1. Manuals
  2. Brands
  3. Contrec Manuals
  4. Controller
  5. 515
  6. Operation manual

Contrec 515 Operation Manual

Batch/ratio process controller for volumetric analog flowmeters
Hide thumbs Also See for 515:
Table of Contents

Advertisement

Quick Links

Download this manual
Model 515 Flow Computer
Operation Manual
BR02
Application
Batch/Ratio Process Controller
for
Volumetric Analog Flowmeters
17 June 2017

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 515 and is the answer not in the manual?

Questions and answers

Related Manuals for Contrec 515

Summary of Contents for Contrec 515

  • Page 1 Model 515 Flow Computer Operation Manual BR02 Application Batch/Ratio Process 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 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 BR02 - 17 June 2017 515 BR02 - 17 June 2017...
  • Page 4 515 BR02 - 17 June 2017...

  • Page 5: Table Of Contents

    RS-232 Port RS-485 Port (Optional) Earthing and Shielding 4 Operation Front Panel Operation Default Variable Status LEDs Front Panel Keys Main Menu Items Setting the Batch Preset Setting the Flow Control Setpoints Data Logs 515 BR02 - 17 June 2017...
  • Page 6 Test Menu System Messages Error Messages Warning Messages Prompt 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 515 BR02 - 17 June 2017...
  • Page 7 Printer Protocol Types of Printouts Printer Data Control 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 BR02 - 17 June 2017...
  • Page 8 515 BR02 - 17 June 2017...
  • Page 9 Relay Connection Diagram RS-485 Interface Connections Batch Operation with Manual or Automatic Reset Batch Operation with Automatic Restart Calibration Menu Tree Sheet 1 Calibration Menu Tree Sheet 2 RS-232 Cable Connections to a Computer RS-485 Connections 515 BR02 - 17 June 2017...
  • Page 10 515 BR02 - 17 June 2017...

  • Page 11: Introduction

    Backlit display with LCD backup Overview The 515 BR02 application is a batching flow controller for delivery of preset quantities at preset flowrates using a volumetric analog input. Batch control can operate in preset or on-off modes, while flow control can be set to local (manual) or PI loop mode.

  • Page 12: 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 storage of up to 1000 transactions with time and date stamps. 515 BR02 - 17 June 2017...

  • Page 13: Main Menu Variables

    These contacts are normally open and can be used to drive external relays, valves, pump circuits etc. The advanced option provides another two relays that can be used as fully programmable alarms for any rate type variable. 515 BR02 - 17 June 2017...

  • Page 14: Software Configuration

    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. 515 BR02 - 17 June 2017...
  • Page 15 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.
  • Page 16 Introduction 515 BR02 - 17 June 2017...

  • Page 17: Specifications

    ASCII, Modbus RTU, Printer* Battery Life 5 years (typical) Transducer Supply Voltage 8 to 24 volts DC, programmable Current 70 mA @ 24 V, 120 mA @ 12 V maximum Protection Power limited output 515 BR02 - 17 June 2017...
  • Page 18 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. Printer protocol is available only if RTC option is installed. 515 BR02 - 17 June 2017...

  • Page 19: Installation

    Rear Connectors Port 22 mm 25 mm 145 mm 138 mm Front Panel Mounting Clip Min. 189 mm 67 mm 70 mm 139 mm 147 mm Panel Cut-out Figure 2 500 Series Instrument Panel Mounting 515 BR02 - 17 June 2017...

  • Page 20: Electrical Connection

    17 Vi + DC power input DC power in 12-28V RS232 port 9-pin serial port 18 SH E Shield terminal E Mains ground AC power in 100- N Mains neutral MAINS 240VAC A Mains active 515 BR02 - 17 June 2017...

  • Page 21: Inputs

    Figure 5 Internally Powered Voltage Transmitter 4-20 mA Inputs For externally powered current loops, connect each transmitter to a pair of input terminals as shown in Figure 6. Refer to for specific terminal numbers for this application. 515 BR02 - 17 June 2017...

