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Contrec 515 Operation Manual

Flow computer
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Model 515 Flow Computer
Operation Manual
Application HC04
Heat Calculator - Flow Computer
for
Stacked Differential Pressure Meters
(ISO 5167 & V-Cones)
8 June 2007

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Summary of Contents for Contrec 515

  • Page 1 Model 515 Flow Computer Operation Manual Application HC04 Heat Calculator - Flow Computer Stacked Differential Pressure Meters (ISO 5167 & V-Cones) 8 June 2007...
  • Page 2 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.

  • Page 3: Safety Notice

    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 515 HC04 - 8 June 2007...
  • Page 4 515 HC04 - 8 June 2007...

  • Page 5: Table Of Contents

    RC Network for Interference Suppression Communications RS-232 Port Infra-red Port RS-485 Port (Advanced Option) Earthing and Shielding 4 Operation Normal Operation Default Total Status Lamps Front Panel Keys Main Menu Items Peak Flowrates Data Logs Model Information 515 HC04 - 8 June 2007...
  • Page 6 Appendix A Glossary Glossary Appendix B Model Numbers Product Codes Custom Version Codes Application Information Code Appendix C Units of Measurement Available Units of Measurement Appendix D Reference Tables Properties of Commonly Used Materials Index 515 HC04 - 8 June 2007...

  • Page 7: List Of Figures

    Output 4-20mA Connection Diagram Output Pulse Connection Diagram Relay Connection Diagram RS-485 Interface Connections Logged Data Display Methods Calibration Menu Tree Sheet 1 Calibration Menu Tree Sheet 2 RS-232 Cable Connections to a Computer RS-485 Connections 515 HC04 - 8 June 2007...
  • Page 8 515 HC04 - 8 June 2007...

  • Page 9: Chapter 1 Introduction

    • 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.

  • Page 10: Operation Modes

    (1997). The temperature limits are dependent on the system pressure: 0°C < t < t at system pressure saturation 32°F < t < t at system pressure saturation Formulas ρ Volume flow = Mass flow / flow Power = Mass flow x (h 515 HC04 - 8 June 2007...

  • Page 11: Analog Input Scaling

    P max P min – where: = minimum point (equivalent to offset) = maximum point (P – P is equivalent to span) = normalised signal (0 to 1) with correction applied for a flow input 515 HC04 - 8 June 2007...

  • Page 12: Displayed Information

    There are three communication ports available as follows: • RS-232 port (standard) • RS-485 port (advanced option) • Infra-red port (on front panel) The ports are available for remote data reading, printouts and for initial application loading of the instrument. 515 HC04 - 8 June 2007...

  • Page 13: Isolated Outputs

    Temperature sensor inputs can be either PT100, PT500, 4-20mA, 0-5V or 1-5V signals. Analog Analog Analog Analog Input 1 Input 2 Input 3 Input 4 Hi Flow Feed Flow Option Energy Load Return Flow DP Meter Temperature Transmitters Figure 1 Typical Application Diagram 515 HC04 - 8 June 2007...

  • Page 14: Limitations Of Use

    The formulae used, when either of the cone types (V-Cone or Wafer-Cone) are selected, have been supplied by McCrometer. The accuracy and applicability of the use of these differential pressure flowmeters should be confirmed by referring to the manufactures documentation. 515 HC04 - 8 June 2007...

  • Page 15: Approvals

    Generic Immunity Standard EN 50082-1 Residential, Commercial & Light Industry Environment. • Generic Immunity Standard EN 50082-2 Industrial Environment. In order to comply with these standards, the wiring instructions in Chapter 3 - Installation must be followed. 515 HC04 - 8 June 2007...
  • Page 16 Introduction 515 HC04 - 8 June 2007...

  • Page 17: Chapter 2 Specifications

    Voltage 250 volts AC, 30 volts DC maximum Real Time Clock (Optional) (solid state relays use AC only) Battery Type 3 volts Lithium button cell (CR2032) Current 3A maximum Battery Life 5 years (typical) 515 HC04 - 8 June 2007...

