YOKOGAWA CM6G User Manual

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User ’s Manual

Model CM6G Gas Calorimeter

IM 11R02A01-02E

6th Edition

u Introduction

Thank you for purchasing Model CM6G Gas Calorimeter.

In order to have the product deliver its full capabilities, read this instruction manual thoroughly before you use it.

On how to use the Gas density meter, read the instruction manual which comes with the product.

WARNING

Since the ignition starts until it completes, or right after the ame is extinguished, sample gas mixed with the air will be released from the top of the equipment into the installation space. Even though the sample gas will be diluted su󰀩ciently by the air, great attention should be paid to the

following points if the sample gas contains harmful gases such as CO.

• Conrm that the air is supplied before introducing the sample gas.

• 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.

n About This Manual

• This manual should be passed on to the end user so that the user can refer to the manual whenever they need.

• If the product is not used in a manner specied in this manual, the safety of this product may

be impaired.

• 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 permission.

• 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 e󰀨ort 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 o󰀩ce.

n Drawing Conventions

Some drawings may be partially emphasized, simplied, or omitted, for the convenience of

description.

n Inspection on delivery

After the delivery, open the product package carefully and inspect for damages caused during the transport. Should there be any damage or breakage on the product, please contact YOKOGAWA

immediately. Retain all the packing materials, containers and boxes that came with the product. After unpacking, make sure the delivered products include all of the component equipment you ordered. When conrming the specications, refer to the model and su󰀩x codes indicated on the

nameplate on the product. The models are indicated on the name plates. Check also those of accessories. For further information, please read subsection 1.2 of this document.

IM 11R02A01-02E 6th Edition :May 10, 2019-00

u Safety Precautions

n Safety,Protection,ModicationoftheProduct

• In order to protect the system controlled by the product and the product itself and ensure safe operation, observe the safety precautions described in this user’s manual. We assume no liability for safety if users fail to observe these instructions when operating the product.

• If this instrument is used in a manner not specied in this user’s manual, the protection

provided by this instrument may be impaired.

• If any protection or safety circuit is required for the system controlled by the product or for

the product itself, prepare it separately.

• Be sure to use the spare parts approved by Yokogawa Electric Corporation (hereafter simply referred to as YOKOGAWA) when replacing parts or consumables.

• Modication of the product is strictly prohibited.

• The following safety symbols are used on the product as well as in this manual.

WARNING

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 and health including risk of injury, electric shock, or fatalities. or the damages to instruments. The manual describes what special care the operator must take to avoid such risks.

CAUTION

This symbol indicates that the operator must refer to the instructions in this manual in order to prevent the operator or instrument from being injured, or damaged.

The following are signal words to be found only in our instruction manuals.

CAUTION

This symbol gives essential information to avoid damages of soft or hardware, or system failure.

NOTE

This symbol indicates information that complements the present topic.

n Warning and Disclaimer

• The product is provided on an “as is” basis. YOKOGAWA shall have neither liability nor responsibility to any person or entity with respect to any direct or indirect loss or damage arising from using the product or any defect of the product that YOKOGAWA can not predict in advance.

n Trademark policy

All company or product and product names mentioned in this document are trade names, trademarks or registered trademarks of their representative companies. In this document, trademarks or trade names are not indicated with TM or ® as trademark symbols.

IM 11R02A01-02E 6th Edition :May 10, 2019-00

u After-sales Warranty

n Do not modify the product.

n Yokogawa warrants the product for the period stated in the pre-purchase quotation Yokogawa

shall conduct dened 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.

n During the warranty period, for repair under warranty, carry or send the product to the local

sales representative or service o󰀩ce. 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.

• If we replace the product with a new one, we won’t provide you with a repair report.

n In the following cases, customer will be charged repair fee regardless of warranty period.

• Failure of components which are out of scope of warranty stated in instruction manual.

• Failure caused by usage of software, hardware or auxiliary equipment, which Yokogawa

Electric did not supply.

• Failure due to improper or insu󰀩cient maintenance by user.

• Failure due to modication, misuse or outside-of-specications operation which Yokogawa

does not authorize.

• Failure or damage caused by relocation of the instrument.

• Failure due to power supply (voltage, frequency) being outside specications or abnormal.

• Failure caused by any usage at location or its maintenance that Yokogawa does not authorize.

• Any damage from re, earthquake, storms and oods, lightning, disturbances, riots, warfare,

radiation and other natural changes.

n Yokogawa does not warrant conformance with the specic application at the user site.

Yokogawa will not bear direct / indirect responsibility for damage due to a specic application.

iii

n Yokogawa Electric will not bear direct / indirect responsibility for any damage an end user might

incur, when the user congures the product into systems or resells the product.

n Maintenance service and supplying repair parts will be covered for ve years after the

production ends. For repair for the product, please contact the nearest sales o󰀩ce described in

this instruction manual.

IM 11R02A01-02E 6th Edition :May 10, 2019-00

Blank Page

Model CM6G Gas Calorimeter

IM 11R02A01-02E 6th Edition

CONTENTS

u Introduction ....................................................................................................i

u Safety Precautions .......................................................................................ii

1. Outline ....................................................................................................... 1-1

1.1 StandardSpecications ................................................................................... 1-1

1.2 ModelandSu󰀩xCodes ...................................................................................1-3

1.3 ..............................................................Standard Systems for Each Application

1-4

1.4 ExternalDimensions ........................................................................................ 1-6

1.5 ....................................................................................Principle of Measurements

1-10

Toc-1

2. Installation, Piping, Wiring ...................................................................... 2-1

2.1 Installations .......................................................................................................2-1

2.2 Externalpiping .................................................................................................. 2-1

2.3 ExternalWirings ................................................................................................ 2-4

3. Construction and Function ..................................................................... 3-1

3.1 Air Pressure Regulating System ..................................................................... 3-1

3.2 Gas Pressure Control Section ......................................................................... 3-1

3.3 Di󰀨erentialPressureDetectionPart ............................................................... 3-4

3.4 Calorie Detector ................................................................................................ 3-5

