Contrec 104D User manual

MAN104DV1.4
FIELD MOUNTED
RATE TOTALISER
MODEL 104D
March 2015

MAN104D-V1.4

MAN104DV1.4
CONTENTS
1. Introduction 1
2. Specification 2
3. Operation 4
3.1 Display 4
3.2 Test Mode 5
3.3 Filtering 6
3.4 Calculation of Rate and Total 7
3.5 Total Conversion 8
3.6 Frequency Cutoff 9
4. Programming 10
4.1 Program Steps 11
5. Example 14
6. Outputs 15
7. Flowmeter Input 18
8. Installation 23
8.1 Wall Mounting 23
8.2 Removing the Front Panel 24
8.3 The Main Electronics 26
8.4 Wiring 27
8.5 Terminal Designations 27
Index 28

MAN104D-V1.4

Introduction 1
MAN104DV1.4
1. INTRODUCTION
The Model 104D Rate Totaliser is a microprocessor based instrument, Loop
Powered with a 4-20mA output and Alarms. It accepts a frequency or pulse input
from a wide range of flowmeters. The instrument displays flow Rate, a Resettable
Total and an Accumulated Total directly in engineering units.
The instrument is compatible with a wide range of flowmeters including turbine,
paddlewheel and positive displacement flowmeters.
The instrument is fully programmable from the front panel; the user can program
scaling factors, decimal point positions, filter constants and timebase.
The Model 104D Rate Totaliser conforms to the EMC-Directive of the Council of
European Communities 2004/108/EC, the LVD directive 2006/95/EC and the
following standards:
EN61326:2013 Electrical equipment for
measurement, control and
laboratory use –EMC requirements :
Residential, Commercial & Light
Industry Environment & 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 Section 8.4
must be adhered to.

2Specification
MAN104D-V1.4
2. SPECIFICATION
General
Display: LCD which is continuously powered.
Resettable Total: 7 digits with 10mm (0.4") high digits. Resettable
from front panel.
Accumulated Total: Displayed when the ACCUM TOTAL button is
pressed.
Rate: 4½ digits with 8.5mm (0.33") high digits.
K-factor: The pulses per unit of measure (eg. pulses/gallon)
is programmable in the range 0.000001 to
999,999.
Decimal Points: Decimal point positions are fully programmable
for both rate and total.
Timebase: Rate can be displayed in units per second, minute,
hour or day.
Frequency Range: 0.01Hz to 10kHz.
Signal Type: Link settable for sinewave (15mV P-P minimum),
open collector, reed switch, pulse or Namur
proximity switch.
Scale: The 4mA and 20mA points are programmable.
Resolution and Linearity: 0.05% of span.
Accuracy: 0.05% of span at 25°C.
0.1% (typ) of span, full temperature range.
Update Time: 0.5 second.
Connection: Two-wire.
Loop Power Supply: 9-28 Volts.
Supply Backup: 2 x User replaceable Lithium battery.
Outputs: Two open collector outputs suitable for driving DC
solenoids or external relays. The outputs can be
programmed to provide high and low flow alarms
or pulse output and low flow alarm.
Switching Power: 750mA. 30VDC maximum.

Specification 3
MAN104DV1.4
Pulse Duration: 1ms if CAL0 = 2 (unscaled pulse output).
If CAL0 = 1 (scaled pulse output) the duration of
the pulse automatically adjusts to the output
frequency:
a. 1ms if output > 50Hz.
b. 10ms if output = 5...50Hz.
c. 100ms if output < 5Hz.
Physical
Temperature: Operating temperature: -20°C to 60°C.
Dimensions: 97mm (3.8") high x 150mm (5.9") wide x 41mm
(1.6") deep (cable glands not included).
Protection: Sealed to Nema 4X or IP67 standards.
Cable Entry: By cable glands.
Wall Mounting: Universal mounting bracket supplied as standard.
Pipe Mounting: A galvanised metal bracket is available which
enables the Model 104D to be attached to a 2"
vertical or horizontal pipe.
Turbine Meter Adaptor: An optional mounting stem is available for
mounting the Model 104D directly on turbine
flowmeters which have a 1" NPT boss or 1" BSP
boss.

