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CM2-CVM100-2001
GasCVD® Natural Gas CalorimeterModel CVM400User’s Manual
NOTICEWhile the information in this manual is presented in good faith and believed to be accurate, Azbil Corporation disclaims any implied warranty of merchantability or fitness for a particular purpose and makes no express warranty except as may be stated in its written agreement with and for its customer. In no event shall Azbil Corporation be liable to anyone for any indirect, special or consequential damages. This information and specifications in this document are subject to change without notice.
© 2012 Azbil Corporation All Rights Reserved.
Safety Precautions for Use
For safe use of the product, the following symbols are used in this manual.
WARNING Warnings are indicated when mishandling the product might result in the death or serious injury of the user.
CAUTION Cautions are indicated when mishandling the product might result in minor injury to the user or damage to property.
In describing the product, this manual uses the icons and conventions listed below. ■
Use caution when handling the product.
The indicated action is prohibited.
Be sure to follow the indicated instructions.
Handling Precautions:Handling Precautions indicate items that the user should pay attention to when handling the GasCVD.
To use this product correctly and safely, always observe the following precautions. We are not responsible for damage or injury caused by the use of the product in violation of these precautions.
Handling Precautions for This Product Installation Precautions
WARNINGWhen installing, use proper fittings and proper tightening torque for connections to the process and to the exhaust. Gas leakage is dangerous because process gas and calibration gas are flammable. Please refer to the leak check instructions in this manual and verify that there is no gas leakage.Do not use the product except at the rated pressure, specified connection standards, and rated temperature. Use under other circumstances might cause damage that leads to a serious accident.For wiring work in an explosion-proof area, follow the work method stated in the explosion-proof policy.
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CAUTIONAfter installation, do not step or stand on this unit. Doing so may damage the device or cause injury.Bumping the glass of the display with a tool may cause damage or injury. Be careful.
Install the device correctly. Incorrect or incomplete installation will cause output errors and violation of regulations.This product is quite heavy. Protect your feet with safety shoes when working.
Do not subject the product to shock or impact.
Wiring Precautions
WARNINGDo not do wiring work with wet hands or while electricity is being supplied to the product. There is a danger of electric shock. When working, keep hands dry or wear gloves, and turn off the power.
CAUTIONWhen wiring, check the specifications carefully and make sure to wire correctly. Incorrect wiring can cause device damage or malfunction.Supply electric power correctly according to the specifications. Supplying power that differs from the specifications can damage the device.Use a DC power supply that has overload protection.
Maintenance Precautions
WARNINGWhen removing this device for maintenance, be careful of residual pressure or resid-ual process gas. Leakage of process gas is dangerous.
When working on the vent, check its direction so that people do not come into con-tact with vented gas. There is a danger of burns or other physical harm.
When the device is being used in an explosion-proof area, do not open the cover. Opening the cover may cause an explosion.
CAUTIONThis product was kept under carefully controlled conditions until it was shipped. Never try to modify this device. Doing so could damage it.
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Precautions for Using Communication DevicesWhen using a communication device such as a transceiver, cell phone, PHS phone, or pager near this
device, observe the precautions below. Otherwise, depending on the transmission frequency, this device
may not function properly.
Determine beforehand the minimum distance at which the communication device will not affect the
operation of this device, and maintain a separation greater than that distance.
Make sure the cover of its transmitter section of this device is closed before using the communication
device.
Precautions for CommunicationIf transmitter output is reduced to 3.2 mA or less because of burnout, etc., communication with a HART
communicator may not be possible. Try turning off the power, rebooting, and restarting communication.
Hazardous Area CertificationsGasCVD complies with the types of protection that are based on the standards listed below.
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ATEX Flameproof and Dust Certifications 1. Marking information
0344 DEKRA 11ATEX0036 X
II 2G Ex d IIB T6 Gb;
II 2D Ex tb IIIC T80 °C Db; -20 °C ≤ Tamb ≤ +50 °C; IP66
2. Applicable standards- EN 60079-0: 2009- EN 60079-1: 2007- EN 60079-31: 2009
3. Special conditions for safe use3-1. To maintain a degree of protection of at least IP 66, in accordance with IEC 60529, suitable Ex
d certified cable entries must be used and correctly installed. Unused openings must be closed
with suitable Ex d certified stopping plugs.
3-2. For model numbers in the form “CVMxxx–xyxxxx -...”:
If y=1, all entries have 1/2 NPT thread.
3-3. For connection of an external grounding or bonding conductor a cable lug should be used. The
conductor should be mounted so that it will not loosen or twist.
3-4. The maximum process pressure is 110 kPa (abs.).
3-5. The process temperature range is from -20 °C to +50 °C.
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IECEx Flameproof and Dust Certifications 1. Marking information
IECEx DEK 11.0016X
Ex d IIB T6 Gb;
Ex tb IIIC T80 °C Db; -20 °C ≤ Tamb ≤ +50 °C; IP66
2. Applicable standards- IEC 60079-0: 2007
- IEC 60079-1: 2007
- IEC 60079-31: 2008
3. Special conditions for safe use3-1. To maintain a degree of protection of at least IP 66, in accordance with IEC 60529, suitable Ex
d certified cable entries must be used and correctly installed. Unused openings must be closed
with suitable Ex d certified stopping plugs.
3-2. For model numbers in the form “CVMxxx–xyxxxx -...”:
If y=1, all entries have 1/2 NPT thread.
3-3. For connection of an external grounding or bonding conductor a cable lug should be used. The
conductor should be mounted so that it does not loosen or twist.
3-4. The maximum process pressure is 110 kPa (abs.).
3-5. The process gas temperature range is from –20 °C to +50 °C.
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Metrology Approval (OIML R140 Compliant) Requirements
• Process alarm setting: Upper alarm value 100 %, Lower alarm value 0 %, Hysteresis 0 %.
See 4.5.4, Process alarm.
• Operating temperature: -10 °C to +40 °C
• Measured gas component limit: CO2 < 2 mol %, N2 < 7 mol %, C4+ < 1.2 mol %
• The latest SCV value is saved when the power is down. See 4-9-4: Log.
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Table of Contents
Chapter 1: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1: Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2: Definition of terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-3: GasCVD measuring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-4: GasCVD structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Chapter 2: Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-1: GasCVD standard accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-2: Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-3: Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-4: Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Chapter 3: Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133-1: Before using GasCVD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133-2: Starting GasCVD operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143-3: Stopping GasCVD operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143-4: Modes and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Chapter 4: Operation Using HART Communicator . . . . . . . . . . . . . . . . . . . 174-1: Starting communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4-1-1: Connecting Communicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174-1-2: Establishing communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174-1-3: Checking basic data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-2: Top menu (menu tree) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184-3: Process variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204-4: Basic setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204-5: Detailed setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4-5-1: Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204-5-2: Signal condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204-5-3: Output condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214-5-4: Process alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234-5-5: Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4-5-5-1: Analog output trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234-5-5-2: SCV trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254-5-5-3: Manual calibration / auto calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4-6: Device information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294-7: Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304-8: Review (read only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304-9: Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4-9-1: Diag status (read only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314-9-2: Operating time (read only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314-9-3: Device alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314-9-4: Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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Chapter 5: Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335-1: Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335-2: Replacement parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Chapter 6: Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Appendix: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37A-1: Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37A-2: Natural gas superior calorific value calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
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Chapter 1: IntroductionThank you for purchasing the GasCVD (“gas calorific value determining device”) Natural Gas Calorimeter. GasCVD measures gas properties using Azbil Corporation’s own thermal flow sensor and calculates the SCV (superior calorific value) using a unique correlation method based on support vector regression (SVR) analysis. GasCVD transmits the SCV as 4-20 mA analog output and communicates with HART Communicator. To ensure both safety and efficiency, please read this manual carefully before you operate the instrument.
