515 BF03 Om

Model 515 Flow Computer
Operation Manual
Application BF03
Batch/Flow Controller
for
Mass Frequency Flowmeters
15 August 2021
Model 515 Flow Computer - Operation Manual
© Contrec Ltd 2021

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
Red Hat. Portions created by Red Hat are Copyright © 1998, 1999, 2000 Red Hat, Inc.
(http://www.redhat.com). All rights reserved
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: sales@contrec.co.uk
Website: www.contrec.co.uk
Contrec Systems Pty Ltd

5 Norfolk Avenue Ringwood, Melbourne 3134 AUSTRALIA
Tel: +61 4 413 505 114
Email: info@contrec.com.au
Contrec - USA, LLC

916 Belcher Drive Pelham AL 35124 USA
Tel: +1 (205) 685 3000 Fax: +1 (205) 685 3001
Email: contrec@contrec-usa.com
Publication No: 515-BF03-OM - 15 August 2021

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 BF03 - 15 August 2021 iii

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.
iv 515 BF03 - 15 August 2021

Contents
1 Introduction
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Displayed Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Main Menu Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Isolated Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Relay Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Specifications
Specification Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Installation & Maintenance

Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cleaning and Decontamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Panel Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Rear Panel 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
4-20 mA Output Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Digital Output Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Control Relays (Alarms) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
RC Network for Interference Suppression . . . . . . . . . . . . . . . . . . . . . . 17
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
COM-1 RS-232 Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
COM-2 RS-485 Port Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
COM-2 Ethernet Port Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Mains Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Earthing and Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Disconnection Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
515 BF03 - 15 August 2021 v

Battery Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4 Operation
Front Panel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Default Variable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Front Panel Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Main Menu Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Detail and Basic Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Setting the Batch Preset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Setting the Flow Control Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Data Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Model Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Flow Control Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Local Flow Control Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Loop Flow Control Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Loop Tuning Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Tuning the Control Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Batch Operation Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Preset Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
On-Off Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Release Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Batch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Operation Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Safety and Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Starting a Batch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Stopping a Batch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Resetting a Batch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Printing a Delivery Docket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Logic Input Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Batch Flow Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Batch Control Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5 Instrument Calibration
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Calibration View Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Calibration Set Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Changing the Instrument Settings . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Program Backup & Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Backup via 500 Series Program Manager . . . . . . . . . . . . . . . . . . . . . . 41
Printing Configuration Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Upload and Clone of Application Software . . . . . . . . . . . . . . . . . . . . . 41
Calibration Menu Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Instrument Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Units of Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
vi 515 BF03 - 15 August 2021

Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Time Settings and Data Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
General Setup Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Test Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
System Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Warning Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Prompt Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6 Communications
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Hardware Interconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Protocols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Simple ASCII Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Requests Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Instrument Responses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Corrupted or Invalid Requests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Modbus RTU Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
List of Data Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Printer Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Types of Printouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Printer Data Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Appendix A Glossary
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Appendix B Model Numbers

Product Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Custom Version Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Application Information Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Appendix C Ethernet Port & Setup

Ethernet Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Connecting 515 Ethernet to Networks/Routers . . . . . . . . . . . . . . . . . . . . . 92
Connecting DataMod via Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
515 BF03 - 15 August 2021 vii

viii 515 BF03 - 15 August 2021
List of Figures
1 Typical Application Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2 500 Series Instrument Panel Mounting . . . . . . . . . . . . . . . . . . . . . . . 9
3 Rear Panel Connections - Original . . . . . . . . . . . . . . . . . . . . . . . . 10
4 Rear Panel Connections - New RS-485 Version . . . . . . . . . . . . . . . . . 10
5 Rear Panel Connections - New Ethernet Version . . . . . . . . . . . . . . . . . 11
6 Logic Inputs Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . 14
7 Output 4-20 mA Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . 15
8 Output Pulse Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . 15
9 Relay Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
10 RS-485 Interface Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
11 Batch Operation with Manual or Automatic Reset . . . . . . . . . . . . . . . . 35
12 Batch Operation with Automatic Restart . . . . . . . . . . . . . . . . . . . . . 36
13 Calibration Menu Tree Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 42
14 Calibration Menu Tree Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 43
15 RS-232 Cable Connections to a Computer . . . . . . . . . . . . . . . . . . . . 67
16 RS-485 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
17 DataMod - Modbus Connection Settings . . . . . . . . . . . . . . . . . . . . . 93
515 BF03 - 15 August 2021 ix

x 515 BF03 - 15 August 2021
Chapter 1
Introduction
Features
• Tailored for mass frequency flow inputs
• Single or Dual stage control
• Preset or manual On-Off modes
• Easy access to batch and flow rate presets
• No-flow, leakage and overflow error detection
• Remote RUN/STOP/RESET functions
• Allows for permissive with prompt
• 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 second language and user tags
• Pulse width and scaling of pulse output
• 4-20 mA retransmission
• Available protocols on communication ports including Printers, Modbus
RTU and TCP/IP
• Front panel adjustment of 8-24 V DC output voltage
• Backlit display with LCD backup
Overview
The 515 BF03 application is a batching flow controller for delivery of preset
quantities at preset flowrates using a mass frequency input. Batch control
can operate in preset or on-off modes, while flow control can be set to local
(manual) or PI loop mode.
This application provides the operator with clear local readout including
flowrate deviation and can be controlled via communications in more
automated systems. There is quick access to commonly used preset values
directly from the front panel if access has been authorized.
515 BF03 - 15 August 2021 1

Introduction
The PI control of the process flow is via a 4-20mA proportional valve or

pump controller. It has integral wind-up protection, a deadband, output hold
and ramp time that can be programmed to reduce wear on valves and
actuators and provide for bumpless operation.
Calculations
The total and flowrate are derived from accurately measured frequency and
the number of received pulses.
mass = pulses / k-factor
mass flow = frequency / k-factor
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.
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.
Main Menu Variables
Main Menu Default Variable

Variables Units Type
Mass kg Total
Process Flowrate kg/min Rate
Process Control Output % Rate
Process Flowrate Deviation % Rate
Preset Quantity * --- ---
* These variables are logged and can be printed but are not shown in main menu.
2 515 BF03 - 15 August 2021

Introduction
Units of Measurement
In the 500 Series instruments there is a wide range of available units of

measurement to be selected from. These can be viewed and selected either
during initial Software Configuration via the 500 Series Program Manager
(see below) or from within the instrument’s calibration settings (if access
has been granted) as per Units of Measurement on page 44.
Communications
There are two communication ports available as follows:
• COM-1 RS-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-isolated outputs can retransmit any main menu variable. The type
of output is determined by the nature of the assigned variable. Totals are
output as pulses and rates are output as 4-20 mA signals. One output is
standard, a second output is available as an option.
Relay Outputs
The relay outputs 1 and 2 are used to control the flow of product for each
delivery. 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 BF03 - 15 August 2021 3

Introduction
Software Configuration
The instrument can be programmed to suit the particular application needs
and the flexible I/O can be assigned as required. Program settings can be
changed either via the front panel (depending on assigned access levels) or
via the 500 Series Program Manager (500-PM software).
The 500-PM software 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 and
text, access levels and more.
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.
The instrument stores all set-up parameters, totals and logged data in non-
volatile memory with at least 30 years retention.
Analog Frequency Relay 1

Output 1 Input
Example
Batch/Flow
Configuration
Proportional Mass On-Off Flow

Control Device Flowmeter Valve
Figure 1 Typical Application Diagram
Approvals
This instrument conforms to the EMC-Directive of the Council of
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.
In order to comply with these standards, the wiring instructions in Chapter

3 - Installation & Maintenance must be followed.
4 515 BF03 - 15 August 2021

Introduction
FCC Declaration
This equipment has been tested and found to comply with the limits for a
Class A digital device, pursuant to Part 15 of the FCC Rules. These limits
are designed to provide reasonable protection against harmful interference
when the equipment is operated in a commercial environment. 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. Operation of this
equipment in a residential area is likely to cause harmful interference, in
which case the user will be required to correct the interference at his own
expense.
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.
Unauthorized changes or modifications could void the user's authority to
operate the equipment.
This device complies with Part 15 of the FCC Rules. Operation is subject to
the following two conditions: (1) this device might not cause harmful
interference, and (2) this device must accept any interference received,
including interference that might cause undesired operation.
515 BF03 - 15 August 2021 5

Introduction
6 515 BF03 - 15 August 2021

Chapter 2
Specifications
Specification Table
Operating Environment Frequency Input (General)
Temperature +5 °C to +40 °C (standard - no coating) Range 0 to 10 kHz for Pulse input type
-20 °C to +60 °C (with conformal coating) 0 to 5 kHz for Coil & NPS input types
-30 °C to +60 °C (ExD housing with heater) Overvoltage 30 V maximum
Humidity 0 to 95% non condensing (conformal Update Time 0.3 sec
coating)
Cutoff frequency Programmable
5% to 85% non condensing (no coating)
Configuration Pulse, coil or NPS input
Power Supply 100-240 V AC (+/-10%) 50-60 Hz (+/-
10%) or 12-28 V DC Non-linearity Up to 10 correction points
Consumption 10 W (max) Overvoltage category II
Pulse
Protection Sealed to IP65 (Nema 4X) when panel
mounted Signal Type CMOS, TTL, open collector, reed switch
Dimensions 147 mm (5.8") width Threshold Signals switch below 1.3 & above 2 volts
(panel option) 74 mm (2.9") height
170 mm (6.6") depth (behind the panel) Coil
Signal Type Turbine and sine wave
Display Sensitivity 15 mV minimum amplitude (typical)
Type Backlit LCD with 7-digit numeric display
and 11-character alphanumeric display NPS
Digits 15.5 mm (0.6") high Signal Type NPS sensor to Namur standard
Characters 6 mm (0.24") high
LCD Backup Last data visible for 15 min after power Logic Inputs
down Signal Type CMOS, TTL, open collector, reed switch
Update Rate 0.3 second Overvoltage 30V maximum
Non-volatile Memory Relay Output

Retention > 30 years No. of Outputs 2 relays plus 2 optional relays
Data Stored Setup, Totals and Logs Voltage 250 volts AC, 30 volts DC maximum
(solid state relays use AC only)
Approvals Current 3A maximum - mechanical relays
Interference compliance 1.5A maximum - solid state relays
Enclosure IECEx, ATEX and CSA approved
enclosures available for hazardous areas Communication Ports
Ports COM-1 RS-232 port
Real Time Clock (Optional) COM-2 RS-485 or Ethernet port (optional)
Battery Type 3 volts Lithium button cell Baud Rate 2400 to 19200 baud
- For Issue 7 option card, type CR2450N Parity Odd, even or none
manufactured by Renata only
Stop Bits 1 or 2
- For conformal coated ‘C’ version, type
BR2032 manufactured by Panasonic only Data Bits 8
- For non-conformal coated versions, type Protocols ASCII, Modbus RTU, Modbus TCP/IP
BR2032 and CR2032 manufactured by (Ethernet Port), Printer
Panasonic or Sony
Battery Life 5 years (typical)
515 BF03 - 15 August 2021 7

Specifications
Transducer Supply
Voltage 8 to 24 volts DC, programmable
Current 70 mA @ 24 V, 120 mA @ 12 V maximum
Protection Power limited output
Isolated Output
No. of Outputs 2 configurable outputs
Configuration Pulse/Digital or 4-20 mA output
Pulse/Digital Output
Signal Type Open collector
Switching 200 mA, 30 volts DC maximum
Saturation 0.8 volts maximum
Pulse Width 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.
8 515 BF03 - 15 August 2021

Chapter 3
Installation & Maintenance
Installation Instructions
The safety of any system incorporating the equipment is the responsibility
of the assembler of the system and should be installed such that there is no
risk of impact damage.
This instrument is intended for fixed installation only, e.g. within a panel or
cabinet, and is not intended for desktop use. It is not suitable for outdoor use
unless fitted into an appropriate outdoor enclosure with a minimum type 3,
IP54, rating. The instrument has a ‘Pollution degree II’ rating.
Cleaning and Decontamination

For general maintenance or to clean an instrument suitable for return to a
service 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 marking label can
be cleaned with 35% Isopropanol or mild detergent.
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 515 instrument.
Side View Top View RS232
Rear Connectors
22 mm 25 mm Port
145 mm 138 mm
Front
74 mm
66 mm
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 BF03 - 15 August 2021 9

Electrical Connection
Rear Panel Connections
Note: Depending on the specification and age of the instrument,

there are different versions of the upper option card. Ensure the instrument
is wired as per the correct terminal designation printed on the rear of the
instrument bezel and below.
Figure 3 shows the connections on the original 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
On the newer rear panel option cards the instrument relays 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).
Note: On these option cards the 6 way relay terminal block is ORANGE.
Figure 4 shows the new option card with the RS-485 port (terminals 19-21).
Figure 4 Rear Panel Connections - New RS-485 Version
10 515 BF03 - 15 August 2021

Figure 5 shows the new option card with the optional Ethernet port in place
of RS-485 port (terminals 19-21).
Figure 5 Rear Panel Connections - New Ethernet Version
Terminal Designations
Terminal Label Designation Comment Terminal Label Designation Comment

