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.
505 FG01 - 17 June 2017

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
505 FG01 - 17 June 2017

vi 505 FG01 - 17 June 2017
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
505 FG01 - 17 June 2017

viii 505 FG01 - 17 June 2017

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.
505 FG01 - 17 June 2017

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

Introduction
505 FG01 - 17 June 2017 3
Labels in brackets reflect factory default configuration. Other configurations are available,
consult your distributor for any change from the default variable names or units of
measurement.
Refer to Available Units of Measurement on page 64 for the list of
available units.
Communications
There are two communication ports available as follows:
•RS-232 port
•RS-485 port
The ports can be used for remote data reading, printouts and for initial
application loading of the instrument.
Retransmission Outputs
The instrument can re-transmit any main menu variable. The digital outputs
can re-transmit totals as pulses. If the instrument has the advanced option, it
outputs rates as a 4-20mA signal.
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.
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.

Introduction
4 505 FG01 - 17 June 2017
Figure 1 Typical Application Diagram
Approvals This instrument conforms to the EMC-Directive of the Council of
European Communities 2014/30/EU, the LVD safety directive 2014/35/EU
and the following standards:
•EN61326:2013 Electrical equipment for measurement, control and
laboratory use – EMC requirements: 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 Chapter
3 - Installation must be followed.
FCC Declaration
This equipment has been tested and found to comply with the limits for a
Class A digital device, pursuant to Part 15 of the FCC Rules. These limits
are designed to provide reasonable protection against harmful interference
when the equipment is operated in a commercial environment. This
equipment generates, uses, and can radiate radio frequency energy and, if
not installed and used in accordance with the instruction manual, might
cause harmful interference to radio communications. Operation of this
equipment in a residential area is likely to cause harmful interference, in
which case the user will be required to correct the interference at his own
expense.
Properlyshieldedandgroundedcablesandconnectorsmustbe used in order
to meet FCC emission limits. Contrec Ltd is not responsible for any radio or
television interference caused by using other than recommended cables and
connectors or by unauthorized changes or modifications to this equipment.
Unauthorized changes or modifications could void the user's authority to
operate the equipment.
D
Flow
Density
Transmitter
Analog
Input
Frequency
Input
Volumetric
Flowmeter
Example
Application
Configuration

Introduction
505 FG01 - 17 June 2017 5
This device complies with Part 15 of the FCC Rules. Operation is subject to
the following two conditions: (1) this device might not cause harmful
interference, and (2) this device must accept any interference received,
including interference that might cause undesired operation.

Introduction
6 505 FG01 - 17 June 2017

7
Chapter 2
Specifications
Specification Table
Operating Environment
Temperature 0°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 6W (typical)
Protection Sealed to IP65 (Nema 4X) when panel
mounted
Dimensions
(panel option) 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 IECEx, ATEX and CSA approved
enclosures available for hazardous areas
Real Time Clock (Optional)
Battery Type 3 volts Lithium button cell (CR2032)
Battery Life 5 years (typical)
Frequency Input (General)
Range 0 to 10kHz
Overvoltage 30V maximum
Update Time 0.3 sec
Cutoff frequency Programmable
Configuration Pulse, coil or NPS input
Non-linearity Up to 10 correction points
Pulse
Signal Type CMOS, TTL, open collector, reed switch
Threshold 1.3 volts
Coil
Signal Type Turbine and sine wave
Sensitivity 15mV p-p minimum
NPS
Signal Type NPS sensor to Namur standard
4-20mA Input
Overcurrent 100mA absolute maximum rating
Impedance 250 Ohms (to common signal ground)
Accuracy 0.1% typical full scale (20 C)
0.2% (full temperature range)
Relay Output
No. of Outputs 2 relays
Voltage 250 volts AC, 30 volts DC maximum
Current 3A maximum
Communication Ports
Ports RS-232 port
RS-485 port
Baud Rate 2400 to 19200 baud
Parity Odd, even or none
Stop Bits 1 or 2
Data Bits 8
Protocols Modbus RTU, Printer*
505 FG01 - 17 June 2017

