Contrec 515 User manual

Model 515 Flow Computer
Operation Manual
Application DG01
Density Converter (Gas)
for
Pulse Output Density Meters
18 June 2017

Model 515 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: 515-DG01-OM - 18 June 2017

515 DG01 - 18 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.
515 DG01 - 18 June 2017

iv 515 DG01 - 18 June 2017

v
1 Introduction
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Equation Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
User Defined Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Analog Input Scaling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Displayed Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Main Menu Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Isolated Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Relay Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Temperature and Pressure Input Types . . . . . . . . . . . . . . . . . . . . . . . . . 6
Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Specifications
Specification Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 Installation
Panel Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Rear Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Terminal Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Frequency (Pulse) Input Connection . . . . . . . . . . . . . . . . . . . . . . . . . 13
Analog Input Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Logic Input Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4-20mA Output Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Control Relays (Alarms) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
RC Network for Interference Suppression . . . . . . . . . . . . . . . . . . . . . . 19
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
RS-232 Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Infra-red Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
RS-485 Port (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Earthing and Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4 Operation
Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Default Variable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Front Panel Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Main Menu Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Default Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Data Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Model Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5 Instrument Calibration
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Contents
515 DG01 - 18 June 2017

vi 515 DG01 - 18 June 2017
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Time Settings and Data Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
General Setup Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Test Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
System Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Warning Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6 Communications
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Hardware Interconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Protocols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Simple ASCII Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Requests Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Instrument Responses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Corrupted or Invalid Requests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Modbus RTU Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
List of Data Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Printer Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Types of Printouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Printer Data Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Appendix A Glossary
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Appendix B Model Numbers
Product Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Custom Version Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Application Information Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Appendix C Units of Measurement
Available Units of Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Appendix D Reference Tables
Properties of Selected Gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

vii515 DG01 - 18 June 2017
List of Figures
1 Typical Application Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Rear Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3 Externally Powered Voltage Transmitter . . . . . . . . . . . . . . . . . . . . . 14
4 Internally Powered Voltage Transmitter . . . . . . . . . . . . . . . . . . . . . 14
5 Externally Powered Current Loop . . . . . . . . . . . . . . . . . . . . . . . . . 15
6 Internally Powered Current Loops . . . . . . . . . . . . . . . . . . . . . . . . 15
7 RTD Connection
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
8 Logic Inputs Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . 17
9 Output 4-20mA Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . 17
10 Relay Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
11 RS-485 Interface Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
12 Logged Data Display Methods . . . . . . . . . . . . . . . . . . . . . . . . . . 24
13 Calibration Menu Tree Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 30
14 Calibration Menu Tree Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 31
15 RS-232 Cable Connections to a Computer . . . . . . . . . . . . . . . . . . . . 52
16 RS-485 Connections
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

viii 515 DG01 - 18 June 2017

1
Chapter 1
Introduction
Features •Pulse input for density
•Temperature and Pressure inputs for density conversion to reference
conditions
•Conversion based on a variety of General Gas equations
•Customer Defined Function (look-up table)
•Versatile User Input available on main menu
•Selection of second language and user tags
•RTC logging with over 1000 entries
•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 density converter application accepts inputs from Sarasota density
meters, temperature and pressure transmitters, and an unassigned input
enabling a variable to be connected as an input to the Customer Defined
Function (look-up table).
The converter calculates line (measured) density from the density meter
period output and uses it together with temperature and pressure readings to
derive density at reference conditions and calculate specific gravity and
other density related variables.
This instrument is compatible with a wide range of density meter pulse
outputs, including millivolt signals, reed switches, Namur proximity
switches and pulse trains via its smart front-panel program selection.
515 DG01 - 18 June 2017

Introduction
2 515 DG01 - 18 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 line density calculations are based on accurately measured average
period of pulses coming from density meters such as Sarasota Industrial
Density Meter FD910, etc.
A variety of calculations are available to suit the nature of the gas and the
measurement conditions. The calculations are valid for the vapour phase of
a gas.
Equations Of State:
•Ideal Gas
•Redlich-Kwong
•Soave-Redlich-Kwong
•Peng-Robinson
Equation Sets
Measured Line Density Correction
where:
Equations of State
In this instrument the calculation of gas properties can be based on one of
the following equations of state. These equations are based around the
general gas law that relates pressure (P), temperature (T), Universal Gas
Constant (R) and compressibility (Z) to the volume (V):
PV = ZRT
The method by which each equation determines the compressibility factor
differs, meaning it is more suited to certain gas types and conditions.
Ideal Gas
The Ideal Gas equation assumes the compressibility factor to be 1. This
equation is suited to gas at low pressure and high temperatures.
= measured line density
DCF = density correction factor (default 1.0)
D_OFFSET = density offset (default 0.0)
DCFD_OFFSET+=