Contrec 515 User manual

Model 515 Flow Computer
Operation Manual
Application HC04
Heat Calculator - Flow Computer
for
Stacked Differential Pressure Meters
(ISO 5167 & V-Cones)
8 June 2007

Model 515 Flow Computer - Operation Manual
© Contrec Pty Ltd 2007
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-HC04-OM - 8 June 2007

515 HC04 - 8 June 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 HC04 - 8 June 2007

iv 515 HC04 - 8 June 2007

v
1 Introduction
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Operation Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Analog Input Scaling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Displayed Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Main Menu Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Isolated Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Relay Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Temperature Input Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Limitations of Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Specifications
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 Installation
Panel Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Rear Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Terminal Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Analog Input Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Logic Input Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-20mA Output Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Pulse Output Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Control Relays (Alarms) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
RC Network for Interference Suppression . . . . . . . . . . . . . . . . . . . . . . 18
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
RS-232 Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Infra-red Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
RS-485 Port (Advanced Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Earthing and Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4 Operation
Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Default Total . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Status Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Front Panel Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Main Menu Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Peak Flowrates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Data Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Model Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Contents
515 HC04 - 8 June 2007

vi 515 HC04 - 8 June 2007
5 Instrument Calibration
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Calibration View Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Calibration Set Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Changing the Instrument Settings . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Calibration Menu Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Instrument Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Units of Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Time Settings and Data Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
General Setup Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Test Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
System Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Warning Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6 Communications
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Hardware Interconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Protocols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Simple ASCII Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Requests Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Instrument Responses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Corrupted or Invalid Requests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Modbus RTU Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
List of Data Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Printer Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Types of Printouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Printer Data Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Appendix A Glossary
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Appendix B Model Numbers
Product Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Custom Version Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Application Information Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Appendix C Units of Measurement
Available Units of Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Appendix D Reference Tables
Properties of Commonly Used Materials . . . . . . . . . . . . . . . . . . . . . . . . 79
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

vii515 HC04 - 8 June 2007
List of Figures
1 Typical Application Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 500 Series Instrument Panel Mounting . . . . . . . . . . . . . . . . . . . . . . 11
3 Rear Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4 Externally Powered Voltage Transmitter . . . . . . . . . . . . . . . . . . . . . 13
5 Internally Powered Voltage Transmitter . . . . . . . . . . . . . . . . . . . . . 13
6 Externally Powered Current Loop . . . . . . . . . . . . . . . . . . . . . . . . . 14
7 Internally Powered Current Loops . . . . . . . . . . . . . . . . . . . . . . . . 14
8 RTD Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
9 Logic Inputs Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . 16
10 Output 4-20mA Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . 16
11 Output Pulse Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . 17
12 Relay Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
13 RS-485 Interface Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
14 Logged Data Display Methods . . . . . . . . . . . . . . . . . . . . . . . . . . 25
15 Calibration Menu Tree Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 30
16 Calibration Menu Tree Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 31
17 RS-232 Cable Connections to a Computer . . . . . . . . . . . . . . . . . . . . 54
18 RS-485 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

viii 515 HC04 - 8 June 2007

1
Chapter 1
Introduction
Features •Suited for heating and/or cooling operation
•Uses IAPWS-IF97 to determine water properties
•Tailored for differential pressure meters with single or stacked
transmitters
•ISO 5167 (2003) DP flow calculations, 9 meter types
•V-Cone DP flow calculations, 2 cone types
•Flow meter can be located in feed or return line
•Allows for non-linear correction
•Selection of second language and user tags
•RTC logging with over 1000 entries
•Infra-red communications port on front panel
•Pulse width and scaling of pulse output
•4-20mA retransmission
•Selectable protocols on serial ports including Modbus RTU and Printer
output
•Front panel adjustment of 8-24V DC output voltage
•Backlit display
•LCD backup
Overview
The 515 HC04 application measures the volume, mass and energy content
of fluid in a heating or cooling system by using single or stacked differential
pressure flow inputs in conjunction with feed and return temperature inputs.
Aselectionof operation modesmakes itsuitablefor variousheating/cooling
applications. Flow is calculated according to equations for ISO 5167 or V-
Cone meters and accurately accounts for thermal expansion.
515 HC04 - 8 June 2007

