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NFE 2923 Q MA 001 - A - Manufacturer's Standard O&M Manual
NFE 2923 Q MA 001 - A - Manufacturer's Standard O&M Manual
PO PO15298
SAN JUAN LNG FACILITY
No. DOCUMENT NFE-2923-Q-MA-001
DOCUMENT N°:
NFE-2923-Q-MA-001
METERING SKID
A 2023-06-06 Issued for Review / Emitido para Revisión DRS ERM MVG
Contenido
1. ULTRASONIC FLOWMETER .................................................................................................................. 3
2. FLOW ALIGNER .................................................................................................................................. 280
3. VALVES – 3/4" ..................................................................................................................................... 287
4. VALVES – 8” 600# ............................................................................................................................... 327
5. VALVE WITH ACTUATOR – 8” 600# .................................................................................................. 344
6. FLOW COMPUTER ............................................................................................................................. 517
No. PO PO15298
SAN JUAN LNG FACILITY
No. DOCUMENT NFE-2923-Q-MA-001
1. ULTRASONIC FLOWMETER
Operating Manual
Issued: 07.05.2021
Version: 10
Firmware: 1.5
Contact
www.rmg.com
Content
1 ABOUT THIS MANUAL ......................................................................... 1
1.1 Objective of the manual ....................................................................................... 1
I
1.2 Specialized knowledge required ....................................................................... 2
1.2.1 Specialized knowledge required .......................................................................... 2
1.2.2 Abbreviations....................................................................................................... 3
1.2.3 Layout of instructions .......................................................................................... 4
1.2.4 Working with the device ...................................................................................... 5
1.2.5 Risk assessment and minimization ................................................................... 11
1.2.6 Validity of the manual ........................................................................................ 13
1.2.7 Transport ........................................................................................................... 14
1.2.8 Scope of delivery ............................................................................................... 16
1.2.9 Disposal of packaging material ......................................................................... 16
1.2.10 Storage .............................................................................................................. 16
1.3 Explosion-proof design .....................................................................................17
1.3.1 General information ........................................................................................... 17
1.4 Inspection and maintenance work ..................................................................18
1.4.1 General information ........................................................................................... 18
5 SAFETY.................................................................................................. 53
5.1 Intended use ........................................................................................................ 54
5.2 Layout of instructions ....................................................................................... 55
5.3 Qualification of the personnel ......................................................................... 56
5.4 Safety instructions ............................................................................................. 57
5.4.1 Hazards during transporting .............................................................................. 58
5.4.2 Hazards during installation ................................................................................ 58
5.4.3 Hazards during start up ..................................................................................... 60
5.4.4 Hazards during cleaning ................................................................................... 61
5.4.5 Hazards during maintenance and repairs ......................................................... 61
5.4.6 Hazards during operation .................................................................................. 62
5.4.7 Hazards for operation in potentially explosive environments ............................ 63
5.5 Responsibilities of the operator ...................................................................... 64
8 INSTALLATION .................................................................................... 95
8.1 Assembly work preparations ...........................................................................96
8.2 Installation of the device ...................................................................................99
8.2.1 Mounting the inlet and outlet piping ................................................................... 99
8.2.2 Installation of the connection box .................................................................... 101
8.3 Connecting the device electrically ............................................................... 103
8.3.1 Connecting the power supply .......................................................................... 108
8.3.2 Digital interfaces of USM-GT400 ..................................................................... 108
8.3.3 Connecting the computer for RMGViewUSM ..................................................... 110
8.3.4 Connecting the flow computer ......................................................................... 110
8.3.5 Connection of external DSfG-Device-F via Modbus ........................................ 113
8.3.6 Interface converter .......................................................................................... 124
8.3.7 Connecting the device to earth ........................................................................ 126
8.4 Installing the pressure connection .............................................................. 128
8.5 Outdoor installation ......................................................................................... 130
10 OPERATION........................................................................................ 134
10.1 Measuring values and parameters ............................................................ 135
10.1.1 Input protection for parameters ....................................................................... 135
10.1.2 Parameter and measuring values with variable units ..................................... 135
10.1.3 Calibration and Service Switch ....................................................................... 136
IV 10.1.4 Interfaces to converters and controllers .......................................................... 136
10.1.5 Interface for service and parameterization ...................................................... 137
10.1.6 Adaptation of the DZU protocol to ERZ 2400 ................................................. 138
10.2 Calling up and changing the parameters via the ultrasonic electronics
139
10.2.1 Calling up the value of a parameter ................................................................ 140
10.2.2 Entering data ................................................................................................... 141
10.2.3 Changing the parameters of protection E and S ............................................. 144
10.3 Parameterize the USM interface ................................................................. 149
10.3.1 Interface 0 ....................................................................................................... 149
10.3.2 Interface 1 ....................................................................................................... 150
10.3.3 Interface 2 ....................................................................................................... 150
10.4 Modbus communication in detail .............................................................. 161
10.4.1 Codes supported ............................................................................................. 161
10.4.2 Data types ....................................................................................................... 161
10.5 Configuration of the current output .......................................................... 163
10.6 List of the measurement values and parameters ................................. 163
VI
Vorsicht
Unintended use voids all warranty claims and the Ultrasonic Flowmeter
USM GT400 can also lose its approvals.
1.2.2 Abbreviations
The following abbreviations are used:
4
Danger
This warning notice informs you of imminently threatening dangers that
can arise due to misuse/operator error. If these situations are not avoided,
death or severe injuries can occur.
Warning
This warning notice informs you of potentially dangerous situations that
can arise due to misuse/operator error. If these situations are not avoided,
minor injuries can occur.
Caution
This notice informs you of potentially dangerous situations that can arise
due to misuse/operator error. If these situations are not avoided, damage
to the device or nearby property can occur.
Note
This notice provides you with helpful tips to make your work easier. This
notice also provides you with further information about the device or the
work process in order to prevent operator error.
5
Danger
All of the following safety notices must be observed!
Disregard of the safety notices can result in danger to the life and limb or
environmental and property damage.
Bear in mind that the safety warnings in this manual and on the device cannot
cover all potentially dangerous situations, because the interaction of various condi-
tions can be impossible to foresee. Merely following the instructions may not suf-
fice for correct operation. Always remain attentive and consider potential conse-
quences.
• Read this operating manual and especially the following safety notices care-
fully before working with the device for the first time.
• Warnings are provided in the operating manual for unavoidable residual
risks for users, third parties, equipment, or other property. The safety in-
structions used in this manual do not refer to unavoidable residual risks.
• Only operate the device in fault-free condition and in observance of the op-
erating manual.
• Compliance with local statutory accident prevention, installation and assem-
bly regulations is also mandatory.
Caution
All notices in the manual must be observed.
Use of the gas chromatograph PGC 9300 is only permitted in accordance
with the specifications in the operating manual.
RMG assumes no liability for damages arising due to disregard of the op-
erating manual.
Danger
Service and maintenance tasks or repairs that are not described in the op-
erating manual must not be carried out without prior consultation with the
6
manufacturer.
Changes to the device are not permitted.
The technical specifications must be observed and followed for safe oper-
ation (see chapter 13: Technical specifications).
Performance limits must not be exceeded.
Please only use screws, bolts, nuts and seals or parts with comparable
characteristic values for installing the meter in the pipeline. (see chapter 7
Construction and Planning)
For safe operation, the device must only be used in the scope of the in-
tended use. (see chapter 5.1 Intended use).
Note
Danger
Danger
Connection of pressurized pipelines must only be carried out by trained
qualified personnel.
Danger
The installation and removal of the USM GT400 may only take place in a
depressurized state and in an explosion-free atmosphere. During the in-
8
stallation process, the descriptions in the operating instructions must be
observed.
In general, it is recommended to carry out an exchange only in consulta-
tion with RMG Service.
After working on pressure-bearing components, the tightness must be
checked.
All of the above points also apply to repair and maintenance work and gen-
erally when the meter has to be opened.
Flange fastening elements, screw plugs, screw connections and check
valves as well as pressure extraction screw connections, valves and pro-
tective tubes must not be loosened during operation.
Operating personnel The operating personnel use and operate the device in
the scope of the intended use. 9
Maintenance personnel Work on the device must only be carried out by qualified
personnel who can carry out the respective tasks on the
basis of their technical training, experience and familiar-
ity with the applicable standards and requirements.
These qualified personnel are familiar with the applica-
ble statutory regulations for accident prevention and can
independently recognize and avoid potential dangers.
Maintenance and clean- Maintenance and cleaning must only be performed by
ing appropriately qualified technicians.
Danger
Danger
The device can be damaged if it is not cleaned as specified in the operat-
ing manual. Only clean the device as specified in the operating manual.
If you do not use the appropriate tool, components may be damaged. The
explosion protection becomes invalid.
• Only clean the device with a slightly damp cloth!
Danger
The USM GT400 must only be used as intended! (Chapter 5.1).
10
Danger
Prevent use of the USM GT400 as a potential climbing aid or use of attach-
ments of the USM GT400 as potential handles.
Danger
The following applies for work in explosion-prone areas (all zones):
12 - Only tools that are approved for Ex Zone 1 are permitted for mainte-
nance and repair tasks. Components can be damaged if you do not
use suitable tools.
The explosion protection is lost.
- Otherwise, work must only be carried out when there is not an ex-
plosive atmosphere.
- The risk of ignition due to impact or friction must be avoided.
- The wiring from and installation of the gas chromatograph PGC 9300
in explosion-prone areas must only be carried out by trained person-
nel in accordance with EN60079-14 and in observance of national
regulations.
- Qualified persons must satisfy the definitions in accordance with
DIN EN 0105 or IEC 364 or directly comparable standards.
- Only trained and instructed personnel are permitted. Work on the
measuring system must only be carried out by qualified persons and
inspected by responsible qualified supervisors.
- Qualified persons have been authorized by the person responsible
for safety of personnel to carrying out such work on the basis of
their training, experience or instruction and familiarity with applica-
ble standards, provisions, accident prevention regulations and sys-
tem conditions. It is essential that these persons are able to recog-
nize and avoid potential dangers in good time.
Caution
Ensure that the power data of the current connection matches the specifi-
cations on the type plate. Observe any applicable national regulations in
the country of use. Use cable that is appropriate for the cable fittings (see
chapter 8.3 Connecting the device electrically).
Danger
Only work on the equipment if you have the appropriate training and quali-
fications.
• Only operate the USM GT 400 in fault-free and complete condition. If you make
technical changes to the device, safe operation can no longer be guaranteed.
• When connecting additional measuring components or additional equipment in
explosion-prone areas, ensure that the appropriate explosion protection is pro-
vided for these components.
• They are intrinsically safe devices for which galvanic isolation must be provided
with connection of these devices.
The USM GT 400 is permitted for operation in Ex Protection Zone 1, but only
within the permissible temperature range (Chapter 13: Technical specifications).
14
1.2.6.3 Responsibility of the operator
As the operator, you must ensure that only adequately qualified personnel work on
the device. Ensure that all employees who work with the device have read and un-
derstood this manual. You are also obligated to train personnel regularly and in-
form them of the dangers. Ensure that all work on the device is carried out exclu-
sively by qualified persons and inspected by responsible qualified supervisors. The
responsibilities for installation, operation, fault rectification, maintenance and
cleaning must be clearly regulated. Instruct your personnel with regard to the risks
involved with working with the device.
Suitable personal protective equipment must be used for all work on the USM
GT400, which you as the operator must provide. This also applies even though all
sharp edges on the device have been removed as far as possible.
1.2.7 Transport
The device is packaged specific to the transport requirements for each customer.
Ensure safe packaging that absorbs light impact and vibrations is used for any fur-
ther transport. Nevertheless, inform the transport company that all types of impact
and vibrations should be avoided during transport.
Warning
Risk of injury during transport
Any foot screws must be mounted if they are provided as a transport safe- 15
guard to prevent rolling and tipping. Additional measures must be taken to
ensure that impermissible rolling and tipping are prevented.
Only use the provided lifting eyes / ring screws to lift the meter. Please ob-
serve the relevant permissible loads for the lifting equipment. Prior to lift-
ing, ensure that the load is securely fastened. Do not stand under sus-
pended loads.
The device can slip, topple over or fall down when being lifted and set
down. The device can fall over if the bearing capacity of the lifting equip-
ment is disregarded. There is a risk of severe injury for nearby persons.
If the device is delivered on a Euro pallet, the device can be transported
on the pallet using a pallet truck or forklift.
The gas meters and accessories must be protected from jarring and vibra-
tions during transport.
The gas meters or any inlet/outlet pieces have a flange as an end piece.
The flanges are sealed with a protective sticker or fitted with a plastic
dummy plug. The protective stickers and/or dummy plugs must be re-
moved without leaving any residue prior to installation in the pipeline.
Residue from this film changes the flow and causes measuring errors!
This protection must be re-applied to the flanges for transport or storage
of the device.
1.2.10 Storage
Avoid extended periods of storage. After storage, inspect the device for damage
and test for correct function. Contact the RMG service department to arrange for
inspection of the device after a storage period of longer than one year. For this
purpose, return the device to RMG.
Code: II 2G Ex de IIB+H2 T6 Gb
The applicable regulations must always be observed during installation and opera-
tion. The device is approved for operation in hazardous areas. The permitted elec-
trical data can be found in chapter 8.3 Connecting the device electrically.
Danger
Risk of destruction by body electricity, e.g. due to friction of clothing - ap-
propriate protective clothing must be worn.
Notice
During installation, it must be ensured that the enclosure protection class
is observed. Direct sunlight must be avoided.
The USM GT400 complies with protection class IP66 due to EN 60529.
Temperature range
MID:
-20°C bis +55°C (Umgebungstemperatur, für eichamtliche Messung)
18
Nach ATEX:
-40°C bis +80°C
Notice
In case of doubt, the limited range of the MID applies: -25°C to +55°C
(optional -40° bis +55°C)
Notice
We recommend at least one check per year (e.g. in connection with the an-
nual calibration).
This chapter provides information on how you can extend the service life of the de-
vice through maintenance. You can only protect the device from premature wear if
you adhere to the maintenance interval described here.
Danger
Work on live electrical equipment is generally prohibited in hazardous ar-
eas (except for intrinsically safe circuits).
In special cases, work can also be carried out on live electrical equipment in haz-
ardous areas if it is ensured that no potentially explosive atmosphere is present.
This may only be done with explosion-proof, approved measuring instruments.
Danger
If access to electrical modules is necessary, the following precautions
must be taken: 19
• The entire device must be disconnected from the power supply.
• When working with electronic assemblies, a connection must be
established between an earthed object and the body.
Notice
Pay attention to accumulation of water in the housing, because the explo-
sion-proof housing is only conditionally protected from water by the gap
protecting against ignition sparks (IP54).
Rusted or corroded gaps must not be cleaned with grinding materials or
wire brushes; chemical means must be used, such as reducing oils. Then
acid-free anti-corrosive agents, such as ESSO RUST BAN 397, Mobil Oil
Tecrex 39 or equivalent products must be applied to the gaps for protec-
tion.
Danger
The seal for the Ex-e housing must be inspected for damage and replaced
as necessary.
Check cable connections and sealing plugs for tight seating.
Damage to the housing can negate the Ex protection!
2 Quick guide
This chapter does not replace the rest of the operating instructions. It shows only a
20 brief section of the steps necessary in order to make the device ready for
operation.
Danger
22
1 Terminal Connections
Fig. 2.1: Connection assignment on the terminal strip
You find recommended cable types in the chapter 8.3 Connecting the device electri-
cally.
2.3 Start up
12 Supply the device with power supply (24 V DC) via the system.
If the power LED illuminates green permanently, the device is ready for
operation.
If the alarm and warning LED do not flash, the device operates trouble-free.
2.4 Earthing
23
1 Earthing screw M6
2 Earthing screw M6
3 Earthing cable
Fig. 2.2: Earthing – Ultrasonic gas meters DN100 (4”) and DN150 (6”)
1 Earthing screw M6
2 Earthing screw M6
3 Earthing cable
Fig. 2.3: Earthing – Ultrasonic gas meters ≥ DN200 (8”)
13 Connect the earthing cable according to the ultrasonic gas meter version
DN100 (4") to DN150 (6") or from DN200 (8").
3 Device overview
In this chapter you will receive information on the main components
of the ultrasonic gas meter and the arrangement of the 25
ultrasonic transducers in the housing of the ultrasonic gas meter.
Content
27
Device data (readings and parameters) can be set and evaluated via the display
and the operating elements.
Moreover, the device data (readings and parameters) can also be shown, evalu-
ated and set using the RMGViewUSM software.
Display screen
First line
Shows the name of the parameter (coordinates) called-up, e.g., p-maximum value
(maximum pressure value).
Second line
Shows the value of the parameter (coordinates) called-up, e.g., 52.00 bar a.
Third line
Shows the coordinate designation, e.g., A-06, thus column A, line 06.
Forth line
Shows the warning, alarm and status messages, e.g., -01 power failure.
Buttons
When the cover is closed, the buttons can be operated through the glass using the
magnet supplied. The cover must not be opened.
29
When holding for a longer time, you can change the columns by quickly
scrolling back.
When holding for a longer time, you can change the columns by quickly
scrolling back.
When holding for a longer time, you can change the lines quickly scrolling
forward.
Change or scroll back in the lines step by step, e.g., from A-01 to A-02.
When holding for a longer time, you can change the lines with quick return.
Enter values.
Reset button
1 The reset button (1) is for RMG service only. If the reset
button is pressed, the ultrasonic electronics is restarted.
Switches
30
1 Flow 6 Calibration
2 Power (calibration switch state)
3 Alarm 7 Service
4 Warning (service switch state)
5 Reset 8 Button states
---
Control panel Panel is being pressed.
31
1 Level 1
2 Level 2
3 Level 3
4 Path 1 and 2
5 Path 3 and 4
6 Path 5 and 6
Fig. 3.5: Transducer paths and levels of the ultrasconic gas meter
The figure shows the arrangement of the transducers that are located in the
ultrasonic gas meter. The arrangement of the transducers in the three levels is
shown in three section representations.
Four transducers are installed per level. The transducers form two paths per level
for the measurement.
Fig. 4.1: Two sensors form one path for the measurement
The transit time from TD1 to TD2 (:= tTD12 ) and from TD2 to TD1 (:= tTD21 )
re calculated according to the following formula:
Formulas
𝐿 𝐿
𝑡𝑇𝐷12 = 𝑡𝑇𝐷21 =
𝑐0 + 𝑣̅ · 𝑐𝑜𝑠𝛽 𝑐0 + 𝑣̅ · 𝑐𝑜𝑠𝛽
These transit times of the ultrasonic pulses are determined by the electronic
ultrasonic system. These are used to determine the average velocity ṽ along the
measuring path:
𝐿2 𝑡𝑇𝐷21 − 𝑡𝑇𝐷12 𝐿2 𝛥𝑡
𝑣̅ = ∙ = ∙
2 ∙ 𝑑 𝑡𝑇𝐷12 ∙ 𝑡𝑇𝐷21 2 ∙ 𝑑 𝑡𝑇𝐷12 ∙ 𝑡𝑇𝐷21
Legend
v̄ Average flow velocity
34 c0 Speed of sound
L: Path length
d: Diameter D
(For a center path. Outer paths have a corresponding value.)
For this calculation, it is important that only the transit times and the device param-
eters such as the transducer distance and the angle of the measuring path to the
flow direction are required. All parameters that include a gas dependency are
omitted.
The respective average path velocities (designated with vi = v̄i for the respective
measuring path i) along these measuring paths results analogically to the formula
above.
Under certain conditions such as, e.g., smaller deviations from the tolerances
during the production, it may be necessary to correct the path velocities with a
common factor:
vki = k vi
Legend
vki = Corrected path velocity (m/s)
vw = ∑ wi ∙vki
35
i=1
Flow velocity
Legend
The summation and the weighting specified result from the mathematic Gaussian
integration procedure.
Quality of installation
The USM-GT-400 provides parameters that allow a rating of the installation. If the
values are within given ranges, then good measurement conditions can be as-
sumed. If the values are outside the accuracy of the reading may be affected by
disturbed flow conditions. Please contact in this case the RMG service.
"Manufacturer" on page I
Turbulence
𝑁
1
𝜎𝑖 = √ ∑(𝑣𝑗,𝑖 − 𝑣̅𝑖 )2 ˄ 𝑖 = 1. .6; 𝑁 = 20
𝑁−1
𝑗=1
Variance
𝜎𝑖
𝑇𝑢𝑖 =
𝑣̅𝑖
Turbulence
Legend
v̅i = Time averaged flow velocity along the ultrasonic path
Typical values at very good flow conditions for middle paths are at 2-3%, for the
outer paths, the turbulence increases to 4%. If these values are above 10%, then
disturbed conditions can be assumed affecting the measurement accuracy. At
lowest velocities the turbulence calculation is switched off.
For a fully developed flow the middle path (3 + 4) have the highest velocity, the
two outer paths (1 + 2; 5 + 6) are more or less equal. The profile factor ( PF ) is
typically between 1.05 to 1.20; at values below 1.00 or above 1.50, the flow condi-
tions should be checked.
2(𝑣̅3 + 𝑣̅4 )
𝑃𝐹 =
(𝑣1 + 𝑣̅2 ) + (𝑣̅5 + 𝑣̅6 )
Profile factor
(𝑣̅5 + 𝑣̅6 )
𝑆𝑌 =
(𝑣1 + 𝑣̅2 )
Symmetry factor
Meter performance
This value ( MP ) indicates whether the velocity of all ultrasonic paths could be
measured and involved in the flow calculation. It is calculated on base of the last
20 measurements (same as turbulence).
The highest value is 100%; under normal conditions it is above 95%. Since 2
measurement paths can fail before the USM-GT-400 loses its calibrated accuracy,
the value may drop down to 66%; if the path failure is caused by a defect trans-
ducer
an immediate repair of the failed transducers should be initiated. 37
All of these values are given at the display of the USM-GT-400; they are identical
to the values in the RMGViewUSM.
Legend
vwk = Corrected average flow velocity (m/s)
Kv = Meter factor
These values can be used to calculate the process volume flow rate respectively
the corrected process volume flow:
Legend
Qmk = Corrected process volume flow
A 4th degree polynomial permits the so-called basic correction of the device:
Legend
F1 = Deviation of the error curve (%)
The constants const-Gx (x = m2, m1, 0, 1, 2) are calculated from the measured
value pairs of the deviation with the respective flow velocity. The calculated correc-
tion F1 is used for the corrected average flow velocity for F in the formula above.
Polynomial
The characteristic curve correction is also carried out via a 4th degree polynomial
that represents the error curve of the device.
Qb = Flow (m/s)
const-n = Constants
The constants Konst-n (n = m2 bis n = 2) are calculated from the measured value
pairs error F2i and flow Qbi. The characteristic curve correction Kk is used for fur-
ther calculation of the corrected process volume flow.
Calculation of SoS
𝑆𝑜𝑆 = 𝑐0
𝐿 𝑡𝑇𝐷12 +𝑡𝑇𝐷21
= ∙
2 𝑡𝑇𝐷12 ∙𝑡𝑇𝐷21
This first option is pretty fast and is almost permanently "online" available.
The temporal correlation of the actual gas composition (using the SoS calculated
via the gas composition) to the SoS using method 1 results in the higher temporal
resolution for the gas composition, respectively the calorific value.
41
Transducer TD2 receives at first the ultrasonic pulse (light blue) coming from TD1
at the time (tTD12). This pulse is partially reflected and moves back to TD1 (dark
blue). There this pulse is reflected, too and reaches TD2 (red) again after the time
(tTD12 21 12). The differences of tTD12 21 12 and tTD12 results in a new possibility to cal-
culate SoS:
𝑆𝑜𝑆 = 𝑐0
𝐿 𝑡𝑇𝐷12 +𝑡𝑇𝐷21
= ∙
2 𝑡𝑇𝐷12 ∙𝑡𝑇𝐷21
𝐿 (𝑡𝑇𝐷12 21 12 −𝑡𝑇𝐷12 )
= ∙
2 𝑡𝑇𝐷12 ∙(𝑡𝑇𝐷12 21 12 −2∙𝑡𝑇𝐷12 )
Due to a 10-times smaller variance of the SoS calculation this method offers signif-
icantly more accurate result compared to the standard method (version 1). There
are 2 reasons for this result; first, the transmitter / receiver error is eliminated (es-
pecially TW; the transit time of the pulse in electronic and transducer is different in
the individual transducers) and secondly, any flow turbulence in medium has low-
est influence to the transit time (the time interval between tTD12 and tTD21 is as short
as possible). Having typical measuring conditions, this method can easily be ap-
plied, but there are conditions at which this method may fail.
The SoS calculation according to method 1 and 3 run simultaneously and con-
42 trolled using the same criteria. If correct, the result of the extended measurement
is preferred due to its higher accuracy. Otherwise, the standard method 1 is used;
after any change the measurement conditions, both methods are revalued again. If
correct the extended SoS calculation will be chosen again.
TW-setting
Measurement tolerances and/or errors of the standard method are permanently
controlled using the comparison with the expanded method. Having both values a
correction for TW can be determined. When the calibration switch is open, the TW-
value of the standard measurement can be corrected to the value of the extended
measurement. This is an important adjustment help in case of a transducer re-
placed, but also serves as an accurate path lengths determination between the
transducers during the dry calibration.
“Default air”
All other possibilities to transmit the volume fractions of the individual gas compo-
nents on the USM-GT-400, will use interface 2 of the USM-GT-400.
Terminal connections
44
The following figure shows the terminal connections.
1 Terminal connections
2 COM
3 Gas-Chromatograph
Fig. 4.4: Terminal connections
The SoS calculation depends in addition to the gas components also on the gas
pressure and temperature. How to measure the pressure is described in chapter
8.4; temperature measurement is given in chapter 7.4. Setting of the parameters
AX-02 "SoS Source Temp." and AX-03 "SoS Source Pressure" allows to select
whether these measured values of temperature and pressure are used for AGA-10
calculation or default values AX-04 and AX-05.
45
The electric connection of pressure (p) and temperature (T) has to be done a
terminals 26 to 31; AUX1 = p; AUX2 = T.
Because the content of the telegram may have data from different streams, the
„right“ stream has to be set with the parameter AX-09 "Stream selection". Parame-
ter AX-08 "RMGBus mode" fixes how many components are part of the telegram.
When using a GC9000 this parameter has to be set to "RMGBus" to offer a correct
evaluation for older versions of the software GC9000.
1. Parameter J-25 "Opt. Ser2 mode":
"RMGBus"
2. Schnittstellenparameter von Seriell 2 anpassen:
J-26 „baud“
J-27 „bits“
J-28 „parity“
Match RMGBus master:
„Serial port 2“
3. Parameter AX-01 "AGA-10 source“:
"Serial port 2"
47
48
Time [minutes] in which a new telegram must have come
Timeout: During the transfer of data, an adjustable time-out is
available, generating a status signal if no new data arrived within
the adjusted time.
6. Parameter AX-10
"Modbus-Master Target": "GC9300"?
If yes, continue after 8, otherwise at 7.
7. Parameter AZ-01 - AZ-54
Enter Modbus registers of the gas components and status of the
slave device
49
The following examples demonstrate the classification of the gas components into
the 21 AGA-10 components.
Example 1:
Component Input AGA-10 AGA-10
mol-% unnormalized normalized
50 mol-% mol-%
Methane 35.0 35.0 70.0
Ethane 5.0 5.0 10.0
Propane 1.0 2.0 4.0
Propene 1.0 - -
iso-Pentane 1.0 - -
n-Pentane 1.0 2.0 4.0
CO 2 0.2 1.0 2.0
Ethen 0.8 - -
Hexane+ (5.0) - -
Hexane 3.0 3.0 6.0
Nonane 2.0 2.0 4.0
Sum 50.0 50.0 50.0
Example 2:
Component Input AGA-10 AGA-10
mol-% unnormalized normalized
mol-% mol-%
Methane 80.0 80.0 80.0
Ethane 5.0 5.0 5.0
Propane 2.0 2.0 2.0
n-Butane 1.0 1.0 1.0
neo-Pentane 1.0 - -
n-Pentan 0.0 1.0 1.0
CO 2 0.0 2.0 2.0
Ethen 2.0 - -
Hexane+ 5.0 - -
Hexane - 5.0 5.0
Nitrogen 4.0 4.0 4.0
Sum 100.0 100.0 100.0
The default values are 2. 0 and 1 are identical; there is no batch activated. All
larger values are squared; F-Batch 2 means there are 4 signals superimposed. If
the F-Batch is active the ring down time should be chosen as short as possible,
preferably to 0 ms. The slow batch mode can be activated in coordinate AI-09; it is
to be squared for all paths, too.
The shortest possible response time is therefore obtained with E-9 = 1 and AK-34
to AP-34 = 1. However, these settings should only be used with stable flow profiles
and low noise levels. If necessary, these parameters must be optimized during
commissioning.
5 Safety
In this chapter you will receive information on using the device in a safe manner.
53
Content
When used for its intended purpose, the ultrasonic gas meter is suitable for use in
potentially explosive areas classified as zone 1.
The ultrasonic gas meter complies with the standards, directives and guidelines.
Chapter 16.5, “Standards, directives and guidelines” on page 247
These technical limits must be maintained for a safe use of the ultrasonic gas me-
ter:
Chapter 13, “Technical specifications” on page 177
Danger
This warning instruction informs you of potentially hazardous situations that can
occur as a result of incorrect operation or human error. If these situations are
not avoided, they can lead to fatal or severest injuries.
Warning
This warning instruction informs you of possible hazardous situations that can
occur as a result of incorrect operation or human error. If these situations are
not avoided, they can lead to fatal or severe injuries.
Caution
This warning instruction informs you of possible hazardous situations that can
occur as a result of incorrect operation or human error. If these situations are
not avoided, they can lead to slight or minor injuries.
Notice
This warning instruction informs you of potentially hazardous situations
that can occur as a result of incorrect operation or human error. If
these situations are not avoided, they can result in material damage to
the device or the vicinity.
Dieser Hinweis gibt Ihnen Tipps, wie Sie Ihre Arbeit erleichtern können.
Zusätzlich erhalten Sie mit diesem Hinweis weitere Informationen zum
Gerät oder zum Arbeitsprozess.
Danger
Observe the following safety instructions
Non-observance of these safety instructions can lead to a risk of life and limb
and health of the person as well as damage to the environment or property
damage.
• Before working with the device for the first time, read through this operating in-
struction and, in particular, follow the safety instructions carefully.
• Always keep the operating instructions within reach for use at the place of in-
stallation.
• The operating instruction warns against the residual risks for users, third par-
ties, devices or other material assets. The safety instructions used refer to
residual risks that cannot be avoided due to the design.
• For safe operation, the safety instructions must be observed and followed.
• Operate the device only in a sound state and when observing the operating
instruction.
• Also observe the local legal accident prevention, installation and assembly
• guidelines.
• The manufacturer is not responsible for any damage that result as a conse-
quence of not observing the operating, instruction.
• Service and maintenance work or repairs that are not described in the operat-
ing instruction must not be carried out without previous consultation with the
manufacturer.
• Changes to the device are forbidden.
• For safe operation, the technical specifications must be observed and followed.
Performance limits must not be exceeded.
• For a safe operation, the device must only be used in the scope of its intended
use.
The device is exposed to different life phases, such as, e.g., installation,
start upstart up, operation, maintenance and cleaning.
The following sections must be sorted thematically according to the life phases.
If personnel that have insufficient qualifications carry out work, they can incorrectly
assess hazards. Explosions can occur.
• Carry out the work only if you have the respective qualification and are a
trained specialist person.
• Carry out the installation according to the following standards:
• CAN/CSA-C22.2 No. 0-1191
• CSA C22.2 No. 30
• CSA C22.2 No. 142
• UL 916
• UL 1203
or similar national standards.
• Disconnect the device from the power supply before starting the maintenance
work.
• Securing against reconnection.
• Cordon-off the work area of the device, e.g., using a barrier and signs.
• After switching off the device, wait at least one minute before starting work. En-
sure that the device is voltage-free. Then connect to earth and short-circuit.
If you do not use the appropriate tool and material, component may be dam-
aged. The explosion protection is void.
• Use tools that have been recommended for the respective work in the operat-
ing instruction.
• Make sure that the performance data of the power connection comply with the
specifications of the type plate.
• Use only an Atex or IECEx certified EMC cable screw connection in the protec-
tion category increased safety with a metric thread (M20x1.5).
• Creepage distances and clearances must be maintained.
• Openings for line feeds not used must be sealed by impact resistant, anti-self-
loosening and twisting safe blind plugs.
