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Contrec 515 FA01 Operation Manual

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Model 515 Flow Computer
Operation Manual
Application FA01
Add or Subtract
Flow Computer
for
Volumetric Applications
29 August 2021
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Summary of Contents for Contrec 515 FA01

  • Page 1 Model 515 Flow Computer Operation Manual Application FA01 Add or Subtract Flow Computer Volumetric Applications 29 August 2021...
  • Page 2 Should any questions arise which cannot be answered specifically by this manual, they should be directed to Contrec Limited for further detailed information and technical assistance. Contrec Limited will not accept any liability for either direct or consequential damages resulting from the use or misapplication of the contents of this manual.
  • Page 3 Operating & Storage Temperature Operating: If a heater is being used, DO NOT isolate the instrument in temperatures below -20°C. Storage: DO NOT store the equipment below -20°C. 515 FA01 - 29 August 2021 515 FA01 - 29 August 2021...
  • Page 4 Instrument Disposal Contrec instrumentation should not be thrown into the general waste system. If within EU member states, this instrument should be disposed of according to the guidelines set by the WEEE (Waste Electrical and Electronic Equipment) directive 2012/19/EU.
  • Page 5 RC Network for Interference Suppression Communications COM-1 RS-232 Port COM-2 RS-485 Port Option COM-2 Ethernet Port Option Mains Connection Earthing and Shielding Disconnection Device Maintenance Instructions Battery Replacement Battery Type 515 FA01 - 29 August 2021 515 FA01 - 29 August 2021...
  • Page 6 System Messages 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 515 FA01 - 29 August 2021...
  • Page 7 Appendix A Glossary Glossary Appendix B Model Numbers Product Codes Custom Version Codes Application Information Code Appendix C Ethernet Port & Setup Ethernet Port Connecting 515 Ethernet to Networks/Routers Connecting DataMod via Ethernet Index 515 FA01 - 29 August 2021...
  • Page 8 515 FA01 - 29 August 2021...

  • Page 9: Table Of Contents

    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 DataMod - Modbus Connection Settings 515 FA01 - 29 August 2021 515 FA01 - 29 August 2021...
  • Page 10 515 FA01 - 29 August 2021...
  • Page 11 • Backlit display Overview The 515 FA01 application pack is an add or subtract flow computer that is tailored specifically for volume measurement. It can perform either addition or subtraction on two frequency inputs or on two analog inputs. The flow computer is suitable for accepting signals directly from flowmeters or for collecting re-transmitted signals from other flow computers providing a resultant rate and total.
  • Page 12 - V min)A + V   channelflow t   channeltotal The resultant values are then: ADD result = channel 1 + channel 2 SUB result = channel 1 - channel 2 515 FA01 - 29 August 2021...
  • Page 13 1000 entries of the variables as displayed on the main menu. Main Menu Variables Main Menu Default Variable Variables Units Type Total 1 Total Flowrate 1 /min Rate Total 2 Total Flowrate 2 /min Rate Resulting Total Total Resulting Flowrate /min Rate 515 FA01 - 29 August 2021...
  • Page 14 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 two additional relays available as an option. 515 FA01 - 29 August 2021...
  • Page 15 The software is a Windows based program that is freely available from the download section of the Contrec website. The program can be used to create a custom version of an existing application to be saved for backup purposes and/or to generate a PDF of configuration report for record keeping.
  • Page 16 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 17 CMOS, TTL, open collector, reed switch - For non-conformal coated versions, type Overvoltage 30V maximum BR2032 and CR2032 manufactured by Panasonic or Sony Battery Life 5 years (typical) 515 FA01 - 29 August 2021 515 FA01 - 29 August 2021...
  • Page 18 Programmable: 10 , 20, 50, 100, 200 or 500ms 4-20 mA 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 FA01 - 29 August 2021...
  • Page 19 145 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 FA01 - 29 August 2021 515 FA01 - 29 August 2021...