  • Page 22: Logic Input Connection

    Logic Input Signal Ground Figure 8 Logic Inputs Connection Diagram Outputs The advanced option for the instrument provides two opto-isolated output ports. Either or both can be used for 4-20 mA or pulse outputs. 515 BR02 - 17 June 2017...

  • Page 23: 4-20 Ma Output Connection

    27 (+) and 28 (-). Output channel 2 uses terminals 29 (+) and 30 (-). Vo +8...24V DC External Load Resistor 10K Logic Input Open Pulse Output Collector (OUTn) Output DC Ground Shield Figure 10 Output Pulse Connection Diagram 515 BR02 - 17 June 2017...

  • Page 24: Control Relays (Alarms)

    30 volts DC or 250 volts AC Maximum Current Note: Solid state relays use AC voltage only. Relay 1 Relay Common Alarm Supply Relay 2 Alarm Relay 3 Alarm Relay 4 Alarm Figure 11 Relay Connection Diagram 515 BR02 - 17 June 2017...

  • Page 25: Rc Network For Interference Suppression

    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 Not used 515 BR02 - 17 June 2017...

  • Page 26: Port (Optional)

    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 BR02 - 17 June 2017...

  • Page 27: Operation

    Flow control values • Instrument settings For each total, there is an associated rate as follows: Total Rate Net Volume Net Flowrate Main Line Volume Main Line Flowrate Process Line Volume Process Line Flowrate 515 BR02 - 17 June 2017...

  • Page 28: Default Variable

    Continue to BATCH BATCH hold for two seconds to enter edit mode for the preset if access is authorised. Pressing the key briefly displays the accumulated total. BATCH 515 BR02 - 17 June 2017...

  • Page 29: Main Menu Items

    Hold the key to display the Model information as described in Model Information on page 22. CAL MENU Hold the key to enter Calibration View mode as described in Calibration View Mode page 35. 515 BR02 - 17 June 2017...

  • Page 30: Setting The Batch Preset

    Each entry has a log number, a delivery number and a time and date stamp. When the number of log entries exceeds 999 the oldest log entry is overwritten by the newest one. 515 BR02 - 17 June 2017...
  • Page 31 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 2016 LOG-TM 16/01 515 BR02 - 17 June 2017...

  • Page 32: Model Information

    Local (manual) mode • Loop mode • Tune mode (only available in calibration set mode) • Ratio mode • Blend-1 mode (for blending point after main flowmeter) • Blend-2 mode (for blending point after main flowmeter) 515 BR02 - 17 June 2017...
  • Page 33 The PI controlled output signal is used to maintain the desired process flowrate via the Analog proportional control valve. Output The control of the process line is Main Flow independent of the main flow. Proportional Flowmeters Control Valve Process Flow 515 BR02 - 17 June 2017...
  • Page 34 The desired process flow is determined as a Main Flow ratio of the net (combined) flow (0 to 80% Proportional Flowmeters range). i.e. Control Valve Process Flow  flow Ratio% --------------------------------- - flow flow 515 BR02 - 17 June 2017...

  • Page 35: Tuning The Control Loop

    As the idle position for any On-Off control valve in a batching system is “closed”, a special option in the Batch Mode parameter, RELEASE, allows the valve to be opened from within calibration. For more information, refer Release Mode on page 27. 515 BR02 - 17 June 2017...

  • Page 36: Batch Operation Modes

    A slow flow start feature is available for smoother batching. The automatic overrun compensation feature can be used to improve accuracy and repeatability. An auto-restart feature for automated repeat batches is also available in preset mode. 515 BR02 - 17 June 2017...

  • Page 37: On-Off Mode

    If calibration is exited while in RELEASE mode the On-Off valve will close and the batch mode will default to PRESET mode. 515 BR02 - 17 June 2017...

