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Model 515 Flow Computer

Operation Manual

Application

BR03

Batch/Ratio Process Controller

for

Mass Frequency Flowmeters

15 August 2021

Summary of Contents for 515 BR03

Page 1: ...Model 515 Flow Computer Operation Manual Application BR03 Batch Ratio Process Controller for Mass Frequency Flowmeters 15 August 2021...

Page 2: ...n 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...

Page 3: ...andling 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...

Page 4: ...rical 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 batt...

Page 5: ...el Connections 10 Terminal Designations 11 Terminal Wiring Insulation 12 Relay Wiring 12 Mains Power Wiring 12 Inputs 13 Frequency Input Connection 13 Logic Input Connection 14 Outputs 14 4 20mA Outpu...

Page 6: ...rations 33 Safety and Security 34 Starting a Batch 34 Stopping a Batch 34 Resetting a Batch 35 Printing a Delivery Docket 35 Logic Input Control 35 Batch Flow Errors 36 Batch Control Processes 36 5 In...

Page 7: ...ormat 71 Instrument Responses 72 Corrupted or Invalid Requests 76 Modbus RTU Protocol 77 List of Data Registers 79 Printer Protocol 84 Types of Printouts 85 Printer Data Control 88 Appendix A Glossary...

Page 8: ...viii 515 BR03 15 August 2021...

Page 9: ...gic Inputs Connection Diagram 14 7 Output 4 20mA Connection Diagram 15 8 Output Pulse Connection Diagram 15 9 Relay Connection Diagram 16 10 RS 485 Interface Connections 18 11 Batch Operation with Man...

Page 10: ...x 515 BR03 15 August 2021...

Page 11: ...rompt Uses PI Loop Control Allows for non linear correction Storage of 1000 transactions with time and date stamp Selection of Detail or Basic main menu to suit operator and application Selection of s...

Page 12: ...ection a deadband output hold and ramp time that can be programmed to reduce wear on valves and actuators and provide for bumpless operation Calculations There are three types of control modes in whic...

Page 13: ...232 port COM 2 RS 485 port optional or Ethernet optional The ports are available for remote data reading printouts and for initial application loading of the instrument Isolated Outputs The opto isol...

Page 14: ...oftware is a free comprehensive configuration tool and resource centre that can be used to further tailor an instrument to suit specific application needs including units of measurement custom tags an...

Page 15: ...t This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual might cause harmful interference to radio communications...

Page 16: ...Introduction 6 515 BR03 15 August 2021...

Page 17: ...ed by Renata only For conformal coated C version type BR2032 manufactured by Panasonic only For non conformal coated versions type BR2032 and CR2032 manufactured by Panasonic or Sony Battery Life 5 ye...

Page 18: ...mited output Isolated Output No of Outputs 2 configurable outputs Configuration Pulse Digital or 4 20mA output Pulse Digital Output Signal Type Open collector Switching 200mA 30 volts DC maximum Satur...

Page 19: ...ervice centre for repair or inspection use only a damp cloth and mild detergent Do not use abrasive cleaners or high pressure water jets An instrument must be decontaminated before returning The marki...

Page 20: ...riginal rear panel of the instrument where relays 1 to 4 terminals 32 35 share a single Relay Common terminal 31 Note The 5 way relay terminal block is GREEN Figure 3 Rear Panel Connections Original O...

Page 21: ...g Input ch 4 15 Vo 8 24 volts DC output Overload protected 16 G DC Ground 17 Vi DC power input DC power in 12 28V 18 SH E Shield terminal E AC MAINS E Mains ground AC power in 100 240VAC N N Mains neu...

Page 22: ...he connected circuit 0 75mm 6A current capacity is sufficient Use copper conductors only The maximum current must be 5A as stated in the Specifications Mains Power Wiring Only use UL CSA approved cabl...

Page 23: ...er to Terminal Designations on page 11 for specific terminal numbers for this application Squarewave CMOS or TTL Open Collector Reed Relay Switch Coils with 15mV minimum amplitude typical Namur Proxim...

