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Contrec 515 Operation Manual

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Model 515 Flow Computer
Operation Manual
CR02
Application
Ratio/Blending Process Controller
for
Volumetric Analog Flowmeters
18 May 2007

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  • Page 1 Model 515 Flow Computer Operation Manual CR02 Application Ratio/Blending Process Controller Volumetric Analog Flowmeters 18 May 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 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 CR02 - 18 May 2007 515 CR02 - 18 May 2007...
  • Page 4 515 CR02 - 18 May 2007...

  • Page 5: Table Of Contents

    4-20mA Output Connection Pulse Output Connection Control Relays (Alarms) RC Network for Interference Suppression Communications RS-232 Port Infra-red Port RS-485 Port (Advanced Option) Earthing and Shielding 4 Operation Normal Operation Mode Default Variable & Total 515 CR02- 18 May 2007...
  • Page 6 Error Messages Warning Messages 6 Communications Overview Hardware Interconnection Protocols Simple ASCII Protocol Requests Format Instrument Responses Corrupted or Invalid Requests Modbus RTU Protocol List of Data Registers Printer Protocol Types of Printouts Printer Data Control 515 CR02- 18 May 2007...
  • Page 7 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 Index 515 CR02- 18 May 2007...
  • Page 8 515 CR02- 18 May 2007...
  • Page 9 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 CR02- 18 May 2007...
  • Page 10 515 CR02- 18 May 2007...

  • Page 11: Features

    Backlit display with LCD backup Overview The 515 CR02 application is a single loop process controller measuring the volume flow in a main and process lines using analog flow inputs. It can operate in local (manual), loop, ratio or blend mode and has a tuning menu to easily determine the Proportional Band and Integral Time values used in the PI control algorithm.

  • Page 12: Calculations

    • NON-LINEAR: when the instrument applies correction from the points in the correction table Displayed Information The front panel display shows the current values of the input variables and the results of the calculations. 515 CR02 - 18 May 2007...

  • Page 13: Main Menu Variables

    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 with an additional two available in the advanced option. 515 CR02 - 18 May 2007...

  • Page 14: Software Configuration

    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 CR02 - 18 May 2007...

  • Page 15: Specifications General

    Battery Type 3 volts Lithium button cell (CR2032) Baud Rate 2400 to 19200 baud Battery Life 5 years (typical) Parity Odd, even or none Stop Bits 1 or 2 Protocols ASCII, Modbus RTU, Printer 515 CR02 - 18 May 2007...
  • Page 16 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 CR02 - 18 May 2007...

  • Page 17: Installation Panel Mounting

    Figure 2Figure 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 CR02 - 18 May 2007...

  • Page 18: 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 CR02 - 18 May 2007...

  • Page 19: Externally Powered Voltage Transmitter

    Figure 5 Internally Powered Voltage Transmitter 4-20mA Inputs For externally powered current loops, connect each transmitter to a pair of input terminals as shown in Figure 6. Terminal Designations on page 8 for specific terminal numbers for this application. 515 CR02 - 18 May 2007...

  • Page 20: Externally Powered Current Loop

    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 CR02 - 18 May 2007...

  • Page 21: 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 9 Output 4-20mA Connection Diagram 515 CR02 - 18 May 2007...

  • Page 22: 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 CR02 - 18 May 2007...

  • Page 23: 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. Communications The communication protocols are described in Communications page 53. 515 CR02 - 18 May 2007...

  • Page 24: Rs-232 Port

    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 12 shows the connection of several instruments to a computer using the RS-485 port. 515 CR02 - 18 May 2007...

  • Page 25: 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 CR02 - 18 May 2007...
  • Page 26 Installation 515 CR02 - 18 May 2007...

  • Page 27: Operation Normal Operation Mode

    The default variable determines what the display returns to if the display timeout option is enabled and no buttons are pressed for the selected period (usually 30 seconds). It also determines what is displayed on power up. 515 CR02 - 18 May 2007...

