Contrec 505 Series Installation manual

Model 505 Flow Computer
Operation Manual
Application FG01
Generic Flow Computer
for
Frequency Flow
and Analog 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-FG01-OM - 17 June 2017

505 FG01 - 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.
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iv 505 FG01 - 17 June 2017

v
1 Introduction
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Displayed Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Main Menu Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Retransmission Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Relay Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-20mA Output Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pulse Output Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Control Relays (Alarms) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
RC Network for Interference Suppression . . . . . . . . . . . . . . . . . . . . . . 14
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
RS-232 Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
RS-485 Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Earthing and Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4 Operation
Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Default Total . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Front Panel Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Main Menu Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Peak Flowrates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
User Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Data Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Model Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Contents
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5 Instrument Calibration
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Calibration View Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Calibration Set Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Changing the Instrument Settings . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Calibration Menu Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Instrument Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Time Settings and Data Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
General Setup Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Test Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
System Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Warning Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6 Communications
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Hardware Interconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Protocols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Modbus RTU Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
List of Data Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Printer Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Types of Printouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Printer Data Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

vii
List of Figures
1 Typical Application Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Rear Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3 Externally Powered Current Loop . . . . . . . . . . . . . . . . . . . . . . . . . 12
4 Internally Powered Current Loop . . . . . . . . . . . . . . . . . . . . . . . . . 12
5 Logic Input Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 12
6 Output 4-20mA Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . 13
7 Output Pulse Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . 13
8 Relay Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
9 RS-485 Interface Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
10 Calibration Menu Tree Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 26
11 Calibration Menu Tree Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 27
12 RS-232 Cable Connections to a Computer . . . . . . . . . . . . . . . . . . . . 48
13 RS-485 Connections
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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1
Chapter 1
Introduction
Features •Frequency flow input for mass or volume
•4-20mA input acts as multiplier, divider or independently
•Can convert mass to volume or volume to mass
•Versatile “user value” available on main menu
•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
•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 505 FG01 application allows for great flexibility in configuring its
operation before delivery:
•the frequency input can accept either volumetric or mass flow
•the analog input can accept either temperature, pressure, density or
unitless values
•the analog input can operate independently or as a multiplication
factor/divider to derive the resultant mass or volumetric flow.
A freely programmable “user value” on the main menu can serve as a
setpoint for the 4-20mA output or as an operator identifier to be logged.
This application, by default, is set up to accept a volume flow input,
multiplied by a density on the 4-20mA input to determine the mass flow rate
and total.
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Introduction
2 505 FG01 - 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.
The calculation of totals are exact as the instrument collects all pulses
detected on the input.
total = pulses / k-factor
The flow rate is derived from an accurately measured frequency:
flow = frequency / k-factor
The analog input is normalised to a value (A) between 0 and 1.
Analog Value = (Vmax-Vmin)A+Vmin
The resultant values are then:
FACTOR result = Flow x Analog Value
DIVIDER result = Flow / Analog Value
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
Main Menu
Variables Default Units Variable Type
Total (Volume) L Total
Flowrate (Volume) L/min Rate
Analog Input (Density) kg/m3Rate
ResultingTotal (Mass) kg Total
Resulting Flowrate (Mass) kg/min Rate
User Value - - - Rate