• The line insulation must reach to the terminals. When stripping, the conductor
itself must not be damaged.
• When closing the housing, take care that the seals remain effective in order to
ensure for the protection category IP 66 / NEMA 4X.
• Housing cover or housing with damaged thread must be replaced immediately.
• Observe the applicable national guidelines in the individual countries.
• Use cables that match the cable glands.
Gas may represent a risk to life and limb in different ways. Depending on the gas
type, different hazards may have an effect on you with respective consequences.
You may experience intoxication and injuries. There is also a risk of explosion.
• Before working, inform yourself about the media in the system.
• Install the device only when the system is switched off, depressurized and se-
cured.
• Make sure that there is no potentially explosive gas mixture at the installation
location.
The device is exposed to high pressures. If components under pressure are re-
moved / assembled, the high pressure may escape suddenly causing the compo-
nent to fly around. Mortal danger!
The device can be heated or cooled by the temperature of the gas. You may be
subject to burns when making skin contact with the device.
• Wear protective gloves that protect against heat and cold for this work.
63
Breakages or cracks may be caused to the device if the gas temperature or ambi-
ent temperature is outside the specified temperature ranges. Gas escaping may
cause intoxication and burns. Risk of explosion!
• Never exceed the maximum gas temperature and / or ambient temperature of
80°C.
Content
6.1 Transport 66
6.1.1 Scope of supply 66
6.1.2 Transporting the device 67
6.1.3 Unpacking the device 67
6.1.4 Disposal of packaging material 70
6.1.5 Prior to installation 70
6.1.6 Removing the transporting locks 71
6.2 Packing the device for transportation 73
6.3 Storage 79
6.3.1 Packing the device for storage 79
6.3.2 Checking the device after storage 80
6.1 Transport
The device will be packed to customer-specifics according to the transport require-
ments. In this chapter you will receive information on the standard packaging of
66
the device.
The scope of supply may deviate depending on the options of the orders.
Component Quantity
Ultrasonic gas meter 1
USM GT400 (including US-Electronic)
Extension box 1
(In countries where ATEX / IECEx
standards apply, connected at the
ultrasonic electronic)
Special tools to open the US electronic 2
Inlet and outlet spool piece 1 (optional)
Certificate of flow calibration 1
Certificate of material used 1
Certificate of stability 1
Certificate of density 1
Software RMGViewUSM 1
67
1 Euro pallet
2 Retaining bolts x 2
3 Ultrasonic gas meter
4 Retaining strap x 2
5 Timber wedge x 2
Fig. 6.1: Device secured on a Euro pallet
The device is as standard supplied on a Euro pallet (1). The device can be pro-
tected by a customer-specific outer packaging. To secure the device against tip-
ping-over and rolling away, the device (3) is supplied with retaining straps (4) and
bolted to timber wedges (5). The retaining bolts (2) of the device provide
additional support.
The device can be transported on the pallet using a lifting cart or a fork lift.
1 Retaining bolts
Fig. 6.2: Retaining bolts of the device
3 Make sure that the retaining bolts (1) are screwed in, if necessary.
1 Lifting eyes
2 Lifting gear chains
Fig. 6.3: Attaching the lifting gear
Warning
Risk of injury during transport
The device may be damaged when lifting and putting down, tipping over or
69
falling down. By disregarding the load bearing capacity of the lifting gear, the
device may fall. There is a risk of severe injuries for persons in the vicinity.
• Lift the device only on the intended lifting eyes.
• Before lifting, make sure that the load is safely secured.
• Never stand under suspended loads.
• Observe the weight specifications for the ultrasonic gas meter at hand.
1 Attach a suitable lifting gear (2) to the lifting eyes (1) of the device.
2 Tension the chain of the lifting gear slightly to secure the device.
1 Timber wedge
2 Tension straps
Fig. 6.4: Remove the timber wedges and retaining straps
3 Undo and remove the tension straps (2).
Warnung
Risk of injury during transport
The device may be damaged when lifting and putting down, tipping over or
70
falling down. By disregarding the load bearing capacity of the lifting gear, the
device may fall. There is a risk of severe injuries for persons in the vicinity.
• Lift the device only on the intended lifting eyes.
• Before lifting, make sure that the load is safely secured.
• Never stand under suspended loads.
• Observe the weight specifications for the ultrasonic gas meter at hand.
4 Carefully lift the device with a lifting gear until the Euro pallet can be pulled
from underneath the device.
5 Pull the Euro pallet from under the device.
6 Recommendation: store the Euro pallet for the future or for returning to
RMG for service work.
Hinweis
Damage to the device from contamination and humidity
If transport locks are removed too early, contamination and humidity
may enter the device. The device could be damaged.
▪ Blind plug
▪ Protective sticker 71
▪ Retaining bolts
▪ Recommendation: remove the retaining bolts only if it is absolutely
necessary. This is the only way to ensure that the device does not tip over or
roll away after being installed.
▪ Corrosion protection mat
The flanges are supplied sealed with a protective sticker or blind plug made
of plastic.
1 Protective sticker
2 Flange
Fig. 6.5: Removing the protective sticker
Remove the blind plugs 1 Pull the blind plugs out of the
openings.
For packaging, use the original packaging material and sealing set that was
supplied with the device.
If you no longer have the original packaging material and sealing set, you can or-
der the packaging material and sealing set required from RMG.
RMG service would be pleased to consult you as to how the device should be
packed.
• Euro pallet with timber wedges (with the original packaging, the timber
wedges are already pre-mounted on the Euro pallet).
• Two tensioning straps
• Transport locks
• Sealing set (blind plugs)
• Acid-free corrosion protection agent, e.g., ESSO RUST BAN 397,
Mobil Oil Tecrex 39
Caution
Risk of injury from missing retaining bolts
If the device is put down without the retaining bolts, it can tip over or roll away.
Severe injuries may occur.
• Before starting work, make sure that the retaining bolts are screwed in.
74
The retaining bolts are screwed into the device ex-factory. These ensure for a safe
position.
1 Make sure that the retaining bolts are screwed in and that the counter-nuts
are secured.
1 Lifting eyes
2 Lifting gear chains
Fig. 6.8: Attaching the lifting gear
Warning
Risk of injury during transport
The device may be damaged when lifting and putting down, tipping over or
75
falling down. By disregarding the load bearing capacity of the lifting gear, the
device may fall. There is a risk of severe injuries for persons in the vicinity.
• Lift the device only on the intended lifting eyes.
• Before lifting, make sure that the load is safely secured.
• Never stand under suspended loads.
• Observe the weight specifications for the ultrasonic gas meter at hand.
1 Attach a suitable lifting gear (2) to the lifting eyes (1) of the device.
2 Tension the chain of the lifting gear slightly.
3 Undo the bolted connections from the system so that the device can be lifted
out.
1 Retaining bolts
2 Tension straps
3 Timber wedge
Fig. 6.9: Secure the device on the Euro pallet
Warning
Risk of injury during transport
76 The device may be damaged when lifting and putting down, tipping over or
falling down. By disregarding the load bearing capacity of the lifting gear, the
device may fall. There is a risk of severe injuries for persons in the vicinity.
• Lift the device only on the intended lifting eyes.
• Before lifting, make sure that the load is safely secured.
• Never stand under suspended loads.
• Observe the weight specifications for the ultrasonic gas meter at hand.
5 Carefully place the device on the Euro pallet with the lifting gear.
6 Secure the device using the tensioning straps (2).
The tensioning straps must have a tight fit and must secure the device.
Notice
Damage to the device from corrosion
If the device is not protected against corrosion, the function of the
device may be affected.
• Place the corrosion protection mat inside the device.
1 Clean the device and protect all blank parts against corrosion with an acid-
free corrosion protection agent, e.g., ESSO RUST BAN 397, Mobil Oil Tecrex
39.
Chapter 11.7, “Cleaning the device” on page 167 77
1 Wrench
2 Screwed cable gland
3 Blind plug
Fig. 6.11: Mount the blind plugs
The following sealing bolts supplied must be used in countries where CSA
guidelines apply. If only transport is taking place, you can use 1/2" or 1"
screws with appropriate length as an alternative.
78
1 Protective sticker
2 Flange
Fig. 6.12: Applying the protective sticker
Notice
Damage caused to the device from incorrect storage / transport
If the device is not protected correctly by the packaging material, dirt or humidity
may enter the device and damage it.
• Pack the device according to the instruction.
• Consider the special transport requirements on the packaging material, e.g., for
transport overseas.
• Please contact RMG service in case of doubt.
Use the original packaging that was supplied along with the device. Please contact
RMG service if you have any questions.
6.3 Storage
In this chapter you will receive information on the correct storage of the device.
You are also provided with information that must be observed when storing for
long periods.
Danger
Mortal danger from damage in the warehouse
If the device is stored for longer than one year, the device may be damaged
from incorrect outer packaging or securing of the device. In potentially explosive
environment, a defective device may lead to an explosion. Danger of poisoning!
• Avoid long storage times.
• Have the device checked by RMG service if the storage time is longer than
one year. For this purpose, send the device to RMG.
Notice
Damage caused to the device from incorrect storage / transport
If the device is not protected correctly by the packaging material, dirt or humidity
may enter the device and damage it.
• Pack the device according to the instruction.
• Consider the special transport requirements on the packaging material,
e.g., for transport overseas.
• Please contact RMG service in case of doubt.
If you discover that there is, e.g., any damage or other damage to the device,
the device may only be re-used after consulting RMG.
Content
• DIN pressure stages: The flange joining dimensions comply with the standard
DIN EN 1092.
Notice
The USM GT400 with a nominal width of DN 80 (3“) uses different connec-
tion flanges. Instead of the screw lead-throughs - as in the flanges of all
82
other nominal sizes - there are blind holes with internal threads. Corre-
sponding screws are included in the scope of delivery, but can also be re-
ordered if necessary.
7.2 Seals
Danger
Escaping gas from incorrect seals
If incorrect flange seals are used for several ultrasonic gas meters, potentially
explosive gas mixtures can escape due to leaks. Risk of intoxication and explo-
sion! Moreover, the pressure of the flange increases with the improper tighten-
ing of the screw bolt.
• Make sure that the flat seal does not protrude over the sealing surface into
the pipeline.
Notice
Malfunctions from incorrect seals
If flange seals are used for ultrasonic gas meters that protrude into the pipeline,
the measuring accuracy may be influenced.
• Make sure that the flat seal does not protrude over the sealing surface into
the pipeline.
The durability of the flange connections has been verified for seals with the follow-
ing maximum material values according to the AD2000 regulations.
83
DN d1 d2
in mm (inch) in mm (inch) in mm (inch)
80 (3) 90 (3.54) 142 (5.59) 142 (5.59) 136.5 (5.37) 142 (5.59) 142 (5.59)
89 (3.5)/ANSI150
100 (4) 115 (4.53) 162 (6.38) 162 (6.38) 175 (6.89) 168 (6.61) 168 (6.61)
150 (6) 169 (6.65) 218 (8.58) 218 (8.58) 222 (8.74) 225 (8.86) 225 (8.86)
200 (8) 220 (8.66) 273 (10.75) 273 (10.75) 279 (10.98) 285 (11.22) 292 (11.52)
250 (10) 274 (10.79) 328 (12.91) 330 (12.99) 340 (13.39) 342 (13.46) 353 (13.90)
300 (12) 325 (12.80) 378 (14.88) 385 (15.16) 410 (16.14) 402 (15.83) 418 (16.46)
400 (16) 420 (16.54) 490 (19.29) 497 (19.57) 514 (20.24) 515 (20.28) 547 (21.54)
500 (20) 520 (20.47) 595 (23.43) 618 (24.33) 607 (23.90) 625 (24.61) 628 (24.72)
600 (24) 620 (24.41) 695 (27.36) 735 (28.94) 718 (28.27) 730 (28.74) 745 (29.33)
84
DN d1 d2 d1 d2
in mm (inch) in mm in mm in mm in mm
85
DN d1 d2 d3 d1 d2 d3 d1 d2 d3
in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm
(inch) (inch) (inch) (inch) (inch) (inch) (inch) (inch) (inch) (inch)
100 106.4 127.0 149.4 108 120 144 106.4 120.7 149.4
(4) (4.19) (5.00) (5.88) (4.25) (4.72) (5.67) (4.19) (4.75) (5.88)
150 157.2 182.6 209.6 162 174 200 157.2 174.8 209.6
(6) (6.19) (7.19) (8.25) (6.38) (6.85) (7.87) (6.19) (6.88) (8.25)
200 215.9 233.4 263.7 213 225 257 215.9 225.6 263.7
(8) (8.5) (9.19) (10.38) (8.39) (8.86) (10.12) (8.5) (8.88) (10.38)
250 268.3 287.3 317.5 267 279 315 268.3 274.6 317.5
(10) (10.6) (11.31) (12.50) (10.5) (10.98) (12.40) (10.6) (10.81) (12.50)
300 317.5 339.9 374.7 318 330 366 317.5 327.2 374.7
(12) (12.5) (13.38) (14.75) (12.5) (12.99) (14.41) (12.5) (12.88) (14.75)
400 400 422.4 463.6 414 426 466 400 412.8 463.6
(16) (15.7) (16.63) (18.25) (16.3) (16.77) (18.35) (15.7) (16.25) (18.25)
500 500 525.5 577.9 518 530 574 500 520.7 577.9
86 (20) (19.7) (20.69) (22.75) (20.4) (20.87) (22.60) (19.7) (20.50) (22.75)
600 603.3 628.7 685.8 618 630 674 603.3 628.7 685.8
(24) (23.8) (24.75) (27.00) (24.3) (24.80) (26.54) (23.8) (24.75) (27.00)
7.3 Screws
Temperature range for bolts and nuts
87
-40°C to +80°C
The stability of the flange connection was verified using the screws listed above in
conjunction with the seals listed in Chapter 7.2. Other screw / flange versions have
not been inspected.
Notice
Variant 3 bolts with reduced shank may only be used for devices within the area
of PED (Pressure Equipment Directive) application.
Notice
DN 80
Screws are provided by RMG for the USM-GT400 for diameter DN80.
Depending on the flange type the following hexagonal bolts are used for DN80:
DIN EN 24014 DIN EN 24014 DIN EN 24014 5/8“ - 11 UNC 3/4“ - 10 UNC 3/4“ - 10 UNC
(DIN931 (DIN931 (DIN931 2A x 2 1/8“ 2A x 2 1/4“ 2A x 2 5/8“
88 ISO4014) ISO4014) ISO4014) L=54mm (2 1/8“) L=57,2mm (2 L=66,7mm (2
M16 x 48 M16 x 52 M16 x 56 UNC A320 1/4“) 5/8“)
L=48 mm or ma- L=52 mm or ma- L=56 mm or ma- Grad7 UNC A320 UNC A320
terial: terial: terial: or material: Grad7 Grad7
25CrMo4 25CrMo4 25CrMo4 42CrMo4 or material: or material:
galvanized galvanized galvanized galvanized 42CrMo4 42CrMo4
galvanized galvanized
See chapter 13.6 “Inner diameter of connecting spool pieces” on page 189
With this installation, the device can be used for calibrated measurements
and for secondary measurements.
89
1 Temperature sensor
Fig. 7.4: Unidirectional operation
1 Flow conditioner
2 Temperature sensor
Fig. 7.5: Unidirectional operation compact installation
Bidirectional operation
90
1 Temperature sensor
Fig. 7.6: Bidirectional operation
1 Flow conditioner
2 Temperature sensor
Fig. 7.7: Bidirectional operation compact installation < DN 300 (12")
91
1 Flow conditioner
2 Temperature sensor
Fig. 7.8: Bidirectional operation compact installation ≥ DN 300 (12")
Notice
Malfunctions from pairing the devices incorrectly
If the devices do not match one-another for these installation possibilities,
incorrect measurements may occur.
• Please consult RMG if a Face-to-Face installation is possible with the de-
sired devices and number of devices.
92
1 Tapered bore
2 Inner diameter
Fig. 7.9: Face-to-Face Installation
With this installation option, two or several devices are connected with one-
another via the flanges. Third-party manufacturer devices can also be connected
to RMG devices.
For this purpose, a tapered bore can be applied to the flanges on the inlet and out-
let piping.
The flanges that are used to connect the devices with one-another do not require a
tapering. For third-party manufacturer devices, you have to check if a tapering is
required.
Notice
For the device with the smaller inner diameter it is mandatory to use a tapering.
If two RMG devices are connected with one-another, the inner diameter must be
continuously the same.
Different sized devices cannot be connected to one-another.
The 2 interfaces RS485-1 and RS485-2 have the same features and you may
change in the following1 to 2 (and 2 to 1) freely.
However, the RS 485-1 (in contrary to the RS 485-2) does not permit a parameter-
izable byte sequence for the data types Long and Float. We therefore recommend
that you use the RS 485-1 for the DZU protocol and the RS 485-2 for instance F
communication. You may find more information in chapter 8.3.
94
The cable length must not exceed a length of 500 meters / 1640 feet.
More information on the installation of a flow computer can be found here:
Operating instructions of the flow computer
8 Installation
In this chapter you are provided with information on how you can correctly install
the device and what you have to observe during the process. 95
The tasks of the chapter described must only be carried out by trained and
certified personal.
Content
Warning
Risk of injury during transport
The device may be damaged when lifting and putting down, tipping over or
97
falling down. By disregarding the load bearing capacity of the lifting gear, the de-
vice may fall. There is a risk of severe injuries for persons in the vicinity.
• Lift the device only on the intended lifting eyes.
• Before lifting, make sure that the load is safely secured.
• Never stand under suspended loads.
• Observe the weight specifications for the ultrasonic gas meter at hand.
Caution
Risk of injury from missing retaining bolts
If the device is put down without the retaining bolts, it can tip over or roll away.
Serious injuries may occur.
• Before starting work, make sure that the retaining bolts are screwed in.
Notice
Damage to the device when used as a climbing aid
If the device is used as a climbing aid, components may be damaged.
• Do not use the device as a climbing aid.
• Use a suitable non-slip step that allows you to reach the components easily
and safely.
98
1 Wrench
2 Screwed cable gland
3 Blind plug
Fig. 8.1: Remove the blind plugs
Recommendation: store the blind plugs for the future or for returning to RMG
for service work.
100
1 Inlet piping
2 Ultrasonic gas meter
3 Outlet piping
Fig. 8.2: Installation of the Inlet and outlet piping
The bolted connection of Inlet (1) and outlet piping (3) must be tightened according
to the tightening torque of the plant manufacturer. The tightening torque must com-
ply with the bolts and seals used.
1 Clean the sealing surface of the flange from contamination with a gentle
cleaning agent.
2 Tighten the bolts crosswise in order to avoid tensioning.
Notice
In general, only the horizontal installation of the USM GT400 is strongly
recommended. Turning the meter by more than 2 flange holes should not be
used to avoid the collection of condensates in the sensor pockets. Only in dry
and clean gas, other installation positions might be possible also, but it is not
recommendable.
102
1 Cover
2 Screws
3 Screwdriver
Fig. 8.4: Opening the connection box cover
The device offers the connection by cable that are routed through the flame block.
The wiring in the ultrasonic electronics is carried out ex-factory. The cables are
marked accordingly for connecting and can be connected in a customer’s connec-
tion box.
Maximum assignment
The maximum assignment is always completely available for the connections of
the Ex-de connection box.
• Current / voltage supply (24 VDC)
• Warning message (Warn)
• Alarm message (Alarm)
• Pulse output for "Forwards mode" (Pulse 1) and "Backwards mode" (Pulse 2)
• 2 x direction detectors for bi-directional operation (I/O1/2)
• Interface for RMGViewUSM (RS 485 0)
• Interface for an RMG flow computer (RS 485 1)
• Interface for any flow computer (RS 485 2)
• Analog output (4-20 mA)
• Connection for a pressure sensor as a 2-wire 4-20mA
(AUX1; Terminal 26: [P +] Terminal 27: [P -])
• Connection for a temperature sensor (PT100; AUX2; Terminal28: [PT100 ++],
Terminal 29: [PT100 +] Terminal 30: [PT100 -] Terminal 31: [PT100 -])
Cable specification
The following cable specifications are according to a complete assignment of the
USM-GT-400 ATEX / IECEx version. The cable types listed are recommendations
that can be replaced by technically comparable cable types.
AUX1 LIYCY
2 x 0.75 mm² 6.0mm
AUX2 LIYCY
2 x 2 x 0.75 mm² 8.5 mm
Analog out LIYCY 6.0 mm
4-20 mA 2 x 0.75 mm²
Warning + alarm LIYCY
2 x 2 x 0.75 mm² 8.5 mm
Pulse 1 + pulse 2 + LIYCY (TP)
I/O 1 + I/O 2 4 x 2 x 0.75 mm² 10.7 mm
Twisted pair cable (TP) are only required in case of multiple circuits in one cable.
Otherwise, LIYCY 2 x 0.75 mm² is sufficient for all signal outputs.
In those countries where the standards ATEX and IECEx are valid,
the device is supplied with the connection box Ex-de (1).
The numbers given below at each figure only counts the limited number of cables;
all cables are labeled due to the number of the basic upper terminal block
1 Terminal connections
Fig. 8.7: ½” cable gland with 11 wires, size AWG 18
1 1½” sealing fitting, connected with 11 wires, size AWG 18 (permitted, max.
11; Killark Type ENY-1TM).
For this version, the ERZ 2000 or ERZ 2000 NG cannot be connected via the DZU
protocol (RS 485-1).
106
1 Terminal connections
Fig. 8.8: ¾” cable gland with 20 wires, size AWG 18
2 ¾” sealing fitting, connected with 20 wires, size AWG 18 (permitted, max. 20;
Killark Type ENY-2TM).
1 Terminal connections
Fig. 8.9: Measuring with pressure and temperature
1 Terminal connections
Fig. 8.10: ½“ and ¾“ sealing fittings with up to 31 wires of size AWG 18
3 Connect ¾” sealing fitting with 20 wires of size AWG 18 (permitted, max. 20;
Killark type ENY-2TM) and ½” cable gland with 11 wires of size AWG 18 (per-
mitted, max. 11; Killark type ENY-1TM).
All connections are routed to the outside and can be connected and used.
108
1 Terminal connections
2 Stromversorgung an den Klemmen 24 VDC
Fig. 8.11: Connection assignment on the terminal strip
1 Terminal connections
2 Digital interface RS485-0
3 Digital interface RS 485-1
4 Digital interface RS 485-2
Fig. 8.12: Digital interfaces RS 485-0,1 und 2
The interfaces RS 485-0, RS 485-1 and RS 485-2 are basically equal and can be
set for all possible connections. However, there are minor differences. These are
taken into account in the recommended connections and make it easier to connect
the recommended devices or the PC if they are followed.
109
Notice
Please use the connections as recommended below. If connections are
used differently additional, extensive settings may become necessary.
110
1 Terminal connections
2 Service connection
Fig. 8.13: Connection assignment on the terminal strip
The flow computer is connected to the terminal strip of the external connection
box (1).
1 Terminal connections
2 Connection flow computer 1
3 Connection flow computer 2
Fig. 8.15: Connection assignment on the terminal strip
The 2 interfaces RS 485-1 and RS485-2 are equivalent and you may change in
the following 1 to 2 (and 2 to 1) freely.
The difference is that the RS 485-1 interface does not have a parameterizable byte sequence for
the long and float data types. This interface is particularly suitable for communication using the
DZU protocol. The RS 485-2 is intended for communication via the manufacturer-independent In-
stance-F protocol, as this interface offers a parameterizable byte sequence.
112
1 Terminal connections
2 Connection Warning messages
3 Connection Warning messages
4 Connection Pulse 1
5 Connection Pulse 2
6 Connection RS 485-1
7 Connection RS 485-2
Fig. 8.16: Connection assignment on the terminal strip
All diagnosis functions can be made available via a configuration of the Modbus.
Flow computers from third-party manufacturers can also be connected to the
terminals Pulse 1 and Pulse 2. When parameterizing, take care that the maximum
possible gas flow rate is assigned to a maximum frequency of 2 kHz. All diagnosis
functions are not available.
Since the USM GT400 does not have its own DSfG bus access, its DSfG-in-
stance-F protocol is implemented externally via a flow computer, the ERZ 2000-
NG, which has this access. To realize the access the necessary data are trans-
ferred between the ERZ 2000-NG and USM GT400 via Modbus, which is often
referred to as Instance-F, although it only provides the data required for DSfG
Instance-F.
The corresponding settings can be found in the VK Modbus Master USM menu in
the ERZ2000-NG. The corresponding register expressions can be found in the VJ
register expressions menu. In the USM GT400, the Modbus registers of instance F
are listed in column BA.
Electrical connection
Three serial interfaces for Modbus communication are available on the USM
GT400. For instance F Modbus communication, the RS 485-2 is provided with
terminal 21 (GND), terminal 22 (Data +) and terminal 23 (Data -).
For communication with ultrasonic gas meters via instance F the optional interface
COM 6 for the ERZ2000-NG is necessary. The DIL switches are located on the
115
option card required for this purpose. The jumpers for the RS 485 require a setting
that is shown in the following Figure. After that, the option card is to be placed into
the COM6 and 7 slots, which is the first one from the right looking from the display
116
Fig. 8.21: Slot for the option card with COM 6 and 7 of the ERZ 2000-NG
If the button "DSfG: F-instance COM6/7" in the menu GB Flow rate parameter is
activated, the further necessary settings are suggested in this menu (light yellow-
green background):
117
After the selection of "DZU" in Volume transducer mode the protocol type "DSfG:
F-instance" must be defined in the menu VJ register expressions by button se-
lection. The corresponding registers for the Modbus communication are thus sug-
gested.
118
The proposal must then be "entered", i. e. adopted. In the complete menu you can
see that many other parameters are transferred in addition to the flow rate.
The connection and selection of all other ultrasonic gas meters listed below are
also possible due to legal metrology purposes.
Coordinate VJ98 selected button is used to enter which suggestion was entered.
Notice
Attention:
Even if in the same field with the same register, e. g. the information "swirl" is
transmitted, the value is "swirl" is dependent form the device and path
configuration used. It might be (significantly) different for the various devices.
The same applies to all device-specific parameters.
For communication via Instance-F, the serial interface COM6 must be operated
with parameters 38400 baud, 8 bits, parity None and 1 stop bit as well as the oper-
119
ating mode Universal Modbus master. These can be found in IB serial interfaces in
coordinates IB31 to IB33.
Notice
COM6 is then no longer available for communication with a gas chromato-
graph. Therefore, the Modbus Master communication for GC1 and GC2 in
the coordinates IL50 and IL51 must be realized via the serial interface
COM7.
It has to be deactivated if no Modbus IP is used.
The Modbus address in VK52 must be assigned with the address of the USM
GT400 are the same. They can be found in J-31. Selection values in VK58 and
VK59 are irrelevant because these data types are not included in the instance
protocol.
121
The serial interface RS 485-1 may be used as well but requires a different setting
due to fixed deviating Byte order. It will not be treated here, in case it is required
you may have a look into the German manual of the USM GT400.
The Modbus registers for device-F can be found in chapter 18 the Appendix with
the List of parameters. In the last part of this appendix, you may find the relevant
Modbus registers 32768 to 33022 including the name, a short description a the
type of the registers.
Additional Registers
The following Modbus registers contain additional USM-GT-400 data which are not
included in the tables above. A connected ERZ 2000-NG needs this information so
that its DSfG Device-F can be used.
9086 DSfG-Status
If one of these three bits equals 0 the requesting ERZ 2000-NG gets the message
that the data of the registers 8000 to 80CE are invalid and may not be used for the
external DSfG instance F. In this case the USM is mis-configured and the device-F
will not work. Bits 3 to 15 are currently not in use.
9084 Qt
This register contains a characteristic value of the USM which is dependent from
Qbmax and Qbmin.
The value specifies how many values - of a maximum possible determinable quan-
tity - could be taken into account. If one of ten measurements within a measure-
ment cycle for a path is wrong (i.e. 9 valid measurements) the DSP provides 90%
valid measurements, and the path performance is 90%.
123
The overall performance is the average of the performance of all individual paths
(L-6 to Q-6, valid measurement G1 - G6) for the last n measurements (n = moving
average in E-09; the default is 10 measurements).
Notice
The USM-GT-400 keeps its calibrated accuracy even if up to 2 measurement
paths fails! The value “signal acceptance“ falls down to 66% then.
Exceptions:
• If | Vw | <VwUg (the speed is below the minimum speed), then the path perfor-
mance and the overall performance goes to 100%.
DSfG
• Gas Information Nr. 7 – 4. Überarbeitung 10 / 2009
Technische Spezifikation für DSfG-Realisierungen
Teil 1 Grundlegende Spezifikation
ERZ 2000-NG
In the ERZ2000-NG, with the calibration switch locked, the measured values and
status information are displayed; if the calibration switch is open, the Modbus ad-
124 dresses can be seen (see below).
Detailed information including hourly averages and deviations of the individual val-
ues from the mean value can be found in the higher-level Instance-F menu V,
whose subdirectories VA to VI are structured according to measured value catego-
ries.
Fig. 8.31: Modbus register list in ERZ2000-NG with locked (left) and open (right)
calibration switch
https://www.phoenixcontact.com/online/portal/de?uri=pxc-oc-
itemdetail:pid=2313452&library=dede&pcck=P&tab=1
You may find more details of the interface converters and their product information
at the given links.
Danger
Mortal danger from incorrect earthing
When the device is not correctly connected to earth so that electrostatic
discharge can lead to spark formation, there is a risk of an explosion.
1 Earthing srew M6
2 Earthing srew M6
3 Earthing cable
Fig. 8.36: Connect to earth – Ultrasonic meters DN150 (6") and DN100 (4")
127
1 Earthing screw M6
2 Earthing screw M6
3 Earthing cable
Fig. 8.37: Connect to earth – Ultrasonic meters DN200 (8")
Cable specifications
From a cable length of 1 m, you must use a screened cable for the data and net-
work cable. The screen must be applied on both sides or only on one side (meter
or control room).
Transducer
The transducers are metallic connected to the meter housing. You do not have to
earth the transducer separately. You must ensure that the conductive connection
with the pipeline of the measuring system is established.
The pressure connection can be equipped with a shut-off valve (1 and 2) or with-
out a shut-off valve (3 and 4). If the device is ordered without a shut-off valve, the
connection is provided with a union nut (clamping screw connection) or a female
thread.
129
130
1. Please pay attention to the ambient temperature, it must not exceed the range
from -40°C to 55°C.
2. Please prevent any contact of the USM-GT-400 with chemically aggressive
gases and vapors. These gases and vapors may not damage the protective
coating nor the materials used. The materials used can be found below in the
section "Technical data".
3. The USM-GT-400 may not be completely buried or submerged in water.
4. The display must not be exposed to direct sunlight for a longer period of time
(> 5 minutes). In this case please use the recommended sun
protection (see next picture), that can be supplied from RMG service.
131
5. If you expect higher temperatures than 55°C, then the USM-GT-400 has to be
protected under a large sunshield (weather protection roof or similar).
9 Start Up
In this chapter you will receive information on start up after installation.
132
Content
• Path lengths
• Axial distances
• Limit values
For this purpose, the content of the valid measurements (in %) are checked in the
coordinates L-6 to Q-6. They should be 100% at zero flow and should also not fall
below 70% under difficult flow conditions, for example, with high flow rates.
10 Operation
This chapter provides you with information for working with parameters, lists and
134 measurement values.
Content
Example:
Several parameters and measuring values have the entry &v: for a variable unit.
The unit m/s is currently set for this variable. All parameters and measuring values
with this variable unit should be converted to ft/s.
Under coordinate AG-32 the value for the unit m/s is converted to ft/s. All parame-
ters and measuring values with this variable unit &v: are converted to ft/s.
Notice
• Calibration and service switch must always be closed in custody
transfer operation!
identified via its firmware version and its checksum (CRC-16). Therefore, for
matching checksum and version number is deposited at the PTB (registration au-
thority). The checksum itself can be verified via the display or via Modbus.
138
Notice
This mode can be used only in areas where the MID is applied!
The parameters can be called up and changed via the display with control
panel or RMGViewUSM.
Software instructions RMGViewUSM (separate document)
1 Switch point
2 Magnet
Fig. 10.1: Magnet for operating the buttons
When the cover of the ultrasonic electronics is closed, the buttons can be operated
using the magnets supplied. In order to operate the buttons with the magnets (2),
the magnet must be placed on the glass in the position with the switching point (1)
of the button.
The button has been allocated with the following functions for
navigating:
• Press the button briefly: one column to the right, e.g., from
A to B.