1 FINP 1+ Frequency Input 1+ Mass Flow Input 19 + RS485 (+)
RS485 Optional RS485 port may
2 FINP 2+ Frequency Input 2+ Not used 20 COM-2 - RS485 (-) be replaced by Ethernet
port port.
3 SG - Signal ground 21 G RS485 ground
4 EXC V 1+ Excitation Term 1+ Not used 22 1+ Switch 1 Remote Run
5 EXC V 2+ Excitation Term 2+ Not used 23 2+ Switch 2 Remote Stop/Reset
6 EXC V 3+ Excitation Term 3+ Not used 24 LOGIC 3+ Switch 3 Permissive Input
INPUTS
7 + Analog Input ch 1 (+) CAL Switch – In field
AINP1 Not used 25 4+ Switch 4
access protection
8 - Analog Input ch 1 (-)
26 C- Signal ground
9 + Analog Input ch 2 (+)
AINP2 Not used 27 + Output ch 1 (+)
10 - Analog Input ch 2 (-) OUT1 Process control output
28 - Output ch 1 (-)
AINP3 Not used 29 + Output ch 2 (+)
12 - Analog Input ch 3 (-) OUT2
30 - Output ch 2 (-)
AINP4 Not used Term 31 - Common 1-4
14 - Analog Input ch 4 (-) 31 RC Relay Common 1-2
on legacy option card
15 Vo + 8-24 volts DC output Overload protected
32 R1 Relay 1 Single Stage Control
16 G - DC Ground
33 R2 Relay 2 Dual Stage Control
17 Vi + DC power input DC power in 12-28V RELAYS
34 R3 Relay 3
18 SH E Shield terminal
35 R4 Relay 4
E E Mains ground
AC power in 100- Term 36 only available on
AC 36 RC Relay common 3-4
N N Mains neutral new style option card
MAINS 240VAC
A A Mains active RS232 COM-1 port 9-pin serial port
515 BF03 - 15 August 2021 11

Terminal Wiring Insulation
Terminals 1-30 are all rated at <35Vdc and wiring with basic insulation is
adequate.
Use copper conductors only.
Relay Wiring
Relay terminals are 31-35 or 31-36 depending on the version of option card
fitted. When controlling circuits powered by mains, or voltages >35Vdc, it
is necessary to use UL/CSA approved cabling with supplementary
insulation and a current capacity suitable for the connected circuit.
(0.75mm², 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 cabling with supplementary insulation and

copper conductors. A minimum cable cross section area of 0.75mm² (18
AWG) is required. However, this must be selected with respect to the
installed overcurrent protection device and in accordance with the local
relevant 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.
12 515 BF03 - 15 August 2021

Inputs
Frequency Input Connection
Connect pulse or frequency input signals from devices such as: TTL,
CMOS, open collector, reed relay switch, coil and Namur proximity switch,
as shown below. For better signal integrity, it is recommended to use
shielded cable. Refer to Terminal Designations on page 11 for specific
terminal numbers for this application.
Squarewave, CMOS or TTL

Frequency
+ Input
(FINPn)
3 Signal Ground
18 Shield
Open Collector
+V
NPN PNP
Frequency Frequency
+ Input + Input
(FINPn) (FINPn)
3 Signal Ground Signal Ground

3
18 Shield Shield
18
Reed Relay Switch

Frequency
+ Input
(FINPn)
3 Signal Ground
18 Shield
Coils - with 15mV minimum amplitude (typical)

Frequency
+ Input
(FINPn)
~
3 Signal Ground
18 Shield
Namur Proximity Switch

NPS 15 Vo +8V DC
Frequency
+ Input
(FINPn)
18 Shield
515 BF03 - 15 August 2021 13

Logic Input Connection

These inputs are designed to be connected to CMOS, TTL, open collector
signals or a voltage free contact switch. A minimum activation time of
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.
A remote push-button key can be connected to the Logic Inputs as shown

below. Logic Input Control on page 34 describes the function of the
inputs.
Logic Input
22 1+
23 2+
24 3+
25 4+
26 C-
Signal Ground
Figure 6 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.
CAUTION
Due to the dual-purpose nature of the outputs, take care not to
set the output as an open collector pulse type signal when
connected to a 4-20 mA loop circuit.
4-20 mA Output Connection

Figure 7 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
14 515 BF03 - 15 August 2021

515
+
4-20 mA
Output DC supply
(OUTn) 9-24V
-
Load
18
Shield
Figure 7 Output 4-20 mA Connection Diagram
Digital Output Connection

Figure 8 shows a connection example for a pulse output. Output channel 1
uses terminals 27 (+) and 28 (-). Output channel 2 uses terminals 29 (+) and
30 (-).
500
Vo +8...24V DC 15
External Load
Resistor 10K
Logic Input
+
Open Pulse Output

Collector (OUTn)
Output
DC Ground 16
18
Shield
Figure 8 Output Pulse Connection Diagram
515 BF03 - 15 August 2021 15

Control Relays (Alarms)

The standard instrument has two relays, which are used for the dual stage
batch control. The relays can drive external devices such as valves, pump
circuits or external relays.
The advanced option has two extra relays that can be freely assigned as
alarm relays. The operation of alarm relay(s) can be set to various modes as
described in Alarms on page 55. On the newer option card the separate
common terminal for relays 1 and 2 and another common terminal for relays
3 and 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 (open) contacts which open (close) when the instrument
displays any error message as listed in Error Messages on page 64, or if
there is a loss of power to the instrument.
The output characteristics of the relays are:
Maximum Voltage 30 volts DC or 250 volts AC

Maximum Current 3 A for EMR, 1.5A for SSR
Note: Solid state relays (SSR) use AC voltage only.
Relay 1 500
RC Relay 1-2 Common
1-2
MOV Control Supply
R1
Relay 2
MOV Control
R2
Relay 3
MOV Alarm/Load
R3
Relay 4
MOV Alarm/Load
R4
Supply
RC
3-4 Relay 3-4 Common
Figure 9 Relay Connection Diagram
16 515 BF03 - 15 August 2021

RC Network for Interference Suppression

When driving inductive loads with the relay outputs, it is recommended to
use RC suppression networks (often called “Snubbers”), fitted at the load
end, for the following reasons:
• To limit the amount of electrical noise caused by arcing across the
contacts, which may, in extreme cases, cause the microprocessor to act
erratically or cause other unwanted interference with connected signals.
• To protect the 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 the electrical industry. The values of R and C are
dependent entirely on the load. However, if the user is unsure of the type of
snubber to use, values of 0.25 F and 100  will usually suffice. Note that
only UL and mains approved RC suppression networks should be used.
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 BF03 - 15 August 2021 17

Communications
The communication protocols are described in Communications on
page 67.
COM-1 RS-232 Port

The COM-1 RS-232 port has a 9-pin DB female connector and has the
following pinout:
6 7 8 9
1 2 3 4 5
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 Not used
Note: The instrument does not require a null-modem cable for connection
to a personal computer. Refer to Hardware Interconnection on
page 67 for cable 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 10 shows the connection of several instruments to a computer using
the RS-485 port.
Host Twisted Pair

Computer
+
Load
120 ohms
-
Comms
Gnd
Gnd Gnd
+ - + -
19 20 21 19 20 21
Instrument Instrument
Figure 10 RS-485 Interface Connections
18 515 BF03 - 15 August 2021

COM-2 Ethernet Port Option

An Ethernet module is an available option, 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.
Mains Connection
Earthing and Shielding
A case earthing point is provided via the mains inlet. Note that this earthing
point is for the case only and there is electrical isolation between this point
and all electronic circuits. For EMC purposes, or when the instrument is
connected to mains, this point must be connected to a good earth.
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.
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.
Maintenance Instructions
Occasionally it may be necessary to open the unit in order to change the Real
Time Clock battery. No other service operations are permitted. In order to
perform these operations and maintain safety it is essential to follow the
instructions below. 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 BF03 - 15 August 2021 19

Battery Replacement
INSTRUMENT MUST BE POWERED DOWN
1. Remove the top row of terminal blocks (19-36) and any communication
cables if applicable.
2. Remove the two pan head machine screws on each side of the rear panel.
3. Withdraw the option card from the instrument.
4. Firmly press the battery holder tab to release the coin cell 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 Type
Only the battery type and manufacturer stated below

should be used.
1. Instruments manufactured with issue 7 option card – CR2450N,

Manufacturer RENATA ONLY*
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.
20 515 BF03 - 15 August 2021

Chapter 4
Operation
Front Panel Operation

This instrument is a batch controller that is capable of controlling the rate of
flow during a delivery. Batch control can be via a PRESET or an ON-OFF
mode, while flow control can be via a LOCAL (manual) or LOOP (PI
control) mode. The controller can be used in any combination of these
modes to achieve the required functionality.
The instrument can also be programmed 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 batch controller or to display the values recorded and
calculated by the instrument.
There are several categories of information that the instrument can display:
• Totals
• Rates
• Batch preset values
• Flow control values
• Instrument settings
For each total, there is an associated rate as follows:
Total Rate
Mass Mass Flowrate
515 BF03 - 15 August 2021 21

Operation
Default Variable
In some applications, a particular variable is of more interest than others,

and for this reason a default variable can be assigned during instrument
calibration. The default variable is used in the following ways:
• Determines what the display returns to when the Stop key is pressed
while viewing other items in the main menu list.
• Determines what the display returns to if the display timeout option is
enabled and no buttons are pressed for the selected period (usually 30
seconds).
• Determines what is displayed on power up or exit of Calibrate mode.
Status LEDs
The status LEDs illuminate to show the following conditions:
Run Run Solid led: The instrument has a batch in progress.

Set Fast flashing led: Batch paused.
Alarm
Cal Slow flashing led: Waiting for valves to close.
Set 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.
Cal The instrument is in Calibrate View mode.
Front Panel Keys

RUN Press the RUN key to start or resume a batch. The run led will illuminate.
STOP Press the STOP 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 resumed or the STOP key can be held again to end the batch and the
run led will turn off. The STOP key is also used to stop the next batch if in
automatic restart count down, can be used to return the display directly to
the default variable (total) when scrolling through the main menu items and
can be used to acknowledge flow errors without resetting the total.
RESET Use the RESET key to step directly to the HOLD.SET - TO RESET prompt
within the main menu items. Holding SET at this point will clear the batch
totals or the DISPLAY key can be pressed to step onto the HOLD.SET - TO
PRINT prompt if the printer option has been selected.
The instrument makes three beeps when it resets the totals and two beeps
when a printout is started.
DISPLAY Press the DISPLAY key to step or scroll through the main menu items.
BATCH Hold the BATCH key to display the current batch preset value. Continue to
hold for two seconds to enter edit mode for the preset if access is authorised.
Pressing the BATCH key briefly displays the accumulated total.
22 515 BF03 - 15 August 2021

Operation
Main Menu Items
The main menu in this instrument consists of the following items. The
DISPLAY key is used to step or scroll through the list. The full menu can only
be viewed if the batch controller has been stopped and reset .
DISPLAY
Description Options

MASS Mass Hold the SET key to display (or edit) the batch
preset or briefly press to view the accum total
P-FLOW Process flowrate Hold the SET key to display (or edit) the
controlling setpoint
P-CTRL Process control output Hold the SET key to display (or edit) the
controlling setpoint
DEVIAT Process flowrate Hold the SET key to display (or edit) the
deviation controlling setpoint
TO RESET Reset delivery total Hold the SET key to manually reset the current
delivery (batch) total.
TO PRINT Only shown if a printer Hold the SET key to manually print a delivery
protocol is used. docket.
REPORT PRINT Only shown in Detail Hold the SET key to print log report as defined in
Menu if a printer the TM/LOG section of calibration.
protocol is used
LOGGED DATA Only shown in Detail Hold the SET key to display data logs as
Menu if real-time clock described in Data Logs on page 25.
option is installed
MODEL INFO Only shown in Detail Hold the SET key to display the Model
Menu information as described in Model Information
on page 26.
CAL MENU Only shown in Detail Hold the SET key to enter Calibration View
Menu mode as described in Calibration View Mode on
page 38.
515 BF03 - 15 August 2021 23

Operation
Detail and Basic Menu
The 515 instrument has the option to switch the main menu from the full
Detail menu to a Basic menu. The Detail menu includes all of the main
menu variables and the HOLD SET sub menu items as listed above. In the
Basic menu only the application or operator essential main menu variables
are shown. The main menu variables to be shown in the basic menu need to
be selected in the 500 Series Program Manager prior to the application
software being downloaded to the instrument. The 500 Series Program
Manager (500-PM) is Windows based configuration and resource tool for
the 500 Series and is freely available from the www.contrec.co.uk website.
To switch between the Detail and Basic menu, while in the main menu,
press and hold the DISPLAY and SET keys together for 5 seconds. When
switching to the Detail menu the display will briefly show:
display DETAIL MENU.
When switching to the Basic menu the display will briefly show:
display BASIC MENU.
When the application software 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 Preset

SET The batch preset can only be set while the instrument is in the idle state, i.e.
batch is complete or has been stopped and reset. Hold the SET key to
display the current preset value while viewing the total variable. The display
of the preset will change from view mode to edit mode after 2 seconds if
access has been enabled in calibration. Once in edit mode the Set indicator
will illuminate and the preset value can be changed in the same way as in
calibration set mode, see Changing Numeric Settings on page 40. The
SET key is used to exit edit mode.
Limit on Batch Size
To prevent accidental entry of large batch quantities, a maximum batch limit

can be programmed during calibration. The operator is then prevented from
entering a batch quantity which exceeds this value.
Common Preset Values
If the batching application continually uses a regular set of preset values

then quick access can be provided to these. In calibration, there is the
opportunity to enter up to 20 commonly used preset values.
24 515 BF03 - 15 August 2021