3.4.1 Burner Unit ......................................................................................... 3-8

3.4.2 High/Low Alarm Action ....................................................................... 3-9

3.4.3 Ignition ............................................................................................... 3-9

3.5 Computing Station .......................................................................................... 3-10

3.5.1 Display ............................................................................................. 3-10

3.5.2 Contents of the Data Display ........................................................... 3-13

3.5.3 Correcting Computation ................................................................... 3-14

3.6 Density Meter ................................................................................................... 3-16

4. Preparation of Operation ......................................................................... 4-1

4.1 Sampling Section (Outside panel) .................................................................. 4-1

4.2 Status of Valves ................................................................................................. 4-1

4.3 Water Supply (For Steel Mill Use) .................................................................... 4-1

4.4 Supply of the Air ................................................................................................ 4-2

4.5 Supply of Power ................................................................................................ 4-2

4.6 TheZeroAdjustmentoftheDi󰀨erentialPressureTransmitter .................... 4-2

4.7 AirDi󰀨erentialPressureAdjustment .............................................................. 4-3

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4.8 Pressure Adjustment of the Gas Line .............................................................4-3

5. Operation ................................................................................................... 5-1

5.1 Start Operation .................................................................................................. 5-1

5.2 Stopping Operations ........................................................................................ 5-2

6. Calibration ................................................................................................. 6-1

6.1 Supply of the Calibration Gas .......................................................................... 6-1

6.1.1 For Town Gas Use .............................................................................6-1

6.1.2 For Steel Mill Use ............................................................................... 6-2

6.2 Span Adjustment of the Calorie Detector.......................................................6-2

6.3 Calibration of the Computing Station ............................................................. 6-4

6.4 Calibration of the Density Meter ...................................................................... 6-4

7. Maintenance .............................................................................................. 7-1

7.1 Daily Check ........................................................................................................ 7-1

7.1.1 Air, Gas Di󰀨erential Pressure Adjustment ......................................... 7-1

7.1.2 Take Out the Water Out of the Drain Pot (Pump for Steel Mill Use) .. 7-1

7.1.3 Take Out the Drain from the Air Set ................................................... 7-1

7.2 Regular Check ................................................................................................... 7-2

7.2.1 Cleaning of the Orice Plate and Replacement of O-ring .................7-2

7.2.2 Fulo Filter (For Steel Mill Use)..........................................................7-3

7.2.3 Line Filter (For Town Gas Use) .......................................................... 7-3

7.2.4 Washing Bubbler or Pressure Regulating Pot ................................... 7-4

7.2.5 Dehumidier (For Steel Mill Use) ....................................................... 7-4

7.2.6 Density Meter ..................................................................................... 7-4

7.3 Check at the Regular Service .......................................................................... 7-5

7.3.1 Check the Burner Flame .................................................................... 7-5

7.3.2 Zero Adjustment of the Di󰀨erential Pressure Transmitter .................. 7-6

7.3.3 Others ................................................................................................ 7-6

8. Troubleshooting ....................................................................................... 8-1

8.1 Gas Sampling Pressure Regulating Section ................................................. 8-1

8.2 Air Pressure Adjustment Section ....................................................................8-2

8.3 Di󰀨erentialPressureTransmitterSection ...................................................... 8-2

8.4 Signal Section ................................................................................................... 8-3

8.5 Computing Station ............................................................................................ 8-5

8.6 Other Troubleshooting ..................................................................................... 8-5

Revision Information ...............................................................................................i

IM 11R02A01-02E 6th Edition :May 10, 2019-00

<1. Outline>

1. Outline

Model CM6G Gas calorimeter measures and controls a caloric value of gases, Wobbe-Index (hereinafter referred to as WI), a theoretical air requirement, and a heat input for various kind of

gas burning furnaces.

It detects a temperature rise of a sample gas, whose pressure is normally controlled, by burning it at a burner through the medium of air.

It picks up the ow rate of the sample gas and the air as the di󰀨erential pressure signal and outputs a signal of WI after compensating calculation of the indication di󰀨erence caused by the ow rate variation.

It also detects density of the sample gas by a density meter, and add to WI signal density

compensation, then, outputs a caloric signal.

1.1 StandardSpecications

EMC : EMC Regulatory Arrangement in Australia and New Zealand Korea Electromagnetic Conformity Standard Class A

A급 기기　(업무용 방송통신기자재) 　이 기기는 업무용(A급) 전자파적합기기로서 판매자 또는 사용자는 이 점을 주의하시기 바라며, 가정외의 지역에서 사용하는 것을 목적으로 합니다.

한국 전자파적합성 기준

1-1

n Town Gas Application

Measurement Object : Measurement and control of WI or the caloric value of fuel gas

Measuring Range : 3 to 62 MJ/Nm

Sample Conditions :

Dust ; 5 mg/Nm Temperature ; 50°C or less Humidity ; dew point of 0°C or less Pressure ; (1) 10 to 20 kPa

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 Ω or less

Alarm Contact Output :

Flame o󰀨 alarm; 100 V AC, 5 A, closed when alarm occurs (resistance

Orice Temperature alarm; 100 V AC, 3 A, closed when alarm occurs

Contact Input : Remote ignition (Custom order); 24 V DC, 0.1A or more

for town gas.

or less

(2) 10 kPa or under: with pump (3) 100 to 600 kPa: with pressure reducing valve

load) when contact is opened, the leakage current is 2 mA or less (100 V AC)

(resistance load)

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Repeatability

Measurement Measuring range (Note 1) Repeatability

Caloric value

MJ/Nm

Note 1: High caloric value means 6.3 MJ/Nm3 or more. Low caloric value means below 6.3 MJ/Nm3.