• Press the button longer: depending on the duration of
pressing the button:
- one column to the left, e.g., from B to A.
- continuously column by column to the left, e.g., from
U to F.
Select the line of the coordinate on the control panel of the ul-
trasonic electronics using the button.
The coordinates (column and line) of the parameter are selected. The value of the
parameter is shown on the display.
Observe the designations of the columns and the rights assigned. 141
“Input protection for parameters” on page 135
A parameter that is entered in the protection E or S can only be changed
when the calibration switch is open. For a value / parameter / measure-
ment value S, the code word also has to be entered for the ultrasonic elec-
tronics.
If this parameter is changed then the device is no longer considered as cal-
ibrated.
• Only carry out these tasks if you are authorized.
“Changing the parameters of protection E and S” on page 144
Depending on the type of data, you are offered different selection options when
making entries.
In order to change data, the coordinate of the parameter must be selected.
“Calling up the value of a parameter” on page 140
1. Press the button until the next value is marked in the display.
▪ Example for data type Integer (I) and Long integer (L)
Data type Example
Integer (I) D-10 Qb-min time
142
Long integer (L) AF-02 electronic no.
1. Press the button until the next value is marked in the display.
1. Press the button until the next value is marked in the display.
Notice
The data type text is not a text in the actual sense, but a bit combination.
1. Press the button until the next value is marked in the display.
1. Press the button until the next value is marked in the display
This chapter provides you with information for changing parameters that are pro-
144 tected by the calibration switch and also by the code word of the ultrasonic elec-
tronics. This affects all parameters that are stored in the coordinates for columns E
and S. For a parameter in column S, the code word also has to be entered for the
ultrasonic electronics.
Danger
Danger to life from opening the device
If the cover or the housing of the device is opened in an area with a potentially
explosive environment, then the device is no longer suitable to be used in the
area with a potentially explosive environment. Risk of explosion!
• Open the device only when the device is voltage free.
Mortal danger from damaged components
If threaded holes, bolts or the sealing surfaces of the housing are damaged, the
spark protection gap can no longer be guaranteed. Sparks resulting may lead to
an explosion.
• Proceed with care when working with the bolt connections.
• Replace damaged components with new ones.
• Make sure that no parts of the housing are damaged.
Please note that for this task the official seal must be broken. The device
must not be used for calibrated operation if the official seal is broken.
If the task is carried out by RMG service, the device does not have to be
calibrated by a testing institute. The device is provided with a new official
seal by RMG service.
• Führen Sie diese Arbeiten nur aus, wenn Sie dazu befugt sind.
145
1 Threaded pin
2 Boreholes for inserting the special tools
3 Special tool (2 pieces)
Fig. 10.2: Opening the cover
1 Cover
Fig. 10.3: Opening the cover
146
1 Calibration switch
Fig. 10.4: Opening the calibration switch
1 Cover
2 Position O-ring
Fig. 10.5: Screw down the cover
1 Each time you open the ultrasonic electronic you have to expect that the O-
ring is damaged. Therefore, this damaged O-ring has to be replaced with a
new one in general. (RMG provides a replacement kit with O-ring, grease, ...
sales number: 38.03.001.00)
2 Screw the cover on with both hands.
3 Insert the special tools into the boreholes.
4 Tighten the cover with the special tools.
5 Screw in threaded pin hand tight.
6 Switch on the system.
If you do not have the password for the ultrasonic electronics, request the 147
code word from RMG Service.
1 Enter the code word for the ultrasonic electronics under coordinate AG-4.
1 Calibration LED
Fig. 10.6: Check LED
1 Check LED.
The Calibration lights up. The calibration switch has been
opened correctly.
4 Activate the button with the magnet in order to position the cur-
sor on the value of the parameters to be changed.
5 Activate the button with the magnet in order to set the desired
value.
▪ Conclude work
1 Switch off the system power supply.
2 Open the cover of the ultrasonic electronics.
“Opening the cover of the ultrasonic electronics” on page 145
3 Press calibration switch (A) downwards to close it.
4 Close the cover of the ultrasonic electronics.
“Screw down the cover of the ultrasonic electronics” on page 146
1 Calibration switch
Fig. 10.7: Close the calibration switch
10.3.1 Interface 0
10.3.2 Interface 1
10.3.3 Interface 2
152
• The configuration is carried out via software (coordinate J-30) and hardware
(switch).
• The DIP switch is located on the optional card in the ultrasonic electronics
housing.
To activate the Modbus Master, the mode must be set to Modbus master.
Coordinates AW-08 and AW-09 indicate the time since of the last AGA10 calcula-
tion respectively the time of last update of the gas components.
153
Using the coordinates AZ-01 Formula Methane to AZ-50 Formula Status the USM-
input variables are linked to the PGC gas data.
There are different data types: double-precision floating point = D (Double float),
simple-precision floating point = F (Float), 32-bit unsigned integer = U (Long) and
16-bit unsigned integer = u (short).
155
Fig. 10.11: Gas component
Unit Conversion
Not all possible gas components can be filled. Then these gas components are to
be distributed according to the distribution rules.
If components as hexane, heptane, octane, nonane and decane are not given indi-
vidually, but as a sum of hexane plus higher alkanes, eg Register in F8272, this
156
sum can be split according to the rule of thirds to the components. Hexane, hep-
tane, octane, nonane and decane are then distributed to 81: 27: 9: 3: 1. Normal-
ized this results in 81/121: 27/121: 9/121: 3/121: 1/121. The coordinates AZ-31 to
AZ-40 become to:
Constants
It might be possible that components required from the USM-GT-400 are not given
from the PGC, for example water and hydrogen sulfide. These can be set to 0:
An expression with more than 20 characters begins with the less significant coordi-
nate AZ-01 and then continues with one with higher significant AZ-02. Unused
high-order coordinates are filled with spaces.
The formulas combining the USM-GT-400 input variables with the PGC data may
not exceed a maximum of 60 Modbus registers.
It is possible that a PGC is not providing its status in this form. Instead, there may
be:
Register 10: It shows the number of pending alarms. When showing 0 the PGC
is free of alarms. It is a 16-bit integer register.
Register 2: It is a bit coded information. In the measuring mode of the PGC the
bit is set to 4. It is a 32-bit integer register.
The following considerations help to formulate the state-formation in coordinate
AZ51:
• The first part of a 16-bit integer registers will be imported. The number of pend-
ing alarms shows the data type of an unsigned integer (unsigned short int). The
prefix is a small u. The register address is 10, therefore, the value u10 should
be requested.
• The value is checked to be 0. The first term is found to be u10 == 0. The result
is true if u10 contains a 0.
• For the second part, a 32-bit integer registers is imported. This value has to be
158 read bitwise. It is a 32-bit unsigned integer (unsigned long int). The prefix is a
large U. Register address is 2; the value U2 must be
requested.
• Now it is checked whether any bit is set to 4. As operator the bitwise "and" has
to be used (&). The second part of the expression results to U2 & 4. The result
is 0 when the bit with the value 4 is not set and a value other than 0 is set. Bits
with other values then 4 do not affect the result.
• The two partial expressions are joined via a logical "and" (&&). Following the
bracket rules both subexpressions have to be put in brackets. The complete ex-
pression for AZ-51 is found to be (u10== 0)&&(U2&4).
Modulo % equal ==
Sign - not equal to =!
Terms may be
• a?b:c means: if a then b else c
• brackets: ()
• constants:
Integers, for example, 42
Floating point, for example, 1.234
Exponential, for example, 1.2345E-3
unsigned, the sign is realized by the operator sign
AX-92 MB_Pause: The requests of the USM-GT-400 to the PGC are summarized
in a block. Between two blocks will be an interval. AX92 coordinate indicates the
interval time.
AX-93 MB_Timeout: Maximum time between a PGC request and the associated
response.
Note to the coordinates AX94 to AX97: The numbers represent the significance.
It increases with the value of the byte. The sequence is read from left to right.
160
AY-46 telegram counter: Here all correct PGC answers are counted.
AY-49 MB timeouts: Here the timeouts detected on the Modbus are counted. The
counter is incremented when no PGC-answer arrives within the time set in AX-93.
AY-50 MB error-counter: Here all incorrect PGC answers are counted.
AY-51 MB error register: If an unexpected answer from the PGC arrives, this co-
ordinate indicates the related Modbus register.
AY-52 MB error answer: Here the PGC answers are counted with exception
code.
AY-55 MB_ErrorBits: This coordinate informs about problems occurring during
the link of the USM-input variables with the PGC data. However displayed is a
three-digit hexadecimal number instead of any bit combination.
Bit 0 - 7: If a link was formulated incorrectly, a coded number here indicates the
first failed formula. Examples:
0 = formula methane is faulty
1 = formula nitrogen is faulty
6 = formula H2S is faulty
Bit 8: Reserved
Bit 9: 0 = no error.
1 = Error for the formulation.
Bit 10: Reserved
Bit 11: Reserved
Bit 12: In the formulas for linking the USM input variables with the PGC data more
than 60 Modbus registers were used in total.
AY-56 MB_InStatus: Here the evaluation result of the status formula (AZ-51 to
AZ-54) is given.
Data type Register Value Byte Byte Byte Byte Byte Byte Byte Byte
1 2 3 4 5 6 7 8
float 2 273,15 0x93 0x33 0x43 0x88
text 10 USM 0x53 0x55 0x30 0x5A 0x2D 0x38 0x50 0x36
GT400
0x00 0x00 0x00 0x00 0x00 0x00 0x00 0x00
0x00 0x00 0x00 0x00
intd 1 44067 0xAC 0x23
double 4 14,2740 0x13 0x58 0x8A 0xCF 0x8C 0x4C 0x40 0x2C
long 2 100000 0x86 0xA0 0x00 0x01
Reply:
Start Char :
Slave Address 01 01
Function 03 03
Byte Count 02 02
Data Hi (Reg 2000) A8 A8
Data Lo (Reg 2000) 01 01 Wert = A801
LRC 51 06
carriage return CR 44
line feed LF
The damping value in I-09 can be used to specify how quickly the output current
reacts to a change in the physical quantity. The fastest possible reaction occurs
with the value of 0.
The lists for parameter and measured values are in appendix 18.
11 Maintenance
164 In this chapter, you are provided with information as to how you can extend the
service life of the device through maintenance. You can only protect the device
against premature wear when observing the maintenance schedules described
here.
Content
In the course of a recalibration from RMG, the device will also be checked
for leaks at the same time.
If the device is used with the permitted gases, the service life of the seals is
unlimited.
Notice
Recommendation: The battery should be changed on the regular base of
recalibration but latest each 10 years.
The special tool from RMG must be used for changing the transducers.
You can find out more about changing the transducers with the tool here:
Service manual for changing the transducers and ultrasonic electronics (sepa- 167
rate document)
You can find out more about changing the ultrasonic electronics here:
Service manual for changing the transducers and ultrasonic electronics (sepa-
rate document)
▪ Performing cleaning
1 Free the device from rough and lose dirt with a soft brush.
2 Clean the viewing window of the ultrasonic electronics with a moist cloth.
168
Warning
Risk of injury from work carried out incorrectly
During decommissioning and removal work, there is a risk of severe injuries
from components under pressure and highly explosive atmospheres if the sys-
tem has not been correctly disconnected from the gas supply network and the
power supply in advance.
• Before starting work, switch off the device and secure it against being
switched back on.
• Depressurize the device.
• Only specialist personnel are allowed to undertake the decommissioning.
Observe the applicable national and local guidelines for disposal. Ask your
local authorities about the legal guidelines at your company location as well
169
as about the regional disposal companies or collecting points.
The device mainly comprises materials that can be disposed of as old metal. In the
following we shall specify the components that may not be disposed of as old
metal.
Ultrasonic electronics
Electric components are contained in the housing of the ultrasonic electronics that
must be disposed of as electric waste. In order to remove the ultrasonic electron-
ics, you have to remove the cover of the ultrasonic electronics.
Chapter 10.2.3, “Opening the cover of the ultrasonic electronics” on page 145
Battery
The battery is attached to the PCB of the ultrasonic electronics. In order to remove
the battery, you have to remove the cover of the ultrasonic electronics.
Chapter 10.2.3, “Opening the cover of the ultrasonic electronics” on page 145
Transducer
The transducer comprises titanium, plastic and heavy metals (e.g., lead in piezo
crystal). The transducers must be disposed of according to the applicable national
and local guidelines.
In order to remove the transducers, RMG service shall inform you of the proce-
dure.
Content
12.1 Alarm messages 171
12.2 Warning messages 172
0
Notes 175
Active warning messages are displayed with a + in front of the message number. 171
Warning messages that can be acknowledged are displayed with a - in front of the
message number.
12.3 Notes
No. Message Explanation
181 Sys. Temp Min System temperature to low
175
182 Sys. Temp Max System temperature to high
183 Rawdata len Length of the raw data telegram wrong
184 Rawdata crc Checksum of the raw data telegram wrong
185 P-LOG full Parameter log memory full
186 DSP-info len Length of the DSP info telegram wrong
187 DSP-info crc Checksum of the DSP info telegram wrong
188 SoS calc. status Status of the SoS calculation
12.4 Troubleshooting
If you cannot find a solution to your problem with the RMG component in
the table below, then please contact the RMG service.
„Manufacturer“ on the inside cover
• Note the active message (number and text) in order to be able to dis-
cuss the problem with RMG service.
No. Description
45 The current output is freely configurable (is only code word protected). Violating the
limit value may occur in an otherwise trouble-free operation if the limits are selected
too close together. In this case, the limits can simply be adjusted. The limits are set
ex-factory in such a manner that they correspond with the limit values of the assigned
measured values, e.g., flow. A limit value violation occurs at the current outlet only if
the meter, for example, is run-over and thus also reports a QVb max error (No.78).
60-65 AGC limits can be violated if an actual fault is at hand on the sensors or it is simply
caused by the operating conditions. In order to limit the cause, one should compare
the values of all paths in L-16/17 to Q-16/17. If only the AGC value of a single path
deviates then one has to expect a defect. If all paths are affected then the cause may
be contamination or condensation deposits on the transducer heads or, also an oper-
ating pressure that is simply too low if, for example, the system has not been applied
yet. If the actual operating pressure deviates significantly from that previously speci-
fied, the parameters must be adjusted by the service. For extremely fluctuating oper-
ating conditions, there is an option for switching the attenuator on and off automati-
cally here, which does not always lead to an optimum setting of the gain as this is
only a 2-point regulation
No. Description
78 QVb max limit appears when the meter is actually run. Then all measuring paths in L-
7 to Q-7 should supply respectively high flow velocities. If only one values stands sig-
nificantly out here then it is probably a malfunction of the path affected.
176 100-105 Path errors occur if one or more of the criterion monitored are violated permanently
so that the content of valid measurement falls below the permitted limit value. If all
measuring paths are affected at the same time, the cause for this is usually due to
unsuitable operating conditions. If, for example, high-pressure gas is not applied to
the system, but it is filled with nitrogen at atmospheric pressure, path error messages
are activated as the limit value for the gain (AGC limit) is exceeded as well as the
speed of sound may fall short or the signal leaves the permissible range of the evalu-
ation window. Change the operating conditions or have the parameters adapted to
the desired mode of operation (service deployment)! Contamination or the accumula-
tion of condensation may also be a possibility. Errors on an individual path typically
indicate a malfunction or a defect of the affected transducer or the corresponding wir-
ing. Check the wiring and plug connectors! Only qualified personnel must change the
transducer!
110-115 The flow velocity of the single paths measured are monitored at the limit values ± 50
m/s. If this is a tangible exceeding of the limit value by the actual flow velocity or it is
a malfunction of an individual path, can be determined by comparing the single meas-
urements in L-7 to Q-7. A subsequent error is no. 78.
120-125 The speed of sound of the single paths measured are monitored at the limit values ±
500 m/s. When using a gas (e.g., hydrogen) that deviates strongly with regard to the
speed of sound, a parameterization must be carried out (service). If strongly deviating
speed of sound are to be expected, the function "Signal Tracking" can also be acti-
vated in AI-27 that then adjusts the respective speed of sound range of the evaluation
window. In case of a path error 100-105, the speed of sound is set to 0 so that the
path can also be clearly identified as faulty on the basis of the measuring value, even
if the reconstructed path velocity with the aid of the replacement-value function ap-
pears plausible.
130-135 These additional messages are helpful in faulty path cases (100-105) in order to de-
und termine the defective transducer of the path affected. Naturally, these error messages
are also triggered if the evaluation electronics were defective, but then, all at the
140-145 same time.
150-155 The monitoring of individual paths with regard to their deviation from the average val-
und ues with respect to measuring variable such as speed of sound and gain (AGC = au-
tomatic gain control) serves the premature recognition of possible irregularities. Thus,
170-175 one has the option to already identify conspicuous paths when the limit values rele-
vant for the calibration have not been violated for the validity of the measurement yet.
Possible causes are identical with those described in 100 -125.
13 Technical specifications
In this chapter you will receive information on the performance data of the device.
177
Content
Protection class IP 66
Notice
In general, the gas to be measured must not build any condensates in the
operating range of the USM (flow, pressure and temperature range) and
must be free of corrosive and aggressive components, liquids and solids.
In case of deviating conditions a suitable operation has to be agreed with
the RMG service.
Notice
In accordance with the German TR-G19 – the USM GT400 is suitable and
approved for use in custody transfer applications –
in natural gases with a maximum hydrogen content of 10 mol-% without a
loss of the accuracy.
Since there are currently no certified test rigs in Germany to calibrate meters with
higher hydrogen-containing gases, an accuracy above 10 mol-% cannot be tested
or certified.
Not custody transfer measurements are of course possible in natural gases with a
hydrogen content above 10 mol%. However, a reduced measuring range must be
taken into account if applicable. Please contact RMG for further information.
182
1 Type plate
Fig. 13.1: Position of the type plate
183
184
In this chapter you will receive information on the dimensions for the versions NEC
and ATEX /IECEx.
ANSI pressure stages: The flange connecting dimensions comply with the
standard ASME B 16.5.
DIN pressure stages: The flange connecting dimensions comply with the
standard DIN EN 1092.
185
1 Front view
2 Side view
3 Top view
Space requirements for sensor exchange
S0: at non pressure flowmeter
S1: Flowmeter under pressure (with special tool)
Fig. 13.4: Weights and dimensions NEC
The version NEC and version ATEX / IECEx have identical dimensions. The table
of the versions can be found on the following location:
Fehler! Verweisquelle konnte nicht gefunden werden.188
186
1 Front view
2 Side view
3 Top view
Space requirements for sensor exchange
S0: at non pressure flowmeter
S1: Flowmeter under pressure (with special tool)
Fig. 13.5: Weights and dimensions NEC
187
Due to the different sizes of the individual components, the device in DN80 is
shown separately.
100 300 400 97.2 102.3 107.1 330 595 415 250 - 100 125
(4) (11.81) (15.75) (3.83) (4.03) (4.22) (12.99) (23.43) (16.34) (9.84) (220) (276)
150 450 450 146.4 154.1 159.3 340 470 470 300 - 160 180
(6) (17.72) (17.72) (5.76) (6.07) (6.27) (13.39) (18.5) (18.5) (11.81) (353) (397)
200 600 800 193.7 202.7 207.3 360 530 565 375 1520 300 380
(8) (23.62) (31.5) (7.63) (7.98) (8.16) (14.17) (20.87) (22.24) (14.76) (59.84) (661) (838)
250 750 1000 242.8 254.5 260.4 380 650 615 400 1550 450 560
(10) (29.53) (39.37) (9.56) (10.02) (10.25) (14.96) (25.59) (24.21) (15.75) (61.02) (992) (1235)
300 900 900 288.8 303.2 309.7 395 700 660 425 1575 550 670
(12) (35.43) (35.42) (11.37) (11.94) (12.19) (15.55) (27.56) (25.98) (16.73) (62.01) (1213) (1477)
400 1200 1200 363.5 381.0 292.2 500 750 750 475 1620 950 1050
(16) (47.24) (47.24) (14.31) (15.0) (11.50) (19.69) (29.53) (29.53) (18.70) (63.78) (2094) (2315)
500 1500 1500 455.6 477.8 493.8 550 900 860 525 1670 1500 1650
(20) (59.06) (59.06) (17.94) (18.81) (19.44) (21.65) (35.43) (31.5) (20.67) (65.75) (3307) (3638)
600 1200 1500 547.7 574.7 595.8 550 1000 1045 600 1725 1550 2500
(24) (47.24) (59.06) (21.56) (22.63) (23.46) (21.65) (39.37) (41.14) (23.62) (67.91) (3417) (5512)
1 189
Maximum diameter at the flange, depending on tapering.
2
Approximate dimension.
3
Approximate values. Weights can vary due to casting tolerances.
The blue marked inner diameters for every ANSI pressure rating are to be under-
stood as a recommendation if no inner diameter is specified by the customer.
The device must not be used for a calibrated operation if the official seal is
broken.
1 Seal
Fig. 13.7: Position of the official seal on the type plate
193
194
195
196
External elements
00.65.142.00 Weather protection cover for electronics housing
00.64.923.00 Complete grill element DN 100 (4”)
00.64.855.00 Complete grill element DN 150 (6”)
00.64.811.00 Transducer cover for DN 80 (3”) to DN 150 (6”)
00.64.798.00 Grill element DN 200 (8”)
00.64.860.00 Grill element DN 250 (10”)
00.64.862.00 Grill element DN 300 (12”)
00.64.864.00 Grill element DN 400 (16”)
00.64.866.00 Grill element DN 500 (20”)
00.64.868.00 Grill element (middle level) DN 600 (24”)
00.64.926.00 Grill element (outer levels) DN 600 (24”)
87.06.050.00 Cable bushing M20x1.5 (Ø 3‐9)
87.06.051.00 Cable bushing M20x1.5 (Ø 6‐12)
84.08.023.00 Shut-off valve NV2F-4N-R-K 2x1/4NPT inn.H.
Pipe bundles
00.64.767.01 Pipe bundle for DN 100 (4”)
00.64.767.02 Pipe bundle for DN 150 (6”)
200
00.64.767.03 Pipe bundle for DN 200 (8”)
00.64.767.04 Pipe bundle for DN 250 (10”)
00.64.767.05 Pipe bundle for DN 300 (12”)
00.64.767.06 Pipe bundle for DN 400 (16”)
00.64.767.07 Pipe bundle for DN 500 (20”)
00.64.767.08 Pipe bundle for DN 600 (24”)
Transducers
00.64.758.00 USM-transducer type TNG 20-SP (3”-6”), 200 kHz, up to 150 bar(a)
00.65.000.00 USM-transducer type TNG20-SHP (3”-6”), 200 kHz, up to 300 bar(a)
00.64.757.00 USM-transducer type TNG 10-CP (8”-40”), 120 kHz, up to 150 bar(a)
00.64.839.00 USM-transducer type TNG10-CHP (8”-40”), 120 kHz, up to 300 bar(a)
Interface converter
30.00.212.00 RS 485 to USB converter for top hat rail (I‐7561U‐G CR)
35.00.023.00 RS 485 to Ethernet converter (FL Comserver)
The following tables show the parameters that can be shown and edited using the
RMGViewUSM software or via the display with control panel.
The abbreviations in the Type and Protection (Prot.) columns have the following
meanings:
Type Protection
F Float R Reading Value
M Menu S Official Key
I Integer F free programmable
U Unixtime C Codeword
L Long Int. CS Code and Official Key
T Text
D Double
C Code
Pressure
202 A-01 Pressure 6252 2 F R → Units: Pressure a Shows the measured pressure
A-03 Current Input 6254 2 F R mA Shows the input value in mA
A-05 p min value 1392 2 F S → Units: Pressure a Measuring pressure min. value
A-06 p max value 1394 2 F S → Units: Pressure a Measuring pressure max. value
A-09 p set value 1396 2 F S → Units: Pressure a Measuring pressure default value
A-11 p at base cond. 1398 2 F S → Units: Pressure a base pressure
A-12 curr. inp. gradient 1400 2 F S Gradient (correction of the mA value)
A-13 curr. inp. offset 1402 2 F S Offset (correction of the mA value)
A-14 p err. min 1404 2 F S → Units: Pressure a Lower error limit of measuring pressure
A-15 p err. max 1406 2 F S → Units: Pressure a Upper error limit of measuring pressure
A-17 p mode 4078 1 M S Operating mode of measuring pressure
0x0000 OFF (d)
0x0001 SET VALUE
0x0002 4-20mA
0x0003 4-20mA_ERR
Temperature
USE09-C Qm
Parameters
USE09-C polynom-B
Flow correction
G-40 dir. 1: flowrate 11 1640 2 F S → Calib. units: Q Linear interpolation direction 1: flow
rate 11
G-41 dir. 1: error 11 1642 2 F S % Linear interpolation direction 1: error 11
G-42 dir. 1: flowrate 12 1644 2 F S → Calib. units: Q Linear interpolation direction 1: flow
206 rate 12
G-43 dir. 1: error 12 1648 2 F S % Linear interpolation direction 1: error 12
G-44 dir. 2: flowrate 1 1650 2 F S → Calib. units: Q Linear interpolation direction 2: flow
rate 1
G-45 dir. 2: error 1 1652 2 F S % Linear interpolation direction 2: error 1
G-46 dir. 2: flowrate 2 1654 2 F S → Calib. units: Q Linear interpolation direction 2: flow
rate 2
G-47 dir. 2: error 2 1656 2 F S % Linear interpolation direction 2: error 2
G-48 dir. 2: flowrate 3 1658 2 F S → Calib. units: Q Linear interpolation direction 2: flow
rate 3
G-49 dir. 2: error 3 1660 2 F S % Linear interpolation direction 2: error 3
G-50 dir. 2: flowrate 4 1662 2 F S → Calib. units: Q Linear interpolation direction 2: flow
rate 4
G-51 dir. 2: error 4 1664 2 F S % Linear interpolation direction 2: error 4
G-52 dir. 2: flowrate 5 1666 2 F S → Calib. units: Q Linear interpolation direction 2: flow
rate 5
G-53 dir. 2: error 5 1668 2 F S % Linear interpolation direction 2: error 5
G-54 dir. 2: flowrate 6 1670 2 F S → Calib. units: Q Linear interpolation direction 2: flow
rate 6
G-55 dir. 2: error 6 1672 2 F S % Linear interpolation direction 2: error 6
G-56 dir. 2: flowrate 7 1674 2 F S → Calib. units: Q Linear interpolation direction 2: flow
rate 7
G-57 dir. 2: error 7 1676 2 F S % Linear interpolation direction 2: error 7
G-58 dir. 2: flowrate 8 1678 2 F S → Calib. units: Q Linear interpolation direction 2: flow
rate 8
G-59 dir. 2: error 8 1680 2 F S % Linear interpolation direction 2: error 8
G-60 dir. 2: flowrate 9 1682 2 F S → Calib. units: Q Linear interpolation direction 2: flow
rate 9
G-61 dir. 2: error 9 1684 2 F S % Linear interpolation direction 2: error 9
G-62 dir. 2: flowrate 10 1686 2 F S → Calib. units: Q Linear interpolation direction 2: flow
rate 10
G-63 dir. 2: error 10 1688 2 F S % Linear interpolation direction 2: error 10
G-64 dir. 2: flowrate 11 1690 2 F S → Calib. units: Q Linear interpolation direction 2: flow
rate 11
G-65 dir. 2: error 11 1692 2 F S % Linear interpolation direction 2: error 11
G-66 dir. 2: flowrate 12 1694 2 F S → Calib. units: Q Linear interpolation direction 2: flow
rate 12
G-67 dir. 2: error 12 1698 2 F S % Linear interpolation direction 2: error 12
Freq.,Pulse Outputs
0x0002 DIRECTION
INV.