1-1: Precautions Unpacking
GasCVD is a precision instrument. When unpacking, handle it with care to prevent accident or damage. Don’t touch electronic parts. Check that the following items are included:
1. GasCVD main unit 2. Hex wrenches (small and large, 1 each) 3. Hexagon head bolts for mounting (M8, length 10 mm, 2 bolts) 4. Manual (CD-ROM)
Verifying the specifications
The specifications for this device are written on the nameplate.
Compare these specifications to those in the appendix or the specification sheets, and verify that the CVM400 GasCVD matches your order. In particular, be sure to check the following items.
1. SCV calculation parameter 2. Explosion-proof structure 3. Approvals 4. Pipe and cable entry connection
InquiriesIf you have any questions regarding the specifications, contact your local Azbil Corporation representative. When making an inquiry, be sure to provide the Model and the Product No.
Storage precautions
When storing this instrument before use, observe the following instructions:
1. Store indoors at room temperature and humidity, in a place safe from vibration and shock. 2. Store the device packed in the same way that it was shipped.
When storing this instrument after usage, observe the following instructions:
1. Flush the inside of the flow path with dry methane gas to remove any residual fluids and then put the seal plugs on the inlet and outlet of GasCVD.
2. Tighten the display cover and terminal box cover in order to prevent ingress of moisture.
3. Return the instrument to its original packing.
4. Store the device indoors at room temperature and humidity in a place safe from vibration and shock.
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Installation environment
Install in a sheltered place. Prevention of direct exposure to sunshine, rain, snow, and wind is required.
Application/measured gas specifications
GasCVD can be used for natural gas only. Gas specifications are as follows: Component limits: CO2 < 2 mol %, N2 < 7 mol %, C4
+ < 2 mol % Gas temperature: -10 to +50°C Max. gas pressure: 110 kPa (abs.)
For OIML metrology approval, please refer to Metrology Approval on page ii of the Safety section.
1-2: Definition of terms
GasCVD A natural gas “calorific value determining device” CVM400 GasCVD model No. OIML R140 The International Organization of Legal Metrology’s measuring
systems for gaseous fuel SCV Superior calorific value NG Natural gas Pure methane Methane gas 4.5 (99.995% or more) SVR Support vector regression CF Abbreviation of Calibration factorSensor Micro Flow sensor, designed and built by Azbil CorporationSensor temp Temperature measured by temperature sensor on the sensor chips HART® HART communication protocolHART Communicator HART 475 communicator,CommStaff (azbil)SP Set point: The set value of each variablePV Process variable: The present value of each variableURV Upper range valueLRV Lower range valueAO Analog outputDO Digital output
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1-3: GasCVD measuring system4-20 mAOUTPUT
DC 24 VPower supply
OUT
POWER
STATUS
CALIB
Relay
DC 24 VPower supply
Gas OutletOpen to the air
DC 24 VPower supply
PRESSUREREDUCINGVALVE
SOLENOIDVALVE
PRESSURESWITCH
SAMPLECONDITIONINGUNIT
FLOW METER50 ± 10 ml / minVALVE
SAMPLINGPROBE
CALIBRATIONGAS CYLINDER(PURE CH4)
PIPE LINE
FILTER
1-4: GasCVD structure
Adapter
Outlet
ManifoldSensor
Inlet
Conduit
Front cover
Terminalcover
Terminalblock
LCD display
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Chapter 2: InstallationThis section provides information about installing GasCVD. It includes procedures for mounting, piping and wiring GasCVD. GasCVD is normally placed after a sample-conditioning unit or inside of the sample-conditioning box.
WARNINGWhen installing, use proper fittings and proper tightening torque for connections to the process and to the exhaust. Gas leakage is danger-ous because process gas and calibration gas are flammable. Please refer to the leak check instructions in this manual and verify that there is no gas leakage.Do not use the product except at the rated pressure, specified connec-tion standards, and rated temperature. Use under other circumstances might cause damage that leads to a serious accident.For wiring work in an explosion-proof area, follow the work method stated in the explosion-proof policy.
CAUTIONAfter installation, do not step or stand on this unit. Doing so may dam-age the device or cause injury.Bumping the glass of the display with a tool may cause damage or injury. Be careful.Install the device correctly. Incorrect or incomplete installation will cause output errors and violation of regulations.This product is quite heavy. Protect your feet with safety shoes when working.Do not subject the product to shock or impact.
2-1: GasCVD standard accessoriesGasCVD comes with the following standard accessories.
• Hex wrenches (small and large, 1 each)• Hexagon head bolts (M8, length 10 mm, 2 bolts)
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2-2: MountingThe figure below shows a sample mounting method for GasCVD. GasCVD comes with hexagon head bolts. The mounting bracket is user-supplied.
Dimensions for installing GasCVD are shown below. There are mounting screw holes on the bottom.
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Install GasCVD at not more than a 10 degree angle from the horizontal.
2-3: Piping
WARNINGBoth the process gas and calibration gas (pure methane) are flam-mable, and if mixed with air and ignited, they may explode. For safety, do the following before beginning to work.•Useagasdetectortomakesurethatnoflammablegascanbe
detected in the work area, instruments, or surrounding air. We rec-ommend the continued use of the gas detector during work.
•Sincealeakageofgasmightoccurduringwork,removeanyflam-mable objects from the workplace.
•Topreventgasabsorptionbythehumanbody,keeptheworkplaceventilated.
Also, after piping work is complete, refer to “Piping leak check” on page 8 and make sure that there is no leakage from connected parts, etc., before starting a test-run or regular operation.
Inside the adapters in both sides of manifold, there's gas inlet and outlet of GasCVD. Make sure the gas flow direction is the same as the arrow on the surface of the manifold. Make sure that the adapters do not loosen when attaching the pipes.
There are two types of screws for piping, 1/8 NPT female or Rc1/8, depending on the GasCVD model.
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Material
For piping the GasCVD and sample conditioning unit, use stainless steel 316 tube or equivalent that is specialized for gas analysis use or is finished with an inert internal surface treatment so that it does not degas impurities. Avoid using plastic, elastomer, copper, brass or steel tube. Use stainless steel 316 tube fittings.
Sample conditioning unit
The following illustration shows a minimal system for a sample-conditioning unit. In some cases, additional filters, oil mist separator, drier, and so forth might be required, depending on the properties of the gas. Evaluate which components are needed within the sample-conditioning unit from the gas properties, and avoid increasing the inner volume by adding useless components, since that will interfere with speedy gas replacement.
SAMPLECONDITIONINGUNIT
FLOW METERFlow rate50 ± 10 ml/min
SOLENOID VALVENC
NO
PRESSUREREDUCINGVALVE
Gas OutletOpen to the air
DC 24 VPower supply
CALIB
Set pressure ≤ 110 kPa (abs.)