  • Page 20: Rear Panel Connections - Original

    1 and 2 (terminals 32-33) share Relay Common 1-2 (terminal 31) and relays 3 and 4 (terminals 34-35) share Relay Common 3-4 (terminal 36. N.B. The 6 way relay terminal block is ORANGE. Figure 4 Rear Panel Connections - New RS485 Version 515 FA01 - 29 August 2021...

  • Page 21: Rear Panel Connections - New Ethernet Version

    E Mains ground Term 36 only available on AC power in 100- RC Relay common 3-4 N Mains neutral new style option card MAINS 240VAC A Mains active RS232 COM-1 port 9-pin serial port 515 FA01 - 29 August 2021...
  • Page 22 Electrical Code of Practice as dictated by the Authority Having Jurisdiction (AHJ). The terminal designations (L/N/E) are clearly indicated just above the mains input connector on the rear panel of the instrument. 515 FA01 - 29 August 2021...
  • Page 23 Reed Relay Switch Frequency Input (FINPn) Signal Ground 18 Shield Coils - with 15 mV minimum amplitude (typical). Frequency Input (FINPn) Signal Ground Shield Namur Proximity Switch Vo +8V DC Frequency Input (FINPn) Shield 515 FA01 - 29 August 2021...

  • Page 24: Externally Powered Voltage Transmitter

    Shield Figure 6 Externally Powered Voltage Transmitter Connect internally powered voltage transmitters as shown in Figure 7. Vo +8...24V DC Signal Transmitter Analog Input (AINPn) DC ground Shield Figure 7 Internally Powered Voltage Transmitter 515 FA01 - 29 August 2021...

  • Page 25: 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 FA01 - 29 August 2021...
  • Page 26 Figure 11 shows the connections for a 4-20 mA output. Output channel 1 uses terminals 27 (+) and 28 (-), output channel 2 uses terminals 29 (+) and 30 (-). Maximum Load Resistance = (Supply-9) / 0.02 ohms 515 FA01 - 29 August 2021...
  • Page 27 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 12 Output Pulse Connection Diagram 515 FA01 - 29 August 2021...
  • Page 28 Note: Solid state relays (SSR) use AC voltage only. Relay 1 RC Relay 1-2 Common Alarm/Load Supply Relay 2 Alarm/Load Relay 3 Alarm/Load Relay 4 Alarm/Load Supply Relay 3-4 Common Figure 13 Relay Connection Diagram 515 FA01 - 29 August 2021...
  • Page 29 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 FA01 - 29 August 2021...
  • Page 30 Figure 14 shows the connection of several instruments to a computer using the RS-485 port. Twisted Pair Host Computer Load 120 ohms Comms 19 20 21 19 20 21 Instrument Instrument Figure 14 RS-485 Interface Connections 515 FA01 - 29 August 2021...
  • Page 31 If mounted in an ExD enclosure, before proceeding, refer to the ExD manual for further information. This work may need to be scheduled and carried out in accordance with the local electrical Code of Practice. 515 FA01 - 29 August 2021...