0x0003 INPUT
0x0004 TEST
208 0x0005 CPU
H-17 mode ext. warn- 2186 1 M C Mode in the case of external warning
ing
0x0000 OFF (d)
0x0001 LOW_POWER
H-20 Test Alarm a. 1 M C Tests the warning and alarm contacts
Warn 4081
0x0000 OFF (d)
0x0001 TEST
Current Output
Serial Ports
0x0005 57600
J-27 opt. ser2 bits 2114 1 M F Optional serial interface -2 number of
bits
0x0000 7
210 0x0001 8 (d)
J-28 opt. ser2 parity 2115 1 M F Optional serial interface -2 parity
0x0000 NONE (d)
0x0001 EVEN
0x0002 ODD
J-29 Modbus-2 proto- 2178 1 M F Optional serial interface -2 Modbus op-
col erating mode (Off, Ascii or RTU)
0x0000 OFF
0x0001 RTU (d)
0x0002 ASCII
J-30 Modbus-2 hw- 2179 1 M F Optional serial interface -2 Modbus
mode hardware (RS232 or RS485)
0x0000 RS232
0x0001 RS485 (d)
J-31 Modbus-2 ad- 2180 1 I F Optional serial interface -2 Modbus ad-
dress dress (ID)
J-32 Modbus-2 reg.off- 2181 1 I F Optional serial interface -2 Modbus reg-
set ister offset
J-33 Modbus-2 gap 2182 1 I F Optional serial interface -2 Modbus
time turn-off time
J-34 Long Byte Order 2251 1 M F Ser-2 Modbus byte order with long:
(1,0)(3,2) or (3,2)(1,0)
0x0000 NORMAL
0x0001 SWAPPED (d)
J-35 Float Byte Order 2252 1 M F Ser-2 Modbus byte order with float:
(1,0)(3,2) or (3,2)(1,0)
0x0000 NORMAL
0x0001 SWAPPED (d)
J-36 Double Byte Or- 2253 1 M F Ser-2 Modbus byte order with double:
der (1,0)(3,2)(5,4)(7,6) or (7,6)(5,4)(3,2)(1,0)
0x0000 NORMAL (d)
0x0001 SWAPPED
J-37 DZU-2 address 2285 1 I F Serial interface -2 DZU slave ID (ASCII:
00-99)
J-38 serial-2 status 780 10 T R Optional serial interface -2 status
J-39 DZU Interval 2111 1 I S tics Optional serial interface -2 DZU-interval
J-40 DZU Checksum 2255 1 M F Serial interface -1, initial DZU checksum
Preset value
0x0000 0x00 (d)
0x0001 0x7F
DSP,FPGA values
O-24 p4.2 snr (X) 6746 2 F R dB Path 4.2 signal-to-noise ratio (3X-meas-
urement)
O-26 path-4 turbulence 6782 2 F R % Path 4 turbulence
214
Path5 Meas. Values
Q-08 velocity vc6 6210 2 F R → velocity unit Path 6 corrected path velocity vc
Q-09 SoS6 6030 2 F R → velocity unit Path 6 Speed of Sound
Q-10 path-6 delta SoS 6090 2 F R % Path 6 Path-SoS / Mean-SoS
Q-12 path-6 fault 4035 1 I R hex Path 6 path error
215
Q-13 path-6 status 4045 1 I R hex Path 6 path status
Q-14 p6.1 Amplitude 7015 1 I R % Path 6.1 amplitude in per cent
Q-15 p6.2 Amplitude 7025 1 I R % Path 6.2 amplitude in per cent
Q-16 p6.1 AGC-level 6050 2 F R dB Path 6.1 Automated Gain Control
Q-17 p6.2 AGC-level 6070 2 F R dB Path 6.2 Automated Gain Control
Q-18 p6.1 snr 6650 2 F R dB Path 6.1 signal-to-noise ratio
Q-19 p6.2 snr 6670 2 F R dB Path 6.2 signal-to-noise ratio
Q-20 path-6 fault (X) 2275 1 I R hex Path 6 path error (3X-measurement)
Q-21 p6.1 AGC-level (X) 6690 2 F R dB Path 6.1 Automated Gain Control (3X-
measurement)
Q-22 p6.2 AGC-level (X) 6710 2 F R dB Path 6.2 Automated Gain Control (3X-
measurement)
Q-23 p6.1 snr (X) 6730 2 F R dB Path 6.1 signal-to-noise ratio (3X-meas-
urement)
Q-24 p6.2 snr (X) 6750 2 F R dB Path 6.2 signal-to-noise ratio (3X-meas-
urement)
Q-26 path-6 turbulence 6786 2 F R % Path 6 turbulence
R-21 p7.1 AGC-level (X) 6692 2 F R dB Path 7.1 Automated Gain Control (3X-
measurement)
R-22 p7.2 AGC-level (X) 6712 2 F R dB Path 7.2 Automated Gain Control (3X-
measurement)
R-23 p7.1 snr (X) 6732 2 F R dB Path 7.1 signal-to-noise ratio (3X-meas-
216 urement)
R-24 p7.2 snr (X) 6752 2 F R dB Path 7.2 signal-to-noise ratio (3X-meas-
urement)
R-26 path-7 turbulence 6788 2 F R % Path 7 turbulence
USE09 Diagnosis
USE09-C Totalizers
ID
AF-75 Transducer 8.2 1554 2 F S → Calib. units: ID: transducer 8/2 length
len. Length
AF-76 Transducer 8.2 2306 1 I S ID: transducer 8/2 year of manufacture
built
AF-77 serial number 790 10 T S ID: serial number USE09
USE09 223
AF-78 version 100 2 F R ID: M32C software version
AF-79 CPU CRC 201 1 I R hex ID: M32C CRC-16
AF-80 Matrix version 200 1 I R ID: M32C Matrix version
AF-81 DSP version 102 2 F R ID: DSP software version
AF-82 DSP CRC 202 1 I R hex ID: DSP CRC-16
AF-83 FPGA version 104 2 F R ID: FPGA software version
AF-84 FPGA CRC 203 1 I R hex ID: FPGA CRC-16
AF-85 fiscal par. CRC 204 1 I R hex ID: fiscally parameters crc-16
AF-86 piecewise lin. CRC 205 1 I R hex ID: piecewise linearization parameters
crc-16
Mode
0x0000 m3
0x0001 acf
AG-35 pulse unit 7033 1 M R Unit: Pulse value
0x0000 Imp/m3
224
0x0001 Imp/cf
AG-36 Units: Temp. 7035 1 M S Unit: temperature
0x0000 °C (d)
0x0001 °F
0x0002 K
0x0003 °Ra
AG-37 Units: Pressure 7036 1 M S Unit: pressure
0x0000 bar (d)
0x0001 psi
AG-38 Units: Pressure a 7037 1 M R Unit: absolute pressure
0x0000 bar_a
0x0001 psi_a
AG-39 Units: Pressure g 7038 1 M R Unit: relative pressure
0x0000 bar_g
0x0001 psi_g
AG-40 Calib. units: 7039 1 M S Calibration unit: length
Length
0x0000 mm (d)
0x0001 in
AG-41 Calib. units: v 7040 1 M S Calibration unit: speed
0x0000 m/s (d)
0x0001 ft/s
AG-42 Calib. units: Q 7041 1 M S Calibration unit: flow
0x0000 m3/h (d)
0x0001 acfh
Faults
AH-05 fault display 2128 1 M S Fault display mode active: Shows all cur-
mode rently active faults
0x0000 NORMAL (d)
0x0001 ACTIVE
AH-06 path error mode 2129 1 M S Error mode in the case of a path failure 225
0x0000 WARNING (d)
0x0001 ALARM
AH-07 fault,warn contact 2254 1 M F Mode for alarm and warning contact
0x0000 NORMAL (d)
0x0001 5_SECONDS
0x0002 HOLD
AH-09 path ok 700 10 T R Indication of the path status (path moni-
toring is considered)
AH-10 hint status 4008 1 M R Current hint status
0x0000 OFF
0x0001 ON
0x0002 QUIT
AH-11 warning status 4001 1 M R Current warning status
0x0000 OFF
0x0001 ON
0x0002 QUIT
AH-12 warn contact 4120 1 M R Current warning contact
0x0000 OFF
0x0001 ON
AH-13 fault status 4000 1 M R Current alarm status
0x0000 OFF
0x0001 ON
0x0002 QUIT
AH-14 fault contact 4121 1 M R Current alarm contact
0x0000 OFF
0x0001 ON
AH-15 USE09 device sta- 4002 1 I R hex USE09 device status
tus
AH-16 Fault bit 0-15 4010 1 I R hex Active faults (bit-coded) 0-15
AH-17 Fault bit 16-31 4011 1 I R hex Active faults (bit-coded) 16-31
AH-18 Fault bit 32-47 4012 1 I R hex Active faults (bit-coded) 32-47
AH-19 Fault bit 48-63 4013 1 I R hex Active faults (bit-coded) 48-63
AH-20 Fault bit 64-79 4014 1 I R hex Active faults (bit-coded) 64-79
AH-21 Fault bit 80-95 4015 1 I R hex Active faults (bit-coded) 80-95
AH-22 Fault bit 96-111 4016 1 I R hex Active faults (bit-coded) 96-111
AH-23 Fault bit 112-127 4017 1 I R hex Active faults (bit-coded) 112-127
AH-24 Fault bit 128-143 4018 1 I R hex Active faults (bit-coded) 128-143
AH-25 Fault bit 144-159 4019 1 I R hex Active faults (bit-coded) 144-159
AH-26 Fault bit 160-175 4020 1 I R hex Active faults (bit-coded) 160-175
AH-27 Fault bit 176-191 4021 1 I R hex Active faults (bit-coded) 176-191
AH-28 Fault bit 192-207 4022 1 I R hex Active faults (bit-coded) 192-207
226
DSP Parameters
0x0002 HOLD
AI-22 amp. regulator 2146 1 I C % Min. range for amplitude control
min
AI-23 amp. regulator 2147 1 I C % Max. range for amplitude control
max 227
AI-24 amp. damping 1448 2 F C Damping for amplitude control
AI-25 theoretical SoS 1368 2 F S → velocity unit Theoretical speed of sound of the fluid
AI-26 ADC gain 2164 1 M S FPGA AD gain 0 dB, +6 dB, -6 dB
0x0000 1 (d)
0x0001 2
0x0002 0.5
AI-27 signal tracking 2169 1 M C Switches signal tracking on or off
0x0000 ON
0x0001 OFF (d)
AI-28 max. track. Offset 2187 1 I C Tics Max. size of the tracking window
AI-37 corr. mode 2256 1 M S Correlation mode
0x0000 OFF (d)
0x0001 FADE_IN
AI-38 corr. length 2189 1 I S Length of the correlation window
AI-39 Batch: amp. min. 2279 1 I S % Batch: Minimum amplitude
AI-47 AmplitudeMin 2000 1 I S % Limit for the input signal (Low)
AI-48 AmplitudeMax 2010 1 I S % Limit for the input signal (High)
AI-49 Vmin 1000 2 F S → Calib. units: v Lower limit for the flow velocity
AI-50 Vmax 1020 2 F S → Calib. units: v Upper limit for the flow velocity
AI-51 Cmin 1040 2 F S → Calib. units: v Lower limit for the speed of sound
AI-52 Cmax 1060 2 F S → Calib. units: v Upper limit for the speed of sound
DSP Parameters 3X
Path1 Parameters
Path2 Parameters
Path3 Parameters
Path4 Parameters
Path5 Parameters
Path6 Parameters
Path7 Parameters
Path8 Parameters
Service
Log Data
Site Information
Remote Control
AGA-10 Values
AGA-10 Config
DSfG Instance-F
BA-09 Gas vol error d.1 32782 2 L R → Unit LF-Volumes Volume of Gas disturbed Flow direction
1 (Vm_err_d1)
BA-10 Gas vol error d.2 32784 2 L R → Unit LF-Volumes Volume of Gas disturbed Flow direction
2 (Vm_err_d2)
BA-11 Valence 32786 2 L R Valency
244
BA-12 Flow > Qt 32788 2 L R Flow bigger Qt (0 = no, unequal 0 = yes)
BA-13 Signal acceptance 32790 2 L R % Signal acceptance
BA-14 Meter error 32792 2 L R Meter disturbed (0 = no, unequal 0 =
yes)
BA-15 Number of Paths 32794 2 L R Number of Paths
BA-16 SoS deviation P1 32796 2 F R % Speed of Sound deviation Path 1
(SoS_1_dev = (SoS_1-SoS)/SoS*100)
BA-17 SoS deviation P2 32798 2 F R % Speed of Sound deviation Path 2
(SoS_2_dev = (SoS_2-SoS)/SoS*100)
BA-18 SoS deviation P3 32800 2 F R % Speed of Sound deviation Path 3
(SoS_3_dev = (SoS_3-SoS)/SoS*100)
BA-19 SoS deviation P4 32802 2 F R % Speed of Sound deviation Path 4
(SoS_4_dev = (SoS_4-SoS)/SoS*100)
BA-20 SoS deviation P5 32804 2 F R % Speed of Sound deviation Path 5
(SoS_5_dev = (SoS_5-SoS)/SoS*100)
BA-21 SoS deviation P6 32806 2 F R % Speed of Sound deviation Path 6
(SoS_6_dev = (SoS_6-SoS)/SoS*100)
BA-22 SoS deviation P7 32808 2 F R % Speed of Sound deviation Path 7
(SoS_7_dev = (SoS_7-SoS)/SoS*100)
BA-23 SoS deviation P8 32810 2 F R % Speed of Sound deviation Path 8
(SoS_8_dev = (SoS_8-SoS)/SoS*100)
BA-24 Path velocity vc1 32896 2 F R m/s Velocity of Gas Path 1
BA-25 SoS P1 32898 2 F R m/s Speed of Sound Path 1
BA-26 Signal acceptance 32900 2 F R % Signal acceptance Path 1
P1
BA-27 SNR P1 AB 32902 2 F R dB Signal-Noise-Ratio AB Path 1
BA-28 SNR P1 BA 32904 2 F R dB Signal-Noise-Ratio BA Path 1
BA-29 AGC-level P1 AB 32906 2 F R dB Automatic gain AB Path 1
BA-30 AGC-level P1 BA 32908 2 F R dB Automatic gain BA Path 1
BA-31 Path velocity vc2 32912 2 F R m/s Velocity of Gas path 2
BA-32 SoS P2 32914 2 F R m/s Speed of Sound Path 2
BA-33 Signal acceptance 32916 2 F R % Signal acceptance Path 2
P2
BA-34 SNR P2 AB 32918 2 F R dB Signal-Noise-Ratio AB Path 2
BA-35 SNR P2 BA 32920 2 F R dB Signal-Noise-Ratio BA Path 2
BA-36 AGC-level P2 AB 32922 2 F R dB Automatic gain AB Path 2
BA-37 AGC-level P2 BA 32924 2 F R dB Automatic gain BA Path 2
BA-38 Path velocity vc3 32928 2 F R m/s Velocity of Gas path 3
BA-39 SoS P3 32930 2 F R m/s Speed of Sound Path 3
BA-40 Signal acceptance 32932 2 F R % Signal acceptance Path 3
P3
BA-41 SNR P3 AB 32934 2 F R dB Signal-Noise-Ratio AB Path 3
BA-42 SNR P3 BA 32936 2 F R dB Signal-Noise-Ratio BA Path 3
BA-43 AGC-level P3 AB 32938 2 F R dB Automatic gain AB Path 3
• PED 2014/68/EU /
EU-type examination certificate (Module B)
ISG-22-14-1630
• ASME B31.3 Ed.2012
• CRN
• FS-1312-249580-001
• FS-1312-249585
In the event of a modification of the device is not authorized by us, this declaration
shall be rendered void.
EC guidelines
2011/65/EU RoHS
DIN EN 334:2009-07 Gas pressure regulators for inlet pressures up to 100 bar
DIN EN 14382 Safety devices for gas pressure regulating stations and installa-
tions - Gas safety shut-off devices for inlet pressures up to 100
bar
CAN C22.2 No. 30 Explosion-Proof Enclosures for Use in Class I Hazardous Loca-
tions
USA Directives
AGA report No. 10 Speed of Sound in Natural Gas and Other Related Hydrocarbon
Gases.
Canada Directives
Plot
Graphic display of one or more measured values.
Meter
In der Software wird der Ultraschallzähler zum Teil als Messwerk bezeichnet.
Device
In the software the ultrasonic gas meter is sometimes called a meter.
Transducer
The transducer or sensor is built into the device. The transducer sends the oppos-
ing transducer an ultrasonic signal. Using the time measured for the ultrasonic
signal to travel the distance between the two transducers, the ultrasonic electron-
ics calculates the gas flow. 12 transducers are built into the device. They are dis-
tributed across three levels with four transducers on every level. Per level two
paths measure the gas flow. A path comprises two opposing transducers.
Sensor
Transducer
Meter
Ultrasonic gas meter (USM)
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
Weitere Informationen
Wenn Sie mehr über die Produkte und
Lösungen von RMG erfahren möchten,
besuchen Sie unsere Internetseite:
www.rmg.com
oder setzen Sie sich mit Ihrer lokalen
Vertriebsbetreuung in Verbindung
2. FLOW ALIGNER
CPA 50E Recomendaciones de Instalación
¿Cómo sabemos que nuestros acondicionadores de flujo son la solución más efectiva para
sus necesidades de acondicionamiento de flujo? Porque han sido ampliamente probados y
evaluados por laboratorios independientes y han demostrado ser superiores para estabilizar
el rendimiento aguas abajo, incluso en las situaciones más exigentes.
Eso significa que siempre obtendrá mediciones precisas, sin importar si se trata de una
aplicación de aire, gas natural, agua, petróleo, petróleo líquido o cualquier otro fluido.
Nos enorgullecemos de la entrega rápida. Tenemos modelos de cara elevada ANSI en stock y
listos para su envío inmediato, y tenemos tiempos de respuesta rápidos para diseños y
fabricación personalizados. Ofrecemos una amplia variedad de materiales y podemos
diseñar para cualquier tamaño de ½ "a 60 pulgadas, múltiples opciones de instalación, baja
temperatura, alta temperatura, NORSOK, NACE y más.
EN 10204 3.1b Se incluyen informes de prueba de materiales con cada parte, así como
cálculos de caída de presión, certificados de control de calidad y dibujos con cada pedido.
Características
• Inventario disponible para entrega rápida. Disponible en configuración de tipo A de cara
elevada ANSI, tamaños de 2 a 16 pulgadas, material 40 y 80, material de acero inoxidable
316.
• Se puede fabricar a medida para tubos de 3/8 ″ - 48 ″.
• Disponible en acero al carbono, 316SS, 304SS, aluminio, Hastelloy, dúplex, Monel, Inconel,
titanio, etc.
• Aplicable a tipos de medidores de flujo, incluidos orificios, ultrasonidos, turbinas, Coriolis y
más.
• Adecuado para su uso en todo tipo de fluidos, incluidos gas natural, petróleo, agua, vapor,
petróleo líquido y más.
• Compatible con las pestañas CPA FloAlign y CPA Paddle para ayudar a levantar, inspeccionar,
instalar y alinear.
• Los informes de calidad del material EN 10204 3.1b se incluyen con cada pedido y están
disponibles en nuestra base de datos en línea.
• ¡AGA3, AGA9, OIMLR-137 y muchos más datos están disponibles!
• Producto completo y soporte técnico de los ingenieros de CPA, incluidas las
recomendaciones de CFD, cartas de cumplimiento, etc.
Hay dos subtipos adicionales del acondicionador de flujo Tipo D: el RTJ hembra (RTJF) y el
RTJ macho (RTJM).
En una configuración RTJM, las juntas están integradas en el acondicionador de flujo, por lo
que no se requieren juntas adicionales y se reduce el espacio entre bridas.
Dado que las juntas integrales en el RTJM están diseñadas para deformarse durante
la instalación, el acondicionador de flujo no debe reutilizarse si se abren las bridas.
Características
• Diseño personalizado para cada aplicación con una amplia gama de opciones de tamaño y
material.
• Disponible para clasificaciones ANSI 150 # a 2500 #, API 2000 a 20000 y brida compacta
Norsok.
• Puede ser diseñado para acomodar cáncamos forjados ASME 18.15.
• Totalmente compatible con los mínimos de espesor de pieza RTJ especificados en ASME
B16.48‐2005 y ASME B31.3‐2004.
Para un RTJM, el acondicionador de flujo debe insertarse en el tubo del medidor aguas
abajo. Este posicionamiento asegura que el acondicionador de flujo esté centrado en relación
con el medidor de flujo y aísla adecuadamente el tubo del medidor aguas arriba.
El CPA 55E y 65E tienen una dirección preferida. Están diseñados para instalarse con el
lado escalonado hacia arriba para un rendimiento adecuado.
Espesor de diseño de junta tipo anillo femenino (RTJF)
Todos los acondicionadores de flujo tipo anillo hembra (RTJF) fabricados por Canada
Pipeline Accessories están diseñados para cumplir con ASME B31.3 y ASME B16.48. Estas
normas proporcionan las dimensiones requeridas para la instalación segura de espacios en
blanco RTJ, espaciadores y persianas de línea.
El grosor del RTJF es un factor importante para determinar qué tan fuerte es la pieza. A
medida que el RTJF se comprime entre sí mediante el atornillado de la brida, fuerzan a las
superficies de la ranura a separarse y someten fuertemente al material entre las ranuras. En
un RTJF con el grosor adecuado, hay suficiente material para resistir las fuerzas que separan
la brida. Si la brida RTJF es demasiado delgada, no habrá suficiente material y resistencia
para evitar que la pieza falle.
Figura 1: Este gráfico visualiza el esfuerzo en una brida conforme a ASME B16.48. Las áreas
de color púrpura oscuro indican que el material está estresado más allá de los límites
aceptables y está cerca de fallar.
En la figura 2 a continuación, el grosor de la brida RTJF se ha reducido al grosor de un anillo
de purga común. Como antes, las áreas de color púrpura oscuro indican material que está
estresado más allá del rango máximo permitido y que está a punto de fallar. Debido a que la
brida en la figura 2 es más delgada, no hay suficiente material para resistir la fuerza que
mantiene juntas las bridas. El área púrpura oscura se extiende por todo el grosor de la
materia, y en este grosor, la brida RTJF está en riesgo de fallar catastróficamente.
Figura 2: Este gráfico visualiza la tensión en una brida delgada de RTJF. Los colores morados
oscuros indican material que está estresado más allá de los límites aceptables y está a punto
de fallar.
Los acondicionadores de flujo de CPA están diseñados para tener en cuenta la tensión a la
que están sometidas las bridas RTJF cuando se instalan. Para el cumplimiento adecuado de
la ingeniería, es muy importante cumplir con las dimensiones especificadas en ASME B31.3
y ASME B16.48. Los diseños más delgados estarán en riesgo de falla severa.
Orientación de placa
Para facilitar la instalación, el acondicionador de flujo CPA Tipo D tiene un marcador de
punto muerto superior grabado en la circunferencia exterior de la brida. Esta flecha grabada
está alineada con el eje de 90 grados del acondicionador de flujo y se proporciona para
ayudar con la orientación del acondicionador de flujo cuando se utilizan medidores de flujo
ultrasónicos.
3. VALVES – 3/4"
No. PO PO15298
SAN JUAN LNG FACILITY
No. DOCUMENT NFE-2923-Q-MA-001
4. VALVES – 8” 600#
DOC NO:NWS 0004.7
BS/BSP/BSE series
Forged Steel Trunnion Ball Valve
Installation,Operation and Maintenance
Instruction
Translated Copy
Page 2 of 16
BS/BSP/BSE series Forged Steel
Trunnion Ball Valve Installation, DOC NO: NWS 0004.7
Operation and Maintenance Instruction REV NO: 2014
Page 3 of 16
BS/BSP/BSE series Forged Steel
Trunnion Ball Valve Installation, DOC NO: NWS 0004.7
Operation and Maintenance Instruction REV NO: 2014
Fig.3
3.2 Handling of Valves
3.4 Ensure enough space to valve operation.
1) The valve should be lifted in correct way so
that the body supports the load. ---------------------------------------------------------------
Caution: ball valve is 90 degrees rotation
-------------------------------------------------------------
operating valves, clockwise close;
2)Caution: Never use handwheel or other
counterclockwise drive open. For lever
protruding parts of the gearbox or actuator operated valves, keep enough space to
not designated for this purpose. If lifting lug operate.
is visible, please use lifting lug, if not, please ---------------------------------------------------------------
follow Fig2.
--------------------------------------------------------------- 3.5 The following care should be taken for
butt-welding valve when welding:
1) If the valve must be installed in full-close
position, please lay oil on the exposure part of
the ball to protect ball from splash welding slag.
---------------------------------------------------------------
Caution: For butt-welding valve with no
nipple pipe , never install valve when the
ball is in close position
Fig.2 lifting with end neck
---------------------------------------------------------------
3) The end protector covers should be kept in
2) During the welding of ball valve, temperature of
place on the end connections during all
handling. Remove only before installation of any point which is 3 inch(75mm) off brazing
the valve. Movement should be careful. seam should not exceed 302℉(150℃).Please
--------------------------------------------------------------- measure temperature with thermopile stick.
Caution: During handling, protect the end
connection faces and fittings against damage
Page 4 of 16
BS/BSP/BSE series Forged Steel
Trunnion Ball Valve Installation, DOC NO: NWS 0004.7
Operation and Maintenance Instruction REV NO: 2014
3) Before finally welding to pipe vessel, please with isolating valves, the bleed valve should be
obturate valve half bottom sealing changed to plug screw.
area(sealing between ball and valve seat and 4) Now the valve is ready to be pressure tested.
sealing between valve seat and bonnet) with 5) After pressure test, turn the valve to fully open
20mm wide bracer. In order to avoid the position before releasing the test fluid. The
sundries enter into this area. Before using or isolate valve should be in fully-opened position
pressure test, contaminant should be cleaned if it is installed on bleed hole and draining hole.
with cleaning ball in piping system. Screw off the screw plug or safety relief valve,
3.6 Hydrostatic Testing releasing the test fluid from body cavity.
When ball valves are installed in a piping 6) Screw on the screw plug or safety relief valve,
system that requires hydrostatic testing of the return the valve to fully open position or other
adjoining pipe, follow these procedures to position need to operate.
minimize any damage that could occur to the 7) For the structure of double piston on both sides,
sealing surfaces and seat seals inside the and no isolating valve on bleed hole, after pressure
valve, and reduce unnecessary leakage. testing, the plug screw should be taken down, and
1) Valve should be in the fully open position when rechange to bleed valve. For valves with bleed
the injection of test fluid begins. This will allow valve, the plug screw should also rechange to bleed
any pipeline debris to be flushed through the valve.
valve bore and out of the piping. Isolating valve 8) If medium is water, the pipe and valve cavity must
should be fully-opened if installed on bleed be dried and exhausted in time, and filling the pipe
hole or draining hole. with nitrogen, injecting grease when necessary,
2) Once the piping system has been purged of material of carbon steel should be painted
debris and the system has been filled anticorrosive oil to avoid corrosion resulting from
completely with the test fluid, the ball valve testing medium, which would affect the valve
should be placed in the partially open performance.
position(approximately 10o from the fully open
position).This allows test fluid into the body 4. Using
cavity of the valve. The isolating valve should 4.1 Products shall worked in specified conditions
be turned to middle position if it is installed on in purchase order.
bleed hole or draining hole. ---------------------------------------------------------------
3) For the structure of double piston on both sides, Caution: anything beyond the purchase
order specified working conditions (media,
and no isolating valve on bleed hole, warning
pressure, temperature, and the external
board should be installed under bleed valve,
environment etc.) are not allowed, otherwise
according to the board, bleed valve above the will produce risk.
diagonal should be taken down before ---------------------------------------------------------------
pressure test, then using the plug screw. Valve 4.2 Valve in normal working condition, should
Page 5 of 16
BS/BSP/BSE series Forged Steel
Trunnion Ball Valve Installation, DOC NO: NWS 0004.7
Operation and Maintenance Instruction REV NO: 2014
keep in fully open or fully closed state. Valve c) Isolating valve: handle paralleling with the
with isolating valve should be installed on channel is full-open position, vertical is full-
bleed hole or draining hole, the isolating hole closed position.
should be in full-open position, others in full-
closed position. We do not recommend that in
order to adjust the pipeline flux and make the
valve in partial open state.
Page 6 of 16
BS/BSP/BSE series Forged Steel
Trunnion Ball Valve Installation, DOC NO: NWS 0004.7
Operation and Maintenance Instruction REV NO: 2014
4.4.3 Use of safety relief valve. Purpose for using page 10.
safety relief valve shall be: pressure relief and 4.5.3 Washing liquid/sealing gum using quantity
Gland
5. Maintenance
5.1 Daily maintenance is the necessary for valves
in good condition. Mainly includes:
a) Check bolts, nuts fastening.
Normal draining
b) Check the sealing situation of stem, body
and bonnet all day long.
Page 7 of 16
BS/BSP/BSE series Forged Steel
Trunnion Ball Valve Installation, DOC NO: NWS 0004.7
Operation and Maintenance Instruction REV NO: 2014
c) Check valve corrosion situation. 5.4 Valve disassemble (refer to valve disassemble
fig 1 & fig 2)
5.2 Gearbox maintenance 5.4.1 After demounting from the piping, release
a) Inspect housing for damage and wear. the possible residual stress in the housing of
b) Check the sealing situation of gearbox and valve.
prevent from water which cause corrosion. 5.4.2 Fix valve vertically on mounting rack. Be
c) Lubricate gear box with approved lubricant careful not to damage the facing ring of
if necessary. flange, close the valve clockwise rotation.
5.4.3 Actuator
5.3 Maintenance Normal Lever:
For your safety, suggest valve repair by NEWAY. a. Remove the bolt, washer and lever;
Pay attention to the following before repairing; b. Remove the retainer, locating board and
a) It is not suggested to repair the valve before locating screw;
pressure relief or when power on. T-Lever:
--------------------------------------------------------------- a. Screw off bolt, take out the steel pipe;
Caution: before repairing, reduce or release b. Remove screw, washer and lever;
pipeline pressure and release valve inner
c. Remove washer, locating board and
cavity pressure, prevent human body from
locating screw;
injuring, cut off power supply of driver
device, prevent valve abnormal movements Gearbox:
cause harm to human body. a. Screw off nut, lift off the gearbox from the
--------------------------------------------------------------- valve, and locate at clean place;
b) Understand pipeline medium, consult with
b. Remove the key and pin from stem;
authoritative department if necessary.
5.4.4 Main Body
---------------------------------------------------------------
Trunnion design:
Caution: it mustn’t maintenance when you
a. Remove screw 24, lift off top flange 8;
don’t know pipe medium clearly. To prevent
injuring, usually requires to wear exposure b. Remove O-ring 23 in top flange, remove
suit or uses protective equipments. fire safe seal 22 from cover 7;
--------------------------------------------------------------- c. Remove screw 21 from cover, and
c) No-smoking, don't use electric device with no
dismount the cover and stem 6 from the
explosive-proof type, fire without permission
body 1 together;
is forbidden.
d. Separate the cover, thrust washer 26 and
d) Removing after and before decomposed, put
bearing 27 from the stem. Take out the
the valve in a vertical position to empty
O-ring 20 and pin 25 from cover;
pipe remaining medium, taking care when open
e. Remove bolt 36 from trunnion 34, remove
and close the valve on several occasions.
the trunnion;
Page 8 of 16
BS/BSP/BSE series Forged Steel
Trunnion Ball Valve Installation, DOC NO: NWS 0004.7
Operation and Maintenance Instruction REV NO: 2014
f. Remove nut 12, take out the bonnet 2 and b. Fix spring 16 on bonnet 2, put the seat
seat retainer 4, gasket 9, seat follower 13, assembly into the bonnet, press the seat
o-ring 10, spring 16 slightly, locate them assembly to contact the spring;
on soft cloth or chipboard. Adown the c. Fix on pin 36 (if available). Fix the valve
flange end, be careful not to damage the body 1 on one bonnet, pay attention to
facing ring of the flange; the position of oil way, and bolt the nut 12
g. Take out the seat retainer, gasket 15, refer to table 1;
washer 14, seat follower, O-ring 17 and Table 1 Fastening suggest torque (Nm)
spring from the bonnet; Size Torque Size Torque
h. Lift out the ball 13 vertically, locate it on
1/2 50~60 1-5/8 1800~2200
soft cloth or chipboard;
9/16 70~80 1-3/4 2200~2600
i. Repeat f & g, separate bonnet and other
5/8 100~130 1-7/8 2800~3300
accessories on the other side;
Trunnion support design: 3/4 160~210 2 3500~4200
Page 9 of 16
BS/BSP/BSE series Forged Steel
Trunnion Ball Valve Installation, DOC NO: NWS 0004.7
Operation and Maintenance Instruction REV NO: 2014
g. Fix O-ring 19/20, injection 40 (if available) attention that the flat trend on ball should
and gasket 18 into cover 7; Fix bearing 27 aim at the hole which for stem;
and thrust washer on stem 6; d. Follow the steps of f, g, h, I of trunnion
h. Tread the stem through valve body to the design, fix the bonnet on the other side,
flat trend of the ball, pay attention to the stem 6, cover 7 and top flange 8, etc;
direction of key trend; Put the fix pin 25 5.6 Former disassemble steps please refer to
into pinhole on the top of valve body, put valve disassemble figures. If have any
on the cover tread through stem and fix questions, please feel free to contact the
pin, bolt the screw 21 refer to Table 1; manufacture;
i. Fix top flange 8, bolt the screw 24; 5.7 To ensure the quality of the valve, suggest to
Trunnion support design: change the soft sealing when re-assemble,
a. Follow the step a, b, c of trunnion design, such as: gasket, thrust washer, valve seat
fix bonnet 2 on the other side; and packing;
b. Put bearing 33 into the bore of trunnion 6 Problem solving
support 34. Fix trunnion support and Some usual troubles are listed below for your
thrust washer 35 together on the ball 3; convenient to seek the solution:
c. Lift up the ball and trunnion support
together through the ball passage with
soft rope, fix them in the body, pay
Page 10 of 16
BS/BSP/BSE series Forged Steel
Trunnion Ball Valve Installation, DOC NO: NWS 0004.7
Operation and Maintenance Instruction REV NO: 2014
section 5.2
1. The operator is malfunctioning;
The valve is 2. Lubricate valve seat with sealant, lubricate
2. Lack of lubricate oil;
difficult to actuator with proper industrial oil;
3. Ice exist in operate system or
operate 3. Heat or inject anti-icing fluid;
in the valve;
4. loosen bolt on top flange and cover; Check
4. Stem is locking
the valve; Check the damage situation;
1. Contaminant on sealing
1. Clean the contaminant;
surface
The seats 2. Re-facing the sealing surface or change the
2. Damage on sealing surface
are leaking sealing packing;
3. Leakage between valve seat
3. Change O-ring;
and bonnet, check whether
Leaking of
closure
Page 11 of 16
BS/BSP/BSE series Forged Steel
Trunnion Ball Valve Installation, DOC NO: NWS 0004.7
Operation and Maintenance Instruction REV NO: 2014
Washing Procedure
Procedure Process
Inject wash liquid Inject adequate wash liquid into each injection through valve
seat
Inject wash liquid Inject adequate wash liquid into each injection through valve
seat
Wet the valve Wait for 1-6 hours, let wash liquid wet the block and dirty
Inject wash liquid Inject adequate wash liquid into each injection through valve
seat
Injection procedure
Procedure Process
2.Check valve
Endure valve is in fully close position
position
3.Inject standard Inject adequate wash liquid into each injection through valve
5.Inject standard Inject adequate wash liquid into each injection through valve
Open and close valve 3-4 times, then turn valve to fully closed
6.Operate valve
position, proportion the sealing lubricant.
Page 12 of 16
BS/BSP/BSE series Forged Steel
Trunnion Ball Valve Installation, DOC NO: NWS 0004.7
Operation and Maintenance Instruction REV NO: 2014
Valve Injection for each Injection Injection for Injection for each
3
size valve seat (oz) for each valve each valve seat
3 valve(cm )
(oz)
(cm )
2” 1 2 25 50
3” 1 2 35 65
4” 2 3 50 100
6” 2 4 65 130
8” 3 6 80 160
10” 3 6 90 180
12” 5 10 135 270
14” 5 10 155 310
16” 6 12 170 335
18” 9 18 265 525
20” 10 20 295 585
22” 11 22 330 655
24” 12 24 350 695
26” 13 26 395 785
28” 13 26 400 800
30” 15 30 445 890
34” 17 34 495 990
36” 21 42 620 1240
40” 32 64 960 1920
42” 34 68 995 1990
Page 13 of 16
earthquake, typhoon etc).
7.5 The other assurances beyond the scope 7.7 NEWAY will track the valve quality and
of this document shall be agreed by user offer various services per user’s
and manufacture. requirements.
7.6 NEWAY can provide on-site installation 7.8 If user disassembles the valve to repair
and commissioning (If it is included in without manufacture’s permission, the
the contract). user will be regarded to giving up the
quality assurance above
.