4Operation
MAN104D-V1.4
3. OPERATION
The Model 104D Rate Totaliser accepts a frequency or pulse input from a wide
range of flowmeters. The instrument is fully programmable with all operating
parameters and calculation constants programmable from the front panel. The
setup parameters are stored in a non-volatile memory and are retained for at
least 10 years in the event of a power loss.
3.1 DISPLAY
The Model 104D displays:
Rate
Resettable Total
Accumulated Total
Both the Rate and Resettable Total are displayed continuously. The Accumulated
Total is displayed only when the ACCUM TOTAL key is pressed.
The keys on the front of the 104D have the following functions:
Pressing this key will display the
Accumulated Total.
This key resets the Resettable Total
at any time.
This key is used during the Program
Mode.

Operation 5
MAN104DV1.4
3.2 TEST MODE
The 104D has a Test Mode which can be entered by simultaneously pressing all 3
front panel keys. The tests are as follows:
Low Test By pressing the ACCUM TOTAL key, the low alarm
output (if installed) will go low. If a 4-20mA option
is installed, the output will go to 4mA.
High Test By pressing the RESET key, and depending on the
programmed pulse output mode, the high alarm
output (if installed):
a. will go low if CAL0 = 0 (high alarm output).
b. will output 100ms pulses every 0.5 sec if CAL0
= 1 (scaled pulse output).
c. will output 1ms pulses every 0.5 sec if CAL0 = 2
(unscaled pulse output).
If a 4-20mA option is installed, the output will go
to 20mA.
Display Test By pressing the PROGRAM key, all segments of the
display will flash.
To exit Test Mode, all three front panel keys are pressed simultaneously.

6Operation
MAN104D-V1.4
3.3 FILTERING
Frequency fluctuations caused by pulsating flow through a flowmeter can
interfere with the precision of the rate. For this reason, the Model 104D has a
digital filter which will average out these fluctuations and enable accurate
readings.
The degree of filtering of the input signal can be adjusted depending on the
amount of fluctuation and the particular application. Values from 1 to 99 can be
programmed where 1 corresponds to no filtering and 99 corresponds to heavy
filtering. Such flexibility in filtering means that highly accurate and stable
readings can be obtained.
When programming the degree of filtering, it is advisable to start with no filtering
(the factor equals 1) and gradually increase until a steady reading is obtained. It is
important that the filtering is not too heavy because this will cause an
overdamped response.
The following graph shows the time to reach 90% and 99% of a new reading for a
step change in input signal.
Filter Factor vs Time to Reach New Reading
(for a step change in input signal)
0
20
40
60
80
100
120
010 20 30 40 50 60 70 80 90 100
Filter Factor
Time to Reach % of
New Reading (seconds)
90% of New Reading 99% of New Reading

Operation 7
MAN104DV1.4
3.4 CALCULATION OF RATE AND TOTAL
The flow rate, R, is calculated as follows:
where fis the input frequency in Hz (pulses/second).
His the timebase of rate and is 1 for seconds, 60 for minutes, 3600 for
hours and 86,400 for days.
Sis the scaling factor (pulses/unit volume).
The scaling factor, S, is equal to the K-factor of the flowmeter expressed in pulses
per unit volume. The K-factor is flowmeter dependant and is supplied with the
flowmeter. It will be either on a calibration certificate or stamped on the body of
the meter.
The user programs the scaling factor and selects the timebase during the
programming procedure.
Rf x H
S
=

8Operation
MAN104D-V1.4
3.5 TOTAL CONVERSION
The Total Conversion Factor is programmed to enable the rate to be displayed in
one engineering unit and the totals to be displayed in another. For example, the
rate can be displayed in gallons/minute and the totals in barrels.
The Total Conversion Factor is a division factor which is used to convert the totals
to a different unit. Therefore, it only affects the totals (both resettable and
accumulated).
Example.
If the Rate is required in gallons/minute:
1. The Scaling Factor would be programmed as pulses per gallon.
2. The Timebase would be programmed as minutes.
If the Totals are required in barrels:
1. The Total Conversion Factor is programmed as 42 because there are 42
gallons in a barrel. All totals will now totalise in barrels.
Below is a table containing common units and their corresponding Total
Conversion constants:
Rate/Unit Time
Totals
Total Conversion Factor
Gallons (US)/Unit Time
Barrels (oil)
42.000
Litres/Unit Time
Kilolitres
1000
Litres/Unit Time
m3
1000
ml/Unit Time
Litres
1000
Mgallons/Unit Time
Acre-feet
0.32587

