Mini-Max Rotary Corrector - User Manual
Contents
1. Seem 117 Sete 11 Table 2 Romet Meter Values 10 www honeywell com Honeywell Rotary Meter Mounting Plate Identification The following pages serve as a reference to identify which instrument mounting plate adapts to which meter Be sure to take into account the meter manufacturer meter series meter size and temperature probe location when ordering or installing the appropriate mounting kit Dresser LMMA 1 5 5M 23M 102M Kit 420 9424 Dresser LMMA 7M 16M Kit 20 9425 Romet 1000 5000 Internal Temperature Probe Kit 20 9426 Romet 7000 16000 Internal Temperature Probe Kit 20 9427 Romet External Temperature Probe Kit 20 9477 www honeywell com ROMET PRE 92 Honeywell Input Sensor The Rotary Corrector receives volume pulses directly from an input sensor mounted in the body of the meter The sensor threads into the rotary meter mounting plate and connects to the Mini Max main board at J2 via a ribbon cable The connector is keyed thus preventing the possibility of incorrect connections Ribbon Cable Sensor Body Sensor Connection to main board Note There are two types of sensors The original Rotary corrector units had the standard sensor p n 40 2910 Newer units will have the REI sensor p n 40 2983 with additional functionality discussed below The two sensor units are physically interchangeable but the REI requires an up dated firmware versio2. conditions are Electronic Index Battery Low Electronic Index Read Error and Electronic Index Write Error Each alarm condition has a specific value associated with it so if multiple alarms have occured Item 435 will appear as a sum of the alarm values Alarm Values 0 No Error l Electronic Index Battery Low 2 Electronic Index Read Error 4 Electronic Index Write Error The time when the REI Alarm first occurred Item 435 Default 00 00 00 Format HH MM SS The date when the REI Alarm first occurred Item 435 Default 01 01 02 Honeywell ROTARY MINI MAX PROVING PROCEDURE DOS Prover Software only Purpose of the Test This procedure describes the testing of Rotary Mini Max accuracy of measuring gas flow through a Roots or Romet rotary meter Rationale For This Procedure Using this approach reasonable test times are achieved and prover accuracy is maximized To accomplish this task a special proving adapter must be used to connect the sensor to the Mini Max The pulses test and test volume values high medium and low flow rates are specified in Tables 1 amp 2 of this procedure These two values need to be entered into the prover program The Mini Max will send output pulses to the prover s OPTO interface to start and stop the prover In addition this procedure is the first version that significantly reduces the complication of meter scaling factors for the user When the meter model is selected the factor is load
3. per hour or cubic meters per hour and has a resolu tion of one tenth of a cubic foot or one thousanth of a cubic meter When enabled the live dial rate can be displayed by scrolling through the meter read list until the following screen appears MINI MAX AT gt EEEEEER Electronic Gas Volume Corrector This screen will remain for approximately three seconds before changing to the wait screen below MINI MAX AT ENEN Electronic Gas Volume Corrector The wait screen will remain anywhere from one to twenty seconds depending on the amount of time it takes for the Mini Max to receive two meter volume pulses through the sensor After receiving the two volume pulses the Mini Max will calculate the flow rate and display it on the LCD If no volume pulses are counted in twenty seconds approximately 1 of meter capacity the flow rate displayed will be zero as shown below After 10 minutes the display will flash TIMEOUT and return to the corrector mode MINI MAX AT SENE Electronic Gas Volume Corrector 14 www honeywell com Honeywell Differential Performance Test The condition of a rotary meter can be measured by performing a simple test called the Differential Perfor mance Test This test requires that the differential pressure across the meter be measured as well as calculating the dial rate Normally calculating the dial rate can be tedious However with the Rotary Corrector installed the dial rat