Operation
These can then be accessed whilst in batch edit mode (described above) by
pressing the DISPLAY key. The pre-programmed values will appear in the
order they were entered in calibration. The display will step through the
presets back to the currently entered value which can still be manually
edited. While displaying the desired preset value, press the SET key to
accept the value and exit edit mode.
Setting the Flow Control Setpoints

SET Hold the SET key to display (or edit) the controlling setpoint while viewing
one of the “rate” variables. The display of the setpoint will change from
view mode to edit mode after 2 seconds if access has been enabled in
calibration. Edit mode can not be entered if a “Preset” batch is in progress.
Once in edit mode the Set indicator 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 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.
When the number of log entries exceeds 999 the oldest log entry is
overwritten by the newest one.
View Data Logs
Use the following procedure to view the data that has been logged by the
instrument:
1. Press the DISPLAY key to scroll through the menu to the LOGGED DATA
prompt.
2. Hold the SET key.
The instrument displays the most recent log record first. The log record
number and corresponding delivery number are shown, for example LR-001
and DEL 1236.
1236
LR-001 DEL
3. Use the or keys to scroll to the delivery number or log record

of interest.
515 BF03 - 15 August 2021 25

Operation
4. Press the DISPLAY key to show the information stored in the selected log
record. Each log record consists of:
• time and date stamp,
• error code
• totals for the delivery.
5. While holding the DISPLAY key use the key to step through the stored
information.
6. While holding the DISPLAY key use the RESET key to print the data for the
displayed log if the printer option has been selected.
The following example shows the format of the time and date stamp at 15:25
(3:25 pm) on 16 January 2019. The day and month alternate with the year in
the bottom right hand corner.
15-25 15-25
LOG-TM 16/01 LOG-TM 2019
Model Information
The model information items display the hardware, software and

application versions of the instrument. This information is mainly for
service personnel. Typical examples are shown below.
DISPLAY
Description

2-1--S- The hardware model information.

Refer to Product Codes on page 89 for full
515 MODEL
information.
F----- The Application number and the assignment of the
inputs. Refer to Application Information Code on
BF03 INPUT
page 90 for more information.
3_0_000 The version of 500-Series Program Manager from
which the application software was compiled.
500-PM VERS
026357 The Customer version code for this installation. Refer
to Custom Version Codes on page 90 for more
CUSTOM VERS
information.
123456 The instrument serial number and unit tag. The serial
number is on the top line and unit tag is on the bottom
ABC123 S/N
left. Both items are entered when the instrument
application software is initially loaded. If the unit tag
is not used the default tag, UNIT, will be used.
26 515 BF03 - 15 August 2021

Operation
DISPLAY
Description

16-15 The time and date when the calibration of the

instrument was last edited. The format of the time and
EDITED 27/08
2019 date is the 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 The instrument Class and Flash (bootloader) version.
FLASH V-019
5 The number of power cycles that have occurred since
the application software was installed.
POWER CYCLE
1
The number of ‘watchdog timer’ (WDT) resets that
have occurred since the application software was
WDT RESET
installed. The WDT Reset count is only shown if a
WDT Reset has occurred.
HOLD.RST If the printer protocol is assigned to one of the
communication ports, the prompt to print the full
CONFIG PRINT
program configuration report will be shown. 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 SET at any time to exit from the Model information.
Flow Control Modes

This instrument can operate in the following flow control modes:
• Local (manual) mode
• Loop mode
• Tune mode (only available in calibration set mode)
Local Flow Control Mode

The desired process control output (P-CTRL %) is manually set via the front
panel or serial communications.
The output signal is used to control a proportional control valve or variable

speed drive to obtain the desired flow. In this mode the flow deviation
(DEVIAT %) is set to zero.
515 BF03 - 15 August 2021 27

Operation
Loop Flow Control Mode

The desired process flowrate set point (P-FLOW SP) is set via the front
panel or serial communications.
The PI controlled output signal is used to maintain the desired process

flowrate via a proportional control valve or variable speed drive.
Loop Tuning Mode

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 parameters and
gain immediate feed back. The Proportional
Band (P-BAND) and Integral Time (I-
Analog Frequency Relay
TIME) are entered to tune the system.
Output 1 Input 1 Output 1
For details on this method see below:

“Tuning the Control Loop”.
Process Flow The RELEASE prompt in batch mode is

used to open the On-Off control valve from
Proportional Flowmeter On-Off
Control Valve Control Valve within calibration.
Tuning the Control Loop
The Process Controller has a special control mode, within the Parameters
section of calibration, to assist in tuning the control loop. This mode
provides a concise list of key parameters and allows for immediate
feedback. The basic principle in tuning the loop is to gradually adjust the
Proportional Band (P-BAND) and the Integral Time (I-TIME) and observe
the response to a step change in the setpoint.
The tune menu provides for this by allowing the P-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 that the response of the system to a
setpoint change can be observed. Unless the menu is quit the program will
step back to start of the tuning menu so that new values of P-BAND and
I-TIME can be entered and the effect of a step change in the setpoint be
monitored.
28 515 BF03 - 15 August 2021

Operation
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
to Release Mode on page 30.
This sequence is used for Loop mode. The tuning procedure is as follows:
1. Before tuning the control loop it is essential to program in the correct
parameters for the flowmeters, including filtering.
2. The actual Process Flow Range (P-FLOW RANGE) should be measured
and entered. It is determined by setting the Control Mode to LOCAL,
Batch Mode to RELEASE, setting the Flow Setpoint (control output) to
100% (20mA) and then observing the steady state flowrate.
3. With the correct Process Flow Range entered and Batch Mode still set to
RELEASE the Control Mode should now be set to LOOP to continue the
tuning procedure.
4. With the Loop Error Deadband (D-BAND) and the Output Ramp Time
(R-TIME) set at zero, the I-TIME should be set to zero (disabled) and the
P-BAND set at 150%.
Gradually decrease the P-BAND value until the system begins to

oscillate 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 begins to oscillate when a small step change of the
setpoint is introduced. When this occurs double the value of the I-TIME.
6. The Deadband and the Output Ramp Time can now be programmed as
required.
The system should be tuned around the flowrate at which the eventual
system will operate. The stability of the loop should then be checked at
various flowrates and setpoints.
Batch Operation Modes

This instrument can operate in the following Batch operation modes:
• PRESET
• ON-OFF
• RELEASE (only available in calibration set mode)
Preset Mode
If the batch mode is PRESET the prestop and shut-off points are
determined by the instrument.
515 BF03 - 15 August 2021 29

Operation
The instrument can be set to count up from zero or down from the preset
value. A slow flow start feature and reduction of flowrate when approaching
the desired quantity 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.
On-Off Mode
If the batch mode is ON-OFF the shut-off point is determined by the

operator.
The instrument will operate in a count up direction. The slow flow start
feature can still be used, but in this mode starting and stopping is determined
by the operator and in this mode there is no End of batch output signal.
Release Mode
The RELEASE prompt in batch mode is used to open the On-Off control
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 dependent on the control mode at the
time. If in LOOP mode PI Loop flow control is activated.
For PI Loop tuning procedures that may need the flow to be “released” for
a considerable time it is important that the flow is directed to an
appropriately sized vessel.
If calibration is exited while in RELEASE mode the On-Off valve will close
and the batch mode will default to PRESET mode.
Batch Operation
Operation Configurations
For batch control this instrument can be used in three main configurations:
• Config 1. Using flow control output plus 1 control relay
• Config 2. Using flow control output only (no relays)
• Config 3. Using 2 control relays (no flow control)
30 515 BF03 - 15 August 2021

Operation
Configuration 1
Flow Control & 1 Relay The Hold Output feature can be used in this
configuration to provide a faster return to
the desired flowrate when the next batch is
started.
Frequency
The analog flow control output can be used
Analog Relay
Output 1 Input 1 Output 1 to operate either a proportional control valve
or a variable speed drive.
The On-Off control valve allows the system

Process Flow to achieve high accuracy batching.
Proportional Flowmeter On-Off
Control Valve Control Valve
Configuration 2
Flow Control Only (no relays) The Hold Output feature must be disabled in
this configuration as the system relies on the
proportional control valve to completely
stop the flow.
Frequency
While this system uses less hardware it is
Analog
Input 1 Output 1 not recommended when high accuracy
batching is required.
Process Flow
Flowmeter Proportional
Control Valve
515 BF03 - 15 August 2021 31

Operation
Configuration 3
2-Stage Relay Control (no flow control) The batch controller can also be used in a
conventional dual stage configuration. The
Control Mode should be set to Local and the
analog flow control output remains unused.
Parameters for slow start and prestop points

Relay 1 Relay 2 are provided to control the operation of
Example of
dual stage Main Flow Relay 2.
batching
Flowmeter Control Valve

A digital output can be programmed as a
pump control signal if required.
Control Valve Bleed Flow
Safety and Security
Before a batch or delivery can be commenced it may be imperative that

certain safety or security measures are in place. Interlocks, grounding
connections, secure keys and identification devices can be used to prevent
untrained or unauthorised personnel from operating the batch controller.
Connecting a Permissive
If this feature has been enabled, the Permissive Input on logic input 3
ensures that a closed circuit to the common terminal (0 volts) must exist
before a delivery can be started. A batch will not continue if the permissive
input is removed and can not be resumed until the permissive input is
restored. A prompt to ‘Connect 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 Batch
The delivery (batch) will start when the RUN key is pressed. The RUN led
will illuminate and the instrument will begin to totalise from zero or, if
programmed for PRESET and count down mode, the display will decrement
from the preset quantity.
The batch controller’s analog output and two relays can be used to control
the delivery of product. These are energised and de-energised as described
below.
32 515 BF03 - 15 August 2021

Operation
Stopping a Batch
The delivery (batch) can be stopped at any time by pressing the STOP key.
Once the process has been interrupted in this way it can be continued by
pressing the RUN key or the batch can be stopped completely by holding
the STOP key until the run led turns off.
When the process is in pause mode, the RUN led will flash to prompt the
operator to continue or abort the batch.
Resetting a Batch
The instrument can be programmed to reset by different means.

• After the end of a batch, the RESET key can be pressed to step directly
to the HOLD.SET - TO RESET prompt in the main menu list. Holding
the SET key at this point will reset the batch total. If the instrument is
programmed to count down, the display will revert to the preset value. If
it is programmed to count up or is operating in ON-OFF mode, the batch
total will clear to zero. The next batch cannot be started until the previous
batch total has been reset.
• If Auto Reset is enabled in the parameters section of calibration, the
batch total will automatically reset when the next delivery (batch) is
started.
Printing a Delivery Docket
If the print option has been enabled, a delivery docket can be printed by
different means. The print prompt can only be accessed or a printout
initiated if there is no delivery (batch) in progress.
• If the AUTO PRINT feature has been Enabled in the TM/LOG menu, a
delivery docket will automatically be printed at the end of each batch at
the same time that the delivery is logged. End of batch occurs when a
batch ends normally or if a batch is manually ended.
• The HOLD.SET - TO PRINT prompt in the main menu can be used to
initiate the printing of a delivery docket. The DISPLAY key can be used to
scroll through the main menu items or the RESET / PRINT key can be
used to step directly to the HOLD.SET - TO RESET prompt and then a
single press of the DISPLAY key will step onto the print prompt. If an
original printout has already been printed, a subsequent delivery docket
will include the text “(DUPLICATE DOCKET)”.
• Previous (logged) delivery transactions can be reprinted from within the
LOGGED DATA menu by scrolling to the desired DEL number, then
while holding the DISPLAY key, press RESET ( PRINT ) key to initiate a
reprint.
515 BF03 - 15 August 2021 33

Operation
Logic Input Control
This instrument allows for remote operation via the logic inputs on the rear
terminals. The logic input have the following functions:
• Logic Input 1 - Remote Run
• Logic Input 2 - Remote Stop/Reset
• Logic Input 3 - Permissive Input
• Logic Input 4 - CAL Switch - In field access protection
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.
For connection details, refer to Logic Input Connection on page 14.
Batch Flow Errors
The instrument has the ability to raise an alarm when it detects a loss of
flow, a quadrature input error, an unexpected/overflow or a leakage in the
system.
• No Flow Error - The no flow condition is detected when the flow
timeout expires during a delivery. There must not be a period of no flow
greater than the timeout value during the delivery.
• Unexpected/Over Flow Error - The overflow condition is detected
when the flow continues longer than the timeout period after the
controller has attempted to stop (or pause) the flow.
• Leakage Error - The leakage condition is detected when an amount
greater than the acceptable total is received without flow being initiated
by the batch controller.
The point at which these errors are detected is dependent on the values
programmed into the calibration parameters such as 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 on
page 44 for more details.
A ‘No Flow’ or ‘Unexpected/Over Flow’ error can be cleared by pressing

the STOP key without resetting the totals. A paused batch may be restarted
or the delivered total remain until a reset action is carried out.
If logging and/or printing is enabled, the highest priority Error/Exception

that occurred during the batch will be included as part of the recorded data.
Refer to Error Messages on page 64 for details on the order of priority.
34 515 BF03 - 15 August 2021