  • Page 28: Status Lamps

    Hold the key to display the accumulated value for the currently ACCUM ACCUM displayed total or to display the peak value for the currently displayed flowrate. See below for further details of peak flowrates. 515 CR02 - 18 May 2007...

  • Page 29: Main Menu Items

    The peak value is the average over a 15 minute ACCUM period since the last reset of totals or powering on of the instrument. Dashes are shown for this value after a reset or power on until the first averaging period has passed. 515 CR02 - 18 May 2007...

  • Page 30: Setpoints

    Use the following procedure to view the data that has been logged by the instrument: key to scroll through the menu to the LOGGED DATA 1. Press the DISPLAY prompt. 2. Hold the key. 515 CR02 - 18 May 2007...

  • Page 31: Model Information

    The hardware model code. Refer to Product Codes on page 75 for more information. MODEL ----FF The Application number and the assignment of the inputs. Refer to Application Information Code CR02 INPUT page 76 for more information. 515 CR02 - 18 May 2007...

  • Page 32: Process Control Modes

    Blend-2 mode (for blending point before main flowmeter) In all of these modes, except Blend-2, the Net flow is the combination of the Main and Process flows. In Blend-2 the Main flow equals the Net flow. 515 CR02 - 18 May 2007...
  • Page 33 For details on this method see below: ”Tuning the Control Loop”. Proportional Flowmeter Control Valve The control and tuning of the process line in Process Flow this mode is independent of the main flow. 515 CR02 - 18 May 2007...
  • Page 34 Output The desired process flow is determined as a Main Flow ratio of the net (combined) flow (0 to 80% Proportional Flowmeters Control Valve range). i.e. Process Flow flow × ------------------------------- Ratio% flow flow 515 CR02 - 18 May 2007...

  • Page 35: Logic Input Control

    The basic principle in tuning the loop is to gradually adjust the Proportional Band (P-BAND) and the Integral Time (I-TIME) and observe the response to a step change in the setpoint. 515 CR02 - 18 May 2007...

  • Page 36: Tuning The Ratio Trim Control

    The ratio trim control is a unique feature that can be used when it is critical for the totals to maintain the correct ratio. If enabled (non-zero), the trim control will modify the process flow to achieve the correct ratio between the totals. 515 CR02 - 18 May 2007...
  • Page 37 These additional internal registers are reset whenever: • the Control Mode is changed, • the Ratio Setpoint is changed, • the Totals are cleared. • the flow control exception is raised. 515 CR02 - 18 May 2007...
  • Page 38 Increase or decrease the T-TIME to achieve the desired response. The Deadband and the Output Ramp Time can now be programmed as required. The stability of the loop should be again checked at a few different working flowrates and ratios. 515 CR02 - 18 May 2007...

  • Page 39: Instrument Calibration 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 CR02 - 18 May 2007...

  • Page 40: 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 CR02 - 18 May 2007...

  • Page 41: 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 CR02 - 18 May 2007...

  • Page 42: Calibration Menu Tree Sheet

    D-BAND E-TIME R-TIME ALRM4 ACTIVE INHIB E-TIME selection DIRECT ACCES ACTIVE INHIB TYPE P-FLOW DIRECT ACCES POINT P-FLOW value RATIO HYST DEVIAT value RATIO value DEVIAT value Figure 14 Calibration Menu Tree Sheet 1 515 CR02 - 18 May 2007...

  • Page 43: 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 15 Calibration Menu Tree Sheet 2 515 CR02 - 18 May 2007...

  • Page 44: 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 CR02 - 18 May 2007...

  • Page 45: Parameters

    Enter the value as a percentage. While the main menu Deviation (error) is within the deadband, the process control signal will remain steady (i.e. the error is treated as zero in the algorithm). 515 CR02 - 18 May 2007...
  • Page 46 399.999%. For blend mode the value must be within the range 0 to 80%. If RATIO or BLEND control mode the live RATIO and DEVIATION values are now shown to give immediate feedback without leaving calibration set mode. 515 CR02 - 18 May 2007...

