Mini CORI-FLOW Compact Coriolis Mass Flow Meters/Controllers for Liquids and Gases

Transcription

1 Instruction manual Mini CORI-FLOW Compact Coriolis Mass Flow Meters/Controllers for Liquids and Gases Doc nr.: H Date: ATTENTION Please read this instruction manual carefully before installing and operating the instrument. Not following the guidelines could result in personal injury and/or damage to the equipment.

2 SCOPE OF THIS MANUAL This manual covers the general part of digital mini CORI-FLOW mass flow instruments for gases and liquids. It treats the general instructions needed for the instruments. More information can be found in other documents. Mini CORI-FLOW instruments have modular instruction manuals consisting of: - Short form instruction manual mini CORI-FLOW (document nr ) - General instructions mini CORI-FLOW (document nr ) - Operation instructions digital instruments (document nr ) - Fieldbus/interface description: - FLOW-BUS Interface (document nr ) - PROFIBUS-DP Interface (document nr ) - DeviceNet Interface (document nr ) - RS232 Interface with FLOW-BUS protocol (document nr ) - Modbus interface (document nr ) page

3 Even though care has been taken in the preparation and publication of the contents of this manual, we do not assume legal or other liability for any inaccuracy, mistake, mis-statement or any other error of whatsoever nature contained herein. The material in this manual is for information purposes only, and is subject to change without notice. Bronkhorst Cori-Tech B.V. June 2011 Warranty The products of Bronkhorst Cori-Tech B.V. are warranteed against defects in material and workmanship for a period of three years from the date of shipment, provided they are used in accordance with the ordering specifications and the instructions in this manual and that they are not subjected to abuse, physical damage or contamination. Products that do not operate properly during this period may be repaired or replaced at no charge. Repairs are normally warranted for one year or the balance of the original warranty, whichever is the longer. See also paragraph 9 of the Conditions of sales. The warranty includes all initial and latent defects, random failures, and undeterminable internal causes. It excludes failures and damage caused by the customer, such as contamination, improper electrical hook-up, physical shock etc. Re-conditioning of products primarily returned for warranty service that is partly or wholly judged nonwarranty may be charged for. Bronkhorst Cori-Tech B.V. prepays outgoing freight charges when any party of the service is performed under warranty, unless otherwise agreed upon beforehand. However, if the product has been returned collect to Bronkhorst Cori-Tech B.V., these costs are added to the repair invoice. Import and/or export charges, foreign shipping methods/carriers are paid for by the customer page 3

4 TABLE OF CONTENTS 1 INTRODUCTION General description Gas / Liquid flow Housing Valves Badger Meter Valves Liquid dosing systems with pumps Sensor measuring principle Mini CORI-FLOW sensor Valve principles Solenoid valve Vary-P valve Pilot operated valve Software for physical properties of gases and liquids (mini) Cori-Flow accuracy INSTALLATION Receipt of equipment Return shipment Service Mounting Notes for temperature considerations Fluid/gas connections Piping Electrical connections Pressure testing Supply pressure System purging Seals Equipment storage Electromagnetic compatibility Electro static discharge OPERATION General Power and warm-up Start-up Zeroing What is zero-stability? Procedure for zeroing Zero-procedure information Alternatives for starting zero procedure Zeroing with the Micro-switch Zeroing through the digital communication Operating conditions Manual operation Analog operation BUS / digital operation RS232 communication cable T-part MAINTENANCE General mini CORI-FLOW sensor Controllers Control valves Solenoid valves Vary-P valve Pilot operated valve K v -value calculation For gases For Liquids Calibration procedure Instrument re-ranging Instrument filter settings INTERFACE DESCRIPTION TROUBLESHOOTING...34 page

5 6.1 General Calibration check Troubleshooting summary general page 5

6 1 INTRODUCTION 1.1 General description Gas / Liquid flow The Bronkhorst Cori-Tech B.V. series mini CORI-FLOW mass-flow meter/controller for gases and liquids is an accurate device for measuring gas and liquid flows up to 200 bara depending on body rating, virtually independent of pressure and temperature changes. The mini CORI-FLOW is a real mass-flow meter/controller and measures the flow in mass, it does not matter what the properties of the gases or liquids are. The system can be completed with a control valve or a pump and flexible readout unit to measure and control gas and liquid flows. Mini CORI-FLOW series by Bronkhorst Cori-Tech B.V. are precise and compact Mass Flow Meters and Controllers, based on the Coriolis measuring principle. Designed to cover the needs of the low flow market, there are 4 models to overlap flow ranges from 5 g/h up to 300 kg/h (full scale values), each offering multirange functionality: factory calibrated ranges can be rescaled by the user, maintaining the original accuracy specs. The instruments are equipped with a robust IP65 weatherproof housing. Instruments of the mini CORI-FLOW series contain a uniquely shaped, single loop sensor tube, forming part of an oscillating system. When a fluid flows through the tube, Coriolis forces cause a variable phase shift, which is detected by sensors and fed into the integrally mounted pc-board. The resulting output signal is strictly proportional to the real mass flow rate. Coriolis mass flow measurement is fast, accurate and inherently bidirectional. The mini CORI-FLOW features density and temperature of the fluid as secondary outputs Housing Each instrument housing style incorporates several provisions to comply with EMC requirements. Also the instrument housing is a robust IP65 weatherproof housing. Meter housing M12-M14 Meter housing M15 Controller housing with metal seal valve page

7 1.1.3 Valves M12, M13 and M14 mini CORI-FLOW controllers are fitted with a fixed or modular valve. The M15 mini CORI-FLOW controller can only be equipped with a modular valve. Integrated valves for liquids and gases For liquids the valve has an extra purge adaptor on top for de-gassing. In case of a modular valve it is attached by means of a port connector. Possible combinations: M12 M13 M14 M15 Liquid C2I F-033CI C2I C5I F-033CI C2I F-033CI C2I C5I F-033CI F-004AI Gas C0I, C1I F-033CI C01, C1I C5I F-033CI C0I, C1I F-033CI C5I F-033CI F-004AI F-012AI, F-013AI Valves: C2I valve Direct operating valve for liquids ( open sleeve) metal sealed with purge connector. C2I valve = normally closed C5I valve Direct operating valve for liquid/gas metal sealed. C5I valve = normally closed page 7