  • Page 18: Communication Ports

    Programmable: 10, 20, 50, 100, 200 or 500ms 4-20mA Output Supply 9 to 30 volts DC external Resolution 0.05% full scale Accuracy 0.05% full scale (20°C) 0.1% (full temperature range, typical) Important: Specifications are subject to change without notice. 515 HC04 - 8 June 2007...

  • Page 19: Chapter 3 Installation

    Figure 2 shows the panel mounting requirements for the 500 Series Instrument. Side View Top View RS232 Rear Connectors Port 22mm 25mm 145mm 138mm Front Panel Mounting Clip Min. 189mm 67mm 70mm 139mm 147mm Panel Cut-out Figure 2 500 Series Instrument Panel Mounting 515 HC04 - 8 June 2007...

  • Page 20: Rear Panel Connections

    + DC power input DC power in 12-28V R4 Relay 4 18 SH E Shield terminal RS232 port 9-pin serial port E Mains ground AC power in 95-135V or N Mains neutral MAINS 190-260V A Mains active 515 HC04 - 8 June 2007...

  • Page 21: Externally Powered Voltage Transmitter

    Shield Figure 4 Externally Powered Voltage Transmitter Connect internally powered voltage transmitters as shown in Figure 5. Vo +8...24V DC Signal Transmitter Analog Input (AINPn) DC ground Shield Figure 5 Internally Powered Voltage Transmitter 515 HC04 - 8 June 2007...

  • Page 22: Externally Powered Current Loop

    The instrument uses 4-wire RTDs to provide optimum accuracy and stability. It is not necessary to have equal cable lengths for the 4-wire RTDs, but they should be no longer than 50 metres. It is also recommended to use shielded twisted pairs. 515 HC04 - 8 June 2007...

  • Page 23: Rtd Connection

    300ms is required to guarantee reading of an input. It is possible to read the status of all the logic inputs via a Modbus register even if they are not used for a control purpose in the application. 515 HC04 - 8 June 2007...

  • Page 24: Outputs

    27 (+) and 28 (-), output channel 2 uses terminals 29 (+) and 30 (-). Maximum Load Resistance = (Supply-9) / 0.02 ohms 4-20mA DC supply Output 9...24V (OUTn) Load Shield Figure 10 Output 4-20mA Connection Diagram 515 HC04 - 8 June 2007...

  • Page 25: Pulse Output Connection

    The output characteristics of the relays are: Maximum Voltage 30 volts DC or 250 volts AC Maximum Current Note: Solid state relays use AC voltage only. 515 HC04 - 8 June 2007...

  • Page 26: Rc Network For Interference Suppression

    The basic principle of the operation is that the capacitor prevents a series of sparks arcing across the contact as the contact breaks. The series resistor limits the current through the contact when the contact first makes. 515 HC04 - 8 June 2007...

  • Page 27: Communications

    Up to 32 units can be connected to a common RS-485 bus. Each unit has a unique address that the host computer uses to identify each instrument. Figure 13 shows the connection of several instruments to a computer using the RS-485 port. 515 HC04 - 8 June 2007...

  • Page 28: Earthing And Shielding

    Overall earth should be connected at the instrument end only. This connection should be as short as possible and connected to the earthing point on the rear terminal at pin 18. 515 HC04 - 8 June 2007...

  • Page 29: Chapter 4 Operation

    The host computer is downloading the application software. The instrument is in Calibrate Set mode. Alarm Alarm The instrument has an error, as indicated on the display panel. The instrument is in Calibrate View mode. 515 HC04 - 8 June 2007...

  • Page 30: Main Menu Items

    ACCUM VOLUME Volume Hold the key to display accumulated total ACCUM V-FLOW Volume flowrate Hold the key to display peak value ACCUM MASS Mass Hold the key to display accumulated total ACCUM 515 HC04 - 8 June 2007...