  • Page 47: 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 CR02 - 18 May 2007...
  • Page 48 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 CR02 - 18 May 2007...

  • Page 49: Outputs

    ALARMS COMMS TM/LOG SETUP TEST END OUT1 Note: In the factory default version of this application output channel 1 ( ) is dedicated as the 4-20mA Process Control signal. Output channel 2 can be freely configured. 515 CR02 - 18 May 2007...
  • Page 50 1.000 generates one pulse for . Similarly, a pulse factor of 3.000 generates one pulse for 3m For more information, see Output Pulse Factor on page 41. The output pulse factor cannot be 0 (zero). 515 CR02 - 18 May 2007...
  • Page 51 75 units/sec (Hz) and the required pulse width of a remote counter is at least 50ms: 1000 -------------- - 10Hz The maximum pulse output frequency is: × ----- - The minimum pulse factor for that frequency is: 515 CR02 - 18 May 2007...

  • Page 52: Alarms

    BD-NO — Band Alarm, Normally Open contacts • BD-NC — Band Alarm, Normally Closed contacts • AL-NO — Equipment Alarm, Normally Open contacts • AL-NC — Equipment Alarm, Normally Closed contacts Press to select the type of alarm required. 515 CR02 - 18 May 2007...

  • Page 53: Communications

    RS-232 Port - A 9-pin female connector on the rear panel of the instrument. • Infra-red Port - Located on the front panel, below the status indicators. • RS-485 Port - (Advanced option only) Terminals on the rear panel. 515 CR02 - 18 May 2007...
  • Page 54 1 or 2 stop bits. DATA The Modbus RTU data format for the 2-register (4-byte) values can be set as either floating point or long integer values. to select FLOAT or INTEGER. 515 CR02 - 18 May 2007...

  • Page 55: 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 CR02 - 18 May 2007...
  • Page 56 YEAR LOGS Set the number of Yearly Logs to appear on the printed log report. The yearly log entry occurs at 00 hours and 00 minutes on the first day of the year. 515 CR02 - 18 May 2007...
  • Page 57 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 CR02 - 18 May 2007...

  • Page 58: General Setup Parameters

    EN ALL - Timeout is enabled for all modes. T-OUT The Display Timeout period defines the delay for the Display Timeout mode if it is enabled. The display timeout period can be from 10 to 99 seconds. 515 CR02 - 18 May 2007...

  • Page 59: Test Menu

    This parameter sets the maximum number of decimal places for displaying or printing main menu totals. Test Menu The Test menu enables you to view the inputs and outputs to and from the instrument. 515 CR02 - 18 May 2007...

  • Page 60: System Messages

    If the actual supply voltage is lower than the preset value (refer to General Setup Parameters on page 48) it may indicate that the output is overloaded. System Messages The instrument displays messages for defined events and fault conditions. 515 CR02 - 18 May 2007...

  • Page 61: Error Messages

    Over Total Limit - You have exceeded the maximum number of logging entries for the Maximum Set combined time bases. The instrument has set the current log setting to the remaining maximum number. 515 CR02 - 18 May 2007...
  • Page 62 The control setpoint is greater than the allowed value. The instrument Maximum Set has set the value to the maximum limit. Either the process flow setpoint is greater than the flow range value or the ratio setpoint in blend mode is greater than 80%. 515 CR02 - 18 May 2007...

  • Page 63: 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 16. 515 CR02- 18 May 2007...

  • Page 64: Rs-232 Cable Connections To A Computer

    Figure 17 RS-485 Connections Infra-red Port The infra-red port is located on the front panel of the instrument. The infra- red port uses the Infra-red Developers Association (IrDA) physical layer format of signal encoding and decoding. 515 CR02- 18 May 2007...

  • Page 65: 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 66: Requests Format

    Likewise, there is only one set of current process variables with “non-accumulated totals”, therefore it also ignores any log number included in the request. 515 CR02- 18 May 2007...