8 C0I / C1I valve Direct operating valve for gases metal sealed C0I valve = normally closed C1I valve = normally open F-033CI valve Vary-P operating valve for liquid/gas elastomeric sealed F-033CI valve = normally closed F-004AI / BI valve Bellow valve for liquid/gas elastomeric sealed F-004AI/BI valve = normally closed F-012AI/F-013AI valve Pilot operated valve for gases elastomeric sealed F-012AI/F-013AI valve = normally closed page

9 1.1.4 Badger Meter Valves For those special applications where the Bronkhorst valves do not meet the specifications anymore we can use Badger Meter valves as a good alternative. Reasons for using an alternative valve could be requirements for: - Higher maximum pressure or delta-pressure - Higher Kv-values - Higher or lower temperatures - Faster response time - Metal sealed (e.g. for supercritical gases like CO2 or ethylene) Badger Meter offers a wide range and variety of valves. These membrane valves are operated indirectly using an I/P-converter with compressed air. The I/P-converter is connected to the controller output of the mini CORI-FLOW. To be able to meet the quality and security standards Bronkhorst is used to, we will accept only those Badger Meter valves which meet the Bronkhorst Quality Norm. This norm includes certain predefined specifications to enable our production department to adjust, optimize and test these valves if they were Bronkhorst valves. Main items on this Bronkhorst Quality Norm are: Limit amount of models: RC200, ¼, ½ and 1 types Special O-ring chambers in valve bodies for Swagelok RS adaptor types (no NPT) If no O-rings possible: adaptors welded to valve body Spindle seals: Kalrez compound 3035 (in stead of Teflon) for reduced emission For operation interface: ABB TEIP11 I/P-converter: input signal 4-20 ma / output signal 0,2-1 bara (or bara) If not possible: Samson positioner Please note that for proper functioning of the pump or valve the MFC needs to be adjusted electrically and also needs to be provided with the right parameter settings. This will be taken care of in our factory. For pump- or valve connections in the field after delivery, please contact your local sales representative page 9

10 1.1.5 Liquid dosing systems with pumps BRONKHORST CORI-TECH B.V. In Bronkhorst liquid mass dosing systems Liqui-Flow or CORI-FLOW instruments control liquid mass flow using a pump through a U/f converter. The pump is just used as an actuator to follow the controller to achieve the wanted mass flow (setpoint). It is not used as a positioner as it normally is, using the standard pump control software. Normally Bronkhorst will take care of all electrical and mechanical connections between the parts as mentioned above are realized, as well as an optimization of the PID-control and a test on water/ipa (when possible). The analog controller output signal, which normally would be used to drive a proportional valve, is limited to either 10 Vdc/15 Vdc and connected to the analog input signal of the pump drive. Each Liquid Dosing System consists of a flow sensor with controlling function, a pump and all inter-connecting material. A filter and check valve can be supplied on request. Furthermore, Bronkhorst will take care of electrical and mechanical connection, testing and optimization including the PID-integrated controller. In addition to the Bronkhorst Liquid Pump for small flow ranges, a complete series of pumps is available for those applications which require higher flow rates, higher pressures, wide control ranges or aggressive fluids. Further to operation in an analog mode, the system can also be used digitally with RS232 or with on-board interface to PROFIBUS-DP, DeviceNet, Modbus-RTU, or FLOW-BUS. See picture below for schematic setup. Please note that for proper functioning of the pump or valve the MFC needs to be adjusted electrically and also needs to be provided with the right parameter settings. This will be taken care of in our factory. For pump- or valve connections in the field after delivery, please contact your local sales representative. page

11 1.2 Sensor measuring principle Mini CORI-FLOW sensor Mini CORI-FLOW mass flow meters/controllers operate according to the Coriolis principle. The instrument can be used to simultaneously measure the mass flow, temperature and density. When a fluid flows through a vibrating tube, Coriolis forces are generated which bend or twist the tube. The extremely small tube displacements are detected by optimally positioned sensors and evaluated electronically. Since the measured phase shift of the sensor signals is proportional to the mass flow, the mini CORI-FLOW measures the mass flow directly. The measurement principle is independent of the density, temperature, viscosity, pressure, heat-capacity or conductivity. The tubes always vibrate at their natural frequency, which is a function not only of the tube geometry and the tube material properties but also the mass of the fluid in the vibrating tubes. 1.3 Valve principles Control valves are not designed to provide positive shut-off, although some models have excellent capabilities for this purpose. It is recommended to install a separate shut-off valve in the line if required. Also pressure surges, as may occur during system pressurisation must be avoided. The following models can be distinguished: Solenoid valve Flow control valve This is considered to be the standard (direct operated) control valve. In general it is a normally closed solenoid valve. The plunger is lifted by the force of the magnetic field of the coil. The orifice under the plunger is removable for optimising the orifice diameter. Also a normally opened solenoid valve is available Vary-P valve flow control valve pressure compensating valve For process conditions where up- and downstream pressure varies much, a special type of valve, VARY-P has been designed. This valve consists of two valves, a solenoid operated control valve and a fixed adjusted pressure compensation valve Pilot operated valve P1 pilot valve pressure compensating valve P2 For high flow rates the pilot operated valve has been designed. A solenoid driven control valve controls the pressure difference across a piston, which lifts the main plunger. flow control valve page 11