  • Page 32 2. Conformal coated “C” version - Type BR2032, manufacturer Panasonic ONLY. 3. Non Conformally coated versions :- BR2032, CR2032, Sony or Panasonic ONLY. *Issue 7 option card can be identified with 6 way (31-36) ORANGE relay connector. 515 FA01 - 29 August 2021...
  • Page 33 The host computer is downloading the application software. The instrument is in Calibrate Set mode. Alarm The instrument has an error, as indicated on the display panel. Alarm The instrument is in Calibrate View mode. 515 FA01 - 29 August 2021 515 FA01 - 29 August 2021...
  • Page 34 See below for further details of peak flowrates. Remote Reset The Remote Reset on logic input 3 (LINP3) has the same function as the front key, as described above. RESET 515 FA01 - 29 August 2021...
  • Page 35 500 Series Program Manager (500-PM Software) prior to the application software being downloaded to the instrument. The 500-PM Software is Windows based configuration and resource tool for the 500 Series and is freely available from the www.contrec.co.uk website. 515 FA01 - 29 August 2021...
  • Page 36 00 hours and 00 minutes on the first day of the year. View Data Logs Use the following procedure to view the data that has been logged by the instrument: 1. Press the key to scroll through the menu to the LOGGED DATA DISPLAY prompt. 515 FA01 - 29 August 2021...
  • Page 37 … … 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 15 Logged Data Display Methods 515 FA01 - 29 August 2021...
  • Page 38 Hold Reset to start the printing of the configuration report. The report will be in a similar format to the report generated by the 500 Program Manager. Press at any time to exit from the Model information. 515 FA01 - 29 August 2021...
  • Page 39 “programmable” parameters, but the correct password must be entered to change the password-protected parameters. Likewise, the CAL switch (Logic Input 4) must be used to accept the password to change the CAL switch protected parameters. 515 FA01 - 29 August 2021 515 FA01 - 29 August 2021...
  • Page 40 To select the next digit, press 6. Press or use the CAL switch on Logic Input 4 (if “Cal switch protected” items exist) to accept the password and proceed. 515 FA01 - 29 August 2021...
  • Page 41 “Cal switch protected” items exist, the CAL switch can be closed for two seconds. The instrument makes two beeps and cancels the Cal and Set indicators. Alarm 515 FA01 - 29 August 2021...
  • Page 42 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 the Instrument Settings section below. 515 FA01 - 29 August 2021...
  • Page 43 The 500-LT (PM Lite) program is a Windows based computer program which can be downloaded for free from the Contrec www.contrec.co.uk website and is part of the package when the Contrec 500 Series Program Manager is installed. The 500-LT provides the option to ‘Upload Application’ or ‘Upload Report Only’.