Operation 9
MAN104DV1.4
3.6 FREQUENCY CUTOFF
A frequency cutoff can be programmed below which flow rate is not registered.
Input frequencies at or below the cutoff are totalised, however, the rate is
displayed as zero.
The frequency cutoff has a default value of 0.25Hz. The cutoff should be left as
0.25Hz unless the flowmeter in use has a lower frequency.
Note that a low cutoff frequency will result in a correspondingly low response of
flow rate update. For example, if the cutoff is set to 0.01Hz the 104D will
continue to display the flow rate for 100 seconds even if the signal stops. This is
because a cutoff frequency of 0.01Hz means that the time interval between
signals is 100 seconds (period = 1/frequency). Therefore, the Model 104D must
wait 100 seconds before it can determine that the flow has actually stopped.

10 Programming
MAN104D-V1.4
4. PROGRAMMING
The Model 104D is fully programmable with all parameters being stored in non-
volatile memory.
The Program Mode can be entered in one of two ways:
1. By removing the lower cover strip (ie. the dark grey strip along the bottom
of the enclosure) and replacing it the wrong side up. This brings a small
magnet on the inside of the cover strip in contact with a reed switch inside
the instrument.
2. By removing the front section of the enclosure which contains the main
processor board and batteries.
The PROGRAM switch is used to step through the program (CAL sequences) and
the (ACCUM TOTAL) and (RESET) keys on the front panel are used to
change and increment the flashing digits. Note that only flashing digits can be
changed.
Up to nineteen CAL steps are accessible depending on which options are installed.
The CAL number is displayed on the lower display and the parameter is displayed
above it.
Parameters in Program Mode that consist of the two parts, whole numbers and
digits after the decimal point, are restricted to having a maximum of 6 significant
digits. Therefore the number of significant digits entered in the whole numbers
determines the number of digits that are able to be entered in the digits after the
decimal point.
For Example
000001 in the whole numbers makes 00000 available after the decimal place.
000100 in the whole numbers makes 000 available after the decimal place.
010000 in the whole numbers makes 0 available after the decimal place.

Programming 11
MAN104DV1.4
4.1 PROGRAM STEPS
Step
Comment
CAL 0
Pulse Output
0 = No pulse output, low and high alarms.
1 = Scaled pulse output and low alarm.
2 = Unscaled pulse output and low alarm.
CAL 1
Scaling Factor - whole numbers.
CAL 2
Scaling Factor - digits after the decimal point.
The scaling factor is the pulses per unit of measure (eg.
pulses/litre, pulses/gallon, etc). The scaling factor can be
programmed in the range of 0.000001 - 999,999.
See Section 3.4.
CAL 3
Cutoff Frequency.
This determines the cutoff frequency in the range of 0.01 -
0.99Hz. The default setting is 0.25HZ.
Note that care must be taken when programming this value
because a low value may cause a slow update time.
CAL 4
Decimal Point for Rate Display.
The flow rate can be displayed with 0, 1, 2 or 3 decimal point
places.
CAL 5
Timebase for Rate.
The rate can be displayed in units per second, minute, hour or
day.
0 = second
1 = minute
2 = hour
3 = day

12 Programming
MAN104D-V1.4
Step
Comment
L 6
Filter.
The filter constant for filtering the input signal.
1 No filtering.
to
99 Very heavy filtering.
CAL 7
Decimal Point for Total Display.
The totals can be displayed with 0, 1, 2 or 3 decimal points.
CAL 8
Total Conversion Factor - whole numbers.
CAL 9
Total Conversion Factor - digits after the decimal point.
The total conversion factor enables the rate to be displayed
in one engineering unit and the totals to be displayed in
another engineering unit. The total conversion factor can be
programmed in the range of 0.000001 - 999,999.
Set to 1.000 if totals and rate are in the same unit, eg. litres.
See Section 3.5.
CAL 10
Low Alarm - whole numbers.
CAL 11
Low Alarm - digits after the decimal point.
CAL 10 to CAL 13 are displayed regardless of whether the high
and low alarms are installed. If the high and low alarms are not
installed, these parameters can be ignored.
CAL 10 & 11 program the flow rate below which the low alarm
relay will close. The value can be programmed in the range
0.000000 to 999,999.