12 1.4 Software for physical properties of gases and liquids. Bronkhorst has access to the physical properties of over 600 fluids in a database called FLUIDAT. Application software, such as FLOW CALCULATIONS, enables the user to calculate properties, not only at 20 C / 1 atm but also at any temperature/pressure combination, both for gases and for liquids. Apply to your distributor for more details about this software. 1.5 (mini) Cori-Flow accuracy Zeroing of a (mini) Cori-Flow instrument is required each time process conditions have been changed. What is zero-stability? Due to mechanical construction of the sensor tubes each (mini) Cori-Flow sensor will have a very small offset signal, even when the mass flow is zero. This is called the zero-stability error and is specified for accuracy separately for all Coriolis instruments. Main reason for this is the fact that this error can be (temporarily) neutralized after performing a zero-action. Immediately after zeroing, zero-stability error is 0%. However, it is allowed to move between a certain band depending on the environment (process) and fluid conditions. In ideal situations, where actual process conditions do not change, this error will remain the same. See below for possible reasons of change of zero-stability. See also paragraph to learn how to zero. Zero-stability depends on the (mini) Cori-Flow model: Model DN (mm) Zero-stability Nominal flow M < 0.1 g/h 100 g/h M < 0.2 g/h 1 kg/h M < 6 g/h 10 kg/h M < 50 g/h 100 kg/h M53 1 < 10 g/h 5 kg/h M54 2 < 50 g/h 50 kg/h M55 4 < 100 g/h 500 kg/h Nominal flow: mass flow rate of liquid at a pressure drop of approx. 1 bar and based on reference conditions of water at approx. 20 C NOTE: In practice zero-stability turns out to be better than the values in the table, but for calculation we will take worst case values. Accuracy The accuracy of a (mini) Cori-Flow is either 0.2% reading for liquids or 0.5% reading for gases. This specification is based on mass flow (e.g. g/h, kg/h, etc.). If the instrument will be used on volume flow (e.g. l/h, ml/min, etc) this will introduce an extra inaccuracy, based on the density (measurement). Process conditions Each time process conditions have been changed significantly a (mini) Cori-Flow needs to be zeroed in order to get rid of the offset error due to zero-stability. At least the very first time an instrument is used a zero procedure will be required. The zero-stability error will mainly change when one or more of the following items change significantly: Temperature (of fluid or environment) Pressure Density of fluid Vibrations working on instrument via environment Pulsation of supply pressure working on instrument page

13 What changes are allowed? How many changes in quantity for certain process conditions are allowed without the need of a new zero procedure for the (mini) Cori-Flow depends on the influence this will have on the mass in the tubes. As soon as a fluid will be measured at its critical point, a small change in process conditions like temperature or pressure can already result in a rapid increase or decrease of density and/or dynamic viscosity. This will also influence the mass (flow) in the sensor tubes and therefore the zero stability. So please try to avoid phase changes or almost phase changes. E.g. CO2 and Ethylene have a large transition area ( no meat, no fish ). Experiences in practice turned out that measuring (and even controlling) in such an area can be highly accurate. So measuring in critical, or even supercritical area s, is good possible with (mini) Cori-Flow. Inaccuracies are to be expected when a phase change takes place. See also gas or liquid. Temperature changes of several C or pressure changes of several bar for e.g. Air when measuring at 20 C and 5 bara will not be a problem. This will not affect density or dynamic viscosity that much. However when measuring e.g. Ethylene at 10 C and 52 bara, a small increase of temperature or decrease of pressure will already result in large changes of density and even phase change. This last example might need a new zero procedure to get rid of offset errors due to zero stability. Error visualization +/- 0.05% repeatability + x % error (zero stability) 0 % -> time - x % error (zero stability) Temperature considerations Effects on accuracy: (Mini) Cori-Flow sensors do have an internal temperature measurement device for measuring fluid temperature and compensation on mechanical changes of the sensor due to temperature changes page 13

14 Error calculation: Total error = accuracy reading ± [(zero stab./flow)x100] [% reading] Example 1: error at 10 kg/h reading at M14 for a liquid (= ±0.2% of reading) zero stability error of M14 < 6 g/h; calculate with 6 g/h Total error = ±(0.2% + (6/10000 * 100))% = ±( )% = ±0.26 % (= ± 26 g/h) Example 2: error at 500 g/h reading at M13 for gases (= ±0.5% of reading) zero stability error of M13 < 0.2 g/h; calculate with 0.2 g/h Total error = ± (0.5% + (0.2/500 * 100))% = ±( )% = ±0.54 % (= ± 2.7 g/h) Example 3: Total error of M14 (at constant temperature) Total error M14 up to 30 kg/h 4% 3% 0.2 %RD + 6 g/h 2% Max. error [%RD] 1% 0% -1% -2% % -4% Flow [g/h] page

15 Gas and liquid (mini) Cori-Flows can be used for gases and liquids. In all instruments capable of density measurement (e.g. mini CORI-FLOW series) there will be an automatic adjustment for change in density. CORI-FLOW M50-series however, cannot measure density. For those instruments it is advisable to calibrate them on air for gases and on water for liquids. Multi-range instrument Thanks to extremely high linearity of the sensor, (mini) Cori-Flow instruments can be easily re-ranged to a different full scale range (100% point). The analog output and the digital measured flow value will be scaled to this FS 100% point. E.g. An M13 can be used for a full scale between 50 g/h and 2000 g/h. Switching between these ranges can be realized using fieldbus, E-7000, Bright module or RS232 interface. There is free tooling software (FlowPlot) available for this purpose. Mini Cori-Flow instruments will get a calibration certificate for all possible FS ranges. The actual FS of the instrument is set to a value wanted by the customer and can be found on the gray sticker on the instrument. Summary In general: a (mini) Cori-Flow instrument is independent of physical properties. Performing an auto-zero on actual conditions (with zero flow) before use will get rid of offsets in the sensor. When these properties, like temperature, pressure, density and dynamic viscosity do not affect the mass in the tube or the mechanical sensor construction to much, error due to zero-stability will be small. Environment conditions are important to the mechanical behaviour of the sensor: Vibrations (of sensor, rack, pipes etc.) with frequencies or harmonics close to the sensor s natural frequency could result in errors in the measurement. Sensor oscillation frequencies vary from Hz, depending on the model. Pulsation of supply pressure may have negative influence on accuracy. Avoiding this is the best. Filtering is an option for improvement. Turbulences in flow may add extra noise to the measured value. Especially with high flow of gases straight pipes with lengths of cm. at least are advisable for realizing a more undisturbed flow. For other applications (e.g. liquids) inlets of about 10x inner diameter of tube are sufficient. Smooth reducing from wide to small tubes is advisable. See below: Optimal angle is approx. 7 Gas bubbles entrapped in liquids (and/or locked-up in sensor tube) give disturbances to flow measurement, especially in the lower flow ranges. Try to avoid this and purge with high flow to remove them. Fluid drops in gas flow (and/or locked-up in sensor tube) give disturbances to flow measurement, especially in lower flow ranges. Try to avoid this and purge with high flow to remove them page 15