Page 24: ...own below Logic Input Control on page 35 describes the function of the inputs Figure 6 Logic Inputs Connection Diagram Outputs The advanced option for the instrument provides two opto isolated output...

Page 25: ...connection example for a pulse output Output channel 1 uses terminals 27 and 28 Output channel 2 uses terminals 29 and 30 Figure 8 Output Pulse Connection Diagram 18 DC supply 9 24V Load Shield 515 4...

Page 26: ...d 4 allow for different signal or supply types to be connected to the control or alarm devices as shown in Figure 9 There is also an equipment failure alarm option This alarm can have normally closed...

Page 27: ...relay contacts against premature wear through pitting or SSR where specified against premature failure RC suppression networks consist of a capacitor and series resistor and are commonly available in...

Page 28: ...termination requirements COM 2 RS 485 Port Option Up to 32 units can be connected to a common RS 485 bus Each unit has a unique address that the host computer uses to identify each instrument Figure...

Page 29: ...instrument end only This connection should be as short as possible and connected to the earthing point on the rear terminal at pin 18 Disconnection Device When powered from a mains supply this unit r...

Page 30: ...battery 5 Identify the part number of the coin cell which is clearly marked on one side of the cell 6 Firmly press the replacement coin cell into the holder 7 Reverse steps 1 3 for re assembly Battery...

Page 31: ...ogrammed to display operator prompts to accept a permissive signal before a delivery or batch can be commenced In normal operation press the buttons on the front panel to control the operation of the...

Page 32: ...tart or resume a batch The run led will illuminate Press the key to halt a current batch The instrument will go into pause mode and the run led will flash at a steady pace The incomplete batch can be...

Page 33: ...olling setpoint P CTRL Process control output Hold the key to display or edit the controlling setpoint DEVIAT Process flowrate deviation Hold the key to display or edit the controlling setpoint TO RES...

Page 34: ...is first installed the default is the Detail menu From that point the menu type is saved and restored on power cycle The menu type will need to be Detail to access the CAL MENU Setting the Batch Prese...

Page 35: ...or will illuminate and the setpoint values are changed in exactly the same way as in calibration set mode Data Logs The instrument will log up to 1000 deliveries batches if the real time clock option...

Page 36: ...ly for service personnel Typical examples are shown below DISPLAY DISPLAY DISPLAY RESET 15 25 LOG TM 16 01 15 25 LOG TM 2019 Description 2 1 S 515 MODEL The hardware model information Refer to Product...

Page 37: ...same as for the data logs This example shows 16 15 4 15pm on the 27th August 2019 This function is available only if the instrument has the real time clock option CLASS 3 FLASH V 019 The instrument Cl...

Page 38: ...cess line is independent of the main flow Tune Mode CAL MODE ONLY This mode is only accessed from within calibration mode and allows the operator to view a concise list of key paramaters and gain imme...

Page 39: ...ed as a ratio of the net combined flow 0 to 80 range i e Blend 2 Mode The desired blending ratio set point RATIO is set via the front panel or serial communications The PI controlled output signal is...

Page 40: ...BAND and I TIME to be programmed and then a Process Flow P FLOW setpoint value to be entered The next items in the menu are the actual live process variable and the deviation from the target value so...

Page 41: ...e when a small step change of the setpoint is introduced When this occurs double the value of the P BAND 5 Next set the I TIME to 20 seconds and gradually decrease the value until the system again beg...

Page 42: ...trol valve from within calibration primarily for tuning and commissioning purposes The RUN led is illuminated while the On Off valve is open The type of flow control while the valve is open is depende...

Page 43: ...ve or a variable speed drive Main Flow Proportional Control Valve Frequency Input 1 Process Flow Flowmeters Analog Output 1 Frequency Input 2 Example of Batch Blend 1 Configuration Relay 1 On Off Valv...

Page 44: ...onnect Permissive is scrolled on the display if the permissive circuit is not closed The Permissive Input feature can be enabled or disabled within the Parameters section of calibration Starting a Bat...

Page 45: ...INT prompt in the main menu can be used to initiate the printing of a delivery docket The key can be used to scroll through the main menu items or the key can be used to step directly to the HOLD SET...