  • Page 31: Peak Flowrates

    If the number of log entries exceeds the programmed number for a particular time interval, the oldest log entry is overwritten by the newest one for that time interval. Also note that the totals are saved as accumulated totals. 515 HC04 - 8 June 2007...
  • Page 32 The system displays the hourly log. The timebase and number of the log are shown, for example LH-001. 3. While holding the key use the key to print the data for the DISPLAY RESET displayed log if the printer option has been selected. 515 HC04 - 8 June 2007...

  • Page 33: Logged Data Display Methods

    … DISPLAY … Hold … show the values for Variable 2 a log entry Variable 1 DISPLAY and press Hold Error code display the main menu variables Figure 14 Logged Data Display Methods 515 HC04 - 8 June 2007...

  • Page 34: Model Information

    This example 2002 shows 16:15 (4:15pm) on the 27th August 2002. This function is available only if the instrument has the real time clock option. Press at any time to exit from the Model information. 515 HC04 - 8 June 2007...

  • Page 35: Introduction

    • Press to return to the main calibration menu. DISPLAY to scroll to the END 3. To exit from the Calibration View mode, press option and press The instrument returns to Normal Operation mode. 515 HC04 - 8 June 2007...

  • Page 36: Calibration Set Mode

    END, then press . Otherwise, from any menu, you can press and hold for two seconds. The instrument makes two beeps and cancels the Cal and Set indicators. Alarm 515 HC04 - 8 June 2007...

  • Page 37: Changing The Instrument Settings

    Units of Measurement The calibration of some parameters is based on the units that are defined for the relevant variables. These units of measurement can been viewed in the UNITS menu in calibration below. 515 HC04 - 8 June 2007...

  • Page 38: Calibration Menu Tree Sheet

    OUT-01 OUT-n selection T-CAL STACK TYPE POINT SW-LO HYST SW-HI ALRM4 AINP1/2 TEMP-F/R selection TYPE TYPE PT100/500 4-20 POINT 0-5/1-5V DEFAULT HYST PT-MIN PT-MAX PT-DEF EXCEPT DEFLT Figure 15 Calibration Menu Tree Sheet 1 515 HC04 - 8 June 2007...

  • Page 39: Calibration Menu Tree Sheet

    Press at any I/O assignment position to move to the next I/O assignment in the submenu (eg pressing on ALRM1 will move you to ALRM2) Figure 16 Calibration Menu Tree Sheet 2 515 HC04 - 8 June 2007...

  • Page 40: Instrument Settings

    YES, then press the key. The instrument makes three beeps to confirm the reset command. The message -RESET- PLEASE WAIT will be displayed as the instrument exits calibration mode and completes a full re-boot sequence. 515 HC04 - 8 June 2007...

  • Page 41: Parameters

    ISO-02 Orifice plate with D-D2 tapping ISO-08 Venturi tube ‘welded’ ISO-03 Orifice plate with flange tapping ISO-09 Venturi nozzle ISO-04 Nozzle to ISA 1932 CONE-01 McCrometer: V-Cone ISO-05 Nozzle ‘long radius’ CONE-02 McCrometer: Wafer-Cone ISO-06 Venturi tube ‘as cast’ 515 HC04 - 8 June 2007...
  • Page 42 Enter the calibration temperature at which the pipe and orifice diameters have been determined. If thermal expansion correction is not required, such as when E-PIPE and E-ORIF are set to zero, the system ignores this setting. 515 HC04 - 8 June 2007...