SAMPLEINGPROBE
CALIBRATIONGAS CYLINDER(PURE CH4)
PIPE LINE
VALVE FILTER
PRESSURESWITCH
Note: CALIB contact output for automated calibration is fixed at NO, so connect NG (Process Gas) for NO side of three-way solenoid valve, and Calibration Gas Cylinder for NC side.
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Pressure and flow rate
Supply the process gas and pure methane gas for calibration to the inlet of GasCVD under the following conditions.• Pressure: ≤ 110 kPa (abs.)• Flow rate: 50 ml/min ± 10 ml/min
Vent line
CAUTIONThe outlet of GasCVD should be connected to a ventilation tube with an inner diameter large enough to not be affected by backpressure. It should open to the air in a place not affected by wind, rain or snow. Natural gas and methane are discharged directly from the vent, so the vent should be located where human beings will not be harmed. When cleaning the inside of the tube by blowing back clean inert gas, to pro-tect the device, do not blow gas into GasCVD.
The outlet of GasCVD should be connected to a ventilation tube with an inner diameter large enough to not be affected by backpressure. It should open to the air in a place not affected by wind, rain or snow. Natural gas and methane are discharged directly from the vent, so the vent should be located where human beings will not be harmed. When cleaning the inside of the tube by blowing back clean inert gas, to protect the device, do not blow gas into GasCVD.
Piping leak check
Conduct a leak test using pure methane (99.995 % CH4). The leak test may be either the soap bubble method or the falling pressure method. If the falling pressure method is used, make sure there are no effects from the wind and no change of temperature. These factors can make it seem that there is some leakage even when none actually exists. If some leakage is observed, tighten the tube fittings and then check again.
The detailed procedure for the leak test is as follows.
Step Action (Soap Bubble Method) Action (Falling Pressure Method)1 Plug the outlet of GasCVD2 Supply pure methane at 300 kPa3 Put liquid soap on the piping connections Stop supplying pure methane and check the
pressure4 Check if there are soap bubbles Wait 10 minutes5 Wipe off the liquid soap with a clean dry
clothCheck the pressure to see whether there is leakage
If soap bubble method is used, wipe the soap off completely after the test. Otherwise it might contaminate the gas or cause corrosion.
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2-4: Wiring When wiring GasCVD, use conduits that are rated as flameproof to attach to the conduit connecting ports. Put cables through the conduits and then connect to GasCVD’s internal terminal block. There are 2 possible types of thread on the conduit connecting ports, either 1/2 NPT female or G1/2 female, depending on the model of GasCVD. The model with M20 connecting ports requires adapters between the ports and the flameproof conduits.
WARNINGDo not do wiring work with wet hands or while electricity is being sup-plied to the product. There is a danger of electric shock. When work-ing, keep hands dry or wear gloves, and turn off the power.
CAUTIONWhen wiring, check the specifications carefully and make sure to wire correctly. Incorrect wiring can cause device damage or malfunction.Supply electric power correctly according to the specifications. Supplying power that differs from the specifications can damage the device.Use a DC power supply that has overload protection.
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The following figures show the wiring connections from GasCVD’s terminal block and detailed examples of wiring at the terminal block.
DC 24 VPower supply
DC 24 VPower supply
DC 24 VPower supply
4-20 mAOUTPUT OUTPUT
POWER
OUT
CALIB
STATUS
Surge killer
Relay
Surge killer
Solenoid valve
CALIB -CALIB +
STATUS -
4 - wire cable with shield
UPPER CONDUIT from LOWER LEVEL of TERMINAL BLOCK
LOWER CONDUIT from UPPER LEVEL of TERMINAL BLOCK
4 - wire cable with shield
STATUS +SHIELD (not using)
24 V -24 V +
OUTPUT -OUTPUT +
Ground wire (independent wire)
SHIELD (not using)
Check the relationship between the external load resistance and the supply voltage. The supply voltage is 24 Vdc ± 10 % and the external resistance is 250–540 Ω. External resistance is the total resistance connected to the output terminals of GasCVD, including the resistance of all cables in the loop plus the internal resistance of the instruments.
External power is required when using the process alarm function or calibration function. Use 26.4 Vdc max., 50 mA max. for STATUS contacts, and 26.4 Vdc max. 1 A max. for CALIB contacts. (For the minimum allowable voltage, please refer to the specifications for the relay or solenoid valve used.)
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The installation of a surge protector suitable for the relay or solenoid valve is required.
If a shielded cable is used, do not connect the shield wire. Instead, ground GasCVD using its ground terminal attached to an independent wire. The ground resistance must be 100 Ω or lower.
The connection of a grounding or equipotential bonding conductor with the external grounding terminal must use the method illustrated below.
CABLE LUG PLAIN WASHER
PLAIN WASHER
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Chapter 3: OperationThis section provides procedures about starting and stopping the operation of GasCVD. This section also provides information about modes and display indication
3-1: Before using GasCVD
WARNING•NeveropenthecasecoverwhileGasCVDisONorinahazardous
location.
•HandleGasCVDwithcare.Itmayloseitsexplosion-proofperfor-mance due to corrosion, deformation, damage to the case cover, or damage to a screw or a joined part.
•Explosion-proofperformanceisnotguaranteedunlessthecaseisLOCKED.Alwaystightenthecasecovercompletelyandlockit.
Opening and tightening the case coverGasCVD has a locking structure. Before opening the case cover, unlock the mechanism using a hex wrench (included).When closing, insert the case cover fully and lock it, using a hex wrench.
Handling Precautions:When a case cover is open, take care dust or moisture does not enter inside it.After mounting case cover, confirm dust or moisture does not enter inside it during use.
Case cover(with display)
Case cover(without display)Lock
Lock
Manifold Adapter Lock
Case
Precautions for Using Communication DevicesWhen using a communication device such as a transceiver, cell phone, PHS phone, or pager near this device, observe the precautions below. Otherwise, depending on the transmission frequency, this device may not function properly.Determine beforehand the minimum distance at which the communication device will not affect the operation of this device, and maintain a separation greater than that distance. Make sure the cover of its transmitter section of this device is closed before using the communication device.
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3-2: Starting GasCVD operationTo start GasCVD operation, follow the steps below.
1 Supply the process gas
2 Set the secondary pressure and flow rate. Flow rate must be 50 ml/min ± 10 ml/min
3 Supply power to GasCVD
For the first 10 seconds after power is turned on, the two software versions of the device are displayed on the indicator. One is the metrology software version and the other is the device software version. During this period the output is determined by the fail safe direction. After 10 seconds GasCVD begins measurement and transmits output automatically.
3-3: Stopping GasCVD operationTo stop GasCVD operation, follow the steps listed below.
1 Turn off the power to GasCVD
2 Shut off the process gas line
Follow the step below when storing GasCVD.
1 Make sure no process gas remains in GasCVD.
2 Purge GasCVD’s gas flow path with pure methane gas.
3 Insert metal plugs into the inlet and outlet in order to keep moisture out.
4 Pack GasCVD as it was packed when it was originally received.
5 Store GasCVD indoors in a safe place at room temperature and humidity.
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3-4: Modes and Indicators
No. Displayed item Description1 5-digit display SCV or status number
2 5-position decimal point display Decimal point
3 (Nothing), X10, X100, X1000 Multiplicand
4 Percentage %
5 16-segment (7-digit) display Units, status, mode
6 Bar Graph Output percentage
7 and When auto calibration is scheduled, and will be lit by turns (blink by turns). When not scheduled, neither will be lit.