Introduction
2515 HC04 - 8 June 2007
The energy calculations are based on the IAPWS Industrial Formulation
(1997) for the thermodynamic properties of steam. The temperature values
are used to determine the density and specific enthalpy. The instrument also
calculates the isentropic exponent and absolute viscosity which are required
for the differential pressure calculations.
Operation Modes
This instrument can be used for various heating and cooling energy delivery
systems by selection one of the following operation modes in calibration:
•HEAT - Heating mode is used when the application is for heating
only and assumes that the Feed Temperature will always
be higher than the Return Temperature (positive∆t). If the
Feed Temperature is lower than the Return Temperature
(negative ∆t), then no Energy is totalised however
Volumetric Flow is still calculated.
•COOL - Cooling mode is used when the application is for cooling
only and assumes that the Feed Temperature will always
be lower than the Return Temperature (negative ∆t). If the
Feed Temperature is higher than the Return Temperature
(positive ∆t), then no Energy is totalised however
Volumetric Flow is still calculated.
•BOTH - This mode caters for applications where the flow of
Energy may be for Heating or Cooling. In this mode
Energy is increased regardless of whether the ∆t is
positive or negative.
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.
The energy calculations are based on the IAPWS Industrial Formulation
(1997). The temperature limits are dependent on the system pressure:
0°C < t < tsaturation at system pressure
32°F < t < tsaturation at system pressure
Formulas
Volume flow = Mass flow / ρ
flow
Power = Mass flow x (hTF - hTR)

Introduction
515 HC04 - 8 June 2007 3
where:
Differential Pressure Equations
This application uses the following general formula for mass flow as per the
ISO 5167 (2003) standard:
where:
For further details of these equations or restrictions of use please refer to the
appropriate standard or relevant documents.
Analog Input Scaling
The analog inputs in this instrument are scaled by the following general
formula:
where:
ρflow = density at flow conditions
hTF = Specific enthalpy at feed
temperature
hTR = Specific enthalpy at return
temperature
qm= mass flow
C = coefficient of discharge
β = diameter ratio of orifice to pipe
ε
= fluid expansion factor... (for water ε = 1.0)
π
= universal constant (3.14159)
d = diameter of orifice (bore)... (for cone type meters substitute d2with D2 β
2)
D = diameter of pipe
∆P = differential pressure
ρ
= density at flow conditions
qm= C
1β4
–
-------------------επ
4
---d22∆Pρ
Pmin = minimum point (equivalent to offset)
Pmax = maximum point (Pmax – Pmin is equivalent to span)
A* = normalised signal (0 to 1) with correction applied for a flow input
fA() Pmin Pmax Pmin–()A*⋅+=

Introduction
4515 HC04 - 8 June 2007
Correction Type
•LINEAR: when the instrument is not required to apply
correction
•NON-LINEAR: when the instrument applies correction from
the points in the correction 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
over 1000 entries of the variables as displayed on the main menu.
Main Menu Variables
Refer to Available Units of Measurement on page 78 for the list of
available units.
Communications
There are three communication ports available as follows:
•RS-232 port (standard)
•RS-485 port (advanced option)
•Infra-red port (on front panel)
The ports are available for remote data reading, printouts and for initial
application loading of the instrument.
A* A=
A* Ac =
Main Menu
Variables Default Units Variable Type
Energy MWh Total
Power MW Rate
Volume m3 Total
Volume Flowrate m3/min Rate
Mass kg Total
Mass Flowrate kg/min Rate
Feed Temperature Deg C Rate
Return Temperature Deg C Rate
Differential Temperature Deg C Rate
Differential Pressure kPa Rate
Reynolds Number E+3 Rate

Introduction
515 HC04 - 8 June 2007 5
Isolated Outputs
The opto-isolated outputs can re-transmit any main menu variable. The type
of output is determined by the nature of the assigned variable. Totals are
output as pulses and rates are output as 4-20mA signals. One output is
standard, a second output is available as an option.
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 with an additional two available in the advanced option.
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, totals and logged data are stored in non-volatile
memory with at least 30 years retention.
Temperature Input Types
Temperature sensor inputs can be either PT100, PT500, 4-20mA, 0-5V or
1-5V signals.
Figure 1 Typical Application Diagram
T
Feed Flow
Temperature
Transmitters
Analog
Input 1
Return Flow
Analog
Input 2
T
Energy
Load
DP Meter
Analog
Input 3
Hi Flow
Analog
Input 4
Option

