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Summary of Contents for Contrec 505 Series
- Page 1 Model 505 Flow Computer Operation Manual BC02 Application Dual Stage Batch Controller Volumetric Analog Flowmeters 17 June 2017...
- Page 2 Should any questions arise which cannot be answered specifically by this manual, they should be directed to Contrec Ltd for further detailed information and technical assistance. Contrec 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 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.
- Page 4 505 BC02 - 17 June 2017...
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Page 5: Table Of Contents
Contents 1 Introduction Features Overview Calculations Analog Input Scaling Displayed Information Main Menu Variables Communications Retransmission & Control Outputs Relay Outputs Software Configuration Approvals 2 Specifications Specification Table 3 Installation Panel Mounting Electrical Connection Rear Panel Connections Terminal Designations Inputs Analog Input Connections Logic Input Connection Outputs... - Page 6 Resetting a Batch Logic Input Control Batch Flow Errors Batch Control Processes 5 Instrument Calibration Introduction Calibration View Mode Calibration Set Mode Changing the Instrument Settings Calibration Menu Tree Instrument Settings Units of Measurement Parameters Inputs Outputs Communications Time Settings and Data Logging General Setup Parameters Test Menu System Messages...
- Page 7 List of Figures Typical Application Diagram 500 Series Instrument Panel Mounting Rear Panel Connections Externally Powered Current Loop Internally Powered Current Loop Logic Input Connection Diagram Signal Input Connection Diagram Output 4-20 mA Connection Diagram Output Pulse Connection Diagram Relay Connection Diagram RS-485 Interface Connections Batch Operation with Manual or Automatic Reset Batch Operation with Automatic Restart...
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Page 9: Features
Chapter 1 Introduction Features • Tailored for volumetric analog input such as vortex flowmeters • Single or Dual stage control • Quick access to common batch quantities • No-flow, leakage and overflow error detection • Remote RUN/STOP/RESET • Allows for square law and non-linear correction •... -
Page 10: Analog Input Scaling
Introduction volumeflow = (V max - V min)A + V volumeflow t volume Automatic overrun compensation calculates the new valve closure point to ensure correct delivery by averaging the overrun amount from the last three complete batches. The overrun compensation value is valid for a new preset value provided the stored overrun is less than 20% of the new preset. -
Page 11: Main Menu Variables
Introduction Main Menu Variables Main Menu Default Variable Variables Units Type Volume Total Volume Flowrate L/min Rate Refer to Available Units of Measurement on page 64 for the list of available units. Communications There are two communication ports available as follows: •... -
Page 12: Approvals
Introduction All set-up parameters, totals and logged data are stored in non-volatile memory with at least 30 years retention. Analog Relay 1 Relay 2 Input Example of dual stage Main Flow batching Control Valve Volumetric Flowmeter Control Valve Bleed Flow Figure 1 Typical Application Diagram Approvals This instrument conforms to the EMC-Directive of the Council of... - Page 13 Introduction Properly shielded and grounded cables and connectors must be 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.
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Page 15: Specifications Specification Table
Chapter 2 Specifications Specification Table Operating Environment 4-20 mA Input Temperature 0 °C to +60 °C (conformal coating) Overcurrent 100 mA absolute maximum rating +5 °C to +40 °C (no coating) Impedance 250 Ohms (to common signal ground) Humidity 0 to 95% non condensing (conformal 0.1% typical full scale (20... - Page 16 Specifications 4-20 mA Output (Optional) Supply 24 volts DC internal, non-isolated Resolution 0.05% full scale Accuracy 0.05% full scale (20C) 0.1% (full temperature range, typical) Important: Specifications are subject to change without notice. Printer protocol is available only if RTC option is installed. 505 BC02 - 17 June 2017...