Page 46: ...d Acceptable Total The open collector outputs can be assigned to activate whenever one of the flow errors occur Refer to Instrument Settings on page 46 for more details A No Flow or Unexpected Over Fl...

Page 47: ...Reset is programmed a new batch is commenced each time the key is pressed Figure 11 Batch Operation with Manual or Automatic Reset RESET RUN Run Run Stop Preset Qty Reset Run Reached Count Up Batch T...

Page 48: ...will flash while the instrument is waiting to automatically restart Figure 12 Batch Operation with Automatic Restart Run Run Stop Preset Qty Run Reached Count Up Batch Total PAUSE Relay 1 Relay 2 Pum...

Page 49: ...parameter Display only you can display the parameter but you cannot change the setting Programmable you can change the setting of the parameter in Calibration Set mode Password protected you can chan...

Page 50: ...ers and you must use the CAL switch on Logic Input 4 to access the Cal switch protected parameters Use the following procedure to enter Calibration Set mode 1 Press to scroll to the CAL MENU prompt 2...

Page 51: ...ument illuminates both the Cal and Set indicators 8 Edit the instrument parameters as required The programmable values are indicated by the flashing display To change a numerical value press to increa...

Page 52: ...y such as the choices of ODD EVEN or NONE for the communications parity bit checking Press or to change the option You can scroll through the options in either direction to make a selection as shown b...

Page 53: ...ed and assigned to one of the 515 communication ports The prompt to hold the Reset key to print the configuration report HOLD RST CONFIG PRINT is found at the end of the Model Info menu described in M...

Page 54: ...TYPE POINT HYST DELAY OUT1 4 20mA PULSE selection PT MIN PT MAX FUNC OUT2 RETRANS OP ERR OP CTRL WIDTH PULSE CTRL MODE OR P BAND P FLOW SP P FLOW value DEVIAT value I TIME OR OR P FLOW RANGE P BAND I...

Page 55: ...t any point to return to the main calibration menu Press at any I O assignment position to move to the next I O assignment in the submenu eg pressing on ALRM1 will move you to ALRM2 if it exists DISPL...

Page 56: ...ed by the CAL switch if any instrument setting has an access level of CAL Switch Protected To edit the units the correct password must be entered or CAL switch used on entry to EDIT mode Press or to s...

Page 57: ...nu Process Flowrate variable It can be determined by setting the process control setpoint to 100 whilst in LOCAL mode and observing the flowrate P BAND The proportional band of PI control algorithm En...

Page 58: ...required batch operation mode PRESET Preset delivery ON OFF Manual delivery RELEASE Release flow loop tuning only available in calibration mode Press or to select either PRESET ON OFF or RELEASE Refer...

Page 59: ...c restart time determines the time that will elapse between the end of one batch and the start of the next A value of zero disables the auto restart feature Enter the value in seconds T OUT SEC The ba...

Page 60: ...in the engineering units of the batch preset DIRECT ACCES If the direct access is enabled then the operator is able to enter edit mode for the batch preset and flow parameters directly from the main...

Page 61: ...auto overrun compensation is disabled Enter the value in the engineering units of the assigned variable UNITS PARAMS INPUTS OUTPUTS ALARMS COMMS TM LOG SETUP TEST END SET UNITS PARAMS INPUTS OUTPUTS A...

Page 62: ...tortion in the input readings of the rate The instrument has a digital filter that averages out these fluctuations As a guide to the degree of filtering to use the following table shows the response t...

Page 63: ...mber of pulses from the flowmeter per unit of volume or mass The K factor cannot be 0 zero NO PTS FINP1 FINP2 This parameter is available for viewing and editing only when the correction type is set t...

Page 64: ...is the approximation that the instrument uses Enter the lowest correction factor frequency as FREQ01 and proceed up to the highest frequency You can press the key to skip the non linear points and go...

Page 65: ...uired PULSE OUTn or 4 20 If above function is set for retransmission you can assign any of the main menu variables to an output The nature of the output depends on the assigned variable Totals are out...