4. using temperature correction the following additional items must be entered or verified 109 Fixed Pressure Factor Fixed 110 Fixed Super Factor Fixed 111 Fixed Factor Temp Live 57 Pulser B Scaling 2 0 94 Pulser B Vol Code CorVol 90 Corr Volume Units Use same value as Item 98 18 Disconnect link with Mini Max Prover Setup on the Laptop 19 Remove the RS 232 communications cable from the laptop Connect the prover s communications cable to the laptop 20 Inthe prover setup screen choose the following Prover Capacity Select the master meter that has the appropriate flow capacity Test Control Mode Set to OPTO Meter Output Set to UC for uncorrected volume Set to TC if using temperature correction 2 Forthe next few steps when the prover software program asks for entry of pulses test and test volume a list of values is provided If the value that you desire is not in the list select Enter from the list then select the value desired 22 Select the pulses test from Table 3 for the high flow capacity 100 from column 2 23 Select the test volume from that same table for the high flow capacity 100 from column 3 24 Enter the 3 flow rates for high medium and low flows in the prover program 25 Enter the pulses test and test volume from that same table for the medium flow capacity 5096 from columns 4 and 5 26 Enter the pulses test and test volume from that same table for the low flow capa
5. 02 and 434 should read the same value 19 Disconnectorunlink from the instrument 20 Check the operation of the LCD by scrolling through the display list using the MI pushbutton 2 Securethe front door by tightening the four Phillips head screws evenly Ensure the door is configured so the MI logo and the LCD are right side up The door is symmetrical and can be rotated to accommodate different meter positions Door Screws MILogo Pushbutton www honeywell com Honeywell Setting up the instrument Parameters There are two item settings that must be made for the Rotary Corrector to function properly The first is the Meter Index Rate Item 098 and the second is the Meter Scaling Factor Item 114 The values at items 098 and 114 are automatically set by the firmware simply by selecting the Meter type and size at item 432 The following two tables show the correct setting for the different meter sizes and manufacturers For manually setting the parameters find the table with the correct meter manufacturer go down the size column to the proper size Go across the row to the column that contains the appropriate setting of Item 114 inrelation to Item 098 Dresser LMMA Meters tem 09822 Item 09823 10 CuFt 100 CuFt Set Item 114 Meter Size to to 0 1896107 0 3792213 0 6321493 1 0666667 1 7066667 2 5284267 Table 1 Dresser LMMA Meter Values RometMetes Meters 10 CuFt 100 Curt Meter Size
6. Be aware that there is one meter mount ing screw internal to the Mini Max for LMMA including 7M 16M installations 10 If provided insert the temperature probe through the appropriate fitting on the adapter mounting plate from within the Mini Max Position the probe to the desired location and secure by tightening the nut using a 7 16 open end wrench Temperature Probe Fitting 11 Ifprovided connect the pressure tubing to the Mini Max and then to the external pressure tap on the meter 12 Placethe battery pack against the side port facing the meter then secure with the Velcro strap Ensure the sensor ribbon cable is folded and condensed as much as possible Battery Pack Velcro Strap 13 Ensure the open end of the air vents are rotated toward the ground so to protect from entrance of moisture Tighten the inside nut to secure the vent in place 14 Connect the battery cable to J3 or J4 on the main board to start up the unit 15 Link to the instrument and select item 432 Choose the appropriate meter model 16 Select item 433 and choose Enabled The sensor will now begin to read andupdate meter volume Choose Prover when proving the instrument 17 Ifdesired place item 434 in the meter reader list 18 Synchronize item 002 with item 434 to have a coordinated totalized uncor volume Do this by writing a value to item 002 that matches the reading at item 434 Note If all is operating correctly item 0
