Units of Measurement on page 64 for the list of
available units.
Main Menu
Variables Default Units Variable Type
Product Volume m3Rate
Product Level m Rate
Volume Full % % Rate
Product Mass kg Rate

Introduction
505 LM01 - 17 June 2017 3
Communications
There are two communication ports available as follows:
•RS-232 port
•RS-485 port
The ports can be used for remote data reading, printouts and for initial
application loading of the instrument.
Retransmission & Control Outputs
The instrument can re-transmit any main menu variable. The digital output
can be used as logic levels for control outputs. If the instrument has the
advanced option, it outputs rates as a 4-20mA signal.
Relay Outputs
The relay alarms can be assigned to any of the main menu variables of a rate
type. The alarms can be fully configured including hysteresis. Two relays
are standard.
Software Configuration
The instrument can be further tailored to suit specific application needs
including units of measurement, custom tags, second language or access
levels. A distributor can configure these requirements before delivery.
Instrument parameters including units of measurement can be programmed
in the field, according to the user access levels assigned to parameters by the
distributor.
All set-up parameters and logged data are stored in non-volatile memory
with at least 30 years retention.

Introduction
4 505 LM01 - 17 June 2017
Figure 1 Typical Application Diagram
Limitations of Use
Density Correction for Pressure Level Sensors
Density correction has been provided for use with pressure level sensors to
cater for a deviation in the product density. This correction is only used in
the calculations when the minimum and maximum points for the level input
have been programmed in a conventional manner. That is, the level
corresponding to the 20mA point is greater than the level for the 4mA point.
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 must be followed.
Level
Transmitter
Analog
Input
L

Introduction
505 LM01 - 17 June 2017 5
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.
Properlyshieldedandgroundedcablesandconnectorsmustbe 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
6 505 LM01 - 17 June 2017

7
Chapter 2
Specifications
Specification Table
Operating Environment
Temperature 0°C to +60°C (conformal coating)
+5°C to +40°C (no coating)
Humidity 0 to 95% non condensing (conformal
coating)
5% to 85% non condensing (no coating)
Power Supply 95-135 V AC or 190-260 V AC
or 12-28 V DC
Consumption 6W (typical)
Protection Sealed to IP65 (Nema 4X) when panel
mounted
Dimensions
(panel option) 147mm (5.8") width
74mm (2.9") height
167mm (6.6") depth
Display
Type Backlit LCD with 7-digit numeric display
and 11-character alphanumeric display
Digits 15.5mm (0.6") high
Characters 6mm (0.24") high
LCD Backup Last data visible for 15min 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 (CR2032)
Battery Life 5 years (typical)
4-20mA Input
Overcurrent 100mA absolute maximum rating
Impedance 250 Ohms (to common signal ground)
Accuracy 0.1% typical full scale (20 C)
0.2% (full temperature range)
Non-linearity Up to 20 correction points (flow inputs)
Remote Key Input
Signal Type CMOS, TTL, open collector, reed switch
Configuration One input set as one of front five keys
Relay Output
No. of Outputs 2 relays
Voltage 250 volts AC, 30 volts DC maximum
Current 3A maximum
Communication Ports
Ports RS-232 port
RS-485 port
Baud Rate 2400 to 19200 baud
Parity Odd, even or none
Stop Bits 1 or 2
Data Bits 8
Protocols Modbus RTU, Printer*
Transducer Supply
Voltage 8 to 24 volts DC, programmable
Current 70mA @ 24V, 120mA @ 12V maximum
Protection Power limited output
Pulse/Digital Output
Signal Type Open collector, non-isolated
Switching 200mA, 30 volts DC maximum
Saturation 0.8 volts maximum
505 LM01 - 17 June 2017

Specifications
8 505 LM01 - 17 June 2017
Important: Specifications are subject to change without notice.
Printer protocol is available only if RTC option is installed.
4-20mA Output (Optional)
Supply 24 volts DC internal, non-isolated
Resolution 0.05% full scale
Accuracy 0.05% full scale (20C)
0.1% (full temperature range, typical)