High caloric value

Low caloric value

High caloric value

Low caloric value

± 0.5% of measured value ± 1.0% of measured value

± 1.0% of measured value ± 1.5% of measured value

Sample Gas Flow Rate : Approx. 10 l/min

Response Time (Note 2):

Max.WImeasured Dead time Response time (63.2%)

50 or more 32 or more, less than 50 13 or more, less than 32 Less than 13

Note 2: Response time varies depending on the WI of a sample gas. This is due to the di󰀨erent sample gas ow rate of the calorimeter. The ow rate is preset depending on the WI of the sample gas to prevent the caloric value at the detector burner from exceeding the upper limit.

Approx. 30 sec or less Approx. 27 sec or less Approx. 23 sec or less Approx. 21 sec or less

Approx. 60 sec or less Approx. 53 sec or less Approx. 47 sec or less Approx. 41 sec or less

Utility :

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), 860 VA max.

Note 3: When you perform a low caloric value measurement, the frequency variation should be within ±0.4%. If the frequency variation

exceeds ±0.4% (especially for exporting overseas), consult with Yokogawa.

1-2

n Steel Mill Application

Measurement Object : Measurement and control of WI or the caloric value of fuel gas for a

Measuring range : 3 to 62 MJ/Nm

Sample Conditions:

Dust; 100 mg/Nm Temperature; 50°C or 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 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 750Ω or less

Alarm Contact Output :

Flame o󰀨 alarm;

Temperature alarm; 100 V AC, 3 A, closed when alarm occurs (resistance load)

Contact Input: Remote ignition (Custom order); 24 V DC, 0.1A or more

Repeatability :

Measurement Measuring range (Note 1) Repeatability

Caloric value

MJ/Nm

steel mill.

High caloric value

Low caloric value

High caloric value

Low caloric value

or less

100 V AC, 5 A, closed when alarm occurs (resistance load) when contact is opened, the leakage current is 2 mA or less (100V AC)

0.5% of measured value

1.0% of measured value

1.5% of measured value

Note 1: High caloric value means 6.3 MJ/Nm3 or more. Low caloric value means below 6.3 MJ/Nm3.

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Sample Gas Flow Rate :Approx. 10 l/min.

Response Time (Note 2):

Max.WImeasured Dead time Response time (63.2%)

50 or more 32 or more, less than 50 13 or more, less than 32 Less than 13

42 sec or less 39 sec or less 36 sec or less 30 sec or less

70 sec or less 60 sec or less 50 sec or less 45 sec or less

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 V AC ± 10%, single phase, 50/60 Hz (Note 3), 1100 VA max.

Note 3: In case of low caloric 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:

0 to 40°C (little temperature variation,particularly no

rapid change )

1-3

1.2 ModelandSu󰀩xCodes

n CM6G Gas Calorimeter

Model Su󰀩xCode Option Code Description

CM6G

Gas

Pressure

Measurement 00

Power supply -5

Range R - - - - - - - - - - Measuring range

Style *C - - - - - - - - - - Style C

Note: Measuring range and unit must be specied.

- - - - - - - - - - - - - - - - -

-S6 - - - - - - - - - - Always - S6

1 2 3 4 5 6 7 8

-6

- - - - - - - - - - Gas calorimeter

- - - - - - - - - -

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 under for steel mill, with preheating

WI measurement

Caloric value measurement (GD400G should be purchased

separately)

100 V AC 50 Hz 100 V AC 60 Hz

l Standard Accessories

Followings are the standard accessories supplied.

• Calorie Detector

Name Q’ty Remarks

Mirror Fuse

For burner ame inspection

1 2

3.15 A (A1113EF)

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• Orice Assembly

Name Q’ty Remarks

O-Ring O-Ring

Hexagon Wrench Hexagon Wrench

P16 (Viton) (Y9114XB)

P20 (Silicon) (L9817MT)

Nominal size 1.5 mm

Nominal size 2.5 mm

n Gas Density Meter

Gas Density Meter compensates a density value in caloric value measurement. It is not required for WI measurement.

Converter: GD400G-N-10-N-/PA

Detector: GD300S-J-/KU

Measuring range and unit (specic gravity or density) should be specied. See GS 11T3E1-01E

for further information.

n Option

You must purchase options separately.

Name Part no. Description

Probe H7800HA Insertion length 650 mm

Probe H7800HB Insertion length 1150 mm

Probe H7800HC Insertion length 1650 mm

Fulo lter G7043XJ Element material: Polypropylene

Pressure reducing valve G7008XF Primary pressure: 15 MPa max.

Pore size: 50 μm

Body: SUS 316 Connection: Rc 1/2

Secondary pressure: 0 to 200 kPa

Material: Brass

1-4

1.3 Standard Systems for Each Application

Application Measurement Systemspecication Su󰀩xcode*

Town Gas

Caloric value

MJ/Nm

Steel Mill

Caloric value

MJ/Nm

* The code is basic for gas pressure and measurement.

Note: A wet sample gas in the town gas application is outside the scope of the standard specications. Consult

with Yokogawa.

Without density meter

With density meter

Without density meter

With density meter

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

Gas pressure 10 to 20 kPa: Quake-proof 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

Gas pressure 8 to 15 kPa: Without preheating Gas pressure 8 to 15 kPa: With preheating Gas pressure 8 kPa or under: Without preheating Gas pressure 8 kPa or under: With preheating

-S6200

-S6300

-S6400

-S6110

-S6210

-S6310

-S6410

-S6500

-S6600

-S6700

-S6800

-S6510

-S6610

-S6710

-S6810

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n Instructions for System Selection

● The quake-proof type gas calorimeter is always equipped with the density meter.