7. Honeywell Honeywell Process Solutions Mini Max Rotary Corrector Direct mount PTZ Volume Corrector for Rotary Meters Supplement to Mini Max User Manual October 2010 V 1 03 Honeywell www honeywell com Honeywell TABLE OF CONTENTS MVNA od Ote dan db RM CURT DIM E 4 TEustallattont DIE Uc DO BS seasons P nins Radio read naden ebd dede 5 Setting theinstr ument Paramet TS annee 9 Instrument Mounting Plate Identification eese teretes 11 Taput SBE ebben nn on one 13 Redundant Electronic Ie a a ac 13 UM II NIE 13 Live Dial Rate Display cie atti to dees teet eee ed hee 14 Differential Performance Test nina nd annales 15 Tiem ET ccs esd T NE EUER rete 16 Met r CVE UNE 17 Revision List 1 00 Initial Release May 2003 1 01 Revision Cover page June 2008 1 03 Honeywell update October 2010 Introduction The Mini Max Rotary Corrector is a full featured Mini Max or Mini Max AT electronic gas volume corrector specially adapted to direct mount to various rotary meters The Rotary Corrector uses a sensor to collect input volume pulses from the sensor well of the rotary meter The Rotary Corrector functions in much the same manner as the standard Mini Max or Mini Max AT A PC desktop or laptop computer is needed to configure and download the Rotary Corrector using MasterLink32 software Detailed information regarding the software is available through the MasterLink32 help screens In additio
8. be entered at this time since they will be changed in this procedure 4 Ifthe Mini Max is not providing temperature correction skip to the next step Install the Mini Max temperature probe into the meter s thermowell 5 Remove the connector end of the Rotary Sensor Probe from the main board Plug the Sensor Proving Adapter male end assembly 40 2977 into the sensor cable it is keyed 6 Plug the Sensor Proving Adapter female end assembly 40 2977 into the main board using the diagram below J2 viewed above the Mini Max main board Figure 1 Line up missing pin with connector plug 2x5 connector 7 Removethe black connector that is on TB1 the Mini Max output pulse connector and plug in the same type of connector that is part of the Rotary Mini Max Prover Cable Assembly 40 2974 Ifa TC proof is being performed move the wire that is on Y to Y on TB1 Note The color of the wires that connect to this black TB1 connector are black on Y Y if using TC and red on K Note If there is further question about the TB1 wiring get a DVM Digital Volt Meter and setit on the 10 volts DC setting Put the red probe on Y Y if using TC and the black probe on K If the DVM reads 0 6 volts instead of 13 volts then the wires must be reversed 8 Connect the opposite end of the prover cable to the small blue prover box on the port labeled I D Pulser 9 Connect all of the prover temperat
9. city 1096 from columns 6 and 7 Note For a faster but less accurate proving operation use the normal open flow and check flow specifications recommended by the prover manufacturer For guaranteed accuracy use the values in table 3 Run the Test 27 Proceed through the rest of the prover responses that are required and start the test which should now run the high medium and low flow prover tests Restore Mini Max 28 Remove the Sensor Proving Adapter 29 Plug the sensor cable back into the black connector that is on TB1 main board figure 1 30 Upload the item file to the Mini Max that was saved before the Mini Max items were modified for the prover needs This will restore the Mini Max to the configuration that it was in prior to prover testing 31 If desired adjust the Mini Max uncorrected and corrected volumes for gas that was bypassed during the proving test 32 If possible it is best practice to observe that the Mini Max is operating properly before leaving the site This can be done by checking all of the item codes and comparing them to a standard item report printout for the site or by simply watching the CORVOL display registering volume if meter not too slow Chose the best technique for your application 33 Caution Ifthis isanew Mini Max installation be careful to complete the installation procedure FD 487 at this time especially the item values which may have been skipped earlier in this procedur
10. correct mounting plate is being used for the specific kind of meter by referencing the stamping on the plate Ensure the threaded sensor hub is facing inside the Mini Max enclosure 5 Without putting undue stress on the sensor connector thread the sensor into the mounting plate This can be accomplished by rotating the plate while holding the sensor or rotating the sensor after removing it from the clips and connector 6 Placethe spiral nylon insulator pointed end first in the temperature probe chamber of the meter and cut to the required length This will help center the probe and reduce the potential risk of stray electrical current coming in contact with the probe 7 Placethe countersink star washers on the four 10 32 