Introduction
6515 HC04 - 8 June 2007
Limitations of Use
•USER - User pre-defined table as per configuration report
ISO 5167 Limits
The formulae in ISO 5167 can be appliedonlywhen the quantities lie within
the limits shown in the table below.
The ISO standard applies only to pressure differential devices in which the
flow remains subsonic throughout the measuring section and is steady or
varies only slowly with time and where the fluid can be considered as single
phase. In addition, each of these devices can only be used within specified
limits of pipe bore size (D) and Reynolds number (ReD).
The calculations are based on upstream temperature and pressure values.
However, the ISO standard assumes that the downstream temperature is the
same as the upstream temperature, therefore a downstream temperature
probe is permissible except where very accurate measurements are required.
If the fluid is a gas, the pressure ratio shall be ≥0.75.
V-Cone Limits
The formulae used, when either of the cone types (V-Cone or Wafer-Cone)
are selected, have been supplied by McCrometer. The accuracy and
applicability of the use of these differential pressure flowmeters should be
confirmed by referring to the manufactures documentation.
Type of device d (mm)
(in) D (mm) (in) βReD
Orifice plate, corner
or D-D/2 tappings ≥12.5 ≥0.5 50 ≤ D ≤1000 2 ≤ D ≤ 40 0.10 ≤ β ≤ 0.75 ReD≥5000 for 0.10 ≤ β ≤ 0.56
ReD≥16000 β2for β> 0.56
Orifice plate flange
tappings ≥12.5 ≥0.5 50 ≤ D ≤1000 2 ≤ D ≤40 0.10 ≤ β ≤ 0.75 ReD≥5000 and
ReD≥170 × β2D (D in millimetres)
ISA 1932 nozzle - 50 ≤ D ≤500
2 ≤ D ≤20 0.30 ≤ β ≤ 0.80 7.0e+04 ≤ ReD≤1.0e+07 for 0.30 ≤ β ≤ 0.44
2.0e+04 ≤ ReD≤1.0e+07 for 0.44 ≤ β ≤ 0.80
Long radius nozzle - 50 ≤ D ≤630
2 ≤ D ≤25 0.20 ≤ β ≤ 0.80 1.0e+04 ≤ ReD ≤1.0e+07
Venturi tube as cast - 100 ≤ D ≤800
4 ≤ D ≤32 0.30 ≤ β ≤ 0.75 2.0e+05 ≤ ReD ≤2.0e+06
Venturi tube
machined - 50 ≤ D ≤250 2 ≤ D ≤10 0.40 ≤ β ≤ 0.75 2.0e+05 ≤ ReD ≤1.0e+06
Venturi tube welded - 200 ≤ D ≤1200
8 ≤ D ≤48 0.40 ≤ β ≤ 0.70 2.0 e+05 ≤ ReD ≤2.0e+06
Venturi nozzle ≥50
≥2 65 ≤ D ≤500 2.5 ≤ D ≤20 0.316 ≤ β ≤ 0.775 1.5e+05 ≤ ReD ≤2.0e+06

Introduction
515 HC04 - 8 June 2007 7
Some applicable ranges of lines sizes and beta values are as follows:
Approvals
This instrument conforms to the EMC-Directive of the Council of European
Communities 89/336/EEC and the following standards:
•Generic Emission Standard EN 50081-1 Residential, Commercial &
Light Industry Environment.
•Generic Emission Standard EN 50081-2 Industrial Environment.
•Generic Immunity Standard EN 50082-1 Residential, Commercial &
Light Industry Environment.
•Generic Immunity Standard EN 50082-2 Industrial Environment.
In order to comply with these standards, the wiring instructions in Chapter
3 - Installation must be followed.
Type of Cone Line sizes(mm)
(in) β
McCrometer
Precision tube V-Cone 12 ≤ D ≤1830 0.5 ≤ D ≤ 72 0.45 ≤ β ≤ 0.80
McCrometer
Wafer-Cone 12 ≤ D ≤152 0.5 ≤ D ≤6 0.45 ≤ β ≤ 0.80