Page 14 of 16
BS/BSP/BSE series Forged Steel
Trunnion Ball Valve Installation, DOC NO: NWS 0004.7
Operation and Maintenance Instruction REV NO: 2014
Bolt
Washer
24
8
Gearbox
22
23
Stud 20
Gearbox 27
Nut
26 31
30
6
28 29
21
7
18 25
19
3
5
4
14
13
17
1
33
15
16
37 35
11
34
12
10
9 36
2
32
Page 15 of 16
BS/BSP/BSE series Forged Steel
Trunnion Ball Valve Installation, DOC NO: NWS 0004.7
Operation and Maintenance Instruction REV NO: 2014
Bolt
Washer
24
Gearbox
25
8
Stud
23
Gearbox
Nut 22
21
41
7
20
40
18
26 19
27
31
6
30 28
32
34 29
3
5
4
14
15
16
9
38
1
37
17 10 13 36 33 35 39
12 11
2
Page 16 of 16
No. PO PO15298
SAN JUAN LNG FACILITY
No. DOCUMENT NFE-2923-Q-MA-001
BS/BSP/BSE series
Forged Steel Trunnion Ball Valve
Installation,Operation and Maintenance
Instruction
Translated Copy
Page 2 of 16
BS/BSP/BSE series Forged Steel
Trunnion Ball Valve Installation, DOC NO: NWS 0004.7
Operation and Maintenance Instruction REV NO: 2014
Page 3 of 16
BS/BSP/BSE series Forged Steel
Trunnion Ball Valve Installation, DOC NO: NWS 0004.7
Operation and Maintenance Instruction REV NO: 2014
Fig.3
3.2 Handling of Valves
3.4 Ensure enough space to valve operation.
1) The valve should be lifted in correct way so
that the body supports the load. ---------------------------------------------------------------
Caution: ball valve is 90 degrees rotation
-------------------------------------------------------------
operating valves, clockwise close;
2)Caution: Never use handwheel or other
counterclockwise drive open. For lever
protruding parts of the gearbox or actuator operated valves, keep enough space to
not designated for this purpose. If lifting lug operate.
is visible, please use lifting lug, if not, please ---------------------------------------------------------------
follow Fig2.
--------------------------------------------------------------- 3.5 The following care should be taken for
butt-welding valve when welding:
1) If the valve must be installed in full-close
position, please lay oil on the exposure part of
the ball to protect ball from splash welding slag.
---------------------------------------------------------------
Caution: For butt-welding valve with no
nipple pipe , never install valve when the
ball is in close position
Fig.2 lifting with end neck
---------------------------------------------------------------
3) The end protector covers should be kept in
2) During the welding of ball valve, temperature of
place on the end connections during all
handling. Remove only before installation of any point which is 3 inch(75mm) off brazing
the valve. Movement should be careful. seam should not exceed 302℉(150℃).Please
--------------------------------------------------------------- measure temperature with thermopile stick.
Caution: During handling, protect the end
connection faces and fittings against damage
Page 4 of 16
BS/BSP/BSE series Forged Steel
Trunnion Ball Valve Installation, DOC NO: NWS 0004.7
Operation and Maintenance Instruction REV NO: 2014
3) Before finally welding to pipe vessel, please with isolating valves, the bleed valve should be
obturate valve half bottom sealing changed to plug screw.
area(sealing between ball and valve seat and 4) Now the valve is ready to be pressure tested.
sealing between valve seat and bonnet) with 5) After pressure test, turn the valve to fully open
20mm wide bracer. In order to avoid the position before releasing the test fluid. The
sundries enter into this area. Before using or isolate valve should be in fully-opened position
pressure test, contaminant should be cleaned if it is installed on bleed hole and draining hole.
with cleaning ball in piping system. Screw off the screw plug or safety relief valve,
3.6 Hydrostatic Testing releasing the test fluid from body cavity.
When ball valves are installed in a piping 6) Screw on the screw plug or safety relief valve,
system that requires hydrostatic testing of the return the valve to fully open position or other
adjoining pipe, follow these procedures to position need to operate.
minimize any damage that could occur to the 7) For the structure of double piston on both sides,
sealing surfaces and seat seals inside the and no isolating valve on bleed hole, after pressure
valve, and reduce unnecessary leakage. testing, the plug screw should be taken down, and
1) Valve should be in the fully open position when rechange to bleed valve. For valves with bleed
the injection of test fluid begins. This will allow valve, the plug screw should also rechange to bleed
any pipeline debris to be flushed through the valve.
valve bore and out of the piping. Isolating valve 8) If medium is water, the pipe and valve cavity must
should be fully-opened if installed on bleed be dried and exhausted in time, and filling the pipe
hole or draining hole. with nitrogen, injecting grease when necessary,
2) Once the piping system has been purged of material of carbon steel should be painted
debris and the system has been filled anticorrosive oil to avoid corrosion resulting from
completely with the test fluid, the ball valve testing medium, which would affect the valve
should be placed in the partially open performance.
position(approximately 10o from the fully open
position).This allows test fluid into the body 4. Using
cavity of the valve. The isolating valve should 4.1 Products shall worked in specified conditions
be turned to middle position if it is installed on in purchase order.
bleed hole or draining hole. ---------------------------------------------------------------
3) For the structure of double piston on both sides, Caution: anything beyond the purchase
order specified working conditions (media,
and no isolating valve on bleed hole, warning
pressure, temperature, and the external
board should be installed under bleed valve,
environment etc.) are not allowed, otherwise
according to the board, bleed valve above the will produce risk.
diagonal should be taken down before ---------------------------------------------------------------
pressure test, then using the plug screw. Valve 4.2 Valve in normal working condition, should
Page 5 of 16
BS/BSP/BSE series Forged Steel
Trunnion Ball Valve Installation, DOC NO: NWS 0004.7
Operation and Maintenance Instruction REV NO: 2014
keep in fully open or fully closed state. Valve c) Isolating valve: handle paralleling with the
with isolating valve should be installed on channel is full-open position, vertical is full-
bleed hole or draining hole, the isolating hole closed position.
should be in full-open position, others in full-
closed position. We do not recommend that in
order to adjust the pipeline flux and make the
valve in partial open state.
Page 6 of 16
BS/BSP/BSE series Forged Steel
Trunnion Ball Valve Installation, DOC NO: NWS 0004.7
Operation and Maintenance Instruction REV NO: 2014
4.4.3 Use of safety relief valve. Purpose for using page 10.
safety relief valve shall be: pressure relief and 4.5.3 Washing liquid/sealing gum using quantity
Gland
5. Maintenance
5.1 Daily maintenance is the necessary for valves
in good condition. Mainly includes:
a) Check bolts, nuts fastening.
Normal draining
b) Check the sealing situation of stem, body
and bonnet all day long.
Page 7 of 16
BS/BSP/BSE series Forged Steel
Trunnion Ball Valve Installation, DOC NO: NWS 0004.7
Operation and Maintenance Instruction REV NO: 2014
c) Check valve corrosion situation. 5.4 Valve disassemble (refer to valve disassemble
fig 1 & fig 2)
5.2 Gearbox maintenance 5.4.1 After demounting from the piping, release
a) Inspect housing for damage and wear. the possible residual stress in the housing of
b) Check the sealing situation of gearbox and valve.
prevent from water which cause corrosion. 5.4.2 Fix valve vertically on mounting rack. Be
c) Lubricate gear box with approved lubricant careful not to damage the facing ring of
if necessary. flange, close the valve clockwise rotation.
5.4.3 Actuator
5.3 Maintenance Normal Lever:
For your safety, suggest valve repair by NEWAY. a. Remove the bolt, washer and lever;
Pay attention to the following before repairing; b. Remove the retainer, locating board and
a) It is not suggested to repair the valve before locating screw;
pressure relief or when power on. T-Lever:
--------------------------------------------------------------- a. Screw off bolt, take out the steel pipe;
Caution: before repairing, reduce or release b. Remove screw, washer and lever;
pipeline pressure and release valve inner
c. Remove washer, locating board and
cavity pressure, prevent human body from
locating screw;
injuring, cut off power supply of driver
device, prevent valve abnormal movements Gearbox:
cause harm to human body. a. Screw off nut, lift off the gearbox from the
--------------------------------------------------------------- valve, and locate at clean place;
b) Understand pipeline medium, consult with
b. Remove the key and pin from stem;
authoritative department if necessary.
5.4.4 Main Body
---------------------------------------------------------------
Trunnion design:
Caution: it mustn’t maintenance when you
a. Remove screw 24, lift off top flange 8;
don’t know pipe medium clearly. To prevent
injuring, usually requires to wear exposure b. Remove O-ring 23 in top flange, remove
suit or uses protective equipments. fire safe seal 22 from cover 7;
--------------------------------------------------------------- c. Remove screw 21 from cover, and
c) No-smoking, don't use electric device with no
dismount the cover and stem 6 from the
explosive-proof type, fire without permission
body 1 together;
is forbidden.
d. Separate the cover, thrust washer 26 and
d) Removing after and before decomposed, put
bearing 27 from the stem. Take out the
the valve in a vertical position to empty
O-ring 20 and pin 25 from cover;
pipe remaining medium, taking care when open
e. Remove bolt 36 from trunnion 34, remove
and close the valve on several occasions.
the trunnion;
Page 8 of 16
BS/BSP/BSE series Forged Steel
Trunnion Ball Valve Installation, DOC NO: NWS 0004.7
Operation and Maintenance Instruction REV NO: 2014
f. Remove nut 12, take out the bonnet 2 and b. Fix spring 16 on bonnet 2, put the seat
seat retainer 4, gasket 9, seat follower 13, assembly into the bonnet, press the seat
o-ring 10, spring 16 slightly, locate them assembly to contact the spring;
on soft cloth or chipboard. Adown the c. Fix on pin 36 (if available). Fix the valve
flange end, be careful not to damage the body 1 on one bonnet, pay attention to
facing ring of the flange; the position of oil way, and bolt the nut 12
g. Take out the seat retainer, gasket 15, refer to table 1;
washer 14, seat follower, O-ring 17 and Table 1 Fastening suggest torque (Nm)
spring from the bonnet; Size Torque Size Torque
h. Lift out the ball 13 vertically, locate it on
1/2 50~60 1-5/8 1800~2200
soft cloth or chipboard;
9/16 70~80 1-3/4 2200~2600
i. Repeat f & g, separate bonnet and other
5/8 100~130 1-7/8 2800~3300
accessories on the other side;
Trunnion support design: 3/4 160~210 2 3500~4200
Page 9 of 16
BS/BSP/BSE series Forged Steel
Trunnion Ball Valve Installation, DOC NO: NWS 0004.7
Operation and Maintenance Instruction REV NO: 2014
g. Fix O-ring 19/20, injection 40 (if available) attention that the flat trend on ball should
and gasket 18 into cover 7; Fix bearing 27 aim at the hole which for stem;
and thrust washer on stem 6; d. Follow the steps of f, g, h, I of trunnion
h. Tread the stem through valve body to the design, fix the bonnet on the other side,
flat trend of the ball, pay attention to the stem 6, cover 7 and top flange 8, etc;
direction of key trend; Put the fix pin 25 5.6 Former disassemble steps please refer to
into pinhole on the top of valve body, put valve disassemble figures. If have any
on the cover tread through stem and fix questions, please feel free to contact the
pin, bolt the screw 21 refer to Table 1; manufacture;
i. Fix top flange 8, bolt the screw 24; 5.7 To ensure the quality of the valve, suggest to
Trunnion support design: change the soft sealing when re-assemble,
a. Follow the step a, b, c of trunnion design, such as: gasket, thrust washer, valve seat
fix bonnet 2 on the other side; and packing;
b. Put bearing 33 into the bore of trunnion 6 Problem solving
support 34. Fix trunnion support and Some usual troubles are listed below for your
thrust washer 35 together on the ball 3; convenient to seek the solution:
c. Lift up the ball and trunnion support
together through the ball passage with
soft rope, fix them in the body, pay
Page 10 of 16
BS/BSP/BSE series Forged Steel
Trunnion Ball Valve Installation, DOC NO: NWS 0004.7
Operation and Maintenance Instruction REV NO: 2014
section 5.2
1. The operator is malfunctioning;
The valve is 2. Lubricate valve seat with sealant, lubricate
2. Lack of lubricate oil;
difficult to actuator with proper industrial oil;
3. Ice exist in operate system or
operate 3. Heat or inject anti-icing fluid;
in the valve;
4. loosen bolt on top flange and cover; Check
4. Stem is locking
the valve; Check the damage situation;
1. Contaminant on sealing
1. Clean the contaminant;
surface
The seats 2. Re-facing the sealing surface or change the
2. Damage on sealing surface
are leaking sealing packing;
3. Leakage between valve seat
3. Change O-ring;
and bonnet, check whether
Leaking of
closure
Page 11 of 16
BS/BSP/BSE series Forged Steel
Trunnion Ball Valve Installation, DOC NO: NWS 0004.7
Operation and Maintenance Instruction REV NO: 2014
Washing Procedure
Procedure Process
Inject wash liquid Inject adequate wash liquid into each injection through valve
seat
Inject wash liquid Inject adequate wash liquid into each injection through valve
seat
Wet the valve Wait for 1-6 hours, let wash liquid wet the block and dirty
Inject wash liquid Inject adequate wash liquid into each injection through valve
seat
Injection procedure
Procedure Process
2.Check valve
Endure valve is in fully close position
position
3.Inject standard Inject adequate wash liquid into each injection through valve
5.Inject standard Inject adequate wash liquid into each injection through valve
Open and close valve 3-4 times, then turn valve to fully closed
6.Operate valve
position, proportion the sealing lubricant.
Page 12 of 16
BS/BSP/BSE series Forged Steel
Trunnion Ball Valve Installation, DOC NO: NWS 0004.7
Operation and Maintenance Instruction REV NO: 2014
Valve Injection for each Injection Injection for Injection for each
3
size valve seat (oz) for each valve each valve seat
3 valve(cm )
(oz)
(cm )
2” 1 2 25 50
3” 1 2 35 65
4” 2 3 50 100
6” 2 4 65 130
8” 3 6 80 160
10” 3 6 90 180
12” 5 10 135 270
14” 5 10 155 310
16” 6 12 170 335
18” 9 18 265 525
20” 10 20 295 585
22” 11 22 330 655
24” 12 24 350 695
26” 13 26 395 785
28” 13 26 400 800
30” 15 30 445 890
34” 17 34 495 990
36” 21 42 620 1240
40” 32 64 960 1920
42” 34 68 995 1990
Page 13 of 16
earthquake, typhoon etc).
7.5 The other assurances beyond the scope 7.7 NEWAY will track the valve quality and
of this document shall be agreed by user offer various services per user’s
and manufacture. requirements.
7.6 NEWAY can provide on-site installation 7.8 If user disassembles the valve to repair
and commissioning (If it is included in without manufacture’s permission, the
the contract). user will be regarded to giving up the
quality assurance above
.
Page 14 of 16
BS/BSP/BSE series Forged Steel
Trunnion Ball Valve Installation, DOC NO: NWS 0004.7
Operation and Maintenance Instruction REV NO: 2014
Bolt
Washer
24
8
Gearbox
22
23
Stud 20
Gearbox 27
Nut
26 31
30
6
28 29
21
7
18 25
19
3
5
4
14
13
17
1
33
15
16
37 35
11
34
12
10
9 36
2
32
Page 15 of 16
BS/BSP/BSE series Forged Steel
Trunnion Ball Valve Installation, DOC NO: NWS 0004.7
Operation and Maintenance Instruction REV NO: 2014
Bolt
Washer
24
Gearbox
25
8
Stud
23
Gearbox
Nut 22
21
41
7
20
40
18
26 19
27
31
6
30 28
32
34 29
3
5
4
14
15
16
9
38
1
37
17 10 13 36 33 35 39
12 11
2
Page 16 of 16
Material List
ML.GP.01.01 Rev. 0
October 2017
Table of Contents
Section 1: Major Component Material List
1.1 Typical G-Series Major Component Material List��������������������������������������������� 5
Table of Contents 3
Section 1: Major Component Material List Material List
October 2017 ML.GP.01.01 Rev. 0
Typical Coatings 7
World Area Configuration Centers (WACC) offer sales support, service,
inventory and commissioning to our global customers.
Choose the WACC or sales office nearest you:
Bonnet Bonnet
*Diaphragm * Diaphragm
Assembly Assembly
* Pintle Assembly * Pintle Assembly
Body Assembly
* Housing Seal O-Ring Body Assembly * Housing Seal O-Ring
Collar
* Filter O-Ring (2)
Pintle Spring
DANGER Refers to conditions or hazards which could result in serious personal injury or death.
WARNING Refers to conditions or hazards which could result in personal injury.
CAUTION Refers to conditions or hazards which could result in equipment or property damage.
NOTE Alerts you to facts or special instructions.
ALL DANGER, WARNING, AND CAUTION NOTICES MUST BE COMPLIED WITH IN FULL
Personal injury, property damage, equipment damage, or leakage due to escaping gas or bursting of
DANGER pressure containing parts may result if this regulator is over pressurized or installed where service
conditions could exceed the limits given in the specifications. To avoid such injury or damage, provide
pressure-relieving or limiting devices (as required by the appropriate code, regulation or standard) to
prevent service conditions from exceeding those limits.
1. SPECIFICATIONS
TYPE 350SS TYPE 360SS TYPE 370SS
Output Ranges: 0-30 psig (0-2.0 BAR), 0-60 psig (0-4.0 BAR), 0-100 psig (0-7.0 BAR), Not applicable
0-150 psig (0-10.0 BAR)
Exhaust Capacity: 1.0 SCFM (1.7 m3/hr) at downstream pressure of Not applicable
10 psig (0.7 BAR) above set point
Maximum Supply
Pressure: 290 psig (20.0 BAR) 150 psig (10.0 BAR)
Maximum Flow 1/4” = 1.2
Coefficients (Cv): 1/2” = 3.3
2. INSTALLATION
2.1 Install the regulator/filter as close as possible to the instrument or tool it is to service.
2.2 Clean all pipelines to remove dirt and scale prior to installation.
NOTE Failures attributable to air supply contamination are not covered by the warranty.
WARNING This instrument vents to atmosphere. The use of gas other than air may create a
hazardous environment.
2.3 Install the regulator/filter so that the direction of flow is from the "IN" to "OUT" connection as
marked on the body of the regulator/filter.
WARNING Non-relieving version does not provide internal relief of excess pressure. To avoid exceeding outlet
pressure limits, a pressure-limiting device should be used.
2.6 Exhaust may be remotely vented by installing tubing to the 1/8" NPT port.
2.7 Apply pipe compound or sealing tape to the male pipe threads prior to installing regulator/filter.
Use caution to prevent the sealant from getting inside the regulator/filter.
3. OPERATION
3.1 Prior to turning on supply air, back off adjusting screw until there is no compression of the
range spring.
3.2 After applying the air supply, output pressure will be increased by rotating the adjustment
screw clockwise. Pressure can be decreased by turning counter clockwise.
3.3 Tighten locknut to maintain desired pressure setting.
4.1 To remove condensate from the Type 350 and Type 370, slowly open drain valve by turning
clockwise and bleed accumulated liquid.
To avoid personal injury, property damage, or equipment damage caused by sudden release of pres-
DANGER sure or explosion of accumulated gas, do not attempt any maintenance or disassembly without first
isolating the regulator from system pressure and relieving all internal pressure from the regulator.
REPAIR KITS
Type 350 Includes: Pintle Assembly, Housing Seal O-Ring, Diaphragm Assembly, Filter Seal O-Ring (2)
Model Porting Description Part Number
Type 350 1/4” NPT Relieving 449-871-068
Type 350 1/4” NPT Non-relieving 449-871-069
Type 350 1/2” NPT Relieving 449-871-070
Type 350 1/2” NPT Non-relieving 449-871-071
Type 360 Includes: Pintle Assembly, Housing Seal O-Ring, Diaphragm Assembly
Model Porting Description Part Number
Type 360 1/4” NPT Relieving 449-871-072
Type 360 1/4” NPT Non-relieving 449-871-073
Type 360 1/2" NPT Relieving 449-871-094
Type 360 1/2" NPT Non-relieving 449-871-095
REPLACEMENT FILTERS
Model Porting Description Part Number
Type 350/370 1/4” NPT 25 micron filter 446-777-011
Type 350/370 1/4” NPT 5 micron filter 446-777-012
Type 350/370 1/2” NPT 25 micron filter 446-777-013
Type 350/370 1/2” NPT 5 micron filter 446-777-014
4.5.3 Other replacement parts are available. Please consult the factory for part numbers and availability.
WARNING These products are intended for use in industrial compressed-air systems only.
Do not use these products where pressures and temperatures can exceed those
listed under Specifications.
Before using these products with fluids other than air, for non-industrial application, life-support systems, or other
applications not within published specifications, consult ControlAir LLC
8 Columbia Drive
Amherst, NH 03031 USA
603-886-9400
Fax: 603-889-1844
www.controlair.com
sales@controlair.com
1
Emerson Process Management
Reliable Solutions
2
Table of Contents
Page 3 Table of Contents
Page 4 Installation on Actuator
Page 5 GO™ Switch: Options L2/L4/Z2/Z4
Page 8 Mechanical Switches: Options M2/M4/M6/K2/K4/K6/T2
Page 10 Inductive Sensors: Options E2/E4/E6/ V2/V4
Page 12 4-20mA Transmitter: Options LX/MX/KX/EX/TX/ZX/0X
Page 16 HART Device Options: LH/MH/KH/EH/TH/ZH/0H
Page 34 D2-FF Discrete Valve Controller Description
Page 35 AS-I Sensor Communication Module (SCM) : Option AS
Page 36 Bus Options
Page 46 ESD Theory of Operation
Page 47 Proof Testing for TopWorx™ D-Series
Page 49 Pneumatic Hookup Procedures
Page 48 Spool Valve and Pilots-Assembly
Page 51 Installation & Maintenance Instructions
Page 54 Proof Testing for TopWorx™ D-Series
Page 56 Dimensions and Materials: TopWorx™ DXP
Page 57 Dimensions and Materials: TopWorx™ DXP - Flameproof
Page 58 Ex d IIC Dimensions and Materials: TopWorx™ DXS
Page 59 Dimensions and Materials: TopWorx™ DXR
Page 60 Indicator Assembly
Page 61 TopWorx™ Certifications
Page 62 Safe Use
Page 64 TopWorx™ D-Series Replacement Part Number List
Page 66 Recommended Operating Temperatures
3
Installation on Actuator
Orientations, Normal and Reverse Acting
Normal acting is full clockwise when the process valve is closed and counterclockwise when the process valve is open. Reverse acting
is full clockwise when the process valve is open and counterclockwise when the process valve is closed.
90° indicator dome assemblies are designed to accommodate any mounting arrangement and can be adjusted up to 9° off axis if
needed. 45° indicator dome assemblies can only accommodate normal acting applications that are mounted parallel ±9°. Consult your
local distributor or factory representative for 45° reverse acting or mounted perpendicular applications.
Mounting
TopWorx™ has numerous mounting bracket kits, both rotary and linear, available to meet your specific application. Consult your local
distributor or factory representative for ordering information. The illustration below shows a direct NAMUR mount on a quarter turn
valve. Refer to your mounting kit documentation for specific mounting instructions.
Storage
Until conduit, conduit covers, and any applicable spool valve port connections are properly installed, the TopWorx™ unit will not support
its IP/NEMA rating as the unit ships with temporary covers. Ensure that it is stored in a dry environment with a relative humidity range
between 10%-95% and a temperature ranging from -40ºF (-40ºC) to 160ºF (71ºC). Once properly installed, the temperature range
listedon the name-plate will supersede this storage temperature range.
Mounting Assembly
Installation Notes
1. Use caution not to allow undue axial (thrust) load on the shaft.
2. Cycle the valve a couple of times prior to final tightening of the mounting kit hardware.
This allows the shaft to self-center in the pinion slot, or coupler. Refer to the dimensions
and materials section of this document for appropriate tightening torque. Please refer to
the Proof Testing section for proper safety function set-up.
3. Always use sound mechanical practices when applying torque to any hardware or making
pneumatic connections. Refer to the Integrated Pneumatic Control Valves section for
detailed information.
4. This product comes shipped with conduit covers in an effort to protect the internal
components from debris during shipment and handling. It is the responsibility of the
receiving and/or installing personnel to provide appropriate permanent sealing
devices to prevent the intrusion of debris or moisture when stored or installed
outdoors.
4
GO™ Switch: Options L2/L4/Z2/Z4
Calibration Procedure
Never perform switch calibration while an area is known to be hazardous.
For intrinsically safe models with L2/L4, the unit must be wired in accordance with the control drawing S-K127 and S-K127A.
For intrinsically safe models with Z2/Z4, the unit must be wired in accordance with the control drawing ES-01743-1 and ES-01744-1.
GO™ Switch calibration may be performed using a Volt-Ohm meter with the Ohm setting across COM and NO. When the switch
is active, the meter will read ≤0.5 Ohms, or the Diode setting may be used simply to indicate continuity. If a 120VAC source is used,
an appropriately sized resistor must be used in series to limit current to a maximum of 1.5 Amperes when circuit rating is unknown or
permanent damage may occur.
For models mounted in perpendicular orientation, the target disk will have to be rotated to realign the target disk to match the
desired orientation.
Step 1: Grasp the target disk and gently lift until the target disk disengages the orientation pin in the shaft.
Step 2: Rotate the disk as needed to realign the targets. Use the images provided on the previous page as a reference.
Step 3: Follow steps 1 through 3 for models mounted in Parallel orientation above.
For reverse acting applications (Counterclockwise to close), the switch functions will be transposed. Sw 1 (and Sw 3 if in an L4/Z4
model) be-come open. Sw 2 (and Sw 4 if in an L4/Z4 model) become closed.
The target disk has been designed to accommodate various applications and rotations. If your application is different from
those outlined here, please consult the factory for further information.
Differential 0.020 - .150” (0.5 - 3.8mm) Differential 0.020 - .150” (0.5 - 3.8mm)
Operating Operating
-60° to 221°F (-40° to 105°C) -60° to 221°F (-40° to 105°C)
Temperature Temperature
Contact Material Silver cadmium oxide, gold flashed Contact Palladium silver w/sawtooth surface
Material configuration
Sensing Range Approx. 1/10" (2.5 mm) Sensing Range Approx. .050 - .080" (1.3 - 2.0 mm)
5
Continued
GO™ Switch: Options L2/L4/Z2/Z4
NC (Red) Terminal 1
Switch 3 12pt Terminal
12pt Terminal StripStrip
(x2) (x2)
Option L4
Switch 1 Switch 2
Green to GND Ground Green to GND Ground
COM (Black) Terminal 2 COM (Black) Terminal 5
NO (Blue) Terminal 3 NO (Blue) Terminal 6
4-40x0.5
4-40x0.5self
selftap
tapscrew (x6)
screw (x6)
NC (Red) Terminal 1 NC (Red) Terminal 4 Torque
Torque40
40IN-OZ
IN-OZ
Switch 3 Switch 4
Green to GND Ground Green to GND Ground
4-40x0.25 SE
4-40x0.25 selfMSEM
screwscrew
(x2) (x2)
Torque 100
Torque 100IN-OZ
IN-OZ
COM (Black) Terminal 8 COM (Black) Terminal 11
NO (Blue) Terminal 9 NO (Blue) Terminal 12
NC (Red) Terminal 7 NC (Red) Terminal 10 NOTE: Refer to the wiring
diagram on the inside lid of
your product to determine
Option Z2 actual pin out location.
Switch 1
Green to GND Ground
COM (Black) Terminal 2 COM (Black/White) Terminal 5
NO (Blue) Terminal 3 NO (Blue/White) Terminal 6
NC (Red) Terminal 1 NC (Red/White) Terminal 4
Switch 3
Green to GND Ground
COM (Black) Terminal 8 COM (Black/White) COM (Black/White)
NO (Blue) Terminal 9 NO (Blue/White) NO (Blue/White)
NC (Red) Terminal 7 NC (Red/White) NC (Red/White)
Option Z4
Switch 1 Switch 3
Green to GND Ground Green to GND Ground Green to GND Ground Green to GND Ground
COM (Black) Terminal 2 COM (Black/White) Terminal 5 COM (Black) Terminal 14 COM (Black/White) Terminal 17
Switch 2 Switch 4
Green to GND Ground Green to GND Ground Green to GND Ground Green to GND Ground
COM (Black) Terminal 8 COM (Black/White) Terminal 11 COM (Black) Terminal 20 COM (Black/White) Terminal 23
NO (Blue) NC
NO (Blue) Terminal 9 NO (Blue/White) Terminal 12 Terminal 21 NO (Blue/White) Terminal 24
(Red)
*The above terminations are typical and may vary depending on your configuration. Refer to the wiring diagram located on the inside top housing for a wiring diagram specific to your configuration.
6
Continued
GO™ Switch: Options L2/L4/Z2/Z4
Target Arrangement
All TopWorx™ products are factory set for 90° rotation normal acting on parallel orientation with switch 1 (full clockwise) for the process
valve closed position. When changing orientation the target disk will have to be relocated for your application. All target disks are supplied
with 4 slots on 90° increments allowing the TopWorx™ unit to be rotated 90°, 180°, or 270° from standard. Loosen target by rotating CCW
and slide target to desired position. Once target is properly positioned, tighten target by rotating CW and tighten to 20 in-oz.
90° PROCESS VALVE OPEN (OPEN FULL CCW) 90° PROCESS VALVE OPEN (CLOSED FULL CW)
NORMAL ACTING NORMAL ACTING
PARALLEL ORIENTATION PARALLEL ORIENTATION
SW1 FOR PROCESS VALVE CLOSED (NOT MADE) SW1 FOR PROCESS VALVE CLOSED (MADE)
SW3 FOR PROCESS VALVE OPEN (MADE) SW3 FOR PROCESS VALVE OPEN (NOT MADE)
90° PROCESS VALVE OPEN FULL CCW 90° PROCESS VALVE OPEN FULL CW
NORMAL ACTING NORMAL ACTING
PARALLEL ORIENTATION PARALLEL ORIENTATION
SW1 FOR PROCESS VALVE CLOSED (NOT MADE) SW1 FOR PROCESS VALVE CLOSED MADE)
SW2 FOR PROCESS VALVE OPEN (MADE) SW2 FOR PROCESS VALVE OPEN (NOT MADE)
SW3 FOR PROCESS VALVE CLOSED (NOT MADE) SW3 FOR PROCESS VALVE CLOSED (MADE)
SW4 FOR PROCESS VALVE OPEN (MADE) SW4 FOR PROCESS VALVE OPEN (NOT MADE)
7
Mechanical Switches: Options M2/M4/M6/K2/
K4/K6/T2 Calibration Procedure
Never perform switch calibration while an area is
known to be hazardous. Calibration procedures PRODUCT SPECIFICATIONS
for DPDT switches are the same as those for
OPTION M
SPDT switches.
Switch Type Mechanical
Calibration may be performed using a Volt-Ohm meter Sealed No
by using the Ohm setting across COM and NO. When
Circuitry SPDT
the switch is active, the meter will read <0.5 Ohms, or the
Diode setting may be used to indicate continuity. Termination Quick Connect
Rating 15A@125VAC or 250VAC
If a 120Vac source is used, an appropriately sized
resistor must be used in series to limit current to a Conforming to standards UL: 1054
maximum of 15 Amperes when circuit rating is unknown, or Contact Resistance 15MΩmax. (initial)
permanent damage may occur.
Insulation Resistance 100MΩmin. (at 500V DC)
Step 1: With valve in the CLOSED position, disengage the OPTION K
BOTTOM cam from the splined Hub and rotate Clockwise
until SW1 activates. Switch Type Mechanical
Release cam to re-engage splined Hub. Sealed No
Step 2: Rotate valve to the OPEN position. Disengage the Termination Quick Connect
BOTTOM cam from the splined Hub and rotate Clockwise Rating 15A 125V AC or 250V AC
until SW1 activates.
Release cam to re-engage the splined Hub. Conforming to UL recognized and CSA
standards certified, meets MIL-S-8805
Repeat Step 3 above. Contact Gold or silver
*When using the (4) and (6) switch options, use the same Terminals End or side
calibration steps as above for the switches you determine to
indicate OPEN and which indicate CLOSED.