16 2 INSTALLATION BRONKHORST CORI-TECH B.V. 2.1 Receipt of equipment Check the outside packing box for damage incurred during shipment. Should the packing box be damaged, then the local carrier must be notified at once regarding his liability, if so required. At the same time a report should be submitted to: BRONKHORST CORI-TECH B.V. RUURLO HOLLAND If applicable, otherwise contact your distributor. Remove the envelope containing the packing list; carefully remove the equipment from the packing box. Do not discard spare or replacement parts with the packing material and inspect the contents for damaged or missing parts. 2.2 Return shipment When returning material, always describe the problem and if possible the work to be done, in a covering letter. It is absolutely required to notify the factory if toxic or dangerous fluids have been metered with the instrument! This to enable the factory to take sufficient precautionary measures to safe-guard the staff in their repair department. Take proper care of packaging. If possible use the original packing box. Seal instrument in plastic Contaminated instruments must be dispatched with a completely filled in 'declaration on contamination form'. Contaminated instruments without this declaration will not be accepted. Note: If the instruments have been used with toxic or dangerous fluids the customer should pre-clean the instrument. Important: Clearly note, on top of the package, the customer clearance number of Bronkhorst Cori-Tech B.V., namely: NL B01 If applicable, otherwise contact your distributor for local arrangements. 2.3 Service If the equipment is not properly serviced, serious personal injury and/or damage to the equipment could be the result. It is therefore important that servicing is performed by trained and qualified service personnel. Bronkhorst Cori-Tech B.V. has a trained staff of servicemen available. 2.4 Mounting For the M12..M14 proper stable mounting is strongly advised on a rigid, solid base for optimal accuracy. For optimal isolation for vibrations in the area, rubber dampeners can be used. In the picture left an example of what Bronkhorst can provide for these purposes. This is not needed for the M15 because of a different sensor construction (box in box principle). Please see Short form instruction manual mini CORI-FLOW, document nr for more detailed information about mounting. page

17 2.5 Notes for temperature considerations The mini CORI-FLOW has to be installed in such a way that levels of different temperature within the mini CORI-FLOW are avoided. Avoid multiple heating and cooling of the instrument. Temperature shocks have to be avoided in any case. (max. 1 C/sec) After using the mini CORI-FLOW the first time at low temperature tighten the connector screws again in order to prevent any leakage! Please note: if you do not tighten the screws, the leaking connector / fitting can cause damage! After the first shrinking and tightening of the screws, no further precaution is necessary. Note that the maximum temperature in the housing of the mini CORI-FLOW is allowed to be up to 70 ºC max. Also note that a mini CORI-FLOW will have an amount of self-heating due to the power dissipation on the electronics (DSP). This self-heating can be up to approx. 15 ºC. It will be at maximum if there is no flow (less cooling). In practice, there will be a balance between fluid temperature, self heating, cooling effects and ambient temperature at the instrument. If the fluid is really hot, it would help if the instrument is in a cool environment. It will also depend on how well the installation where the instrument has been mounted in/on is capable of cooling. Anyway, one must take care that the instrument in the housing will not exceed the 70 C, otherwise the electronics will be damaged. To check this, the internal temperature sensor can be used. Via FLOW-DDE/E-7000 or Bright it can be read out. (FlowDDE par. 142). Please make sure the temperature value readout here (=actual temperature in housing) will not exceed 70 C. Down below some facts about maximum Tambient and Tfluid: Max. temperature in housing is 70ºC,but: Operating temperature conditions (continuous): Tfluid + Tambient < 110ºC With: Tfluid < 100ºC Tambient < 55ºC For cleaning purpose, instrument without power (continuous) Tfluid + Tambient < 130ºC With: Tfluid < 130ºC T ambient < 80ºC In all situations: Tfluid > 0 ºC Tambient > 0 ºC Storage temperature (dry tube) [ ] ºC page 17

18 2.6 Fluid/gas connections Bronkhorst Cori-Tech B.V. mini CORI-FLOW meters/controllers are equipped with compression or face-sealfittings. For leak tight installation of compression type fittings make sure that the tube is inserted to the shoulder in the fitting body and that no dirt or dust is present on tube, ferrules or fittings. Tighten the nut fingertight; while holding the instrument and then tighten the nut 1 turn. If applicable follow the guidelines of the supplier of the fittings. Special types of fittings are available on request. * Note: Always check your system for leaks, before applying fluid/gas pressure. Especially if toxic, explosive or other dangerous fluids are used. 2.7 Piping BE SURE THAT PIPING IS ABSOLUTELY CLEAN! DO NOT install small diameter piping on high flow rates, because the inlet jet-flow will affect the accuracy. DO NOT mount abrupt angles direct on in- and outlet, especially not with high flow rates. We recommend at least 20 pipe diameters distance between the angle and the instrument. Special care should be taken in regard to reducers placed just in front of the mini CORI-FLOW. High pressure drop and flow disturbance can occur which can influence the mini CORI-FLOW. 2.8 Electrical connections Bronkhorst Cori-Tech B.V. recommends using their standard cables. These cables have the right connectors and if loose ends are used, these will be marked to prevent wrong connection. 2.9 Pressure testing Each CORI-FLOW is pressure tested to at least 1.5 times the working pressure of the process conditions stipulated by the customer, with a minimum of 8 bara. The tested pressure is stated on the flow meter/controller with a RED COLOURED sticker. Check test pressure before installing in the line. If the sticker is not available or the test pressure is incorrect, the instrument should not be mounted in the process line and be returned to the factory. Each instrument is helium leak tested to at least mbar l/s Helium outboard Supply pressure Do not apply pressure until electrical connections are made. When applying pressure to the system, take care to avoid pressure shocks in the system and increase pressure gradually, especially on high pressure units incorporating a piston operated control valve. Make sure in case of a controller that the used valve can withstand the system pressure. Give special attention to the maximum delta pressure of the valve. page