Operation
Batch Control Processes
The batch controller can be programmed to operate in various ways

including:
• Manual Reset (manual start).
• Automatic Reset (manual start).
• Automatic Restart for continuous batches (PRESET mode only).
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 44 for more details.
Manual and Automatic Reset
If Manual Reset the RESET key must be pressed at the end of the batch to
clear the batch total. This must be done before another batch can be started.
If Automatic Reset is programmed, a new batch is commenced each time the
RUN key is pressed.
PAUSE
Preset Qty
Run Stop Run Reached Reset Run
Count Down
Batch
Total
Count Up
Relay 1
Relay 2
Slow Start Time Prestop Qty
End of
Batch
End of Batch
Pump
Control
Analog
Prestop “Hold Output”
Control Disabled
Output Flowrate
Prestop Qty
Analog
“Hold Output”
Control
Prestop Enabled
Output
Flowrate
Hold Output Time
Prestop Qty
Figure 11 Batch Operation with Manual or Automatic Reset
515 BF03 - 15 August 2021 35

Operation
Automatic Restart
If Automatic Restart is enabled the next batch will commence automatically

when the restart timer expires after the end of batch has occurred. The SET
led will flash while the instrument is waiting to automatically restart.
PAUSE
Preset Qty
Run Stop Run Reached Run
Count Down
Batch
Total
Count Up
Relay 1
Relay 2
Slow Start Time Prestop Qty
End of Auto Restart

Batch Time
End of Batch
Pump
Control
Analog
Prestop “Hold Output”
Control Disabled
Output Flowrate
Prestop Qty
Analog
“Hold Output”
Control
Prestop Enabled
Output
Flowrate
Hold Output Time
Prestop Qty
Figure 12 Batch Operation with Automatic Restart
36 515 BF03 - 15 August 2021

Chapter 5
Instrument Calibration
Introduction
The 500 Series instrument calibration settings can be programmed via the
front panel, according to program access levels explained below, or via the
500 Series Program Manager - a freely available Windows based
configuration and resource tool.
After an instrument has been configured by either means to suit the

application requirements, the settings can be recorded or application
software backups or instrument clones created as explained further in
Program Backup & Reports on page 41.
You can view or change the settings of the instrument according to the
access level for each parameter, as set by the 500 Series Program Manager.
There are different types of access to the parameters as follows:
• Not visible - you cannot display or edit the 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 change the setting of the parameter in
Calibration Set mode only if you enter the correct password.
• CAL switch protected - you can change the setting of the parameter in
Calibration Set mode only if you enter by using the CAL switch on Logic
Input 4.
Note: When you enter Calibration Set mode, the instrument prompts to
enter a password only if the password setup via the 500 Series
Program Manager is non-zero (000000 is the factory default value).
Entering any value at the password prompt will allow to change the
settings of the “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 enter
Calibration Set mode to change the CAL switch protected
parameters.
515 BF03 - 15 August 2021 37

Calibration View Mode

Use the following procedure to view the calibration settings of the
instrument:
1. Press DISPLAY to scroll to the CAL MENU prompt.

Run The instrument beeps once, illuminates the Cal indicator and shows CAL
Set
Alarm on the display panel.
Cal
• Press to scroll through the flashing menu headings.
• Press SET to scroll through submenu items.
• Hold DISPLAY to return to the main calibration menu.
3. To exit from the Calibration View mode, press to scroll to the END
option and press SET .
The instrument returns to Normal Operation mode.
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 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 DISPLAY to scroll to the CAL MENU prompt.

Run The instrument beeps once, illuminates the Cal indicator and shows CAL
Set on the display panel.
Alarm
Cal
3. Press to select any flashing menu heading except END.
4. Hold the SET key for two seconds, or if “Cal switch protected” items
exist the CAL switch can be closed for two seconds.
The instrument prompts for a password to be entered if the password is
non-zero, otherwise the password prompt is skipped.
5. If the password prompt is shown, press or to change the value
of the current digit. To select the next digit, press .
6. Press SET or use the CAL switch on Logic Input 4 (if “Cal switch
protected” items exist) to accept the password and proceed.
7. Proceed and observe the access confirmations.
38 515 BF03 - 15 August 2021

• If the CAL switch is used and the password is correct, the instrument
makes two beeps and displays message:
-EDIT- CS_PW MODE
and enables you to change “programmable”, “password protected” and
“CAL switch protected” parameters.
• If the CAL switch is used but the password has been skipped or is
incorrect, the instrument makes one beep and displays message:
-EDIT- CAL_SW MODE
and enables you to change “programmable” and “CAL switch
protected” parameters.
• If the SET key is pressed and the password is correct the instrument
makes two beeps and displays the message:
-EDIT- PASSW MODE
and enables you to change the “programmable” and “password-
protected” parameters.
• If the SET key is pressed but the password has been skipped or is
incorrect, the instrument makes one beep and displays the message:
-EDIT- PROG MODE
and enables you to change only the “programmable” parameters.
Run The instrument illuminates both the Cal and Set indicators.
Set
Alarm
Cal
8. Edit the instrument parameters as required. The programmable values
are indicated by the flashing display.
• To change a numerical value, press to increase a value, or press
to decrease a value. Press a key momentarily to change the value
one number at a time. Hold a key to scroll through the numbers. To
proceed to next digit, press .
• To change an option setting, press or to scroll through the
options.
9. Press SET to accept the currently displayed value and proceed to the next
parameter. You can press DISPLAY to briefly view the current edit mode:
-EDIT- XXXXXX MODE, as described in step 6 above.
Continue to hold the DISPLAY key to return to the main calibration menu.
10.To exit from Calibrate Set mode, press to scroll through the main
calibration menu to END, then press SET . Otherwise, to quick exit from
any menu, you can press and hold SET for two seconds or, if “Cal switch
Run protected” items exist, the CAL switch can be closed for two seconds.
Set
Alarm The instrument makes two beeps and cancels the Cal and Set indicators.
Cal
515 BF03 - 15 August 2021 39

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.
Note: When you change the setting of a parameter, the instrument records
the result as soon as you move to another parameter, or exit from the
Calibration Set mode.
Changing Option Settings
When you display an option that can be changed, the entire option flashes
on the display, 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 below.
ODD EVEN NONE
ODD NONE EVEN
Changing Numeric Settings
The display flashes the digit that can be changed.
6789.123
Press to select the digit that you wish to change.
Press or to increase or decrease the value of the selected digit.
Changing the Decimal Point
To change the position of the decimal point, press to move the flashing
selection until the decimal point flashes. Press or to move the
decimal point to the right or left as required.
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.
40 515 BF03 - 15 August 2021

Program Backup & Reports

Backup via 500 Series Program Manager
As well as programming the 500 Series instruments via the front panel
(according to program access levels), the 500 Series Program Manager
(500-PM) can be used to create a custom version of the application software
and program parameters preset prior to downloading the application
software. Backups of customised applications can be saved as download-
able APX or APL files and the full configuration reports printed or saved as
PDF. The 500-PM is a Windows based programming tool and resource
centre and is freely available from the Contrec www.contrec.co.uk website.
Instruments are often supplied from the factory with the default application
software, but it is by using 500-PM software that program access levels are
set, USER text and messages customised and print headers and footers
entered.
Printing Configuration Report
To assist in keeping an audit trail of the program settings and changes made
via the front panel, the 515 instrument provides the ability to print the
configuration to a local printer if one has been connected 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 Model
Information on page 26. The report can be lengthy and adequate printer
paper must be available (Note: this feature is available starting from version
3.0.377).
Upload and Clone of Application Software
To assist in maintaining a backup for important applications and

installations, the 500-Series Program Utility software (500-LT, version
3.0.377 or higher) can be used to upload the instruments application
software with all of the current program settings.
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’. To use either upload functionality,
the 515 port being used must have printer (PRN) protocol assigned to it.
Once uploaded to the 500-LT, the report can be viewed or printed. The
Upload Application is automatically saved as an APL file. The file can be
used then or reopened later to download to another 515 instrument (of the
same or higher class) to create a clone of the original instrument.
515 BF03 - 15 August 2021 41
Calibration Menu Tree

Figure 13 and Figure 14 show the keys for moving around the calibration
menu tree in Calibration View or Set mode.
Press Continued on next page

UNITS PARAMS INPUTS OUTPUT ALARMS
CTRL MODE
View/Edit LOCAL FINP1
units of LOOP P-FLOW OUT1 ALRM3
measurement TUNE
OR
SIGNAL PULSE FUNC selection
RETRANS
TUNE LOOP NPS TYPE
DBNCE OP-ERR
COIL
OP-CTRL POINT
Press P-BAND P-FLOW RANGE CUTOFF OP-RST
SET I-TIME P-BAND selection OP-END HYST
FILTER
P-FLOW SP I-TIME 4-20 mA PULSE DELAY
CORR
P-FLOW value D-BAND LINEAR NON-LIN PT-MIN WIDTH ALRM4
DEVIAT value R-TIME PT-MAX PULSE
KFACT NO-PTS selection
HOLD CTRL
OR FREQ01 FREQn TYPE
OUT2
HOLD SEC
LOCAL FACT01 FACTn POINT
FUNC
R-TIME RETRANS HYST
OP-ERR
OP-CTRL DELAY
OP-RST
BATCH MODE selection OP-END
PRESET
ON-OFF 4-20 mA PULSE
RELEASE
OR
PT-MIN WIDTH
PRESET ON-OFF
PT-MAX PULSE
PERMIS INPUT PERMIS INPUT
BATCH LIMIT ACCEPT TOTAL
P-STOP VALUE S-STRT SEC
P-STOP %FLOW T-OUT SEC
ACCEPT TOTAL DIRECT ACCES
S-STRT SEC Flow Setpoint
A-STRT SEC P-FLOW value
T-OUT SEC DEVIAT value
COUNT DIR
OR
AUTO RESET
AUTO COMP RELEASE

No-SET BATCH Flow Setpoint
SET-nn BATCH P-FLOW value
DIRECT ACCES DEVIAT value
Flow Setpoint
P-FLOW value
PRESET BATCH
O-RUN COMP
Figure 13 Calibration Menu Tree Sheet 1
42 515 BF03 - 15 August 2021

From previous page Press
COMMS TM/LOG SETUP TEST END
COM-1 / RS232 Exit from

FINP1/2 calibration
DATE FORM
DEFAULT VAR mode
PROTOC AINP1/4
CLOCK YEAR
BAUD SUPPLY VOLT LINP1/4
CLOCK M-DAY
PARITY T-OUT MODE OUT1
CLOCK H-MIN PROCESS
T-OUT SEC OUT2 ON / HI
S-BITS RESET LOGS
OFF / LO
Press REPORT LOGS
RESET ACCUM REL/ALRM
PROCESS
SET COM-2 / RS485 DISPL TAGS
REPORT TYPE OPEN
PROTOC BACK-L T-OUT SUPPLY CLOSED
PRN TYPE
BAUD RATES DP
AUTO PRINT
TOTALS DP
PARITY LAST D-NUM
S-BITS
RTU DATA
RTU ADDR
ASCII ADDR
FLASH PORT
The shaded boxes indicate hardware options
Hold DISPLAY at 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)
Figure 14 Calibration Menu Tree Sheet 2
515 BF03 - 15 August 2021 43

Instrument Settings
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.
SET  UNITS PARAMS INPUTS OUTPUTS ALARMS COMMS TM/LOG SETUP TEST END
ITEM n unit The units for main menu or calibration items can be viewed by pressing
the SET key.
The units of measurement are password protected or will be protected 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 select the required units.

ACCEPT UNITS The Accept Units prompt will only appear if one or more of the units
have been changed.
IMPORTANT: Accepting the change of units will initiate a master

reset. All calibration parameters will revert to their default value (i.e.
those values included in the downloaded instrument software). All totals
and any logged information will be cleared.
Press or to select YES, then press the SET 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.
44 515 BF03 - 15 August 2021

Parameters
CTRL MODE Select the required loop control mode.
• LOCAL - Manual control operating mode
• LOOP - PI loop control operating mode
• TUNE - PI loop control tuning mode
Press or to select the required control mode.

Refer to the section Control Modes for descriptions of each mode.
Note: The flow control items actually shown in the PARAMS menu are dependent on the
CONTROL MODE chosen above. Items that are not relevant for that mode will not appear.
Use the Calibration Menu Tree as a guide to the relevant items.
P-FLOW RANGE The process or loop flow range is the maximum flowrate that the system
will achieve on the process flow line. This value is used by the loop
control algorithm and is entered in the same units as the main menu
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.
Enter the value in percentage. For means of determining this value see
Tuning the Control Loop on page 28.
I-TIME SEC The loop integral time of PI control algorithm. This parameter must be set
to a non-zero value to enable the integral term in the control algorithm.
Enter the value in seconds. For means of determining this value see
Tuning the Control Loop on page 28.
D-BAND % The loop error deadband can be programmed to prevent the output
continuously changing and thereby reducing wear on valves and
actuators. 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).
R-TIME SEC The ramp time limits the rate of change of the loop output signal and
assists in bumpless loop operation when changing operation mode or loop
parameters. It represents the minimum time required for the output signal
to traverse between saturation points (i.e. from 0 to 100% or vice versa).
515 BF03 - 15 August 2021 45

HOLD CTRL The hold control output feature leaves the output signal at its last value at
the end of a batch (flow should be stopped by the on-off valve).
This allows the control actuator to start a new batch without ramping up
from a fully closed position.
Press or to select ENABLE or DISABLE.