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Page 17: Installation Panel Mounting
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 139 mm wide by 67 mm high. Two side clips secure the unit into the panel. Figure 2 shows the panel mounting requirements for the 500 Series Instrument. -
Page 18: Rear Panel Connections
Installation Electrical Connection Rear Panel Connections Figure 3 shows the connections on the rear panel of the instrument. RS232 Port CAUTION Io SG Li Dout Ii SG Fi Vo G Vi SH RS485 RS232 RELAYS MAINS Tx Rx C + + - G + 1+ 2+ R1 RC R2... -
Page 19: Inputs
Installation Inputs Analog Input Connections The analog input (Ii) can accept current signals from 4 to 20 mA. CAUTION Applying levels of input current above the absolute maximum rating (100mA) may cause permanent damage to the input circuitry. 4-20 mA Inputs For externally powered current loops, connect each transmitter to a pair of input terminals as shown in Figure 4. -
Page 20: Logic Input Connection Diagram
Installation Remote Run Input A remote push-button key can be connected to the Logic Input (Li, terminal 9) as shown below. Logic Input (Li) Signal Ground Figure 6 Logic Input Connection Diagram Remote Stop/Reset Input A remote push-button key can be connected to the multipurpose Signal Input (Fi, terminal 14) as shown below. -
Page 21: Digital Output Connection
Installation Internal supply 4-20 mA Output Load (Io) Shield Figure 8 Output 4-20 mA Connection Diagram Digital Output Connection The digital outputs can be programmed in calibration to function as either a flow error signal, end of batch signal, pump control output or a pulse output for retransmission of totals. -
Page 22: Relay Connection Diagram
Installation 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. Relay 1 Relay Common Control Device Supply Relay 2 Control Device Figure 10 Relay Connection Diagram RC Network for Interference Suppression When driving highly inductive loads with the relay outputs, it is recommended to use RC suppression networks (often called “Snubbers”) -
Page 23: Rs-485 Port
Installation The extra RS-232 port 9-pin DB female connector has the following pinout: Pin 1 Not used Pin 2 Transmit (TxD) Pin 3 Receive (RxD) Pin 4 Not used Pin 5 Ground Pin 6 Not used Pin 7 Handshake line (CTS) Pin 8 RTS Out Pin 9... -
Page 24: Earthing And Shielding
Installation Earthing and Shielding It is a good practice to use shielded cable for all signal connections to the instrument. Care must be taken to separate signal cables from power cables to minimize interference. 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. -
Page 25: Operation Front Panel Operation
Chapter 4 Operation Front Panel Operation In normal operation, press the buttons on the front panel to control the operation of the batch controller or to display the values recorded and calculated by the instrument. There are several categories of information that the instrument can display: •... -
Page 26: Front Panel Keys
Operation Solid led: The instrument has a batch in progress. Fast flashing led: Batch paused. Alarm Slow flashing led: Waiting for valves to close. Solid led: The instrument is in Calibrate Set mode. Flashing led: Count down to automatic restart of next batch. Alarm The instrument has an error, as indicated on the display panel. -
Page 27: Setting The Batch Preset
Operation DISPLAY Description Options TO PRINT Only shown if print Hold the key to manually print a delivery option is selected docket. REPORT PRINT Only shown if print Hold the key to print log report as defined in option is selected the TM/LOG section of calibration. -
Page 28: Data Logs
Operation Data Logs The instrument will log up to 100 deliveries (batches) if the real-time clock option is installed. The logs are taken at the end of each batch or upon reset if a batch has been aborted before the preset total has been reached. Each entry has a log number, a delivery number and a time and date stamp. -
Page 29: Model Information
Operation The following example shows the format of the time and date stamp at 15:25 (3:25 pm) on 16 January 2016. The day and month alternate with the year in the bottom right hand corner. 15-25 15-25 LOG-TM 16/01 LOG-TM 2016 Model Information The model information items display the hardware, software and... -
Page 30: Batch Operation
Operation Batch Operation Starting a Batch The delivery (batch) will start when the key is pressed. The RUN led will illuminate and the instrument will begin to totalise from zero or, if programmed for count down mode, the display will decrement from the preset quantity. -
Page 31: Batch Flow Errors
Operation The Remote Stop input can also be used to reset the batch total by holding the logic input low for 2 seconds if the batch is already complete. • Logic Input - Remote Run • Signal Input - Remote Stop/Reset (inhibits remote Run) For connection details, refer to Logic Input Connection on page 11. -