● The CM6G Gas Calorimeter controls the ow rate under a constant di󰀨erential pressure. In

the caloric value measurement, if the density of a sample gas changes, a ow rate error proportional to the reciprocal of the square root of the density of the sample gas, will be generated, which directly a󰀨ects the caloric 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

1-5

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1.4 ExternalDimensions

n For Town Gas Applications

CM6G-S6200, S6210, S6300, S6310, S6400, S6410

1-6

Unit: mm

Mark Name Connection

A SAMPLE GAS IN Rc1/4

SAMPLE GAS OUT

B C INST.AIR IN 　Rc1/4 D STD.GAS IN 　Rc1/4 E STD.GAS IN 　Rc1/4

B D E

250

View X

130

900

700 550 400

300

OR VENT Rc1/2

740 800

Density meter converter

Computing station

Approx.70

1800100

Approx.1970

100

4-Ø14 holes

* CM6G-S610 (with density meter) only

Density meter detector

700 900

Calorie detector

Flowmeter for density meter

100

Maintenance Space

100

800800 500

900

Back

Front

500

Weight: Approx. 300kg

Dim-6210.ai

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n For Town Gas Application (Quake-proof Type)

CM6G-S6110

1-7

30 640 30

700

Ø120 hole

Density meter converter

1500100

Approx. 1670

400

Computing station

FAIL

---CM6G---

ALM

TREND 3

90.00

18.00

Y2Y1X3X1500.0

35.00

1000.0

37.67

100.00

23.02

▼▼▼

△

▽

0.00

14.65

0.0

23.02

▼ C

SHIFT

<<<

YOKOGAWA◇

1000

4-Ø15 holes

100600

Calorie detector

Flowmeter for density meter

100800100

300700

View X

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.

Unit: mm

1000 850

Maintenance Space

1000 100500

Back

Front

500

700

800

Weight: Approx. 350kg

Dim-6110.ai

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n For Steel Mill Application

CM6G-S6500, S6510, S6600, S6610, S6700, S6710, S6800, S6810

1-8

Flowmeter for density meter

Calorie detector

Approx.1970

100

Unit: mm

Mark Name Connection A SAMPLE GAS IN Rc1/2 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

500

600

700

800

1900

1650 1500

150

750

View X

100

300 200 100 0

Fulflo filter

Dehumidifier

740 30(30)

800

350

Washing bubbler

Drain pot

Pressure regulating pot

Density meter converter

Approx. 70

H B

C A

Pump

Computing station

4-Φ14 holes

80 60

Approx.1160

(100)

* CM6G-S610 (with density meter and flowmeter)

** CM6G-S670, CM6G-S680 (with pump)

Density meter detector

700

900

100

500

800

Maintenance Space

540

900260

Back

Front

500

Weight: Approx. 350kg

Dim-6810.ai

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n Dimensions of Options

l Probe

Unit: mm

Part number L H7800HA Approx. 650 H7800HB Approx. 1150 H7800HC Approx. 1650

)( 350Insertion length L

Φ34

1-9

JIS 10K-80-FF Equiv. SUS304

l FuloFilter(Partno.:G7043XJ)

108

Rc1/2Rc1/2

Approx. 350

Unit: mm

l PressureReducingValve(Partno.:G7008XF)

Secondary pressure gauge

0.3MPaG

Rc1

Primary pressure gauge 25MPaG

H7800HA.ai

Unit: mm

Approx. 119

Approx. 38

Handle for pressure control

Approx. 62

Approx. 120

Outlet

Handle for stop valve

Stop valve

Rc1/4

Outlet

開

閉

Safety valve

Approx. 166

Daiflon packing

W22 Left-hand thread

Inlet

Nut

Approx. 81

F2-8.ai

IM 11R02A01-02E 6th Edition :May 10, 2019-00

<1. Outline>

1.5 Principle of Measurements

The instrument detects the temperature di󰀨erence, 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 the instrument amplies the value of temperature di󰀨erence. It adds the compensating calculation to the output signal and measures the caloric value of WI.

1-10

DIFFERENTIAL

PRESSURE

DETECTION

GAS

AIR

Figure 1.1 Measurement principle diagram

BURNING

PRIMARY

MIXING

SECONDARY

TERTIARY

AIR DIVIDING

BLOW

COMPENSATING

CALCULATION

OUTPUT

SIGNAL

When the sample gas is completely burnt by the air, the formula of the increased temperature is as follows:

∆θ = (1.1)

K • Fg

Cps • Fs

where K: Caloric value of the sample gas

Fg: Flow rate of the sample gas

Fs: Air-diluted combustion exhaust gas ow rate

Cps: Constant pressure heat ratio of air-diluted combustion exhaust gas

Air ow rate Fa is big enough compared with the sample gas ow rate Fg (Fa:Fg=50-200:1)

and Cps Cpa, Fs Fa+Fg=Fa ( 1 + g ), therefore, the formula (1.1) is as follows:

∆θ = (1.2)

K • Fg

Cpa • Fa (1 + g)

where Fa: Air ow rate

Cpa: Air constant pressure heat ratio

g: Fg/Fa

When using orice and take out Fa, Fg as a di󰀨erential pressure of before and after orice, Fa

and Fg are represented by the following formula:

Fa = Ka (1.3)

∆ Pa

Fg = Kg

∆ Pg

where: ∆Pa, ∆Pg: Air, gas di󰀨erential pressure between before and after orice

a, ρg: Density of the air and the gas

ka, kg: Orice constant gure of the air and the gas (Orice coe󰀩cient  orice sectional area)

IM 11R02A01-02E 6th Edition :May 10, 2019-00

<1. Outline>

If insert formula (1.3) into formula (1.2), ∆θ is represented by the following formula:

1-11

∆θ = C.K. (1.4)

•

(C =

∆ Pg

∆ Pa

Cpa (1+g)

• • )

According to formula (1.4), if ∆Pa, ∆Pg are constant, temperature di󰀨erence ∆θ is in proportion

to WI (

) or caloric value (K). Thus we can measure continuously WI after ∆θ

measurement, and the caloric value after the measurement and calculation of the density.

IM 11R02A01-02E 6th Edition :May 10, 2019-00

Blank Page

<2. Installation, Piping, Wiring>

2. Installation, Piping, Wiring

2.1 Installations

Observe the following conditions when you install instruments.

(1) Adequate space for maintenance should be provided around the gas calorimeter.

* See “External Dimention” on 1.4.

(2) The base should be horizontal..

(3) 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.

(4) Install the instrument in the place where it is not directly exposed to the current of a

conditioned air.