  • Page 44: Calibration Menu Tree Sheet

    TYPE PT-MIN WIDTH FACT01 FACTn POINT PT-MAX PULSE HYST AINP3/4 FLOW1/2 TYPE 4-20 0-5 /1-5V PT-MIN PT-MAX CUTOFF FILTER CORR LINEAR NON-LIN NO-PTS INP-01 INP-n OUT-01 OUT-n Figure 16 Calibration Menu Tree Sheet 1 515 FA01 - 29 August 2021...

  • Page 45: Calibration Menu Tree Sheet

    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 17 Calibration Menu Tree Sheet 2 515 FA01 - 29 August 2021...
  • Page 46 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 FA01 - 29 August 2021...
  • Page 47 Note: When the debounce circuit is enabled, the maximum input frequency for large amplitude signals is limited to approximately 500 Hz. For low amplitude signals, the maximum frequency can be approximately 200 Hz. Press to select ENABLE or DISABLE. 515 FA01 - 29 August 2021...
  • Page 48 The input filter range is from 0 to 99. A setting of 0 (zero) means that there is no filtering. CORR FINP1 If the input sensor has non-linear characteristics, select NON-LINEAR FINP2 to apply correction factors to the input signal. to select LINEAR or NON-LINEAR. 515 FA01 - 29 August 2021...
  • Page 49 FREQ04 FREQ05 Enter the lowest correction factor frequency as FREQ01 and proceed up to the highest frequency. You can hold the key to skip the DISPLAY non-linear points and go to the next item. 515 FA01 - 29 August 2021...
  • Page 50 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 FA01 - 29 August 2021...
  • Page 51 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 FA01 - 29 August 2021...
  • Page 52 DISPLAY next item. OUT-01 AINP3 This parameter is available for viewing and editing only when the AINP4 correction type is set to Non-linear. OUT- Enter the normalised output value for the correction point. 515 FA01 - 29 August 2021...
  • Page 53 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 44. The output pulse factor cannot be 0 (zero). 515 FA01 - 29 August 2021...
  • Page 54 50 ms: 1000 -------------- - 10Hz The maximum pulse output frequency is:  2 50 ----- - The minimum pulse factor for that frequency is: 515 FA01 - 29 August 2021...
  • Page 55 Each alarm is completely independent, e.g. a High alarm does NOT need to have a higher setpoint than the a Low alarm. 515 FA01 - 29 August 2021...
  • Page 56 200 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 FA01 - 29 August 2021...
  • Page 57 The stop bit setting of the instrument must match the stop bit setting of the communication device that the instrument is connected to. Press to select 1 or 2 stop bits. 515 FA01 - 29 August 2021...
  • Page 58 Therefore, after an interruption to the power supply, the instrument recommences normal operation although there will be no data recorded during the period without a power supply. 515 FA01 - 29 August 2021...
  • Page 59 The Clock H-MIN setting is the current time in hours and minutes for the CLOCK H-MIN real-time clock. HOUR LOGS Set the number of Hourly Logs to appear on the printed log report. The hourly log entry occurs at 00 minutes each hour. 515 FA01 - 29 August 2021...
  • Page 60 REP-03 Weekly Logs Report • REP-04 Monthly Logs Report • REP-05 Yearly Logs Report • REP-06 Previous Day’s 24 Hour Report (0Hr – 23Hr, minimum 48 hourly logs required) Press to select Report Type. 515 FA01 - 29 August 2021...
  • Page 61 Press to select the default total 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 FA01 - 29 August 2021...
  • Page 62 ACCUM The Reset Accumulated Totals function clears all of the accumulated totals and the non-accumulated totals. Press to select YES, then press the key. The instrument makes three beeps to confirm the reset command. 515 FA01 - 29 August 2021...
  • Page 63 This parameter sets the maximum number of decimal places for RATES displaying or printing main menu rates. TOTALS This parameter sets the maximum number of decimal places for displaying or printing main menu totals. 515 FA01 - 29 August 2021...
  • Page 64 You can display the actual DC output supply voltage, which may help with troubleshooting. If the actual supply voltage is lower than the preset value (refer to General Setup Parameters on page 51) it may indicate that the output is overloaded. 515 FA01 - 29 August 2021...
  • Page 65 Flowrate Input The channel 1 flowrate input transmitter (analog input 3) has failed. 1 Failure Flowrate Input The channel 2 flowrate input transmitter (analog input 4) has failed. 2 Failure 515 FA01 - 29 August 2021...
  • Page 66 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 FA01 - 29 August 2021...