Page 66: ...rmation see Output Pulse Factor on page 56 The output pulse factor cannot be 0 zero PT MIN OUTn PT MAX OUTn The Output Minimum Point and Maximum Point are available for viewing and editing only when t...

Page 67: ...on exists The alarm switches off when the alarm condition no longer exists However you may need to configure external alarm devices that require acknowledgement for cancelling an alarm Equipment Failu...

Page 68: ...rm toggles continuously on and off when the process variable is close to the setpoint For a high alarm the alarm activates when the value of the variable rises above the alarm setpoint and deactivates...

Page 69: ...ol NONE If a port is not being used set the protocol to NONE For the selected port press or to select the desired protocol BAUD COM n The Baud setting is the speed of the communication port in data bi...

Page 70: ...continues to log data at the correct times RTU DATA The Modbus RTU data format for the 2 register 4 byte values can be set as either floating point or long integer values Use or to select FLOAT or IN...

Page 71: ...for the real time clock This parameter is programmed in Month Day format for both European and American date formats CLOCK H MIN The Clock H MIN setting is the current time in hours and minutes for th...

Page 72: ...PRINT prompt in the main menu Press or to select ENABLE or DISABLE LAST D NUM This defines the last delivery number so the delivery number counting continues from this value Note this parameter is ac...

Page 73: ...e Display Timeout period defines the delay for the Display Timeout mode if it is enabled The display timeout period can be from 10 to 99 seconds RESET ACCUM The Reset Accumulated Totals function clear...

Page 74: ...r DISABLE RATES DP This parameter sets the maximum number of decimal places for displaying or printing main menu rates TOTALS DP This parameter sets the maximum number of decimal places for displaying...

Page 75: ...ulse train with a pulse width as set for the particular output in the Outputs menu OFF no output For a 4 20mA output such as a rate the output is as follows HI the output is set to 20mA LO the output...

Page 76: ...s a new battery Set the current time and date in the TM LOG menu to clear the error message and to continue data logging at the correct times Note The instrument can continue operating with a failed b...

Page 77: ...You have tried to assign a particular protocol type to more than one serial communication port The instrument has set the protocol to NONE Preset Over Limit Max Set You have exceeded the preset limit...

Page 78: ...Instrument Calibration 68 515 BR03 15 August 2021...

Page 79: ...rface and protocols are selected during calibration COM 1 RS 232 Port The COM 1 RS 232 port provides communication between the instrument and one other device such as a host computer or a printer Note...

Page 80: ...tion in place of the RS 485 port if Modbus TCP IP connection is required In the programming communication settings COM 2 should be set to RTU Modbus 19200 Baud rate even parity and 1 stop bit For furt...

Page 81: ...l on page 84 for full details Simple ASCII Protocol Note Not all ASCII commands are applicable for Batch Controller applications This simple ASCII protocol requires that all requests are initiated wit...

Page 82: ...process variables at the time of the last exit from the calibration edit mode There is only one last edit log therefore if a number is included in the request the instrument ignores the number and ret...

Page 83: ...equest asks the instrument to return the value of one or more requested variables All totals are transmitted as accumulated totals Variables Request and Response Example The following request is for t...

Page 84: ...owing message asks the instrument with address 001 to return the number of logs that the instrument stores A 0 0 1 2 0 0 2 0 3 1 4 1 8 2 5 0 0 0 0 L F C R 6 1 1 6 M W h E N E R G Y L F C R 1 6 5 7 3 M...

Page 85: ...d as a part of the header as it is with the header for all command responses Instrument Information Response Example The following message asks the instrument with address 001 to return the general in...

Page 86: ...rmat but for a non existent option it returns only the message header For example if the instrument received the following request variables message A001 RVT it will return only the header because the...

Page 87: ...e One of four possible events can occur from the master s query If the slave device receives the query without a communication error and can handle the query normally it returns a normal response If t...

Page 88: ...egister 07 Read status register Obtain the content of 1 byte status register 16 Preset data register s Preset one or more 2 byte data registers Code Name Description 01 Illegal function The function c...