(5) Minimal vibration( If much vibration is unavoidable, take an appropriate measure to absorb

shock, e.g, use of vibration-proof robber).

(6) A ventilation system should be provided.

(7) Corrosive gases and dust are present in small quantities and humidity is low.

(8) The water of the sampling system and the drain line do not freeze up.

2-1

WARNING

From the moment the ignition starts until it completes, or right after the ame 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.

2.2 Externalpiping

Refer to the drawing Figure 1.4. on the connections on the panel

The principal points to be taken care are as follows:

• Bent the outlet of the bent piping as U shape, and prevent it from the rain penetration. Set the outlet at higher position as much as possible where there is little fear of physical danger.

• Drain piping shall be conducted below the level of drain outlet on the panel and conrm no

drain is accumulated on the panel bed.

• It is necessary for the sample line of the instrument for steel mill use to provide a slope of more than 1/3, so that there is 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 line with thermal insulation

so as to prevent the drain in the pipe line from freezing.

• Locate the standard gas cylinders at the place where they are comparatively cool and not

exposed to direct sunshine.

IM 11R02A01-02E 5th Edition : Dec. 28, 2016-00

<2. Installation, Piping, Wiring>

Probe Sampling Point

Steam for thermal insulation

Water In

Vent to the

atmosphere

Drain

Safely vent to the atmosphere

Filter

Tetoron Braid Hose

Pipe Φ6/Φ4 Cu

Zero Gas

Span Gas

Valves for maintenance should be installed.

Pipe SUS 15A

Sample Gas Inlet

Std. Gas

Inlet

Pressure Reducing Valve

Wash water inlet

Pipe SUS 15A

Pressure:0.1-0.2MPa

Sample Gas Out

CM6G

Gas

Calorimeter

Pipe SUS 15A or greater

Sample Gas Vent

Sample Gas Out

Pipe SUS 15A

Drain Outlet

Pipe SUS 15A

Steam for blowing back

Pipe SUS 15A

Pressure Reducing Valve

∆H

∆H: Water sealing greater than pressure at sampling point is required.

Seal pot

Note: denotes that piping should be installed at an angle that allows drain to flow downstream and smoothly. F4-1.ai

House Requirements

Temperature: 0 to 40˚C

Not rapid temperature change allowed. Adequate ventilation and lighting provided.

Power Supply

100 V AC±10% 50/60Hz

Max. approx.1100 VA

Output Signal

Alarm Contact

Output Signal

Instrument Air Pressure: 0.3-0.7MPa

Flow rate: Approx. 50Nl/min

Figure 2.1 Recommended Sampling for Steel Mill Use

2-2

Drain

• Sampling point shall be made at the location above or side of the transfer pipe. When the

instrument is mounted on wall, x it with a slope that the top end of the probe is facing

downward.

• When xing the probe, use a ange JIS 10K 80A.

• At the sample gas outlet of the probe, it is recommended to provide a gate valve of 1/2 inch.

Probe

Gate valve (1/2 inch)

Flange

100 or more

Figure 2.2 Mounting of the Probe

Transfer pipe

F4-2.ai

IM 11R02A01-02E 5th Edition : Dec. 28, 2016-00

<2. Installation, Piping, Wiring>

• Fix lter vertically with their drain outlets facing downward. Mount it rmly to wall or to pillar with U bolt-like bolts. Provide 1/2 inch gate valves at the sample gas inlet and outlet. Take an ample space under lters so that checking and replacing of elements can be held easily. For drain exhaust pipes, use exible pipes.

Gate valve (1/2 inch)

2-3

Rc1/2

Out

Fulflo filter

Bush

Flexible tube

Drain

Rc1/4

Drain

Figure2.3ExampleFuloFilterswiththePiping

Union (1/2 inch)

U-bolt

F4-3.ai

IM 11R02A01-02E 5th Edition : Dec. 28, 2016-00

<2. Installation, Piping, Wiring>

2.3 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.

MAIN PANEL

DENSITY METER CONVERTER

COMPUTING STATION

SWITCH BOX

350

CALORIE DETECTOR

2-4

200

Figure 2.4　SwitchBoxandEarth

SWITCH

NFB

POWER TERMINAL

150

EARTH TERMINAL

SIGNAL TERMINAL

810

Figure 2.5　InsideaSwitchBox

FUSE

IM 11R02A01-02E 5th Edition : Dec. 28, 2016-00

<2. Installation, Piping, Wiring>

n Notes on Wiring

• Turn o󰀨 all power supplies while connecting cables and wires.

• An electrical wiring duct must not be used for the simultaneous connection of a large capacity converter, motor, or power supply.

• When cables are connected in a place with high or low ambient temperatures, use cables suitable for the place.

• The material of cables must be capable of withstanding harmful gases, lizids, oil , or solvents when cables are used in the atmosphere where these harmful substances are present.

• Use crimp terminals with insulated sleeve (M4 screws) for the wire ends.

n Wiring to Peripheral Equipment

l Power Supply

Use a 600 V insulated vinyl cabtyre cable (JIS C3312) with a cross-section area of 2 mm2 or

more, or a wire or cable that is the equivalent or better.

l 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 Ω or less (equivalent to JIS Class D).

2-5

l Analog Output (4 to 20 mA DC)

Use a shielded twisted pair cable with a cross-section area of 0.5 mm2 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 Ω or less.

l Contact Output

Use a 600 V insulated vinyl cabtyre cable (JIS C3312) with a cross-section area of 2 mm2 or

more, or a wire or cable that is the equivalent or better.

The ame extinction alarm contact and orice 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))

Contact Rating

Flame distinction alarm contact 100 V AC 5 A

Orice chamber temperature drop alarm contact 100 V AC 3 A

l Contact Input (Remote Ignition: Made to order)

Input a non-voltage contact as a contact input signal. The contact rating is 24 V DC 1 A. 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 Ω or less. Contact open: 100 kΩ or more.