x 2 screws and mount the adapter plate to the Mini Max using the four screws To assure a reliable seal to the adapter plate push the O ring located around the case side port against the adapter plate Atthis point the Mini Max should be configured to mount onto the meter end Push O ring against adapter plate Temperature Probe Sensor E 8 Identify the meter gasket meter mounting screws and lockwashers Meter Gasket www honeywell com Honeywell 9 Placethe meter gasket against the meter end and attach the Mini Max with adapter plate to the meter using the meter mounting screws and lockwashers Four lockwashers are provided in the kit and they can be placed onto any of the mounting screws
11. e Especially important are items 92 98 and other application specific items that were changed during the prover testing 34 Caution Be sure to set Index Mode Item 433 from Prover to Enabled This will restore the unit to proper corrector mode and remove Proving from the LCD display Wrap Up 35 The prover test is now complete The Rotary Mini Max is ready to be used 20 www honeywell com Honeywell Rotary Rotary Meter Prover Configuration si Prover Rotary Meter Prover Configuration si Drive Pulses Test Pulses Test Pulses Test Rate FOr VOSI Volume Per lesi arime a Volume Meter Size Roots Meters E Meters 15M 10 5 50 4 40 3 30 3M 10 10 100 9 90 6 60 16M 100 6 600 5 500 5 500 23M 100 8 800 7 700 7 700 RM2000 10 6 60 5 50 4 40 RM3000 10 8 80 7 70 6 60 Table 3 Meter Proving Values 21 Find Out More To learn more about Mercury Instruments products contact your Honeywell Process Solutions representative visit www mercuryinstruments com or call 513 272 1111 Automation and Control Solutions Honeywell Process Solutions 3940 Virginia Ave Cincinnati OH 45227 MERDA 513 272 1111 October 2010 www honeywell com 2010 Honeywell Honeywell
12. e can be displayed via the Live Dial Rate Display The measured values of the dial rate and differential pressure can then be compared to intial factory data to determine if the meter is performing within specifications For more information consult the meter manufacturer s documentation Item No Item Name 432 Rotary Meter Model 433 REI Mode 434 REI Uncorrected Volume Backup 435 REITAlarm 436 RElAlarm Time 437 REI Alarm Date 16 www honeywell com Description Model of the rotary meter the instrument is mounted to This item will automatically set Items 098 and 114 to their appropriate values Default 0 Select O Not Applicable 10 Dresser 102M 1 Dresser 1 5M 11 Romet RM1000 2 Dresser 3M 12 Romet RM1500 3 Dresser 5M 13 Romet RM2000 4 Dresser 7M 14 Romet RM3000 5 Dresser 11M 15 Romet RM5000 6 Dresser 16M 16 Romet RM7000 7 Dresser22M 17 Romet RM11000 8 Dresser 38M 18 Romet RM16000 9 Dresser 56M Item used to select the type and operation of the redundant uncorrected volume index Select 0 Disabled Default 1 Enabled Standard Configuration 2 Prover Total accumulated uncorrected volume from the Redundant Electronic Index Item 434 is expressed in the units selected at item 092 Unc Vol Units When the unit is operating properly the value at Item 434 should match the value at item 002 Uncorrected Volume Item used to indicate whether an alarm has occured in relation to the Redundant Electronic Index The Alarm
13. ed into item 114 automati cally for normal rotary corrector operation When prover mode is selected a divide by 32 is removed internally to allow the corrector to receive pulses faster Also PROVING is put up on the LCD screen When the unitis later taken out of prover mode the LCD returns to normal displaying and internal scaling factors are returned to those that are selected by the meter model Equipment Documentation amp Software Needed This procedure Mercury Document Procedure Rotary Mini Max Proving FD 489 Model 5 Roots Prover or equivalent Rotary Mini Max Laptop Computer Prover Software DOS version for the Model 5 Prover Mercury Master Link Software Mercury Cable Assembly Rotary Mini Max Prover 40 2974 Mercury Assembly Sensor Proving Adapter 40 2977 Note The last 2 items on this list may be acquired by purchasing the Rotary Mini Max Proving Kit 20 9459 Equipment Connections 1 Mount the meter to be tested on the test stand 2 Screw the Sensor Probe into the rotary mounting plate inside the Mini Max You may need to remove the battery pack to do this Route the sensor cable under the battery pack and under the hold down clip 3 Mount the Rotary Mini Max to the meter using the bolts that are provided in the installation kit If this is anew instrument and the meter is being set up for field installation follow the installation instructions FD 487 Note Item values specified in FD 487 do not have to
14. n 2 40 or higher to support its added features Redundant Electronic Index REI The REI sensor has the ability to store input pulses from the meter The Mini Max reads the value from the REI and converts it to an uncorrected volume reading scaled to the units selected at item 092 To activate this feature item 433 must be set to Enabled The converted value is stored at item 434 Since Item 434 is a backup reading it is only updated on a serial link meter read or start of gas day Itis not updated on hourly Audit Trail logs or volume pulse inputs In normal operation the value of item 434 should match or be very close to the value of item 002 REI Alarms A set of alarms are associated with the REI sensor The alarm status is stored in Item 435 A value of zero 0 indicates that there is no alarm currently active in the REI A value other than zero indicates that an alarm has occurred in the REI MasterLink32 will automatically intepret the value and display the alarm description See the table below for a description of alarm codes Value Cause CC S SS 3 Battery Low amp Read Enor 5 Bateylow amp Wi eEmr 6 Read Enor amp Write Enor 7 Battery Low Read Error amp Write Emor o Live Dial Rate Display The Rotary Corrector has the ability to display live dial rate on the LCD This feature is enabled at Item 129 The dial rate is displayed in units of cubic foor
15. n to its small sturdy case the Rotary Corrector offers these and other features ntegral design i e Instrument drive not required High performance low power microprocessor Extended battery life Audit Trail memory capacity 40 days of daily or hourly FLASH memory hence no plug in EPROMs Field programmable firmware updates Two Form A outputs for Volume and one Form A output for Alarms e Software selectable Pulse Widths for volume pulses e Serial port CMOS with automatic baud rate settings optional RS 232 port High speed data transfers up to 38 4 kbaud On board surge protection for serial amp pulse data Field replaceable Alkaline batteries Electronic uncorrected volume backup Note This manual is intended for use as a supplement to the Mini Max Operators Guide and should be used in conjunction with that manual www honeywell com Honeywell INSTALLATION INSTRUCTIONS OF THE MINI MAX ROTARY CORRECTOR Dresser amp Romet 1 Remove the contents from the box and from the mounting kit bag 2 Reviewthe contents and identify each item per the parts list included 3 Selectthe adapter mounting plate four 10 32 x 2 SS flat head screws 60 1374 and four coun tersink star washers 20 9505 Meter Adapter Flathead Screws Plate D 60 1374 D Star Washers 20 9505 Sensor Hub 4 Identify the proper orientation of the adapter mounting plate in relationship to the meter Ensure the
16. ure and pressure sensor cables on the prover 10 Connect the prover main airflow hose to the test stand and prover master meter Observe all safety precautions listed in the prover operation manual especially keeping hands clear of the meter inlet port 11 Connect the laptop to the Mini Max using the communications cable 12 Connect the prover s little blue box to its computer box B Software Installations Needed go to Mini Max Item Setup if software is already installed 13 Install the Prover Software on the laptop computer 14 Install MasterLink32 Software on the laptop computer Mini Max Item Setup Important Step 15 If the Mini Max items have been previously set up or have been set up according to special factory specifications upload the items and save them in an item file using MasterLink32 16 To getthe Mini Max configured for prover testing these items values must be entered or verified using MasterLink32 Find Table 3 at the end of this procedure Item Description Value or Setting 432 Rotary Meter Model Select Meter Model being tested 433 Index Mode Prover 56 Pulser A Scaling 2 0 93 Pulser A Vol Code UncVol 124 Revs Per Wakeup 1 98 Meter Index Code Select From Table 3 92 Uncorr Volume Units Use the same value as item 98 0 Corrected Volume 00000000 2 Uncorrected Volume 00000000 18 www honeywell com Honeywell 17 Ifthe Mini Max is not providing temperature correction skip to the next step When
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