Page 89: ...sters represent different data types as specified in the tables I Integer 2 bytes Holding Register L Long Integer 4 bytes 2 registers P Programmable Format 4 bytes 2 registers The Programmable Format...

Page 90: ...ine Flowrate R P 9 Process Line Mass R P 11 Process Line Flowrate R P 13 Process Mass Ratio R P 15 Process Flowrate Ratio R P 17 Process Control Output R P 19 Process Flowrate Deviation R P 21 Preset...

Page 91: ...calculations 10 process parameters out of range 11 input is over limit 12 no flow error detected 13 overflow error detected 14 leakage error detected 20 system failure 21 power supply is low 22 new or...

Page 92: ...ation 1 RTU controlled by Modbus register 46 B0 relay 1 LSB B1 relay 2 B2 relay 3 B3 relay 4 R W I 48 Delivery Number Provides the delivery number batch record for a stored transaction determined by M...

Page 93: ...c The usage of these parameters can be dependent on other instrument settings For full description please refer to the Modbus Accessible Parameters on page 50 Register Name Comments Read Only or Read...

Page 94: ...ions Protocol options for the RS 232 or RS 485 port A list of log report types and printer types available at the end of the TM LOG calibration menu Report Types The list of report types is as follows...

Page 95: ...le unit value etc Custom Footer Lines separation line Note that blank header and footer lines are not printed Instrument Serial Number and Unit Tag The instrument serial number and unit tag is the sam...

Page 96: ...eader Lines Instrument Serial No Tag Logged Delivery No number Date Time Status Variable unit value Variable unit value etc Custom Footer Lines separation line Log Report Printing As there is the like...

Page 97: ...n 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 i e separation line Del No Data Not Available separation line De...

Page 98: ...th this printer to check for paper status before printing If a print is attempted but there is no paper the PAPER OUT message will be scrolled The instrument will continue to poll the printer for pape...

Page 99: ...he input signal K factor The K factor is a constant value associated with frequency type flowmeters It is a scaling factor used in calculations to determine flow rate Linear Correction A scaling of th...

Page 100: ...90 515 BR03 15 August 2021...

Page 101: ...hanical relays only 2 2 electromechanical and 2 solid state relays 3 Solid state relays only Power Supply U Inputs for 12 28VDC and 100 240 VAC 50 60Hz Previous Models A 110 120 VAC E 220 240 VAC D In...

Page 102: ...in Instrument Information Request on page 75 Code Description Origin Code Identifies Distributor 00 Factory Default Application 01 Contrec Systems Pty Ltd Melbourne Australia 02 Contrec Limited West...

Page 103: ...indicates a generic analog input such as for density or level C indicates a user code input d indicates a density input F indicates a generic flow input such as for volume or mass H indicates a high...

Page 104: ...s Ethernet 515s are set as default to DHCP Dynamic Host Configuration Protocol which should allow your network router to automatically find and assign an IP address to the instrument providing there a...

Page 105: ...enter this into the Host Name IPv4 Address tab within DataMod s Modbus Connection Settings as per Figure 17 Ensure all other settings are correct as per the Datamod User Guide and the 515 Ethernet Gui...

Page 106: ...96 515 BR03 15 August 2021...

Page 107: ...ntrol 33 BATCH key 22 batch limit 24 batch modes 31 batch preset common values 24 batch processes 36 battery failed 66 life 60 new 66 battery replacement 20 battery type 20 baud rate 59 C CAL switch p...

Page 108: ...uipment failure alarm 57 error messages 66 Ethernet COM 2 port 19 70 exception codes 81 Exception Status 73 F features 1 flash driver port assignment 60 format date 61 frequency input connection 13 fr...

Page 109: ...0mA 14 digital 15 pulse factor 56 outputs menu 54 P panel LEDs 22 mounting 9 rear 10 parameter CAL switch protected 39 display only 39 not visible 39 password protected 39 programmable 39 parameters m...

Page 110: ...4 setpoint alarm 58 settings instrument 46 setup menu 62 shielding 19 snubber 17 software configuration tool 4 specifications 7 standards 5 starting a batch 34 status LEDs 22 stop bits 59 STOP key 22...

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