8
Continued
Mechanical Switches: Options M2/M4/M6/K2/K4/K6/T2
Switch# Connection Color Code Terminal# Switch# Connection Color Code Terminal#
NC Red 1 NC1 Red 1
1 COM Black 2 COM1 Black 2
NO Blue 3 NO1 Blue 3
1
NC Red/White 4 NC2 Red/White 4
2 COM Black/White 5 COM2 Black/White 5
NO Blue/White 6 NO2 Blue/White 6
NC Yellow 7 NC1 Yellow 7
3 COM Brown 8 COM1 Brown 8
NO Orange 9 NO1 Orange 9
2
NC White/Yellow 10 NC2 White/Yellow 10
4 COM White/Brown 11 COM2 White/Brown 11
NO White/Orange 12 NO2 White/Orange 12
NC White 13
5 COM Gray 14
NO Violet 15 NOTE: Refer to the wiring diagram on
the inside lid of your product to determine
NC Pink 16 actual pin out location
6 COM White/Gray 17
NO White/Violet 18
9
Inductive Sensors: Options E2/E4/E6
Calibration Procedure
When installing a TopWorx™ product with P&F NAMUR sensors, use of a commercially available switch tester like P&F part#
ST0-03 is suggested.
Step 2: Rotate valve to the OPEN position. Disengage the TOP cam from the splined hub and rotate counter-clockwise until SW2
activates. Release cam to re-engage the splined hub.
Step 3: Cycle valve CLOSED and OPEN several times to insure switches will maintain calibration.
Step 2: Rotate valve to the OPEN position. Disengage the BOTTOM cam from the splined hub and rotate clockwise until SW1 activates.
Release cam to re-engage the splined hub.
*When using the (4) and (6) switch options, determine which switches are to indicate OPEN and which indicate CLOSED and
then use the same calibration steps as above.
**Switches may also be set at midpoint, or any point, of travel for Dribble Control, or any other logic necessary for the
application.
SwitchOption
Switch OptionE2
E2 Switch Option
Switch Option E4
E4 SwitchOption
Switch OptionE6E6
10
Continued
Inductive Sensors: Options E2/E4/ Wiring Chart
E6 Product Specifications
LEAD WIRE TERMINATIONS CHART
SWITCH # LEAD COLOR TERMINAL#
PRODUCT SPECIFICATIONS 1 BROWN + 1
General specifications
BLUE - 2
Switching element function NAMUR NC
2 BROWN + 3
Rated operating distance Sn 2 mm
BLUE - 4 4
Installation embeddable
3 BROWN + 5
Output polarity NAMUR BLUE - 6
Assured operating distance Sa 0 ... 1.62 mm 4 BROWN + 7
Reduction factor rAl 0.25 BLUE - 8
Reduction factor rCu 0.2 5 BROWN + 9
Reduction factor rV2A 0.7 BLUE - 10
Nominal ratings
6 BROWN + 11
Nominal voltage Uo 8V BLUE - 12
Switching frequency f 0 ... 1000 Hz
Hysteresis H typ. % NOTE: Refer to the wiring diagram on
the inside lid of your product to determine
Current consumption actual pin out location
Measuring plate not detected ≥3 mA
Measuring plate detected ≤1 mA
Standard conformity
11
4-20mA Transmitter: Options LX/MX/KX/EX/TX/ZX/0X
The 2-wire 4-20mA transmitter will generate a nominal 4 – 20mA output for full-range actuation of the valve. The transmitter is capable of
generating signals below 4mA and above 20mA if the position sensor indicates an out of range value.
Features:
1) Single push button easy calibration eliminates zero/span calibration interaction in both clockwise and counterclockwise actuator/
valve rotation directions.
2) Non-volatile memory of set points (set points remain after loss of power)
3) 4-20mA power connection is not polarity sensitive
4) No internal backlash – direct shaft position feedback
5) No gear wear or mechanical binding
6) Small package size for easier access to limit switch cams. The small packaging allows for additional options that can be mounted
in the valve monitoring enclosure
7) Position measurement range from 20º to 320º. Factory set for 20º to 180º operation in counter clockwise rotation to open and 20º
to 90º operation in clockwise rotation to open applications.
8) Advanced diagnostics includes detection of dead band, out of range indication and detection of internal memory errors
9) Transmitter PCB is potted and sealed
10) Included with all valve monitoring switching options, incl. DPDT mechanical
11) +/- 1% position linearity for the complete device
12) Selectable +/- 3% over and under travel capability or full linear options set during calibration
13) Hysteresis: 0.5% of full-scale
14) Repeatability: 0.3% of full scale
15) Temperature Range: -40º to 85ºC
Red
12
Continued
4-20mA Transmitter: Options LX/MX/KX/EX/TX/ZX/0X
Apply power to
device, LED on
Is button pressed
and held for at least NO
0.5 seconds?
YES
Calibrate counterclockwise, Calibrate clockwise, device Calibrate counterclockwise, Calibrate clockwise, device
device waits for 4ma set point, waits for 4ma set point, LED device waits for 4ma set point, waits for 4ma set point, LED
LED flashes code 3-1, rotary flashes code 3-2, rotary LED flashes code 5-1, linear flashes code 5-2, linear
Is button pressed
and released? NO
YES
YES
User moves valve to 20ma position Is the actual reading Start position is too
greater than maximum low or in dead band,
NO LED flashes code 4-3
4ma value?
Is button pressed
YES
and released? NO
Start position is too high,
YES LED flashes code 4-4
Is the set point within Has greater than Has less than Wrong direction of
required range and has at maximum allowed minimum allowed rotation occurred, LED
least 20 degree of rotation rotation occurred? NO rotation occurred? NO flashes code 4-7
been detected?
YES YES Less than allowed
YES
rotation has occurred,
LED flashes code 4-5
Device stores set points, LED on
Greater than allowed
rotation has occurred,
LED flashes code 4-6
Is malfunction detected
in stored set points? NO
YES
Internal error, LED
flashes code 4-1
13
Continued
4-20mA Transmitter: Options LX/MX/KX/EX/TX/ZX/0X
Troubleshooting
Error Code and Problem Table
Flash Codes
( first count – second count ) Interpretations
0-0 Calibrated
3-1 Counter-Clockwise Calibration, Waiting to calibrate the 4mA position, Rotary Mode
3-2 Clockwise Calibration, Waiting to calibrate the 4mA position, Rotary Mode
5-1 Counter-Clockwise Calibration, Waiting to calibrate the 4mA position, Linear Mode
5-2 Clockwise Calibration, Waiting to calibrate the 4mA position, Linear Mode
14
Continued
4-20mA Transmitter: Options LX/MX/KX/EX/TX/ZX/0X
D-Series Replacement Procedure: 4-20mA Position Transmitter
(Use the following installation procedure to replace an existing D-Series in the field)
Typically the 4-20mA Position Transmitter module and potentiometer options are already installed in TopWorx™ valve controller products.
Use the following installation directions only if you are replacing an existing unit
The potentiometer has been factory set for typical valve rotation ranges from 2º to 180º in counter-clockwise rotation applications from
the 4mA position to the 20mA position and from valve rotation ranges from 2º to 90º in clockwise rotation applications from the
4mA position to the 20mA position. Please contact TopWorx™ for proper potentiometer set up for ranges greater than specified
above.
TRANSMITTER MODULE
BRACKET
ALIGNMENT BOSS
15
4-20mA Transmitter with HART: Options LH/MH/KH/EH/ZH/0H
Features and Specifications
Description
The TopWorx HART 4-20 mA Position Transmitter is a 2-wire high impedance slave transmitter. It is capable of both analog and digital
signaling. The transmitter and DD (Device Descriptions) are registered with FieldComm Group™ and supports HART 7.
Valve position is sensed directly through a position sensor with hard endpoint detection capability via limit switches.
Features:
-Local user interface via Graphic LCD
-Selectable endpoint hysteresis ±3 %
-Internal device temperature
monitoring
-Point to Point and Multi-drop mode
-Burst mode and Event Notification
-Supports NE-107 and NE-43
-Five-point valve position calibration
-Polarity and overvoltage protection
-Alarms and counters
16
Specifications:
For additional device specifications that include commands, please refer to ES-06116-1 HART Instruction Manual Supplement.
Device Information
Wiring Diagram
Note: Optional cable shield to be connected on one cable end only. If connected on device side, make sure switchbox housing and
grounding strap are properly earth grounded.
17
Figure 2: Loop Current Alarm High/Low Selection
Overview:
Manufacturer TopWorx
Device Variables:
Table 1: Device Variables
18
9 Cycle Count None User selectable to SV,TV, or QV Counted valve strokes 0 to 9999999
0 = Opened,1 =
Closed,2 = Opening,
10 Valve State None User selectable to SV,TV, or QV Indicates current valve position 3 = Closing,4
= Stopped,5 =
Un-known
Highest Device Highest ambient temperature seen
11 degC, degF User selectable to SV,TV, or QV -55 to 130
Temperature by the device.
2 Loop Current Saturated S Set when the loop current output has reached the physical limit. 19 – 04
3 Loop Current Fixed N Active during loop test and multi-drop mode. 19 – 08
4 More Status Available N Active when any bit in the Additional Field Device Status is set. 19 – 10
1 Low Frequency Oscillator Fault F Oscillator in the analog module failed to start. 00-02
3 Temperature Sensor Failure S Reset the device. Contact factory if the alert persists. 00-08
0
4 Calibration Span Failed S Valve travel calibration end set-point failed. 00-10
5 Cycle Count Limit Alert M Cycle count exceeded user set alert value. 00-20
7 Valve Calibration Required S Valve travel needs to be calibrated into the device. 00-80
19
0 Last Close Stroke Time Alert M Valve stroke time is greater than the user defined value. 01 – 01
1 Last Open Stroke Time Alert M Valve stroke time is greater than the user defined value. 01 – 02
2 Closed Dwell Time Alert M Valve dwell time is greater than the user defined value. 01 – 04
3 Open Dwell Time Alert M Valve dwell time is greater than the user defined value 01 – 08
1
4 Electrical Hardware Failure F Reset the device. Ensure loop power is properly sup-plied. 01 – 10
5 DAC Output Voltage Out of Range F Loop current driver voltage out of range. 01 – 20
2 0 Transition Dwell Time Alert M Transition dwell time of the valve is greater than the user defined value.
Maintenance Required [Condensed
0 M 06 – 01
Status]
1 Device Variable Alert S 06 – 02
6 Unused - Returns 0 - - 06 – 40
7 Unused - Returns 0 - - 06 – 80
0 Device Variable Simulation Active C Device has been placed in simulation mode. 08 – 01
3 Watchdog Reset Executed F Processor was reset due to failure to kick the watchdog timer. 08 – 08
8
4 Power Supply Conditions Out of Range M Low board level supply voltage. 08 – 10
5 Environmental Conditions Out of Range M Device temperature exceeded limits of -50 °C to 85 °C. 08 – 20
6 Electronic Defect F 08 – 40
3 Unused - Returns 0 - - -
9
4 Unused - Returns 0 - - -
5 Unused - Returns 0 - - -
6 Unused - Returns 0 - - -
7 Unused - Returns 0 - - -
Operation
White left Button: From the main screen, press one Green Select Button: used to select an option and
time to show status screen. On any other screen, this move to its secondary menu.
button is used to return to the previous level of screens
Red LED Shows when Switch 2
is Activated
Hysteresis/Valve Mode of the valve endpoint readings can be adjusted to 0% (Linear Mode) or 3% (Rotary Mode). At 3% hysteresis, an
over or under travel correction of the valve end points are set within 3%. In other words, the output will be 4mA for 3% range travel from
the low-end calibration set point and 20mA for 3% range travel on the high-end calibration set point. If the valve position exceeds 3% of
over travel, then values below 4mA or above 20mA will be output. At 0% hysteresis, the position readings at both valve open and closed
end points will be exact with no over and under travel correction.
To change the end-point hysteresis (default 3%), press the three times until “HYSTERESIS” is shown. Press the Green Select
button.
The 0% option is displayed. Press the Green Select button to set the hysteresis to 0%. or press the button to move to the 3%
hysteresis screen. Press the Green Select button to set the hysteresis to 3%. A success screen will show the hysteresis (Deadband)
setting.
To execute 2-point Clockwise valve calibration: From the main screen (Figure 6-1) press the three times on the HART device until
“SET VALVE CAL” is shown (Figure 6-2). Press the Green Select button and the device will ask, “ARE YOU SURE?” (if you want to
continue with valve calibration) as shown in Figure 6-3. Press the Green Select button to get to the calibration menu. Cycle through the
different calibration options by pressing the button. Press the Green Select button to select “2 POINT CW” calibration (Figure 6-4).
The device asks “PLACE VALVE AT 0%” (Figure 6-5). Rotate shaft to the desired 0% position and press the Green Select button. Select
“STORE 0% AS OPEN?” (Figure 6-6). The screen should now show “PLACE VALVE AT 100%” (Figure 6-7). Rotate the shaft clockwise
until shaft is in the 100% or “CLOSED” position. Press the Green Select button again to see “STORE 100% POINT?” (Figure 6-8). After
pressing the Green select button, the screen will show “SUCCESS” (Figure 6-9) and then return to the home screen. The output current
reading should be 20mA when the target is at 100% (CLOSE). The current reading should be 4ma when the target is at the 0% (OPEN)
position. If these are both true, the device is calibrated correctly.
21
22
Figure 5: Local User Interface Flow Chart
23
Figure 5: Local User Interface Flow Chart
24
Figure 5: Local User Interface Flow Chart
1 2
3 4
5 6
7
5 9
68
For additional accuracy, utilize the 5-point calibration. This feature is typically used in conjunction with valve positioners to more
accurately align both system’s valve position measurement.
To execute 5-point Clockwise valve calibration: From the main screen on the HART Device, press the button four times until “SET
VALVE CAL” is shown. Press the Green Select button and the device will ask, “ARE YOU SURE?” (if you want to continue with valve
calibration). Press Green Select to get to the calibration menu. Cycle through the different calibration options by pressing the
button.
Press Green Select to select “5 POINT CW TO CLOSE” calibration. The device asks “PLACE VALVE AT 0%” (Figure 6-5). Rotate shaft
to the desired 0% position and press the Green Select. Select “STORE 0% AS OPEN?”. The other option is “STORE 0% AS CLOSE”.
The device will then cycle through the same procedure at 25%, 50%, 75% and then 100% valve rotation. At the 100% location, the
screen should now show “PLACE VALVE AT 100%”. Rotate the shaft clockwise until shaft is in the 100% or “CLOSED” position. Press
the Green Select again to see “STORE 100% POINT?”. After pressing the Green select the screen will show “SUCCESS” and then
return to the home screen. The output current reading should be 20ma when the target is at 100% (CLOSE), 16ma at 75%, 12ma at
50%, 8ma at 25% and 4ma at 0% (OPEN).
25
Remote (Not at Device) Calibration/Set-up
Remote calibration/setup can be performed at a maintenance/control system or handheld device. The user has the option of configuring
the device either through a guided or manual setup. For example; by executing the calibration method through AMS as shown in Figure
7.
Another example is setting up threshold configuration of the device as shown in Figure 8: Manual Setup Device Configuration
Example . Many features are available utilizing a control system, maintenance system or handheld. For example:
26
Figure 8: Manual Setup Device Configuration Example
27
Table 4: Manual Setup Device Configuration Example
28
29
Alerts
If the status indicator LED(Orange) is flashing, then the device has an alert. From the home screen on the HART device, press the
White Left button once to get to the status screen. The status of the device will be indicated. Each status code is accompanied with brief
description. For additional information on the status code and recommended action, refer to Table 5: Status Codes
Alerts are also available remotely at the control system or handheld device. An example is shown Figure 10:
30
Table 5: Status Codes
Primary Variable Out of The Primary Variable is beyond its Check the valve for over travel.
260 PRI VAR OUT LIM
Limits operating limit. Recalibrate the device.
The loop current has reached its Check the valve for over travel.
Loop Current
262 LOOP I SATUR8D maximum or minimum value and cannot Verify the position sensor is
Saturated
increase or decrease any further. connected and not in the deadband.
Low Frequency The low frequency clock source failed Reset the device. Contact factory if
11 LFO FAULT
Oscillator Fault to start. the alert persist.
Temperature Sensor The device temperature sensor has Reset the device. Contact factory if
13 TMP SNS FAULT
Failure failed. the alert persist.
31
Displayed Status at Device
Last Close Set when the stroke time is outside Valve maintenance is recommend-
20 CLS STR TIME Stroke Time the range set by the upper and ed. Adjust the limits according to
Alert lower limit ranges. the valves stroke time.
Last Open Set when the stroke time is outside Valve maintenance is recommended.
21 OPN STR TIME Stroke Time the range set by the upper and lower Adjust the limits according to the
Alert limit ranges. valves stroke time.
Set when the stroke time is outside Stroke/Partially stroke the valve to
Closed Dwell Time
22 CL DWEL TIME the range set by the upper and lower reset the timer, clear the counter
Alert
limit ranges. manually, increase the limit.
Set when the stroke time is outside Stroke/Partially stroke the valve to
Open Dwell Time
23 OP DWEL TIME the range set by the upper and lower reset the timer, clear the counter
Alert
limit ranges. manually, increase the limit.
Electrical Hardware Set when an electrical component on Reset the device. Ensure loop power
24 ELECTRIC HDWARE
Failure the device failed. is properly supplied.
DAC Output Voltage The loop transistor drive voltage is Reset the device. Ensure loop power
25 DAC OUT RANGE
Out of Range higher than expected. is properly supplied.
The device detected an issue with Check the wiring connections for the
26 POSITN SENSOR Position Sensor Fault
the position sensor. positions sensor / potentiometer.
The device detected an issue with Check the wiring connections for
27 LIM SW FAULT Limit Switch Fault
the limit switch. each limit switch.
This bit is set if any of the device Check that the process inputs have
71 DEVICE VARIABL Device Variable Alert
variables are in an alert state. not exceed the device senor limits.
Failure [Condensed Signal invalid due to malfunction in Check the additional device status
73 FAILURE STATUS
Status] the device or sensor. bits for details.
32
Displayed Status at Device
Status Text - Text - Line Status Description Alert Description Recommended Action
Code Line 2 3
Function Check Signal temporarily invalid due to on- Check the additional device status
75 FUNCT CHECK
[Condensed Status] going work on the device. bits for details.
96 ELECTR DEFECT Electronics Defect Internal electronics failure. Contact the factory.
Device Configuration
97 CONFIG LOCKED The device is locked by the host. Unlock the device.
Locked
100 SIMUL ACTIVE Status Simulation Active Status alerts are being simulated. Disable Status Simulation mode.
Certifications:
Ex ia IIC Ga
Tamb = -40ºC to +80ºC Input Simple apparatus Inputs
Device Entity Parameters:
Ui 28 V Ui 0
Ii 100 mA
Pi 0.7 W
Ci 11 nF Ci 22.993 μF
Li 14 μH Li 14 μH
Uo 7.71 V
Io 100 mA
Po 0.7 W
Co 0.993 μF
Lo 3541 μH
33
D2-FF Discrete Valve Controller Description & Speci- Intrinsically Safe Input Parameters:
fication Bus Connector pins 1 to 3
I.S. Parameters FISCO Parameters
The TopWorx™ D2-FF Discrete Valve Controller combines position sensing
and monitoring with FOUNDATION Fieldbus communications and pilot valve Ui 30V Ui 17.5V
output drivers. It in-corporates the following features:
Ii 380mA Ii 380mA
Pi 1.5W Pi 5.32W
FOUNDATION Fieldbus digital communication:
• Link active scheduler capability/Link Master (LAS) Ci 5nF Ci 5nF
• Pre-instantiated** blocks include Resource Block (RB), Transducer Li 10μH Li 10μH
Block (TB), Analog Input (AI) Function Block, Discrete Output (DO)
Function Block, 2 Discrete Input (DI) Function Block, Proportional,
Integral, and Derivative (PID) Function Block Electrical Specifications
• GO Switch option for open/close status or two external Limit/Auxiliary
switch inputs Current Consumption 17.65mA nominal
• Function block instantiation, live download, auto commission/
replacement Max. Applied Voltage 35VDC
• Fast function block execution time: DI: 15ms, AI: 15ms, DO: 20ms,
PID: 20ms Operating Voltage 9-32VDC
• Easy integration into AMS and DeltaV systems
• Device Dashboards powered by enhanced Electronic Device Fieldbus Specifications
Description Language (EDDL)
• Comaptible with Honeywell Experion, Yokogawa PRM & Fieldmate, Topology Point to Point
ABB 800xA and GE Mark Vie Host systems Bus with Spurs
Daisy Chain
Tree
Position sensing/monitoring
Cable Twisted Pair
• GO switch option for open/close status
• Potentiometer option for position percentage
Bus Length 1900m (max)
indication, can be used for any rotation
range between 20 and 320 degrees. End
Transmission Speed 31.25 kbit/s
position offsets are adjustable.
Control and monitor inputs and outputs Intrinsically Safe Yes
• Supports single/double and normal reverse
Function Block DI 15ms
acting actuators Execution Times AI 15ms
• Local LEDs for visual indication DO 20ms
• Local push buttons for calibration PID 20ms
• Remote configuration from control system
or field communicator
• Stroke valve method
• Cycle count monitoring
• Open/close time monitoring
• Temperature monitoring
• Open/short circuit protection
• Integrated field diagnostics and alert systems
• Embedded NAMUR NE 107 diagnostics
• External Limit/Auxiliary switch monitoring
**Pre-instantiated blocks are the pre-installed factory default function blocks. Instantiation is the capability to add blocks to and delete
blocks from FF devices on the link. Up to 15 additional copies of each function block can be added to a device (except the transducer
and resource blocks). Not an available feature in some DSC systems.
34
Bus Option AS: ASi with GO Switches and optional pilot(s)
Wiring Diagram:
Wiring Diagram:
GREEN ASI +
N/O GRN CLOSE
SW2 ASI -
N/C BRN YELLOW + OUTPUT 0
GREEN: - SOLENOID
INPUT 0- CL SW YELLOW +
INPUT 0+ OUTPUT 1
-
0V YELLOW +
INPUT 1- OUTPUT 2
-
INPUT 1+ GREEN: GREEN
OP SW +
INPUT 2
-
COM WHT GREEN +
N/O GRN OPEN INPUT 3
SW1
-
N/C BRN ES-02927-1
35
Bus Options AS/A0: ASi — continued —
Openness 800+ products, 150 Vendors
Maximum Devices
Maximum Devices
Primary Usage
• Master/Slave with cyclic polling
• Manchester Bit Encoding implemented via Alternating Pulse Modulation (APM)
Flat: 2 wire flat AS-i cable (1.5mm conductors) Yellow for communications / Black for additional power
Device Addressing Automatic when connected one at a time to the segment or with Handheld Addressing Unit
Website www.as-interface.com
EN 61326-1:2006, EN 61000-4-2:1995 inc. A2:2001, EN 61000-4-3:2002, EN 61000-4-4:2004 inc.
Electromagnetic Compatibility
A1:2010, EN 61000-4-6:2009, EN 61000-4-8:1993 inc. A1:2001, EN 55011:2009 inc. A1:2010
36
Bus Options DN: DeviceNet with GO Switches and Optional Pilot Valve(s)
37
Bus Options DN/D0: DeviceNet — continued —
Remote multiplexer, compatible with ODVA’s DeviceNet protocol for discrete I/O. This is a product family which
Description:
supports three (3) discrete inputs, two (2) discrete outputs, and 1 analog 10-bit input.
DeviceNet Device Profile: General Purpose Discrete I/O, Class 7 with objects:
Identity (Class 1)
- Message Router (Class 2)
- DeviceNet (Class 3)
- Assembly (Class 4) -------- 5 instances
- Connection (Class 5)
- Parameter (Class Fhex) ---10 instances
- Valve (Class 6Ehex)
- Alarm (Class 6Fhex) --5 instances
- Alarm Group (Class 70hex) --2 instances
DeviceNet Conformance: Designed to conform to the ODVA DeviceNet Specification Volume I, Version 2.0 and Volume II, Version
Communications: 2.0. Predefined Master/Slave Connection Set, Group 2 Only Server
Polled I/O
DeviceNet I/O Protocols:
Change-of-state (COS), Cyclic
Module Status(MS): green/red bi-color LED
Status Indicators:
Network Status(NS): green/red bi-color LED
Standard Conformity
EN 61326-1:2006, EN 61000-4-2:2009, EN 61000-4-3:2006 inc. A2:2010, EN 61000-4-4:2004 inc.
Electromagnetic Compatibility A1:2010, EN 61000-4-5:2006, EN 61000-4-6:2009, EN 61000-4-8:2010, EN 55011:2009 inc.
A1:2010, EN 55014-1:2006
38
Bus Options DN/D0: DeviceNet — continued —
How to Install and Establish DeviceNet Communications
1. The address and baud rate are pre-set to 63 and 125k baud at the factory.
2. The user may change these values via dip switch reconfiguration at any time (see the following tables)
3. A change to the baud rate will NOT take effect until the device is reset with either a RESET command or a power cycle.
4. A change to the address will be saved internally and will cause the unit to immediately undergo a soft reset. Upon restart
the new address will be active, along with the new baud rate, if previously changed.
Address Selection
Bit Positions
Byte 7 6 5 4 3 2 1 0
39
Bus Options DN/D0: DeviceNet — continued
— Table 2 Poll Response (Input Data) Assembly Instance 2
Bit Positions
Byte 7 6 5 4 3 2 1 0
Using Assembly instance 3 (Parameter 10), the cycle open and close times are added on to the poll bytes as shown below:
Table 3 Poll Response Assembly Instance 3
Byte Description
1 Input Status Bits
2 Alarm Bits
3 AI LSB
4 AI MSB
5 LS Byte of Last Open Time
6 MS Byte of Last Open Time
7 LS Byte of Last Close Time
8 MS Byte of Last Close Time
Using Assembly instance 4, the cycle count is added on to the poll bytes as shown below:
40
Bus Options DN/D0: DeviceNet — continued —
How to Energize and De-energize Valve Solenoids
1. Reconnect the device and allocate a Poll Connection to the device from the client.
2. Issue a Poll command from the client with a data value of 00, 01, or 02. Each of the two possible outputs will be turned ON
or OFF, as defined by a corresponding bit value of 1 or 0. Note that having both open and close bit set is an illegal state
and will be ignored by the controller.
Setting the Reset Alarms bit to 1 clears the Open and Close Time counters and resets all active alarm notification bits. As long as this bit
is set, the alarms will be inactive.
The Enable Cal Mode bit is set to 1 to allow calibration of the limit switches sense positions. When the device is commanded into
Cal Mode, normal operation of the outputs is disabled. The Closed and Open limit switches can then set active, which will cause the
associated input LEDs to be activated, along with activating the corresponding Input 1 or Input 2 status bits.
The Reset Cycle Count bit is set to 1 to clear the cycle counter.
Parameters
The TopWorx device is software-configured for several parameters. Table 7 defines the legal values and the default values for the I/O
configuration selections available.
3 Cycle Count Limit 0 to Disabled 0 Maximum number of valve cycles before triggering
4294967295 alarm
4 Analog High Limit 0 to 1024 Disabled 1024 Highest analog value before triggering alarm
5 Analog Low Limit 0 to 1024 Disabled 0 Lowest analog value before triggering alarm
6 DeviceNet Fault Action 0 or 1 Use Fault Value 0 0 = Use Fault Value
1 = Hold last State
7 DeviceNet Fault Value 0 or 1 OFF 0 0 = OFF
1 = OPEN
2 = CLOSE
3 = No Change
8 DeviceNet Idle Action 0 or 1 Use Fault Value 0 0 = Use Fault Value
1 = Hold Last State
9 DeviceNet Idle Value 0 or 1 OFF 0 0 = OFF
1 = OPEN
2 = CLOSE
3 = No Change
10 Assembly configuration 0 or 4 Standard Assembly 1 See Table 1 through Table 5
41
Bus Options DN/D0: DeviceNet — continued —
Definitions of these parameters are as follows:
1. Max Open Time: Maximum allowed time in 10’s of milliseconds for valve to open before triggering alarm.
2. Max Close Time: Maximum allowed time in 10’s of milliseconds for valve to close before triggering alarm.
3. Cycle Count Limit: Maximum number of valve cycles before triggering alarm.
4. *Analog High Limit: Highest analog value before triggering alarm.
5. *Analog Low Limit: Lowest analog value before triggering alarm.
6. Output Fault Action: Selection to determine whether each output will hold its last state or assume the value identified in
the next parameter upon a device fault.
7. Output Fault Value: The value each output will assume after a Fault if Fault Value is selected above (hold last state is not
selected).
8. Output Idle Action: Selection to determine whether each output will hold its last state or assume the value identified in the
next parameter if an Idle Command is issued by the Master.
9. Output Idle Value: The value each output will assume upon an Idle Command if Idle Value is selected above (hold last
state is not selected).
10. Assembly Configuration: This determines what data is returned in the poll response.
42
Bus Options PB: Profibus with GO Switches and Optional Pilot Valve(s)
43
Bus Options PM/PB: Profibus protocol — continued —
Type of Network Device Bus
Physical Media Twisted pair, fiber
Network Topology Bus, Ring, Star
Maximum Devices max. 126 stations on one bus (maximum of 244 bytes input and output data possible for each slave)
Maximum Distance "93.75Kbps and less - 1200 meters 500Kbps - 400 meters
1.5Mbps - 200 meters 12Mbps - 100 meters"
DP 93.75Kbps and less - 1200 meters
500Kbps - 400 meters
1.5Mbps - 200 meters
12Mbps - 100 meters
Maximum Distance with repeaters 9,500 meters with repeaters
(max. of 9 repeaters can be used)
Communication Methods Peer-to-peer, multicast or cyclic master-slave (uses token passing sequence)
Primary Usage Used for Discrete and Analog for PLC, Variable Speed Drives, Remote I/O communications
Power & Communications Power is supplied separately from communications bus (can be supplied on a parallel power bus)
Device Power Supply Devices are powered separately from communications bus. A 5A fuse must be placed in series with the input power terminals.
NOTE: In order to meet EMC requirements the Profibus communication cabling must be encased by conduit and properly grounded to the device
housing."
ID 09ED HEX Transmission rate (kBaud) 9.6 19.2 93.75 187.5 500 1200 1500
Software Parameters
Output Fail Closed Fail Open Dual Coil Intput Diagnostic
Byte 1 Byte 1 Byte 1
Bits Bits Bits
7 n/a n/a n/a n/a 7 n/a n/a 7 n/a
6 n/a n/a n/a n/a 6 n/a n/a 6 n/a
5 n/a n/a n/a n/a 5 n/a n/a
5 n/a
4 n/a n/a n/a n/a 4 n/a n/a
4 n/a
3 n/a n/a n/a n/a 3 SPARE Input 4
3 n/a
2 n/a n/a n/a n/a 2 SPARE Input 3
2 Hard Wired
1 Output 2 n/a n/a High Closed 1 High Closed Input 2 high
1 Hard Wired
0 Output 1 High Open High Closed High Open 0 High Open Input 1 high
0 Hard Wired
Low Closed Low Open high
44
Reed Switch Sensor Communication Module (SCM) Calibration: Options R2/R4
Options R2: SCM Calibration
Step 1
For standard explosion-proof units: Using a 24VDC
Secondary or
Dual Pilot Spool
regulated power supply, connect (+) to COM and (-) to NO
To I/O
Valve Terminals terminals. Limit current to the internal limit switches below
Logic
maximum current ratings.
Signal IN
Caution: Many power supplies do not have
To I/O current limiting; therefore, ALWAYS use a load
Voltage IN for resistor with a value of 200 to 2500 Ohms in
Pilot Valve
To I/O
Control
series with the COM or NO legs of the circuit or
Logic
damage may occur.
Signal IN
To Pilot Valve Step 2
To I/O With the valve in the CLOSED position, disengage the
lower cam from the splined Hub and rotate clockwise until
the Red LED lights. Release the cam to re-engage the
splined Hub, making sure it is seated on the splines. This
Option
OptionR4:
R4SCM
: SCM sets the CLOSED limit switch.
Step 3
Cycle the valve to the OPEN position using the attached
control equipment.
Step 4
Secondary or While the valve is in the OPEN position, disengage the
To I/O Dual Pilot Spool upper cam from the splined Hub and rotate the upper cam
Valve Terminals
counterclockwise until the Green LED lights. Release the
Logic
Signal IN
cam to re-engage the splined Hub, making sure to seat the
cam on the splines. This sets the OPEN limit switch.
To I/O
Voltage IN for Step 5
Pilot Valve
To I/O Control Cycle valve several times to insure limit switches maintain
Logic calibration.
Signal IN Check that the target assembly is secure to the actuator
To Pilot Valve pinion, and all air connections are tight.
To I/O
NOTE: Refer to the wiring diagram on the inside lid of your product
to determine wiring configuration and actual pin out location.