8 Flag Calibration failure
9 Key Write protected
10 # and $
This will be lit only when operating SCV Trim with external switch.When setting by HART communicator, it will not be lit.
Bar Graph Display
The indicated values are displayed in terms of percentage on a 22-segment graph. For descriptive purposes we will refer to the 22 segments as S0–S21, going from left to right.
The indicated value in percentage terms (DISP) corresponds to the lighting or blinking of the segments as shown below.
15
Operation mode
Normal Operation
SCV exceeds 105 % (45.5 MJ/m3) SCV is lower than –5 % (34.5 MJ/m3) Non-critical status Non-critical status
Calibration mode
Calibration in process Calibration factor (CF) error
Loop test mode
FAILSAFE / STATUS / CALIB simulation mode
FAIL SAFE simulation mode STATUS simulation mode
CALIB simulation mode
Error mode
Example of Critical error Non-critical status
16
Chapter 4: Operation Using HART CommunicatorThis section explains how to configure GasCVD using HART® Communicator. For details on the Communicator, please refer to the user’s manual for HART® Communicator 375/475.
4-1: Starting communications4-1-1: Connecting Communicator
The Communicator can be connected directly to the signal terminals on GasCVD’s terminal block, or at any location in the 4–20 mA loop. The polarity of the connection does not matter.
ReceivingInstrument
Power Supply
250 Ω
HART® Communicator
4-1-2: Establishing communicationThis procedure starts communication between GasCVD and the Communicator.
Step Action and/or Description
1Turn on the Communicator.The Communicator runs a self-test check and then determines if it is connected to GasCVD.
2
If you receive a communication error message (No Device Found), check thefollowing.• Loop resistance: Is the Communicator connected with a minimum of 250 Ω
resistance?• Power supply: Is power being applied? Is there greater than 21.6 V at the GasCVD
terminal?Correct any problems, and try communication again.
3When the “Online” display appears, communication is established. The flashing heart icon in the upper middle indicates that the devices are communicating.
17
4-1-3: Checking basic dataThis procedure starts communication between GasCVD and the Communicator.
Step Action and/or Description
1From the “Online” menu, enter “Device” by pressing the right arrow key (") on the Communicator keypad.
2 Press the down arrow ($) key to scroll down to menu-item.
1. Device information• Manufacturer• Model• Device_ID• GasCVD serial number• Device Tag• Long Tag• Date • Descriptor• Message• Serial number• Final assembly number• Distributor• Config change counter• Revision number (HART version, Device revision, Software revision, Hardware revision)• Write protect• Production No.• Software version (OIML S/W ver., Operation S/W ver.)
2. Configuration parameter• Fail safe direction (default is downscale)• SCV trim (default is 0 MJ/m3)• Hold time (default is 20 minutes)• First calib. time (default is 24 hours)• Interval (default is 7 days)• CF1-CF5 (default is 1.00000)• Config proc. alarm / Lower alarm value (default is 35MJ/m3 (0%))• Config proc. alarm / Upper alarm value (default is 45MJ/m3 (100%)• Config proc. alarm / Hysteresis (default is 5 %)• Config temp. alarm / Lower alarm value (default is 50 °C)• Config temp. alarm / Upper alarm value (default is 70 °C)• STATUS selection (default is Process alarm)• STATUS type (default is Normally Open)
4-2: Top menu (menu tree)The top menu consists of 3 items:
1. Process variables2. Device3. Diagnostics
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Menu tree1st 2nd 3rd 4th 5th 6th
Device setup1 Process variables Process variables
1 PV (SCV)2 PV (%)3 PV (AO)4 Sensor temp.
2 Device Device1 Basic setup Basic setup
1 Device Tag2 Unit3 t1/t24 LRV5 URV
2 Detailed setup Detailed setup1 Sensors Sensors
1 Micro oven temp. SP2 Sensor temp.3 Rh4 Rud
2 Signal condition Sig1 Unit2 LRV3 URV4 PV � %)5 Damping
3 Output condition Output condition1 Analog output An
1 PV � AO)2 Loop test3 Fail safe direction4 Fail safe simulation5 Output low limit6 Output high limit7 Diag status
2 Digital output Digital output1 STATUS output2 STATUS type3 STATUS selection4 STATUS simulation5 CALIB output6 CALIB type7 CALIB simulation8 Diag status
3 HART output HART output1 Polling address2 Loop current mode3 Num req preams4 Num res preams
4 Process alarm Process alarm1 Proc. alarm status2 Config proc. alarm Co
1 Lower alarm value2 Upper alarm value3 Hysteresis (0% to 5%)4 Diag status
5 Calibration Calibration1 Analog output trim Trim analog output
1 D/A trim2 Scaled D/A trim
2 SCV trim SCV trim1 SCV trim SCV trim
1 SCV raw2 SCV trim
(-2.00 to 2.00)3 PV (SCV)4 Diag status
2 SCV trim value reset3 Manual calibration Manual calibration
1 CALIB simulation2 Hold time3 Manual calib. Start4 CF view5 CF reset6 Diag status
4 Auto calibration Auto calibration3 Device information Device information 1 Auto calib Start/Stop
1 Manufacturer 2 Hold time2 Model 3 First calib time3 Device_ID 4 Interval4 GasCVD serial number 5 Next calib time5 Device Tag 6
Auto calibStart/Stopoperation6 Long Tag
7 Date 7 CF view8 Descriptor 8 CF reset9 Message 9 Diag status10 Serial number11 Final assembly number12 Distributor13 Config change counter15 Revision number Revision number
1 HART version2 Device revision3 Software revision4 Hardware revision
16 Write protect17 Production No.18 Software version Software version
1 OIML S/W ver.2 Operation S/W ver.
4 Miscellaneous Miscellaneous1 Maximum device variables2 Extended field device status3 Device profile
5 Review3 Diagnostics Diagnostics
1 Device status Device status1 Diag status2 Operating time3 Device alarm Device alarm
1 Temp. alarm status2 Config temp. alarm Co
1 Lower alarm value2 Upper alarm value3 Diag status
3 Calib status4 Log Log
1 Calib log view2 Calib log clear3 Error log view4 Error log clear5 Config log view6 Config log clear7 Latest SCV at PD Lat
1 Total operating time at PD
2 SCV at PD2 Diag setup
(Not available)
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4-3: Process variablesThis is for checking the operation output.
Process variablesPV (SCV) (read): CV value of outputPV (%) (read): % full scale of output
PV (AO) (read): Current output in mA
Sensor temp (read): Temperature of the sensor chip
4-4: Basic setupThis is for checking the basic setup.Device " Basic setup
Device Tag (read/write): Maximum 8 characters (alphabetic and numeric)
Unit (read): MJ/m3
t1/t2 (read): 15 °C/15 °C
LRV (read): 35
URV (read): 45
4-5: Detailed setup4-5-1: Sensors
This section shows how to read the Micro oven temp SP and Sensor temp.Device " Detailed setup " Sensors
Micro oven temp SP(read):
The sensor t ip temperature set t ing, which is f ixed at 60 °C.