  • Page 38: Batch Operation

    A digital output can be programmed as a batching Relay 1 Analog Input4 Main Flow Main Flow pump control signal if required. Flow Control Flowmeters Valves Process Flow Bleed Flow Proportional Control Valve 515 BR02 - 17 June 2017...

  • Page 39: Safety And Security

    STOP When the process is in pause mode, the RUN led will flash to prompt the operator to restart or abort the batch. 515 BR02 - 17 June 2017...

  • Page 40: Resetting A Batch

    Batch Flow Timeout and Acceptable Total. The open collector outputs can be assigned to activate whenever one of the flow errors occur. Refer to Instrument Settings page 40 for more details. 515 BR02 - 17 June 2017...

  • Page 41: Batch Control Processes

    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 40 for more details. 515 BR02 - 17 June 2017...

  • Page 42: Batch Operation With Manual Or Automatic Reset

    Batch End of Batch Pump Control Analog “Hold Output” Control Disabled Output Prestop Qty Analog “Hold Output” Control Enabled Output Hold Output Time Prestop Qty Figure 13 Batch Operation with Manual or Automatic Reset 515 BR02 - 17 June 2017...

  • Page 43: Batch Operation With Automatic Restart

    End of Time Batch End of Batch Pump Control Analog “Hold Output” Control Disabled Output Prestop Qty Analog “Hold Output” Control Enabled Output Hold Output Time Prestop Qty Figure 14 Batch Operation with Automatic Restart 515 BR02 - 17 June 2017...
  • Page 44 Operation 515 BR02 - 17 June 2017...

  • Page 45: Instrument Calibration

    • 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 BR02 - 17 June 2017...

  • Page 46: 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 BR02 - 17 June 2017...

  • Page 47: 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 BR02 - 17 June 2017...

  • Page 48: Calibration Menu Tree

    AUTO RESET DEVIAT value AUTO COMP No-SET BATCH SET-nn BATCH DIRECT ACCES RELEASE Flow Setpoint Flow Setpoint FLOW value FLOW value DEVIAT value DEVIAT value PRESET BATCH Figure 15 Calibration Menu Tree Sheet 1 515 BR02 - 17 June 2017...
  • Page 49 I/O assignment position to move to the next I/O assignment in the submenu (eg pressing on ALRM1 will move you to ALRM2 if it exists) Figure 16 Calibration Menu Tree Sheet 2 515 BR02 - 17 June 2017...

  • Page 50: 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 BR02 - 17 June 2017...

  • Page 51: 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 BR02 - 17 June 2017...
  • Page 52 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. Enter the value in the engineering units of the batch preset. 515 BR02 - 17 June 2017...
  • Page 53 The automatic reset feature allows the previous batch total to be reset automatically when a new batch is started with the RUN key. Press to select ENABLE or DISABLE. 515 BR02 - 17 June 2017...
  • Page 54 P-FLOW Preset Loop/Process flowrate setpoint. This setpoint is only available for LOOP control and TUNE modes. The value of the setpoint must not be greater than the process flow range (P-FLOW RANGE). 515 BR02 - 17 June 2017...

  • Page 55: Inputs

    The cut-off setting is the percentage of the span of the input values. All inputs at or below the cut-off value are considered negligible to the instrument and are ignored. In this case, the instrument uses the minimum value (set at PT-MIN). 515 BR02 - 17 June 2017...
  • Page 56 The input filter range is from 0 to 99. A setting of 0 (zero) means that there is no filtering. CORR AINP3 Analog input non-linearity can be corrected as follows: AINP4 • LINEAR • NON-LINEAR to use the following linearity correction parameters to select LINEAR or NON-LINEAR. 515 BR02 - 17 June 2017...
  • Page 57 DISPLAY next item. OUT-01 AINP3 This parameter is available for viewing and editing only when the correction type is set to Non-linear. OUT- Enter the normalised output value for the correction point. 515 BR02 - 17 June 2017...