**Install per control drawing #ES-01743-1
45
ESD Theory of Operation
The purpose of the TopWorx™ Emergency Shut-Down (ESD) model is to partially stroke a valve that maintains a full open or full closed
position for an extended period of time while offering an ESD function. A partial stroke test (PST) verifies functionality of critical valves
that must be in their fail position during an emergency. Increasing the frequency of partial stroke testing (i.e. reducing the proof test
interval) improves the SIL (Safety Integrity Level) that the system can achieve through a reduction in the PFD avg (Average Probability
of Failure On Demand). These partial stroke tests can be performed without shutting down or disrupting the process. In an emergency,
the ESD function overrides partial stroke testing and the valve moves to its fail position.
This ESD unit incorporates a sensor communication module (SCM-ESD) to perform the partial stroke test, verify its status, and output
that status back to the user. In combination with the SCM, the ESD unit uses either the optional TopWorx™ pilot and spool valve or
a customer supplied solenoid valve to drive the actuator during both normal operation and partial stroke testing. A TopWorx™ GO™
Switch is included for partial stroke confirmation and two (2) limit switches built into the SCM confirm open and close position.
Once the unit is installed, the SCM-ESD must be calibrated for that specific valve, actuator, and solenoid exhaust settings. During
calibration, the unit records the time to partially stroke the valve. All future PST times are compared to this original value for determining
the test status. To pass a PST, the time must be within +/-20%, 30%, or 40% of the stored calibration value. This PST time tolerance
can be changed prior to calibration.
The partial stroke test is initiated via an optional partial stroke test button with a lockable cover, the calibration button on the top of the
SCM, or a pulsed DO from the PLC. Upon issuing a PST command, the SMC-ESD begins a timer while switching a relay to de-energize
the pilot/ solenoid. The valve moves from its normal position toward its fail position until the GO™ Switch is made. Once made, the
SCM energizes the pilot/solenoid and the valve moves to its normal position while outputting the PST status.
DIAGNOS-
RELAY
PARTIAL
STROKE TEST
FEEDBACK
24VDC(+) COM
LOAD
24VDC(-) WW NO
200(4W) to
2500(1/2W)Ohms
47
48
Pneumatic Hookup Procedures
Prior to connecting the supply air to the spool valve, flush the ™
Highly Recommended
TopWorx™ highly recommends Locktite 567 brand thread sealant.
Do not use a hard setting pipe compound. If Teflon thread seal tape is
used, start the wrap on the second thread from the leading thread of the
fitting. This will prevent tape shreds from contaminating the spool valve
seals.
VALVE SPECIFICATION
ITEM PERFORMANCE
MEDIA AIR
MIN: -25C (-13F)
MEDIA TEMPERATURE MAX: +65C (149F)
OPERATIONAL AMBIENT MIN: -25C (-13F)
TEMPERATURE MAX: +65C (149F)
MIN: 30 PSI (2 BAR)
INLET/SYSTEM PRESSURE MAX: 145 PSI (10 BAR)
OPERATIONAL PRESSURE MIN: 30 PSI (2 BAR)
DIFFERENTIAL MAX: 145 PSI (10 BAR)
SAFE WORKING PRESSURE 150 PSI (10.3 BAR)
FLOW/Cv(Kv) CV=1.06 (KV=.92)
BODY PORT CONNECTIONS 1/4" npt (1.06Cv), 1/2" npt (3.7Cv)
ALLOWABLE LEAKAGE Ext: 3.9 cc/min, int: 25 cc/min
OPTIMAL DESIGN LIFE 1 MILLION CYCLES
BODY: ALUMINIUM (BLACK ANODIZED)
AND STAINLESS STEEL 316L;
MATERIAL IN CONTACT W/ FLUID INTERNAL: STAINLESS STEEL, LT
NITRILE, PTFE, ACETAL
49
Spool Valves and Pilots
50
Installation & Maintenance Instructions 1.06Cv and 3.7Cv
MOUNTED, AIR OPERATED, SPRING RETURN AND DUAL PILOT, OFFERED IN ALUMINIUM AND STAINLESS STEEL
CONSTRUCTIONS, WITH AND WITHOUT MANUAL OVERRIDE (MO),
DESIGNED FOR 30 PSI TO 145 PSI (2 BAR TO 10 BAR) FOR TOPWORX CONTROLLER
WARNING: To prevent the possibility of death, serious If not connected, all exhaust ports must be protected with
injury or property damage, the Spool Valve and Pilot Valve Stainless Steel Exhaust Protectors. Connect these
must be installed and serviced only by a qualified service Exhaust Protectors to ports 3 and 5 of the valves. When used
technician avoiding the following hazards: outside, or stored for longer periods of time, and/or where
exposed to harsh environments (dusts, liquids etc.).
• Pressure hazard. Depressurize valve and vent Exhaust Protectors must be used. The reliability of the valve
cannot be guaranteed if an exhaust protection other than that
hazardous or combustible fluid to a safe area before supplied is used. Refer “Exhaust Restriction” section.
inspection or removal of the valve from service.
• Electrical hazard. Turn off all electrical power to Pilot • Storage conditions: protected from exposure to weather;
storage temperature: -40°C to +70°C, Relative humidity:
Valve. 95%.
• Risk of electric shock – More than one disconnect • The Valve must be kept in its original packaging as long as
switch may be required to de-energized the device for it is left unused. The protective covers must not be removed
from the connection ports and solenoid operators.
servicing. • Ambient temperature: -25°C to +65°C. The maximum
• Explosion, fire or toxic gas hazards. Extinguish all temperature of the fluid does not exceed the ambient
open flames and avoid any type of sparking or ignition temperature.
• After storage at low temperature, the spool valves
during leakage testing. must gradually be brought to operating temperature
prior to pressurization.
DESCRIPTION • The Valves are intended to be operated within the technical
1.06Cv and 3.7Cv feature options for spring return, dual pilot, with characteristics specified on the nameplate.
and without manual operator valves. • Changes to the products may only be made after consulting
the manufacturer or his representative.
Stainless Steel version: Body and End Cap are offered in SS 316L • These solenoid spool valves are designed to operate
material. Aluminum version: Body and End Cap are Black Anodized. with filtered air.
Pipe connection for 1.06Cv: 1/4’” NPT • Spool Valve Rating: 30 psi to 150 psi (2 Bar to 10 Bar).
Pipe connection for 3.7Cv: 1/2’” NPT • -40C version of Pilot Valve Pressure Rating: 30 psi to 116
All valves are configured for internal pilot pressure supply. Pilot psi (2 Bar to 8 Bar).
pressure supply is from Pilot Valve mounted inside the TopWorx • Ensure that Pressure supply to the Pilot valve shall be
Indicator Box as shown in Figure 1. 30 psi to 116 psi (2 Bar to 8 Bar) as minimum 30 psi (2
Bar) pressure is required for Spool valve to operate and
Versions isolated from atmosphere: The internal parts of the maximum limit of Pilot Valve is 116 psi (8 Bar).
valve are isolated from the outside atmosphere in order to provide
protection in aggressive environments. All the exhaust ports of the
spool valve are pipable, providing better environmental protection,
particularly recommended for sensitive areas such as clean Caution:
rooms and applications in the pharmaceutical or food processing Installation of a Valve
industries. It is necessary to connect pipes or fittings to the exhaust Check Nameplate for correct catalog number, pressure and service.
ports to protect the internal parts of the spool valve if used outside Never apply incompatible fluids or exceed pressure rating of the
or in harsh environments (dusts, liquids etc.). valve. Installation and maintenance to be performed by qualified
personnel only.
SPECIAL CONDITIONS FOR SAFE USE
• Do not connect the pressure supply to the exhaust port
3. The "environmentally protected” construction is not
adapted for NO function. Contact us for functions available
in specific versions. Connect pipes for the required
functions in accordance with this documentation and the
port markings on the product.
51
Future Service Considerations ASSEMBLY OF 3.7Cv VERSIONS:
• Provision should be made for performing seat leakage, Steps to assemble 3.7Cv series valve:
external leakage and operational tests on the valve with a 1. Interface Plate Assembly will be mounted on Indicator Box
nonhazardous, non-combustible fluid. with the help of 4 screws for Spring Return versions and 4
• When assembling this product to a pilot to ATEX 2014/34/ Screws for Dual Pilot versions.
EU, take the least favorable category, maximum working 2. Spool Valve is mounted on the Interface Plate Assembly.
pressure and temperature into account. Compliance with screws are used to mount the Spring Re-turn versions and 4
the Essential Health and Safety Requirements has been Screws to mount the Dual Pilot versions as shown in figures
assured by compliance with the European Standards EN 3 & 4.
13463-1. The mounting position for he pilots as shown in 3. Interface Plate Assembly: TopWorx to manufacture Interface
figure 1 (a). Plate, and Sub-assembly of Plate, O Ring, and Ball plug
Dual Pilot
Air Operated
TopWorx™
ASSEMBLY Indicator Box
• ASSEMBLY OF 1.06Cv VERSIONS: 1.06Cv series valves
are directly mounted on Indicator Box. Spring return Interface Plate
and dual pilot both mount with 4 screws. See figure 1 & Assembly
2.TopWorx Indicator Box shown in the pictures are only for
illustration purpose. Fig.4
3.7Cv Dual Pilot -
Aluminum & Stainless
Steel, With & Without MO
TopWorx™
Indicator Box
TopWorx™
TopWorx™
Indicator Box
Indicator Box
Fig.1
1.06Cv Spring Return - Interface Plate
Aluminum & Stainless Interface Plate
Steel, With & Without MO Assembly
Assembly
Manual Override
TopWorx™
The MO is indicated with symbol in ( ) Figure 5. MO provides
Indicator Box manual operation when desired or during an electrical power
outage. Refer to figure 4 for MO Operation. To engage valve
manually, insert a screwdriver into arrow slot, push the MO forward
till it stops and then rotate it as far as possible to “2”. Valve will
now be in the same position as when the solenoid is energized. To
disengage MO, rotate arrow slot as far as possible to “0”.
Cleaning
Fig. 5 Manual Overide
Maintenance of the valves depends on the operating conditions.
They must be cleaned at regular intervals. During servicing,
the components must be checked for excessive wear. The
components must be cleaned when a slowing down of the cycle is
noticed even though the pilot pressure is correct or if any unusual
noise or a leak is detected.
Sound emission
The exact determination of the sound level can only be carried out
by the user having the valve installed in his system. The emission
of sound depends on the application, fluid and type of equipment
used.
Preventive maintenance
• Prepare and follow routine inspection schedule based on the
media, environment and frequency of use.
• Keep the medium flowing through the valve as free from dirt and
foreign material as possible. Depending on medium and service
conditions, clean valve strainer or filter as required to keep the
valve free of contamination. In the extreme case, contamination
will cause faulty valve operation and the valve may fail to shift.
• Operate the valve at least once a month to check its function.
General recommendations for pneumatic connection: • If problems arise during maintenance or in case of doubt, please
contact us or one of our authorized representatives.
Connect piping or tubing to valve according to markings on valve
body. Refer to flow diagrams in OPERATION section. Apply pipe Troubleshooting
compound sparingly to male pipe threads only. If applied to valve Incorrect outlet pressure: Check the pressure on the supply
threads the compound may enter the valve and cause operational side of the valve; it must correspond to the values indicated on the
difficulty. Avoid pipe strain by properly supporting and aligning nameplate.
piping. When tightening the pipe, do not use valve or solenoid as
a lever. Locate wrenches applied to valve body or piping as close Caution: Observe the minimum pilot pressure value 3 Bar.
as possible to connection point. To avoid personal injury or damage to equipment, check that
the valve operates correctly before putting it back into
Caution: To avoid damage to the valve body, DO NOT operation.
OVERTIGHTEN PIPE CONNECTIONS. If PTFE tape, paste,
spray or similar lubricant is used, use extra care when Troubleshooting
tightening due to reduced friction.
Replace the entire valve.
• Threaded ¼ and ½ port versions:
Connection of the Spool Valve: Connect pipes as indicated on
the label: pressure inlet at port 1. Pressure outlet at ports 2 and
4. The exhausts are channeled through the valve to ports 3 and
5.
EXHAUST RESTRICTION
Valve function: The Exhausts are channeled through the
valve to ports 3 and 5. The Exhaust Speed can be controlled
by using adjustable Exhaust Reducers. Caution: Do not seal off
the Exhaust as this will prevent the Valve from shifting. For best
results, do not restrict flow through the Exhaust below Cv 0.10
(ø2 mm). If Exhaust is fully restricted, then the Valve will not
shift.
EXHAUST PROTECTOR
Depending on the versions (1.06 or 3.7 Cv),
Stainless steel exhaust protectors can be used.
1/4” NPT Part# PS-01236-1
1/2” NPT Part# PS-01237-1
53
Continued-Proof Testing for D-Series TopWorx™
Sira Test & Certification Ltd has conducted a Failure Mode, Effect and Diagnostic Analysis (FMEDA) of the D-Series Discrete Valve
Controller against the requirements of IEC61508-2.
To download more information concerning the TopWorx™ D-Series Valve Controller, including a copy of the Sira
Functional Safety Assessment Report visit us online at http://www.topworx.com Or call 502-969-8000
54
54
Continued-Proof Testing for D-Series TopWorx™
55
Dimensions and Materials: TopWorx™ DXP
Casted aluminum bracket is recommended for installation with SS 8553 valve in vibrating environment.
MATERIALS OF CONSTRUCTION
56
Dimensions and Materials: TopWorx™ DXP - Flameproof Ex d IIC
Casted aluminum bracket is recommended for installation with SS 8553 valve in vibrating environment.
MATERIALS OF CONSTRUCTION
57
Dimensions and Materials: TopWorx™ DXS
Casted aluminum bracket is recommended for installation with SS 8553 valve in vibrating environment.
MATERIALS OF CONSTRUCTION
58
Dimensions and Materials: TopWorx™ DXR
Casted aluminum bracket is recommended for installation with SS 8553 valve in vibrating environment.
MATERIALS OF CONSTRUCTION
Polycarbonate, UV F1
Indicator Dome rated
Seals Silicone
59
Indicator Assembly
IndicatorDome,
Indicator Dome,
+±5°
5Oadjustable
adjustable
Polycarbonate
Polycarbonate 10-32
10 - 32Captive
Captivescrews,
screws,
withkeyed
with keyedmask.
mask. Stainless
stainless (x4)
steel (x4)
Several rotation
Several rotationand
and
form
form options.
options
O-Ring
O-ring
Available
AvailableininBuna-N,
Buna-N,
Silicone, EPDM, Viton
Silicone Color-coded Indicator
Color-coded indicator is
is
available in several
available several
coordinating rotations and
and
forms for various valve
types, such as 9090°,, 180
0 0
180°,
and Thru-divert
and applications.
thru-divert applications
Cam/Shaft Assemblies
60
TopWorx™ D-Series Certifications
PESO
Ex ia IIC T* Gb; Ex tb IIIC T* Db
Ex ib IIC T* GB; Ex tb IIIC T* Db
IECEx SIR 14.0078X / Sira 14ATEX2241X
IECEx BAS 11.0022X / Baseefa 11ATEX0035X (FF)
USL/CNL Class I, Div 1, GrABCD
UL File E125326
EAC RU C-US.ГБ08.В.02500
NEPSI GYJ13.1297X
InMetro NCC12.1260X, NCC12.0767X
PESO P347552
*Operating and Ambient temperature ratings vary depending on bus/sensor option(s), reference certificate for specific markings available.
61
Safe Use
User instructions (in compliance with ATEX 2014/34/EU Directive, Annex II, 1.0.6)
Instructions for safe selection, installation, use, maintenance and repair
1) The equipment may be used in zones 0, 1 or 2.
2) The equipment may be used in the presence of flammable gases and vapors with apparatus groups IIC or IIB or IIA and with
temperature classes T1 or T2 or T3 or T4 or T5 or T6.
3) The equipment is certified for use in ambient temperatures in the range of -50°C to +60°C and should not be used outside this
range. (NOTE: Ambient temperature range may change according to protection method)
4) The equipment is to be installed by suitably trained personnel in accordance with the applicable code of practice (typically IEC
60079-14)
5) Under certain extreme circumstances, the plastic cover over the valve position indicator may generate an ignition-capable level
of electrostatic charge. Therefore, particularly in the event of an installation in zone 0, the equipment shall not be installed in a
location where the external conditions are conducive to the build-up of electrostatic charge, e.g. wind-blown dust, etc. Additionally
the equipment shall only be cleaned with a damp cloth.
6) Periodic inspection of the equipment and system should be performed by suitably trained personnel in accordance with the
applicable ode of practice (typically IEC 60079-17) to ensure it is maintained in a satisfactory condition.
7) The equipment does not require assembly or dismantling.
8) The equipment is not intended to be repaired by the user. Repair of the equipment is to be carried out by the manufacturer, or their
approved agents, in accordance with the applicable code of practice.
For Explosion Proof installations, the internal ground connection shall be used and the external ground connection, if supplied in addition,
is supplemental bonding allowed where local authorities permit, or is required.
When installing with a third party listed nipple-mount solenoid, it is the responsibility of the installer to provide fittings, and apparatus,
suitable for the area classification in accordance with the National Electrical Code.
All cable entry devices or conduit stopping boxes shall be certified according to protection type and suitable for the conditions of use and
correctly installed.
The IIC enclosures are excluded from use in carbon disulphide atmospheres.
The air pressure to the valve block, when fitted, shall not exceed 150 PSI.
1. The IIC enclosures are excluded from use in carbon disulphide atmospheres.
2. The air pressure to the valve block, when fitted, shall not exceed 150 PSI.
3. For ambient temperatures above 110ºC, the degrees of ingress protection IP66 and IP67 are not endorsed.
4. The slotted hexagonal head cover screws are not of standard form; they shall only be replaced with identical screws sourced from
the equipment manufacturer.
5. The hexagonal head cover screws are to be replaced only with stainless steel 304, grade A2-70 or A4-80 screws to ISO 35061.
6. Cover fasteners are to be tightened to a torque valve of 10.85Nm (8 ft./lbs) minimum.
Continued
62
Special Conditions or Safe Use Continued (Intrinsically Safe Installations)
The D-Series Intrinsically Safe TopWorx™ may contain one or more devices covered by the following certificates:
The installer shall confirm which certified sub-assemblies are contained within the equipment and ensure compliance with the appropriate
certificate (with particular reference to input parameters)
Number Description
PTB 99ATEX2219X plus supplement 1 Pepperl & Fuchs slot-type initiators, types SJ… & SC...
PTB 00ATEX2032X plus Supplements 1 & 2 Pepperl & Fuchs cuboidal inductive sensors, type NJ...
PTB 00ATEX2048X plus Supplements 1, 2 & 3 Pepperl & Fuchs cylindrical inductive sensors, types NC… & NJ...
PTB 00ATEX2049X plus Supplement 1 Pepperl & Fuchs SN sensors, type NJ...
KEMA 02ATEX1090X plus Amendment 1 Turk two-wire proximity sensors type …-….-.Y1. /….
IFM inductive proximity switch type NE****, NF****, NG****, NI****,
PTB 01ATEX2191 NN****, NT****, NS****
LCIE 02ATEX6122X Crouzet electro-valve type 81519xxx
Sira 12ATEX2192U 4-20 mA Transmitter Module
1. The 4-20 mA loop circuit and the various additional sub-assemblies (switches, sensors and valves) shall be treated as separate
intrinsically safe circuits.
2. The DXR (resin) enclosure shall only be installed where there is a low risk of mechanical damage.
3. The switchbox may contain simple switches, which shall have a maximum input power (Pi) of 1.3 W for T4 or 0.7 W for T6 from an
intrinsically safe supply.
4. For a T4 temperature class, the switchbox may contain simple switch and resistor arrangements, which shall have a maximum
input power (Pi) of 0.7 W from an intrinsically safe supply. These are not permitted for a T6 temperature class.
5. For a T6 temperature class, the input parameters to sensors covered by PTB 99ATEX2219X, PTB 00ATEX2032X, PTB
00ATEX2048X or PTB 00ATEX2049X shall be limited to Ui = 16V, Ii = 25mA, Pi = 64mW.
6. For a T6 temperature class, the Turck proximity sensors listed in certificates KEMA 02ATEX1090X shall have the maximum input
parameters as follows:
7. Type AX & GX: Ui = 15V, Ii = 20mA, Pi = 200mW
8. All other sensors: Ui = 15V, Ii = 60mA, Pi = 130W
9. When the equipment incorporates a 4-20 mA Transmitter Module (Sira 12ATEX2192U), the manufacturer may apply the marking
“II 1G’ or ‘II 2 D’ or ‘II 2 GD’. A T6 temperature class is not permitted with this Module fitted. The ambient temperature is limited
to a maximum range of -40ºC to +53ºC, but this range may be reduced, depending on the enclosure and gasket type, as well
as the internal sub-assemblies fitted. Additionally, the output from the 4-20mA Transmitter Module shall only be connected to a
Novotechnic WAL30 potentiometer
Preventative Maintenance
The TopWorx™ DXP/DXS Switchbox is designed to operate for one million cycles without servicing. Call the factory when you are
approaching this milestone for a preventative maintenance kit and instructions.
63
TopWorx™ D-Series Replacement Part Number List
"Standard shaft
AV-SSB201 Buna-N O-Rings & (2) cam Assembly w/ Hardware"
"NAMUR Shaft
AV-NSB201 Buna-N O-Rings & (2) cam Assembly w/ Hardware"
"Shaft Replacement Kits
GO™ Switches (L2 - Manufactured after July 1, 2007)"
"Standard shaft
AV-SSB205 Buna-N O-Rings & (2) Target Assembly w/ Hardware"
"NAMUR shaft
AV-SNB205 Buna-N O-Rings & (2) Target Assembly w/ Hardware"
"Shaft Replacement Kits
SCMs with Reed Switches (R2)"
"NAMUR Shaft
AV-NSB203 Buna-N O-Rings & (2) cam Assembly w/ Hardware"
"Standard Shaft
AV-SSB203 Buna-N O-Rings & (2) cam Assembly w/ Hardware"
Consult Factory
To order replacement parts or for information concerning parts or spool valve options not listed call
TopWorx™ at 502-969-8000
64
TopWorx™ D-Series Replacement Part Number List Continued
* If you are needing a replacement for a TopWorx™ switchbox with a non-ASCO spool valve, please consult the factory for a kit number.
65
Recommended Operating Temperatures
Option Switch Description Switchbox (NO Integrated Solenoid) Switchbox (WITH Integrated Solenoid)
66
™
info.topworx@emerson.com
www.topworx.com
The Emerson logo is a trademark and a service mark of Emerson Electric Co. ©2016
Emerson Electric Co. ©2016 TopWorx™, All rights reserved.TopWorx™, and GO™ Switch
are trademarks of TopWorx™. All other marks used in this document are the property of their
respective owners. Information contained herein - including product specifications is subject to
change without notice.
ES-01857-1 R26
67
SENSOR USING SENSOR USING SENSOR USING
1.25” PISTON .50” PISTON .25” PISTON
X X X
X X X
X X X
No. PO PO15298
SAN JUAN LNG FACILITY
No. DOCUMENT NFE-2923-Q-MA-001
6. FLOW COMPUTER
Totalflow product line
User manual
2104349 (AD)
Proprietary information
© Copyright 2018 ABB, All rights reserved.
Intellectual property & copyright notice
©2018 by ABB Inc., Totalflow (“Owner”), Bartlesville, Oklahoma 74006, U.S.A. All rights reserved.
Any and all derivatives of, including translations thereof, shall remain the sole property of the Owner, regardless
of any circumstances.
The original US English version of this manual shall be deemed the only valid version. Translated versions, in
any other language, shall be maintained as accurately as possible. Should any discrepancies exist, the US
English version will be considered final.
Notice: This publication is for information only. The contents are subject to change without notice and should not
be construed as a commitment, representation, warranty, or guarantee of any method, product, or device by
Owner.
Inquiries regarding this manual should be addressed to ABB Inc., Totalflow Products, Technical
Communications, 7051 Industrial Blvd., Bartlesville, Oklahoma 74006, U.S.A.
Trademark Ownership
Windows® is a registered trademark of Microsoft
Teflon® is a registered trademark of Dupont
Table of contents
Introduction ........................................................................................................................................... x
Organization & style.................................................................................................................................. x
Getting help .............................................................................................................................................. x
Before you call ............................................................................................................................ x
Key symbols ............................................................................................................................................. x
Safety practices and precautions ............................................................................................................. xi
Safety guidelines ...................................................................................................................... xii
Safety first ................................................................................................................................ xii
Equipment markings ................................................................................................................. xiii
Grounding the product .............................................................................................................. xiii
Operating voltage ..................................................................................................................... xiii
Danger from loss of ground ......................................................................................................xiii
Safe equipment ....................................................................................................................... xiv
Fuse replacement .................................................................................................................... xiv
Compliance ............................................................................................................................................ xiv
EU Directive 2012/19/EU - Waste Electrical and Electronic Equipment (WEEE) .................... xiv
1 System description ............................................................................................................. 1–1
1.1 Overview ................................................................................................................................ 1–1
1.1.1 Capabilities............................................................................................................... 1–2
1.1.2 Functionality ............................................................................................................. 1–2
1.1.3 Flow computer calculations ...................................................................................... 1–3
1.1.4 Log period records ................................................................................................... 1–4
Display function ........................................................................................................ 1–5
1.1.6 Display annunciators ................................................................................................ 1–5
1.2 Computer hardware ................................................................................................................ 1–7
1.2.1 Enclosure ................................................................................................................. 1–8
1.2.2 G4 EX main processor board ................................................................................. 1–10
1.2.3 G4 EX termination board ........................................................................................ 1–12
1.2.4 Explosion proof multivariable transducer (EXIMV) ................................................. 1–17
1.2.5 Display assembly ................................................................................................... 1–19
1.2.6 Resistive temperature detector (RTD) .................................................................... 1–19
1.2.7 6270 Optional Equipment Unit (OEU) .................................................................... 1–20
1.2.8 Solar panel ............................................................................................................. 1–21
1.2.9 Lithium battery........................................................................................................ 1–22
1.3 G4 EX application licensing .................................................................................................. 1–22
1.3.1 Credit Key (USB).................................................................................................... 1–24
1.4 Laptop computer running PCCU32 ...................................................................................... 1–24
1.5 Local G4 EX connectors ....................................................................................................... 1–25
1.5.1 RS-232 serial PCCU cable (round military cable) .................................................. 1–25
1.5.2 PCCU32 USB connection ...................................................................................... 1–25
1.5.3 Bluetooth connectivity ............................................................................................ 1–26
1.5.4 Network connectivity (dynamic IP with router)........................................................ 1–26
2 Installation ............................................................................................................................ 2–1
2.1 Unpacking and inspection ...................................................................................................... 2–1
2.1.1 Unpacking ................................................................................................................ 2–1
2.1.2 Inspection ................................................................................................................. 2–1
2.1.3 Damaged components ............................................................................................. 2–1
2.2 2” Pole mount installation ....................................................................................................... 2–1
2.2.1 Type A ...................................................................................................................... 2–2
2.2.2 Type B ...................................................................................................................... 2–3
2.2.3 Type C ..................................................................................................................... 2–4
2.2.4 Manifold input lines .................................................................................................. 2–6
List of tables
Table 1–1 XFC family genealogy ....................................................................................................... 1–1
Table 1–2 Typical G4 EX display options ........................................................................................... 1–5
Table 1–3 Default annunciator locations ............................................................................................ 1–6
Table 1–4 G4 EX status and alarm description .................................................................................. 1–6
Table 1–5 G4 EX main processor board specifications ................................................................... 1–11
Table 1–6 Explosion proof EXIMV specifications ............................................................................. 1–18
Table 1–7 Standard RTD probes ...................................................................................................... 1–20
Table 1–8 Standard Thermowells ..................................................................................................... 1–20
Table 3–1 Configurable calculation factors ...................................................................................... 3–31
Table 3–2 Fpv analysis data ............................................................................................................. 3–32
Table 3–3 Gas Orifice Constants ..................................................................................................... 3–33
Table 3–4 Alarm Limits ..................................................................................................................... 3–34
Table 3–5 G4 EX Displayed Items ................................................................................................... 3–35
Table 4–1 Calibration configurable parameters ............................................................................... 4–19
Table 5–1 Visual alarm codes ............................................................................................................ 5–3
Table 5–2 Specifications for solar panels ......................................................................................... 5–10
Table 5–3 RS-232 field wiring on the G4 EX termination board ...................................................... 5–18
Table 5–4 RS-485 field wiring on the G4 EX termination board ...................................................... 5–21
Getting help
At Totalflow, we take pride in the ongoing support we provide our customers.
When you purchase a product, you receive documentation which should answer
your questions; however, Totalflow Technical Support provides you an 800
number as an added source of information.
If you require assistance, call:
USA: (800) 442-3097 International: 001-918-338-4888
Key symbols
The following symbols may be used frequently in this manual. These are intended
to catch your eye and draw your attention to important information.
Safety guidelines
- DO NOT open the equipment to perform any adjustments, measurements,
maintenance, parts replacement, or repairs until all external power supplies
have been disconnected.
- For assembly, electrical connection, installation and maintenance of the
device, only a qualified and authorized specialist should attempt these
tasks. A specialist would be one who is experienced in either assembly,
electrical connection, installation or maintenance of a given device and
holds the necessary qualifications for the task.
- When opening covers or removing parts, exercise extreme care "live parts
or connections can be exposed".
- Installation and maintenance must be performed by person(s) qualified for
the type and area of installation according to National and Local codes.
- Capacitors in the equipment can still be charged even after the unit has
been disconnected from all power supplies.
Safety first
Equipment markings
Operating voltage
Before switching on the power, check that the operating voltage listed on the
equipment agrees with the power being connected to the equipment.
Fuse replacement
Fuses used on Totalflow electronic boards are surface mount and field repair
should not be attempted. Most fuses automatically reset themselves, but if a
known problem exists, the board should be sent in for repair or replacement.
Compliance
ABB Industrial Automation, Measurement and Analytics, is committed to actively protecting the
environment. Do not dispose of WEEE as unsorted municipal waste. Collect WEEE separately.
Participation in the management of WEEE is critical to the success of WEEE collection.
Electrical and electronic equipment marked using the crossed-out wheeled bin symbol
shall not be mixed with general household waste. Correct disposal at a recycling
facility will help save valuable resources and prevent potential negative effects on
health and the environment. These steps ensure compliance with the Waste Electrical
and Electronic Equipment (WEEE) Directive.
Waste electrical and electronic equipment (WEEE) shall be treated separately using the national
collection framework available to customers for the return, recycling, and treatment of WEEE.
1.1.2 Functionality
Functions of the G4 EX reflect a design that is practical, straightforward and
efficient. It is simple to use and easy to learn. This functionality allows for saving
time that is usually allotted for calculations and report preparation. This flow
computer allows the user to perform the following with a minimum of effort,
maximum speed and greater accuracy.
Display function
During operation, the front panel LCD continuously scrolls through the operating
parameters. Table 1–2 shows the typical displayed parameters; however, many
parameters with a register address can be displayed. The duration that the
parameter is displayed can vary from 1 to 255 seconds (default is five seconds); a
setting of zero seconds will set any item to Off. See the Program Display section
and the PCCU32 Help Files for additional information.
Annunciator Application
A1 Measurement Tube 1
A2 CIM 0
A3 Valve Control
A4 COM2
A5 Plunger
A6 Local-COM0
A7 System
A8 TF Remote – COM1
Indicator Description
System
LL Low Lithium Battery Alarm: When LL (low lithium) is displayed, lithium battery voltage is not
sufficient to maintain SRAM data. A new lithium battery measures approximately 3.6 VDC.
Display Application
1 A number represents the Display Group number currently being displayed.
The displayed item’s value is above the Data High Limit value specified on the display Item
↑
Setup screen.
The displayed item’s value is below the Data Low Limit value specified on the display Item
↓
Setup screen.
Do not attempt to loosen the end cap before loosening the set
screw. Doing so may damage threads on the unit.
1.2.1.1 Dimensions
Width
Unit w/o External w/ External Height Depth
PCCU PCCU
US 7.87” 9.50” 11.25” 8.34”
Metric 199.90 mm 241.30 mm 285.75 mm 211.84 mm
(7.87)
¾ NPT CONDUIT ENTRIES
¾ NPT CONDUIT ENTRIES
(01.53)
XFCG4 EX
(30º)
(01.84)
(3.76)
Component Description
Power 9 to 30 VDC
SWVBAT: 1 fused with 2.5 amp PTC
External Power
VBAT: 1 fused with 2.5 amp PTC
Charger No Charger
Application (Totalflow.exe) runs out of 16M SRAM. RAM memory has lithium
backup battery.