Sensor temp (°C) (read):The operating sensor temperature. GasCVD maintains accuracy in an ambient temperature range of –10 to +50 °C by temperature compensation.
Rh (read): Sensor resistance Rh at 60 °C (for manufacturer use).
Rud (read): Sensor resistance Rud at 60 °C (for manufacturer use).
4-5-2: Signal conditionThis section shows how to read the signal condition.Device " Detailed setup " Signal condition
Units (read): MJ/m3
LRV (read): 35
URV (read): 45
PV (%) (read): % full scale of output
Damping (read/write): Not supported at present.
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4-5-3: Output condition Analog output
This section shows how to configure the analog output.Device " Detailed setup " Output condition " Analog outputAnalog output level is shown in the diagram below.
Normal operating condition
Analog output
Analog Output Level
20 mA100%
4 mA0%3.2 mA
Output high limit(–5%)
2.4 mAFailsafe (burnout)
downscale (–10%)
21.6 mAFailsafe (burnout)
upscale (110%)
20.8 mAOutput high limit
(105%)
PV (AO) (read): Analog output current value (mA)
Loop test (read/write):
GasCVD can be set to a constant-current source mode, andautomatically returns to the calorie measuring condition.g Regular operating condition as CVM • 4mA: Sets the output signal level to 4 mA (0%) • 20mA: Sets the output signal level to 20 mA (100%) • 4g8g12g16g20 mA manual switching: output signal
level is switched sequentially. After 20 mA the test ends. • Other Enter any value between 3.2 and 20.8 mA.
Whether communicator is connected or not, constant current mode will be released in ten minutes, and it will return to ordinary measuring condition.
Fail safe direction (read/write):
When a critical failure occurs, GasCVD sets the analog output to the fail safe (burnout) direction, either down (2.4 mA (-10%) ) or up (21.6 mA (110%) ).The default setting is down (2.4 mA).
Fail safe simulation (read/write):
Simulates the fail safe condition. After the fail safe simulation starts, it will continue for ten minutes and then automatically stop.
Output low limit (read): For checking the lowest current output within the normal output range (fixed at 3.2 mA (-5% F.S.) ).
Output high limit (read): For checking the highest current output within the normal output range (fixed at 20.8 mA (105% F.S.) ).
Diag status (read):Whether an error or failure has occurred is shown by a hexadecimal digit. If neither an error nor a failure has occurred, “0x00000000” is shown.
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Digital output
This section shows how to configure the digital output. There are two digital outputs, namely STATUS output and CALIB output.Device " Detailed setup " Output condition " Digital output
STATUS output (read): Tells if STATUS contact output is No alarm or Alarm.
STATUS type (read/write):
Configures STATUS contact output to open or close the circuit upon detection of an alarm condition. The default setting is NO. • Normally Open (NO): When no alarm is detected, contact output is
OPEN. When an alarm is detected, contact output is CLOSE.
• Normally Close (NC): When no alarm is detected, contact output is CLOSE.
When an alarm is detected, contact output is OPEN.
STATUS selection (read/write):
Select STATUS output item from below. • None • Process alarm (default) • Sensor temp. alarm • Calibration in process or failure • Process + Sensor temp. • Sensor temp. + Calibration • Calibration + Process • All
STATUS simulation (read/write):
Simulates the condition of the STATUS contact output, OPEN or CLOSE.After status contact output simulation starts, it continues for ten minutes and then automatically stops. If “Continue” is clicked before that time, the simulation continues for two hours more.
CALIB output (read): Tells if CALIB contact output is OPEN or CLOSE.
CALIB type (read):
The CALIB contact output is fixed at NO. • Normally Open (NO): In non-calibration, gas will flow from flow pass
(NO) of NG (process gas) to GasCVD, and in the beginning of calibration it will flow from flow pass (NC) of calibration gas to GasCVD.
CALIB simulation(read/write):
Simulates the condition of the CALIB contact output, OPEN or CLOSE.If CALIB simulation is set, simulation time for contact output will be ten minutes. If continued before end, it will be two hours. If not continued, it will be stopped automatically in 10 minutes.
Diag status (read):Whether an error or failure has occurred is shown by a hexadecimal digit. If neither an error nor a failure has occurred, “0x00000000” is shown.
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HART outputThis section shows how to configure the HART output.Device " Detailed setup " Output condition " HART output
Polling address (read): 0 (fixed)
Loop current mode (read): Enabled (fixed)
Num req preams (read): 5 (fixed)
Num res preams (read/write): 5 (default)
Note: GasCVD is not suitable for multidrop use.
4-5-4: Process alarmThis shows how to configure the process alarm.Device " Detailed setup " Process alarmWhen an alarm condition is detected, the alarm code is displayed on the LCD, the STATUS contacts are activated if digital output has been configured, and the alarm is logged in the status history of the device.
Proc. alarm status (read): Shows the condition of the process alarm, No alarm or Alarm.
Config proc. alarm (read/write):
There are 3 possible settings. The upper limit cannot be equal to or less than the lower limit. • Lower alarm value: Threshold of lower l imit alarm
(setting range: 34.5 to 45.5 MJ/m3 (-5 to 105%), default 35 MJ/m3)
• Upper alarm value: Threshold of upper l imit alarm (setting range:34.5 to 45.5 MJ/m3 (-5 to 105%), default 45 MJ/m3)
• Hysteresis: The hysteresis threshold is selectable from 0 to 5 % in 1 % increments (default : 5%). Hysteresis is set in lower part of Upper alarm and upper part of Lower alarm.
On OIML R140 compliant models, the lower alarm value and upper alarm value must be set in the 0–100 % range.
• Sample operation of process alarm
HysteresisUpper alarm value
(Upper alarm value) - (Hysteresis)
Process (SCV)
Hysteresis(Lower alarm value) - (Hysteresis)
Lower alarm value
STATUS contact(DO select)
Upper alarm detect
Lower alarm detect
Upper/Loweralarm detect
23
4-5-5: CalibrationThis section provides information about analog output trim, SCV trim and calibration.Device " Detailed setup " Calibration
4-5-5-1: Analog output trim Before you start
Output signal calibration (adjustment of the D/A conversion unit) is unnecessary under ordinary operating conditions. Normally, a Azbil Corporation authorized service provider performs this work. End-users who must do this work need the equipment listed below.
Equipment• High-precision ammeter or voltmeter with accuracy of 0.03 % FS or higher• Resistor, 250 Ω ± 0.005 %• HART® Communicator or CommStaff
Set-upDevices will be connected as shown in the following figure.
Power Supply
250ΩHigh-PrecisionAmmeter
HART® Communicator(or CommSta�)
RecievingInstrument
Calibrating the Analog Output SignalTo calibrate GasCVD’s analog output circuit, use its constant-current source mode.
Device " Detailed setup " Calibration " Analog output trim " D/A trimDevice " Detailed setup " Calibration " Analog output trim " Scaled D/A trim
24
D/A trim procedure:
1When a prompt appears, connect the precision ammeter or voltage meter in loop to check reading. Press OK.
2
The following display prompts will appear:“Setting field device output to 4 mA.” —Press OK.“Enter meter value.” —Key in meter value, then press OK.“Is field device 4.000 m A output equal to the reference meter reading?