Page 32: Batch Operation With Manual Or Automatic Reset
Operation In each of the above modes and configurations the parameters can be programmed to determine the behaviour and timing of relays and output signals. The following figures provide examples of some batch operations. Refer to Instrument Settings on page 30 for more details. Manual and Automatic Reset If Manual Reset the key must be pressed at the end of the batch to... -
Page 33: Instrument Calibration Introduction
Chapter 5 Instrument Calibration Introduction You can view or change the settings of the instrument according to the access level for each parameter as set by the manufacturer. There are four levels of access to the parameters as follows: • Not visible - you cannot display or edit the parameter. -
Page 34: Calibration Set Mode
Instrument Calibration Calibration Set Mode In Calibration Set mode, you can change the settings of the “programmable” parameters. You must enter the system password to change the setting of the “password-protected” parameters. Use the following procedure to enter Calibration Set mode: to scroll to the CAL MENU prompt. -
Page 35: Changing The Instrument Settings
Instrument Calibration Changing the Instrument Settings In Calibration Set mode, the display flashes the item that can be changed. For option settings, the display flashes the complete option. For a numeric parameter, the display flashes one digit at a time, you can change the value of the flashing digit as required, then move the flashing cursor to change another digit. -
Page 36: Calibration Menu Tree Sheet
Instrument Calibration Calibration Menu Tree Figure 14Figure 14 and Figure 15 show the keys for moving around the calibration menu tree in Calibration View or Set mode. Press Continued on next page OUTPUT PARAMS INPUTS UNITS View/Edit units of AINP DOUT1/2 BATCH LIMIT... -
Page 37: Calibration Menu Tree Sheet
Instrument Calibration Press From previous page COMMS TM/LOG SETUP TEST Exit from AINP RS232 DEFAULT calibration DATE FORM Press mode LINP1 PROTOC SUPPLY VOLT CLOCK YEAR DOUT1/2 CLOCK M-DAY T-OUT MODE PROCESS BAUD CLOCK H-MIN T-OUT PARITY RESET LOGS RESET ACCUM A-OUT A-OUT... -
Page 38: Instrument Settings
Instrument Calibration Instrument Settings Units of Measurement The Units menu allows the units to be viewed and edited if necessary without the reloading of new application software. Any change in units will result in a full reset to initially downloaded settings. Therefore, any required changes to units of measurement should be made before changing any other settings. -
Page 39: Parameters
Instrument Calibration Parameters PARAMS UNITS INPUTS OUTPUTS COMMS TM/LOG SETUP TEST END BATCH LIMIT The batch limit determines the maximum batch preset value that can be entered. If a value of zero is entered for this parameter then no limit is applied. - Page 40 Instrument Calibration PARAMS UNITS INPUTS OUTPUTS COMMS TM/LOG SETUP TEST END AUTO RESET This parameter is available for viewing and editing only when the batch automatic restart time is set to zero. The automatic reset feature allows the previous batch total to be reset automatically when a new batch is started with the RUN key.
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Page 41: Inputs
Instrument Calibration PARAMS UNITS INPUTS OUTPUTS COMMS TM/LOG SETUP TEST END Modbus Accessible Parameters The following PARAMS menu items are also accessible via Modbus communications. For a complete Modbus parameter listing, refer to Instrument Configuration Parameters on page PRESET BATCH Enter the batch preset quantity. - Page 42 Instrument Calibration INPUTS UNITS PARAMS OUTPUTS COMMS TM/LOG SETUP TEST END FILTER AINP Input fluctuations caused by pulsating flow tend to create distortion in the input readings of the rate. The instrument has a digital filter that averages out these fluctuations.
- Page 43 Instrument Calibration INPUTS UNITS PARAMS OUTPUTS COMMS TM/LOG SETUP TEST END NO-PTS AINP This parameter is available for viewing and editing only when the 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.
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Page 44: Outputs
Instrument Calibration Outputs OUTPUTS UNITS PARAMS INPUTS COMMS TM/LOG SETUP TEST END FUNC n The digital output can function as either a pulse output for retransmission of totals, a no flow error signal, a pump control output or an end of batch signal. - Page 45 Instrument Calibration OUTPUTS UNITS PARAMS INPUTS COMMS TM/LOG SETUP TEST END PT-MIN A-OUT The output minimum value corresponds to the 4 mA point and the output PT-MAX A-OUT maximum value corresponds to the 20 mA point. Setting the output range differently from the input range enables the instrument to amplify the input signal.