  • Page 58: Outputs

    (Note: there is no End of batch signal if Batch mode is ON-OFF). Press to select RETRANS, OP-ERR, OP-CTRL or OP-END 515 BR02 - 17 June 2017...
  • Page 59 1.000 generates one pulse for . Similarly, a pulse factor of 3.000 generates one pulse for 3 m For more information, see Output Pulse Factor on page 50. The output pulse factor cannot be 0 (zero). 515 BR02 - 17 June 2017...
  • Page 60 50 ms: 1000 -------------- - 10Hz The maximum pulse output frequency is:  2 50 ----- - The minimum pulse factor for that frequency is: 515 BR02 - 17 June 2017...

  • Page 61: Alarms

    Each alarm is completely independent, e.g. a High alarm does NOT need to have a higher setpoint than the a Low alarm. 515 BR02 - 17 June 2017...

  • Page 62: Communications

    Infra-red Port - Discontinued - Although program settings may be visible in calibration, the required hardware is no longer available. The PROTOC INFRA Infra-red protocol assignment ( ) should be set to NONE INFRA and the remaining settings can be ignored. 515 BR02 - 17 June 2017...
  • Page 63 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 BR02 - 17 June 2017...

  • Page 64: Time Settings And Data Logging

    The instrument will log a total of 1000 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. 515 BR02 - 17 June 2017...
  • Page 65 The Printer Protocol Report Type determines the nature of the printout from the REPORT PRINT - HOLD.SET prompt in the main menu. The following report types available in this instrument are: • REP-10 Preset number of latest logs Press to select Report Type. 515 BR02 - 17 June 2017...

  • Page 66: General Setup Parameters

    Press to select the default variable display. SUPPLY VOLT The instrument provides a power-limited supply for external transducers. Press to set the transducer supply voltage between 8 and 24 volts DC as required. 515 BR02 - 17 June 2017...
  • Page 67 Note: The user-defined tags can be entered into the instrument only by the manufacturer or the distributor. Press to select the Display Tags option as follows: • DEFAULT - the instrument displays the default (English) tags • USER - the instrument displays the user-defined tags. 515 BR02 - 17 June 2017...

  • Page 68: Test Menu

    For a 4-20 mA output, such as a rate, the output is as follows: • HI - the output is set to 20 mA. • LO - the output is set to 4 mA. 515 BR02 - 17 June 2017...

  • Page 69: System Messages

    Power Supply The input and/or output power supply voltage is too low, ensure is Low that: (a) input power supply voltage is within the specified range (b) output power supply is not overloaded. 515 BR02 - 17 June 2017...

  • Page 70: Warning Messages

    You have exceeded the preset limit. The instrument will set the Max Set maximum allowed value. Prompt Messages The system displays prompt messages as described in the following table: Prompt Messages Description Connect Permissive Connect permissive to proceed with batching. 515 BR02 - 17 June 2017...

  • Page 71: Communications

    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 BR02 - 17 June 2017...
  • Page 72 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 BR02 - 17 June 2017...

  • Page 73: 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 74: 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 that request. 515 BR02 - 17 June 2017...

  • Page 75: Instrument Responses

    8 9 1 2 3 . 4 5 6 V O L U M E 10 11 12 13 14 15 16 17 18 19 20 22 23 24 25 26 27 Value (aligned right) Unit (aligned left) Item (aligned left) 515 BR02 - 17 June 2017...
  • Page 76 K J / K G S P - E N T The following message to an instrument, requests the current values for the default rate and total: : A 0 0 1 : R V D ? 515 BR02 - 17 June 2017...
  • Page 77 Clear the logs except for the “last edited” log Clear Data Request Example The following message asks the instrument with address 001 to clear the logged data that the instrument stores: : A 0 0 1 : R C L ? 515 BR02 - 17 June 2017...