HOLD SEC The hold control output time determines when the loop control takes over
after a batch starts or resumes. This can provide time for the on-off valve
to open and flow to reach a stable flowrate before the systems resumes
loop control.
BATCH MODE Select the 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 to the section Batch Modes for descriptions of each mode.
Note: The batch control items actually shown in the PARAMS menu are dependent on the
BATCH MODE chosen above. Items that are not relevant for that mode will not appear. Use
the Calibration Menu Tree as a guide to the relevant items.
PERMIS INPUT The permissive input feature ensures that a batch will not be allowed until
a permissive contact is closed. A prompt to connect permissive is
displayed. The requirement for the permissive can be enabled or disabled.
For more details, refer to Logic Input Control on page 34.

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.
Enter the value in the engineering units of the batch preset.

P-STOP VALUE The prestop value determines when relay 2 deactivates and the control
output reduces as the batch approaches the preset quantity.
46 515 BF03 - 15 August 2021

P-STOP %FLOW The batch prestop flowrate is programmed as a percentage of the
loop/process flowrate setpoint and is used to slow the flow the flow
during the prestop stage of batching.
ACCEPT TOTAL The batch acceptable total is the minimum total for the system leakage to
be logged (a value of zero disables logging of leakages). It also allows
small totals due to “meter skips” and vibration to be discarded without
being considered as a valid delivery.

S-STRT SEC The batch slow start time determines when relay 2 activates after the start
or resumption of a batch.
Enter the value in seconds.

A-STRT SEC The batch automatic 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.

T-OUT SEC The batch flow timeout determines the length of no flow time that the
instrument will wait during a batch before raising a no flow error. It also
determines when an overflow error is raised if flow does not cease within
the timeout period after the controller attempts to stop the flow. A value
of zero disables these flow timeout features.

COUNT DIR The batch count direction determines whether the batch total counts up
from zero to the preset value or down from the preset to zero.
Press or to select UP or DOWN.

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.
515 BF03 - 15 August 2021 47

AUTO COMP The batch automatic overrun compensation allows the instrument to
automatically compensate for any consistent overrun at the end of the
batch. Overrun is typically due to the slowness of a valve to close or a
pump to stop on receiving a signal from the batch controller and results
in the delivered quantity being greater than the entered preset.
In calculating the amount to be compensated for the instrument uses the

average overrun from the last three batches. An overrun of more than
20% is considered invalid and will not be included in the calculations.

No-SET BATCH To provide faster access to commonly used preset values a number of
batch presets can be preprogrammed into the instrument. This parameter
allows the number of batch presets to be entered.
Press or to select a number between 1 and 20.

SET-01 BATCH Enter the commonly used preset values for quick access via the front
to panel.
SET-n
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 menu by
holding the SET key while viewing the preset. If disabled, the changes
can only be made from within the calibration set mode (or via serial
communications, see below). Select the direct access mode as required.

Modbus Accessible Parameters
The following PARAMS menu item(s) are also accessible via Modbus communications. For
a complete Modbus parameter listing, refer to Instrument Configuration Parameters on
page 81.
P-CTRL SP Preset process control signal setpoint. This setpoint is only available for
LOCAL control mode.
Enter the value in the engineering units of the assigned variable.
If LOCAL control mode the live P-FLOW value is now shown to give immediate feedback
without leaving calibration set mode.
P-FLOW SP 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).
48 515 BF03 - 15 August 2021

If LOOP control or TUNE mode the live P-FLOW and DEVIATION values are now shown
to give immediate feedback without leaving calibration set mode.
PRESET BATCH Enter the batch preset quantity. This setpoint is only available for
PRESET batch mode.

O-RUN COMP Enter a fixed value batch overrun compensation that will allow the
instrument to compensate for any consistent overrun at the end of the
batch. Overrun is typically due to the slowness of a valve to close or a
pump to stop on receiving a signal from the batch controller and results
in the delivered quantity being greater than the entered preset.
This value is only used for batch overrun compensation when auto
overrun compensation is disabled.
Inputs
Frequency Input 1
INPUT For this application, the Frequency Input Channel 1 is assigned to mass
P-FLOW FINP1 flowrate.
SIGNAL FINP1 Frequency input 1 signal type.
Press or to select COIL, NPS or PULSE.

DBNCE FINP1 Switches and relays have metal contacts to make and break circuits. The
contact bounce introduces random signals into the circuit. The instrument
has a debounce circuit to eliminate this problem.
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.
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CUTOFF FINP1 The Cut-off is the lowest frequency for which the instrument continues
to calculate a rate from the flowmeter.
The value for the cut-off is specified as the frequency of the flowmeter in
Hertz.
Be careful when setting low cut-off values because the display update
time for the flow rate becomes very long. For example if the cut-off is set
to 0.01 Hz, and the measured flow stops, the instrument continues to
display the flow rate for 100 seconds before it can determine that the flow
has actually stopped.
FILTER FINP1 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.
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.
Filter setting A Seconds to reach 90% Seconds to reach 99%
of full swing of full swing
0 0 0
2 2 4
4 4 8
6 5 10
10 8 15
15 12 23
20 14 27
25 18 34
35 25 48
45 32 62
60 42 82
75 52 102
90 62 122
99 68 134
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
to apply correction factors to the input signal.
Use or to select LINEAR or NON-LINEAR.
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KFACT1 unit This parameter is available for viewing and editing only when the
correction type is set to Linear.
The K-factor of the flowmeter is the number of pulses from the flowmeter
per unit of volume (or mass). The K-factor cannot be 0 (zero).
NO-PTS FINP1 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 or to select a number between 1 and 10 for the number

of correction points.
515 BF03 - 15 August 2021 51

FREQ01 FINP1 This parameter is available for viewing and editing only when the
to correction type is set to Non-linear.
FREQn
Enter the frequency for this correction point.
The instrument uses linear interpolation between the correction points

except that the correction factor for FREQ01 is used from 0 Hz up to
FREQ01. Similarly, the instrument maintains the correction factor for the
highest frequency setting up to the maximum input frequency.
The following diagram shows the scaling factors at different frequencies

for a hypothetical flowmeter. The heavy black line represents the actual
scaling factor of the flowmeter. The light black line is the approximation
that the instrument uses.
Scaling
Factor
FACT02
FACT03
FACT01 FACT05
FACT04
Frequency
FREQ01 FREQ02 FREQ03 FREQ04 FREQ05
Enter the lowest correction factor frequency as FREQ01 and proceed up

to the highest frequency. You can press the DISPLAY key to skip the
non-linear points and go to the next item.
FACT01 FINP1 This parameter is available for viewing and editing only when the
to correction type is set to Non-linear.
FACTn
Enter the scaling factor for this correction point in the same units of
measure as the single K-factor above.
The correction factor cannot be 0 (zero).
Outputs
Note: In the factory default version of this application output channel 1 (OUT1) is dedicated
as the 4-20mA Process Control signal. Output channel 2 can be freely configured.
52 515 BF03 - 15 August 2021

FUNC OUTn The isolated output can function as either a passive 4-20 mA output, or a
pulse/logic open collector output:
• RETRANS - Retransmit totals as a pulse output or rates type
variables as a 4-20mA signal.
• OP-ERR - An error signal that will become active for the no flow,
overflow or leakage error conditions.
• OP-CTRL - A control signal that is active during a batch, can be
used as a pump control or indicator.
• OP-RST - A control signal that produces a 300ms pulse that can
be used to reset remote counters etc. Activates when the controller’s
total(s) are reset.
• OP-END - A control signal that reflects the End of Batch
condition (Note: not applicable if Batch mode is ON-OFF).
Press or to select the function required.

PULSE OUTn If above function is set for retransmission, you can assign any of the
or “main menu” variables to an output. The nature of the output depends on
4-20
the assigned variable. Totals are output as pulses and rates are output as
4-20 mA passive signals.
Press or to select the variable that is required as an output. The

top of the display shows the type of output signal that is assigned to the
variable.
CAUTION
Due to the dual-purpose nature of the outputs, take care not to
set the output as an open collector pulse type signal when
connected to a 4-20 mA loop circuit.
WIDTH OUTn The Output Pulse Width is available for viewing and editing only when
the assigned variable is a total (pulse output) type.
Pulse output is usually used to drive remote counters. Set the pulse width
(in milliseconds) as required by the remote counter.
Press or to set to: 10, 20, 50, 100, 200 or 500 ms.
515 BF03 - 15 August 2021 53

PULSE OUTn The Output Pulse Factor is available for viewing and editing only when
the assigned variable is a total (pulse output) type.
The Output Pulse Factor is the scaling factor for the retransmission of the
measured total quantity.
For example, if “volume” is chosen as an output variable and engineering

unit is cubic metres, then a pulse factor of 1.000 generates one pulse for
1 m3. Similarly, a pulse factor of 3.000 generates one pulse for 3 m3.
For more information, see Output Pulse Factor on page 54.
The output pulse factor cannot be 0 (zero).

PT-MIN OUTn The Output Minimum Point and Maximum Point are available for
PT-MAX OUTn viewing and editing only when the assigned variable is a rate (4-20 mA
output) type.
The output minimum value corresponds to the 4 mA point and the output
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. You can drive a chart recorder that
“zooms in” on a specified range of values instead of displaying the full
operating range of the transducer.
For example, if “volume flow” is chosen as an output variable and

engineering unit is cubic metres per minute, then setting the minimum
point to 30 and the maximum point to 100 would reflect the volumetric
flow rate range of 30 to 100 m3/min. At rates above the maximum and
below the minimum points, the output remains at 20 mA and 4 mA
respectively.
Output Pulse Factor
Increasing the output pulse width reduces the maximum frequency at which
a total variable can be retransmitted. Pulses will be missed if the output
cannot “keep up” with the rate of total counts. You can use the output pulse
factor to ensure that this maximum is not reached.
The maximum pulse output frequency is determined by:

1000
--------------------------------------------------------Hz
 2  pulse width in ms 
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The minimum pulse factor required is determined by:

max rate of total
------------------------------------------------------------------
max pulse output frequency
For example: To calculate the required pulse factor to avoid losing counts
in retransmission if a total counts at a maximum rate of 75 units/sec (Hz) and
the required pulse width of a remote counter is at least 50 ms:
1000
The maximum pulse output frequency is: --------------- = 10Hz
2  50
75
The minimum pulse factor for that frequency is: ------ = 7.5
10
Alarms
The alarm relay(s), in the advanced option, can be assigned to rate variables
such as flowrate, or set as an equipment failure alarm.
The alarm switches “on” whenever an alarm condition 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 Failure Alarm
Any alarm relay can be assigned as an equipment failure alarm. This alarm
setting can have normally closed (open) contacts that open (close) when the
instrument displays any error message as listed in Error Messages on page
64.
RELAY ALRMn Select a rate variable to assign to the alarm relay.
Note: If the alarm type is set to “equipment alarm”, this relay assignment
setting is ignored.
Press or to select the variable that is required as an alarm.
515 BF03 - 15 August 2021 55

TYPE ALRMn The options available for alarm types are as follows:
• HI-NO — High Alarm, Normally Open contacts
• HI-NC — High Alarm, Normally Closed contacts
• LO-NO — Low Alarm, Normally Open contacts
• LO-NC — Low Alarm, Normally Closed contacts
• BD-NO — Band Alarm, Normally Open contacts
• BD-NC — Band Alarm, Normally Closed contacts
• AL-NO — Equipment Alarm, Normally Open contacts
• AL-NC — Equipment Alarm, Normally Closed contacts
Press or to select the type of alarm required.

POINT ALRMn The Alarm Setpoint is available for viewing and editing for any alarm
type except ‘equipment alarms’.
The Alarm Setpoint is the value (in engineering units of assigned

variable) at which the alarm condition occurs and therefore the alarm is
on.
Each alarm is completely independent, e.g. a High alarm does NOT need
to have a higher setpoint than the a Low alarm.
HYST ALRMn The Alarm Hysteresis is available for viewing and editing for any alarm
type except ‘equipment alarms’.
Alarm hysteresis loops occur when the alarm 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 when the value falls below the
alarm setpoint minus the amount of the hysteresis setting (if any).
For a low alarm, the alarm activates when the value of the variable falls
below the alarm setpoint and deactivates when the value rises above the
alarm setpoint plus the amount of the hysteresis setting (if any).
For a band alarm, the alarm activates whenever the value of the variable
is outside the setpoint plus or minus the amount of the hysteresis.
For example, with a high alarm setpoint of 200, and a hysteresis setting
of zero, a value oscillating between 197 and 202 will cause the alarm to
toggle on at 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.
DELAY ALRMn The Alarm Delay is programmed in seconds and can be used to eliminate
undesired alarm activation during start-up or shutdown operation.
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Communications
The instrument has the following communication ports:

• COM-1 RS-232 Port - A 9-pin female connector on the rear panel of the
instrument.
• COM-2 RS-485 or Ethernet Port (optional) - Terminals or socket on
the rear panel. Ethernet connection requires COM-2 setting to be: RTU
(Modbus), 19200 Baud rate, even parity and 1 stop bit.
• COM-3 Port - A special communications port that is only applicable to
some applications.
SET  UNITS PARAMS INPUTS OUPUTS ALARMS COMMS TM/LOG SETUP TEST END
PROTOC COM-n The Communications Protocols can be assigned to the communication
ports as follows (a protocol cannot be assigned to more than one port at
a time):
• ASCII - Simple ASCII
• RTU - Modbus RTU
• PRN - Printer Protocol
• 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 bits per
second.
The baud rate of the instrument must match the baud rate of the
communication device that the instrument is connected to.
Use or to select 2400, 4800, 9600 or 19200 baud.

