Contrec 515 User manual

Model 515 Flow Computer

Operation Manual

Application LM02

Single Tank Level Monitor

for

Analog Level Sensors

28 April 2021

Model 515 Level Monitor - Operation Manual

The instructions given herein cover the general description, installation, operation and maintenance of the subject

equipment. Contrec Ltd reserves the right, without prior notice, to make engineering refinements that may not be

reflected in this manual.

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.

Part of the software embedded in this product is eCos - Embedded Configurable Operating System, a trademark of

The software in this product was in part provided by Red Hat and any express or implied warranties, including, but

not limited to, the implied warranties of merchantability and fitness for a particular purpose are disclaimed. In no

event shall the author be liable for any direct, indirect, incidental, special, exemplary, or consequential damages

(including, but not limited to, procurement of substitute goods or services; loss of use, data, or profits; or business

interruption) however caused and on any theory of liability, whether in contract, strict liability, or tort (including

negligence or otherwise) arising in any way out of the use of this software, even if advised of the possibility of such

damage.

Contrec Ltd

Riverside, Canal Road, Sowerby Bridge,

West Yorkshire HX6 2AY UNITED KINGDOM

Tel: +44 1422 829944

Email: [email protected]

Website: www.contrec.co.uk

Contrec Systems Pty Ltd

5 Norfolk Avenue Ringwood, Melbourne 3134 AUSTRALIA

Tel: +61 4 413 505 114

Email: [email protected]

Contrec - USA, LLC

916 Belcher Drive Pelham AL 35124 USA

Tel: +1 (205) 685 3000 Fax: +1 (205) 685 3001

Email: [email protected]

Publication No: 515-LM02-OM - 28 April 2021

515 LM02 - 28 April 2021 iii

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.

This document must be consulted in all cases where the following “Caution” safety symbol is

used :

Qualified Personnel

The instrument must be installed, operated and serviced by persons who have been properly

trained and authorised. Personnel must read and understand this manual prior to installation and

operation of the instrument. Refer to section 3 for further information regarding permitted

maintenance operations. The safety of any system incorporating the equipment is the

responsibility of the assembler of the system.

Static Hazard

The 500 series flow computer uses high speed CMOS circuitry which is sensitive to static

damage. The user should observe accepted safety practices for handling electronic devices,

especially during servicing. Once the unit is installed, grounded and interconnected, the chances

of static damage are greatly reduced.

Voltage Hazard

Before connecting power to the instrument, ensure that the supply voltage for the AC or DC

input is suitable. The AC voltage rating is as stated on the instrument rating plate. Personnel

should take all due care to avoid electric shock. For safe operation it is essential to connect a

mains safety earth to the A.C. power inlet. Do not operate at altitudes above 2000m.

Welding Hazard

Do not perform electric welding in close proximity to the instrument or its interconnecting

cables. If welding in these areas must be performed, disconnect all cables from the instrument.

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. Operate only in a clean, dry and pollutant-free environment.

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 LM02 - 28 April 2021

i v 515 LM02 - 28 April 2021

Disconnection Device

When powered from a mains supply this unit requires the provision of a suitable mains isolation

device, capable of interrupting both poles of the supply and meeting your local wiring

regulations, to be suitably located and easily accessible near to the installed instrument. It must

be marked as the disconnecting device for the equipment. It must be suitably rated with respect

to the cross sectional area of the supply conductors.

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. If outside of the EU, this equipment should be

responsibly disposed of according to local and national regulations for EEE

(Electrical and Electronic Equipment).

By not discarding of this product along with other house hold waste you are

preserving natural resources and reducing waste sent to landfill and incinerators.

Remove batteries and dispose of separately (see Disposal of Batteries) before disposal of

Contrec instrumentation.

Disposal of Batteries

Batteries have an environmental impact. Safe and responsible disposal should

be undertaken.