IM 11R02A01-02E 5th Edition : Dec. 28, 2016-00

<2. Installation, Piping, Wiring>

2-6

IM 11R02A01-02E 5th Edition : Dec. 28, 2016-00

<3.Construction and Function>

F00.ai

3. Construction and Function

TypicalSystemConguration

Gas Calorimeter

Calorie Detector

Solenoid Valve

Computing Station

---CM6G---

TREND 3

18.00

Y2Y1X3X1500.0

35.00

1000.0

100.00

0.00

0.0

▼ C

<<<

YOKOGAWA◇

Differential Pressure Transmitter

Orifice Assembly

FAIL ALM

90.00

37.67

23.02

▼▼▼

△

▽

14.65

23.02

SHIFT

Output 4-20mA DC

1 to 5V DC

Density Meter

Gas Pressure Regulating Unit

Air Pressure Regulating Unit

Calorific Value WI (Wobbe Index)

Sample Gas

Instrument Air

3-1

Item Function / Description

Calorie detector

Detects WI or caloric value. Generates an alarm and takes protective

actions when the burner ame goes out or abnormal combustion occurs.

Computing station (digital) Calculates WI or caloric value. Displays selected parameters, e.g., each

di󰀨erential pressure and caloric value. Adjusts zero / span and others.

Density meter Measures density used for calculation of caloric value. Not required for

WI measurement.

Di󰀨erential pressure transmitter Detects di󰀨erential pressure of gas and air before and after orice, and

converts it to an electrical signal.

Orice assembly Gas and air orices housed in the constant temperature chamber.

Solenoid valve Serves as a safety valve to shut o󰀨 the sample gas ow.

Figure 3.1 Components and Functions of Model CM6G Gas Calorimeter

3.1 Air Pressure Regulating System

Refer to Figure 3.2, 3.3 and 3.4. 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). Then the pressure is set by needle valve (V-16) to a di󰀨erential pressure of 500 Pa.

The air is controlled at 40°C in the preheater, which helps the temperature control by the orice.

When the temperature rises above 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.

3.2 Gas Pressure Control Section

Refer to Figure 3.2, 3.3 and 3.4.The gas pressure regulating section has two di󰀨erent types; town

gas use and steel mill use.

IM 11R02A01-02E 5th Edition : Dec. 28, 2016-00

<3.Construction and Function>

l Town Gas Use

The sample gas, introduced through line lter (3-1), increases its pressure by pump, or

decreases by pressure reducing valves, according to the pressure at the sampling point. The

pressure gauge (3-2) indicates 8 to 18 kPa and the owmeter (3-3) approx. 10 l/min, respectively. The sample gas, then, is set its di󰀨erential 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, the sample gas is introduced to the density meter with the ow rate of 1 l/min, through the owmeter (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 ow rate approx. 10 l/min.

l Steel Mill Use

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 ows through the washing bubbler (3-2) and the fulo lter (3-3), and then secure a constant pressure in the pressure regulating pot (3-4) through the water sealed pipe from the dehumidier (3-5), then set the di󰀨erential pressure by the pressure reducing valve (3-6) to 500 Pa.

To increase the pressure by the pump, a drain pot (3-9) is added. When the density

compensation system is equipped, the sample gas is supplied to the density meter with its ow rate of 1 l/min, through the owmeter (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 owmeter (4-2) with the ow

rate about 10 l/min.

3-2

Standard Flow Sheet

1. Town Gas Application (Standard Type)

CM6G-S6200, S6210, S6300, S6310, S6400, S6410

No. Item 1-1 Calorie detector 1-2 Solenoid valve 1-3 Orifice assembly 1-4 Differential pressure transmitter (air) 1-5 Differential pressure transmitter (gas) 1-6 Computing station 2-1 Air set 2-2 Pressure reducing valve 2-3 Pressure gauge 2-4 Preheating chamber 2-5 One touch coupler

V-1

V-2

SAMPLE GAS IN

SAMPLE GAS OUT OR VENT

Maximum back pressure is 1.5 kPa and no pressure fluctuation is allowed.

No. Item 3-1 Line filter 3-2 Pressure gauge 3-3 Flowmeter 3-4 Pressure reducing valve 3-5 Pressure gauge 3-6 Pressure reducing valve 3-7 Diaphragm pump (when specified) 3-8 Pressure reducing valve (when specified) 4-1 Pressure reducing valve for standard gas

3-8

V-4

3-1

3-7

V-5

V-3

5-1

5-2

*1: CM6G-S610 (with density meter) *2: CM6G-S630 (with diaphragm pump) *3: CM6G-S640 (with pressure reducing valve)

V-11

V-6

V-13

5-3

V-7

3-2

3-3

3-4

3-6

3-5

V-12

GAS DP.T

1-1

1-2

No. Item

5-1 Density meter detector (when specified) 5-2 Density meter converter (when specified) 5-3 Flowmeter for density meter (when specified) 6-1 Zero gas (supplied by customer) 6-2 Span gas (supplied by customer) 7-1 Pressure reducing valve for cylinder (optional) 7-2 Pressure reducing valve for cylinder (optional)

V1...16 Ball valve, needle valve

1-6

1-3

AIR DP.T

1-5

1-4

V-16

4-1

2-4

2-3

V-15

2-1

V-14

2-2

2-5

V-9

V-8

V-10

FLOW-6410.ai

INST.AIR IN

0.3~0.7MPa

50Nl/min

STD GAS IN (ZERO)

7-1

7-2

6-2

STD GAS IN (SPAN)

6-1

Figure 3.2 Flow Sheet (for Town Gas)

IM 11R02A01-02E 5th Edition : Dec. 28, 2016-00

<3.Construction and Function>

2. Town Gas Application (Quake-proof Type)

CM6G-S6110

No. Item 3-1 Line filter 3-2 Pressure gauge 3-3 Flowmeter 3-4 Pressure reducing valve 3-5 Pressure gauge 3-6 Pressure reducing valve 4-1 Pressure reducing valve 5-1 Density meter detector 5-2 Density meter converter 5-3 Flowmeter for density meter

No. Item 6-1 Zero gas (supplied by customer) 6-2 Span gas (supplied by customer) 7-1 Pressure reducing valve for cylinder (optional) 7-2 Pressure reducing valve for cylinder (optional)

V1...16 Ball valve, needle valve

3-3

V-4

V-1

V-2

SAMPLE GAS IN

(10 to 20kPa)

SAMPLE GAS OUT

OR VENT Maximum back pressure is 1.5 kPa and no pressure fluctuation is allowed.