  • Page 43: Inputs

    As a guide to the degree of filtering to use, the following table shows the response time (in seconds) to reach 90% and 99% of a step change in input. The value A is the filter constant that the user can set. 515 HC04 - 8 June 2007...
  • Page 44 This parameter is available for viewing and editing only when the AINP4 correction type is set to Non-linear. Enter the number of non-linearity correction points. Press to select a number between 1 and 20 for the number of correction points. 515 HC04 - 8 June 2007...
  • Page 45 Enter the normalised output value for the correction point. STACK AINP3 Select YES to stack AINP3 as the low range input with AINP4 as the high range input. Select NO to use AINP3 as the only flow input. 515 HC04 - 8 June 2007...
  • Page 46 You can set the default value during instrument commissioning so that it is available immediately if you select the Default input type at a later date. Enter the value in the engineering units of assigned variable. 515 HC04 - 8 June 2007...

  • Page 47: Outputs

    (pulse output) type. Pulse output is usually used to drive remote counters. Set the pulse width (in milliseconds) as required by the remote counter. Press to set to: 10, 20, 50, 100, 200 or 500ms. 515 HC04 - 8 June 2007...
  • Page 48 “keep up” with the rate of total counts. You can use the output pulse factor to ensure that this maximum is not reached. The maximum pulse output frequency is determined by: 1000 ------------------------------------------------------- - Hz × pulse width in ms 515 HC04 - 8 June 2007...

  • Page 49: Alarms

    Select a rate variable to assign to the alarm relay. Note: If the alarm type is set to “equipment alarm”, this relay assignment setting is ignored. Press to select the variable that is required as an alarm. 515 HC04 - 8 June 2007...
  • Page 50 200 and toggle off below 200. However, if the hysteresis is set to 5, the value of the variable must fall below 195 to cancel the alarm. The alarm will reactivate only when the value again rises above 200. 515 HC04 - 8 June 2007...

  • Page 51: Communications

    The stop bit setting of the instrument must match INFRA the stop bit setting of the communication device that the instrument is connected to. Press to select 1 or 2 stop bits. 515 HC04 - 8 June 2007...

  • Page 52: Time Settings And Data Logging

    In this case, you should set the current time and date so that the instrument continues to log data at the correct times. 515 HC04 - 8 June 2007...
  • Page 53 The hourly log entry occurs at 00 minutes each hour. LOGS Set the number of Daily Logs to appear on the printed log report. The daily log entry occurs at 00 hours and 00 minutes each day. 515 HC04 - 8 June 2007...
  • Page 54 Generic roll printer (prints first line first) • PRN-03 Slip printer TM295 Press to select Printer Type. PRINT ACCUM Select whether the accumulated totals are printed in addition to the non- accumulated totals for printer protocol. 515 HC04 - 8 June 2007...

  • Page 55: General Setup Parameters

    INSTANT - When the user presses the key, the instrument RESET resets all non-accumulated totals. • DELAYED - When the user presses the key and holds it for RESET two seconds, the instrument resets all non-accumulated totals. 515 HC04 - 8 June 2007...

  • Page 56: Test Menu

    UNITS PARAMS INPUTS OUTPUTS ALARMS COMMS TM/LOG SETUP AINP units The units are displayed according to the calibration setup for the analog input. If unused or set to Default the input is 4-20mA and displayed in 515 HC04 - 8 June 2007...

  • Page 57: System Messages

    The manufacturer or distributor can enter user-defined text for the messages. This user-defined text is displayed, instead of the default (English) messages, when the Display Tags option in the Setup menu is set to USER. 515 HC04 - 8 June 2007...

  • Page 58: Error Messages

    Power Supply is Low The input and/or output power supply voltage is too low, ensure that: (a) input power supply voltage is within the specified range (b) output power supply is not overloaded. 515 HC04 - 8 June 2007...

  • Page 59: Warning Messages

    The instrument has set the current log setting to the remaining maximum number. Already Assigned to You have tried to assign a particular protocol type to more than one Other Port serial communication port. The instrument has set the protocol to NONE. 515 HC04 - 8 June 2007...
  • Page 60 Instrument Calibration 515 HC04 - 8 June 2007...