Specifications
8 505 FG01 - 17 June 2017
Important: Specifications are subject to change without notice.
Printer protocol is available only if RTC option is installed.
Transducer Supply
Voltage 8 to 24 volts DC, programmable
Current 70mA @ 24V, 120mA @ 12V maximum
Protection Power limited output
Pulse/Digital Output
Signal Type Open collector, non-isolated
Switching 200mA, 30 volts DC maximum
Saturation 0.8 volts maximum
Pulse Width Programmable: 10, 20, 50, 100, 200 or
500ms
4-20mA Output (Optional)
Supply 24 volts DC internal, non-isolated
Resolution 0.05% full scale
Accuracy 0.05% full scale (20C)
0.1% (full temperature range, typical)

9
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.
shows the panel mounting requirements for the 500 Series Instrument.
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
505 FG01 - 17 June 2017

Installation
10 505 FG01 - 17 June 2017
Electrical Connection
Rear Panel Connections
Figure 2 shows the connections on the rear panel of the instrument.
Figure 2 Rear Panel Connections
Terminal Designations
RS232 Port
CAUTION
MAINS
E N A
AC MAINS
123 456789101112131415161718 192021
RS485 RS232 Io SG Li Dout Ii SG Fi Vo GViSH RELAYS
+-GTxRx C + - + 1+ 2+ + - + + - + E R1 RC R2
TerminalLabel Designation Comment
1RS485 + RS485 (+)
2 - RS485 (-)
3 G Comms ground
4RS232 Tx RS232 data out Same RS232 port as
DB9 connector
5 Rx RS232 data in
6 C CTS (Clear to send)
7 Io + 4-20mA output Advanced option
8 SG - Signal Ground 0V
9 Li + Logic input
10 D OUT 1+ Open collector o/p 1 Digital outputs
11 2+ Open collector o/p 2
12 Ii + 4-20mA input Sensor input
13 SG - Signal Ground 0V
14 Fi + Frequency input Flow input
15 Vo + 8-24 volts DC output 70mA power limited
16 G - DC Ground
17 Vi + DC power input DC power in 12-28V
18 SH E Shield terminal
19 RELAYS R1 Relay 1
20 RC Relay Common
21 R2 Relay 2
EAC
MAINS
E Mains ground ACpowerin95-135V
or 190-260V
N N Mains neutral
A A Mains active
RS232 port 9-pin serial port

Installation
505 FG01 - 17 June 2017 11
Inputs
Frequency Input Connection
Connect pulse or frequency input signals from devices such as: TTL,
CMOS, open collector, reed relay switch, coil and Namur proximity switch,
as shown below. For better signal integrity, it is recommended to use
shielded cable. Refer to Terminal Designations on page 10 for specific
terminal numbers for this application.
Squarewave, CMOS or TTL
Open Collector
Reed Relay Switch
Coils - with 15 millivolts peak to peak AC minimum
Namur Proximity Switch
18 Shield
Signal Ground
13
Frequency
Input
(Fi)
14
Signal Ground
18 Shield
13
Frequency
Input
(Fi)
14
Signal Ground
18 Shield
13
Frequency
Input
(Fi)
14
NPN PNP
+V
Signal Ground
18 Shield
13
Frequency
Input
(Fi)
14
~
18
Signal Ground
Shield
13
Frequency
Input
(Fi)
14
15 Vo +8V DC
18 Shield
NPS
Frequency
Input
(Fi)
14

Installation
12 505 FG01 - 17 June 2017
Analog Input Connections
The analog input (Ii) can accept current signals from 4 to 20mA.
4-20mA Inputs
For an externally powered current loop, connect the transmitter to the input
terminals as shown in Figure 3.
Figure 3 Externally Powered Current Loop
Connect internally powered current loops as shown in Figure 4.
Figure 4 Internally Powered Current Loop
Logic Input Connection
These input(s) are designed to be connected to open collector signals or a
voltage free contact switch. A minimum activation time of 300ms is
required to guarantee reading of an input.
Remote Key Input
Connect a remote push-button key to the Logic Input as shown below. Refer
to REMOTE KEY on page 33 in to define the function of the key.
Figure 5 Logic Input Connection Diagram
+-
Transmitter
Analog
Input
(Ii)
12
13
15
12
+
-Analog
Input
Vo +8...24V DC
(Ii)
Transmitter
Signal Ground
8
Logic Input
(Li)
9