V-3

3-1

5-1

5-2

Figure 3.3 Flow Sheet (for Town Gas)

1-5

1-3

AIR DP.T

1-4

1-6

V-16

4-1

2-4

2-2

2-3

V-15

2-5

V-8

2-1

V-14

V-9

V-10

FLOW-6110.ai

INST.AIR IN

0.3 to 0.7MPa

50Nl/min

STD GAS IN (ZERO)

7-1

7-2

STD GAS IN (SPAN)

6-1

6-2

1-1

3-3

3-4

3-6

3-5

V-12

GAS DP.T

1-2

3-2

V-11

V-5

V-6

V-7

V-13

5-3

IM 11R02A01-02E 5th Edition : Dec. 28, 2016-00

<3.Construction and Function>

3. Steel Mill Application

CM6G-S6500, S6510, S6600, S6610, S6700, S6710, S6800, S6810

No. Item 3-1 Pressure gauge 3-2 Washing bubbler 3-3 Fulflo filter 3-4 Pressure regulating pot 3-5 Dehumidifier 3-6 Pressure reducing valve 3-7 Line filter 3-8 Diaphragm pump (when specified) 3-9 Drain pot (when specified) 4-1 Pressure reducing valve for cylinder 4-2 Flowmeter

No. Item 5-1 Density meter detector (when specified) 5-2 Density meter converter (when specified) 5-3 Flowmeter for density meter (when specified) 6-1 Water Flowmeter 7-1 Probe (optional) 7-2 Fulflo filter (optional) 9-1 Pressure reducing valve for cylinder (optional) 9-2 Pressure reducing valve for cylinder (optional) 10-1 Standard gas cylinder (supplied by customer) 10-2 Standard gas cylinder (supplied by customer) 11-1 Drain pot (supplied by customer)

V1...16 Ball valve, needle valve

3-4

WATER IN

DRAIN

9-1

9-2

7-1

10-2

SAMPLE GAS IN

11-1

STD.GAS IN

(SPAN)

STD.GAS IN

10-1

7-2

WATER IN

DRAIN OUT

(ZERO)

SAMPLE GAS OUT

2-5

4-1

V-9

V-10

V-1

3-9

V-8

3-1 V-3

3-2

V-13

V-4

V-6

V-5

6-2

3-8

V-2

V-7

*1: CM6G-S610 (with density meter) *2: CM6G-S670, CM6G-S680 (with diaphragm pump)

SAMPLE GAS VENT

SAMPLE GAS OUT

4-2

V-11

V-12

3-3

5-3

3-6

3-7

3-5

3-4

1-2

5-1

5-2

1-1

1-5

1-3

V-16

1-4

2-4

2-2

1-6

V-15

2-3

2-1

V-14

INST.AIR IN

FLOW-6810.ai

Figure 3.4 Flow Sheet (Steel Mill Use)

3.3 Di󰀨erentialPressureDetectionPart

In order to calculate the di󰀨erential pressure correction value, the ow rate is acquired from the orice as a di󰀨erential pressure and converted to an electrical signal using the di󰀨erential pressure transmitter. The orice is housed in a constant temperature chamber (orice assembly), the temperature of which is maintained at approximately 50°C by the temperature controller, to prevent the temperature drift of the actual ow rate.

When the temperature exceeds 90°C, the safety thermostat is activated to shut o󰀨 the heater power supply. When the temperature falls after the power supply is shut o󰀨, the alarm thermostat

is activated to provide an alarm (closed contact) output.

CAUTION

Power is supplied to the di󰀨erential 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.

IM 11R02A01-02E 5th Edition : Dec. 28, 2016-00

<3.Construction and Function>

MAIN PANEL

ORIFICE ASSEMBLY

DIFFERENTIAL PRESSURE

TEMPERATURE CONTROLLER

TRANSMITTER

Figure3.5Di󰀨erentialPressureDetectionEquipment

3-5

No. Name

Air inlet

Gas inlet

Air outlet

Gas outlet

Air differential pressure take-out

Gas differential pressure take-out

Orifice section

No. Name

9 10 11 12 13 14

Figure3.6OriceAssembly

3.4 Calorie Detector

The calorie detector consists of a burner unit, which detects the temperature di󰀨erence before and after the sample gas is burned, a detected signal amplication 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 0 - 20 mV to 1 - 5 V DC and input to the computing station. If burner ame extinction or excessive combustion occurs, an alarm (closed

contact) output is produced.

Gas orifice section Crotchet joint Fitting screw Heat conversion block Heater plate Safety thermostat (up) Alarm thermostat (down)

13·14

No.

Thermistor (check)

Thermistor (control)

Temperature check terminal

Neon lamp

Terminal

Name

F0506.ai

IM 11R02A01-02E 5th Edition : Dec. 28, 2016-00

<3.Construction and Function>

PRINTED CIRCUIT BOARD ASSEMBLY

BURNER UNIT

IGNITION TRANS. ASSEMBLY

Figure 3.7 Calorie Detector

3-6

POWER Lamp

IGNIT Lamp

Figure 3.8 Front Panel Assembly

SAFE EV Switch

LOW AL Volume

MEAS Lamp

ALARM Lamp

START Switch

POWER Switch

METER Switch

SPAN Volume

IM 11R02A01-02E 5th Edition : Dec. 28, 2016-00

<3.Construction and Function>

Table 3.1 Function and operation procedure for each switch of the calorie detector

Name Function and operation procedures

“POWER” switch • Power supply switch.

• When the switch turns to “ON”, the power is supplied to the calorie detector and at the

same time the lamps, “POWER” and “ALARM” are lit on.