  • Page 61: Communications Overview

    It is not possible to communicate directly with a printer via a parallel port. Computers use either a DB9 or a DB25 connector, and the connections to each type are shown in Figure 17. 515 HC04 - 8 June 2007...

  • Page 62: Rs-232 Cable Connections To A Computer

    18. Up to 32 units can be connected to the interface at a maximum distance of 1200 metres. Twisted Pair Host Computer Load 120 ohms Comms 19 20 21 19 20 21 Instrument Instrument Figure 18 RS-485 Connections 515 HC04 - 8 June 2007...

  • Page 63: Protocols

    • ASCII - In this ASCII protocol each command and response is a string of ASCII characters. This proprietary protocol is developed by Contrec to allow for simple information interchange. The main advantages of this mode are that it allows extended time intervals to occur between characters without causing a timeout error and that messages can be sent and monitored easily with a simple ASCII terminal.

  • Page 64: Simple Ascii Protocol

    000, the instrument returns the current process variables. If the log request is included, the log number defines the specific log entry by counting backwards. The most recent log entry for a timebase is 001. 515 HC04 - 8 June 2007...

  • Page 65: Instrument Responses

    The instrument response time to any enquiry is not more than 300ms. The responses from the instrument are in the following format: HEADER DATA DATA DATA The components of the response message are as follows: 515 HC04 - 8 June 2007...
  • Page 66 The following request is for the only instrument that is connected to the communication port to return the values of all main menu variables. : A 0 0 1 : R V A ? 515 HC04 - 8 June 2007...
  • Page 67 Return the number of daily logs :RLW? Return the number of weekly logs :RLM? Return the number of monthly logs :RLY? Return the number of yearly logs :RLR? Return the number of log records (non- timebased logging) 515 HC04 - 8 June 2007...
  • Page 68 Return the general information about the instrument such as Model number, Application number, Version and Serial numbers etc. These items are returned as a block in the same format as shown on the display in the “Model Info” menu. 515 HC04 - 8 June 2007...

  • Page 69: Corrupted Or Invalid Requests

    For example, if the instrument received the following request variables message :A001:RVT? it will return only the header because there is no T option for the ‘Variables Request’ message. 515 HC04 - 8 June 2007...

  • Page 70: Modbus Rtu Protocol

    The address of the instrument is programmable in the range from 1 to 247. Some addresses are reserved according to PI-MBUS-300 and have a special meaning: • 0 = Broadcast, no response required from slave devices • 248 to 255 Reserved 515 HC04 - 8 June 2007...

  • Page 71: List Of Data Registers

    The registers are grouped in blocks that relate to a particular function of the instrument. Note: Conventional numbering of registers often starts from 1, therefore be aware that “register 1” in this case has “address 0” and so on. 515 HC04 - 8 June 2007...
  • Page 72 03 - clear non-accumulated totals Reserved * DT = Data Type of 2-register (4 byte) values can be set as Floating Point or Long Integer values † I = Integer (2 bytes) (Holding Registers) 515 HC04 - 8 June 2007...
  • Page 73 22 = new or failed clock battery 23 to 29 reserved 30 = alarm 1 active 31 = alarm 2 active 32 = alarm 3 active 33 = alarm 4 active * I = Integer (2 bytes) (Holding Registers) 515 HC04 - 8 June 2007...
  • Page 74 Unused inputs are configured as 4-20mA. * I = Integer (2 bytes) (Holding Registers) † DT = Data Type of 2-register (4 byte) values can be set as Floating Point or Long Integer values 515 HC04 - 8 June 2007...

  • Page 75: Printer Protocol

    A customized printout can be provided which can have up to 4 header lines and 3 footer lines. It is also possible to include or exclude each main menu items on the printout. If any customizing of the printout is required discuss this with the distributor. 515 HC04 - 8 June 2007...