  • Page 78: 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 BR02 - 17 June 2017...

  • Page 79: 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 BR02 - 17 June 2017...

  • Page 80: 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 BR02 - 17 June 2017...
  • Page 81 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 BR02 - 17 June 2017...
  • Page 82 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 BR02 - 17 June 2017...
  • Page 83 0 = Idle/Local Control from logic inputs 1 = Stop Suspend current batch 2 = Run Resume/start batch 3 = Reset Clear current batch totals ‡ 51 to 99 Instrument See next table for details. Parameters 515 BR02 - 17 June 2017...
  • Page 84 * I = Integer (2 bytes) (Holding Registers) † L = Long Integer (2 register = 4 bytes) ‡ DT = Data Type of 2-register (4 byte) values can be set as Floating Point or Long Integer values 515 BR02 - 17 June 2017...
  • Page 85 For full description, please refer to the Modbus Accessible Parameters on page 44. Register Name Comments Read Only or Type Read/Write Preset Control Output Setpoint Preset Flowrate Setpoint Preset Ratio Setpoint Batch Preset Value 59 to 99 Reserved 515 BR02 - 17 June 2017...

  • Page 86: Printer Protocol

    A printout can only be initiated if a batch is not in progress. If printing is not required, do not select printer protocol. The format of this printout will be: 515 BR02 - 17 June 2017...
  • Page 87 The printout will have the time and date stamp corresponding to when the log was taken. After the print has been initiated there will be the opportunity to scroll to view another log entry and print again. 515 BR02 - 17 June 2017...
  • Page 88 -------------------------------------------- <separation line> Delivery No. Date & Time & Status Variable unit value Variable unit value etc. -------------------------------------------- <separation line> Delivery No. Date & Time & Status Variable unit value Variable unit value etc. 515 BR02 - 17 June 2017...

  • Page 89: Printer Data Control

    Some printers will also transmit an Xoff character in response to other events such as printer being off-line, print head not engaged or power being removed. The specific behaviour of the printer being used should be noted. 515 BR02 - 17 June 2017...
  • Page 90 When 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 BR02 - 17 June 2017...
  • Page 91 A normalised input ranges from 0 to 1.000. For 4-20 mA input, the signal is Input set to 0 at 4 mA and the signal is set to 1.000 at 20 mA. Passive Output Requires an external power supply. Signal 515 BR02 - 17 June 2017...
  • Page 92 515 BR02 - 17 June 2017...

  • Page 93: Appendix B Model Numbers

    Note: The first character represents the CPU installed (factory use only). The remaining 6 characters only MODEL represent hardware that affects the operation. Note: Example full product part number is 515.111USC-BR02 (this is the number used for placing orders). 515 BR02 - 17 June 2017...

  • Page 94: Custom Version Codes

    Assignment type F-tP-- SC01 INPUT Application number The Application Information code is returned as part of a General Instrument request (as described in Instrument Information Request on page 68). 515 BR02 - 17 June 2017...
  • Page 95 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 BR02 - 17 June 2017...
  • Page 96 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 General Input Pressure, Temperature, Density, Length (Level), Factor 515 BR02 - 17 June 2017...
  • Page 97 20, 21 failed date format life declaration FCC default variable baud rate delay, alarm digital output 515 BR02 - 17 June 2017...
  • Page 98 Modbus data format instrument Modbus RTU protocol address mode request format display timeout responses process control settings set calibration interconnections, communication view calibration interference suppression model numbers isolated outputs modes, batch control mounting 515 BR02 - 17 June 2017...
  • Page 99 LEDs protocol stop bits report types STOP key printer types stopping a batch 515 BR02 - 17 June 2017...
  • Page 100 TOTAL key tuning control loop unit tag units menu variable, default version, customer view data logs 20, 21 warnings 515 BR02 - 17 June 2017...

Table of Contents