1 Yes 2 No”• If the two are not equal, select No, press ENTER, and then enter the new meter
value. (As many as 4 digits after the decimal point can be input. Return to the “Enter meter value” prompt until the field device output equals the reference meter.)
• If the two are equal, select Yes and press ENTER.
3
The following display prompts will appear:“Setting field device output to 20mA.” —Press OK.“Enter meter value.” —Key in meter value, then press OK.“Is field device 20.000 mA output equal to the reference meter reading?
1 Yes 2 No”• If the two are not equal, select No, press ENTER, and then enter the new meter
value. (As many as 4 digits after the decimal point can be input. Return to the “Enter meter value” prompt until the field device output equals the reference meter.)
• If the two are equal, select Yes and press ENTER.
Note: In the case of scaled D/A trim, voltage will be displayed instead of current. Example: 4,000 mA → 1.000 V, 20.000 mA → 5.000 V As many as 4 digits after the decimal point can be input. For example: 1.0001,
4.9999.
4-5-5-2: SCV trimSCV trim adjusts the SCV output by shifting it. If the SCV of the process gas is known and is slightly different from GasCVD’s output, you can fix the output using this shift adjustment. (See figure below.)This function adjusts the formula used for calculation in order to shift the output, but it does not improve the accuracy of the output.Device " Detailed setup " Calibration " SCV trim
SCV trim (read/write):Increases or decreases the SCV output from –2 MJ/m3 to +2 MJ/m3 in increments of 0.001 MJ/m3 (approx. ±0.0025 % of reading). Set the amount to increase or decrease and press ENTER.
SCV tr im value reset (read/write):
Clears the SCV trim setting and restores the factory default (±0 MJ/m3)
Before SCV trim
Process gas_SCV(MJ/m3) Process gas_SCV(MJ/m3)
SCV trim: -0.3MJ/m3
Gas
CVD
outp
ut_S
CV(
MJ/
m3 )
Gas
CVD
outp
ut_S
CV(
MJ/
m3 )
After SCV trim (-0.3 MJ/m3)
GasCVD output 39.77MJ/m3
Real SCV 39.47MJ/m3GasCVD output 39.47MJ/m3
Real SCV 39.47MJ/m3
25
4-5-5-3: Manual calibration / auto calibrationCalibration compensates for sensor sensitivity drift caused by long-term use or long-term storage. GasCVD has already been calibrated at the factory but you should recalibrate it with your own calibration gas (pure methane gas) to ensure the accuracy of analysis in the following cases:
• When first installing GasCVD.• When an unused GasCVD is returned to active service.• At a calibration interval decided by the user. The recommended calibration cycle is
once per week.
The calibration gas must be pure methane 4.5 (≥99.995 %). The consumption of calibration gas depends on the sampling system. If Hold time is set to 20 minutes and the flow rate is 50 ml/min, the consumption will be about 500 ml for one calibration.
There are two methods of calibrating GasCVD, Manual Calibration and Auto Calibration. The difference between the two methods lies in whether calibration is repeated at a user-defined interval or not. The calibration procedure during hold time is the same. The calibration procedure is described below.
Note: During manual calibration and after auto calibration has started, settings cannot be changed and simulations cannot be run.
Step Calibration procedure
1Turn CALIB contact output on. Change the inlet gas from process gas to calibration gas. The LCD displays “Calib” and the output is held at the latest SCV value.
2 Wait for the first half of hold time.
3
Execute calibration and calculate the new calibration factors (CFs). If all the new CFs are within the 0.99–1.01 range, the calibration was successful and the CFs are changed to the new ones. If one or more CFs are outside the 0.99–1.01 range, the calibration has failed and the CFs have not been changed.
4Turn the CALIB contact output off. Change the inlet gas from calibration gas to process gas.
5 Wait for the second half of hold time to allow replacement of the gas.
6At the end of the hold time, the calibration process and “Calib” mode end. The LCD shows the normal operation display and the output hold is cleared.
If calibration fails, an alarm flag appears on the LCD display. The flag means that there was a calibration failure, and it is not cleared until calibration succeeds. The calibration log is updated regardless of success or failure.
26
Manual calibrationThis shows how to execute Manual calibration.Device " Detailed setup " Calibration " Manual calibration
CALIB simulation (read/write):
OPEN/CLOSEWhen GasCVD is newly installed with the sampling system, use this CALIB contact control command to switch the solenoid valve and check the calibration gas replacement time in order to decide the hold time for calibration.
Hold time (read/write):
The hold time setting range is from 2 to 120 minutes. (default: 20min) Calibration takes place halfway through the hold time. Allow enough hold time for replacement of the process gas with calibration gas.Hold time > gas replacement time × 2 + α (α:Preparation time)
Manual calib start (read/write):
Selecting “Manual calib start” starts the hold time of the manual calibration process.Once "Manual calib start", it cannot stop till end.
CF view (read):
You can check the four CFs generated by the latest successful calibration. The factory default CF settings are all 1.00000. CFs serve as a correction factor for SCV calculation and also allow the user to track sensor sensitivity drift.
CF reset (read/write): “CF reset” clears the latest CFs, restores the default values of 1.00000, and clears the calibration failure flag and alarm.
Diag status (read):Whether an error or failure has occurred is shown by a hexadecimal digit. If neither an error nor a failure has occurred, “0x00000000” is shown.
• Sample operation of manual calibrationSCV
OutputHold time
Caliration
Timefinish
OFFON
CALIB contact
STATUS contact(DO select)
ON OFF
strart
27
Auto calibrationThis shows how to execute automatic calibration.Device " Detailed setup " Calibration " Auto calibrationAuto calibration will repeatedly execute manual calibration at a user-defined interval.
Auto cai lb Star t /Stop (read): Shows if auto calibration has been set.
Hold time (read/write): The same parameter as hold time in manual calibration.The default setting is twenty minutes.
First calib t ime (read/write):
Setting range is 0–24 hours. The setting is activated once “Auto calib Start/Stop” is set, The default setting is twenty-hour hours.
Interval (read/write): Setting range is 1–180 days. The recommended calibration cycle and default setting is once per week (7 days).
Next ca l ibrat ion t ime (read): The remaining time to the next calibration.
Auto cal ib Star t /Stop operation (read/write):
When “Start” is set, auto calibration starts. When “Stop” is set, auto calibration stops. “ n ” appears and blinks on the LCD display if Auto calib is scheduled.
CF view (read):
You can check the four CFs generated by the latest successful calibration. The factory default CF settings are all 1.00000. CFs serve as a correction factor for SCV calculation and also allow the user to track sensor sensitivity drift.
CF reset (read/write): “CF reset” clears the latest CFs, restores the default values of 1.00000, and clears the calibration failure flag and alarm.
Diag status (read):Whether an error or failure has occurred is shown by a hexadecimal digit. If neither an error nor a failure has occurred, “0x00000000” is shown.
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• Sample operation of auto calibration
Hold time: 20 minFirst calib time: 13 hInterval: 1 day
ON
ONON
Auto calib Start set Start StartFinish Finish Time
ON
CALIB contact
STATUS contact(DO select)
OFF
OFFOFF
OFF
Calibration
Hold time
INTERVALINTERVALFirst calib timeSCV
OutputHold time
Calibration
Handling Precautions:If there is a power loss during auto calibration, “First calib time” and “Interval time count” stop. After restoration of power, they continue count-ing time from the stopping point. If needed, please set “First calib time” and “Interval” again.