In all EU member states, as per Directive 2006/66/EC, batteries must not be

thrown away with general waste. Contact your local environmental authority

for information regarding disposal or recycling of used batteries, alternatively

they can be returned directly to Contrec Ltd. for disposal.

Please Contact Contrec Ltd before returning batteries for disposal.

Explanation of IEC Symbols Used

You should familiarise yourself with the following symbols which are used both within this

manual and on the instrument itself.

This document must be consulted in all cases where the following “Caution” safety

symbol is used.

DC Input (DC).

AC Input (AC).

Protective Earth Terminal.

v

1 Introduction

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Displayed Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Main Menu Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Isolated Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Relay Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Analog Input Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2 Specifications

Specification Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3 Installation & Maintenance

Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Cleaning and Decontamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Panel Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Rear Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Terminal Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Terminal Wiring Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Relay Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Mains Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Analog Input Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Logic Input Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4-20 mA Output Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Logic Output Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Control Relays (Alarms) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

RC Network for Interference Suppression . . . . . . . . . . . . . . . . . . . . . . 15

Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

COM-1 RS-232 Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

COM-2 RS-485 Port Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

COM-2 Ethernet Port Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Mains Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Earthing and Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Disconnection Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Battery Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Contents

515 LM02 - 28 April 2021

v i 515 LM02 - 28 April 2021

4 Operation

Normal Operation Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Default Variable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Front Panel Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Main Menu Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Detail and Basic Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Data Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Model Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Alarms Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Operation of Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5 Instrument Calibration

Calibration View Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Calibration Set Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Changing the Instrument Settings . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Program Backup & Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Backup via 500 Series Program Manager . . . . . . . . . . . . . . . . . . . . . . 31

Printing Configuration Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Upload and Clone of Application Software . . . . . . . . . . . . . . . . . . . . . 31

Calibration Menu Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Instrument Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Units of Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Time Settings and Data Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

General Setup Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Test Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

System Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Warning Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Alarm Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

6 Communications

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Hardware Interconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Protocols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Simple ASCII Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Requests Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Instrument Responses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Corrupted or Invalid Requests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Modbus RTU Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

List of Data Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Printer Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Types of Printouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

515 LM02 - 28 April 2021 vii

Printer Data Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Appendix A Glossary

Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Appendix B Model Numbers

Product Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Custom Version Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Application Information Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Appendix C Units of Measurement

Available Units of Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Appendix D Ethernet Port & Setup

Ethernet Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Router Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Configuring DataMod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

viii 515 LM02 - 28 April 2021

i x515 LM02 - 28 April 2021

List of Figures

1 Typical Application Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2 500 Series Instrument Panel Mounting . . . . . . . . . . . . . . . . . . . . . . . 7

3 Rear Panel Connections - Original . . . . . . . . . . . . . . . . . . . . . . . . . 8

4 Rear Panel Connections - New RS-485 Version . . . . . . . . . . . . . . . . . . 9

5 Rear Panel Connections - New Ethernet Version . . . . . . . . . . . . . . . . . . 9

6 Externally Powered Voltage Transmitter . . . . . . . . . . . . . . . . . . . . . 11

7 Internally Powered Voltage Transmitter . . . . . . . . . . . . . . . . . . . . . 12

8 Externally Powered Current Loop . . . . . . . . . . . . . . . . . . . . . . . . . 12

9 Internally Powered Current Loops . . . . . . . . . . . . . . . . . . . . . . . . 12

10 Output 4-20 mA Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . 13

11 Output Logic Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . 14

12 Relay Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

13 RS-485 Interface Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

14 Logged Data Display Methods . . . . . . . . . . . . . . . . . . . . . . . . . . 22

15 Calibration Menu Tree Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 32

16 Calibration Menu Tree Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 33

17 RS-232 Cable Connections to a Computer . . . . . . . . . . . . . . . . . . . . 51

18 RS-485 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

x 515 LM02 - 28 April 2021

Contrec 515 User manual

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