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)