19 2.11 System purging If explosive gases are to be used, purge the process with inert dry gas like Nitrogen, Argon etc. for at least 30 minutes at a high enough flow. In systems with corrosive or reactive fluids, purging with an inert gas is absolutely necessary, before taking in use. Preventing chemical reactions inside the tubes or instrument as this will tend to clog up or corrode the system. Complete purging is also required to remove such fluids from the system before exposing the system to air. It is preferred not to expose the system to air, when working with these corrosive fluids Seals Bronkhorst Cori-Tech B.V. has gathered a material compatibility chart from a number of sources believed to be reliable. However, it is a general guide only. Operating conditions may substantially change the accuracy of this guide. Therefore there is no liability for damages occurring from the use of this guide. The customer s application will demand its own specific design or test evaluation for optimum reliability. So check if the seals like O-rings and plunger are correct for the process Equipment storage The equipment should be stored in its original packing in a cupboard warehouse or similar. Care should be taken not to subject the equipment to excessive temperatures, humidity, vibrations or shocks page 19

20 2.14 Electromagnetic compatibility BRONKHORST CORI-TECH B.V. Conditions for compliance with EMC requirements All instruments described in this manual carry the CE-mark. Therefore they have to comply with the EMC requirements, as they are valid for these instruments. However compliance with the EMC requirements is not possible without the use of proper cables and connector/gland assemblies. For good results Bronkhorst Cori-Tech B.V. can provide standard cables. Otherwise follow the guidelines as stated below. 1. Connector mini CORI-FLOW 8 DIN CONNECTOR AMPHENOL C091 31D METAL RING TRANSPARANT TUBING FOLD THE SHIELD OF THE CABLE BACK OVER THE CABLE.(THE SHIELD MUST BE AROUND THE CABLE) SHIELD OF THE CABLE SHOULD BE CONNECTED TO THE CONNECTORHOUSING O-RING solder-side Amphenol 8-pin DIN connector female CABLE LIYCY 8x0.25mm 2 SHRINK SOLDERCONTACTS WITH SHRINKTUBING BRE 160 BLACK OR EQ. 20 mm 8 DIN CONNECTOR BINDER SERIE BLACK TUBING DETAIL SHIELD OF THE CABLE SHOULD BE CONNECTED TO THE CONNECTORHOUSING FOLD THE SHIELD OF THE CABLE BACK OVER THE CABLE.(THE SHIELD MUST BE AROUND THE CABLE) O-RING DETAIL solder-side Binder 8-pin DIN connector female SHRINK SOLDERCONTACTS WITH SHRINKTUBING BRE 160 BLACK OR EQ mm CABLE LIYCY 8x0.25mm 2 page

21 2. Cable gland assembly shield 15 mm 35 mm Fold the shield of the cable back over the cable (shield must be around the cable). shielded cable e.g. LAPP LiYCY shield metal cable gland e.g. HUMMEL HSK-M-EMV Mount the metal PG cable gland as shown in the drawing above. Note: When connecting the system to other devices (e.g. to PLC), be sure that the integrity of the shielding is not affected. Do not use unshielded wire terminals. 1. For FLOW-BUS S(F)TP data (patch) cable connection to M12 connectors follow the instructions of the supplier. It is important to use shielded twisted pair cables and shielded RJ45 modular jack connectors. 2. For PROFIBUS-DP, Modbus or DeviceNet data cable connections follow the instructions of the cable suppliers for the specific field-bus system Electro static discharge This instrument contains electronic components that are susceptible to damage by static electric discharges. Proper handling procedures must be taken during installation, removing and connecting the electronics page 21

22 3 OPERATION BRONKHORST CORI-TECH B.V. 3.1 General The Bronkhorst Cori-Tech B.V. instruments are designed in such a way that they will meet user process requirements in the best possible way. The mini CORI-FLOW meters/controllers can be powered from +15 Vdc to +24 Vdc. When providing your own power supply be sure that voltage and current rating are according to the specifications of the instrument(s) and furthermore that the source is capable of delivering enough power to the instrument(s). Cable wire diameters should be sufficient to carry the supply current and voltage losses must be kept as low as possible. When in doubt: consult factory. Mini CORI-FLOW instruments can be operated by means of: 1. Analog interface (0...5Vdc/0...10Vdc/0...20mA/4...20mA) 2. RS232 interface (connected to COM-port by means of special cable on Baud) 3. FLOW-BUS 4. PROFIBUS-DP 5. DeviceNet 6. Modbus 7. other fieldbus interfaces on request Option 1 and 2 are always present on multibus instruments. An interface to any available fieldbus is optional. Operation via analog interface, RS232 interface and an optional fieldbus can be performed at the same time. A special parameter called control mode indicates to which setpoint the controller should respond: analog or digital (via fieldbus or RS232). The RS232 interface behaves like a FLOW-BUS interface. When using more interfaces at the same time, reading and operation can be done simultaneously without problems. When changing a parameter value, the last value send by an interface will be valid. Also the push-button switch and the LED s on the left side of the instrument can be used for manual operation of some options. The green LED will indicate in what mode the instrument is active. The red LED will indicate error/warning situations. 3.2 Power and warm-up Before switching on power, check if all connections have been made according to the hook-up diagram which belongs to the instrument. Check fluid connections and make sure there is no leakage. If needed, purge the system with a proper fluid. For a gas instrument only purging with gases is allowed. Liquid instruments may be purged with either a gas or a liquid, whatever is needed for the purpose. Turn on power and allow at least 30 minutes to warm up and stabilise. In cases where no electronics are involved (valves only) warming up is not needed. During warm-up period, fluid pressure may either be on or off. 3.3 Start-up Turn on fluid supply gently. Avoid pressure shocks, and bring the instrument gradually up to the level of the actual operating conditions. Also switch off fluid supply gently when shutting down. page