  • Page 67: Rs-232 Cable Connections To A Computer

    Computers use either a DB9 or a DB25 connector, and the connections to each type are shown in Figure 18. Instrument Computer/Printer Common Optional Optional DB25 Figure 18 RS-232 Cable Connections to a Computer 515 FA01 - 29 August 2021 515 FA01 - 29 August 2021...
  • Page 68 COM-2 should be set to RTU (Modbus), 19200 Baud rate, even parity and 1 stop bit. For further advice and example of Ethernet port usage and setup, refer to Ethernet Port & Setup on page 82 in the Appendix. 515 FA01 - 29 August 2021...
  • Page 69 • 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 70 Log Type LH - hourly log LD - daily log LW - weekly log LM - monthly log LY - yearly log LE - last edit log LN - current totals displayed as Non-accumulated 515 FA01 - 29 August 2021...
  • Page 71 Value (aligned right) Unit (aligned left) Item (aligned left) Note: The decimal point in the Value is always at character position 8. Therefore whole numbers are aligned right at the decimal point, with trailing zeroes. 515 FA01 - 29 August 2021...
  • Page 72 1 8 : 2 5 : 0 0 1 2 6 . 4 5 5 V O L U M E 2 0 . 4 3 7 m 3 / M V - F L O W 515 FA01 - 29 August 2021...
  • Page 73 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 FA01 - 29 August 2021...
  • Page 74 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 FA01 - 29 August 2021...
  • Page 75 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 FA01 - 29 August 2021...
  • Page 76 Slave device busy The slave is engaged in processing a long duration program command. The master should re-transmit the message later when the slave is free. 515 FA01 - 29 August 2021...
  • Page 77 (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 preset, one data value. 515 FA01 - 29 August 2021...
  • Page 78 06 - current totals are non-accumulated values, register 38 is ignored. Log Number If set to 0, current variables and Date/Time are retrieved Clear Data 01 - clear logs 02 - clear accumulated totals 03 - clear non-accumulated totals Reserved 515 FA01 - 29 August 2021...
  • Page 79 Subtraction calculation used Relay State 0 to 15 Binary representation of relay state. 0 = open; 1 = closed. B0 = relay 1 (LSB) B1 = relay 2 B2 = relay 3 B3 = relay 4 515 FA01 - 29 August 2021...
  • Page 80 Raw analog input data. 4-20mA inputs are read in Amperes. Analog Inp.2 0-5V or 1-5V inputs are read in Volts Analog Inp.3 RTD inputs are read in degrees Kelvin. Analog Inp.4 Unused inputs are configured as 4-20mA. 515 FA01 - 29 August 2021...
  • Page 81 A customized printout can be provided which can have up to 6 header lines and 6 footer lines. It is also possible to include or exclude each main menu item on the printout. If any customizing of the printout is required discuss this with the distributor. 515 FA01 - 29 August 2021...
  • Page 82 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 28. 515 FA01 - 29 August 2021...
  • Page 83 <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 FA01 - 29 August 2021...
  • Page 84 “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 FA01 - 29 August 2021...
  • Page 85 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 FA01 - 29 August 2021...
  • Page 86 Communications 515 FA01 - 29 August 2021...
  • Page 87 The 500 Series Program Manager (500-PM software) is a Windows based Software program that is freely available from the download section of the Contrec website. The program is a comprehensive configuration tool and resource centre that can be used to tailor an instrument to suit specific application needs including program settings, units of measurement, custom tags/text, access levels and more.
  • Page 88 515 FA01 - 29 August 2021...
  • Page 89 (factory use only). The remaining 6 characters only MODEL represent hardware that affects the operation. Note: Example full product part number is 515.111USC-FA01 (This is the number used for placing orders). 515 FA01 - 29 August 2021 515 FA01 - 29 August 2021...
  • Page 90 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 91 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 FA01 - 29 August 2021...
  • Page 92 (providing there are addresses available). If your network cannot locate the instrument you may need to run the ‘Digi Discovery’ tool (Contrec guide available on request) or enter the Ethernet module’s MAC address within your router settings. If required, the instrument can also be set to a static IP address, however it is strongly advised that only IT competent persons access and edit site network and 515 Ethernet settings.
  • Page 93 Ensure all other settings are correct as per the Datamod User Guide and the 515 Ethernet Guide - Establishing a Connection to Datamod. Both of these documents are available from Contrec on request. Figure 20 DataMod - Modbus Connection Settings 515 FA01 - 29 August 2021...
  • Page 94 515 FA01 - 29 August 2021...
  • Page 95 CAL switch-protected parameter calculation mode 515 FA01 - 29 August 2021 515 FA01 - 29 August 2021...
  • Page 96 LEDs weekly yearly logic input connection glossary main menu hardware connections basic and detailed hourly logging main menu items hysteresis, alarm mains connections maintenance 9, 21 515 FA01 - 29 August 2021...
  • Page 97 ASCII operation, normal communication output Modbus RTU connections printer 4-20mA pulse factor, output pulse pulse output pulse factor outputs menu RATE key real-time clock panel rear panel LEDs relay outputs mounting relays, alarm rear 515 FA01 - 29 August 2021...
  • Page 98 TOTAL key total, default unit tag units menu units of measurement upload application software version, customer view data logs 515 FA01 - 29 August 2021...

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