  • Page 67: Instrument Responses

    (24-hour clock) space space space The instrument Exception Status codes that the instrument returns for the ASCII protocol are the same as those described for the Modbus RTU protocol in Instrument Exception Status on page 65. 515 CR02- 18 May 2007...
  • Page 68 V - F L O W 7 6 2 7 . 1 1 7 M A S S 3 4 4 . 4 6 0 K G / M M - F L O W 515 CR02- 18 May 2007...
  • Page 69 : A 0 0 1 : R L H ? The instrument response would be similar to the following: A 0 0 1 2 0 0 2 / 0 3 / 1 4 1 8 : 2 5 : 0 0 515 CR02- 18 May 2007...
  • Page 70 “Model Info” menu. Instrument Information Response Example The following message asks the instrument with address 001 to return the general information about the instrument: : A 0 0 1 : R I G ? 515 CR02- 18 May 2007...

  • Page 71: Corrupted Or Invalid Requests

    2 bytes Except for broadcast messages, when a master device sends a query to a slave device, it expects a normal response. One of four possible events can occur from the master’s query: 515 CR02- 18 May 2007...
  • Page 72 Read data register(s) Obtain the content of one or more 2-byte data registers. Preset data register Preset one 2-byte data register. Read status register Obtain the content of 1-byte status register. Preset data register(s) Preset one or more 2-byte data registers. 515 CR02- 18 May 2007...

  • Page 73: List Of Data Registers

    “register 1” in this case has “address 0” and so on. Current and Logged Process Data This block of registers is available for the retrieval of current or logged process data with its matching time and date information. 515 CR02- 18 May 2007...
  • Page 74 Clear Data 01 - clear logs 02 - clear accumulated totals 03 - clear non-accumulated totals Reserved * FP = Floating Point (2 registers = 4 bytes) † I = Integer (2 bytes) (Holding Registers) 515 CR02- 18 May 2007...
  • Page 75 33 = alarm 4 active * I = Integer (2 bytes) (Holding Registers) Instrument Control and I/O This block of registers is available in some applications to give access to important information in the instrument. 515 CR02- 18 May 2007...
  • Page 76 Analog Inp.4 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 CR02- 18 May 2007...
  • Page 77 For full description, please refer to the ‘Modbus Accessible Parameters’ in Parameters on page 35. Register Name Comments Read Only or Type Read/Write Loop Control Output Setpoint Loop Flowrate Setpoint Loop Ratio Setpoint 57 to 99 Reserved 515 CR02- 18 May 2007...

  • Page 78: 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 CR02- 18 May 2007...

  • Page 79: 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 21 515 CR02- 18 May 2007...
  • Page 80 <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 CR02- 18 May 2007...
  • Page 81 “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 CR02- 18 May 2007...

  • Page 82: 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 CR02- 18 May 2007...

  • Page 83: 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 515 CR02 - 18 May 2007...
  • Page 84 515 CR02 - 18 May 2007...

  • Page 85: Product Codes

    For example: Model No. 515.111EFC Displayed on the 500 Series as:(only h/w that MODEL affects the operation is represented) Note: Example full product part number is 515.111EFC-CR02 (This is the number used for placing orders). 515 CR02 - 18 May 2007...

  • Page 86: 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 87 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 CR02 - 18 May 2007...

  • Page 88: 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 CR02 - 18 May 2007...

  • Page 89: Index

    DISPLAY key 18, 19 display-only parameter 515 CR02 - 18 May 2007...
  • Page 90 Modbus accessible parameters address Modbus data format request format Modbus RTU protocol responses mode settings display timeout interconnections, communication normal operation interference suppression process control isolated outputs set calibration view calibration model numbers 515 CR02 - 18 May 2007...
  • Page 91 14, 43, 53 status lamps RS-485 14, 43, 54 stop bits power supply interruption suppression, interference printer system data control errors error messages messages protocol warnings report types printer types terminal designations test menu 515 CR02 - 18 May 2007...
  • Page 92 TOTAL key total, default trim control tuning tuning control loop tuning trim control unit tag units menu variable, default version, customer view data logs warnings weekly logging yearly logging 515 CR02 - 18 May 2007...

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