Programming 13
MAN104DV1.4
Step
Comment
CAL 12
High Alarm or Pulse Output Factor - whole numbers.
CAL 13
High Alarm or Pulse Output Factor - digits after the decimal
point.
CAL 12 & 13 program the flow rate above which the high alarm
relay will close. The value can be programmed in the range
0.000000 to 999,999.
If the scaled pulse output is selected (see CAL0 = 1), then the value
will represent the total per pulse, eg. 5 litres per pulse.
CAL 14
4mA Retransmission - whole numbers.
CAL 15
4mA Retransmission - digits after the decimal point.
CAL 14 to CAL 15 represent the flow rate at which 4mA will be
output. If the 4-20mA retransmission is not installed, these
parameters can be ignored.
CAL 16
20mA Retransmission - whole numbers.
CAL 17
20mA Retransmission - digits after the decimal point.
CAL 16 & 17 are the flow rates at which the output will reach
20mA.
SOFT
Software Version.

14 Example
MAN104D-V1.4
5. EXAMPLE
A flowmeter produces 20.538 pulses per litre and has a maximum output
frequency on 200Hz. It is required to display the flow rate in litres/min with 1
decimal point and the total in litres with no decimals. A 4-20mA output is
installed and 4mA is to represent 0 litres/m and 20mA is to represent
500 litres/m. The instrument is then programmed as follows:
Calibration mode is entered by removing the lower cover strip (ie. the dark grey
strip along the bottom of the enclosure) and replacing it the wrong side up.
The following values are then entered:
Step
Value of
Parameter
Description
CAL00
1
Scaled Pulse Output
CAL01
00020
Scaling Factor (whole numbers)
CAL02
5380
Scaling Factor (decimals)
Cal03
0.25
Cutoff Frequency
Cal04
1
Rate decimal position
Cal05
1
Timebase
Cal06
01
Filter disabled
Cal07
0
Total decimal position
Cal08
0001
Total Conversion (set to 1.0000)
Cal09
0000
Total Conversion (decimals)
Cal10
00000
Low Alarm
cal11
0000
Low Alarm
Cal12
00000
High Alarm
Cal13
0000
High Alarm
Cal14
00000
4mA Output (whole numbers)
Cal15
0000
4mA Output (decimals)
Cal16
00500
20mA Output (whole numbers)
Cal17
0000
20mA Output (decimals)
SOFT
X.XX
Software Version

Outputs 15
MAN104DV1.4
6. OUTPUTS
This version combines features of the DC powered with a 4-20mA output.
The 4-20mA output provides a two-wire retransmission of the flow rate. Both the
4mA and 20mA points are fully programmable so that the output can span across
the entire operating range or, alternatively, across a small section of the
operating range.
The instrument draws its operating power from the 4-20mA loop and uses lithium
batteries for backup if the 4-20mA loop is interrupted. The alarm/pulse outputs
are not supported if the 4-20mA loop is interrupted.
The two Lithium cells are 3.6V, AA types. e.g. TADIRAN SL360/S, SAFT LS14500EX.
Note the battery polarity when replacing.
Specification
Resolution and Linearity: 0.05% of span.
Accuracy: 0.05% of span at 25°C.
0.1% (typ) of span, full temperature range.
Response (4-20mA): 0.5 second.
Loop Power Supply: 9-28 Volts.
Since the 4-20mA output is designed to provide power to the Model 104D, it is
not isolated from the input. Hence, all sensors must be self-powering (such as
reed switches and coils). If external power is required to power the sensor (eg.
Namur switches, Hall effect sensors or opto-sensors), the power supply delivering
the external power must be isolated from the 4-20mA loop supply
Typical Connection

16 Outputs
MAN104D-V1.4
Connection to a Sensor requiring External Power
Open collector outputs are also provided for high and low flow rate alarms. If a
pulse output is programmed, terminals 6 and 5 will act as a pulse out. The output
can sink up to 750mA and can be used to power external relays, lights or audible
alarms. The outputs are internally protected against voltage spikes caused by
relays and coils.
Both outputs are separately isolated via opto-isolators.
The switching points can be programmed during the setup mode and the low flow
alarm will switch on whenever the flow rate drops below the programmed flow
rate. Similarly, the high alarm switches on whenever the flow exceeds the high
setpoint.
If a scaled pulse output is programmed, a pulse will be output every preset value
of the total. For example, if the total is in litres, then programming 5 will output
one pulse every 5 litres. If an unscaled pulse output is programmed, output
pulses will follow input frequency from a flowmeter.Specification for Alarm
Outputs
Maximum Current (sink): 750mA.
Maximum Voltage: 30Vdc.
Saturation Voltage: 0.8Vdc across outputs when in the "on" state.