" " and " " are shown here alternately.
29
4-6: Device informationThis shows how to read and write device information. (Follow the maximum character number)Device " Device information
Manufacturer (read): Azbil Corporation
Model (read): CVM400-xxxxxx-xxxx-x
Device ID (read): XXXXXX
GasCVD serial number(read): 32XXXXXX
Device Tag (read/write): Maximum 8 characters (alphabetic and numeric)
Long Tag (read/write) Maximum 32 characters (alphabetic and numeric)
Date (read/write):
mm/dd/yyyy • mm: month, 2-digit number • dd: day 2-digit number • yyyy: year 4-digit number
Descriptor (read/write): Maximum 16 characters (alphabetic and numeric)
Message (read/write): Maximum 32 characters (alphabetic and numeric)
Serial number (read): "0" (fixed)
Final assembly number (read/write): Instruments update No.
Distributor (read): Seller
Config change counter (read): Setting change counter
Revision number: For details, See the table below.
Write protect: For details, See the table below.
Production No. (read): Production No.
Software version: For details, See the table below.
Revision numberHere various revisions regarding HART communication can be confirmed.Device " Device information " Revision number
Revision number (read):
There are 4 types of revision. • HART version • Device revision • Software revision • Hardware revision
Write ProtectSoftware write protection can be checked. . Device " Device information " Write protect
Write protect (read): NO: Not Write ProtectedNot supported at present.
Software versionHere S/W version unique to GasCVD can be confirmed.Device " Device information " Software version
Software version (read):There are 2 types of version. • OIML S/W version • Operation S/W version
Note: The software version is shown as follows: Ex:ver. 1.0 " 10, ver. 1.1 " 11
30
4-7: MiscellaneousThis section shows how to read the Miscellaneous.Device " Miscellaneous
M a x i m u m d e v i c e variables (read): "1" fixed
Extended f ield deviceStatus (read): "0" fixed (not used)
Device profile (read): "Process Automation Device" fixed
4-8: Review (read only)This section shows how to read the Review.Device " ReviewAll setting data of GasCVD will be shown.
4-9: DiagnosticsThis section provides information about the Device status.Device " Device statusIf a process alarm is detected, it is reflected on the indicator display and in the status contact output. If a critical failure is detected, it is reflected on the indicator display, and output changes according to the burnout (fail safe) setting.
4-9-1: Diag status (read only)The results of self-diagnostics can be checked.Device " Device status " Diag status
If a critical failure error or non-critical status alarm is detected, a status message is shown using the error code or alarm. Refer to chapter 6, “Troubleshooting.”
4-9-2: Operating time (read only)Device " Device status " Operating timeGasCVD has 2 counters, used for the calibration setting and the time stamp for the log.
• Total operating time (in hours) since shipment from the factory. Example: Total operating time: xxxxx h• Latest operating time (in hours) since the latest power on. Example: Latest operating time: xxxxx h
4-9-3: Device alarmsDevice " Device status " Device alarm
Temp. alarm status (read): Shows if Temp alarm is occurring or not
Config temp alarm(read/write):
There are 3 possible settings. The upper limit cannot be equal to or less than the lower limit. • Lower alarm value: Threshold of lower limit alarm (setting
range: 50–70 ℃. Default is 50 ℃.) • Upper alarm value: Threshold of upper limit alarm (setting
range: 50–70 ℃. Default is 70 ℃.)
Calib. status (read): For checking the latest calibration result.
31
• Sample operation of status alarm
Upper alarm value
Temp. (˚C)
Lower alarm value
STATUS contact(DO select)
Upper alarm detect
Lower alarm detect
Upper/Loweralarm detect
4-9-4: Log Three types of log (Calib. log, Error log, and Config log) are stored in GasCVD. Each log keeps the latest 5 records. Latest SCV at PD, which is the SCV just before both power failure and suspension of power supply, is also stored in GasCVD. HART Communicator can read all three log files and latest SCV at PD.
Device " Device status " Log
Calib log view(read):The latest 5 calibration result records, including S/F(success or failure), CF1–CF5 (the 5 calibration factors), and total operating times.
Calib log clear (read/write): Clears calibration logs.
Errorlogview(read): The latest 5 error code records (operations involving a parameter change) and total operating times.
Errorlogclear(read/write): Clears error logs.
Config log view(read): The latest 5 configuration records (operations involving a parameter change) and total operating times.
Config log clear (read/write): Clears configuration logs.
Latest SCV at PD (read):
The SCV just before power-down and total operating times.
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Chapter 5: Maintenance5-1: Calibration
When end users calibrate GasCVD, pure methane gas must be used. For OIML R140 compliant models, calibration is required at least every 90 days. Refer to 4-5-5-3: for calibration gas requirements, as well as calibration setup and execution.
Maintenance Precautions
WARNINGWhen removing this device for maintenance, be careful of residual pressure or residual process gas. Leakage of process gas is danger-ous.When working on the vent, check its direction so that people do not come into contact with vented gas. There is a danger of burns or other physical harm.When the device is being used in an explosion-proof area, do not open the cover. Opening the cover may cause an explosion.
CAUTIONThis product was kept under carefully controlled conditions until it was shipped. Never try to modify this device. Doing so could damage it.
Calibration gas consumption and cylinder exchange cycleCalibrate using pure methane gas (purity of 99.995 % or better, = methane 4.5). Methane gas consumption (in ml) during calibration can be calculated by multiplying 50 ml/min by half of the hold time (min). For example, if the hold time is 20 minutes, methane gas consumption will be approximately 500 ml.A corroded gas cylinder is dangerous because it contains high-pressure methane. Install the gas cylinder in a safe area where it will not corrode. Change the gas cylinder if you find corrosion. Even if no corrosion is found, changing the gas cylinder every two years is recommended.
5-2: Replacement partsChanging and cleaning the sensor and wet parts cannot be done by the customer. Replacement filters for the inlet and outlet of the adapters are the only parts required for normal periodical maintenance. Refer to the WARNING and CAUTION notices in chapter 3-1 before starting maintenance. The spare parts list is shown below.
Refer to the WARNING and CAUTION notices in 3-1 before starting maintenance.
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Replacement parts
Part name Part No. QuantityO-rings (for covers) 80347035-00100 5
Cover (without window) 80347036-00100 1
Cover (with window) 80347052-00100 1
Hex wrenches (large, small) 80347037-00100 1 each
Adapters1/8NPT 80347038-00100
2Rc 1/8 80347038-00200
Filters and O-rings 80347039-00100 10
Changing the filterThe filter in the adapter is held by an O-ring. Remove the O-ring and then remove and change the filter. Install a new O-ring after changing the filter and confirm that the filter is securely installed.
Filter
O-ring
Changing the adaptersIf the adapters seem to be plugged up, they must be changed using the following procedure. The inside of the adapters cannot be cleaned. When ordering, make sure that the thread specification for the adapter is correct. The adapter is important for maintaining the flameproof structure. Replace adapters in a safe place, and assemble carefully. After the replacement, conduct a leak check according to "Piping leak check" in section 2-3.
WARNINGWhen replacing adapters, make sure to refer again to the warnings in section 2.3, “Piping,” and section 3.1, “Before using GasCvD.”
