Contrec 515 User manual

Model 515 Flow Computer
Operation Manual
Application FA02
Add or Subtract Flow Computer
for
Mass Applications
18 June 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-FA02-OM - 18 June 2017

515 FA02 - 18 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.
515 FA02 - 18 June 2017

iv 515 FA02 - 18 June 2017

v
1 Introduction
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Calculation Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Analog Input Scaling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Displayed Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Main Menu Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Isolated Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Relay Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Limitations of Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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
Analog Input Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Logic Input Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-20mA Output Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pulse Output Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Control Relays (Alarms) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
RC Network for Interference Suppression . . . . . . . . . . . . . . . . . . . . . . 16
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
RS-232 Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
RS-485 Port (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Earthing and Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4 Operation
Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Default Total . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Front Panel Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Main Menu Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Peak Flowrates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Data Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Model Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5 Instrument Calibration
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Calibration View Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Contents
515 FA02 - 18 June 2017

vi 515 FA02 - 18 June 2017
Calibration Set Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Changing the Instrument Settings . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Calibration Menu Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Instrument Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Units of Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Time Settings and Data Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
General Setup Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Test Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
System Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Warning Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6 Communications
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Hardware Interconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Protocols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Simple ASCII Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Requests Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Instrument Responses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Corrupted or Invalid Requests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Modbus RTU Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
List of Data Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Printer Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Types of Printouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Printer Data Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
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

vii515 FA02 - 18 June 2017
List of Figures
1 Typical Application Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Rear Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3 Externally Powered Voltage Transmitter . . . . . . . . . . . . . . . . . . . . . 12
4 Internally Powered Voltage Transmitter . . . . . . . . . . . . . . . . . . . . . 12
5 Externally Powered Current Loop . . . . . . . . . . . . . . . . . . . . . . . . . 13
6 Internally Powered Current Loops . . . . . . . . . . . . . . . . . . . . . . . . 13
7 Logic Inputs Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . 14
8 Output 4-20mA Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . 14
9 Output Pulse Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . 15
10 Relay Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
11 RS-485 Interface Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
12 Logged Data Display Methods . . . . . . . . . . . . . . . . . . . . . . . . . . 22
13 Calibration Menu Tree Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 28
14 Calibration Menu Tree Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 29
15 RS-232 Cable Connections to a Computer . . . . . . . . . . . . . . . . . . . . 50
16 RS-485 Connections
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

viii 515 FA02 - 18 June 2017

1
Chapter 1
Introduction
Features •Programmable for either frequency or analog flow inputs
•Tailored for mass units of measure
•Freely assignable alarms for high or low levels
•Selection of second language and user tags
•RTC logging with over 1000 entries
•Programmable pulse width and scaling of pulse output
•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 515 FA02 application pack is an add or subtract flow computer that is
tailoredspecificallyfor mass measurement. It can perform either addition or
subtraction on two frequency inputs or on two analog inputs.
The flow computer is suitable for accepting signals directly from
flowmeters or for collecting re-transmitted signals from other flow
computers providing a resultant rate and total. The instrument displays the
flow rate and total for each channel as well as the result.
The frequency input is compatible with a wide range of frequency signals,
including millivolt signals, reed switches, Namur proximity switches and
pulse trains via its smart front-panel program selection. The analog input
can be scaled and have filtering, non-linear correction and cutoff points
applied to the signal.
Calculation Modes
This instrument is capable of operating in the following modes:
515 FA02 - 18 June 2017

Introduction
2 515 FA02 - 18 June 2017
• Addition, (Channel 1 + Channel 2)
• Subtraction, (Channel 1 - Channel 2)
When subtraction mode is selected the larger flow should be connected to
channel 1. The instrument can also be programmed to perform the
calculation on either the frequency inputs (FINP1 and FINP2) or the analog
inputs (AINP3 and AINP4).
The operation mode can be observed via Modbus RTU communications.
Please refer to Instrument Control and I/O on page 61 for further details.
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.
For frequency inputs the calculation of totals are exact as the instrument
collects all pulses detected on each channel.
channel total = pulses / k-factor
The flow rates are derived from an accurately measured frequency:
channel flow = frequency / k-factor
For analog inputs, to derive the flow rate, the analog input is normalised to
a value (A) between 0 and 1.
channel flow = (Vf max-Vf min)A+Vfmin
The resultant values are then:
ADD result = channel 1 + channel 2
SUB result = channel 1 - channel 2
Analog Input Scaling
The analog inputs in this instrument are scaled by the following general
formula:
where:
channeltotal channelflow t

=
Pmin = minimum point (equivalent to offset)
Pmax = maximum point (Pmax – Pmin is equivalent to span)
f
A Pmin Pmax Pmin–A*+=