23 3.4 Zeroing What is zero-stability? Due to mechanical construction of the sensor tubes each Coriolis sensor will have a very small offset signal, even when the mass flow is zero. This is called the zero-stability error and is specified for accuracy separately for all Coriolis instruments. Main reason for this is the fact that this error can be neutralized after performing a zero-action. Immediately after zeroing, zero-stability error is 0%. However it is allowed to move between a certain band depending on the environment and fluid conditions. In ideal situations where actual process conditions do not change, this error will remain the same. Each time process conditions have been changed significantly a mini CORI-FLOW needs to be zeroed in order to get rid of the offset error due to zero-stability. At least the very first time an instrument is used a zero procedure will be required. The zero-stability error might change when one or more of the following items change significantly: Mainly: Temperature (of fluid and environment) Mounting position of instrument Less important: Dynamic viscosity of fluid Vibrations working on instrument via environment Pulsation of supply pressure working on instrument Pressure Density of fluid Procedure for zeroing (See also Short form instruction manual mini CORI-FLOW, document nr ) Warm-up instrument for at least 30 minutes. Purge as long as needed with fluid to make sure there is no gas in the liquid or no condensate in the gas Fill instrument with fluid under process conditions. Close all valves at output to establish zero flow. Closing valves at input will not be critical (under circumstances even better to let them open) but extra shut-off valves at output should be closed, as well as control valve of instrument e.g. by means of setpoint = 0% or control mode = close valve. To start the zero procedure: Press push-button switch (#) on the side of the instrument and hold it (LED s will respond) until only the green LED is burning and then release the button. This command is also possible via any available fieldbus- or RS232 interface. The zeroing procedure will start at that moment and can be monitored by the LED s. The green LED will blink until the procedure is ready. This will take about 30 seconds. When it is ready it will burn green continuously again Zero-procedure information If the instrument has problems finding a proper and stable zero, it will repeat the auto-zero step a few times (max. 4 times). Each time no proper zero can be achieved, the instrument will give a short notice signalling its LED s after the procedure. The red and green LED will blink turn-by-turn for a few seconds to indicate that the auto-zero wasn t able to find a zero (because of too much noise in the signal). This is mostly the case when the instrument is placed in a vibrating environment. When ready zeroing after trying several (max. 4) times, the final result for the zero value will be a moving average value of all attempts. The instrument will save this zero value into its non-volatile memory and will keep this value until a next zero-procedure will be performed. This value (Sensor Input Zero Scale Adjustment) can be accessed (read/written), via parameter 218 in the parameter table of FlowDDE (note: Depending on firmware of instrument). The mini CORI-FLOW will accept a proper zero only if the measured signal is within a limited noise band. Best way to achieve this is to avoid external noise influences. However, when this is not possible, filter settings of the mini CORI-FLOW can be changed to improve noise immunity. Important: Always make sure that there is absolutely no flow when the instrument is performing the (auto-)zero procedure and there are no vibrations or pulsating inlet pressures page 23

24 3.4.4 Alternatives for starting zero procedure Through FLOW-BUS, using an E-7000 readout/control module. Through FLOW-BUS, via a RS232/FLOW-BUS converter using software on a PC or PLC. Through RS232, using software on a PC or PLC Through RS232, using a Bright compact local readout/control module Through other fieldbus system (PROFIBUS-DP/DeviceNet/ModBus) Zeroing with the Micro-switch Before using the instrument zeroing is required. Set process conditions After warm-up, pressure up and fill system including the mini CORI-FLOW according to the process conditions. Stop flow Make sure there is no flow through the instrument by closing the shut-off valves before and after the instrument. Press and hold, until GREEN LED is on, than release button With no flow, use the push-button switch (#) on the left side of the instrument to start the zero adjustment procedure. Press the push-button (#) and hold it, after a short time the red LED will go ON and OFF then the green LED will go ON. At that moment release the push-button (#). Zeroing The zeroing procedure will start at that moment and the green LED will blink fast. The zeroing procedure waits for a stable signal and saves the zero. If the signal is not stable, zeroing will take long and the nearest point to zero is accepted. The procedure will take approx. 25 sec. Make sure that there is no flow through the instrument when performing the zeroing procedure. Ready When indication is showing 0% signal and the green indication LED is continuously on, then zero has been performed well Zeroing through the digital communication It is also possible to start the zero adjustment procedure through the FLOW-BUS, using an E-7000 readout/control unit or a software program on a PC, connected to a FLOW-BUS interface module. The following parameters must be used for zeroing an instrument: Initreset [unsigned char, RW, , DDEpar. = 7, Proces/par. = 0/10] Cntrlmode [unsigned char, RW, , DDEpar. = 12, Proces/par. = 1/4] CalMode [unsigned char, RW, , DDEpar. = 58, Proces/par. = 115/1] Set process conditions Warm-up, pressure up the system and fill the instrument according to the process conditions. Stop flow Make sure there is no flow through the instrument by closing the shut-off valves before and after the instrument. Send parameters Send the following values to the parameters in this sequence. Initreset 64 Cntrlmode 9 Calmode 255 Calmode 0 Calmode 9 Zeroing The zeroing procedure will start at that moment and the green LED will blink fast. The zeroing procedure waits for a stable signal and saves the zero. If the signal is not stable zeroing, will take long and the nearest point to zero is accepted. The procedure will take approx. 25 sec. Make sure there is no flow through the instrument when performing the zeroing procedure. Ready When indication is showing 0% signal and the green indication LED is burning continuously again, then zeroing has been performed well. Also parameter control mode goes back to its original value. As last send 0 to parameter initreset. page