PARITY COM-n The Parity bit helps to detect data corruption that might occur during
transmission.
The parity bit setting of the instrument must match the parity bit setting
of the communication device that the instrument is connected to.
Press or to select EVEN, ODD, or NONE.

S-BITS COM-n The Stop bit indicates the end of a transmission. Stop bits can be 1 or 2
bit periods in length. The stop bit setting of the instrument must match
the stop bit setting of the communication device that the instrument is
connected to.
Press or to select 1 or 2 stop bits.
515 BF03 - 15 August 2021 57

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 INTEGER.

RTU ADDR The Modbus RTU protocol address must be in the range of 1 to 247.
When multiple instruments (slaves) are connected to one communication
device (master), each assigned address must be unique.
Note: The master device uses the RTU address 0 (zero) for broadcasting
to all connected slave units.
ASCII ADDR The ASCII protocol address identifies each communicating device.
The address must be in the range of 1 to 255. When multiple instruments

(slaves) are connected to one computer (master), each assigned address
must be unique.
FLASH PORT The Flash Driver Port assignment defines the communication port for
downloading software into the instrument.
The default setting of this assignment is the RS-232 port. The Ethernet
port, if fitted, can not be used as the Flash port.
Press or to select RS-232 (COM-1), RS-485 (COM-2) or

NONE.
Time Settings and Data Logging
Instrument Clock
The instrument has a real-time clock for recording logged events. The clock
displays the time and the date. The date format can be set to European
format (day/month/year) or American format (month/day/year). The time
clock uses the 24-hour format.
The clock will continue to operate for up to 5 years (typically) on the

internal battery if there is no power connected to the instrument. 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.
Note: If there is an interruption to the power supply and the battery has
failed, the instrument displays an error message when the power
supply is restored. In this case, you should set the current time and
date so that the instrument continues to log data at the correct times.
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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.
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 or to select DAY-M or M-DAY

CLOCK YEAR The Clock Year defines the current year for the real-time clock.
CLOCK M-DAY The Clock M-DAY setting defines the current month and date 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 the
real-time clock.
RESET LOGS Reset the logged data. You may need to reset (clear) the logged data if
you change the time/log settings.
REPORT LOGS The Printer Protocol Report Logs defines the number of latest logs to be
included into a printable report.
Set the number of logs between 1 and 99.

REPORT TYPE 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 or to select Report Type.
515 BF03 - 15 August 2021 59

PRN TYPE The Printer Protocol Printer Type allows the nature of the printer being
used to be specified. The following printer types available in this
instrument are:
• PRN-01 Generic computer printer
• PRN-02 Generic roll printer (prints first line first)
• PRN-03 Slip printer TM295
• PRN-04 Label (roll) printer - Citizen CMP30L
Press or to select Printer Type.

AUTO PRINT The Auto Print function, if enabled, allows a delivery docket print out to
occur automatically at the End of Batch. If disabled, a printout must be
initiated via the HOLD.SET - TO PRINT prompt in the main menu.

LAST D-NUM This defines the "last delivery number”, so the delivery number counting
continues from this value. Note: this parameter is accessible only when
Logging is reset (either explicitly or when application is loaded into unit).
Enter the required delivery number.
General Setup Parameters

DEFAULT VAR Select the main menu variable to display on power up or when the display
timeout period has elapsed if it is enabled.
Press or to select the default variable display.

SUPPLY VOLT The instrument provides a power-limited supply for external transducers.
Press or to set the transducer supply voltage between 8 and 24

volts DC as required.
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T-OUT MODE If the Display Timeout mode is enabled, and there is no user activity for
the defined timeout period, the display panel returns to the default
display.
This function is useful for the following reasons:

• to return the display to a preferred variable after the user has finished
reading other information,
• to cancel the calibration mode and return to the default display if the
user does not exit from the calibration mode for any reason.
Press or to select the display timeout function as follows:

• DISABLE - Timeout is completely disabled.
• EN DISP - Timeout is enabled during Normal mode and Calibration
View mode.
• EN EDIT - Timeout is enabled during Calibration Set mode.
• EN ALL - Timeout is enabled for all modes.
T-OUT SEC The 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 clears all of the accumulated
totals and the non-accumulated totals.
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.
Note: The user-defined tags can be entered into the instrument only by
the manufacturer or the distributor.
Press or 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 BF03 - 15 August 2021 61

BACK-L T-OUT If the backlight timeout is enabled, and there is no user activity (any keys
pressed) for a period of 10 seconds, the display backlight switches off to
save power. The backlight switches on when a key is pressed. Select the
backlight timeout mode as required.

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 or printing main menu totals.
Test Menu
The Test menu enables you to view the inputs and outputs to and from the
instrument.
In Calibration Set mode (by entering the system password), you can control
the outputs and the alarms as described in the table below.
FINPn Hz The frequency of the input to FINPn is displayed in Hertz.
AINPn units The units are displayed according to the calibration setup for the analog
input. If unused or set to Default the input is 4-20mA and displayed in
mA.
LINPn STATE You can view the state of the logic inputs. If the input is an open contact
or inactive it will display HI. If the input is a closed contact or active it
will display LO.
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OUTn STATE You can control the state of the outputs. Press the or 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.
For a pulse output, such as a total, the output produces a pulse train as
follows:
• ON - a pulse train with a pulse width as set for the particular output
in the Outputs menu.
• OFF - no output.
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.
ALRMn STATE You can control the state of the relays (alarms). Press the or
or keys to set the selected relay as follows:
REL-n
• PROCESS - the relay operates according to the current values of the
inputs and the relay settings as programmed.
• OPEN - the relay output contacts are set to “open”.
• CLOSED - the relay output contacts are set to “closed”.
SUPPLY V 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 60) it may indicate that the output is
overloaded.
System Messages
The instrument displays messages for defined events and fault conditions.
The manufacturer or distributor can enter user-defined text for the

messages. This user-defined text is displayed, instead of the default
(English) messages, when the Display Tags option in the Setup menu is set
to USER.
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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 20 There are failed components on the CPU card and technical support
Failure is required.
Power Supply 21 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.
New/Failed 22 The real-time clock has lost the correct time because the battery has
Battery - Set failed, or there is a new battery. Set the current time and date (in the
Time 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 battery,

but the correct time will be lost if there are interruptions to
the power supply.
No Flow 12 The no flow condition is detected when the flow timeout expires
Detected during a delivery. There must not be a period of no flow greater
than the timeout value during the delivery.
Unexpected/ 13 The unexpected/over flow condition is detected when the flow
Over Flow continues longer than the timeout period after the controller has
attempted to stop (or pause) the flow.
Leakage 14 The leakage condition is detected when an amount greater than the
Detected acceptable total is received without flow being initiated by the
batch controller.
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.
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Warning Messages Description

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.
Preset Over Limit - 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.
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66 515 BF03 - 15 August 2021

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.
Hardware Interconnection
The instrument has two communication ports:
• COM-1 RS-232 port on the rear panel (DB9 female connector)
• COM-2 RS-485 port on the rear panel (optional) or Ethernet (optional)
The appropriate interface 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: A printer must have a serial port to be able to be directly connected

to the flow computer. 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 15.
Instrument Computer/Printer
TxD 2 2 RxD 3
RxD 3 3 TxD 2
Common
GND 5 5 GND 7
Optional
CTS 7 7 RTS 4
Optional
RTS 8 8 CTS 5
DB9 DB9 DB25
Figure 15 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.
515 BF03 - 15 August 2021 67

Communications
COM-2 RS-485 Port Option
The COM-2 RS-485 port enables communication with multiple devices.

Each device has a unique address so that the “master” device can
communicate with specific “slave” devices.
On RS-485 links, an external terminating resistor must be connected at the

furthest end of the cable. When multiple instruments are connected, they
should be “daisy chained” in a multidrop configuration as shown in Figure
16. Up to 32 units can be connected to the interface at a maximum distance
of 1200 metres.
Host Twisted Pair

Computer
+
Load
120 ohms
-
Comms
Gnd
Gnd Gnd
+ - + -
19 20 21 19 20 21
Instrument Instrument
Figure 16 RS-485 Connections
COM-2 Ethernet Port Option
An Ethernet module is an available option, 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 further advice and example of Ethernet port usage and setup, refer to
Ethernet Port & Setup on page 92 in the Appendix.
Protocols
The communications protocols can be assigned to the communication ports
on the instrument as follows:
• ASCII - Simple ASCII
• RTU - Modbus RTU
• PRN - Printer Protocol
• 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. Also a protocol cannot be assigned to more than
one port at a time as described in Communications on page 57.
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Communications
• 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.
• Modbus RTU - Modbus RTU is an industry-standard protocol which
allows the instrument to be easily connected to computers running
supervisory software systems. The main advantage of this mode is that
its greater character density allows better data throughput than ASCII
mode, however each message must be transmitted in a continuous
stream.
• Printer - In the Printer protocol there is a selection of printer types.
Please refer to the Printer Protocol on page 82 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 with a
colon ( : ) and terminated with a carriage return (CR). The message
termination can include a linefeed before the carriage-return ( LFCR), but it
is the carriage-return that acts as the message termination.
All responses by the instrument are terminated with a linefeed and a

carriage-return ( LFCR).
Requests Format
The format of a request to the instrument is as follows:
:A001:LR001:XXX? LFCR
Address Log Log Command Linefeed

timebase number Carriage-return
Each request must include the address and command portions. The
underlined section is an optional part of the request string.
Address
In multipoint communications, each instrument must have a unique address

and it is essential in the request for identifying a particular instrument.
However, it may be set to 000, for special broadcast commands. For single-
instrument communications, the address can also be set to 000 in the
request.
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Communications
Refer to Communications on page 57 for setting the instrument address.
Note: The instrument always responds with its address in the header
regardless of the type of request.
Log Type and Number
The log type and number enables a communicating device to retrieve data
from the instrument. The data can be from the event-based logs or from the
current process variables with the either accumulated or non-accumulated
(resettable) totals.
The log request is optional. If the log request is not included, or the log
number is set to 000, the instrument returns the current process variables. If
the log request is included, the log number defines the specific log entry by
counting backwards. The most recent log entry for a timebase is 001.
The “last edit” log records the 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
returns the data at the time of the last edit. 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.
The types of the logs applicable to this instrument are as follows:
Log Type
LE - last edit log
LR - logged records (non-timebased logging)
LN - current totals displayed as Non-accumulated
The number of the log entry is the same as shown on the front panel of the
instrument. For example, a request for LR003 would return the data for the
log entry two batches prior to the most recent batch log entry.
Instrument Responses
The instrument response time to any enquiry is not more than 300 ms. The
responses from the instrument are in the following format:
HEADER LFCR
DATA LFCR
DATA LFCR
.
.
.
DATA LFCR
L C
F R
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Communications
The components of the response message are as follows:
Header
The format of the response header from the instrument is as follows:

A001 YYYY/MM/DD HH:MM:SS 00
Address Date Time Exception Status

(24-hour clock)
space space space
The instrument Exception Status codes that the instrument returns for the
ASCII protocol are the same as those described for the Modbus RTU
protocol in Instrument Exception Status on page 79.
Data
The format of the data variables from the instrument is as follows:
8 9 1 2 3 . 4 5 6 M 3 V O L U M E
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 22 23 24 25 26 27
space
space
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.
Variables Request
The variables request asks the instrument to return the value of one or more
requested variables. All totals are transmitted as accumulated totals.
Command Description
:RVA? Return all variables
:RVD? Return the default Total and Rate
:RV0? … Return the specific variable. The numbers relate to the
:RV9? position in the variables menu. For example, V0 is Energy,
V1 is Power and so on.
Variables Request and Response Example
The following request is for the only instrument that is connected to the
communication port to return the values of all main menu variables.
: A 0 0 1 : R V A ? LF C
R
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Communications
The following is an example of a hypothetical instrument response. Refer to

on page 2 for the list of variables that would be returned for this application.
L C
A 0 0 1 2 0 0 2 / 0 3 / 1 4 1 8 : 2 5 : 0 0 0 0 F R
L C
6 . 1 1 6 M W h E N E R G Y F R
L C
1 6 . 5 7 3 M W P O W E R F R
L C
1 3 2 0 . 5 3 0 m 3 V O L U M E F R
L C
5 8 . 3 0 0 m 3 / M V - F L O W F R
L C
7 6 2 7 . 1 1 7 K G M A S S F R
L C
3 4 4 . 4 6 0 K G / M M - F L O W F R
L C
2 3 0 . 0 0 0 D E G C T E M P F R
L C
1 . 2 6 0 M P A P R E S S F R
L C
0 . 1 7 4 m 3 / K G S P - V O L F R
L C
2 8 8 6 . 7 6 0 K J / K G S P - E N T F R
L C
F R
The following message to an instrument, requests the current values for the
default rate and total:
L C
: A 0 0 1 : R V D ? F R
The instrument response would be similar to the following:

L C
A 0 0 1 2 0 0 2 / 0 3 / 1 4 1 8 : 2 5 : 0 0 0 0 F R
L C
1 2 6 . 4 5 5 m 3 V O L U M E F R
L C
2 0 . 4 3 7 m 3 / M V - F L O W F R
L C
F R
Log Request
The log request asks the instrument how many logs will be included in a
printed log report. These are the values described in Time Settings and
Data Logging on page 58.
Command Description
:RLR? Return the number of log records (non- timebased logging)
Log Response Example
The following message asks the instrument with address 001 to return the
number of logs that the instrument stores:
L C
: A 0 0 1 : R L R ? F R
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Communications

L C
A 0 0 1 2 0 0 2 / 0 3 / 1 4 1 8 : 2 5 : 0 0 0 0 F R
L C
2 4 F R
L C
F R
Clear Data Request
The clear data request asks the instrument to clear the data in the selected
registers.
Command Description
:RCN? Clear the non-accumulated (resettable) totals
:RCA? Clear the accumulated totals
:RCL? 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:
L C
: A 0 0 1 : R C L ? F R

L C
A 0 0 1 2 0 0 2 / 0 3 / 1 4 1 8 : 2 5 : 0 0 0 0 F R
L C
F R
Instrument Information Request
The Instrument Information request asks the instrument to return the general
information about the model and version codes. The instrument exception
status is returned as a part of the header as it is with the header for all
command responses.
Command Description
:RIG? Return the general information about the instrument such as
Model number, Application number, Version and Serial
numbers etc. These items are returned as a block in the same
format as shown on the display in the “Model Info” menu.
Instrument Information Response Example
The following message asks the instrument with address 001 to return the
general information about the instrument:
L C
: A 0 0 1 : R I G ? F R
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Communications
The following is an example of a hypothetical instrument response:

L C
A 0 0 1 2 0 0 2 / 0 3 / 1 4 1 8 : 2 5 : 0 0 0 0 F R
L C
5 1 5 M O D E L - 1 1 - F - F R
L C
S C 0 1 I N P U T F - T P - - F R
L C
S C 0 1 V E R S 0 1 0 1 . 0 0 1 F R
L C
C U S T O M V E R S 0 0 0 0 0 1 F R
L C
U N I T S / N 1 2 3 4 5 6 F R
L C
F R
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
Corrupted or Invalid Requests

If the instrument receives a corrupted or incomplete request, there is no
response. The instrument discards any partial request and waits for the next
enquiry.
If the instrument receives a request message in the correct format, 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 there is no T option for the ‘Variables
Request’ message.
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Communications
Modbus RTU Protocol

Modbus RTU (remote terminal unit) is an industry standard protocol that
allows the instrument to be easily interfaced to other communication
devices.
The instrument implements the Modbus protocol as detailed in the Modicon

Modbus Protocol Reference Guide PI-MBUS-300 Rev J (June 1996).
Message Format
In RTU mode, messages start with a silent interval of at least 3.5 character
times. The first field transmitted is the device address. Following the last
transmitted character, a similar interval of at least 3.5 character times marks
the end of the message. A new message can begin after this interval. The
entire message frame must be transmitted as a continuous stream. A typical
message frame is shown below:
Address Function Data CRC Check

1 byte 1 byte n bytes 2 bytes
Except for broadcast messages, when a master device sends a query to a

slave device, it expects a normal response. 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 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. The master program has to process a
timeout condition for the query.
• If the slave receives the query without a communication error, but cannot
handle it (for example, if the request is to read a nonexistent register), the
slave will return an exception response informing the master of the nature
of the error.
Instrument Address
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
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Communications
Function Codes
The instrument accepts the following function codes:
Code Name Description

03 Read data register(s) Obtain the content of one or more 2-byte
data registers.
06 Preset data register Preset one 2-byte data register.
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.
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

01 Illegal function The function code is not a legal action for
the slave.
02 Illegal data address The data address is not a legal address for
the slave.
03 Illegal data value The data value is not a legal value for the
slave.
05 Acknowledge The slave has accepted the request and is
processing it, but a long duration of time
will be required to do so.
06 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.
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Communications
List of Data Registers

The following tables describe the addresses and meaning of the data
registers in the instrument. The registers are grouped in blocks that relate to
a particular function of the instrument. The data values are expressed in the
engineering units that were selected for the variables when the instrument
settings were configured.
Note: Conventional numbering of registers often starts from 1, therefore be

aware that “register 1” in this case has “address 0” and so on.
The data registers 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” data type for 4-byte (2 registers) data values
can be set as either Floating Point or Long Integer via the “Data Type”
program item as described in Communications on page 57.
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
preset, one data value.
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Communications
Current and Logged Process Data
This block of registers is available for the retrieval of current or logged

process data with its matching time and date information.
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 Read Only or Type

Read/Write
1 Mass R P
3 Process Flowrate R P
5 Process Control Output R P
7 Process Flowrate Deviation R P
9 Preset Quantity R P
11 R P
13 R P
15 R P
17 Process Variables R P
19 R P
By default totals are the Accumulated values. If
21 current Non-accumulated (resettable) totals R P
23 are required, set register 37 to 06. R P
25 R P
27 R P
29 R P
31 Year R/W I
32 Month R/W I
Current Date/Time or
33 Date Logged Date/Time Stamp R/W I
34 Hour (see register 38 Log Number). R/W I
Only current Date/Time can be edited
35 Minute R/W I
36 Second R I
37 Log Type 00 - hourly or log records R/W I
01 - daily
02 - weekly
03 - monthly
04 - yearly
05 - last edit of calibration
06 -current totals are non-accumulated values,
register 38 is ignored.
38 Log Number If set to 0, current variables and Date/Time are R/W I
retrieved
39 Clear Data 01 - clear logs R/W I
02 - clear accumulated totals
03 - clear non-accumulated totals
Note: the Clear Data command is not executed

(and register 39 is set to non-zero value) when
the controller has a transaction in progress.
40 Reserved
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Communications
Instrument Exception Status
This register is available to verify the status of the instrument.

Read/Write
41 Exception 00 = no error R I
Status 01 = analog input 1 failure
02 = analog input 2 failure
05 = invalid calibration parameter
06 = invalid reference parameter
07 = invalid property
08 = quadrature input error
09 = no solution for internal 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 failed clock battery
23 to 29 reserved
30 = alarm 1 active
31 = alarm 2 active
32 = alarm 3 active
33 = alarm 4 active
Instrument Control and I/O
This block of registers is available in some applications to give access to

important information in the instrument.

Read/Write
42 Reserved R I
43 Logic Inputs 0 to 15 Binary representation of logic inputs R I
B0 = 0/1 (LSB) input 1 activated/deactivated

B1 = 0/1 input 2 activated/deactivated
44 Operation State Representation of operation status R I
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)
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Communications

Read/Write
45 Relay State 0 to 15 Binary representation of relay state. R I
0 = open; 1 = closed.
B0 = relay 1 (LSB)
B1 = relay 2
B2 = relay 3
B3 = relay 4
46 Relay Control 0 to 15 Binary representation of relay control. R/W I
0 = open; 1 = close.
Note: Only the general relays configurable in the Alarm

section of calibration are able to be viewed and controlled
by Modbus.
B0 = relay 1 (LSB)
B1 = relay 2
B2 = relay 3
B3 = relay 4
47 Relay Control 0 to 15 Binary representation of relay control source. R/W I
Source 0 = Local (controlled by instrument operation) 1 = RTU
(controlled by Modbus register 46).
B0 = relay 1 (LSB)
B1 = relay 2
B2 = relay 3
B3 = relay 4
48 Delivery Provides the delivery number (batch record) for a stored R L
Number transaction (determined by Modbus register 38).
50 Control Mode 0 = Idle/Local Control from logic inputs R/W I
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. R/W P

Parameters
101 Analog Inp.1 Raw analog input data. R P
103 Analog Inp.2 4-20mA inputs are read in Amperes. R P
0-5V or 1-5V inputs are read in Volts
105 Analog Inp.3 R P
RTD inputs are read in degrees Kelvin.
107 Analog Inp.4 Unused inputs are configured as 4-20mA. R P
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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 48.

Read/Write
51 Preset Control Output Setpoint R/W P
53 Preset Flowrate Setpoint R/W P
55 Batch Preset Value R/W P
57 Batch Overrun Compensation Value R/W P
59 to 99 Reserved R/W P
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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 are described below. If chosen, a printer protocol also enables
application/configuration uploading and printing a configuration report, as
shown in Printing Configuration Report on page 41.
Note: Printer output is only available if the Real Time Clock option is fitted.
The selection of Printer Protocol can be made for the Communications

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:

• REP-10 Latest Logs Report
The number of logs printed in each report are determined by the values
programmed for Report Logs in the TM-LOG menu.
Printer Types
The list of available printers is as follows:

• PRN-01 Generic computer printer
• PRN-02 Generic roll printer (printing first line first)
• PRN-03 Slip Printer TM295
• PRN-04 Label (roll) printer - Citizen CMP30L
Customizing a Printout
A customized printout can be provided which can have up to 6 header lines

and 6 footer lines. It is also possible to exclude some main menu items on
the printout. If any customizing of the printout is required discuss this with
the distributor.
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Communications
Types of Printouts
Live Data
The HOLD.SET - TO PRINT prompt in the main menu, is used to initiate a

printout of the current delivery if the printer protocol has been selected. 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:
Custom Header Lines
Instrument Serial No. & Tag
Current Delivery No.

Current Date & Time & Status
Variable unit value
Variable 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 same as the information
shown in the Model Info menu. For more details refer to Model
Information on page 26
Delivery Number
The delivery number that appears on the live data printout shows the
assigned delivery number that is stored with the logged data. This number
is cleared when the Logs are cleared in the TM/LOG menu. If a second print
or docket of the same delivery is generated, the words “(DUPLICATE
DOCKET)” are included at the top of the printout. i.e.
(DUPLICATE DOCKET)
####
DELIVERY No. 000256
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Communications
Individual Log Data
When in the Log Menu and while holding the DISPLAY key to view the
data of the log of interest, the RESET key can be pressed to initiate a
printout of that log entry. 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.
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
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 likelihood that the reports can be of a considerable length it

is strongly recommended that only the 80 Column printer with Z fold
(tractor feed) paper be used. This is just as much for the memory storage of
printer as it is for the reliable paper supply.
There is a HOLD.SET REPORT PRINT prompt under the main menu with
the ability to print the pre-selected type of report. Pressing and holding the
SET key for two seconds will initiate the printout. Any of the Log Reports
will have the following format:
Custom Header Lines
Title of Report <internally set, indicates report type>
Current Date & Time

-------------------------------------------- <separation line>
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Communications
Delivery No.
Variable unit value
Variable unit value
etc.
-------------------------------------------- <separation line>
Delivery No.
Variable unit value
Variable unit value
etc.
-------------------------------------------- <separation line>
Delivery No.
Variable unit value
Variable unit value
etc.
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”, i.e.
-------------------------------------------- <separation line>
Del No. Data Not Available
-------------------------------------------- <separation line>
Delivery No.
Variable unit value
Variable unit value
etc.
If the unit is programmed for 0 logs for the latest log reports then the report
will only consist of the header and ID information and a “Data Not
Available” message.
Custom Header Lines
Title of Report
Current Date & Time

Data Not Available

Custom Footer Lines
-------------------------------------------- <separation line>
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Communications
Printer Data Control

Some printers have limited data buffers and are therefore unable to collect
all the print data being transmitted. The 500 Series has the capability of
software handshaking. The Xon/Xoff characters can be used by any of the
printer types to control the flow of data to ensure that data is not lost.
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.
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. 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
paper and if paper is detected before a communications timeout expires the
print will commence.
COMMS TIMEOUT
This message is relevant for all printer types and will be activated for the
following conditions.
1. If the flow of data is stopped due to software or hardware handshaking

and is not allowed to resume before the communications timeout.
2. If Printer Type is PRN-03 Slip printer and a paper status is requested but
no response is received within the timeout period.
3. Paper Out has been detected for Printer Type PRN-03 but no paper is
inserted within the timeout period.
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.
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Appendix A
Glossary
Glossary
500-PM 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. Custom versions can be saved and configuration
reports generated as a PDF.
ASCII American Standard Code for Information Interchange. For the ASCII
protocol, the instrument receives and transmits messages in ASCII, with all
command strings to the instrument terminated by a carriage return. Replies
from the instrument are terminated with a line-feed and a carriage-return.
Filtering The process of suppressing oscillations or random signals in the 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 A scaling of the input signal to represent the actual flow parameter.
Correction
Modbus RTU The Modbus protocol is a message structure for communications between
controllers and devices regardless of the type of network. In RTU (remote
terminal unit) mode, each 8-bit byte in a message contains two 4-bit
hexadecimal characters. This mode has greater character density than
ASCII and allows better data throughput than ASCII for the same baud rate.
Normalised 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.
NPS Namur Proximity Switch.
Passive Output Requires an external power supply.

