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Model CM6G Gas Calorimeter

1. CALORIE MAIN PANEL DETECTOR DENSITY METER CONVERTER Il COMPUTING gt STATION SWITCH BOX T o EARTH TERMINAL i 7 Figure 5 1 Switch Box and Earth SWITCH SIGNAL TERMINAL NFB 6 o ok el lolo e S le S e EL S O 6 S lo S e O a O S lo e S j a O a O e e e TERMINAL se e e a a e a e O O S le e e S lo 6 o O a O a O lol el lo o 0 le O JTE TE e S le S e 28 o Q eQ Be Es lo 9 S le Ko o la fe ole 2 FUSE Figure 5 2 Inside a Switch Box IM 11R02A01 02E 5 2 lt 5 External Wirings gt 9 1 9 2 5 2 1 5 2 2 5 2 3 5 2 4 5 2 5 Notes on Wiring N WARNING e Cables and wires must be connected after all power supplies are turned off Anelectrical wiring duct must not be used for the simultaneous connection of a large capacity converter motor or power supply lt When cables are connected in a place with high or low ambient temperatures use cables suitable for the place where they are used lt When cables are used in an atmosphere where harmful gases liquids oil or solvents are present use cables made of materials capable of withstanding those things Use crimp terminals with insulated sleeve M4 screws for th
2. Orifice Hole cb Parts No 10 10 0 35 G7025XJ 0 40 G7026XJ A A 0 45 G7027XJ 0 50 G7028XJ 6 0 55 G7029XJ 0 60 G7030XJ 0 65 G7031XJ 0 70 G7032XJ oko 0 75 G7033XJ an 0 80 G7034XJ a 0 85 G7035XJ 0 90 G7036XJ 1 0 G7037XJ a 1 1 G7038XJ Bao 1 2 G7039XJ 12 7 MA 1 3 G7040XJ 1 4 G7041XJ 1 5 G7042XJ F12 5 ai Figure 12 5 Orifice Assembly IM 11R02A01 02E 12 4 lt 12 Replacement Parts gt 12 3 Preheater E7023NG mo Name CT Panno Remas MEM ae a eo o Packing o feo S a Thermostat fa eono S F12 6 ai Figure 12 6 Preheater 12 4 Fulflo Filter G7043XJ COS ame Tan Parte Element G7054XJ pares polypropylene 7057XJ eg E KAI EN Pe forma Sid HD Q F12 7 ai Figure 12 7 Fulflo Filter IM 11R02A01 02E lt 12 Replacement Parts gt 12 5 12 5 Line Filter H7800EC Eno ham a PartNo Remarks o femm E fer S 2 O rin 1 Y9116XB Viton 2 oms Sid vor iin Gas inlet 1 77 AAA Element A Bod guide y F12 8 ai Figure 12 8 Line Filter 12 6 Switch Box H7800HV mo name ay Panno Remas fessan ET eas Ps fess 1 Sero 2A torDenstyMeter Note Depends on specification 12 7 Probe H7800HA H7800H
3. CM6G FAL O CM6G FAL O TREND 3 ALM O ALARM ALM CI wma sal ROCES svsrew wo aal E Zu a ILA ar LA A A a oO u MJ LM J A Push key TA WM VY Push El key 6 e o CA CA lt lt gt E lt lt em gt gt YOKOGAWA lt gt YOKOGAWA lt gt F0518 ai 1 Measuring display 2 Alarm display Figure 6 14 Switching operation to alarm display E Confirmation of Input Output data CM6G FAL CM6G FAL CM6G FAL CO penna Peer pao AMO TUNING MENU AMO VO DATA AMO Mas aa LOL PID 1 Le 5 NGE a Ifa PID2 A VG Push key A T MAI M with lt gt key STC 1 M key a m AE Yo oo O P amp T REG JM Y PF VO DATA _ PF zo E m E GA C lt Teo LS CS kero LS lt lt gt gt YOKOGAWA YOKOGAWA lt gt YOKOGAWA lt gt y F0519 ai 1 Measuring display 2 Tuning display 3 Input Output status display This screen is for confirming Input Output status and for setting X1 X2 and X3 Displayed characters become bigger by pushing key Figure 6 15 Switching operation to Input output status display IM 11R02A01 02E 6 12 lt 6 Construction and Function gt E Parameter setting CM6G FAIL a TUNING MENU AM oo PID 1 PID 2 Push key gt STC 1 STC 2 P amp T REG
4. ES EF Pe 156 009 O 10 9 8 12 0909 5 ee 7 F12 1 ai Figure 12 1 Burner Unit IM 11R02A01 02E 12 2 lt 12 Replacement Parts gt b Print circuit board assembly E7023RA no Name Panno Romane Printed Circuit Board Assembly E7023RA Pe l 3 2 Parts Side Solder Side F12 2 ai Figure 12 2 Print Circuit Board Assembly c Ignition transformer assembly E7023EA no Nam Jay Pano Romans 1 Constant Votage Power Supply Gonverer orem fey far QO a J DA E E OA ORO N F12 3 ai Figure 12 3 Ignition Transformer Assembly d Others Qty Part No No Romane Oring 2 a Burner unit Flange 1 j 1 gt Union x F12 4 ai Figure 12 4 Flange Section of the Calorie Detector IM 11R02A01 02E lt 12 Replacement Parts gt 12 3 12 2 Orifice Assembly E7023NA No name Ja Panno Remato eos 2 Thermostat E7023NS Eos eroorep Eros osen reteriorig102 2 1 Y9119XB 4 1 Upper Lower 2 Upper 3 Lower
5. cccsccceseeceseeeeseeeeseneeeseeeeseeeeseeenseeeeeses 5 2 5 2 1 POWECF SUPPIY caracoles onda Bi deta Un gi acera 5 2 5 2 2 Grounding ANA E AE EUA a AA ENERO NADOS 5 2 5 2 3 Analog Output 4 to 20 MA DC 2 s220ssneennennnennnnnnnnnnnnnennnennn 5 2 5 2 4 Contact Output ea 5 2 5 2 5 Contact Input Remote Ignition Custom Order 5 2 6 Construction and FUNCUON a tan 6 1 6 1 Air Pressure Regulating Section uesnessnennnennnnnnnnnnnnnnnnnnnnnnnnnnnnnannnannnannnanen 6 1 IM 11R02A01 02E IM 11R02A01 02E lt CONTENTS gt 6 2 Gas Pressure Control Section uusnsennrennnennnennnennnnnnnnnnnnnnnnnnnennnannnannrannrannnnn 6 2 6 2 1 TOWN GAS USG isra sia nai ad a a Ag ae era 6 2 6 2 2 SteellMill Use 444 22 Henna 6 2 6 3 Differential Pressure Detection Part assaawsnwanawanananananananananananananenanen 6 5 6 4 Calorie DEteCtON cscinsanscxsncrxsannnsnnttanntnasnnnasnstannatnaserenanchaxnanascoenaanehannetnasernannents 6 6 6 4 1 B mer Uniti asas asana aga a aa ANA iia qeda 6 8 6 4 2 High Low Alarm ACHO kasarane naa kanin aaa gand an sg aka n Sapan agak aaa kah 6 9 6 4 3 IGMIMIOMACUON ANNA end 6 9 6 5 Computing Stato 6 10 6 5 1 Indication SelectiON ooconcocincconiccnnnccnnccnnnccnnnccnnoncc conc conan corran 6 10 6 5 2 Contents of the Data Display sas sasanti ag anaa ngaen ia daana nigan ganggang 6 13 6 5 3 Correcting Computation sana aaa aa a aaa aia 6 14 6 6 Density Met
6. VO DATA SAREE v lt sur YOKOGAWA lt gt 1 Tuning display Push key 2 Parameter setting display CM6G rau PATREG TA Ama Pot 60 00 poz z NC Pos 000 Poa 1000 Pos 7 00 Pog 1600 Por 700 k 2 MLA Poa 60 Pio ao en 00 Bi 00 pia 09 M pia 00 pis 00 En 09 Bir 00 ao E AJA Pio 00 Pat 09 P22 09 Pas 00 FS P24 09 Pas V P26 00 Bar 00 pan 09 Poe 0 po 00 PF LE any gt YOKOGAWA lt gt CM6G ra Fern Am POI 0 00 NLE Pes nos Pos ioo Pos 22 NILA Pos so pi 80 I 2 M Pis 00 yey The characters of parameter Pie oo 5 Pis 2 INIA which can be set is enlarged pis oo Paz 28 ES 5 A by pushing key for g VIR pe 2 moving up and key for PaT 2o ES 88 PF moving down EN en Select a desired parameter GA lt I lt gt gt YOKOGAWA lt gt 3 Parameter setting display The screen is for setting various By using and key parameters such as ZERO and SPAN change the parameter value CM6G TREND 3 yi 18900 x1 9000 v2 3800 X3 5000 10000 3787 10000 _ 2302 gt
7. 2 4 External Dimensions 2 4 1 For Town Gas Application CM6G S6200 S6210 S6300 S6310 S6400 S6410 Unit mm Density meter detector Mark Name Connection A SAMPLE GAS IN Rc1 4 B SAMPLE GAS OUT OR VENT Rc1 2 C INST AIR IN Rc1 4 D STD GAS IN Rc1 4 E STD GAS IN Rc1 4 Density meter Calorie detector converter T Flowmeter for Computing N density meter station rox 70 Approx 1970 1800 o 100 740 30 100 700 100 800 4 014 holes _ 900 CM6G S6L110 with flowmeter Maintenance Space 100 900 2 500 u a ro pinan 1 E si LO Back cl o Front Q Q u AE EEE Dim 6210 eps Figure 2 2 External Dimensions For Town Gas Use IM 11R02A01 02E lt 2 Specifications gt 2 7 2 4 2 For Town Gas Application Quake proof Type CM6G S6110 Unit mm 600 120 hole Density meter converter Computing station Calorie detector o S 8 Flowmeter for x LO a density meter Sl lt 30 640 so Shoo 100 4 015 holes Mark Name Connection A SAMPLE GAS IN Rc1 4 B INST AIR IN Rc1 4 C1 STD GAS IN ZERO Rc1 4 C2 STD GAS IN SPAN Rc1 4 D SAMPLE GAS OUT OR VENT Rc1 2 Wiring to switch box should be made through the bottom Maintenance Space 500 1000 100 e
8. 15 m mi amp ih dh pP o y Y 94 7 Ir 10 19 H 18 No Name No Name No Name 1 Air inlet 8 Gas orifice section 15 Thermistor check 2 Gas inlet 9 Crotchet joint 16 Thermistor control 3 Air outlet 10 Fitting screw 17 Temperature check terminal 4 Gas outlet 11 Heat conversion block 18 Neon lamp 5 Air differential pressure take out 12 Heater plate 19 Terminal 6 Gas differential pressure take out 13 Safety thermostat up 7 Gas orifice section 14 Alarm thermostat down Figure 6 6 Orifice Assembly 6 4 Calorie Detector F0506 ai The calorie detector consists of a burner unit which detects the temperature difference before and after the sample gas is burned a detected signal amplification and ignition and safety sequence circuit and distributor circuits of the transmitter for air and the transmitter for gas The detected signal is converted from approximately O 20 mV to 1 5 V DC and input to the computing station If burner flame extinction or excessive combustion occurs an alarm closed contact output is produced Figure 6 7 Calorie Detector IM 11R02A01 02E PRINTED CIRCUIT BOARD ASSEMBLY IGNITION TRANS ASSEMBLY BURNER UNIT lt 6 Construction and Function gt 6 7 POWER IGNIT MEAS ALARM START Lamp Lamp Lamp Lamp Switch CMEC ta
9. a oo 1465 oo 2302 E o m THALA YOKOGAWA lt gt 5 Measuring display Push key with lt s gt other parameters key twice In finishing the set of parameters and returning to the measuring display which becomes larger characters After returning to Tuning In setting a display 1 by pushing key push CM6G rao Toon aN w PNC 8 ER A sio J ww 4 MIA Y 1800 3883 8 A Y 2 My Y E wm o poo 0 gt Do2 oo 0 A Des o pons o _ oo o po o e Bes oo Bate g De o Bowe o ae w oo w oe TS Dos o pone o Be o me o A Do o Beta o Ben o 8 8 IFE Bee o LPF Bos o Bee 8 lt lt y gt YOKOGAWA o F0520 ai 4 Input Output status display This screen is for confirming Input Output status When an item is selected by pushing its shape of characters becomes larger Figure 6 16 Flow Chart of Various Parameter Setting and Confirmation IM 11R02A01 02E lt 6 Construction and Function gt 6 1 3 6 5 2 Contents of the Data Display Contents of the data display are as follows Table 6 2 Contents of the data displsy NON CORR WI 0 0 to 100 0 0 01 1000 X4 SQT DENSITY A squ
10. 2 Town Gas Application Quake proof Type CM6G S6110 No Item No Item No Item 1 1 Calorie detector 3 1 Line filter 6 1 Standard gas cylinder supplied by customer 1 2 Solenoid valve 3 2 Pressure gauge 6 2 Standard gas cylinder supplied by customer 1 3 Orifice assembly 3 3 Flowmeter 7 1 Pressure reducing valve for cylinder optional 1 4 Differential pressure transmitter air 3 4 Pressure reducing valve 7 2 Pressure reducing valve for cylinder optional 1 5 Differential pressure transmitter gas 3 5 Pressure gauge 1 6 Computing station 3 6 Pressure reducing valve V1 16 Ball valve needle valve 2 1 Air set 4 1 Pressure reducing valve 2 2 Pressure reducing valve 5 1 Density meter detector 2 3 Pressure gauge 5 2 Density meter converter 2 4 Preheating chamber 5 3 Flowmeter for density meter 2 5 One touch coupler oe Et BSA SAMPLE GAS IN A ON Mpa 10 to 20kPa STD GAS IN ZERO SAMPLE GAS OUT FE OR VENT N EN Maximum back pressure 12 is 1 5 kPa and no pressure MIT fluctuation is allowed IN LAN 6 1 STD GAS IN SPAN FLOW 6110 ai Figure 6 3 Flow Sheet for Town Gas IM 11R02A01 02E 6 4 lt 6 Construction and Function gt 3 Steel Mill Application CM6G S6500 S6510 S6600 S6610 S6700 S6710 S6800 S6810 No Item No Item No Item 1 1 Calorie detector 3 1 Pressure gauge 5 1 De
11. Orifice assembly Gas and air orifices housed in the constant temperature chamber Solenoid valve Serves as a safety valve to shut offthe sample gas flow Figure 6 1 Components and Functions of Model CM6G Gas Calorimeter Air Pressure Regulating Section N SEEALSO Refer to Figure 6 2 6 3 and 6 4 The instrument air pressure 300 to 700 kPa is reduced by air set 2 1 to about 200 kPa further reduced to about 20 kPa by the pressure reducing valve 2 2 and after that the pressure is set by needle valve V 16 to the differential pressure 500 Pa The air is controlled at 40 C in the preheater which helps the temperature control by the orifice When the temperature is increased more than 60 C thermostat in the preheater operates and intercepts the power supply of the heater This air pressure regulating section is common to all systems IM 11R02A01 02E 6 2 6 2 6 2 1 6 2 2 lt 6 Construction and Function gt Gas Pressure Control Section The gas pressure regulating section has two different kind types town gas use and steel mill use Town Gas Use CX See Also Refer to Figure 6 2 and 6 3 The sample gas introduced through line filter 3 1 increase its pressure by pump or decrease by pressure reducing valves according to the pressure at the sampling point The pressure gauge 3 2 indicates 8 to 18 kPa and the flowmeter 3 3 approx 10 l min respectively The sample gas then is set its differenti
12. Reverse flow pipe External pipe lt 6 Construction and Function gt 6 9 6 4 2 6 4 3 High Low Alarm Action Higher and lower alarm limits are set for the amplified thermocouple output respectively to execute a sequence The higher alarm limit is the alarm point for the excessive combustion of the burner which is set to approximately 120 of the span The lower alarm limit is the alarm point for the flame extinction of the burner which can be changed in a range appropriate to each measurement range using the LOW AL volume on the front panel of the calorie detector This alarm point is set to an appropriate value in the final adjustment test at the factory before shipment If the higher or lower limit alarm occurs the electromagnetic valve EV is closed to stop the supply of gas Ignition Action When the START switch on the front panel of the calorie detector is pressed the ignition action starts The ignition action constitutes one cycle that consists of the time during which the ignition voltage is applied to the heater T1 and the time during which the voltage is not applied T2 in the case of gas with low calorific value the time during which the preheating voltage is applied This cycle is repeated five times normally The T1 time and T2 time are set independently within the range from approximately 2 to 20 seconds depending on the measurement range and gas composition If the amplified thermocouple o
13. Steel Mill Application Conditions at the Sampling Point Changed the description of the pressure 1 Section 2 1 2 Steel Mill Application Alarm Contact Output Added of the description page 2 3 Section 2 2 1 Gas Calorimeter Table Changed the descriptions of the system specification page 2 4 Section 2 2 2 Standard Accessories Calorie Detector Changed the part number of the fuse page 2 5 Section 2 3 1 Standard Systems for Each Application Table Changed the descriptions of the system specification page 2 6 Section 2 4 1 For Town Gas Application Added weight page 2 7 Section 2 4 2 For Town Gas Application Quake proof Type Added weight page 2 8 Section 2 4 3 For Steel Mill Application Added weight and deleted the figure of the pressure regulating pot page 5 2 Section 5 2 4 Contact Output Added of the description page 12 2 Section 12 1 Calorie Detector E7023TA b Print circuit board assembly E7023RA Changed the part number of the fuse Printed Circuit Board Assembly and Relay Section 12 1 Calorie Detector E7023TA c Ignition transformer assembly E7023EA Changed the parts number of the Relay YOKOGAWA lt gt All Rights Reserved Copyright 2009 5th Edition Feb 2014 YK IM 1 1 RO2A01 02E Subject to change without notice 4th Edition Yokogawa Electric Corporation lt 2 Specifications gt 2 1 2 Specifications 2 1 Standard Specifications EMC EMC
14. uunnnannsnnannsnnnannannannunnnannannannnnnannannannnnnnannannnnnnannannannnannn 12 4 12 5 Line Filter H7800E6 uc 12 5 12 6 Switch Box H7800HV is ccoo 12 5 12 7 Probe H7800HA H7800HB H7800HC coocccccnnccccnonosnennennanncnnenenannnanannrnncnnnas 12 5 12 8 Temperature Controller E7023RE secerenenanena nana nena nana nena nana nana nana nanananen 12 6 E Principle of Measurement uuus444400n000nnn0nnnnnnnnnnnnnnnnnnnnnnnnannnnnnnnnnnnnnnnnnnnnnnn 1 Custmer Maintenance Parts List 0sesenersawananenanene CMPL 11R02A01 02E Revision Information de Ta e nee i IM 11R02A01 02E lt 1 Outline gt 1 1 1 Outline Model CM6G Gas calorimeter is used to measure and control the calorific value of gases Wobbe Index the theoretical air requirement and the heat input for various kind of gas burning furnaces It detects the temperature rise of the sample gas which pressure is normally controlled by burning it at the burner through the medium of air It picks up the flow rate of the sample gas and the air as the differential pressure signal and gives you an output signal of WI after compensating calculation of the indication difference caused by the flow rate variation It also detects density of the sample gas by a density meter and add to WI signal density compensation then gives you an output of the calorific signal IM 11R02A01 02E lt 2 Specifications gt 2 1 2 Specifications 2
15. 100 NX 1000 Approx 1670 1500 100 4 015 holes Mark Name Connection A SAMPLE GAS IN Rc1 4 B INST AIR IN Rc1 4 C1 STD GAS IN ZERO Rc1 4 C2 STD GAS IN SPAN Rc1 4 D SAMPLE GAS OUT OR VENT Rc1 2 Wiring to switch box should be made through the bottom Maintenance Space 500 1000 100 M e te al TF 8 8 j Back a qe o Front 3 00 Weight Approx 350kg CARS Dim 6110 ai Figure 2 3 External Dimensions For Town Gas Use Quake proof Type IM 11R02A01 02E 2 8 lt 2 Specifications gt 2 4 3 For Steel Mill Application CM6G S6500 S6510 S6600 S6610 S6700 S6710 S6800 S6810 X Unit mm Mark Name Connection 80 A SAMPLE GAS IN Rc1 2 Density meter B SAMPLE GAS OUT Rc1 2 C SAMPLE GAS OUT Rc1 2 D STD GAS IN Rc1 4 E WATER IN Rc1 2 F DRAIN OUT Rc1 2 G INST AIR IN Rc1 4 H SAMPLE GAS VENT Rc1 4 2000 o 20000 LO onon m o Pump 1900 1650 Density meter EA j 1500 converter Flowmeter for ar Computing density meter Fulflo filter dh station e EE D Denumiaer Approx 40 SN Calorie detector AP o Zu oe 7 750 Washing bubbler 2 100 lt Drain pot 100 Pressure regulating pT pot 30 740 30 100 800 4 214 holes o o CM6G
16. clean or replace as according to the paragraph 10 2 2 4 Check the indication of the pressure gauge 3 1 is approx 6 kPa lf there is no water accumulated in the washing bubbler no indication appeared on the pressure gauge in such case supply water to the washing bubbler lf the pump is attached and its suction ability decreased the case might happen that the pressure gauge does not indicate the normal value after the adjustment by only V 2 and V 3 5 When introducing the calibration gas check the indication of the flowmeter 4 2 is approx 10 l min When cannot be adjusted by the pressure reducing valve 4 1 it is likely that the pressure reducing valve is defective 6 Check the element of the fulflo filter 3 3 lf it is clogged clean or replace as according to the paragraph 10 2 2 7 Check the water level of the pressure regulating pot lf necessary supply water or clean 8 Check if the bubbles are coming out 3 6 pcs sec from the pipe A of the pressure regulating pot Even after using V 11 V 12 fail to adjust clean the piping inside the dehumidifier as according to the paragraph 10 2 5 Note no bubbles are coming out however in case of low calorie gas 9 When the density meter is attached check if the indication of the flowmeter 5 3 is 0 5 to 1 l min 10 Check if the indication of the computing station is 500 when setting the indication of X3 G PRESS gt When the adjustmen
17. this manual A DANGER This symbol indicates that an operator must follow the instructions laid out in this manual in order to avoid the risks for the human body of injury electric shock or fatalities The manual describes what special care the operator must take to avoid such risks N WARNING This symbol indicates that the operator must refer to the instructions in this manual in order to prevent the instrument hardware or software from being damaged or a system failure from occurring N CAUTION This symbol gives information essential for understanding the operations and functions Media No IM 11R02A01 02E 4th Edition Oct 2011 YK IM 11R02A01 02E All Rights Reserved Copyright 2008 Yokogawa Electric Corporation ii lt INTRODUCTION gt A TIP This symbol gives information that complements the current topic N SEEALSO This symbol identifies a source to be referred to amp This symbol indicates Protective Ground Terminal p This symbol indicates Function Ground Terminal Do not use this terminal as the protective ground terminal This symbol indicates Alternating current A DANGER During the time from the start of ignition action to ignition and directly after flame extinction sample gas mixed with the air will be released from the top of the equipment into the installation space of the equipment Even though the sample gas will be diluted sufficiently by the air great attention
18. Reserved Copyright 1996 Yokogawa Electric Corporation CMPL 11R02A01 02E YOKOGAWA Subject to change without notice 3nd Edition Apr 2011 YK Yokogawa Electric Corporation Revision Information e Title Model CM6G Gas Calorimeter O Manual No IM 11R02A01 02E Oct 2011 4th Edition All over revised Chapter 2 Subsection 2 1 1 Town Gas Application Alarm Contact Output Changed of description Added the item of Contact Input Panel Changed of panel color Subsection 2 1 2 Town Gas Application Range Changed of description Alarm Contact Output Changed of description Added the item of Contact Input Panel Chaned of panel color Sunsection 2 2 1 Gas Calorimeter Changed of style code Nov 2008 3rd Edition Revised with the change of style code B Chapter 2 Subsection 2 1 1 Rated current of alarm contact output is corrected to 3A Subsection 2 1 2 Description about Range is revised Subsection 2 2 2 Change to style B in MS code table Subsection 2 3 1 Suffix code S3610 is corrected to S6310 Section 2 4 The item Hexagon Wrentch is deleted from table list of calorie detector standard accessory Section 2 5 page2 6 to 2 8 Drawings of Computing Station change to Model YS1700 Subsection 2 5 2 In item 1 lengh of H7800HC is corrected Chapter 3 Section 3 1 Description about conditioned air is added Section 3 2 Explanation about piping is added to body Therma
19. an angle that allows drain to flow downstream and smoothly F4 1 ai Figure 4 1 Recommended Sampling for Steel Mill Use IM 11R02A01 02E 4 2 lt 4 Outside Pipings gt lt Sampling point shall be made at the location above or side the transfer pipe and in case of being installed on the side location fix it with a slope that the top end of the probe is facing downward lt When fixing the probe use a flange JIS 10K 80A lt Atthe sample gas outlet of the probe recommend to provide a gate valve of 1 2 inch Gate valve 1 2 inch Transfer pipe F4 2 ai Figure 4 2 Mounting of the Probe e Fix filter vertically with their drain outlets facing downward but firmly to wall or to pillar using something like U bolt Provide 1 2 inch gate valves at the sample gas inlet and outlet Take an ample space under filters so that checking and replacing of elements can be held easily For drain exhaust pipe use a flexible pipe Gate valve 1 2 inch F4 3 ai Figure 4 3 Example Fulflo Filters with the Piping IM 11R02A01 02E lt 5 External Wirings gt 5 1 5 External Wirings External wires shall be connected from the terminal block of the switch box inside the panel Use M4 terminal screws Use appropriate crimp terminals at the wire ends
20. by the zero point adjustment will return to the value before the adjustment Zero Adjustment Screw FO7O5 EPS Figure 7 1 Differential Pressure Transmitter IM 11R02A01 02E 7 4 7 7 7 8 lt 7 Preparation of Operation gt Air Differential Pressure Adjustment Switch the computing station to the Input Output status display refer to Figure 6 15 and check X2 A PRESS Adjust V 16 so that the indicated value becomes 500 If the indicated value of the pressure gauge 2 3 has deviated from 20 kPa set the indicated value to 20 kPa using the pressure reducing valve 2 2 and make the adjustment in b again Pressure Adjustment of the Gas Line For the pressure adjustment of the gas line we use the air El For town gas use a b j Close V 6 and connect the one touch coupler 2 5 Open V 7 and V 8 Turn the switch SAFE EV of the calorie detector to RELEASE in this time the solenoid valve of the gas line open and the alarm is released By adjusting the pressure reducing valve 4 1 set the flow rate of the flowmeter 3 3 to 10 l min In this time the pressure gauge 3 2 indicate 8 to 18 kPa Adjust by using the pressure reducing valve 3 4 the pressure gauge 3 5 to become approx 3 kPa When a density meter is attached adjust the throttle valve of the flowmeter 5 3 so that the indication becomes 0 5 to 1 Imin Set the indication of the computing station to Input Output status
21. correct to the value at the standard differential pressure Eo Eo 6 1 In the computing program each differential pressure is extracted of the square root and provide a differential pressure correcting computation The signal after corrected is range suppressed ZERO and to further extended to SPAN In case when it has a preheat circuit deduct the amount of preheated value and extend to SPAN then being range suppressed and shall be extended again to SPAN Further as to generate the output of the calorific signal the following density correction is necessary K C WI A Pg 6 2 Also it is necessary for each signal to operate with a timing matched with the signal of the calorie detector and for this reason dynamic characteristic function is provided A CORR RATE A TIME G CORR RATE G TIME Remarks In case of pre heating circuit exists the formula is as follows K g A A Pg H A Pg APa APa H Pre heat calorie Ci C2 Constant Pg Density of the gas A C1 6 3 If the correction computation of the differential pressure is provided to AB in the formula 6 3 it is shown as per the following formula ein a Sep ie E 6 4 AN A Pa A Pg A Pg The second clause of the right part in the formula 6 4 represent the preheat calorie which as you can see in the formula 6 4 the matters concerning the preheating is varied according to the change of differential pressure APg In this computing
22. display and check X3 G PRESS Adjust by pressure reducing valve 3 6 so that the indication X3 becomes 500 When the pressure indication of the pressure gauge 3 5 differs from about 3 kPa adjust again the procedure in item e then conduct the adjustment When the adjustment completed close V 8 V 7 separate the one touch coupler 2 5 and open V 6 Set the SAFE EV switch of the calorie detector to SET E For steel mill use a b IM 11R02A01 02E Close V 4 connect the one touch coupler 2 5 and open V 5 and V 8 Set the switch SAFE EV of the calorie detector to RELEASE when the solenoid valve of the gas line open and the alarm is released Adjust the flow rate of the flowmeter 4 2 by using the pressure reducing valve 4 1 to become about 10 l min In this time the pressure gauge 3 1 indicates approx 6 kPa When the density meter is attached adjust the indication of the flowmeter 5 3 to 0 5 to 1 l min by using V 11 Adjust by using V 12 the number of bubbles come out from the pipe A of the pressure regulating pot 3 4 3 6 pcs sec Open V 12 fully in case of the low calorie instrument when no bubbles came out Set the indication of the computing station to Input Output status display and check X3 G PRESS With the pressure reducing valve 3 6 adjust the indication X3 to become 500 When the number of bubbles from pipe A be changed adjust the nu
23. is necessary GAS IN GAS OUT BLOW HEX BOLT CAP PIPE PACKING CASE DRAIN 6J DRAIN Ll os A DIFFUSION CASE PIPE FROM PIPE TO DETECTOR Ds BIETER PIPE L 338 St PIPE A PIPE TO DENSITY He DRAIN HOLE WATER DRAIN HOLE L 383 NORMALLY PLUGGED NORMALLY PLUGGED a Washing bubbler b Pressure regulating pot F10 6 ai Figure 10 5 Washing Bubbler and Pressure Regulating Pot IM 11R02A01 02E lt 10 Maintenance gt 10 5 10 2 5 Dehumidifier For Steel Mill Use If the naphthalene is too much contained in the sample gas in spite of the gas gone through the washing bubbler there might happen the case such naphthalene can hardly be cleaned and contaminated in the state of being crystallized in the pipings inside the dehumidifier If such case happen stop the sample gas flow and remove 4 pipes atthe top of the dehumidifier and introduce the hot water of 70 C to 80 C the naphthalene is dissolved into the hot water and no contamination left PRESSURE REDUCING VALVE ULFLO FILTER ORIFICE ASSEMBLY Aj DENSITY METER n O CIRCUIT BREAKER POWER POWER LAMP COOL COOL LAMP F11 7 ai TERMINAL BLOCK DRAIN TO PRESSURE REGULATING POT Figure 10 6 Dehumidifi
24. line with thermal insulation so as to prevent drain in the pipe line to be freezed e Locate the standard gas cylinders at the place where they are not exposed to direct sunshine and comparatively cool Probe N Safely vent to the atmosphere House Requirements A Temperature O to 40 C Not rapid temperature change allowed u xN a Adequate ventilation and lighting provided Steam for ye Valves for maintenance gt SL Steam for thermal t should be installed Se X nz lo ls ON Y E AAA blowing back a insulation D Pipe SUS 15A or greater gt 1 Pipe SUS 15A Pipe SUS 15A SHT pe Sample Gas Inlet Tetoron Braid Hose Std Gas Pipe 6 4 Cu Inlet Power Supply FF 100 V AC 10 50 60Hz il Max approx 1100 VA Sample Gas Out Sample Gas Vent Sample Gas Out gt Output Signal gt Alarm Contact Pipe 6 04 Cu Output Signal Pressure O1 Pressure CM6G I i 1 Pipe SUS 15a Instrument Air 1 Reducing Gas De Pressure 0 3 0 7MPa Water In Calorimeter Flow rate Approx 50NI min Drain Outlet Pipe SUS 15A Pressure 0 1 0 2MPa Drain i gt gt A ANA A 4 2A Must be A a we AH Water sealing greater than pressure at sampling point is required water sealed Seal pot Must be water sealed an Zero Gas Span Ga Brain Pipe SUS 15A Note denotes that piping should be installed at
25. ofthe span Butane or Butene Air 20 to 30 of maximum value ofthe span Propane or Propylene Air 25 to 40 of maximum value ofthe span Output 1t05 V DC 4 to 20 mA DC simultaneously non isolated load resistance 7500 or less Alarm Contact Output Flame off alarm 100 VAC 5A closed when alarm occurs resistance load Temperature alarm 100 VAC 3A closed when alarm occurs resistance load Contact Input Remote ignition Custom order 24 V DC 0 1A or more Repeatability Measuring range Note 1 Repeatability High calorific value 0 5 of measured value Low calorific value 1 0 of measured value Calorific value High calorific value 1 0 of measured value MJ Nm Low calorific value 1 5 of measured value Note 1 High calorific value means 6 3 MJ Nm or more Low calorific value means below 6 3 MJ Nm Sample Gas Flow Rate Approx 10 l min Response Time Note 2 Max WI measured Response time 63 2 50 or more 42 sec or less 70 sec or less 32 or more less than 50 39 sec or less 60 sec or less 13 or more less than 32 36 sec or less 50 sec or less 13 or less 30 sec or less 45 sec or less Note 2 Response time varies depending on the WI of a sample gas This is due to the different sample gas flow rate of the calorimeter The flow rate is preset depending on the WI of the sample gas to prevent the calorific value at the detector burner from exceeding the upper unit IM 11R02A01 02E lt 2 Specificati
26. or auxiliary equipment which Yokogawa Electric did not supply e Failure due to improper or insufficient maintenance by user e Failure due to modification misuse or outside of specifications operation which Yokogawa does not authorize e Failure due to power supply voltage frequency being outside specifications or abnormal e Failure caused by any usage out of scope of recommended usage lt Any damage from fire earthquake storms and floods lightning disturbances riots warfare radiation and other natural changes Yokogawa does not warrant conformance with the specific application at the user site Yokogawa will not bear direct indirect responsibility for damage due to a specific application m Yokogawa Electric will not bear responsibility when the user configures the product into systems or resells the product Maintenance service and supplying repair parts will be covered for five years after the production ends For repair for this product please contact the near est sales office described in this instruction manual IM 11R02A01 02E lt CONTENTS gt i Model CM6G Gas Calorimeter IM 11R02A01 02E 4th Edition CONTENTS INTRODUCTION 2 a een i For the safe use of this equipment nusannannsnnnnnnnnnnnnnnnnnnnnnunnunnnnnnnnnnnnnnnennnnnnnnnnnnennnnann i After sales WarranWVo cui iii 1 OU An nO 1 1 2 SPEEINCAHONS ct cantada ee tases cape ose ai Naba ank aaa aki kennen 2 1 2 1 Standard Specifica
27. pressure to 500 9 2 1 When no Preheating Circuit Exist IM 11R02A01 02E Set the computing station to Input Output status display with X1 NON CORR WI Introduce the span gas and after ignition wait until the indication X1 becomes stable Adjust the indication using the SPAN potentiometer on the front side of the calorie detector to become the specified value x WI is used to find out the x value Example WI value of the span gas 7960 WI WI value of the upper range 8000 WI 7960 o 8000 x 100 99 5 x lt 9 Calibration gt 9 3 9 2 2 When Preheating Circuit Exists x Suspend the supply ofthe sample gas Same as the gas line pressure adjustment explained in paragraph 6 1 8 introduce the air to the gas line Set the SAFE EV switch of the calorie detector to RELEASE when the preheating voltage is applied to the ignition heater of the burner unit by which the increased temperature with an effect of the preheating is detected by the thermocouple Switch the METER switch of the calorie detector to P MEAS and measure XS of the computing station Wait until the indicated value is stabilized and then record the value E0 mV Switch the SAFE EV switch of the calorie detector to SET Stop the air supply to the gas line supply the span gas and start the ignition action Measure X5 of the computing station Wait until the indicated value is stabilize
28. status status i Ignition action starts Not ignition Ignitied Excessive A Ignition action Ignition action starts Figure 6 11 Ignition Sequence IM 11R02A01 02E 6 1 0 lt 6 Construction and Function gt 6 5 Computing Station By calculate the calorie detector signal with each differential pressure signal the WI signal is generated And on the same time the calorific signal is generated by compensating the density with the density signal Each input after A D conversion digitally computed then D A conversion generate DC 4 to 20 mA DC 1 to 5 V output 6 5 1 Indication Selection E Explanation of display indication FAIL lamp TREND 3 ALARM lamp Y1 Clorific value green IN CEMEG ns X1 NON CORR WI yellow Trend u ne X3 Gas differential Y2 WI value light blue p 3800 x3 su pressure Pa pink RL Y2 MAX range of WI X3 MAX range of gas a IS light blue differential pressure pink _ Y1 MAX range of IM Calorific value green X1 MAX range of NON ren Trend data indicator 1 to 4 i S Y1 green Calorific value CORR WI value yellow Yilgreen Cs ight blue ANO A NON CORR WI X1 MIN range of NON V X3 pink differential gas pressure Pa CORR WI value yellow TE ae LPF Y1 MIN range of oo 2302 Calorific value green X3 MIN range of gas ee A differential pressure pink i
29. 0 sec orless 60 sec or less 32 or more less than 50 27 sec orless 53 sec or less 13 or more less than 32 23 sec or less 47 sec or less 13 or less 21 sec or less 41 sec or less Note 2 Response time varies depending on the WI of a sample gas This is due to the different sample gas flow rate of the calorimeter The flow rate is preset depending on the WI of the sample gas to prevent the calorific value at the detector burner from exceeding the upper limit IM 11R02A01 02E 2 2 lt 2 Specifications gt Utility Instrument Air Approx 50 Nl min pressure 300 to 700 kPa dew point of 0 C or less Power Supply 100 VAC 10 single phase 50 60 Hz Note 3 860 VA max Note 3 In case of low calorific value measurement frequency variation should be within 0 4 If frequency variation exceeds 0 4 consult with Yokogawa Panel Construction For indoor installation rack panel Paint Color Munsell 3 2PB7 4 1 2 inside and outside Ambient Temperature O to 40 C little temperature variation particularly no rapid change in temperature allowed 2 1 2 Steel Mill Application Measurement Object Measurement and control of WI or the calorific value of fuel gas for a steel mill Measuring range 3 to 62 MJ Nm Sample Conditions Dust 100 mg Nm or less Temperature 50 C or less Pressure 1 8 kPa or over standard 2 8 kPa or under with pump Range Select scale range Span General Gas 30 to 50 of maximum value
30. 1 Standard Specifications 2 1 1 Town Gas Application Measurement Object Measurement and control of WI or the calorific value of fuel gas for town gas Measuring Range 31062 MJ Nm Sample Conditions Dust 5 mg Nm or less Temperature 50 C orless Humidity dew point of 0 C or less Pressure 1 10 to 20 kPa standard 2 10 kPa or under with pump 3 100 to 600 kPa with pressure reducing valve Range Select scale range Span General Gas 30 to 50 of maximum value ofthe span Butane or Butene Air 20 to 30 of maximum value of the span Propane or Propylene Air 25 to 40 of maximum value ofthe span Output 1 to 5 V DC 4 to 20 mA DC simultaneously non isolated load resistance 750 Q or less Alarm Contact Output Flame off alarm 100 VAC 5A closed when alarm occurs resistance load Temperature alarm 100 VAC 3A closed when alarm occurs resistance load Contact Input Remote ignition Custom order 24 V DC 0 1A or more Repeatability Measuring range Note 1 Repeatability Wi High calorific value 0 5 of measured value Low calorific value 1 0 of measured value Calorific value High calorific value 1 0 of measured value MJ Nm Low calorific value 1 5 of measured value Note 1 High calorific value means 6 3 MJ Nm or more Low calorific value means below 6 3 MJ Nm Sample Gas Flow Rate Approx 10 l min Response Time Note 2 Max WI measured Response time 63 2 50 or more 3
31. 22 0 PC 420mA CALORIFIC 23 0 gt OUTPUT DE 1 5 DC 1 5V Se 24 Te wi OUTPUT O6 25 04 gt 94 DC 1 5V DC 1 5V DIFFERENTIAL PRESSURE TRANSMITTER AIR PENSIDEMEIEE er O3 26 gt OPTIONAL 27 0 OUTPUT O7 0 8 3 D 250 Q 4 Figure 11 1 Signal Circuit Diagram 123456789 elo ojo alae ajo ajo ojo aloe ofo 10 11121314151617 18 1920212223242526 27 a ojojojojo aja ale eel Figure 11 2 Terminal Block of the Calorie Detector IM 11R02A01 02E lt 11 Troubleshooting gt 11 5 11 5 Computing Station If the value is all normal each input of the computing station shows the following normal values in the table Mark of input data Normal indication A PRESS Pa 500 50 G PRESS Pa 500 50 SQT DENSITY Same as density meter When pre heating circuit does not exist O to 100 is almost in proportion to 0 the highest level WI value in the measurement range When preheating exists about 20 to 100 is almost in proportion to 0 The highest level WI value of the measurement range The lamps of both alarm and fail of the computing station are lighted in the following case 1 Lighting of the alarm lamp Yellow color It lights when the input or output signal is cut off But in this ca
32. Application Standard Type CM6G S6200 S6210 S6300 S6310 S6400 S6410 No Item No Item No Item 1 1 Calorie detector 3 1 Line filter 5 1 Density meter detector when specified 1 2 Solenoid valve 3 2 Pressure gauge 5 2 Density meter converter when specified 1 3 Orifice assembly 3 3 Flowmeter 5 3 Flowmeter for density meter when specified 1 4 Differential pressure transmitter air 3 4 Pressure reducing valve 6 1 Standard gas cylinder supplied by customer 1 5 Differential pressure transmitter gas 3 5 Pressure gauge 6 2 Standard gas cylinder supplied by customer 1 6 Computing station 3 6 Pressure reducing valve 7 1 Pressure reducing valve for cylinder optional 2 1 Air set 3 7 Diaphragm pump when specified 7 2 Pressure reducing valve for cylinder optional 2 2 Pressure reducing valve 3 8 Pressure reducing valve when specified 2 3 Pressure gauge 4 1 Pressure reducing valve V1 16 Ball valve needle valve 2 4 Preheating chamber 2 5 One touch coupler paa SAMPLE GAS IN A s nmin STD GAS IN ZERO SAMPLE GAS OUT 7A OR VENT akd aig 724 Maximum back pressure Il is 1 5 kPa and no pressure Mm Da iNet fluctuation is allowed FLOW 6410 ai 1 CM6G S60110 with density meter 2 CM6G S6300 with diaphragm pump 3 CM6G S64L10 with pressure reducing valve Figure 6 2 Flow Sheet for Town Gas
33. B H7800HC a ree o p F12 9 ai Figure 12 9 Probe IM 11R02A01 02E 12 6 lt 12 Replacement Parts gt 12 8 Temperature Controller E7023RE No Name Qty PartNo For orifice chamber and Temperature Controller E7023RE preheating chamber Case F12 10 ai Figure 12 10 Temperature Controller IM 11R02A01 02E SE Principle of Measurement gt 1 E Principle of Measurement The instrument is to detect the temperature difference using a thermocouple between the exhaust combustion gas made after sample gas is burnt in the burner and the feed air at the inlet of the burner then amplify and add the compensating calculation to the output signal and measure the calorific value of WI gt DIFFERENTIAL BURNING MIXING PRESSURE DETECTION E 2 2 1 GAS gt d gt gt gt BLOW ER PRIMARY SECONDARY gt COMPENSATING CALCULATION AIR gt aoa MA TERTIARY OUTPUT V _ SIGNAL DIVIDING Figure 1 1 Measurement principle diagram When the sample gas is burnt by the air the formula of the increased temperature is as follows K Fg AQ Y 1 1 Cps Fs where K Calorific value of the sample gas Fg Flow rate ofthe sample gas Fs Air diluted combustion exhaust gas flow rate Cps Constant pressure heat ratio of air d
34. J Nm Gas pressure 10 to 20 kPa Standard Gas pressure 10 kPa or under With pump Gas pressure 100 to 600 kPa With pressure reducing value Steel Mill Without Gas pressure 8 kPa or over Without preheating density Gas pressure 8 kPa or over With preheating meter Gas pressure 8 kPa or under Without preheating Gas pressure 8 kPa or under With preheating Calorific value Gas pressure 8 kPa or over Without preheating MJ Nm Gas pressure 8 kPa or over With preheating Gas pressure 8 kPa or under Without preheating Gas pressure 8 kPa or under With preheating Corresponding Suffix Code of S6 gas pressure and measurement Note A wet sample gas in the town gas application is outside the scope of the standard specifications Consult with Yokogawa 2 3 2 Instructions for System Selection 1 The quake proof type gas calorimeter is always equipped with the density meter 2 The CM6G Gas Calorimeter controls the flow rate under a constant differential pressure In the calorific value measurement if the density of a sample gas changes a flow rate error proportional to the reciprocal of the square root of the density of the sample gas 1 Veg will be generated which directly affects the calorific value Therefore density compensation is required using a density meter For the WI measurement a density meter is not required since the WI is a value proportional to 1 Wpg IM 11R02A01 02E 2 6 lt 2 Specifications gt
35. Maintenance gt 10 3 10 2 2 Fulflo Filter For Steel Mill Use The material of the element is polypropylene The cleaning and the replacement of the element shall be carried out as under mentioned a o o d Turn the nut and remove the cover Pull out the element and clean or replace Assembly is carried out in contrary order to above When the packing or gasket is worn out replace it PACKING ME H COVER AAR GASKET Gi ELEMENT TENSION BOLF CASE AJANIN F11 4 ai Figure 10 3 Fulflo Filter 10 2 3 Line Filter For Town Gas Use Disassemble 3 screws and open the cover there inside exist the element If it is stained replace by a new one Also ifthe O ring is fatigued replace it ELEMENT SCREW O RING GAS INLET FILTER Y ELEMENT La l te GUIDE BODY Figure 10 4 Line Filter IM 11R02A01 02E 1 0 4 lt 10 Maintenance gt 10 2 4 Washing Bubbler or Pressure Regulating Pot If inside of case become dirty by the weeds grown in the water pull the plug at the bottom of the bubbler and exhaust and renew the water If inside the bubbler is stained remove the cover and clean it Be careful not to scatter the water around the panel When the water level becomes higher than the drain exhaust outlet position there would be a possible contamination in the exhaust pipe line so the cleaning
36. Regulatory Arrangement in Australia and New Zealand Korea Electromagnetic Conformity Standard Class A 2 1 1 Town Gas Application Measurement Object Measurement and control of WI or the calorific value of fuel gas for town gas Measuring Range 310 62 MJ Nm Sample Conditions Dust 5 mg Nn or less Temperature 50 C or less Humidity dew point of 0 C or less Pressure 1 10 to 20 kPa 2 10 kPa or under with pump 3 100 to 600 kPa with pressure reducing valve Range Select scale range Span General Gas 30 to 50 of maximum value of the span Butane or Butene Air 20 to 30 of maximum value of the span Propane or Propylene Air 25 to 40 of maximum value of the span Output 1 to 5 V DC 4 to 20 mA DC simultaneously non isolated load resistance 750 Q or less Alarm Contact Output Flame off alarm 100 VAC 5A closed when alarm occurs resistance load when contactis opened the leakage current is 2 mA or less 100 VAC Temperature alarm 100 VAC 3A closed when alarm occurs resistance load Contact Input Remote ignition Custom order 24 V DC 0 1A or more Repeatability Measuring range Note 1 Repeatability Wi High calorific value 0 5 of measured value Low calorific value 1 0 of measured value Calorific value High calorific value 1 0 of measured value MJ Nm Low calorific value 1 5 of measured value Note 1 High calorific value means 6 3 MJ Nm or more Low calorific value me
37. S60110 with density meter and flowmeter CM6G S67L10 CM6G S68L10 with pump Maintenance Space 540 260 900 500 Weight Approx 350kg Dim 6810 ai Figure 2 4 External Dimensions For Steel Mill Use IM 11R02A01 02E 5 2 lt 5 External Wirings gt 5 1 5 2 5 2 1 5 2 5 Notes on Wiring N WARNING e Cables and wires must be connected after all power supplies are turned off An electrical wiring duct must not be used for the simultaneous connection of a large capacity converter motor or power supply lt When cables are connected in a place with high or low ambient temperatures use cables suitable for the place where they are used lt When cables are used in an atmosphere where harmful gases liquids oil or solvents are present use cables made of materials capable of withstanding those things Use crimp terminals with insulated sleeve M4 screws for the wire ends Wiring to Peripheral Equipment Power Supply Use a 600 V insulated vinyl cabtyre cable JIS C3312 with a cross section area of 2 mm or more or a wire or cable that is the equivalent or better Grounding Connect a grounding wire to the grounding terminal inside the panel A grounding wire must be connected so that the grounding resistance becomes 100 Q or less equivalent to JIS Class D Analog Output 4 to 20 mA DC Use a shielded twisted pair cable with a cross section area of 0 5 mm or m
38. User s Manual Model CM6G Gas Calorimeter IM 11R02A01 02E vigilantplant YOKOGAWA 4 IM 11R02A01 02E Yokogawa Electric Corporation 4th Edition lt INTRODUCTION gt i INTRODUCTION For the safe use of this equipment E About This Manual This manual should be passed on to the end user The contents of this manual are subject to change without prior notice The contents of this manual shall not be reproduced or copied in part or in whole without permis sion This manual explains the functions contained in this product but does not warrant that they are suitable for the particular purpose of the user Every effort has been made to ensure accuracy in the preparation of this manual However when you realize mistaken expressions or omissions please contact the nearest Yokogawa Electric representative or sales office This manual does not cover the special specifications This manual may be left unchanged on any change of specification construction or parts when the change does not affect the functions or performance of the product If the product is not used in a manner specified in this manual the safety of this product may be impaired E Safety and Modification Precautions Follow the safety precautions in this manual when using the product to ensure protection and safety of the human body the product and the system containing the product E The following safety symbols are used on the product as well as in
39. al pressure to 500 Pa by pressure reducing valve 3 4 and 3 6 and at this time the pressure gauge 3 5 indicates approx 3 kPa When the density compensation system is equipped it is introduced to the density meter with the flow rate of 1 I min through the flowmeter 5 3 The standard gas is reduced its pressure to 8 to 18 kPa by the pressure reducing valve 4 1 and supplied same as the sample gas with the flow rate approx 10 l min Steel Mill Use CX See Also Refer to Figure 6 4 The pressure of the sample gas is increased by the pump according to that of the sampling point The pressure gauge 3 1 indicates approx 6 kPa The sample gas then flows through the washing bubbler 3 2 and the fulflo filter 3 3 and then secure a constant pressure in the pressure regulating pot 3 4 through the water sealed pipe from the dehumidifier 3 5 then set the differential pressure by the pressure reducing valve 3 6 to 500 Pa In case of increasing the pressure by the pump the drain pot 3 9 is added When the density compensation system is equipped the sample gas is supplied to the density meter with its flow rate of 1 l min through the flowmeter 5 3 The pressure of the standard gas is reduced by the pressure reducing valve 4 1 to about 6 kPa and is supplied by the flowmeter 4 2 with the flow rate about 10 I min IM 11R02A01 02E lt 6 Construction and Function gt 6 3 Standard Flow Sheet 1 Town Gas
40. ans below 6 3 MJ Nm Sample Gas Flow Rate Approx 10 l min Response Time Note 2 Max WI measured Response time 63 2 50 or more 30 sec or less 60 sec or less 32 or more less than 50 27 sec or less 53 sec or less 13 or more less than 32 23 sec or less 47 sec or less 13 or less 21 sec or less 41 sec or less Note 2 Response time varies depending on the WI of a sample gas This is due to the different sample gas flow rate of the calorimeter The flow rate is preset depending on the WI of the sample gas to prevent the calorific value at the detector burner from exceeding the upper limit IM 11R02A01 02E 2 2 lt 2 Specifications gt Utility Instrument Air Approx 50 Nl min pressure 300 to 700 kPa dew point of 0 C or less Power Supply 100 VAC 10 single phase 50 60 Hz Note 3 860 VA max Note 3 In case of low calorific value measurement frequency variation should be within 0 4 If frequency variation exceeds 0 4 consult with Yokogawa Panel Construction For indoor installation rack panel Paint Color Munsell 3 2PB7 4 1 2 inside and outside Ambient Temperature O to 40 C little temperature variation particularly no rapid change in temperature allowed 2 1 2 Steel Mill Application Measurement Object Measurement and control of WI or the calorific value of fuel gas for a steel mill Measuring range 3 to 62 MJ Nm Sample Conditions Dust 100 mg Nn or less Temperature 50 C or
41. are root of the sample gas 4 density X5 TCorLOWALARM mV Thermocouple electromotive force or 0 to 30 2 flame extinction alarm threshold value Output Y1 cal MJ NM Calorific value gt 1 YN dala poz SRA spenadusment TT P04 A CORR RATE Air differential pressure signal 0 0 to 200 0 computing correction rate P05 A TIME sec Time constant of air differential 0 0 to 100 0 pressure signal delay time G CORR RATE Sample gas differential pressure 0 0 to 200 0 signal computing correction rate P07 G TIME sec Time constant of sample gas 0 0 to 100 0 differential pressure signal delay time P08 PRESS ALARM SET Yo Differential pressure warning setting 0 0 to 100 0 1 Differs depending on each specification 2 Switched by pressing the METER switch IM 11R02A01 02E 6 1 4 lt 6 Construction and Function gt 6 5 3 Correcting Computation As this calorimeter sets the differential pressure of both sample gas APg and air APa to 500 Pa but in order to correct the indication error due to the variation of the differential pressure Flow rate the correcting computation is practiced The detection signal is obtained through the measurement with the standard differential pressure of 500 Pa but if each differential pressure change to APg and APa 500 Pa the detection signal shall be changed from Eo to E o AA Pg ANA Pa Therefore if we multiply the detection signal E o YAPa yAPg we can
42. as WI or cal e Repeat 2 or 3 times the above adjustments f When complete the adjustment suspend the supply of the calibration gas Other Adjustment The adjustment of P04 A CORR RATE P06 G CORR RATE and POS A TIME P07 G TIME is usually unnecessary Reserve the record of the data in the initial stage But when replacing the thermocouple the regular adjustment for the specific characteristic is performed but such adjustment consult to our service personnel Calibration of the Density Meter Regarding GD400G Gas density meter refer to attached Instruction Manual IM 11T3B1 01E IM 11R02A01 02E lt 10 Maintenance gt 10 1 10 Maintenance 10 1 Daily Check 10 1 1 Air Gas Differential Pressure Adjustment Confirm the air or gas differential pressure or adjust the indication of X2 A PRESS X3 G PRESS to the 500 The way how to adjust shall be carried out according to the paragraph 7 7 and 7 8 10 1 2 Take Out the Water Out of the Drain Pot Pump for Steel Mill Use If the drain is accumulated open V 7 and take it out and after the drain is taken out be sure to close the valve 10 1 3 Take Out the Drain from the Air Set Turn the knob at the bottom of the air set and take out the drain After the drain is taken out be sure to turn the knob to close tightly ADJUSTMENT KNOB LOCK NUT GAUGE FOR SECONDARY PRESSURE DRAINAGE KNOB Fit t ai Figure 10 1 Air Set IM 11R02A01 02E 10 2 l
43. as supply suspended and the burner extinguished the lamp MEAS of the calorie detector is lit off and the lamp ALARM on c Set the switch of the calorie detector SAFE EV to RELEASE d Inthe case of the town gas use close V 6 and open V 7 V 8 In case of the steel mill use close V 4 and open V 5 V 8 By such operation the sample gas in the gas line is blown off by the air e After continuing the blow for 3 to 5 min turn off the POWER switch of the calorie detector and ifthe density meter is attached cutthe power supply switch inside the density meter f Turn off all switches of the switch box g Lastly close V 14 and stop the air supply 8 2 2 Short Time Stopping Same as mentioned above suspend the supply of sample gas only If this state is to be held the warm up time is not necessary for the restarting operation IM 11R02A01 02E 9 9 1 9 1 1 lt 9 Calibration gt 9 1 Calibration For calibration zero and span gases are necessary Use the gas with the specifications as near to each measuring range for both lower limit and upper limit as possible Supply of the Calibration Gas For Town Gas Use N SEE ALSO Refer to Figure 6 2 and 6 3 Close V 6 and open V 7 In this time the burner is extinguished But ifthe pump is attached close V 6 and open V 7 after turn off the power supply of the pump Adjust the secondary pressure of the pressure reducing valve for calibr
44. ate the differential pressure correction value the flow rate is acquired from the orifice as a differential pressure and converted to an electrical signal using the differential pressure transmitter The orifice is housed in a constant temperature chamber orifice assembly the temperature of which is maintained at approximately 50 C by the temperature controller to prevent the temperature drift ofthe actual flow rate When the temperature exceeds 90 C the safety thermostat is activated to shut off the heater power supply When the temperature falls after the power supply is shut off the alarm thermostat is activated to provide an alarm closed contact output N WARNING Power is supplied to the differential pressure transmitter and the temperature controller from the calorie detector To operate the transmitter and the controller turn on the calorie detector switch of the switch box and the POWER switch on the front panel of the calorie detector MAIN PANEL ORIFICE ASSEMBLY heel DIFFERENTIAL PRESSURE TRANSMITTER TEMPERATURE CONTROLLER Figure 6 5 Differential Pressure Detection Equipment IM 11R02A01 02E lt 6 Construction and Function gt 7 o o 16 3
45. ation gas cylinder to become approx 200 kPa Open V 9 or V 10 and introduce the calibration gas Adjust the indication of the flowmeter 3 3 by the pressure reducing valve 4 1 to become about 10 l min In case of only indication check its adjustment of approximately 2 to 3 l min is permissible Push the START switch of the calorie detector to ignite Set the computing station to Input Output display screen refer to Figure 6 15 Ifthe indication of X2 A PRESS and X3 G PRESS is not 500 adjust each with the pressure reducing valve 3 6 and V 16 In the case of the density meter being attached confirm and readjust if necessary the indication of the flowmeter 5 3 When the calibration is completed close V 9 V 10 V 7 and open V 6 In the case of the pump being attached supply the power supply of the pump as the next step Push the START switch of the calorie detector to ignite Confirm and readjust if necessary the gas differential pressure and the flow rate to the density meter Do not forget to close the root valve of the calibration gas cylinder IM 11R02A01 02E 9 2 lt 9 Calibration gt 9 1 2 For Steel Mill Use N SEE ALSO Refer to Figure 6 2 and 6 3 9 2 Close V 4 and open V 5 The burner is extinguished However ifthe pump being attached turn off the power supply of it in advance Set the secondary pressure of the pressure reducing valve for calibra
46. d and then record the value Ec mV Set the computing station to Input Output status display and adjust the SPAN potentiometer of the calorie detector so that X1 will show the specified value x WI is to be used to find out the value of x For example WI value of the upper range 1200 WI WI value of the span gad 1190 WI Eo 4mV Ec 19mV 19 x x 100 99 3 19 4 x 1190 100 lt 4 a xp N I Ec l A I I gt 8 83 E l WI value of the span gas WC l WI value of the upper range Ws l Ec l x 100 Ec Eo WE Eo D Wc 7 0 WI value of the span WI value of the upper range WOBBE INDEX WI F0703 ai Figure 9 1 How to Find Out x When Preheating Circuit Exists IM 11R02A01 02E 9 4 9 3 9 3 1 9 3 2 9 3 3 9 4 lt 9 Calibration gt Calibration ofthe Computing Station Usually this calibration only is conducted The calibration is conducted as follows according to the difference of the output e WI output Calibrate with WI value WI calorie output Calibrate with WI value and confirm the calorific value e Calorie output Calibrate with calorific value In case of existing the preheating the bias adjustment is carried out firstly Bias Adjustment This adjustment is carried out only when the preheating circuit exists a Suspend the supply of the sample gas and introduce the air to the gas
47. e Switch START POWER ON o 0 0 O A IA POWER IGNIT MEAS ALARM O L kd OFF METER TI Switch sano ll I SAFE EV METER FF FF RELEASE P MEAS o 2 40 60 80 100 8 8 SET LOW AL SEAN Volume YOKOGAWA sare EV Switch LOW AL SPAN o o LOWAL Volume After diselectrifying perform the adjustment by using SPAN volume and LOW AL volume Figure 6 8 Front Panel Assembly Table 6 1 Function and operation procedure for each switch of the calorie detector Name Function and operation procedures POWER switch Power supply switch e Turn to ON power supply is supplied to the calorie detector and at the same time light the amps POWER and ALARM START switch e After one push on START switch the gas is supplied to the burner unit and operate the ignition On the same time light the lamp IGNIT the lamp ALARM is lit off e If ignite within the preset time the lamp IGNIT is lit off but light the lamp MEAS e If not ignite within the preset time the lamp IGNIT is lit off and light the lamp ALARM again SAFE EV switch Normally leave the switch at SET portion e When adjust the differential pressure turn it to RELEASE When the lamp ALARM is let off alarm is released and solenoid valve of the gas line is opened e If leave the switch position stay at RELEASE from SET nothing happens but in such case no a
48. e 12 2 Print Circuit Board Assembly c Ignition transformer assembly E7023EA No mame aw Panno Remas 1 Constant Votage Power Supply Converter errer DO CE E DA Co Co ORO ORO F12 3 ai Figure 12 3 Ignition Transformer Assembly d Others ne Sy Panne Remake Oring Yono 2 saul Burner unit Flange 1 Union A F12 4 ai x PS af gt e NOA Figure 12 4 Flange Section of the Calorie Detector IM 11R02A01 02E
49. e isin econ anaa a ga ag A aaa 6 16 Preparation of Operation 0esenanewananewwnnne aana nawan a nana ao nn nanen nnmnnn nnn 7 4 7 4 Sampling SOC is sie cise cise cise esse cscs NENGNA ENE ence NANANG ANA SANANA NSAN SNENA 7 1 7 2 Status of Valve Soniais ndane aeran sea daea eaa e a Eaa Area aA aa aa Ae Aaaa 7 1 7 3 Water Supply For Steel Mill Use uuunsnensnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnannnennnannnannn 7 1 7 4 Supply Of the Air sasagaran an gagana gagas anaa as 7 2 7 5 Supply Of POWET lt lt 0imiii ns 7 2 7 6 The Zero Adjustment of the Differential Pressure Transmitter 7 3 7 7 Air Differential Pressure Adjustment nunesnessnennnnnnnnnnnnnnnnnnnnnnnnnennnennnennnannn 7 4 7 8 Pressure Adjustment of the Gas Line 0es0esarsnesaran ananem ananem ananem ananananen 7 4 An 8 1 8 1 Start Operation ran RADO ORAR DRNA TARTAS 8 1 8 1 1 Introduction of the Sample Gas ooooocincccinoccnnoconocccconcnnonocnnnrcnnnnnonannn 8 1 8 1 2 Start Operation of the Calorie Detector ooooocoocccncccincccinccciccccccaccnnnos 8 1 8 1 3 Differential Pressure Readjustment enenneenneennenneenneen 8 1 8 2 STOPPING OperatiONS siii Tn Acida 8 2 8 2 1 Long Timer StOPPINg run 8 2 8 2 2 Short Time Stopping sacada dea nennen nennen 8 2 Calibrador 9 1 9 1 Supply of the Calibration GaS oooncocnncconnccnnnccnnnnccnnnncnnnnennnnennnnnnnnencnnnnnnnnnnnn 9 1 9 1 1 For Town Gas Usero ada ad ada a
50. e of the calorimeter The flow rate is preset depending on the WI of the sample gas to prevent the calorific value at the detector burner from exceeding the upper unit IM 11R02A01 02E 2 3 lt 2 Specifications gt Utility Panel Water Approx 0 2 l min pressure 200 to 600 kPa Instrument Air Approx 50 Nl min pressure 300 to 700 kPa dew point of 0 C or less Power Supply 100 V AC 10 single phase 50 60 Hz Note 3 1100 VA max Note 3 In case of low calorific value measurement frequency variation should be within 0 4 If frequency variation exceeds 0 4 consult with Yokogawa Construction Paint Color For indoor installation rack panel Munsell 3 2PB7 4 1 2 inside and outside Ambient Temperature 0 to 40 C little temperature variation particularly no rapid change in 2 2 2 2 1 temperature allowed Model and Suffix Codes Gas Calorimeter Model Suffix Code Option Code Description Gas calorimeter Always S6 Gas Pressure ON O TIR VUN Gas pressure 10 to 20 kPa for town gas quake proof Gas pressure 10 to 20 kPa for town gas Gas pressure 10 kPa or under for town gas Gas pressure 100 ro 600 kPa for town gas Gas pressure 8 to 15 kPa for steel mill without preheating Gas pressure 8 to 15 kPa for steel mill with preheating Gas pressure 8 kPa or under for steel mill without preheating Gas pressure 8 kPa or und
51. e wire ends Wiring to Peripheral Equipment Power Supply Use a 600 V insulated vinyl cabtyre cable JIS C3312 with a cross section area of 2 mm or more or a wire or cable that is the equivalent or better Grounding Connect a grounding wire to the grounding terminal inside the panel A grounding wire must be connected so that the grounding resistance becomes 100 Q or less equivalent to JIS Class D Analog Output 4 to 20 mA DC Use a shielded twisted pair cable with a cross section area of 0 5 mm or more or a cable that is the equivalent or better and install it separately from the power supply and alarm output cables and sources of electromagnetic interference A shielded cable must be connected to the frame ground FG beside each of the output terminals The load resistance from the perspective of this equipment must be 750 Q or less Contact Output Use a 600 V insulated vinyl cabtyre cable JIS C3312 with a cross section area of 2 mm or more or a wire or cable that is the equivalent or better The flame extinction alarm contact and orifice chamber temperature drop alarm contact must be non voltage dry contacts and the contact rating must be as follows at Rain Flame distinction alarm contact 100 VAC 5A Orifice chamber temperature drop alarm contact 100 VAC 3A Contact Input Remote Ignition Custom Order Anon voltage contact must be input as a contact input signal The contact rating is 24 V DC 1A The open
52. er 10 2 6 Density Meter It is recommended to replace the O ring of the GD300S detector every 2 or 3 years and wash the sensor if necessary Consult to our service for washing the sensor IM 11R02A01 02E 1 0 6 lt 10 Maintenance gt 10 3 Check at the Regular Service 10 3 1 Check the Burner Flame Whether the sample gas is completely burnt or not shall be judged by observing the shape and the color of the burner flame lt The shape of the flame for the complete combustion is as shown in Figure 10 7 A of a shape sharply outlined and the height of the inner flame is about a half size of the outer flame When the primary air is too much the flame becomes as shown in Figure 10 7 B flickering and when the secondary air is not sufficient the flame outline is the same lt When the primary air is not sufficient the color of the flame is clear yellow and sometimes soots come out When there is any blockade or leakage is the air line the flame becomes like the shape as shown in Figure 10 7 D OUTER FLAME INNER FLAME B C D F11 8 ai A Figure 10 7 Burner Flames IM 11R02A01 02E lt 10 Maintenance gt 10 7 Check the flames of the burner according to the following procedures As to the adjustment of the squeezing screw of the primary air and the secondary air and the cleaning of the air distribution part ask to our service personnel a Remove the screw 4 pcs fixing the external pipe t
53. er for steel mill with preheating Measurement WI measurement Calorific value measurement GD400G should be purchased separately Power supply 100 VAC 50 Hz 100 VAC 60 Hz Range Measuring range Style Note Measuring range and unit must be specified Style C IM 11R02A01 02E 2 4 lt 2 Specifications gt 2 2 2 Standard Accessories Followings are the standard accessories supplied e Calorie Detector Name QU PartNo Mirror 1 E7023FF 644Y02 Brass Fuse 2 A1113EF 3 15A e Orifice Assembly O Ring Y9114XB P16 Viton O Ring L9817MT P20 Silicon Hexagon Wrench L9827AB Nominal size 1 5 mm Hexagon Wrench L9827AC Nominal size 2 5 mm 80 F2 1 ai Figure 2 1 Mirror 2 2 3 Density Meter Gas Density Meter is required for density compensation in calorific value measurement It is not required for WI measurement Converter GD400G N 10 N L1 PA Detector GD300S J LV KU Measuring range and unit specific gravity or density should be specified IM 11R02A01 02E lt 2 Specifications gt 2 5 2 2 4 Option 2 3 2 3 1 2 3 2 Name Panno Description Fulflo filter G7043XJ Element material Polypropylene Pore size 50 um Body SUS 316 Connection Re 1 2 Pressure reducing valve G7008XF Primary pressure 15 MPa max Secondary pressure O to 200 kPa Material Brass Standard Systems for Each Appl
54. f Y2 MIN range of WI light blue lt lt sHIFT gt gt The key for switching screens Unused YOKOGAWA lt gt Pushing this key switching this screen to ALARM screen In pushing it again this screen returns 1 F0516 ai Figure 6 12 Measuring Display CM6G ALARM PROCESS SYSTEM a oa E B ER oo The screen is changed to ALARM display by following the operation marked as 1 in Figure 6 12 ALM LR ALARM items such as X1 to X4 Y1 and Y2 are displayed EVT ON STC EVENT EVT CLR ge AAAAFERPF Vv U lt lt sHiFT gt YOKOGAWA lt gt F0517 ai Figure 6 13 Alarm Display IM 11R02A01 02E lt 6 Construction and Function gt 6 1 1 E Switching to alarm display
55. gulating pot Figure 2 4 External Dimensions For Steel Mill Use IM 11R02A01 02E lt 2 Specifications gt 2 9 2 4 4 Dimensions of Options 1 Probe Part number L H7800HA Approx 650 H7800HB Approx 1150 H7800HC Approx 1650 Insertion length L Unit mm JIS 10K 80 FF Equiv SUS304 2 Fulflo Filter Part no G7043XJ 108 m Rc1 2 Approx 350 3 Pressure Reducing Valve Part no G7008XF Secondary pressure gauge Handle for pressure contro Approx 119 Approx 38i_ Approx 62 Approx 120 f 0 3MPaG Handle for stop valve pe Rc1 H7800HA ai Unit mm Unit mm Primary pressure gauge 25MPaG Daiflon packing Inlet X Safety valve Approx 81 Outlet Approx 166 F2 8 ai IM 11R02A01 02E lt 3 Installations gt 3 1 3 Installations Observe the following conditions when installation being held RA w N a Se LS YH Adequate space for maintenance should be provided around the gas calorimeter The base should be horizontal Ambient temperature is 0 to 40 C and no rapid change in ambient temperature is allowed Rapid change here means a change of approximately 10 C within 30 minutes Install the instrument in the place where it is not directly exposed to the current of a conditi
56. he defect of the pressure regulator 5 Confirm the pressure gauge 3 5 indicate approx 3 kPa lf the pressure cannot be satisfactorily set by the pressure reducing valve 3 4 it may be defective 6 When the density meter is attached confirm the indication of the flowmeter 5 3 is 0 5 to 1 l min lf no indication appeared on the flowmeter the trouble is considered to be due to the clogging of the gas pipe inside the density meter 7 Confirm the indication of the computing station is about 500 after set the indication to X3 G PRESS When the differential pressure setting is impossible with the pressure reducing valve 3 6 itis due to the defect of the pressure reducing valve 8 Forall gas lines check any leakage at each joint connection IM 11R02A01 02E 11 2 lt 11 Troubleshooting gt 11 1 2 For Steel Mill Use As for the sampling system outside the panel this is recommended by our company 1 Check if the water level of the drain pot 11 1 equipped outside the panel is higher than 15 kPa 2 Check for any findings of clogging accumulation of drain or leakage in the pipings between the probe 7 1 and the fulflo filter 7 2 equipped outside When found any clogging blow by the air When the piping has any U bending the drain is likely to be accumulated there so in such case give a slope to the piping 3 Check the element of the outside fulflo filter 7 2 When found clogged
57. hen remove the connectors to the terminal of the hot junction detecting point b Disassemble the external pipe and take out the jet plate by pulling upward The direction to pull for removal is shown in Figure 10 8 by the sign of arrow c Insert the attached mirror herewith into the ventilator d When ignite the flame reflected on the above mirror can be observed from slanting upside e Assembly shall be conducted in the contrary way to the above procedures CONNECTOR DETECTOR FOR 47 A 4 HOT JUNCTION IT E A 4 TERMINAL BOARD EXHAUST PIPE 4 IN 3 AL 1 DETECTOR FOR z SCREW 4 pcs COLD JUNCTION Fal 7 le 4 IGNITION TRANS BURNER UNIT A 4 ASSEMBLY F REN MIRROR VENTILATOR a CS JET PLATE I EXTERNAL PIPE COMBUSTION SECONDARYAIR f PIPE THROTTLE SCREW PRIMARY AIR THROTTLE SCREW Co gt F10 9 ai Figure 10 8 Flame Checking 10 3 2 Zero Adjustment of the Differential Pressure Transmitter Adjust according to the procedure described in paragraph 7 6 10 3 3 Others If necessary conduct each regular check mentioned in paragraph 10 2 IM 11R02A01 02E lt 11 Troubleshooting gt 11 1 11 11 1 11 1 1 Troubleshooting The cause measured value shows
58. ication Standard Systems for Each Application Application System specification Town Gas WI Without Gas pressure 10 to 20 kPa Standard density Gas pressure 10 kPa or under With pump Gas pressure 100 to 600 kPa With pressure reducing value Calorific value With Gas pressure 10 to 20 kPa Quake proof MJ Nm density Gas pressure 10 to 20 kPa Standard meter Gas pressure 10 kPa or under With pump Gas pressure 100 to 600 kPa With pressure reducing value Steel Mill Without Gas pressure 8 to 15 kPa Without preheating density Gas pressure 8 to 15 kPa With preheating meter Gas pressure 8 kPa or under Without preheating Gas pressure 8 kPa or under With preheating Calorific value With Gas pressure 8 to 15 kPa Without preheating MJ NM density Gas pressure 8 to 15 kPa With preheating meter Gas pressure 8 kPa or under Without preheating Gas pressure 8 kPa or under With preheating Corresponding Suffix Code of S6 gas pressure and measurement Note A wet sample gas in the town gas application is outside the scope of the standard specifications Consult with Yokogawa Instructions for System Selection 1 The quake proof type gas calorimeter is always equipped with the density meter 2 The CM6G Gas Calorimeter controls the flow rate under a constant differential pressure In the calorific value measurement ifthe density of a sample gas changes a flow rate error proportional to the reciprocal of the
59. ie Detector Confirm the switch SAFE EV is set at SET then push the switch START Differential Pressure Readjustment When the burner be ignited and the output becomes stable after 20 to 30 min adjust again the differential pressure El For town gas use a When the pressure indication of the pressure gauge 3 5 differs from approx 3 kPa adjust it by the pressure reducing valve 3 4 b When the density meter is attached and the flowmeter 5 3 indicate out of 0 5 to 1 l min adjust its indication again c Setthe computing station to Input Output status display refer to Figure 6 15 If the indication of X2 A PRESS and X3 G PRESS is not 500 adjust each with the pressure reducing valve 3 6 and V 16 E For steel mill use a When the density meter is attached adjust again the indication of the flowmeter 5 3 by V 11 b When the number of bubbles coming out from the pipe A is not constant adjust it by V 12 c Setthe computing station to Input Output status display refer to Figure 6 15 If the indication of X2 A PRESS and X3 G PRESS is not 500 adjust each with the pressure reducing valve 3 6 and V 16 IM 11R02A01 02E 8 2 lt 8 Operation and Suspension gt 8 2 Stopping Operations 8 2 1 Long Timer Stopping a Close V 1 In case of the standard pressure for steel mill use close V 4 If the pump is attached switch the pump off at first b When the g
60. iluted combustion exhaust gas Air flow rate Fa is big enough compared with the sample gas flow rate Fg Fa Fg 50 200 1 and Cps Cpa Fs Fa Fg Fa 1 g therefore the formula 1 1 is as follows Ke Fg MA 1 2 Cpa Fa 1 g where Fa Air flow rate Cpa Air constant pressure heat ratio g Fg Fa IM 11R02A01 02E 2 SE Principle of Measurement gt When using orifice and take out Fa Fg as a differential pressure of before and after orifice Fa and Fg are represented by the following formula A Pa APg Fa Ka Fg Kg 1 3 Pa Pg where APa APg Air gas differential pressure between before and after orifice Pa Pg Density of the air and the gas ka kg Orifice constant figure of the air and the gas Orifice coefficient X orifice sectional area If insert formula 1 3 into formula 1 2 AB is represented by the following formula 1 APg A8 C hK 1 4 Pg A Pa 1 Kg C Ka A Pa Cpa 1 g According to formula 1 4 if APa APg are constant temperature difference Ad is in proportion to WI k NPg or calorific value K Thus we can measure continuously WI after AB measurement and the calorific valve after the measurement and calculation of the density IM 11R02A01 02E Customer Model CM6G Maintenance Gas Calorimeter Calorie Detector Parts List Item Part No Qty Description 1 E7023RA 1 Print Cir Board Assy 2 E7023EA 1 Ignition Trans Assy All Rights
61. inda 9 1 9 1 2 For Steel Mill Use 22004240044400nnnsnnnnennnnnnnnnnnnnennnnnnnnnenn 9 2 9 2 Span Adjustment of the Calorie Detector s0rs0esaranenananananananananananan 9 2 9 2 1 When no Preheating Circuit Ekist asas ea as aa nea cana an ea nena ea nea nn 9 2 9 2 2 When Preheating Circuit Exists sak rana KANANE AAN arinin 9 3 9 3 Calibration of the Computing Station es0rs0esarsn aseran aa ananem ananem anane 9 4 9 3 1 Bias Adjustment iii 9 4 9 3 2 Zero and Span Adjustment soia sakan AKA DA A RARA RIA SARA nara SARA TA KAN KAEN KAR 9 4 9 3 3 Other ADJUSUMBNE citania TA ea 9 4 lt CONTENTS gt iii 9 4 Calibration of the Density Meter unnnnsnnsennrennnennnennnennnennnennnennnennnennrennrennnenn 9 4 10 Maintenance ann 10 1 10 1 Daily Check s iii 10 1 10 1 1 Air Gas Differential Pressure Adjustment nen 10 1 10 1 2 Take Out the Water Out ofthe Drain Pot Pump for Steel Mill USG j ona die 10 1 10 1 3 Take Out the Drain from the Air Set nennen 10 1 10 2 Regular Gheck saari wan aan KARENAN NENENG N ENERE WENANG KANGA G ENENGENA ceca 10 2 10 2 1 Cleaning of the Orifice Plate and Replacement of O ring 10 2 10 2 2 Fulflo Filter For Steel Mill ISE sarasa kasatan aaa AAK A SEK ENAKAN EKA gan 10 3 10 2 3 Line Filter For Town Gas USG sasasi nase 10 3 10 2 4 Washing Bubbler or Pressure Regulat
62. ing Pot 10 4 10 2 5 Dehumidifier For Steel Mill Use 00400rarasenernaenannnenanaa ena anen ene 10 5 10 2 6 Density Meter uosa ea rra cana 10 5 10 3 Check at the Regular Service unnnsnnssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnenannnannnannnannnanenanen 10 6 10 3 1 Check the Bumer Flame een 10 6 10 3 2 Zero Adjustment of the Differential Pressure Transmitter 10 7 10 3 3 Others cai en nennen 10 7 11 Troubleshooting supina 11 1 11 1 Gas Sampling Pressure Regulating Section nursnensnenannnonnnonnnonnnennnennnannn 11 1 11 1 1 For Town Gas Usern nase ae ie ie nd 11 1 11 1 2 For Steel Mil USG vota asas asasaran agan arena 11 2 11 2 Air Pressure Adjustment Section s0es0esars0esaran ena ean ena ean ananem anana enananen 11 2 11 3 Differential Pressure Transmitter Section s00rsaneranenanwnnawan anan anananan 11 3 11 4 Signal Section oa 11 3 11 5 Computing Station isas aas tasa eU DA AENG LUA KAGAN A AR K ANG ANANA LAIO SAIA NASA AA AENG KANGA NAHAN 11 5 11 6 Other Troubleshooting usas tasas aas ITALIA AI TARA TIA ran 11 5 12 Replacement Par 12 1 12 1 Calorie Detector E7023TA 4arsaneranena nana anan anan anan anan anan ana nawan ana nana nananenenenanen 12 1 12 2 Orifice Assembly E7023NA sarasa sana apan ana ANAN ENE NANA HEN ANE RANENA ENENG WENEHNA KENE NARAH ANA NENGNA 12 3 12 3 Preheater E7023NG 55555455595958 65 agan aan risas 12 4 12 4 Fulflo Filter G7043XJ
63. l insulation line and steam line is added to Figure 3 1 Section 3 3 In Figure 3 4 drawings of Computing Station change to Model YS1700 Chapter 5 In Figure 5 1 and 5 5 drawings of Computing Station change to Model YS1700 Subsection 5 5 1 Complete revision Application of Model YS1700 operation Subsection 5 5 2 In table 5 3 items X6 to 8 Y5 to 6 and P08 to 30 are added Subsection 5 5 3 Equation 5 2 and 5 3 are revised Figure numbers of 5 17 and 5 18 are changed Chapter 6 Explanation about computing station operation is revised in subsection 6 1 7 a amp b 6 1 8 town gas g amp h steel mill f amp g and 6 2 3 both of c Range of flow rate is expanded 0 5 1 l min in subsection 6 1 8 town gas f steel mill d and 6 2 3 town gas b Chapter 7 Explanation about computing station operation is revised in subsection 7 1 1 f 7 1 2 f amp g 7 2 1 a amp b 7 2 2 h 7 3 1 c 7 3 2 b amp d Description about indication check is added to subsection 7 1 1 d and 7 1 2 d Title is changed and description with See also is inserted to subsection 7 1 1 d and 7 1 2 d Subsection 7 3 3 POS is corrected to P02 Chapter 9 Explanation about computing station operation is revised in subsection 9 1 1 7 and 9 1 2 10 Range of flow rate is expanded 0 5 1 l min in subsection 9 1 1 6 and 9 1 2 9 Description about indication check is added to 9 1 1 4 Subsection 9 1 2 Unit Pa is corrected to kPa Sectio
64. larm signal is given even when extinguishing the burner so be careful of this matter e When the switch shows RELEASE it doesn t start even if the switch START be pushed METER switch Pressing this switch switches the indication of the indicator and the X5 display 1 of the computing station between P MEAS and LOW AL The switching does not affect the final output and sequence action SPAN volume e With this span volume you can adjust the output of the calorie detector to 1 5 V DC e If turn to the right the span point becomes bigger LOW AL volume The level set for the extinction alarm lower alarm is decided by this volume e If turn to the right the alarm level becomes higher POWER lamp e When the lamp is lit power is being supplied to the calorie detector differential pressure transmitter and temperature controller IGNIT lamp During the lamp is lighting this is ready to be ignited MEAS lamp During the lamp is lighting it is under the measurement condition ALARM lamp During the lamp lighting alarm function is being given 1 The display range of X5 is 0 to 30 0 mV P MEAS and LOW AL indicate the following values Signal Name Display Value P MEAS Thermocouple electromotive force 0 20 0 mV LOW AL Flame extinction alarm threshold value 0 10 0 mV 0 100 IM 11R02A01 02E 6 8 lt 6 Construction and Functi
65. less Pressure 1 8 to 15 kPa 2 8 kPa or under with pump Range Select scale range Span General Gas 30 to 50 of maximum value ofthe span Butane or Butene Air 20 to 30 of maximum value ofthe span Propane or Propylene Air 25 to 40 of maximum value ofthe span Output 1t05 V DC 4 to 20 mA DC simultaneously non isolated load resistance 7500 or less Alarm Contact Output Flame off alarm 100 VAC 5A closed when alarm occurs resistance load when contactis opened the leakage current is 2 mA or less 100V AC Temperature alarm 100 VAC 3A closed when alarm occurs resistance load Contact Input Remote ignition Custom order 24 V DC 0 1A or more Repeatability Measuring range Note 1 Repeatability High calorific value 0 5 of measured value Low calorific value 1 0 of measured value Calorific value High calorific value 1 0 of measured value MJ Nrr Low calorific value 1 5 of measured value Note 1 High calorific value means 6 3 MJ Nm or more Low calorific value means below 6 3 MJ Nm Sample Gas Flow Rate Approx 10 l min Response Time Note 2 Max WI measured Response time 63 2 50 or more 42 sec or less 70 sec or less 32 or more less than 50 39 sec or less 60 sec or less 13 or more less than 32 36 sec or less 50 sec or less 13 or less 30 sec or less 45 sec or less Note 2 Response time varies depending on the WI of a sample gas This is due to the different sample gas flow rat
66. line b Set the SAFE EV switch of the calorie detector to RELEASE c Setthe computing station to Input Output status display After the indication Y4 BIAS CHECK become stable 20 to 30 minutes adjust the Y4 value of the PO3 BIAS will become 0 0 by the data setting key Note In the above operation c Y4 and P03 are not displayed on the same screen For bias adjustment select and display Y4 and P03 alternatively d When complete the adjustment turn the switch SAFE EV of the calorie detector to SET and suspend the air supply to the gas line Zero and Span Adjustment a Introduce the zero gas and ignite b Set the computing station to Input Output status display Adjust with the P01 ZERO of the operator to be the Y2 WI or Y1 MJ Nm WI value or the calorific value of the calibration gas c Change from zero gas to span gas when if let the span gas start flowing before the zero gas valve is not completely closed the burner is not extinguished Same in the case of the other way If burner is extinguished ignite d Set the indication of the computing station to Input Output status display After the indication Y2 WI or Y1 cal becomes stable adjust with the P02 SPAN of the operator to become WI value or the calorific value of the calibration gas Display P02 adjust by the data setting key Confirm the result of the adjustment after displaying it
67. mber of bubbles by using V 12 and then carry out the adjustment When complete the adjustment close V 8 and V 5 separate the one touch coupler 2 5 and open V 4 Turn the switch SAFE EV of calorie detector to SET 8 lt 8 Operation and Suspension gt 8 1 Operation Start Operation A DANGER e Confirm the air is supplied before start operation e Confirm that the ventilation system is running before introducing the gas Introduction of the Sample Gas El For town gas use a Open V 1 fully b When the pump is attached turn the power supply switch of the pump to ON in this time c When the pressure is 100 to 200 kPa or increased by the pump adjust by V 5 so that the indication of the pressure gauge 3 2 become 8 to 18 kPa While the pressure is reduced by the pressure reducing valve adjust the indication of the pressure gauge 3 2 to become 8 to 18 kPa by the pressure reducing valve 3 8 E For steel mill use a Inthe case that the pressure is above 8 kPa open V 4 and in the case that the pressure is increased by the pump open V 1 V 4 respectively Oo wm When the pump is attached turn on the power supply switch of the pump in this time o wa Adjust the pressure of the pressure gauge 3 1 using V 3 in the case of standard pressure above 8 kPa and using V 2 V 3 in the case of the pressure increased by the pump to become approx 6 kPa Start Operation of the Calor
68. n 9 4 In item 2 The value 200 is corrected to 20 Section 9 4 In Figure 9 1 alphabet marks of the computing station terminal are corrected to number marks No 19 and No 20 are written in the station E If you want to have more information about Yokogawa products you can visit Yokogawa s home page at the following web site Home page http www yokogawa com an EA IM 11R02A01 02E terminal and connected to No 1 and No 2 of the calorie detector respectively Terminal Numbers of distoributor are revised in the body and Figure 9 1 Section 9 5 ltem 1 is revised 2 is deleted 3 is partially changed and printed as item 2 Chapter 10 Subsection 10 1 1 In item 8 part No is corrected to Y9107XB Aug 2007 2nd Edition All over revised Jun 2009 1st Edition Newly published IM 11R02A01 02E User s Model CM6G Manual Gas Calorimeter Supplement Thank you for selecting our Model CM6G Gas Calorimeter User s Manual IM 11R02A01 02E 4th Edition supplied with the product some revisions additions have been made Please replace the corresponding pages in your copy with the attached revised pages Revisions page 2 1 Section 2 1 Standard Specifications Added EMC standard Section 2 1 1 Twon Gas Application Conditions at the Sampling Point Changed the description of the pressure 1 Section 2 1 1 Twon Gas Application Alarm Contact Output Added of the description page 2 2 Section 2 1 2
69. nsity meter detector when specified 1 2 Solenoid valve 3 2 Washing bubbler 5 2 Density meter converter when specified 1 3 Orifice assembly 3 3 Fulflo filter 5 3 Flowmeter for density meter when specified 1 4 Differential pressure transmitter air 3 4 Pressure regulating pot 6 1 Water Flowmeter 1 5 Differential pressure transmitter gas 3 5 Dehumidifier 7 1 Probe optional 1 6 Computing station 3 6 Pressure reducing valve 7 2 Fulflo filter optional 2 1 Air set 3 7 Line filter 9 1 Pressure reducing valve for cylinder optional 2 2 Pressure reducing valve 3 8 Diaphragm pump when specified 9 2 Pressure reducing valve for cylinder optional 2 3 Pressure gauge 3 9 Drain pot when specified 10 1 Standard gas cylinder supplied by customer 2 4 Preheating chamber 4 1 Pressure reducing valve for cylinder 10 2 Standard gas cylinder supplied by customer 2 5 One touch coupler 4 2 Flowmeter 11 1 Drain pot supplied by customer V1 16 Ball valve needle valve 7 1 STD GAS IN SPAN STD GAS IN ZERO SAMPLE GAS SAMPLE GAS VENT SAMPLE GAS OUT INST AIR IN WATER IN Aa DRAIN IM 11R02A01 02E 1 CM6G S6 2 CM6G S67 Figure 6 4 Flow Sheet Steel Mill Use 1O with density meter 0 CM6G S68 0 with diaphragm pump FLOW 6810 ai lt 6 Construction and Function gt 6 5 6 3 Differential Pressure Detection Part In order to calcul
70. o 8 Back eo o N Front 8 oe OA Dim 6110 ai Figure 2 3 External Dimensions For Town Gas Use Quake proof Type IM 11R02A01 02E 2 8 lt 2 Specifications gt 2 4 3 For Steel Mill Application CM6G S6500 S6510 S6600 S6610 S6700 S6710 S6800 S6810 x Unit mm Mark Name Connection 80 D nsitv meter A SAMPLE GAS IN Rc1 2 60 PERAN B SAMPLE GAS OUT Rc1 2 40 C SAMPLE GAS OUT Rc1 2 ee D STD GAS IN Rc1 4 E WATER IN Rc1 2 F DRAIN OUT Rc1 2 G INST AIR IN Rc1 4 H_ SAMPLE GAS VENT _ Rc1 4 coco o 99909 Q ron m o Pump AS N pins E E Flowmeter for converter Computing density meter station e D Approx 70 s m Calorie detector fe Washing bubbler 2 lt Drain pot Pressure regulating LT pot 740 30 100 800 4 14 holes 100 700 900 CM6G S6D10 with density meter and flowmeter CM6G S67 10 CM6G S6800 with pump View X Maintenance Space 540 260 900 500 N Pipe Packing Drain L en Pipe to Pipe from AR calorie detector ala filter en L 338 L 363 Pipe A Pipe to density meter L 383 Drain hole Dim 6810 ai E S ERC A m a re ee al Normaly plugged Pressure re
71. on gt 6 4 1 Burner Unit The sample gas burns inside the burner unit and a thermocouple detects the burning temperature increase The air is introduced from the air inlet and divided to the primary secondary and tertiary air The primary and secondary ones are for burning the sample gas and the tertiary is for diluting and stirring the exhaust gas The sample gas is mixed with the primary air In case of the low calorie gas the primary air is throttled and burnt completely by the secondary air Then the combustion temperature generates and burnt gas is promptly diluted and stirred by the tertiary air Finally the gas is exhausted out from the top of the calorie detector The increased temperature is measured with the difference of the electromotive force between the cold junction point located at the air inlet and the hot junction point inside the mixed diluted exhaust gas The heating wire wound the burner tip is used for both ignition and preheating In case of low calorie gas m mi Lead wire F6 9 ai Heater wire Figure 6 9 Burner Tip Assembly 1 Figure 6 10 Burner Unit IM 11R02A01 02E Hot junction detect point Cold junction detect point Air divider Secondary air throttle screw Primary air throttle screw Air inlet Gas inlet ep ajara Connector Burner tip assembly Combustion pipe Stream contact pipe Measuring pipe
72. oned air Minimal vibration is allowed If much vibration is unavoidable take an appropriate measure to absorb shock e g use of vibration proof robber A ventilation system should be provided Corrosive gases and dust are present in small quantities and humidity is low The water of the sampling system and the drain line do not freeze up A DANGER During the time from the start of ignition action to ignition and directly after flame extinction sample gas mixed with the air will be released from the top of the equipment into the installation space of the equipment Use the equipment in a well ventilated environment equipped with a ventilation system IM 11R02A01 02E lt 4 Outside Pipings gt 4 1 4 Outside Pipings The connections for panel refer to the drawing Figure 2 2 Figure 2 3 and Figure 2 4 The principal points to be taken care are as follows lt Bent the outlet of the blow piping as shape U and prevent it from the rain penetration Set the location of the outlet at higher position as much as possible where there is little fear of danger Drain piping shall be conducted so that it stays below the drain outlet and no drain accumulated on the panel bed lt tis necessary for the sample line of the steel mill use instrument to provide a slope of more than 1 3 so that there happens no blockade to the gas line by the drain at the bending part of the piping Make piping as short as possible Equip the sample
73. ons gt 2 3 Utility Water Approx 0 2 l min pressure 200 to 600 kPa Instrument Air Approx 50 Nl min pressure 300 to 700 kPa dew point of 0 C or less Power Supply 100 VAC 10 single phase 50 60 Hz Note 3 1100 VA max Note 3 In case of low calorific value measurement frequency variation should be within 0 4 If frequency variation exceeds 0 4 consult with Yokogawa Panel Construction Forindoor installation rack panel Paint Color Munsell 3 2PB7 4 1 2 inside and outside Ambient Temperature O to 40 C little temperature variation particularly no rapid change in temperature allowed 2 2 Model and Suffix Codes 2 2 1 Gas Calorimeter Model Suffix Code Option Code Description Gas calorimeter Always S6 Gas pressure 10 to 20 kPa for town gas quake proof Gas pressure 10 to 20 kPa for town gas Gas pressure 10 kPa or under for town gas Gas pressure 100 ro 600 kPa for town gas Gas pressure 8 kPa or over for steel mill without preheating Gas pressure 8 kPa or over for steel mill with preheating Gas pressure 8 kPa or under for steel mill without preheating Gas pressure 8 kPa or under for steel mill with preheating Gas Pressure 1 2 3 4 5 6 7 8 Measurement WI measurement Calorific value measurement GD400G should be purchased separately Power supply 100 VAC 50 Hz 100 VAC 60 Hz Range Measuring range Style Style C Note Measuring range and
74. or closed state of the input is determined by the resistance value from the perspective of this equipment The resistance value also includes the wiring resistance Contact closed 200 Q or less Contact open 100 kQ or more IM 11R02A01 02E 6 lt 6 Construction and Function gt 6 1 Construction and Function Typical System Configuration 6 1 Gas Calorimeter r Calorie Detector Density Meter Output 7 samana gt Calorific Value Differential Pressure NIN Nad aa Transmitter A Gas 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Y E o a o D 2 a D Pressure Sample Gas Solenoid Regulating Valve Unit i Air Pressure Instrument Air Regulating Unit l Kae ar ai ern JJ Function Description Calorie detector Detects WI or calorific value Generates an alarm and takes protective actions when the burner flame goes out or abnormal combustion occurs Computing station digital Calculates WI or calorific value Displays selected parameters e g each differential pressure and calorific value Adjusts zero span and others Density meter Measures density used for calculation of calorific value Not required for WI measurement Differential pressure transmitter Detects differential pressure of gas and air before and after orifice and converts it to an electrical signal
75. ore or a cable that is the equivalent or better and install it separately from the power supply and alarm output cables and sources of electromagnetic interference A shielded cable must be connected to the frame ground FG beside each of the output terminals The load resistance from the perspective of this equipment must be 750 O or less Contact Output Use a 600 V insulated vinyl cabtyre cable JIS C3312 with a cross section area of 2 mm or more or a wire or cable that is the equivalent or better The flame extinction alarm contact and orifice chamber temperature drop alarm contact must be non voltage dry contacts and the contact rating must be as follows when contact is opened the leakage current is 2 mA or less 100V AC Flame distinction alarm contact 100 VAC 5A Orifice chamber temperature drop alarm contact 100 VAC 3A Contact Input Remote Ignition Custom Order Anon voltage contact must be input as a contact input signal The contact rating is 24 V DC 1A The open or closed state of the input is determined by the resistance value from the perspective of this equipment The resistance value also includes the wiring resistance Contact closed 200 Q or less Contact open 100 kQ or more IM 11R02A01 02E 12 2 lt 12 Replacement Parts gt b Print circuit board assembly E7023RA No Name ty Paro Remarks Printed Circuit Board Assembly Ezoza i i iE 1 3 2 Parts Side Solder Side Figur
76. program if there is preheating circuit multiply the constant by the differential pressure signal and after correcting the differential pressure to the preheating the deduction of the preheat calorie is computed IM 11R02A01 02E lt 6 Construction and Function gt 6 1 5 Gas differential Air differential pressure signal pressure signal DYNAMIC CHAR FUNCTION CORRECTION DYNAMIC CHAR FUNCTION A CORR RATE CORRECTION A TIME ZERO FR Correction of density i o density SPAN i signal 1 i v Extraction Remarks is variable constant i 1 1 i O Wi signal 1 Calorific signal Jo FOS2tai Figure 6 17 Computing Block Diagram Preheating Circuit Does Not Exist Gas differential Air differential pressure signal pressure signal O DYNAMIC CHAR FUNCTION CORRECTION DYNAMIC CHAR FUNCTION CORRECTION G CORR RATE A CORR RATE G TIME Remarks is variable constant O O Pre heat temperature WI signal check signal PRR Teese J F0522 ai Figure 6 18 Computing Block Diagram Preheating Circuit Exists IM 11R02A01 02E 6 1 6 lt 6 Construction and Function gt 6 6 Density Meter The GD4006 is used for gas density meter Regarding GD400G Gas density meter refer to attached Instruction Manual IM 11T3B1 01E IM 11R02A01 02E lt 7 Preparation of Operation gt 7 1 T 7 1 7 2 7 3 Preparation of Operation N WARNING Before s
77. ropriate value is 23 V 11 lf difficult to obtain the normal value it is due to the defect of the distributor in the calorie detector Measure 15 and 16 on the terminal block of the calorie detector The appropriate value is 23 V 11 lf difficult to obtain the normal value it is due to the defect of the distributor in the calorie detector Measure 8 and 7 on the terminal block of the calorie detector The appropriate value is 3 V 0 2V gt lf the measured value varied very much in spite of the air pressure control section being normal it is likely the differential pressure transmitter considered to be defective Measure 6 and 7 on the terminal block of the calorie detector The appropriate value is 3 V 0 2V gt If the measurement value is greater than the appropriate value even though the gas pressure controller is normal the differential pressure transmitter considered to be defective IM 11R02A01 02E 11 4 lt 11 Troubleshooting gt 7 When the density meter is attached measure 3 and 4 of the density meter lf the appropriate value is out of data in spite of no leakage calibrate as according to the paragraph 7 4 Regarding GD400G Gas density meter refer to attached Instruction Manual IM11T3B1 01E CALORIE DETECTOR COMPUTING STATION ME ATENG STAL DC 1 5V o 165 DIFFERENTIAL PRESSURE un o 20 TRANSMITTER GAS s Br y DC 4 20mA DC 0 20mA
78. se the computing inside the station is kept working Change to Alarm display refer to Figure 6 14 and examine the cause of the alarm lamp lighting Lighting of the fail lamp Red color The lighting of the fail lamp means an occurrence of an abnormal trouble produced inside the instrument When a fail occurs the analog output and status output reserve the value just before the occurrence of the failure Such preservation power has a tendencying of decreasing gradually along with the lopse of the time Also the alarm lamp lights when the operation of the pressure adjustment for the gas air line but the lighting when other than under the time of measurement is not abnormal 11 6 Other Troubleshooting Check and deal with measures mentioned in paragraph 11 1 to 11 5 As to the trouble not mentioned in this manual contact to our service personnel The replacement parts shall be ready for your service as per details mentioned in the Replacement Parts in next paragraph 12 IM 11R02A01 02E lt 12 Replacement Parts gt 12 1 12 Replacement Parts 12 1 Calorie Detector E7023TA a Burner unit E7023BU mo Nama Ja Paro Remarks 4 ForsueionDeteetontemma ferv 2 Cots Juncion Detection Termina Eero 5 BurerTipAssemby i erzo a forns va Von 5 Jore orna vera on 10 coiso fe fera n Eo I E rone d 1 NING
79. should be paid to the following points ifthe sample gas contains harmful gases such as CO e Confirm that the air is supplied before introducing the sample gas e Use the equipment in a well ventilated environment equipped with a ventilation system Do not expose your face above the top of the calorie detector IM 11R02A01 02E lt INTRODUCTION gt iii After sales Warranty E Do not modify the product E During the warranty period for repair under warranty carry or send the prod uct to the local sales representative or service office Yokogawa will replace or repair any damaged parts and return the product to you Before returning a product for repair under warranty provide us with the model name and serial number and a description of the problem Any diagrams or data explaining the problem would also be appreciated e lfwe replace the product with a new one we won t provide you with a repair report e Yokogawa warrants the product for the period stated in the pre purchase quotation Yokogawa shall conduct defined warranty service based on its standard When the customer site is located outside of the service area a fee for dispatching the maintenance engineer will be charged to the customer In the following cases customer will be charged repair fee regardless of war ranty period e Failure of components which are out of scope of warranty stated in instruction manual Failure caused by usage of software hardware
80. square root of the density of the sample gas 1 Veg will be generated which directly affects the calorific value Therefore density compensation is required using a density meter For the WI measurement a density meter is not required since the WI is a value proportional to 1 Vpg IM 11R02A01 02E 2 6 lt 2 Specifications gt 2 4 External Dimensions 2 4 1 For Town Gas Application CM6G S6200 S6210 S6300 S6310 S6400 S6410 Unit mm Density meter detector Mark Name Connection A SAMPLE GAS IN Rc1 4 B SAMPLE GAS OUT OR VENT Rc1 2 Cc INST AIR IN Rc1 4 D STD GAS IN Rc1 4 E STD GAS IN Rc1 4 1 Calorie detector Density meter converter Flowmeter for Computing N density meter Station Approx 1970 1800 100 740 30 CM6G S6L110 with flowmeter Maintenance Space 100 900 500 _ T 7 Pp az s Back acl o S Front ol l Weight Approx 300kg Li A A A A A A A Dim 6210 eps Figure 2 2 External Dimensions For Town Gas Use IM 11R02A01 02E lt 2 Specifications gt 2 7 2 4 2 For Town Gas Application Quake proof Type CM6G S6110 Unit mm 120 hole Density meter converter Computing station Calorie detector i Flowmeter for density meter 0 30 1100 3 640 100 800
81. switch on the front panel of the calorie detector d Measure each of the output terminals on the terminal block with a voltmeter and adjust the voltage to 1 V DC using the zero adjustment screw on the differential pressure transmitter The terminal numbers for gas are 15 and 16 and those for air are 17 and 18 e Use a flat head screwdriver to make the adjustment Turn the screw clockwise to increase the output and turn the screw counterclockwise to decrease the output The adjustment amount of the zero point varies depending on the speed at which the zero adjustment screw is turned To make a fine adjustment turn the screw slowly and to make a rough adjustment turn the screw quickly f When the adjustment is completed connect the impulse lines while making sure there is no leakage Remarks Such adjustment shall be conducted whenever the location where the panel being installed is changed N WARNING Be sure to make this adjustment every time the installation location of the panel is changed AN WARNING Power is supplied to the differential pressure transmitter from the calorie detector To operate the differential pressure transmitter turn on the calorie detector switch of the switch box and the POWER switch on the front panel of the calorie detector AN WARNING After the zero point adjustment is completed do not turn off the transmitter immediately If the power is turned off within 30 seconds the value adjusted
82. t 10 Maintenance gt 10 2 Regular Check Refer to Figure 6 2 6 3 and 6 4 The flow sheet depends on the specification 10 2 1 Cleaning of the Orifice Plate and Replacement of O ring When something like dust adhere to the orifice holes the output power decreased Therefore clean them with the following way u SHE N A 7 u CROTCHET JOINT O HOLDING ORIFICE SCRE ASSEMBLY e oo AN HEX HOLE SCREW O RING P20 F10 2 ai Figure 10 2 Orifice System Oo 0 a D O Br EN Ss IM 11R02A01 02E Suspend the supply of the sample gas then blow the gas line with the air Remove the crotchet joint Turn the holding screw and take out Pull out slowly to the direction as shown on Figure 10 2 Loosen the set screw by using the hexagonal wrench attached there to and take out the orifice plate together with the cover plate For the cleaning use something like a supersonic cleaner and never insert into the orifice holes anything like a stick or rod When the O rings are worn out replace them with the spare parts When the cleaning and replacement completed assemble the parts according to the order contrary to above mentioned Remarks The orifice system is temperature controlled by a plate heater so better finish the cleaning and replacement as quick as possible lt 10
83. t is impossible even by using the pressure reducing valve 3 6 it is likely the pressure reducing valve is defective 11 For all gas lines check the leakage at each joint connection 11 2 Air Pressure Adjustment Section 1 Check the secondary pressure gauge of the air set 2 1 is about 200 kPa gt When the adjustment of the air set is impossible even when the primary pressure of the instrument air is normal it is likely the air set is defective 2 Check the pressure gauge 2 3 indicates approx 20 kPa We cannot adjust it when even using the pressure reducing valver 2 2 it is likely the pressure reducing valve is defective 3 Ifthe above are found normal we can adjust by using V 16 the air differential pressure to 500 IM 11R02A01 02E lt 11 Troubleshooting gt 11 3 11 3 Differential Pressure Transmitter Section Check the orifice section of the orifice assembly When the orifice plate is contaminated clean it as according to the paragraph 10 2 1 Check any leakage in the pressure transmission pipe of each differential pressure transmitter Check the temperature thermistor resistance value setting of orifice assembly lf the resistance value is not 3 6 to 4 2 KQ the temperature controller may have a failure 11 4 Signal Section Measure the output of each components by using digital voltmeter 1 Set the METER switch on the front panel of the calorie detector to P MEAS and meas
84. tart operation check outside wirings pipings and confirm no gas leakage found Refer to Figure 6 2 6 3 and 6 4 Sampling Section a Ifthe drain pot is located outside the panel supply water fully until the water overflows from the drain outlet b Open the gate valve when it is in the sample line c _ If two fulflo filters are located in parallel on the sample line one of them is not used Status of Valves Confirm and open or close according to the following table For town gas use Open or Close Open or Close For steel mill use Open or Close Open or Close Remarks Valve with the mark are the flow adjustment use and preliminary adjusted and not necessary to adjust Water Supply For Steel Mill Use a Open valve V 13 and supply water until it overflows from the drain exhaust outlet of the washing bubbler 3 2 and the pressure regulating pot 3 4 Refer to Figure 6 4 b The flowmeter 6 1 indicates the flow rate of 0 2 l min IM 11R02A01 02E 7 2 7 4 7 5 lt 7 Preparation of Operation gt Supply of the Air Open valve V 14 and supply the air The normal pressure is as undermentioned Pressure Gauge Normal pressure Pressure gauge of air set approx 200 kPa Pressure gauge 2 3 approx 20 kPa When the pressure is not normal adjust it by the following procedures a Adjust the pressure gauge of the air set to become approx 200 kPa using the air set valve 2 1 When turn the val
85. tion gas cylinder to approx 200 kPa Open V 9 or V 10 and introduce the calibration gas Using the pressure reducing valve 4 1 adjust the indication of the flowmeter 4 2 to become about 10 l min In case of only indication check its adjustment of approximately 2 to 3 l min is permissible Push the START switch of the calorie detector to ignite Set the computing station to Input Output status display refer to Figure 6 15 The indication of X3 G PRESS is adjusuted to 500 with the pressure reducing valve 3 6 In the case of the density meter being attached confirm and readjust the flow rate Confirm X2 A PRESS in Input Output status display and adjust X2 to 500 by using V 16 When completed the calibration close V 9 V 10 V 5 and open V 4 In the case of the pump being attached supply the power supply of the pump as the next step Push the START switch of the calorie detector to ignite Readjust both the gas differential pressure and the flow rate to the density meter Do not forget to close the root valve of the calibration gas cylinder Span Adjustment of the Calorie Detector This adjustment is not necessary for the usual calibration This adjustment is held in the case such as the replacement of the thermocouple of the burner unit This adjustment is different depending upon ifthe preheating circuit exists or not This adjustment is to be held after regulating each differential
86. tions u 22s4400nnnennnnnnnnnnnnnnnannnnannnnnnnnnnnnnnannnnannnnnn 2 1 2 1 1 Town Gas Application sinad doada o E IN a aga Ala TI N 2 1 2 1 2 Steel Mill Application 4404444044240sn nen Dan ia nea Dean ea Dena Dos 2 2 2 2 Model and Suffix Codes 24uu422u4440024400nnn0nnnnannnnnnnnnnnnnnnnnnnnannnnnnnnnnnnnnnnnn 2 3 2 2 1 Gas Galorimeler carta Moda hana cdi aga ag aa aa Ana ua n 2 3 2 2 2 Standard Access0oriles sana nan aranana aaa nean anan anana nean 2 4 2 2 3 Density Meter SAN Ag Ka ab 2 4 2 2 4 Options ii in 2 5 2 3 Standard Systems for Each Application sa0esanesenesen ena nena nana nanananenanen 2 5 2 3 1 Standard Systems for Each Application oooonoccncininnncnnnninccccccccnnos 2 5 2 3 2 Instructions for System Selection ooooncociccnnccnnconnconcnnnconncnrccnaccnncon 2 5 2 4 External Dimensions 4s442a0nn4annnnannnnannnnannnnnnnnnnnnnnnnnnnnannnnannnnnnnnnnnnn 2 6 2 4 1 For Town Gas Application sasasi adiasa aaa saa aana aaa iiini did agan dah aaa 2 6 2 4 2 For Town Gas Application Quake proof Type 2 7 2 4 3 For Steel Mill Application wisin ia 2 8 2 4 4 Dimensions of Options 4 u4440u4nn4nnnnnnnnnnnnnnnnnennnnnnnnnenn 2 9 3 PP e 3 1 4 Outside PIpiNgS canica een 4 1 5 External WIrings cet ii 5 1 5 1 Notes on WITING sarawa anawa 0 5 2 5 2 Wiring to Peripheral Equipment
87. unit must be specified IM 11R02A01 02E 2 4 lt 2 Specifications gt 2 2 2 Standard Accessories Followings are the standard accessories supplied e Calorie Detector Name ay Panno Remarks Mirror 1 E7023FF 644Y02 Brass Fuse 2 A1094EF 3A e Orifice Assembly Name ay Panno Remas O Ring Y9114XB P16 Viton O Ring L9817MT P20 Silicon Hexagon Wrench L9827AB Nominal size 1 5 mm Hexagon Wrench L9827AC Nominal size 2 5 mm 80 F2 1 ai Figure 2 1 Mirror 2 2 3 Density Meter Gas Density Meter is required for density compensation in calorific value measurement It is not required for WI measurement Converter GD400G N 10 N L PA Detector GD300S J LV KU Measuring range and unit specific gravity or density should be specified IM 11R02A01 02E lt 2 Specifications gt 2 5 2 2 4 Option Fulflo filter G7043XJ Element material Polypropylene Pore size 50 um Body SUS 316 Connection Rc 1 2 Pressure reducing valve G7008XF Primary pressure 15 MPa max Secondary pressure 0 to 200 kPa Material Brass 2 3 Standard Systems for Each Application 2 3 1 Standard Systems for Each Application Application System specification Town Gas WI Without Gas pressure 10 to 20 kPa Standard density Gas pressure 10 kPa or under With pump meter Gas pressure 100 to 600 kPa With pressure reducing value Calorific value Gas pressure 10 to 20 kPa Quake proof M
88. ure X5 of the computing station If preheating is not required the appropriate output is approximately O to 20 mV which is nearly proportional to 0 to WI value namely the highest value in the measurement range If preheating is required the appropriate output is approximately 4 to 20 mV which is nearly proportional to O to WI value namely the highest value in the measurement range For example When the WI value of the highest level in the measuring range is 100 WI ifthe sample gas is 80 WI the output voltage is about 16 mV when no preheating circuit In spite of both the gas pressure control section and the differential pressure being normal the output is widely different it is likely to be some blockade in the air flow distribution line of the burner unit If such case happens check the burner flame as mentioned in paragraph 10 3 1 lf the output has very weak power in spite of the burner being well burning it is likely the wire disconnection in the thermocouple happens Measure 3 and 4 on the terminal board of the calorie detector which normal output when preheating circuit does not exist is 1 to 5 V almost in proportion to 0 to WI value namely the highest value in the measurement range If preheating circuit exist approx 1 8 to 5 V is almost in proportion to 0 to WI value namely the highest value in the measurement range Measure 17 and 18 on the terminal block of the calorie detector The app
89. utput exceeds the lower alarm limit the burner is determined to be ignited and the ignition action is stopped even if it is not completed Ifthe burner is not ignited after the ignition voltage is applied five times the ignition action is stopped after the ignition voltage is applied for the fifth time In that case when the START switch is pressed again the ignition action starts If the burner is extinguished as a result of the alarm removing the cause of the failure and pressing the START switch will start the ignition action again If the alarm occurs due to excessive combustion and the alarm status continues the ignition action cannot be started until the thermocouple output falls below the lower alarm limit 1 Indication lamps turn ON or OFF in accordance with each stage of the sequence Figure 6 11 shows the ignition sequence for which the lower alarm limit is set to 50 Thermocople output 120 Higher alarm limit T t 50 L 4 x Lower alarm limit 0 Hi rn Ignition voltage 4 Low tI Open gt N p EV 4 Close gt i ON ALARM lamp 4 OFF gt ON gt IGNIT lamp i po u j MEAS lamp T u LOFF 4 lt serle gt Ignition action Alarm Measurement Alarm status
90. ve to the right the pressure becomes higher b Adjust the pressure gauge 2 3 to become about 20 kPa using the pressure reducing valve 2 2 and V 16 If turning the valve of the pressure reducing valve to the right the pressure becomes higher Supply of Power a Set the positions of each switch on the front panel of the calorie detector to the followings POWER SAFE EV METER b Turn on the switches of the following components in the switch box e Calorie Detector e Orifice Assembly NFB e Pre heater NFB Computing station e Density meter With density compensation e Dehumidifier For steel mill use only c When turning on the POWER switch on the front of the calorie detector in this time both POWER and ALARM lamps are lit which means it is in the state of alarm d When supplying power to the computing station the alarm lamp on the front yellow goes on and off but this is not out of order e POWER switch on in gas density meter in case of with GD400G f After elapsed for about 60 minutes the lamp of the orifice assembly starts flickering the temperature of the orifice constant chamber become stable IM 11R02A01 02E lt 7 Preparation of Operation gt 7 3 The Zero Adjustment of the Differential Pressure Transmitter a Remove the impulse lines from the transmitters b Turn on the main breaker of the switch box and the calorie detector switch c Turn on the POWER
91. very much different from normally observed is mainly considered by two cases one is due to the change of gas composition caused by the change of the process conditions and another is due to the failure ofthe measuring system If the trouble is considered coming from the failure of the measuring system the following items should be checked as for troubleshooting Gas Sampling Pressure Regulating Section Refer to Figure 6 2 6 3 and 6 4 For Town Gas Use 1 Check if any blockade or leakage exist in the sampling line up to the panel lf any blockade found blow the sampling line by air 2 Check the filter element of the line filter According to the paragraph 10 2 3 clean or replace 3 Ifabove is normal the pressure gauge 3 2 indicates 8 to 18 kPa When the pump is attached and if the pressure does not indicate normal value even after open V 5 fully the decrease of the suction ability of the pump might be a cause of trouble lf the pressure reducing valve is attached and the indication of the pressure gauge 3 2 does not change even after the operation of the pressure reducing valve 3 8 the pressure reducing valve may be defective 4 When introducing the check gas confirm the indication of the flowmeter 3 3 is about 10 l min In case of only indication check its adjustment of approximately 2 to 3 l min is permissible lf the flow rate can not be satisfactorily set by the pressure regulator 4 1 it is due to t

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