25 3.5 Operating conditions Each instrument has been adjusted for customer process conditions, if possible. Controllers or valves may not operate correctly, if process conditions vary too much, because of the restriction of the orifice in the valve. Please change supply- or backpressure to improve control behaviour. If this does not help, contact your local sales representative to assist you. 3.6 Manual operation By means of manual operation of the push-button switch (#) some important actions for the instrument can be selected/started. These options are available in both analog and BUS/digital operation modes. (See also manual operation in document number ) These functions are: - Reset (instrument firmware-program reset) - Reset in case of an alarm - Zeroing - Restore factory settings (in case of unintentionally change of the settings) for FLOW-BUS only: - Automatic installation to FLOW-BUS (installs instrument to free address) - Remote installation to FLOW-BUS (instruments will be installed by E-7000 or PC-software) 3.7 Analog operation Digital instruments can be operated with analog signals through the 8-pin circular connector. The instruments are compatible in use with analog instruments on this point. Analog operated instruments, can be hooked up using an 8-wire shielded cable, connected according to the Bronkhorst Cori-Tech standard. Each electronic PC-board is set for one of the following output (and corresponding input) signals: Signal output (sensor) input (setpoint) code signal signal A 0 5 Vdc 0 5 Vdc B 0 10 Vdc 0 10 Vdc F 0 20 ma (sourcing) 0 20 ma (sinking) G 4 20 ma (sourcing) 4 20 ma (sinking) Current output signals Sourcing instrument output 0V common I + ma - For meters only the output signal is available. At analog operation the following parameters are available: - measured value - setpoint (controllers only) - valve voltage (controllers only) page 25

26 Note: When operating the instrument through the analog interface it is possible to connect the instrument to any supported fieldbus system (or RS232-interface with special cable) for reading/changing parameters (e.g. controller response or other fluid selection). For FLOW-BUS versions of the instruments a readout/control module for digital instruments can be temporarily connected to the M12 fieldbus connector. 3.8 BUS / digital operation Operation via fieldbus reduces the amount of cables to build a system of several instruments and offers more parameter values to be monitored/changed by the user. See instruction manual: operating digital mass flow / pressure instruments for more details (document nr ). Operation by means of a fieldbus adds a lot of extra features (compared to analog operation) to the instruments. Such as: - adjustable filter settings to smoothen or speed-up the output signal - setpoint slope (ramp function on setpoint for smooth control) - adjustment of controller output (response time) for valve or pump control (PID-settings) - direct reading at readout/control module or host computer - testing and self diagnosis - response alarm (setpoint-measure too high for too long time) - several control/setpoint modes (e.g. purge/close valve) - master/slave modes for ratio control (FLOW-BUS only) - identification (serial number, model number, device type, user tag) - adjustable minimal and maximal alarm limits - (batch) counter - adjustable response time for controller when opening from zero - adjustable response time for normal control - adjustable response time for stable control ( setpoint-measure < 2%) Special software like FlowDDE, FlowPlot and FlowView can be used to control these settings. For operation of digital instruments by means of a specific fieldbus system or RS232, see following documents (available as PDF-file): for FLOW-BUS document number: for PROFIBUS-DP document number: for DeviceNet document number: for RS232 document number for Modbus document number page

27 3.9 RS232 communication cable T-part BRONKHORST CORI-TECH B.V. Fieldbus Power,Analog input, Analog output RS232 Note: Special RS232 cable has partnr and consists of a T-part with 1 male and 1 female 8-pin DIN connector on one instrument-side and a normal female sub-d 9 connector on the side of the computer. By means of this cable it is possible to offer RS232 communication and still be able to connect power-supply and analog interface through the (analog) 8-pin DIN connector. RS232 communication is only possible with a baudrate of 38.4 KBaud and can be used for either: Uploading new firmware by means of a special program (for trained Bronkhorst-service personnel only) Servicing your instrument using Bronkhorst-service programs (for trained Bronkhorst-service personnel only) Operating your instrument using FLOWDDE, FLOWB32.DLL or RS232-ASCII protocol (end user) page 27

28 4 MAINTENANCE 4.1 General BRONKHORST CORI-TECH B.V. No routine maintenance is required to be performed on the meters or controllers. In case of severe contamination it may be required to clean the valve orifice separately. 4.2 mini CORI-FLOW sensor The mini CORI-FLOW sensor is constructed in such a way that there is very little dead volume. The sensor is maintenance free. 4.3 Controllers All sensor types can be combined with a control valve to be operated together as a control loop. Controller systems are either available as separate units; a sensor and a control valve, or as an integrated unit. If applicable maintenance procedures are described under control valves 4.4 Control valves Control valves cannot be used for shut-off and/or on-off applications. Pressure surges, as may occur during system pressurisation or deflation must be avoided Solenoid valves These are considered to be the directly operated control and pilot valves. They can be disassembled in the field by the user for cleaning and servicing. The parts can be cleaned with a cleaning liquid, or in an ultrasonic bath. To disassemble the valve proceed as follows: a) disconnect the instrument connector (not necessary with separate valve) b) remove the hex nut on top of the valve assembly c) lift the cover (coil) assembly d) unscrew the flange e) lift valve assembly carefully from the base f) unscrew set screw for the orifice and subsequently loosen the orifice and the orifice holder g) remove the plunger assembly Clean parts and carefully re-assemble in reverse order. It is recommended to replace the O-rings prior to reassembly. After having re-assembled the control valve, it is recommended to check the control characteristics of the valve. This can best be done by using a separate variable 15 Vdc power supply source. Proceed as follows: - disconnect the valve leads and connect to supply source - apply gas pressure as per working conditions - apply power by gradually increasing voltage - the valve should open at 7 Vdc 3 Vdc - the fully opened position is reached at approx. 9 Vdc 1.5 Vdc. In case the valve does not operate within the voltage levels stated, then it must be disassembled, and the orifice must be adjusted to the proper position. Re-assemble valve and repeat procedure if required Vary-P valve The vary-p valve is designed to cope with extremely varying process conditions on either upstream or downstream side of the valve or a combination of these. p can vary over a wide range. The basic control valve is a direct operated solenoid control valve. The design has been patented. For orifice selection and maintenance other than the pilot valve consult the factory. page