Memory Application and configuration files permanently stored in 32M Flash.
Registry (MAC address, etc.) is stored in 256 byte E2PROMSD Card
SD Card optional (512M/1G)
6 Ports Available
Dedicated PCCU/MMI (RS-232 or USB)
2 Onboard User Programmable RS-232/RS-422/RS-485 Ports
Comm. Ports USB (Client)
NOTE: A special cable is required, and the user must check with Totalflow for a
list of drivers to support Client peripherals.
Ethernet Bluetooth – Standard on the Main Electronics board
The digital input reads an external contact. This is primarily used as a status input
to read external equipment. The contact must be closed to be considered “ON”.
The “ON” condition is recorded in the log period alarms and can trigger the action
of the G4 EX’s digital voltage output. OFF is defined as an open contact.
Selectable de-bounce can be enabled or disabled within PCCU32. See the
PCCU32 Help Files for additional information.
DI electrical specifications
- Open circuit voltage: 5 VDC (Internally pulled up to 5 VDC Nom.).
- Short circuit leakage current: -395 uA typical.
The digital output can be used in conjunction with a measurement tube (AGA-3,
AGA-7 or liquid measurement) and triggered on the following measurement
parameters or conditions:
- Differential pressure over high limit
- Volume set point
- Differential pressure under low limit
- Flow temperature low
- Static pressure over high limit
- Flow temperature high
- Static pressure under low limit
- Flow rate low
- Low charger voltage
- Flow rate high
- Remote sense is on
- Trip on digital input
Custom programmable by Totalflow or user programmable with IEC 1131
programming language
DO electrical specifications
- Open circuit voltage: 0 VDC
- Short circuit leakage current: 0 uA typical
- Output capacitance: 1000 pF typical
- Maximum allowable voltage range on output: 0.5 VDC to 29.4 VDC
Output specifications
- Open drain FET type
The 6270 OEU system with battery and solar panel is rated for
Class I, Division 2 locations only or can be installed in non-
hazardous locations.
Technical Data
Nominal capacity @
2.1 Ah
2 mA, to 2V
Rated voltage 3.6 V
Wires AWG 24
Enclosure UL 94V2
Mounting Hook and loop fastner
Operating
-55°C to +85°C/-67°F to +185°F
temperature range
Making a local connection to the meter may be accomplished one of three ways.
Traditionally, local connections have been made using the RS-232 PCCU cable
with the round military connector on one end and a serial port connector on the
other. The second method involves the local connection being made using a USB
cable. The third method utilizes the standard onboard Bluetooth wireless
connection. These methods are discussed below.
The local connection (serial military connector) requires an RS-232 serial port on
the host computer (generally a laptop). A PCCU cable is required to connect the
host computer to the meter’s round military connector (see Figure 1–20).
Connecting the PCCU cable to the meter will cause the annunciator in the LCD to
display an upper case letter “L” for local connect.
2.1.1 Unpacking
The G4 EX and RTD are shipped in a specially designed shipping carton which
contains the unit, mounting brackets, parts list and wiring and interconnect
diagrams. The solar panel and the battery pack with applicable hardware are
shipped in a separate carton.
Carefully remove the items from each carton.
2.1.2 Inspection
- Inspect the shipping carton for damage. If the shipping carton is damaged,
keep it until the contents have been inspected for damage.
- Inspect the unit’s exterior for dents, chipped paint, etc.
- Inspect the LCD window for breakage.
- Visually inspect the electronic boards, cables and EXIMV for damage.
1) Attach the pole mount bracket to the top of the 2” pipe with the U-bolts. Use
the provided hex nuts, flat washers and spring lock washers to tighten the
pole mount bracket to the 2” pipe.
2) Position the provided back clamp on the pole mount bracket, and align the
mounting holes between the two pieces.
3) Upon alignment, take the G4 EX and its attached transducer and set it
within the recessed groove on the back clamp.
4) Once the G4 EX and its transducer have been properly positioned, attach
the device to the brackets using the provided U-bolt. Use the hex nuts, flat
washers and spring lock washers to tighten the device to the mounting
brackets (see Figure 2–1).
2.2.2 Type B
6) Remove the lower two hex screws, hex nuts, flat washers and spring lock
washers from the transducer’s attached mounting brackets.
7) With the associated hardware removed, align the transducer’s bottom
mounting holes with those on the pole mount bracket.
8) Upon alignment, replace the hex screws, hex nuts, flat washers and spring
lock washers through their respective mounting holes on the mounting
brackets and into the pole mount bracket. Upon completion, tighten (see
Figure 2–2).
2.2.3 Type C
1) Attach the pole mount bracket to the top of the 2” pipe with the U-bolts. Use
the provided hex nuts, flat washers and spring lock washers to tighten the
pole mount bracket to the 2” pipe.
2) Position the provided back clamp on the pole mount bracket, and align the
mounting holes between the two pieces.
3) Upon alignment, take the G4 EX and its attached transducer and set it
within the recessed groove on the back clamp.
4) Once the G4 EX and its transducer have been properly positioned, attach
the device to the brackets using the provided U-bolt. Use the hex nuts, flat
washers and spring lock washers to tighten the device to the mounting
brackets (see Figure 2–3).
Back Clamp
2) Using snap ring pliers, adjust the probe length so that it is spring loaded
against the bottom of the Thermowell.
3) Screw the probe connector into the Thermowell.
HEAD
UNION
NIPPLE
THERMOWELL
CUSTOMER
SUPPLIED LINE
METER RUN
If the probe assembly is too long or too short, the user may need
to change nipple lengths.
The 6270 OEU system with battery and solar panel is rated for
Class I, Division 2 locations only or can be installed in non-
hazardous locations.
1) Using the instructions supplied with the mounting kit, attach the bracket to
the back of the enclosure unit.
2) Position the unit on the 2” mounting pipe, and secure in place with two U-
bolts, flat washers, lock washers and two bolts (see Figure 2–10).
To extend the life of the battery pack, fully charge the battery
prior to installation. Systems using solar panels may not fully
charge the battery. Charging the battery fast will remove the
oxide buildup and will improve the life of the battery.
The 6270 OEU system with battery and solar panel is rated
for Class I, Division 2 locations only or can be installed in
non-hazardous locations.
7) Do not connect the other end of the cable to the 6270 OEU until the main
battery pack has been connected and the user has been instructed to do so.
8) Remove the hole plug from the OEU, and install the cord connector.
If the meter has been given a security code, the user needs to
ensure they have entered that code in PCCU32’s System Setup
screen (see Figure 3–1). However, if the meter has been cold
started, the security code will be reset to factory default, and
historical data will be lost.
If the user has several meters on their network, they may find it
helpful to create a desktop shortcut for each meter. For
instructions on how to accomplish this task, follow steps 10 – 12;
otherwise, the user may continue on to the next section.
10) Create a desktop shortcut, and assign a name to it. For the sake of the
example, the following will use the meter’s ID for the shortcut name.
11) The user will now need to point to the version of PCCU32 that they want to
use (the user may have multiple versions of PCCU32 on their laptop). It
should be noted that it must be PCCU32 version 7.05.5 or later.
12) The user will then need to identify the network protocol to be used (TCP)
and the network ID (see Figure 3–11).
For example:
- Point to the folder with PCCU32 in it.
- Point to PCCU32.exe.
- Point to the protocol (TCP).
3.3.1 Date/time
The G4 EX date and time should be set before other tube parameters are entered.
This insures that events are properly dated and time tagged. Attention should be
given that the date and time are set correctly and should agree with the collection
equipment. PCCU32 or WinCCU can be used to update the date and time of the
device.
3.3.2 Station ID
The station identifier code should uniquely identify one G4 EX from that of any
others.
Description Format Note
Station ID XXXXXXXXXX 10-digit alphanumeric
3.3.3 Location
The location field can hold up to 24 alphanumeric characters to describe its
location. An example would be the lease name, county name or road number.
Description Format Note
Station ID XXXXXXXXXXXXXXXXXXXXXXXX 24-digit alphanumeric
Figure 3–22 Send Role Based Access Control File dialog box
3.5.2 Access/view the Credit Key with PCCU32 7.0 (or later)
To access and view the credit key, the user must use PCCU32 7.0 (or later). The
credit key is a secure device and only accessible through PCCU32.
4) When the Credit Key License Utility screen displays, click Load to view
available credits on the USB key (see Figure 3–27).
This is the same dialog box that the user would use to add more
credits to the credit key.
To transfer application credits to the G4 EX, the user will need to connect to the
G4 EX with PCCU32 7.0 or later.
1) Open PCCU32. Once open, move to the top of the tree-view, and click on
the App Licensing tab (see Figure 3–31).
2) Install the credit key in an available USB port.
3) Click the Load button to view the available credits.
This screen enables the user to see the licensing status of the G4
EX as well as the available credits on the credit key. The left pane
shows the type and amount of the available credits on the credit
key. The upper right pane is for information purposes only. It
shows the various available applications and the type/amount of
credits necessary to run the application. The standard credits (and
four general credits) are free with the purchase of the G4 EX. The
lower right pane displays the licensing status of the G4 EX. It
shows what credits are in the machine, what credits are being
used and any surplus or deficit of credits. A surplus of credits is
highlighted in green. A deficit of credits is highlighted in red.
To transfer application credits to the G4 EX, the user needs to connect to the G4
EX unit with PCCU32 7.0 or later.
1) Open PCCU32. Once open, move to the top of the tree-view, and click on
the App Licensing tab.
2) Install the credit key in an available USB port.
3) Click the Load button to view the available credits.
3.6 G4 EX configuration
AGA-3 AGA-3
Calculation Parameter AGA-7 ISO-5167
1985 1992
Fpb (Pressure Base Factor) Yes N/A N/A N/A
Ftb (Temperature Base Factor) Yes N/A N/A N/A
Fg (Specific Gravity Factor) Yes N/A N/A N/A
Fb (Orifice Factor) Yes N/A N/A N/A
Ftf (Flowing Temperature Factor) Yes N/A N/A N/A
Y (Expansion Factor) Yes Yes N/A Yes
Fr (Reynolds Number) Yes N/A N/A N/A
Fa (Orifice Thermal Expansion
Yes N/A N/A N/A
Factor)
1 NX19 GCN, NX19 GCNM, AGA-8 1992 Gross and AGA-8 1992 Detail
2 See Fs for AGA-7 Fpv2
3 Only AGA-3 1992 Gross and Detail
4 Not an AGA factor. Fw is a factor which compensates for water vapor in the gas stream and its effect on volume
measurement.
5 Not an AGA factor. Faux is a user set multiplier to compensate for liquids in the gas stream. Defaults to 1.
6 Discharge Coefficient Type-only AGA-3 1992 and ISO-5167-1
7 NX19 GCN, NX19 GCNM, AGA-8 1992 Gross
8 Enter the Heating Value in Btu per SCF. Not used in volume calculations. Only used for calculating MMBTU for reports.
3.6.6 Constants
On a single tube gas orifice meter, there are certain constants or parameters that
may need to be entered or changed from the default values. Table 3–3 displays
the list of these constants.
4.1.3 Cleanliness
Because a G4 EX installation is primarily exposed to external environmental
conditions, it is important that it be regularly inspected for cleanliness, both
externally and internally. Foreign contaminants can cause damage to interior
mounted components that can render the G4 EX inoperable.
4.4.1.1 Method 1
1) The user will need to open the door to the unit. Locate the Reset button on
the G4 EX termination board.
J16
PWR
4.4.1.2 Method 2
1) Open the door to the unit. Ensure that there is voltage on the battery and
that the jumper is enabled.
2) Remove power to the board, and then reconnect. This will initiate a warm
boot.
4.4.2.1 Method 1
1) Open PCCU32. The user needs to ensure that they are not connected
initially and are at the Totalflow splash screen.
2) Click the 32-Bit Loader icon on the toolbar. This takes the user to the 32-Bit
Loader screen.
3) Within the screen, the user needs to select the Reload radio button.
4) Ensure that all of the checkmarks are removed from the various software
option. Once this has been accomplished, place a check in the options list
beside Shutdown Flash and Start Flash.
5) Select the needed connection type from the available drop-down menu.
6) Upon completion, click the Start button.
4.4.2.2 Method 2
4.4.2.3 Method 3
1) Move into Entry mode within PCCU32.
2) Once this has been completed, click the Terminal icon on the PCCU32
window toolbar. This will bring up the Terminal window.
3) Once in the Terminal window, move to the terminal prompt (->), and type in
the following: BOOT=WARM. Press Enter on the keyboard to initiate the
warm boot.
1
4
LITHIUM
Lithium Battery
L1 Connector
4.5.2.1 Method 1
1) Open PCCU32. The user needs to insure that they are not connected
initially and are at the Totalflow splash screen.
2) Click the 32-Bit Loader icon on the toolbar. This takes the user to the 32-Bit
Loader screen.
3) Within the screen, the user needs to select the Reload radio button.
4) Make sure that all of the checkmarks are removed from the various software
options. Once this has been accomplished, place a check in the options list
beside Shutdown Flash, Delete tfData and Start Flash. A prompt will display
that warns that a cold boot is occurring. Click the Yes button to initiate a
cold boot.
4.5.2.2 Method 2
1) Move into Entry mode within PCCU32.
2) Once this has been completed, click the Terminal icon on the PCCU32
window toolbar. This will bring up the Terminal window.
3) Once in the Terminal window, move to the terminal prompt (->), and type in
the following: BOOT=COLD. Press Enter on the keyboard to initiate the
warm boot.
4) Gain access to the rear termination board by loosening the countersunk hex
socket locking set screw in the rear end cap. Use a 1/16” hex wrench to
perform this task. Upon completion, unscrew the end cap.
5) Disconnect the power connector (J16) from the board mounted connector
(see Figure 4–5).
AI/DO2(+)
DO/AI2(+)
AI/DO2(-)
DO/AI2(-)
DI/PI (-)
DI/PI(+)
There are a pair of jumper wires required for
RS-485 only: wire J19, Pin 9 to Pin 7 and
Wire Pin 8 to Pin 6 on the terminating board.
J12 Jumper:
Jumper Pin1 to Pin 2 for AI For all intermediate boards, Jumper J9, Pin 2
Jumper Pin 2 to Pin 3 for DOUT2 J5 to Pin 3
J3
+ AI - + DI - + DO -
J9 Terminates RS-485
on COMM1
J12 J6 J13 COMM1
1 3 1 3
J19 (RS-232/RS-485)
J8 COMM1
(WHT) RTD OUT 5 I/O EXPANSION 9 CTS/RBUS(-)
(WHT) RTD + 4 6 9 8 RXD/RBUS(+)
(BLK) RTD - 3 TXD/TBUS(-)
RTD PROBE 1 5
7
(BLK) RTD IN 2 6 RTS/TBUS(+)
S2
(DRAIN) SHIELD 1
J2 5 J9 RRTS COMM1
ETHERNET 1
4 OPERATE COMM1
RTD
3 COMM2 SW
3
SECURITY J7 2 GND
S3
1 VBATT
J16
1
PWR
MMI
J20 Note:
COMM2 Pinouts are shown to the outside for clarity,
but all of the Phoenix connectors are wired
XFCG46200EX and attached to the inside.
POWER/TERM
BOARD 1 2 3 4 5 6 7 8 9
1 3
2103344-XXX J11
CTS/RBUS(-) Jumpers for RS-485 Mode Only
RXD/RBUS(+)
TXD/TBUS(-)
RTS/TBUS(+)
RRTS COMM2
J11 Terminates RS-485
OPERATE COMM2
on COMM2
COMM2 SW
GND
VBATT
COMM2
(RS-232/RS-485)
R1
Processor Card
CONTRAST
1
SD CARD
J2
1 16
SD CARD
J3
JTAG
J5
1
4
J4 LITHIUM
XA1
Lithium Battery
L1 Connector
1 49
J1
SENSOR
13 1
14 2
J6
Sensor Connector
13) Take the replacement G4 EX board and attach the sensor cable and the
ribbon cable to their corresponding connectors.
Please note that both the sensor cable and ribbon cable pin
1 wire are red. The red edge (pin 1) of the cable should plug
into the outer most edge of the connector (pin 1).
14) Take the lithium battery cable and attach the cable to its corresponding
connector (J5).
15) Align the mounting holes on the G4 EX board with the standoffs,. Once
aligned, snap the board into place within the device.
16) Once in place, line up the LCD board mounting holes to the G4 EX board.
Gently connect the LCD board into the G4 EX board via the J2 connector.
17) Take a small slot head screwdriver and attach the LCD board to the G4 EX
board using the four mounting screws.
Rear Cap
Term Board
Ribbon Cable
Note: The single red wire on the cable goes
to Pin 1 of both connectors
Stand-off
(4 places)
MMI Connector
2 50
1 49
J1
Please note that the ribbon cable pin 1 wire is red. The red
edge (pin 1) of the cable should plug into the outer most
edge of the connector (pin 1).
10) Depending on the configuration that the user selected from the factory,
attach either the USB cable (J4), Ethernet cable (J7) or MMI cable (J21) to
their respective connection.
11) Next, attach the Comm 1 (J19), Comm 2 (J20) and power (J16) connections
to their respective connectors.
12) Upon completion, take the four socket mounting screws, and attach the
termination board in the G4 EX device.
4) Gain access to the rear termination board by loosening the countersunk hex
socket locking set screw in the rear end cap. Use a 1/16” hex wrench to
perform this task. Upon completion, unscrew the end cap.
5) Disconnect the power connector (J16) from the board mounted connector
(see Figure 4–5).
6) Gain access to the LCD assembly by loosening the countersunk hex socket
locking set screw in the front end cap. Use a 1/16” hex wrench to perform
this task. When completed, unscrew the end cap.
7) After the end cap has been removed, gently pull the graphic overlay plate
away from the snap on standoffs.
8) Using a small flat head screw driver, remove the four screws that hold the
LCD board to the G4 EX device.
9) Gently disconnect the LCD board from the G4 EX board, J2 connector (see
Figure 4–6). Lift the board from the device.
10) To reinstall the LCD board, repeat steps 8 through 9 in reverse order. Do
not over tighten screws.
11) Once the LCD board is reinstalled, apply power to the G4 EX (step 5), and
verify that the information displayed on the LCD is correct.
12) Adjust the contrast potentiometer, R1, for optimum display.
13) Replace the graphic overlay plate that was removed earlier.
4) After the end cap has been removed, gently pull the graphic overlay plate
away from the snap on standoffs.
5) Upon completion, gently remove the lithium battery connector (J5) from the
G4 EX board.
6) Once the lithium battery connector is removed, snap the board out of the
device. Please note that the board is still connected to device through the
cables in the back.
7) After the G4 EX board has partially been removed, unplug the sensor
connector cable (J6) and the ribbon cable (J1) from the G4 EX board. This
will allow the board to be completely removed from the device.
8) The user will now see a manufacturing plate. The lithium battery assembly
is located on the back of this plate in a small battery enclosure. Carefully
remove the plate from the snap on standoffs.
9) The lithium battery assembly is attached to the manufacturing plate by a
Velcro strip. Gently remove the lithium battery from the Velcro strip.
10) Take the new lithium battery, and attach the Velcro edge of the battery to
the Velcro strip in the battery enclosure on the manufacturing plate.
11) Once the lithium battery is attached to the manufacturing plate, snap the
plate back into the device using the appropriate standoffs.
12) Take the G4 EX board, and attach the sensor cable and the ribbon cable to
their corresponding connectors.
Please note that both sensor cable and ribbon cable pin 1
wire is red. The red edge (pin 1) of the cable should plug into
the outer most edge of the connector (pin 1).
XFCG4EX
- +
HIGH SIDE
LOW SIDE EQUALIZER VALVE
EQUALIZER VALVE
VENT TO
ATMOSPHERE
8) Gain access to the rear termination board by loosening the countersunk hex
socket locking set screw in the rear end cap. Use a 1/16” hex wrench to
perform this task. Upon completion, unscrew the end cap.
9) Disconnect the power connection (J16) from the termination board mounted
connector.
4.13 Calibration
The calibration mode allows the user to calibrate, check and zero the static and
differential pressure. Additionally, this mode allows the user to set the bias for the
resistance temperature detector (RTD). During the initial calibration, the
parameters shown in Table 4–1 will need to be configured.
4) Click on the Enter Pressure Check Value, and select Continuous to update
the current reading.
5) Verify that the vent valve is closed (see Figure 4–12).
6) Open both the high and low equalizer valves.
7) Close both the downstream and upstream tap valves.
8) Open the atmospheric vent valve.
9) Enter a pressure marker for atmospheric pressure (PSIA). Enter zero if in
Gauge mode or the barometric pressure (or contract value) if in Absolute
mode. Click the OK button.
10) Close the atmospheric vent valve.
11) Click on the Enter Pressure Check Value.
12) Connect Calibration Standard to the calibration test port.
13) Pressure to the next preferred verification pressure.
14) When the current reading stabilizes, enter the pressure value from the
calibration source. Remember to add the barometric pressure if the
pressure type is Absolute. Click the OK button.
15) Repeat steps 11 through 14 for each pressure check value.
16) When all the static pressure markers have been set, determine if calibration
is required. If no calibration is required, return the manifold to service before
exiting Calibration mode.
7) Move to the 100% Cal Point parameter field. Once there, apply five volts to
the AI terminals.
8) Enter a value that represents the full range and represents the desired
engineering units. Upon completion, click the OK button.
9) If 3 Point calibration was selected, move to the 50% Cal parameter field.
Once there, apply three volts to the AI terminals.
10) Enter a value that represents 50% and represents the preferred engineering
units.
2) Select the RTD tab within the Analog Inputs tab sub-menu under Onboard
I/O in the Calibration window.
3) Select whether to perform a 3 Point, 5 Point or Bias calibration. Note that if
a 3 Point is selected, there will be 3 Target values and 3 Cal Point buttons.
If 5 Point is selected, there will be 5 Target values and 5 Cal Point buttons.
5.1.5 Communication
Troubleshooting the communications for this unit requires that both pieces of
equipment be tested: the G4 EX comm ports and the communication device. This
is discussed in more detail in the Communications Overview section. Other
communication troubleshooting information is shared in the following categories:
RS-232, RS-485, and RS-422 Communications.
10) Perform the following three procedures found next in this chapter.
- RTD Continuity Test
- RTD Resistive Test
- RTD Impedance Test
11) Contact Totalflow to repair or replace the EXIMV.
5.3.1 Overview
This section focuses on determining what was has caused the G4 EX to lose
power. Generally, loss of power can be attributed to only the power supply
system. However, if the power supply system is used for powering a transceiver or
other peripheral equipment, a problem with that equipment may drain the battery
and cause the G4 EX to lose power.
The following procedures represent tests that the user can implement to deduce
the problem that exists with the powering of the unit.
AI/DO2(+)
DO/AI2(+)
AI/DO2(-)
DO/AI2(-)
DI/PI (-)
DI/PI(+)
There are a pair of jumper wires required for
RS-485 only: wire J19, Pin 9 to Pin 7 and
Wire Pin 8 to Pin 6 on the terminating board.
J12 Jumper:
Jumper Pin1 to Pin 2 for AI For all intermediate boards, Jumper J9, Pin 2
Jumper Pin 2 to Pin 3 for DOUT2 J5 to Pin 3
J3
+ AI - + DI - + DO -
J9 Terminates RS-485
on COMM1
J12 J6 J13 COMM1
1 3 1 3
J19 (RS-232/RS-485)
J8 COMM1
(WHT) RTD OUT 5 I/O EXPANSION 9 CTS/RBUS(-)
(WHT) RTD + 4 6 9 8 RXD/RBUS(+)
(BLK) RTD - 3 TXD/TBUS(-)
RTD PROBE 1 5
7
(BLK) RTD IN 2 6 RTS/TBUS(+)
S2
(DRAIN) SHIELD 1
J2 5 J9 RRTS COMM1
ETHERNET 1
4 OPERATE COMM1
RTD
3 COMM2 SW
3
SECURITY J7 2 GND
S3
1 VBATT
J16
1
PWR
MMI
J20 Note:
COMM2 Pinouts are shown to the outside for clarity,
but all of the Phoenix connectors are wired
XFCG46200EX and attached to the inside.
POWER/TERM
BOARD 1 2 3 4 5 6 7 8 9
1 3
2103344-XXX J11
CTS/RBUS(-) Jumpers for RS-485 Mode Only
RXD/RBUS(+)
TXD/TBUS(-)
RTS/TBUS(+)
RRTS COMM2
J11 Terminates RS-485
OPERATE COMM2
on COMM2
COMM2 SW
GND
VBATT
COMM2
(RS-232/RS-485)
Panel Max Volts @ PMax Open Circuit Load Resistance Loaded Voltage
5 4.5W 16.5V 20.5V 50 Ω 25W 13.5V
10 10W 16.8V 21V 30 Ω 25W 17.5V
20 20W 16.8V 21V 15 Ω 25W 17.8V
30 30W 16.8V 21V 10 Ω 40W 17.8V
TO CHARGER REGULATOR
RED DMM CONNECTOR
TO BATTERY CABLE
5.4.1 Overview
These troubleshooting procedures are applicable to the G4 EX with an installed
radio in the optional 6270 OEU Enclosure unit. Use Figure 5–7 as an aid in
troubleshooting communication problems. The three basic types of radio
communication that can be used between the G4 EX and a radio receiver are:
- RS-232 Communications port programmable
- RS-485 Communications port programmable
- RS-422 Communications port programmable
The radio/modem may be powered one of two ways: always on or switched. The
user’s specific system set up will determine what steps are needed to power the
radio/modem.
When switching power to a radio with Inhibit (Sleep) mode, the communication 1
port or switched power line will move to the radio’s Inhibit(Sleep) mode input.
Power out will move to the radios.
Verify unit
ID#, Security
Code and
Protocol are
Correct.
Verify jumper
and terminal &
pin wiring are
correct.
NO
Does Unit Transceiver
YES NO Transceiver
Respond to Host Supply voltage Investigate
END Supply voltage
Comm Request? Test Transceiver
within Specs?
Issues
YES
Investigate NO
Voltage supply
Power Supply
from unit
Issues
> 11.9 VDC?
Figure 5-4
YES
Substitute
YES
Unit Respond to Communication
Host Comm Test Cable
Request?
NO
Contact
Is NO Is NO
Totalflow
Communication Communication Technical
RS-232? RS-485? Support
YES YES
RS-232 RS-485
Communication Communication
Test Test
Does Unit
Respond?
YES
NO
Transceiver
NO
Comm Check
Test Passed?
YES
The following helpful hints will aid the user after the
communication equipment has been installed and set up:
6.2.3 Installation
If the unit is currently operating, data must be collected from the unit and the
configuration files saved prior to beginning this procedure.
J21 PCCU
Connector
I/O Daughter
Card
J2 1
DI1(+)
DI1(-)
DI2(+)
DI2(-)
1 DI3(+)
AI1(+) I/O Daughter Card DI3(-)
AI1(-)
DI4(+)
AI2(+)
DI4(-)
AI2(-)
AI3(+) 8
DO1(+)
DO2(+)
DO3(+)
DO4(+)
DO1(-)
DO2(-)
DO3(-)
DO4(-)
AI3(-)
AOut(+)
AOut(-) 1 8
8 J3
J1
6.2.9 Implementation
J3 J6 J5
The DI/PI inputs will accept sensor inputs
which meet the IEC-60947-5-6 electrical
SECURITY characteristics.
+ AI - + DI - + DO - ON
J8
J19
RTD IN I/O EXPANSION
J2 1 COMM1
RTD - 8
6 9 DI1(+)
RTD +
DI1(-)
RTD OUT 1 5 6
DI2(+)
SHIELD 5
J2 DI2(-) To Third Party
RTD 4
1 DI3(+) Digital Input Devices
AI1(+) 3
I/O Daughter Card DI3(-)
4 3 2 1
OFF 2
AI1(-) P/N: 2102458 DI4(+) 1
ON
AI2(+)
To Third Party AI2(-)
DI4(-) SW1
2
Analog Devices J21 AI3(+) 8J16 -
DO1(+)
DO2(+)
DO3(+)
DO4(+)
DO1(-)
DO2(-)
DO3(-)
DO4(-)
1
SEE SHEET 2 MMI
PWR +
AI3(-)
ON OFF
AOut(+) 4
1
AOut(-) 1 3 SW2 8
2
8 J3 1
J1
J20 COMM2
1 2 3 4 5 6 7 8
Totalflow flow meters employ a 250 OHM resistor to convert the 4-20 mA
transmitter current loop to a 1-5 VDC signal. In some meters, this conversion is
made by attaching a 250 OHM resistor across the 4-20 mA input pins (see the
next figure – schematic A). Some meters use a small three-pin jumper to select an
onboard 250 OHM resistor (see the next figure – schematic B). Still, other meters
employ an electronic switch to select the 250 OHM resistor (see the next figure –
schematic C). In the figures , VCC represents the voltage source used to power
the transmitter. In many instances, VCC could be tied to the meter’s VBAT.
With a solar paneled system, such as many Totalflow installations, available
voltage to power the 4-20 transmitter can become an issue. Batteries in a battery
backed solar installation can drop to 12 VDC or less. Some transmitters may not
be able to drive 20 mA into a 250 OHM load with only 12 VDC applied to them.
Fully charged batteries, connected to an operational battery charger, may be
sitting at about 13.5-14 VDC.
External to
Flowmeter
flowmeter VCC
AI + 2-wire (line powered)
To A/D Converter
4-20ma transmitter
1 3
Onboard 250Ω
resistor selected
using three-pin
jumper
250Ω B
AI -
Again, the 4-20 mA transmitter that was selected by the user must be fully
operational at voltages as low as VCC – 5 VDC. Again, VCC is the source voltage
available at the user’s site, and 5 VDC represents the voltage dropped across the
meter’s 250 OHM resistor at the maximum loop current (20 mA).
Totalflow can provide a 12 to 24 VDC converter. This converter can be powered
from the meter’s VBAT (either comm ports or J16). The converter’s 24 VDC output
can then be used to power the 4-20 mA transmitter loop. In other words, VCC
would now be 24 VDC. Subtracting the 5-volts dropped across the 250 OHM
resister would leave 19 VDC to power the transmitter.
6.3.2 Example 1
If the 4-20 mA transmitter can drive full range (20 mA through the 250 OHM
resistor), the user has essentially converted a 4-20 mA current range into a 1-5
VDC voltage range. The analog to digital (A/D) converter used in Totalflow
equipment expects a 1-5 VDC signal. During field calibration, the user might have
the 4 mA of loop current represent 10bbls of fluid per hour and 20 mA represent
100bbls. The conversion to voltage (using the 250 OHM resistor) would be as
follows:
1 VDC = 10bbls/hour
5 VDC = 100bbls/hour
Assuming that the A/D converter is ranged between 0 and 5 VDC and the
converter is resolving 15 bits, the user would expect to resolve about 150μ VDC
(or .0006 mA). These numbers translate to about .003 bbl (3 thousandths of a
barrel or about one half fluid ounce).
6.3.3 Example 2
If the 4-20 mA transmitter cannot drive full range (20 mA through the 250 OHM
resistor), the user may want to reduce the value of the resistor. For this example,
the following will drop it to 125 OHM (or half). A 4-20 mA current would now be
converted to a 5-2.5 VDC voltage range. Again, during field calibration, the user
would have the 4 mA current represent 10bbls per hour and the 20 mA signal
represent 100bbls per hour. The voltage conversion (using the 125 OHM resistor)
would be as follows:
.5 VDC = 10bbls/hour
2.5 VDC = 1000bbls/hour
The A/Ds full range is still 0-5 VDC; however, the user is only using about half of
its range capability. Just like the resistor value, the ability to resolve barrels of fluid
per hour has been cut in half. The overall accuracy remains unchanged, but the
user can only resolve about 0.006bbls (6 thousandths of a barrel or about one
fluid ounce).
6.3.4 Conclusion
If the 4-20 mA transmitter that is being used cannot drive a full 20 mA through the
250 OHM resistor, the user can reduce the resistive value. However, as the
resistive value is reduced, resolution (not overall accuracy) will be reduced
proportionally. If the user drops the resistive value by half (250 OHMs to 125
OHMs), the resolution will be reduced by half.
To reduce the resistive value of an onboard resistor, the user can add an external
resistor across the analog input pins. This places the two resistors in parallel with
one another. The parallel combination produces an equivalent resistance that is
External to
Flowmeter
flowmeter VCC
Onboard 250 ohm
resistor selected using 2-wire (line powered)
4-20ma transmitter
three-pin shunt +
1 3
External resistor added
R2 across onboard resistor
R1 250 Ohm
250 Ohm
–
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