Introduction
8515 HC04 - 8 June 2007

9
Chapter 2
Specifications
General Inputs
Outputs
Operating Environment
Temperature -20°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 Typically 6W
Protection Sealed to IP65 (Nema 4X) when panel
mounted
Dimensions 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 ATEX, FM, CSA and SAA approved
enclosures available for hazardous areas
Real Time Clock (Optional)
Battery Type 3 volts Lithium button cell (CR2032)
Battery Life 5 years (typical)
Analog Input (General)
Overcurrent 100mA absolute maximum rating
Update Time < 1.0 sec
Configuration RTD, 4-20mA, 0-5V and 1-5V input
Non-linearity Up to 20 correction points (flow inputs)
RTD Input
Sensor Type PT100 & PT500 to IEC 751
Connection Four Wire
Range -100°C to 300°C
Accuracy 0.1°C typical
4-20mA Input
Impedance 100ohms (to common signal ground)
Accuracy 0.05% full scale (20°C)
0.1% (full temperature range, typical)
0-5 or 1-5 Volts Input
Impedance 10Mohms (to common signal ground)
Accuracy 0.05% full scale (20°C)
0.1% (full temperature range, typical)
Logic Inputs
Signal Type CMOS, TTL, open collector, reed switch
Overvoltage 30V maximum
Relay Output
No. of Outputs 2 relays plus 2 optional relays
Voltage 250 volts AC, 30 volts DC maximum
(solid state relays use AC only)
Current 3A maximum
515 HC04 - 8 June 2007

Specifications
10 515 HC04 - 8 June 2007
Important: Specifications are subject to change without notice.
Communication Ports
Ports RS-232 port
RS-485 port (optional)
Infra-red port
Baud Rate 2400 to 19200 baud
Parity Odd, even or none
Stop Bits 1 or 2
Protocols ASCII, Modbus RTU, Printer
Transducer Supply
Voltage 8 to 24 volts DC, programmable
Current 70mA @ 24V, 120mA @ 12V maximum
Protection Power limited output
Isolated Output
No. of Outputs configurable output
Configuration Pulse/Digital or 4-20mA output
Pulse/Digital Output
Signal Type Open collector
Switching 200mA, 30 volts DC maximum
Saturation 0.8 volts maximum
Pulse Width Programmable: 10, 20, 50, 100, 200 or
500ms
4-20mA Output
Supply 9 to 30 volts DC external
Resolution 0.05% full scale
Accuracy 0.05% full scale (20°C)
0.1% (full temperature range, typical)

11
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.
Figure 2 500 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
515 HC04 - 8 June 2007

Installation
12 515 HC04 - 8 June 2007
Electrical Connection
Rear Panel Connections
Figure 3 shows the connections on the rear panel of the instrument.
Figure 3 Rear Panel Connections
Terminal Designations
RS232 Port
CAUTION
MAINS
ENA
AC MAINS
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
RC R1 R2 R3 R4
RELAYS
+ - G1+2+3+4+C- + - + -
RS485 LOGIC INPUT OUT1 OUT2
123456789101112131415161718
FINP SG EXC V AINP1 AINP2 AINP3 AINP4 Vo G Vi SH
1+2+-1+2+3++-+-+-+-+-+E
Terminal Label Designation Comment
1 FINP 1+ Frequency Input 1+ Not used
2 FINP 2+ Frequency Input 2+ Not used
3 SG - Signal ground
4 EXC V 1+ Excitation Term 1+ Not used
5 EXC V 2+ Excitation Term 2+ For AINP1 RTD input
6 EXC V 3+ Excitation Term 3+ For AINP2 RTD input
7AINP1 + Analog input ch 1 (+) Feed temperature input
8 - Analog input ch 1 (-)
9AINP2 + Analog input ch 2 (+) Return temperature input
10 - Analog input ch 2 (-)
11 AINP3 + Analog input ch 3 (+) Main or low flow input
12 - Analog input ch 3 (-)
13 AINP4 + Analog input ch 4 (+) High flow stacked input
14 - Analog input ch 4 (-)
15 Vo + 8-24 volts DC output Overload protected
16 G - DC Ground
17 Vi + DC power input DC power in 12-28V
18 SH E Shield terminal
EAC
MAINS
E Mains ground AC power in 95-135V or
190-260V
N N Mains neutral
A A Mains active
19
RS485
+ RS485 (+)
Advanced option20 - RS485 (-)
21 G RS485 ground
22
LOGIC
INPUTS
1+ Switch 1
23 2+ Switch 2
24 3+ Switch 3
25 4+ Switch 4
26 C- Signal ground
27 OUT 1 + Output ch 1 (+)
28 - Output ch 1 (-)
29 OUT 2 + Output ch 2 (+) Advanced option
30 - Output ch 2 (-)
31
RELAYS
RC Relay common
32 R1 Relay 1
33 R2 Relay 2
34 R3 Relay 3 Advanced option
35 R4 Relay 4
RS232 port 9-pin serial port
Terminal Label Designation Comment