29 4.4.3 Pilot operated valve This control valve is an indirect control valve, consisting of a spring loaded membrane/orifice system which is positioned by a solenoid operated direct control (pilot valve). The two devices are integrated in one block. Basically follow the same procedures for dis-assembly as stipulated under Solenoid valves For cleaning purposes it may be required to dis-assemble further, i.e. also remove the membrane assembly. For pilot operated valves the maximum pressure drop is limited to 20 bard. If the pressure drop during start-up is higher, it is preferred to install a bypass valve. During start-up this valve should be opened. Also the minimum pressure drop is limited. For exact figures consult factory or proceed according to the technical data and/or additional instructions given by the sales office or department. Note: When pressure testing a system incorporating a pilot operated control valve, a special procedure must be followed in order to prevent damage to the valve. In such cases it is necessary to contact the factory prior to do this. 4.5 K v -value calculation This calculation method can be used to determine the K v -value of the main orifice of a control valve For gases Determine desired p across valve. p must be at least 20% of supply pressure, or in closed loop systems, of total pressure difference in the loop. If p is 20-50% of supply pressure, use formula: K v m n T 514 n p p 2 under critical If P is % of supply pressure, use formula: K v m 257 p1 n T n over critical Units: m = flow [kg/h] p 1 = supply pressure [bara] p 2 = downstream pressure [bara] p = pressure difference (p 1 - p 2 ) [bara] T = temperature [K] n = density [kg/m 3 n ] The orifice diameter can be determined by: d= 7.6 K v [mm] page 29

30 4.5.2 For Liquids Determine desired p across valve. p must be at least 50% of supply pressure Kv-value calculation K v m p 1000 Units: flow - m (kg/h) 3 density - (kg / m ) at 20 C and 1 atm. delta p - p(bard) The orifice bore diameter can be determined by: d 7.6 Kv [mm] For C2 type of valves the diameter of the orifice can be calculated as shown above or looked up in the graph below. customer vh 2O = vcustomer H 2 O in which: v = volume flow = density d = 1.0 mm d = 0.7 mm 10 4 d = 0.5 mm 10 4 d = 0.37 mm d = 0.3 mm d = 0.2 mm 10 3 d = 0.14 mm 10 3 d = 0.1 mm O v H O (ml/h) P m a x P (b a r) If liquids have viscosity s >15 mpa.s (water = 1 mpa.s), the flat orifice and plunger type control mechanism cannot be used. For measuring systems only check maximum possible viscosity with factory. page

31 4.6 Calibration procedure All instruments are factory calibrated on all possible ranges, independent of customer conditions. Calibration will be performed with water under normal temperature and atmospheric conditions (20 C and 1 bara). After calibration the instruments will be dried thoroughly. Instruments will be calibrated using water on 6 points over the full flow range where the instrument can be used for. Because Coriolis instruments measure mass flow, they will have the same accuracy for all fluids and therefore calibrations on actual fluids will not be necessary. Also density will be calibrated and calibration checks on air will be performed. For the flow calibration, the instrument will be set to the maximum full scale value and seven points (including zero) will be compared with a reference. All points will be shown in a graph to illustrate that they are within limits of total accuracy (±0.2% ±Zero Stability). After this calibration, the actual capacity (full scale) value will be set to the wanted flow value ordered by the enduser. This value can be easily changed on site by the enduser using Bronkhorst tooling software (FlowDDE and FlowPlot) which can be downloaded from the website: Thus re-ranging the instrument will be possible between a minimum and a maximum capacity. Over this complete range the instrument calibration certificate will be valid. Analog outputs (A: 0 5Vdc /B: 0 10Vdc /F: 0 20mA /G: 4 20mA) for flow and analog inputs for giving setpoints to controllers, will be adjusted as ordered. These adjustments include an extra uncertainty of < ±0.1% at each input as well as at each output. The analog output and -input maximum values are equal to the actual capacity (full scale) value of the instrument and will be linear to the flow. If the instrument will be re-ranged: actual capacity will be set to another value, this analog value will get another meaning. The original, factory set, actual capacity (full scale) value and type of analog signal will be displayed on the grey sticker on the instrument. This will be the value what the instrument had been ordered for. G: 4 20mA analog input and output Capacity (FS) = 150 g/h Mix Example: M13 instrument has a maximum flow of max g/h. It will be calibrated up to 2000 g/h on 7 points, including zero. Enduser wants to use it with 4 20 ma and orders the instrument for 150 g/h. When the instrument leaves the factory 20mA will correspond with 150 g/h. After re-ranging it to a full scale of 500 g/h, 20mA will correspond with 500 g/h Mix. After re-ranging it to a full scale of 2000 g/h, 20mA wil correspond with 2000 g/h. Note: The fluidname Mix is just indicative for actual use. However, the meter will measure all fluids with same accuracy as long as the instrument is capable of handling the fluid (pressure drop, corrosion resistance, suitability of valve or pump etc.) page 31

32 4.7 Instrument re-ranging Re-ranging can easily be performed by changing the capacity of the instrument. This can be performed by using FlowPlot, E-7000 or Bright readout/control module, RS232 digital communication or any available fieldbus communication interface supporting parameter 21: capacity. Capacity can be set between minimum capacity and maximum capacity. The actual values depend on the type of instrument. FlowPlot can be downloaded at: Example of changing flow range using FlowPlot: Enter max flow range here (capacity) or move the slider. 4.8 Instrument filter settings Changing filter settings can be done using FlowPlot. FlowPlot can be downloaded at: Output filter: Dynamic display factor and Static display factor are filter settings for readout only (at analog output and digital output). Output signal filtering at stable situation and at a flow-step can be set separately. Sensor filter: Exponential smoothing factor is the most important filter parameter to influence the stability of the meter and will also influence the controller behaviour, where it will be provided as input for the controller. Adaptive smoothing factor does not have functionality for a mini CORI-FLOW. For a mini CORI-FLOW it will temporarily switch off the filter during a flow-step to enable fast controller behaviour together with strong filtering. For all filter settings: A value can be entered between 0 and 1, where values close to 0 will filter strongly and slow down the output. A value close to 1 will speed-up the output and will introduce more noise. At value = 0, the filter has been switched off. No signal is put-through: no signal changing. At value = 1, the output is equal to the input: no filtering at all. page