Also, do adapter replacement work in a safe place, assembling the parts carefully. After the replacement, conduct a leak check according to "Piping leak check" in section 2-3.
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Step Action
1Turn off the power, stop the process gas, and wait until the secondary pressure is zero. Then disconnect the terminal wiring and piping, and put them in a safe place.
2 Loosen the setscrew of the hexagonal part of adapters in both sides of manifold
3 Loosen the adapters and remove them
4 Check the new adapters to make sure that the threads and O-ring are not damaged
5Tighten the new adapter till foot of an adapter touch the manifold and cannot be tighten any more.
6 Tighten the setscrew of the hexagonal part of adapters in both sides of manifold
Handling Precautions:Do not damage the O-ring, as damage will cause leakage of the process gas.
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Chapter 6: TroubleshootingThe following describes the meaning of the status messages and the related troubleshooting procedures.
If GasCVD does not work normally or not at all, check the following points.
• Check the result of self-diagnostics with the Communicator. • Check for any leakage at the pipe connections. • Check if flow rate of process gas is within specification.• Check for loose or broken wires. • Check for wrong wiring. • Check that the supply voltage and load resistance are in accordance with the
specifications. • Check that the pressure and temperature are within specifications. • Check for nearby sources of strong magnetism or electrical noise.
Status message
Indicator Display
Status message on Communicator Meaning Output Required Action
Critical Failure
Sensor characteristic data fault
Sensor characteristic data failure Burnout Contact appropriate personnel
Suspect input Input data error Burnout Check the inlet gas specification. Contact appropriate personnel
NVM fault Nonvolatile memory failure Burnout Bad electronics board. Contact
appropriate personnel
RAM fault RAM failure Burnout Bad electronics board. Contact appropriate personnel
Status message
Indicator Display
Status message on Communicator Meaning Output Required Action
Non-critical Status
PV > 105% SCV exceeds 105 %(> 45.5 MJ/m3)
20.8mA (105% saturated)
Check the process gas pressure and flow
PV < -5% SCV is less than –5 %(< 34.5 MJ/m3)
3.2mA (-5% saturated)
Check the process gas pressure and flow
Calibration failure CF < 0.99 or 1.01 < CF Current SCV output
Check the calibration gas pressure and flow. Retry calibration
Calibration in processDevice is operating in calibration mode(counting down hold time)
Latest SCV is held Wait until hold time ends
Loop test in operation Device is operating in output mode
Output mode current
Go to the output mode menu and end output mode
Fail safe simulation in operation
Device is operating in Fail safe simulation mode
Burnout high/low
Go to simulation menu and end the simulation mode
STATUS output simulation in operation
Device is operating in STATUS output simulation mode
Current SCV output
Go to the simulation menu and end the simulation mode
CALIB output simulation in operation
Device is operating in CALIB output simulation mode
Current SCV output
Go to the simulation menu and end the simulation mode
Process Alarm Detected
SCV is beyond output alarm upper/lower limit
Current SCV output
Check the output and the alarm setting
Sensor Temp. Alarm Detected
Sensor temp. is beyond sensor hi/lo limit
Current SCV output
Check the ambient temp. and alarm setting
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Appendix: A-1: SpecificationsSTANDARD SPECIFICATIONSInstrument
Process gas connection port: NPT 1/8 (F), Rc 1/8Electrical conduit: NPT 1/2 (F), M20 Case structure: IEC IP66 Flame-proof structure: ATEX: II 2G Ex d II B T6 Gb; II 2D Ex tb IIIC T80 °C Db IECEx: Ex d IIB T6 Gb, Ex tb IIIC T80 °C Db Display: LCDCalorie display: 5 digitsUnits: SCV, MJ/m3
% display: setting range is shown by a % and by a bar graphAutomatic calibration setting display: and light up alternately when set.Calibration factor display: a flag is shown if calibration failsCommunications: HART protocol ver. 7.0 (with CommStaff or HART 475 Communicator)Power: 24 Vdc ±10 %, 0.3 A max. (inrush current at startup)Output: Analog output: 4–20 mAdcContact output: 24 Vdc ±10 %, 50 mA max. (transistor contact for status);
24 Vdc ±10 %, 1 A max. (transistor contact for calibration)Paint: Baked acrylic resin finishColor: Housing: Light beige Front cover: Dark beige Terminal cover: dark beige
MaterialCase material: Housing: aluminum alloy (ADC 12) Front cover: aluminum alloy (ADC 12) Terminal cover: aluminum alloy (ADC 12) Window: reinforced glass Cover O-ring: NBR rubber Wet parts materials: Manifold: SUS304 stainless steel Adapter: SUS304 stainless steel µTCD sensor: platinum, glass, gold, Kovar, silicon O-ring: Fluoro rubber
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Process gas specifications Natural gas (NG), in gas form only Temperature: –10 to 50 °C Pressure: 110 kPa (abs) max. (at GasCVD process connection port inlet) Flow rate: 50 ±10 ml/min Dust: Less than 1 µm in diameter, 1 mg/m3 max. Mist: none at –20 °C Moisture: dew-point temperature –20 °C max.
Calibration conditions Calibration: Automatic/Manual Calibration gas: Pure methane (99.995 purity min.)
Installation conditions Ambient temperature: –10 to 50 °C Ambient humidity: 95 % RH max. Mass: 2.5 kg
Accuracy Repeatability: ±0.5 % of reading (natural gas model), ±0.2 % of reading (OIML R140 CVDD compliant model) Accuracy: ±1.5 % of reading (natural gas model), ±1 % of reading (OIML R140 CVDD compliant model)
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Model number table
Dimentions
CVM400 - - -
1/8NPT (F)Rc 1/81/2 NPT (F)M20OIML R140 CVDD (*1)±1.5 % of readingATEX flameproofIEC flameproofHARTGas composition type 1: Natural gasGas composition type 6: OIML R140 CVDD compliant
Without DisplayWith DisplayStandard finishCorrosion-proof finish15°C/15°C0°C/0°CSCV MJ/m3
NoTest reportTraceability certificateOIML/MID certificateMaterial certificate
Process connection
Electrical conduit connection
Accuracy
Explosion-proof structure
CommunicationsGas type
Indicator
Paint
Gas calorific value calculation parametersOutput units
Basic Model Number Optional Selection OptionsSelection
13
12
LM
EG
HAF
XA
XB
12
1
X1234
*1. OIML R140 model can be used under gas calorific value calculation parameters of 15°C/15°C.
86
2550
120 130
35103
67
66 2-M8×1.25Depth 8
45°
58
35
160
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A-2: Natural gas superior calorific value calculationGasCVD calculates SCV following ISO 6976 (1996).The calculation parameters and engineering units used by GasCVD are shown below.Parameters and range t1: t2:
GasCVD t1/t2 Range Remarks
Standard 15/15 °C 35–45 MJ/m3 Italian SCV calculation
Option 0/0 °C T.B.D.
Option 15/0 °C T.B.D.
Option 25/0 °C T.B.D.
Option 20/20 °C T.B.D.
Option 25/20 °C T.B.D.
GasCVD Unit Range Remarks
Standard MJ/m3 35–45 MJ/m3
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Document Number: CM2-CVM100-2001
Document Name: GasCVD® Natural Gas Calorimeter Model CVM400 User’s Manual
Date: Aug. 2012 (initial)Issued/Edited by:
