INSTRUCTION MANUAL TRX-5000 SERIES THERMAL FLOW METER CONVERTER TOKYO KEISO CO., LTD. IM-ES769 NOV., Thank you for having purchased our product.

Transcription

1 INSTRUCTION MANUAL TRX-5000 SERIES THERMAL FLOW METER CONVERTER IM-ES776-0E NOV., 2003 Thank you for having purchased our product. This instruction manual deals with items how to install TRX-5000 series thermal flowmeter converter and describes about matters requiring attention in handling it. Please make sure to read this manual before using the converter together with the instruction manual of detectors to be combined. After reading the manual, keep it in a safe place for future reference. Please note that the contents of this manual is subject to be changed without prior notice. Detector Type TH-1100 TH-1100SP TH-1100HQ TH-1200 TH-1400 TH-1500 TH-1500HQ TH-1600 TH-1700 TH-1800 Instruction Manual No. F-H-41 IM-ES760 F-H-26 F-H-42 IM-ES769 F-H-43 F-H-28 F-H-44 IM-ES772 IM-ES773 Technology and Heart TOKYO KEISO CO., LTD.

2 CONTENTS 1. Notation rules...1 Safety symbols...1 General information symbols Operational notes...2 General notes...2 Material...2 Maintenance and inspection...2 Control safety Precaution for handling Confirmation of type and specification Precaution in transportation Precaution in storage Installing site Safety precaution General description Outline Features Standard specification Flow rate range table Model type code table System configuration Outside dimension Detailed drawing of front panel Installation Wiring Standard accessory cable...15 a) Cable structure 15 b) Cable end treating method Schematic of wire connection...18 a) Standard type and one with pulse output 18 b) Option circuit board Wiring Temperature input i -

3 7. Operation ) Setting up the thermal flowmeter 21 2) Resetting totalization indication 21 3) Temperature correction function Maintenance Instrument used for maintenance Checking converter Detector resistance check Temperature sensor (Resistance temp. sensor) resistance check Troubleshooting Circuit construction Function to change flow rate range Measuring principle Flow velocity and flow rate accuracy Service network Warranty ii -

4 1. Notation rules Safety symbols This manual classifies safety notes using the following symbols. WARNING If this indication is disregarded and this instrument is operated incorrectly, serious injury or fatal accident may result. CAUTION If this indication is disregarded and this instrument is operated incorrectly, injury or property damage may result. General information symbols This operation manual classifies general information notes using the following symbols: NOTE Indicates procedures or information required to operate this product. REFERENCE Indicates information that should be understood to enable this product to be operated safely and comfortably. ( P. ) The indicated page contains information other than notes that should be referenced

5 2. Operational notes General notes WARNING This product is delivered after manufacturing and adjustment. Inspection have been conducted based on the optimum quality control method for industrial instruments. If any attempt is made to modify or change this instrument, it may fail to perform as intended, or incompatibility or accidents may result. Do not modify or change this instrument in any way. If it is necessary to modify or change it, contact Tokyo Keiso Co. WARNING Be sure to operate the instrument within the ranges of the specifications for fluid pressure and temperature listed in the Approval drawing. If the instrument is operated out of these ranges, it may become defective or be damaged. CAUTION During transportation and storage, ensure to prevent moisture, dirt or sand from entering the instrument as such will cause damage or render the instrument defective. CAUTION Use this product only as an Industrial instrument. Material The material of this product is described in the approval drawing. Although we make every effort to select the optimal material for the customer's specifications, it may not be perfect due to the presence of foreign matter. Thus you are responsible for checking anticorrosivity and compatibility. Maintenance and inspection WARNING When removing this product from your process for maintenance or inspection, make sure there is no object to be measured remaining in the instrument. If the object is corrosive or toxic, the operator may be adversely affected. CAUTION The frequency and contents of the maintenance and inspection of this product vary depending on the operational conditions. See the relevant section of this manual or check the actual operational conditions

6 Control safety WARNING Although this product is delivered after manufacturing, adjustment and inspection have been conducted based on the optimum quality control method for industrial instruments, an unexpected defect may occur. If this product is used for process control that may result in a critical safety problem, take all necessary actions to maintain safety

7 3. Precaution for handling This thermal flowmeter is our original thermal mass flowmeter. With a unique measurement principle based on heat transfer phenomena, it is designed to measure a flow rate of the gas at high accuracy, which flows through a pipe or duct. This device is delivered after full inspection at our factory. To make it doubly sure, check its appearance for any harmful damages upon its arrival at your site. This manual describes how to handle the thermal flowmeter properly and the precautions for use. Prior to actually using this product, be sure to read this manual together with the instruction manual for the combined detector for proper handling of the flowmeter. After reading the manual, keep it carefully. If you have any inquiries, contact our dealer from whom you purchase the equipment or our nearest office listed on the last page of this manual Confirmation of type and specification Collate the MODEL and MFG. NO. inscribed on the FLOWMETER tag plate attached to the top or side of the converter with those on the PICKUP tag plate (see Fig. 1.1) with the Specifications column in the Approval Drawing, and confirm that there is no difference in both of these tags. When you make an inquiry, please let us know the MFG. NO. and TYPE inscribed on the FLOWMETER/PICKUP tag plate or described in the Approval Drawing. (* MFG. NO. is a control number for our product.) FLOWMETER TAG NO. MODEL MFG.NO. DATE TOKYO KEISO CO., LTD. MADE IN JAPAN PICKUP TAG NO. MODEL MFG.NO. TOKYO KEISO CO., LTD. MADE IN JAPAN Fig Example of tag plate 3. 2 Precaution in transportation This product is a precision device. Pay attention when handling it in transportation, etc. In order to prevent the detector from damages or contamination due to an accident which may happen during transportation, it shall be transported to the installing site in the same packing conditions as it is originally shipped from our factory Precaution in storage If a precision device like this product is not installed for a long time after it has been delivered to you, it may have troubles such as corrosion, deteriorated insulation of the electrical system. If long-term storage is expected, observe the following points. 1 Store the flowmeter and the accessory cables in the same package as delivered originally from factory. 2 Choose a proper storage site which meets the following conditions. Place free from the rain and water - 4 -

8 Place free from vibrations and shocks Ambient temperature of 0 to 60 (Place where there is no sudden change in temperature.) Humidity of 80 % RH or less Store the product at a normal temperature and humidity (approx. 25 and 65 % RH). 3 When storing the flowmeter which has been used once, observe the following points: Clean it if the converter is stained. In order to prevent damages on the converter, protect it with a packing material such as an air cap. (In order to prevent deterioration of the electronic parts, put a dehumidifying agent, etc. in a package for storage.) Since the converter and detector correspond to each other at 1:1, pack and store the converter per our MFG. NO., including their accessories Installing site The TRX series thermal flowmeter converter has been designed to properly run under the severe environmental condition, but it is recommended to install the converter at a place easily accessible for maintenance/inspection. Determine an installation site, considering the following points, so that you can use the flowmeter stably for a long time at high accuracy. 1 Ambient temperature (Ambient temperature range: -10 to 60 ) Avoid installing at a place where the temperature gradient or change is great. If it is exposed to the radiant heat from the plant, provide heat insulation, or choose a well-ventilated area for installation. 2 Atmospheric condition Avoid installing it in the corrosive atmosphere. When using in the corrosive atmosphere, choose a well-ventilated place or purging environment. Do not use for a long time in a place where a corrosive gas stagnates. After measurement is completed in such an environment, move the converter immediately out of the corrosive atmosphere. Avoid installing in the dusty atmosphere. 3 Shocks and vibrations The converter has been designed resistant to shocks and vibrations. However, install it in a place free from them as much as possible. 4 Noise Avoid installing this device close to a noise supply such as a compressor, high-voltage line inverter. A detector-converter cable exclusively designed for the thermal flowmeter is doubly shielded to fully cope with noise. If the cable is long, however, noise may enter. Others Do not put a heavy substance on this device because it may lead to a breakage, nor install it in an unstable place as it is heavy

9 3. 5 Safety precaution 1 If the thermal flowmeter shows any abnormality such as smoking or emitting a foul odor or strange sound, turn off the AC power immediately and contact our nearest office. If it is used in an abnormal condition, it could cause a fire or electric shock. The customer should never repair it on his own. It is dangerous. 2 Never disassemble or remodel the converter. A trouble could be caused. 3 This converter is designed water-proof, but be sure to apply a water-proof treatment such as water-proof cable gland to a cable insertion port to prevent an entry of the rain. Otherwise, the rain could enter inside the converter, resulting in an electric shock or trouble. 4 Do not disconnect a connection cable while using the thermal flowmeter(power on). It could cause an electric shock or trouble. Be sure to turn off the power prior to disconnecting the cable. 5 The converter is heavy. Be careful when installing it onto the wall, 2B pipe, etc. When it is install at a place which is influenced by vibration etc., the fixed part of converter is to be reinforced. 6 This converter is designed to be water-proof. However, it is recommended to install it at a place free from the rain as much as possible. If the rain enters inside the converter in adjusting or checking it, it could cause an electric shock or trouble

10 4. General description 4. 1 Outline TRX-5000 series is a converter designed for a water-proof construction thermal flowmeter of field installing type. With the microcomputer-mounting signal processing circuit, high-precision/high-performance capacities have been achieved and functions necessary for process monitoring and controlling such as indication of flow rate/totalization, analog output, pulse output and serial output (RS232C) can be mounted. By mounting temperature correction function of option specification and inputting temperature signal from temperature sensor of external installation, it is also possible to measure mass flow rate at a higher degree of accuracy even for the line of which process temperature widely changes. In addition, data setting on maximum 16 ranges or up to 16 types of gas is available in advance. This, together with mounting of the simplified self-diagnosis function, enables to quickly cope with the situation when an unexpected trouble takes place. Additional functions such as sample hold function to correspond to purge type thermal flowmeter detector, solenoid valve control output and contact output are made available by mounting an option circuit board Features 1 High precision The flow rate of various types of gas can be measured with a high accuracy within ±2.0 % full scale by the measurement principle of our originality. 2 Wide range ability The measurement accuracy is sufficiently maintained for practical purpose even in a flow rate range as low as 0.5m/s. The drawback of traditional orifice type and vortex type gas flowmeters has thus been broken through. 3 High durability Long life ensured by using high-reliability electronic parts. 4 Mass flow rate measurement Thermal mass flowmeter for gases based on TOKYO KEISO's original heat transfer theory. Capable of measuring almost all general gases because of the measurement theory by which theoretical analysis was established. If a gas temperature changes a little, an output change with respect to a gas temperature change will be as little as 0.1 % full scale/ (maximum), thus allowing measurement of a mass flow rate without correcting the temperature. If the gas temperature changes greatly or high flow rate accuracy is required, a temperature correcting circuit can be optionally added inside the TRX-5000 converter and mass flow rate measurement can be made at high accuracy by inputting a temperature signal(resistance temp. sensor: Pt100Ω, voltage signal, etc.) from the outside. An effect of pressure is as little as 0.1 % full scale/ kg/cm 2 (maximum) owing to the measurement principle based on the heat transfer phenomenon, and the high accuracy mass flow rate measurement can be made without correcting the pressure

11 4. 3 Standard specification * For specifications other than standard one, refer to the approval drawing. Converter specification Display : Flow rate 6 digit LED (Display range ~ ) : Totalization 8 digit LCD (with reset) * Totalization counter driven by lithium battery (Life is about 7 years.) Flow rate range, object gas Output : Analog output : Pulse output * Temperature correction function Option circuit board function Refer to Flow rate range table on Instruction Manual of the detector to be combined. 4 ~ 20mADC, Allowable load resistance 500Ω Open collector, 35VDC, 50mA (max.) Pulse width 50 ~200ms (variable by step of 10ms) : Standard 50ms Pulse rate setting range 1~600c/min, 6~36000c/h (for pulse width 50 ~70ms) Pulse rate setting range 1~300c/min, 6~18000c/h (for pulse width 80 ~140ms) Pulse rate setting range 1~150c/min, 6~9000c/h (for pulse width 150 ~200ms) * Pulse output synchronizes with totalization display. Resistance temp. sensor Pt100Ω (external installation) and temperature signal input are required separately. * For detailed contents of temperature correction function, refer to 7 Operation: 3) Temperature correction function. Sample hold function compatible with purge type thermal flowmeter detector and input/output purge control signal are added. Purge control input (Open collector), Purge signal output (Open collector + contact output), Contact output (Flow switch or abnormality alarm) Accuracy : Flow rate/totalization indication: ±2% F.S. ±1 digit Analog/pulse output: ±2% F.S. Response time Cable length Power supply Power consumption Electrical connection Withstand voltage Insulation resistance 5 seconds (against 63% step response) Up to maximum 50m (Exclusive cable connecting converter and detector) 100V, 110V, 115V, 200V, 220V, 240VAC ± 10%, 50/60Hz 30VA (maximum use time) Screw terminal block Between primary side terminal and case: 1500VAC (1 minute) Note) To be tested by having the noise filter-grounding terminal inside the converter main body floated from the case. Refer to Detailed drawing of converter interior on page 12. When making withstand voltage test, make sure to short-circuit terminals 1-2 (temperature difference signal input). When test is conducted without floating the grounding terminal from the case, about 6mA current flows. Between primary side terminal and casing: 20MΩ or larger at - 8 -

12 500VDC Structure and weight Material and painting color Wire connecting joint Mounting method Converter ambient temperature Detector specification Jet flow prevention structure (IP 65 equivalent), Approximate weight 4.5kg (excluding accessory cable) Aluminum alloy die casting (ADC), Cobalt blue (Munsell 3.0BP3.5/10.5) 5-G1/2 (female thread) Mounting on wall or 2B pipe 10 ~ 60 ºC For the specification of detector, refer to the approval drawing or the instruction manual of the detector to be combined. Accessories Special exclusive cable Detector ~ Converter exclusive cable, Standard length 10m x 1 piece * For cable length, refer to the approval drawing. Spare fuse Converter installing bracket Midget type, 125V-1A x 1piece 2B pipe mounting bracket : 1 set, option (For wall mounting, no bracket is attached.) 4. 4 Flow rate range table * For the measurable flow rate range of this flowmeter, refer to the Flow rate range table in the instruction manual for the detector to be combined

13 4. 5 Model type code table ٱٱٱ-ٱٱٱٱ-ٱٱٱTRX-5 Converter: TRX-5 Model type code Contents 1 Flow rate Indication 3 Flow rate + Totalization Output 3 4 ~ 20mA+Pulse output Temperature correction Power supply Cable length Electric connection 2 pipe mount fitting 0 No correction 1 Resist. temp. sensor (Pt100Ω) 2 4 ~ 20mADC temp. signal 3 1~5VDC temp. signal Option (Additional option circuit board) 1 100VAC ±10% 2 110VAC ±10% 3 115VAC ±10% 4 200VAC ±10% 5 220VAC ±10% 6 240VAC ±10% 1 5m 2 10m (standard) 3 15m 4 20m 5 25m 6 30m 7 40m 8 50m F Others 1 G1/2 F Others 0 Not provided 1 Provided 1 Open collector input (Standard) Purge control input 2 Contact input (Manual SW) TRX-5000 series converter Combination detectors 1. TH-1100 series (Nominal aperture 50mm up) TH-1100 (HQ) series (Nominal aperture 50~100mm) TH-1100 (SP) series (Nominal aperture 150mm up) 2. TH-1200 series (Nominal aperture 50~150mm) 3. TH-1400 series (Nominal aperture 50mm up) 4. TH-1500/TH-1700 series (Nominal aperture 15~50mm) TH-1500(HQ) series (Nominal aperture 15~25mm) 5. TH-1600/TH1800 series (Nominal aperture 15~50mm) * For the detector type and detailed specification, refer to the delivery specification sheets or the instruction manual of the combining detector. Option (Additional option circuit board) 1 Open collector + Contact output Purge output 2 Open collector + AC output Option (Additional option circuit board) 1 Flow switch Contact output 2 Abnormality alarm output

14 4. 6 System configuration Flow rate Totalization* * Selection (Yes/No) Analog output: 4~20mADC Totalization*/Pulse output: Open collector * Selection (Yes/No) TOKYO * Selection (one out of the followings) Temperature correction signal input : Pt100Ω : 4 ~ 20mADC input : 1 ~ 5VDC input Detector ~ Converter Special exclusive cable Detector AC power supply * Option circuit board (option) Purge control input (Open collector) Purge signal output (Open collector + Contact) Flow switch/abnormality alarm output (Contact) 4. 7 Outside dimension 206 φ φ Wiring joint G1/2 308 Weight: app. 4.5kg Wiring joint G1/2 Weight: app. 6.5kg B Pipe

15 4. 8 Detailed drawing of front panel 4 5 THERMAL FLOWMETER Flow rate indicator (6-digit LED) 2 Totalization indicator (8-digit LCD) 3 Totalization indicator reset switch 4 LED for operation check (Simplified self-diagnosis function) 6 1: Green LED, 2~4: Red LED DIPSW LED RESE DC4~ 7 8 For the method of operation check, refer to 8. 2 Checking converter. 5 DIPSW (Operation check switch) For the method of operation setting method, refer to 8. 2 Checking converter. 6 SW1 (ROM range selection switch) 7 4~20mADC output zero adjustment VR 8 4~20mADC output span adjustment VR 9 9 Wiring port (G1/2 x 5) Note) The detailed drawing of front panel (above) and the detailed drawing of converter interior (below) show the front panel and converter interior loaded with full option specifications. * Detailed drawing of converter interior BATTERY TRX-5000 (indication) circuit board 2 LED for indication of flow rate 3 Totalization indicator (8-digit LCD) 4 Totalization indicator reset switch 5 Battery for driving totalization indication 6 4~20mADC output zero adjustment VR 7 4~20mADC output span adjustment VR 8 LED for operation check 9 DIPSW (operation setting switch) 10 SW1 (ROM range selection switch) 11 TRX-5000 (CPU) circuit board 12 TRX-5000 (ANALOG) circuit board 13 AC power supply connector for purge output 14 TRX-5000 (option) circuit board (* Option) 15 Fuse for purge output (AC output) (* Option) 16 Option circuit board input/output terminal board (Refer to 6. 2 Schematic of wire connection ). 17 TRX-5000 power supply fuse 18 AC power supply terminal 19 Power supply noise filter 20 Input/output signal terminal board (Refer to 6. 2 Schematic of wire connection )

16 5. Installation * Regarding installation of converter When installing a converter, pay attention to the following items. For the installing site, refer to 3. 4 Installing site. There are 2 different methods of installing the converter. One is mounting on a wall and the other is mounting on 2B pipe. For the latter mounting method, pipe mounting brackets (option) are necessary. As bolts for wall mounting (M8 x 3) are not included in accessory supplies, customers are requested to prepare the bolts, selecting bolts length to suit the fitting part panel thickness. For the outside dimension and rough construction of the converter, refer to 4. 7 Outside dimension and to Fig. 3. 1/3. 2 Converter installing drawing. When installing the converter, make sure that the wiring joints become downward. Note) Pay attention when installing the converter as it weighs about 4.5kg ~ 6.5kg. For wiring of the converter, refer to 6. Wiring. The converter is of water-proof construction, however, it is necessary to provide water-proof cable gland to prevent rain water from penetrating from the wiring joint. * Converter installing method. 1) Wall mounting type Refer to Fig Converter installing drawing and drill 3 holes on the wall or panel and fix the converter with screws. 1 Drill 3 bolt holes on the wall or panel for fixing the converter. 2 Temporarily set 2 M8 bolts for fixing the bottom part of the converter on the wall or panel, leaving proper clearances in which the recess parts at the bottom of the converter can be inserted. Fit in the bottom part of the converter to the bolt clearances. 3 4 While adjusting the posture of the converter, fix the upper part of the converter with a M8 bolt. Tighten firm 2 fixing bolts at the bottom of the converter that were temporarily set. Note) When mounting the converter directly on a concrete wall, fix the converter with the bolts after driving in anchors into the wall

17 2) 2B pipe mounting type As illustrated in Fig Converter installing drawing, sandwich the 2B pipe (50A stanchion) between the fitting metal and the bracket, and then tighten it with the accessory bolt. The 2B pipe mounting type converter can be used as the wall mounting type by removing the fitting metal on the rear side of the converter. Converter installing drawing B Pipe Fitting metal Bolt 308 Converter fixing hole φ9 or M8 (3 places) Bracket Fig Fig

18 6. Wiring 6. 1 Standard accessory cable An exclusive special cable with end treatment for connecting the converter and the detector is included in accessory supplies of the thermal flowmeter. (Pin crimped type terminals are connected on the converter side. Depending on the type of the detector, a water-proof type connector or round crimped type terminals are connected on the detector side.) Note) The power cable and signal cables (other than the exclusive cable) are not included in the accessory supplies. Customers are requested to prepare these cables themselves. For the length of the exclusive cable, refer to the approval drawing. The maximum length of exclusive cable available for TRX-5000 converter is 50m. Note) Use the exclusive cable in length as originally delivered without cutting it as much as possible, since the cut end of the cable not properly treated may give cause to noise generation and resultant trouble in operation. When it is inevitable to cut the cable to a shorter length, treat the cable end by referring to item b) Cable end treating method on the next page. a) Cable structure Water-proof connector Cable Pin crimped type terminal Detector side connector type Round crimped type terminal Cable Pin crimped type terminal Detector side round crimped terminal type

19 * Water-proof connector specification (Shell size 20) Maker: Nanahoshi Scientific Laboratory Type No.: NJW-207-PF-12 Contact No./Diameter: 12/φ1 Rating: 5A/250V Withstand voltage/insulation resistance:1000v/1000mω or larger Marginal operating voltage: 250V Wire conductor cross-section area: 0.5mm 2 Blue wire (2mm 2 ) Inner coaxial wire (black) Core wire 0.5mm 2 Outer shield braid wire Coaxial outer braided wire White wire (2mm 2 ) Cable sheath (Gray) Cable connecting method: Soldering Cross-cut section of Cable b) Cable end treating method Use the accessory exclusive cable in length as originally delivered without cutting it as much as possible. When it has inevitably to be cut shorter for using convenience, treat the cable end by referring to the following procedures. Do not cut the cable to a length shorter than 4m, since it is necessary to change (or readjust) the power supply voltage of the heating current according to the length of the cable. * Illustration for explaining cable end treatment Thermal contraction tube φ3 42 Temp. diff. signal line ( ) Temp. diff. signal line (+) 50 Inner coaxial wire (Black) Thermal contraction tube φ6 10 Soldering Thermal contraction tube (φ20 50) Cable Shield line Heating current signal line Heating current signal line 8 Blue wire (2mm 2 ) 150 White wire (2mm 2 ) 15 Cable sheath Outer shield braided wire

20 1 Using a cutter, cut and remove the outer cable sheath in length of about 200mm from the end. At this time, pay attention not to damage the sheathing of the inner cable. Cut off the outer shield braided wire, leaving about 20mm. 2 Cut off the inner cable sheath according to the dimension of the above illustration. 3 After cutting off the sheath of the inner coaxial wire, separate the shield wire from the core wire as illustrated above and cover them with thermal contraction tubes. 4 As illustrated above, turn the outer shield braided wire inside out and cover the cable sheath with it. 5 Solder the 2mm 2 x200mm vinyl coated cable to the outer shield braided wire that was turned inside out in procedure 4 above. After completing soldering, adjust the cable length and trim the sheath at the top end of the cable by about 8mm. 6 Cover the portion soldered in procedure 5 above with a thermal contraction tube. 7 Attach pin crimped type terminals at the tip of each cable. Table 4. 1 Crimped type terminal and connection terminal in use Cable Crimped terminal Terminal No. Inner core wire For 1.25mm 2 1 * Coaxial braided wire For 2mm 2 2 * Blue wire (2mm 2 ) For 2mm 2 3 White wire (2mm 2 ) For 2mm 2 4 Outer shield braided wire For 2mm 2 5 * The inner core wire and braided wire are thin, and the crimped attachment of terminal connection may become incomplete. After connecting the terminal, be sure to solder the connecting part

21 6. 2 Schematic of wire connection a) Standard type and one with pulse output SENSOR INPUT ΔT (+) (-) I (+) (-) E SCALED ANALOG OUTPUT (+) (-) SCALED PULSE OUTPUT (+) (-) TEMPERATURE INPUT (Pt100Ω) (A) (B1) (B2) FUSE POWER SUPPLY E 15 (E) (C) DC4~20mA OPEN COLLECTOR In case of other than resistance thermometer bulb input Pt100Ω To detector Exclusive Cable for Thermal Flowmeter TEMPERA TURE INPUT DC4-20mA OR DC1-5V (+) (-) Note) When temperature correction function is attached, if temperature signal is not inputted, the output and indication become clipped (hung-up). Power Thermometer * Regarding pulse output Converter Box Interior (C) (E) 10 9 R External Equipment +E(V) * Since the pulse output is open collector output (insulation type transistor contact output), take care not to confuse the positive and negative polarity when connecting external equipment. Open collector output Pulse width: 50ms (standard) Rating: 35VDC/50mA (max.) Vcesat = 1.2V E Vceset +E(V):DC+5~35V 50 (ma) R

22 b) Option circuit board PULSE INPUT PULSE OUTPUT * In case of AC power supply purge output specification Fuse (+) (- ) (+) (- ) Connector (+) (-) (+) (-) NO NC COM NO NC COM Control signal Input Open collector Purge signal Output Open collector Flow rate alarm output or Abnormality alarm output Purge signal output AC power supply purge signal output (For solenoid valve control) AC power * Contact output rating 125VAC, 0.4A 250VAC, 30VDC, 0.2A 2.0A 6. 3 Wiring 1 Remove the lid of the terminal box at the bottom of the converter with a ( ) screwdriver and connect the signal and power supply cable to the terminal board. For details of signal cable connecting method, refer to 6. 1 Standard accessory cable and 6. 2 Schematic of wire connection. 2 Connect the exclusive cable (to link detector and converter) to the connector. * Precautions for wiring 1 When wiring, the minimum bending radius of cables should be 15cm or larger. 2 Do not cut the detector ~ converter exclusive cable to a shorter length or do not use general-purpose cable sold on the market, as it may cause noise troubles and flow rate measurement errors. * Exclusive cable between Detector ~ Converter The cable used for linking the converter and the detector is our original cable of special type. For the ordered cable length, see the approval drawing. As for the cable structure, refer to 6. 1 Standard accessory cable. 3 For anti-noise measures and cable protection, install the cable in a wire conduit or cable duct. When installing the cable in a wire conduit, select the conduit size by giving considerations to the dimension of the connector (Max. outside diameter of connector x length: φ26 x 62mm, Cable thickness: About 11mm) that connects the exclusive cable of connector type specification

23 4 The connector of the connector specification detector is of water-proof construction with male/female coupling structure. When the detector is installed outdoors, do not leave the detector without connecting the exclusive cable. Should rain water penetrate into the connector, it would give a cause to corrosion of cable or connector pin. After installation of the detector, if certain length of time is expected to complete wiring arrangement, protect the detector from rain water by the accessory blind cap or by a plastic bag. 5 In case of temperature correction input specification, input the signal that meets the input signal specification of the converter [Resistance temp. sensor (Pt100Ω) or analog temperature input signal (4~20mADC/1~5VDC)] Temperature input When using the resistance temp. sensor for this flowmeter temperature correction input, select the resistance temp. sensor that conforms to JIS C 1604 (3-wire type Pt100Ω, A class). As for the sheath, select one that has good response properly as long as there is no handling problem (strength, corrosiveness, etc.). Note) Note that, in case of the converter with temperature correction function, if temperature signal is not inputted, the indication of the flow rate and the analog output will take the HOLD status

24 7. Operation * The thermal flowmeter has been fully adjusted and set upon shipment from the factory. Once the wiring between the detector and converter is completed, it will be immediately ready to measure a flow rate. For the detailed specifications, see the approval drawing. 1) Setting up the thermal flowmeter 1 Confirm that the detector is correctly installed on the piping line. 2 Confirm that wiring of the converter ~ detector cable, external output signal cable and the power supply cable is correctly arranged. 3 Turn ON power supply and confirm that the green LED at the lower right of the converter front panel is lit up. (Refer to 4. 8 Detailed drawing of front panel.) When this green LED does not come ON, perform Power-ON-Reset (once turn OFF power supply, and then turn it ON again) and see if this has effected the green LED to light up. When the green LED is still OFF, refer to 8. Maintenance and thoroughly check the converter and the detector. 4 With the above, the setting-up procedures has been completed. 2) Resetting totalization indication The totalization on the indicator can be reset by pressing the reset switch located on the right of the indicator. (For the location of the reset switch, refer to 4. 8 Detailed drawing of front panel.) 3)Temperature correction function Temperature correction can automatically be executed by selecting the temperature correction function and inputting temperature signal (selecting one out of resistance temp. sensor Pt100Ω, 4~20mADC and 1~5VDC). When the temperature correction function is not selected, the output error of the thermal flowmeter due to temperature change is about ±0.1% F.S./ºC (max.), although is somewhat different depending on the gas composition. Calibration of a thermal flowmeter is generally performed using in-company calibration facilities (applying comparison method by wet process or dry process gas meter) by measuring the flow rate characteristics inherent to the sensor (relationship between heating current I and flow rate Q ) against the calibration gas (generally using air) at the fluid temperature and pressure of the calibration time and converting it to the flow rate characteristics of the specification gas using the gas substance value of the specification gas at that temperature and pressure. Accordingly, at temperature other than specification temperature, errors in flow rate measurement take place due to the difference between the substance value used for the above conversion and the gas characteristics of the actually measuring fluid (in case where specification gas temperature and the fluid temperature of actual measurement widely differ). When temperature correction function is selected, in order to eliminate the above-mentioned substance value error, the specification temperature range is divided into 7 sections and the flow rate characteristics of the specification gas at each section of the temperature range are stored in ROM memory. Then, external temperature signal is read in through the A/D converter, based on which the temperature correction of flow rate is made by interpolating the flow rate characteristic data stored in the ROM

25 * According to the measuring principle based on the heat conduction phenomena (The substance value concerning heat conduction makes little or no change with the pressure changes.), the pressure error is as small as within about ±1.0% F.S./MPa (max.), although it somewhat varies depending on the gas composition. This range of an error is considered almost ignorable in general operating conditions. * For output error by temperature/pressure changes, refer to the item Regarding accuracy of flow speed and flow rate in the instruction manual of the detector to be combined

26 8. Maintenance A simple method of checking the condition of the thermal flowmeter before starting initial operation and re-starting operation is described in the following. For wire connecting method of the thermal flowmeter, refer to 6. Wiring in this instruction manual and the wiring diagram in the approval drawing. When an abnormality is found in the following checks, contact our business office or our nearest sales agent Instrument used for maintenance For maintenance of the converter, a digital multimeter for measuring resistance of the detector and other measuring instruments are necessary. Measuring instrument used for maintenance work should be limited to the instrument whose performance is well maintained and controlled Checking converter * As for the purge operation (option), refer to item 3) Regarding option operation (Purge control mode). 1) Checking converter 1 Check of operation status by LED ON/OFF position The following converter operation status can be checked by the LED 1~4 located at the lower left just off center of the front panel of the converter. LED ON/OFF position LED Note Gree Red Red Red Operation status Indication 4~20mADC Analog output Totalization Pulse output Normal Normal Ind. Normal output Normal output At 0% operation check 0% Ind. 4mA output 0% output At 50% operation check 50% Ind. 12mA output 50% output At 100% operation check 100% Ind. 20mA output 100% output Heating current value abnormal 0% Ind. 4mA output Stop Temperature input for temp. correction is abnormal. Hold Hold Stop Flow rate range over (120% over) 120% over 23.2mA Continued Heating current value and temperature input are abnormal. Hold Hold Stop Temperature input is abnormal, and flow rate range over Hold Hold Stop External ROM error Zero Ind. 0mA output Stop Other and compound errors Note 1) : LED in ON position, : LED in OFF position 2 Operation check (Setting contents of SW1 and DIPSW) The setting and operation status of the converter can be checked by operating the DIPSW at the lower left part of the front panel. * It is necessary to remove the top lid (glass window) of the converter

27 (1) SW1 setting contents SW1 OFF ON 1 ~ 4 Note 1) External ROM range setting (16 ranges) 5 Note 2) CPU External ROM 6 DC0~20mA DC4~20mA Note 1) For detail, refer to 11. Flow rate range changing function. Note 2) Since data for 1 range size can be inputted into CPU, it is possible to select either to use CPU data or to use external ROM data. (When the converter is delivered with multi-range or with external ROM, the simulation data (data different from specification) may be inputted in CPU data. Bear this point in mind. (2) DIPSW setting contents DIPSW OFF ON 1 Note 1) Regular mode Calibration mode 2 Note 2) With temperature correction Without temperature correction 3 Note 3) Flow rate indication Temperature indication 4 Note 4) Regular mode and output check Purge control mode (Waiting) Note 1) When turning ON power supply while DIPSW1 taking the ON position, the system enters into the calibration mode. Normally, do not use this way of operation. In case of multi-range specification, re-loading of ROM range data is performed. (After changing ROM range selection SW, change of the range is executed by operating DIPSW1 in way of OFF => ON => OFF.) * Re-loading of ROM range data is executed also by Power-ON-Reset operation. Note 2) The operation can be selected in case of temperature correction specification only. In other specification, the operation is fixed to Without temperature correction. Note 3) The operation can be selected in case of temperature correction specification only. In other specification, the operation is fixed to Flow rate indication. Also in case of setting DIPSW2 in ON position (Without temperature correction, the operation is fixed to Flow rate indication. Note 4) The operation can be selected in case of With purge control mode (option) only. In other specification, the operation is fixed to the regular mode. For the purge control mode (option), refer to 8. 2, 4) regarding option operation (Purge control mode)

28 (3) DIPSW setting operation (Output check) * In case where purge control mode (option) is mounted, output check is made effective by setting DIPSW4 in OFF position. DIPSW Contents 5 6 ON OFF 0% output check OFF ON 50% output check ON ON 100% output check 2) Adjustment (1) Adjustment of internal digital indicator The internal digital indicator displays the value as calculated by CPU, which cannot be adjusted. When executing zero adjustment and span adjustment, the ROM data has to be changed. (2) Adjustment of 4 ~ 20mADC Adjustment Zero adjustment Span adjustment Adjusting method Converter panel DC4 ~ 20mA to be adjusted by ZERO trimmer Converter panel DC4 ~ 20mA to be adjusted by SPAN trimmer Note 8) Note 9) Note 8) Make adjustment under status of 0% operation check or zero flow rate. Note 9) Make adjustment under status of 100% operation check. (3) Totalization indication and pulse output adjustment The totalization indication and pulse output are determined by the ROM data. When data has to be changed, please inquire at our sales department

29 3) Optional operation (Purge control mode) (1) Check of operation status by LED ON/OFF position The following converter operation status can be checked by the LED 1~4 located at the lower left just off center of the front panel of the converter. LED ON/OFF position LED Note Gre Red Red Red Operation status Indication 4~20mADC Analog output Totalization Pulse output Hold Hold Stop Hold Hold Stop Purge operation Note 2) (in spare h old) Hold Hold Stop/ Cont. Purge operation Note 2) (in signal output) Hold Hold Stop/ Cont. Purge operation in abnormality (in spare hold) Note3) Purge operation in abnormality (in signal output) Note3) Note 1) : LED in ON position, : LED in OFF position Note 2) It is possible to select whether to stop totalization during purge operation or to continue at the hold value by optional data setting. Note 3) LED1 (green) maintains its status same as immediately before purge operation and, on completion of purging, it changes the operation status. On the contrary, also when operation abnormality takes place during purge operation, the abnormality indication is given after the purge operation has been completed. (The condition of indication, analog and totalization varies depending on each abnormality situation.) * The purge operation and in-abnormality purge operation are limited to the case where option circuit board is mounted and setting is arranged. (2) Setting for operation The purge control mode can be selected by setting of the DIPSW. 1 DIPSW setting operation (Setting of purge control mode) * The operation is made effective by setting DIPSW4 in ON position. DIPSW 5 6 ON OFF OFF ON Purge internal control Contents (To control all the time factors by internal operation) Purge external control 1 Note 5) (To synchronize the purge cycle only with external control signal) Purge external control 2 (To determine the purge cycle and purging time by ON ON Note 6) external control signal) Note 5) Timing chart of purge internal control operation Note 5)

30 TP Purge cycle Sample hold Purge output THS TI TSH TP : Purge cycle Standard time : 1h (Setting range: 1~24h) * In case of external control 1, synchronized with external input control signal TI : Purge output time Standard time : 10s (Setting range: 0~60sec) THS : Spare sample hold 1 Standard time : TSH : Spare sample hold 2 Standard time : 2s (Setting range: 0~20sec) 20s (Setting range: 1~60sec) Note 6) Timing chart of purge control 3 operation TP External input signal cycle Sample hold Purge output TH S TI TSH TP : Purge cycle Synchronized with external input control signal TI : Purge output time Depends on the ON-time of external input control signal THS : Spare sample hold 1 Standard time: 2s (Setting range: 0~20sec) TSH : Spare sample hold 2 Standard time: 20s (Setting range: 1~60sec)

31 8. 3 Detector resistance check Connection of detector is made in 2 different ways: one is with a connector and the other is on the terminal board. For detail, refer to descriptions concerning detector resistance check in the instruction manual of each detector. Note) When a trouble occurs during operation using detector in combination with converter, check the detector resistance as above, together with checking according to 8. 4 Temperature sensor (Resistance temp. sensor) resistance check and 8. 2 Checking converter Temperature sensor (Resistance temp. sensor) resistance check 1 When the thermal flowmeter is already in use, turn power supply OFF. * Make sure to turn OFF the power before removing wire connections, since disconnecting wiring without cutting off power supply could cause to a trouble with the system. The lamp and error code also light up sometimes, even though there is nothing wrong with the converter. 2 Remove the cable for resistance temp. sensor from the connector terminal. 3 Measure, by a digital multimeter or a tester, the resistance between the cables (A, B1, B2) for the resistance temp. sensor. * When checking the thermometer resistance, the resistance of the cable is added on. Depending on the cable length, the resistance value may somewhat differ from those in the following table. 4 After checking, connect the connector and turn ON the power. (Check has been completed.) Approximate resistance value of resistance temp. sensor Resistance temp. sensor terminals Resistance value Remarks Between A B 1 About 110Ω * In case of normal sensor temperature Between A B 2 About 110Ω * In case of normal sensor temperature Between B 1 B 2 - To be conductive (by connecting cable) * The above resistance value of the thermometer bulb changes as temperature changes. For detail, refer to JIS C 1604 reference material. A B1 B2 Pt100Ω Reference (JIS C 1604 Resistance temp. sensor: Pt100Ω Reference resistance value) Temperature (ºC) Resistance value (Ω) * The above Pt100Ω reference resistance values represent those of device itself not including the resistance value of the accessory cable

32 9. Troubleshooting When the converter fails to work properly, search the cause of the trouble along the following items. (1) Check the converter LED according to Item 8. 2, 1) 1 Check of operation status by LED ON/OFF position and confirm the current status of the operation in respect of indication, 4~20mA DC output and totalization pulse output. 1 Heating current value abnormal Wire breakage of temperature difference input, wire breakage of heating current line, erroneous wiring, incomplete contact and abnormality of heating current lower limit due to different specification gas are considered as possible causes of the trouble. (In case of H 2 and He specification, when other gas (Ar in particular) is filled, heating current lower limit abnormality sometimes occurs.) Countermeasures: Confirmation of specification gas component and actual gas component (Ref. Approval drawing), Confirmation of wire connection (Ref Schematic of wire connection), Confirmation of detector resistance value (Ref Detector resistance check) 2 Abnormality of temperature input for temperature correction Wire breakage of temperature sensor input, erroneous wiring, incomplete contact and range over of specification temperature correction are considered as possible cause of the trouble. Countermeasures: Confirmation of specification temperature correction range and actual temperature (Ref. Approval drawing), Confirmation of wire connection (Ref Schematic of wire connection), Confirmation of temperature sensor (Ref Temperature sensor (resistance temp. sensor) resistance check) 3 Flow rate range over (Exceeding 120%) The temperature difference input wiring connection may be in reverse polarity or gas flows at a rate over 120% of the specification flow rate. The indication gives a larger value because of the difference of component between the specification gas and the actual gas. The flow velocity is increased and indication gives larger value because the pipe gauge of the actual piping is different from the specification inside diameter. Countermeasures: Confirmation of the specification flow rate, gas component, inside diameter of piping and actual conditions. (Ref. Approval drawing), Confirmation of wire connection (Ref Schematic of wire connection) 4 Abnormality of heating current value and temperature input Abnormality of heating current value, temperature input for temperature correction or a compound abnormality of these items is considered. Countermeasures: Take measures according to the contents of troubleshooting concerning heating current value abnormality and temperature input for temperature correction abnormality. 5 Temperature input abnormality and flow rate range over A compound abnormality of temperature input for temperature correction and flow rate range over (120% above) is considered

33 Countermeasures: Take measures according to the contents of troubleshooting concerning temperature input for temperature correction abnormality and flow rate range over (120% above). 6 External ROM error External ROM is designated (SW 5: ON) without mounting external ROM, ROM range without data input is selected, or data cannot be read due to damage of external ROM is considered as possible cause of the trouble. Countermeasures: Confirmation of flow rate range (Ref. Approval drawing and 11. Flow rate range changing function ), Confirmation of external ROM mounted or not mounted (Ref * Detailed drawing of converter interior) 7 Others and compound abnormality Of other abnormalities, there are internal calculation overflow, data range over and pulse Co over. As compound errors, all combinations of (1) ~ (6) above are considered. Countermeasures: Confirm the status of indication, 4~20mADC output and totalization pulse output and then confirm the countermeasures against above (1) ~ (6) in order. (2) Regarding abnormality that neither LED nor indication is not lit. 1 Neither LED nor indication is lit even when power is supplied. The specification power supply voltage and the actual power supply voltage are different, or blown-up of power supply fuse is considered as possible cause of the trouble. Countermeasures: Confirmation of specification power supply voltage and actual power supply voltage (Ref. Approval drawing), Confirmation of power supply fuse (Ref * Detailed drawing of converter interior) 2 Flow rate measurement error is large. Measurement errors due to specification differences of gas component, temperature, pressure, pipe inside diameter; measurement errors due to wrong direction in detector mounting, dust and mist contamination on detector sensor part; influence of flow velocity distribution due to insufficient pipe length of straight portion; measurement error due to installation condition where pulsation is generated; or erroneous connection of detection items and converter items when multiple sets of flowmeter are delivered: These are considered as possible causes of the trouble. Countermeasures: To confirm contents of each cause of trouble listed above one by one (Ref. Approval drawing) 3 Indications fluctuate widely. Dust and mist contamination on the detector sensor part, influence by disturbance of flow speed distribution due to insufficient pipe length of straight portion; influence of pulsation in flow; incomplete contact of temperature difference wire line and heating current wire line; poor insulation of the detector; incomplete contact of temperature sensor: These are considered as possible causes of the trouble. Countermeasures: Confirmation of pipe installation, terminal connection, cables, detector resistance value (Ref Detector resistance check), Confirmation of temperature sensor (Ref. Temperature sensor (resistance temp. sensor) resistance check)