Signal
Watchdog The WDT is used to monitor the activity of the micro processor and will
Timer (WTD) force a reboot if the micro processor stops, while power is applied, due to
any internal or external influences.
515 BF03 - 15 August 2021 87

88 515 BF03 - 15 August 2021
Appendix B
Model Numbers
Product Codes
Model Supplementary Code Description
515 . - BF03
1 Panel mount enclosure
2 Field mount enclosure (NEMA 4X / IP66)
Enclosure 3/5 Explosion proof Ex d (IECEx/ATEX), metric glands

(5 specifies heater)
Explosion proof Ex d (CSA), NPT glands
4/6
(6 specifies heater)
4 logic inputs, 1 isolated output, 2 relays (only relay type 1 is
0
available), RS-232 (DB9) communication port
4 logic inputs, 2 isolated outputs, 4 relays, real-time clock data
Output Options 1
logging, RS-232 (DB9) and RS-485 communication ports
4 logic inputs, 2 isolated outputs, 4 relays, real-time clock data
2
logging, RS-232 (DB9) and Ethernet communication ports
1 Electromechanical relays only
Relay Type 2 2 electromechanical and 2 solid state relays
3 Solid state relays only
Inputs for 12-28VDC and 100-240 VAC, 50-60Hz
U
Power Supply (Previous Models: A = 110/120 VAC, E = 220/240 VAC)
D Input for 12-28VDC power only
Standard option (now with backlight & LCD backup)
Display Panel Options S
(original Full option: F, with Infra-Red comms, no longer available)
Conformal coating - required for maximum environmental
C operating range. Recommended to avoid damage from
PCB Protection moisture and corrosion.
None - suitable for IEC standard 654-1 Climatic Conditions up
N
to Class B2 (Heated and/or cooled enclosed locations)
Defines the application software to be loaded into the
Application Pack Number BF03
instrument
For example: Model No. 515.111USC
Displayed on the 500 Series as:
Note: The first character represents the CPU installed 2-1--S-
(factory use only). The remaining 6 characters only
represent hardware that affects the operation.
515 MODEL
Note: Example full product part number is 515.111USC-BF03 (this is the number used for
placing orders).
515 BF03 - 15 August 2021 89

Custom Version Codes
Code Description
00 Factory Default Application
01 Contrec Systems Pty. Ltd. Melbourne Australia
02 Contrec Limited. West Yorkshire UK

Origin Code
03
Identifies 04 Contrec-USA, LLC. Pelham AL 35124 USA
Distributor
05 Flowquip Ltd. Halifax UK
06
etc.
0 English (Default)
1 German
2 Dutch
User Language 3 French
4 Spanish
5
etc.
000
Distributor’s own choice. Possibly a code that identifies the
Distributor’s Code … customer and the application.
999
For example: 02 3 157 023157

Displayed on the 500 Series as:
CUSTOM VERS
Application Information Code

The Application Information code is an aid for users and service personnel to determine the type
of inputs that are used in a particular application. The Application Information code is displayed
on the instrument as shown below.
Assignment type
F-tP--
BT01 INPUT
Application number
The Application Information code is returned as part of a General Instrument request (as
described in Instrument Information Request on page 73).
90 515 BF03 - 15 August 2021

The Application number identifies the application as in the following examples:
• BC01 - Batch Controller for frequency flow meter

• BF02 - Batch/Flow Controller for analog flow meter
The Input Assignment type indicates the physical input that is assigned to each input on the
instrument. The code is made up from six characters as follows:
FINP1 FINP2 AINP1 AINP2 AINP3 AINP4

X X X X X X
The codes are as follows:
• - - not used in this application

• A - 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 flow input for stacked inputs
• L - indicates a low flow input for stacked inputs
• P - indicates a pressure input
• q - indicates a quadrature input
• t - indicates a temperature input.
For example, F-tP-- 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 BF03 - 15 August 2021 91

Appendix C
Ethernet Port & Setup
Ethernet Port
The optional Ethernet port simplifies the communication network and avoids the need for an
external 3rd party Serial to Ethernet converter. It allows communications via an existing
Ethernet network. In some installations you will need to speak with your network (IT)
administrator in order to correctly set up your network. Applications, such as DataMod
(available via Contrec), can communicate over the Ethernet network to perform remote
monitoring and Data Logging operations.
Within the instrument’s calibration menus the Ethernet port uses the settings for the RS-485 port
that need to match a supplied Ethernet unit as follows:
• Protocol: RTU
• Baud Rate: 19200
• Data Bits: 8
• Parity: Even
• Stop Bits: 1
Data mapping follows the same convention applied to Modbus registers.
Connecting 515 Ethernet to Networks/Routers

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 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. All Ethernet instruments are supplied with the
Ethernet module MAC address printed on the outside of the enclosure and also printed directly
onto the Ethernet Module itself (the Option card would need to be removed to view the physical
Digi Ethernet module).
Contrec Limited will not be held responsible for any changes made to customer router and
network settings. Further guides on how to access the module settings and discovering IP
address’ can be supplied upon request.
92 515 BF03 - 15 August 2021

Connecting DataMod via Ethernet
Using the IP address that you or the network/router has assigned to the 515 instrument, 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
Guide - Establishing a Connection to Datamod. Both of these documents are available from
Contrec on request.
Figure 17 DataMod - Modbus Connection Settings
515 BF03 - 15 August 2021 93

94 515 BF03 - 15 August 2021
Index
Numerics battery
4-20mA failed 64
output 14 life 58
500 Series Program Manager 4 new 64
500-PM software 4, 87 battery replacement 20
battery type 20
A baud rate 57
address, instrument 69
alarm C
delay 56 CAL switch-protected parameter 37
equipment failure 55 calibration
hysteresis 56 backup, reports 41
relays 55 menu 42
setpoint 56 set mode 38
alarms menu 55 view mode 38
application code 90 cleaning 9
approvals 4 clock
FCC Declaration 5 battery 58
ASCII protocol 69 date format 59
real-time 58
B codes
back panel 10 application information 90
backup customer version 90
program 41 exception 79
Program Manager 41 product number 89
basic menu 24 comm port
batch COM-1 RS-232 67
configurations 30 COM-2 RS-485 68
errors 34 common preset values 24
operations 35 communication
print 33 connections 18
reset 33 protocols 68
start 32 communications 3, 67
stop 33 menu 57
batch control 30 connecting permissive 32
BATCH key 22
batch limit 24
batch modes 29
batch preset
common values 24
batch processes 35
515 BF03 - 15 August 2021 95

connections format, date 59
communication 67 frequency input connection 13
communications 18 front panel 21
control relays 16 keys 22
electrical 10 LEDs 22
input 13
mains 19 G
output 14 glossary 87
control loop
tuning 28 H
control modes 27 hardware connections 67
customer version codes 90 hysteresis, alarm 56
customizing a printout 82
I
D input
data log connections 13
viewing 25 frequency 13
date format 59 inputs menu 49
declaration FCC 5 installation 9
decontamination 9 instrument
default variable 22 address 69
delay, alarm 56 request format 69
detail menu 24 responses 70
digital output 15 settings 44
disconnection device 19 interconnections, communication 67
display interference suppression 17
specifications 7 isolated outputs 3
timeout mode 61
K
timeout time 61
DISPLAY key 22 key
display-only parameter 37 BATCH 22
DISPLAY 22
E RESET 22
earthing 19 RUN 22
edit batch preset 24 SET 24
electrical connections 10 STOP 22
equipment failure alarm 55 TOTAL 22
error messages 64 keys, front panel 22
Ethernet COM-2 port 19, 68
L
exception codes 79
Exception Status 71 LEDs, status 22
local flow control 27
F logged data 25
features 1 viewing 25
flash driver port assignment 58 logic input connection 14
flow control logic input control 34
local 27 loop flow control 28
loop 28
tune 28
96 515 BF03 - 15 August 2021

M digital 15
main menu pulse factor 54
basic and detailed 24 outputs menu 52
main menu items 23
mains connections 19 P
maintenance 19 panel
menu LEDs 22
alarms 55 mounting 9
calibration 42 rear 10
comms 57 parameter
inputs 49 CAL switch-protected 37
outputs 52 display-only 37
params 45 not visible 37
setup 60 password-protected 37
test 62 programmable 37
tm/log 58 parameters menu 45
units 44 parity bits 57
messages password-protected parameter 37
error 64 permissive
prompts 65 connect 32
system 63 permissive input 32
warning 64 port
Modbus accessible parameters 48 assignment, flash driver 58
Modbus data format 58 COM-1 RS-232 18, 57
Modbus RTU protocol 75 COM-2 Ethernet 19, 68
mode COM-2 RS-485 18, 57
display timeout 61 COM-3 57
process control 27 flash driver assignment 58
set calibration 38 RS-485 57
view calibration 38 power supply interruption 58
model numbers 89 preset batch value 24
modes, batch control 29 preset mode 29
mounting 9 printer
data control 86
N error messages 86
number protocol 82
model 89 report types 82
serial 26 printer types 82
printing a docket 33
O printout
on-off mode 30 configuration report 41
operation configurations 30 printouts
operation, batch control 30 individual logs 84
operation, control modes 27 live data 83
operation, front panel 21 log report 84
output types 83
connections 14 product number codes 89
4-20mA 14 Program Manager 41
515 BF03 - 15 August 2021 97

programmable parameter 37 system
prompts 65 errors 64
protocol messages 63
ASCII 69 prompts 65
communication 68 warnings 64
Modbus RTU 75
printer 82 T
pulse factor, output 54 terminal designations 11
test menu 62
R timeout
real-time clock 58 mode 61
rear panel 10 time 61
relay tm/log menu 58
connection 16 TOTAL key 22
relay outputs 3 tune mode 28
relays, alarm 55 tuning control loop 28
release mode 30
remote control 34 U
RESET key 22 unit tag 26
resetting a batch 33 units of measurement 3, 44
responses, instrument 70 upload application software 41
RS-232 COM-1 port 18, 57
RS-485 COM-2 port 18, 57 V
RS-485 port 57 variable, default 22
RTU protocol 75 version, customer 90
RUN key 22 view data logs 25
S W
safety & security 32 warnings 64
serial number 26 watchdog timer (WDT) 27
SET key 24 wiring
setpoint, alarm 56 insulation 12
settings mains power 12
instrument 44 relays 12
setup menu 60
shielding 19
snubber 17
software configuration tool 4
specifications 7
standards 4
starting a batch 32
status LEDs 22
stop bits 57
STOP key 22
stopping a batch 33
suppression, interference 17
98 515 BF03 - 15 August 2021

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Model 515 Flow Computer

© Contrec Ltd 2021

Contrec Systems Pty Ltd

Contrec - USA, LLC

Publication No: 515-BF03-OM - 15 August 2021

Operating & Storage Temperature

515 BF03 - 15 August 2021 iii

Explanation of IEC Symbols Used

iv 515 BF03 - 15 August 2021

3 Installation & Maintenance

515 BF03 - 15 August 2021 v

vi 515 BF03 - 15 August 2021

Appendix B Model Numbers

Appendix C Ethernet Port & Setup

515 BF03 - 15 August 2021 vii

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

515 BF03 - 15 August 2021 ix

515 BF03 - 15 August 2021 1

The PI control of the process flow is via a 4-20mA proportional valve or

mass flow = frequency / k-factor

Automatic overrun compensation calculates the new valve closure point to

The instrument can be supplied with a real-time clock for storage of up to

Main Menu Variables

Main Menu Default Variable

2 515 BF03 - 15 August 2021

In the 500 Series instruments there is a wide range of available units of

515 BF03 - 15 August 2021 3

The 500-PM software is a free comprehensive configuration tool and

Analog Frequency Relay 1

Proportional Mass On-Off Flow

Figure 1 Typical Application Diagram

In order to comply with these standards, the wiring instructions in Chapter

4 515 BF03 - 15 August 2021

515 BF03 - 15 August 2021 5

6 515 BF03 - 15 August 2021

Non-volatile Memory Relay Output

515 BF03 - 15 August 2021 7

Important: Specifications are subject to change without notice.

8 515 BF03 - 15 August 2021

Cleaning and Decontamination

The standard mounting procedure is panel mounting in a cutout that is

Figure 2 500 Series Instrument Panel Mounting

515 BF03 - 15 August 2021 9

Note: Depending on the specification and age of the instrument,

Figure 3 Rear Panel Connections - Original

Figure 4 Rear Panel Connections - New RS-485 Version

10 515 BF03 - 15 August 2021

Figure 5 Rear Panel Connections - New Ethernet Version

Terminal Label Designation Comment Terminal Label Designation Comment

515 BF03 - 15 August 2021 11

Terminal Wiring Insulation

Use copper conductors only.

Mains Power Wiring

Only use UL/CSA approved cabling with supplementary insulation and

12 515 BF03 - 15 August 2021

Squarewave, CMOS or TTL

3 Signal Ground Signal Ground