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Page 46: Communications
Instrument Calibration Communications The instrument has three communication ports: • RS-232 Port - Three terminals on the rear of the instrument. There is also an optional 9-pin female connector on the rear panel of the instrument. • RS-485 Port - Terminals on the rear panel. •... -
Page 47: Time Settings And Data Logging
Instrument Calibration COMMS UNITS PARAMS INPUTS OUPUTS TM/LOG SETUP TEST END 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. ADDR The Modbus RTU protocol address must be in the range of 1 to 247. - Page 48 Instrument Calibration TM/LOG UNITS PARAMS INPUTS OUPUTS COMMS SETUP TEST END DATE FORM Clock Date Format The European date format is: dd/mm/yyyy or (Day-Month). The American date format is: mm/dd/yyyy or (Month-Day). Press to select DAY-M or M-DAY CLOCK YEAR The Clock Year defines the current year for the real-time clock.
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Page 49: General Setup Parameters
Instrument Calibration General Setup Parameters SETUP UNITS PARAMS INPUTS OUPUTS COMMS TM/LOG TEST END DEFAULT Select the main menu variable to display on power up or when the display timeout period has elapsed if it is enabled. Press to select the default variable display. -
Page 50: Test Menu
Instrument Calibration SETUP UNITS PARAMS INPUTS OUPUTS COMMS TM/LOG TEST END DISPL TAGS The Display Tags option determines whether the instrument displays the default display tags or the user-defined tags. The display tag setting also defines whether the instrument displays the default error and warning messages, or the user-defined messages. -
Page 51: System Messages
Instrument Calibration TEST UNITS PARAMS INPUTS OUPUTS COMMS TM/LOG SETUP STATE You can control the state of the outputs. Press the keys to set the output state as follows: • PROCESS - the output depends on the current values of the inputs and the calculations that the instrument performs. -
Page 52: Error Messages
Instrument Calibration Error Messages The system displays error messages, and records the associated exception status code, in the order of highest to lowest priority as listed in the following table: Error Status Description - (Highest Priority at top of table). Messages Code CPU Card... -
Page 53: Warning Messages
Instrument Calibration Warning Messages The system displays warning messages as described in the following table: Warning Messages Description Value Has Been Set to You have entered an invalid value for a parameter. Therefore, the Default instrument has set the default value. Already Assigned to You have tried to assign a particular protocol type to more than one Other Port... - Page 54 Instrument Calibration 505 BC02 - 17 June 2017...
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Page 55: Communications Overview
Chapter 6 Communications Overview This chapter describes the communications between the instrument and another communicating device such as a computer or a printer. You should have relevant information about the devices to which the instrument will be connected. Some connection examples are included in this manual, however, the operation and connection of other devices is outside the scope of this manual. -
Page 56: Rs-232 Cable Connections To A Computer
Communications Instrument Computer/Printer Common Optional Optional Terminal DB25 Strip Figure 16 RS-232 Cable Connections to a Computer Note: The instrument requires a cable with straight-through connections. Do not use a null modem cable for RS-232 connection to a computer. RS-485 Port The RS-485 port enables communication with multiple devices. -
Page 57: Protocols
Communications Protocols The communications protocols can be assigned to the communication ports on the instrument as follows: • - Modbus RTU available for all ports • - Printer Protocol available for RS232 and RS485 • NONE - If a port is not being used, set the protocol to NONE. Note: The Printer Protocol is only available if the option with Real Time Clock is installed. - Page 58 Communications • If the slave does not receive the query due to a communication error, no response is returned. The master program has to process a timeout condition for the query. • If the slave receives the query, but detects a communications error (parity or CRC), no response is returned.
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Page 59: List Of Data Registers
Communications Exception Response The instrument forms an exception response by adding 80H to the function code and using an exception code as the 1-byte data field in the returned frame. Implemented exception codes are as follows: Code Name Description Illegal function The function code is not a legal action for the slave. - Page 60 Communications Use the log timebase and log number to retrieve the logged information from the appropriate register. If a particular log number does not exist, or the instrument does not have the optional real-time clock, the time and date stamp and associated variables are set to zero. Register Name Comments...
- Page 61 Communications Note: The Floating Point variable is represented in IEEE-754 Floating Point 4-byte format and requires two 2-byte data registers: IEEE-754 Modicon Registers 1st byte low byte (register X) 2nd byte high byte (register X) 3rd byte low byte (register X+1) 4th byte high byte (register X+1) This means that two data registers must be read or written to obtain, or...