  • Page 76: Types Of Printouts

    Instrument Serial Number and Unit Tag The instrument serial number and unit tag is the same as the information shown in the Model Info menu. For more details refer to Model Information on page 26. 515 HC04 - 8 June 2007...
  • Page 77 <internally set, indicates report type> Current Date & Time Instrument Serial No. & Tag -------------------------------------------- <separation line> Log No. Date & Time & Status Variable unit value <example: total as Accum only> Variable unit value etc. 515 HC04 - 8 June 2007...
  • Page 78 “Data Not Available” will be printed for the missing logs. Custom Header Lines Title of Report Current Date & Time Instrument Serial No. & Tag Data Not Available Custom Footer Lines -------------------------------------------- <separation line> 515 HC04 - 8 June 2007...

  • Page 79: Printer Data Control

    When a communications timeout error has been activated the message COMMS TIMEOUT will be scrolled once, the request to print will be cleared and the instrument will return to its normal mode. 515 HC04 - 8 June 2007...
  • Page 80 Communications 515 HC04 - 8 June 2007...

  • Page 81: Appendix A Glossary

    A normalised input ranges from 0 to 1.000. For 4-20mA input, the signal is Input set to 0 at 4mA and the signal is set to 1.000 at 20mA. Passive Output Requires an external power supply. Signal Resistance Temperature Device 515 HC04 - 8 June 2007...
  • Page 82 515 HC04 - 8 June 2007...

  • Page 83: Product Codes

    For example: Model No. 515.111EFC Displayed on the 500 Series as: (only h/w MODEL that affects the operation is represented) Note: Example full product part number is 515.111EFC-HC04 (This is the number used for placing orders). 515 HC04 - 8 June 2007...

  • Page 84: Custom Version Codes

    Factory Default Application Contrec Pty. Ltd. Melbourne Australia Contrec Pty. Ltd. Sydney Australia Origin Code Contrec Europe Ltd. West Yorkshire UK Identifies Contrec - USA, LLC. Pelham AL 35124 USA Distributor Flowquip Ltd. Halifax UK etc. English (Default) German Dutch...
  • Page 85 For example, is an instrument with FINP1 (frequency input 1) assigned to a flow input, AINP1 assigned to a temperature input and AINP2 assigned as a pressure input. The other inputs are not used. 515 HC04 - 8 June 2007...

  • Page 86: Appendix C Units Of Measurement Available Units Of Measurement

    BT/lb, cal/g, cal/kg, kcal/kg, Mcal/kg Reynolds Number E+0, E+3, E+6 (scaling for unitless variable) Length (Level) m, mm, cm, INCH, FOOT Velocity m/s, m/M, m/h, ft/s, ft/M, ft/h Length K-Factor P/m, P/cm, P/INCH, P/FOOT Area , ft Ratio 515 HC04 - 8 June 2007...

  • Page 87: Appendix D Reference Tables Properties Of Commonly Used Materials

    Expansion in PPM/°F AISI 304 (Stainless Steel) 17.0 30.6 AISI 310 (Stainless Steel) 14.4 25.9 AISI 316 (Stainless Steel) 16.7 30.1 AISI 420 (Stainless Steel) 10.0 18.0 Monel 14.3 25.7 Carbon Steel 11.2 20.2 515 HC04 - 8 June 2007...
  • Page 88 515 HC04 - 8 June 2007...

  • Page 89: Index

    DISPLAY key clock display-only parameter battery date format real-time 515 HC04 - 8 June 2007...
  • Page 90 19, 43, 55 menu input alarms 0-5V calibration 4-20mA comms connections inputs analog outputs failure params setup sensor failure test specifications tm/log types units inputs menu messages installation error system warning Modbus data format 515 HC04 - 8 June 2007...
  • Page 91 19, 43, 55 status lamps RS-232 19, 43, 53 stop bits RS-485 19, 43, 54 suppression, interference 515 HC04 - 8 June 2007...
  • Page 92 TOTAL key total, default unit tag units menu version, customer view data logs 23, 24 warnings weekly logging yearly logging 515 HC04 - 8 June 2007...

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