9
Chapter 3
Installation
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
139mm wide by 67mm high. Two side clips secure the unit into the panel.
Figure 2 shows the panel mounting requirements for the 500 Series
Instrument.
500 Series Instrument Panel Mounting
145mm
Side View
22mm
70mm
67mm
139mm
25mm
66mm
Min. 189mm
Panel Cut-out
Front
Panel
74mm
Mounting Clip
138mm
147mm
Rear Connectors Top View RS232
Port
505 LM01 - 17 June 2017

Installation
10 505 LM01 - 17 June 2017
Electrical Connection
Rear Panel Connections
Figure 2 shows the connections on the rear panel of the instrument.
Figure 2 Rear Panel Connections
Terminal Designations
RS232 Port
CAUTION
MAINS
E N A
AC MAINS
123 456789101112131415161718 192021
RS485 RS232 Io SG Li Dout Ii SG Fi Vo GViSH RELAYS
+-GTxRx C + - + 1+ 2+ + - + + - + E R1 RC R2
TerminalLabel Designation Comment
1RS485 + RS485 (+)
2 - RS485 (-)
3 G Comms ground
4RS232 Tx RS232 data out Same RS232 port as
DB9 connector
5 Rx RS232 data in
6 C CTS (Clear to send)
7 Io + 4-20mA output Advanced option
8 SG - Signal Ground 0V
9 Li + Logic input
10 D OUT 1+ Open collector o/p 1 Control output
Not used
11 2+ Open collector o/p 2
12 Ii + 4-20mA input Level input
13 SG - Signal Ground 0V
14 Fi + Frequency input Not used
15 Vo + 8-24 volts DC output 70mA power limited
16 G - DC Ground
17 Vi + DC power input DC power in 12-28V
18 SH E Shield terminal
19 RELAYS R1 Relay 1
20 RC Relay Common
21 R2 Relay 2
EAC
MAINS
E Mains ground ACpowerin95-135V
or 190-260V
N N Mains neutral
A A Mains active
RS232 port 9-pin serial port

Installation
505 LM01 - 17 June 2017 11
Inputs
Analog Input Connections
The analog input (Ii) can accept current signals from 4 to 20mA.
CAUTION
Applying levels of input current above the absolute maximum
rating (100mA) may cause permanent damage to the input
circuitry.
4-20mA Inputs
For an externally powered current loop, connect the transmitter to the input
terminals as shown in Figure 3.
Figure 3 Externally Powered Current Loop
Connect internally powered current loop as shown in Figure 4.
Figure 4 Internally Powered Current Loop
Logic Input Connection
These input(s) are designed to be connected to open collector signals or a
voltage free contact switch. A minimum activation time of 300ms is
required to guarantee reading of an input.
+-
Transmitter
Analog
Input
(Ii)
12
13
15
12
+
-Analog
Input
Vo +8...24V DC
(Ii)
Transmitter

Installation
12 505 LM01 - 17 June 2017
Remote Key Input
A remote push-button key can be connected to the Logic Input as shown
below. Refer to REMOTE KEY on page 35 to define the function of the
key.
Figure 5 Logic Input Connection Diagram
Outputs
The basic instrument has two digital logic outputs (in this application only
DOUT1 is used). The advanced option also provides a 4-20mA output port.
4-20mA Output Connection
Figure 6 shows the connections for a 4-20mA output.
Maximum Load Resistance = 900 ohms
Figure 6 Output 4-20mA Connection Diagram
Logic Output Connection
Figure 7 shows a connection example for a logic control output. Output
channel 1 uses terminals 10 (+) and 8 (-). Output channel 2 uses terminals
11 (+) and 8 (-).
Signal Ground
8
Logic Input
(Li)
9
18
+
-
Load
Shield
505
4-20mA
Output
(Io)
7
8
Internal supply