- Page 62 Communications Register Name Comments Read Only or Type Read/Write Operation State Representation of operation status 0 = Reset 1 = Maintenance 2 = Completed 3 = Waiting to restart 4 = Paused 5 = Waiting for timeout 6 = Running (Slow Start) 7 = Running (Prestop) 8 = Running (Full Flow) 45 to 47...
- Page 63 Communications Instrument Configuration Parameters This block of registers is available in applications to give access to some important instrument parameters (i.e. fluid properties etc.). The usage of these parameters can be dependent on other instrument settings. For full description, please refer to the Modbus Accessible Parameters on page 33.
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Page 64: Printer Protocol
Communications Printer Protocol A printer protocol is available in the 500 Series. It provides the ability to print out live data, individual logged data and to do some report-style printing of logged data. The method of printing these and the format of the printouts is described below. - Page 65 Communications Custom Header Line 1 Custom Header Line 2 Custom Header Line 3 Custom Header Line 4 Instrument Serial No. & Tag Current Delivery No. Current Date & Time & Status Variable unit value Variable unit value etc. Custom Footer Line 1 Custom Footer Line 2 Custom Footer Line 3 ------------------------------------------- <separation line>...
- Page 66 Communications Since each log entry stores the delivery totals only, the printout will not have any accumulated totals. The format of the printout with this exception is the same as the LIVE DATA printout: Custom Header Lines Instrument Serial No. & Tag Logged Delivery No.
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Page 67: Printer Data Control
Communications -------------------------------------------- <separation line> Delivery No. Date & Time & Status Variable unit value Variable unit value Custom Footer Lines -------------------------------------------- <separation line> Reports such as “Latest Logs” will print in the historical order, and for those logs that have no data (e.g. unit was powered off at the time) the print will show “Data not available”. - Page 68 Communications Error Messages There are two printer error messages that can be displayed. PAPER OUT This message is related to the Printer Type PRN-03 TM295 Slip printer. It is standard procedure with this printer to check for paper status before printing.
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Page 69: Appendix A Model Numbers Product Codes
Appendix A Model Numbers Product Codes Model Supplementary Code Description - BC0 Panel mount enclosure Field mount enclosure (NEMA 4X / IP66) Explosion proof Ex d (IECEx/ATEX), metric glands Enclosure (5 specifies heater) Explosion proof Ex d (CSA), NPT glands (6 specifies heater) Basic - RS232 and RS485 serial ports, 2 relays, 2 pulse outputs, rear key input... -
Page 70: Custom Version Codes
Custom Version Codes Code Description Factory Default Application Contrec Systems Pty. Ltd. Melbourne Australia Contrec Limited. West Yorkshire UK Origin Code Identifies Contrec-USA, LLC. Pelham AL 35124 USA Distributor Flowquip Ltd. Halifax UK etc. English (Default) German Dutch User Language... - Page 71 The Application number identifies the application as in the following examples: • BC01 - single channel batch controller for frequency flow input. • FC01 - single channel flow computer for frequency flow input The Input Assignment type indicates the physical input that is assigned to each input on the instrument.
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Page 72: Appendix B Units Of Measurement Available Units Of Measurement
Appendix B Units of Measurement Available Units of Measurement The following is a list of the available units of measurement used across the range of 500 Series applications. Units Type Available units of measurement Volume , Km , Ltr, mL,Gal, KGal, MGal, ft , kft , Mft , bbl... -
Page 73: Index
Index Numerics codes 4-20mA application information input customer version output exception product number common preset values analog input communication connections connections scaling protocols application code communications 3, 47 approvals menu FCC Declaration connections communication communications back panel control relays batch electrical errors input... - Page 74 menu features calibration flash driver port assignment comms format, date inputs front panel outputs keys params LEDs setup test tm/log hardware connections units messages error infra-red port prompts input system 4-20mA warning connections Modbus accessible parameters analog Modbus data format inputs menu Modbus RTU protocol installation...
- Page 75 parameter RUN key display-only not visible scaling analog input password-protected serial number programmable SET key parameters menu settings parity bits instrument password-protected parameter setup menu port shielding assignment, flash driver snubber flash driver assignment specifications infra-red standards RS-232 14, 38, 47 starting a batch RS-485 15, 38, 48...
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