“START” switch • One push on “START” switch introduces gas to the burner unit and operates the ignition.

• At the same time, the lamp “IGNIT” is on while the lamp “ALARM” is lit o󰀨.

• If ignition occurs within the preset time, the lamp “IGNIT” is lit o󰀨 but the lamp “MEAS”

turns on.

• If ignition does not occur within the preset time, the lamp “IGNIT” is lit o󰀨 and the lamp

“ALARM” turns on again.

“SAFE EV” switch • Normally leave the switch at “SET”.

• When you adjust the di󰀨erential pressure, turn it to “RELEASE”. Then the lamp “ALARM” is let o󰀨, alarm is released and solenoid valve of the gas line is opened.

• Switching over from “SET” to “RELEASE” during the operation does not a󰀨ect anything.

However, if you leave the switch at “RELEASE”, no alarm signal is given even when the

burner ame is o󰀨.

• When the switch shows “RELEASE”, “START” switch does not start the operation.

“METER” switch •The indication of the indicator and the X5 display(*1) of the computing station switches

between “P.MEAS“ and “LOW AL“

• The switching does not a󰀨ect the nal output and sequence action.

“SPAN” volume • With this span volume you can adjust the output of the calorie detector to 1 - 5 V DC.

• If you turn this to the right, the span point becomes bigger.

“LOW AL” volume • The level for the extinction alarm (lower alarm) is set by this volume.

• If you turn this to the right, the alarm level becomes higher.

“POWER” lamp • When the lamp is lit, power is being supplied to the calorie detector, di󰀨erential pressure

transmitter, and temperature controller.

“IGNIT” lamp • While the lamp is lit, the ignition proceeds.

“MEAS” lamp • While the lamp is lit, the system is under the measurement condition.

“ALARM” lamp • While the lamp is lit, alarm is being released.

(*1) The display range of X5 is 0 to 30.0 mV. “P.MEAS“ and “LOW AL“ indicate the following values.

3-7

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 5th Edition : Dec. 28, 2016-00

<3.Construction and Function>

3.4.1 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 di󰀨erence 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 (when lower calorie gas is being used.)

Heater wire

Burner

tip

Lead wire

3-8

Figure 3.9 Burner Tip Assembly

12 11 10

3 4

Figure 3.10 Burner Unit

F0509.ai

No. Name

1 Hot junction detect point 2 Cold junction detect point 3 Air divider 4 Secondary air throttle screw 5 Primary air throttle screw 6 Air inlet 7 Gas inlet 8 Connector 9 Burner tip assembly 10 Combustion pipe 11 Stream contact pipe 12 Measuring pipe 13 Reverse flow pipe 14 External pipe

IM 11R02A01-02E 5th Edition : Dec. 28, 2016-00

<3.Construction and Function>

Ignition action starts

3.4.2 High/Low Alarm Action

Higher and lower alarm limits are set for the amplied thermocouple output, respectively, to execute a sequence. The higher alarm limit is the point to alarm the excessive combustion of the burner, which is set to approximately 120% of the span. The lower alarm limit is the point to alarm the ame extinction

of the burner. You can change the limit by “LOW AL”volume on the front panel of the calorie

detector. However, the lower alarm limit is set to an appropriate value in the nal 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

3.4.3 Ignition

Press START on the front panel of the calorie detector to start ignition. One cycle of an

ignition constitutes (T1) and (T2). (T1) is when the ignition voltage is applied to the heater

(T1). (T2) is when the voltage is not applied (when using low caloric value, the time when the preheating voltage is applied). The cycle repeats ve times normally. (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 amplied thermocouple output exceeds the lower alarm limit, the burner is determined to

be ignited and the ignition action is stopped even if it is not completed. If the burner is not ignited

even after the ignition voltage is applied ve times, the ignition action is stopped after the ignition voltage is applied for the fth time. In that case, press START to start the ignition again.

If the burner ame is extinguished in the event of an alarm, after removing the cause of the failure, press START to start the ignition again. If the alarm occurs due to excessive combustion,

you cannot resume the ignition 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 3.11 shows the ignition sequence for which the lower alarm limit is set to 50%.

3-9

Thermocouple output

(Higher alarm limit)

(Lower alarm limit)

Ignition voltage

ALARM lamp

IGNIT lamp

MEAS lamp

Figure 3.11 Ignition Sequence

120%

50%

Hi Low Open Close

ON OFF ON OFF ON OFF

Ignition action starts

T1T2

Ignition action

Alarm status

Not ignition

Measurement status

Ignitied

Ignition action

Alarm status

Excessive combustion

Time

IM 11R02A01-02E 5th Edition : Dec. 28, 2016-00

<3.Construction and Function>

3.5 Computing Station

The computing station generates WI signal by calculating calorie detector signal with each

di󰀨erential pressure signal. It compensates the density with the density signal and generates the caloric signal.

Each input signal is digitally computed after A to D conversion then D to A conversion. It generates DC 4 to 20 mA (DC 1 to 5 V) output.

3.5.1 Display

n Display indication

FAIL lamp

TREND 3

Y1: Calorific value (green)

Y2: WI value (light blue)

X3: MAX range of gas differential pressure(pink)

X1: MAX range of NON CORR. WI value(yellow)

X1: MIN range of NON CORR. WI value(yellow)

X3: MIN range of gas differential pressure(pink)

Unused

---CM6G---

TREND 3 Y1 Y2

18.00

35.00

1000.0

100.00

0.00

0.0

SHIFT

YOKOGAWA

90.00

500.0

37.67

23.02

14.65

23.02

FAIL

ALM

F0516.ai

ALARM lamp

X1: NON-CORR.WI% (yellow)

X3: Gas differential pressure (Pa) (pink)

Y2: MAX range of WI (light blue)

Y1: MAX range of Calorific value (green)

Trend data (indicator 1 to 4)

Y1(green) : Calorific value Y2(light blue): WI X1(yellow) : NON-CORR. WI X3(pink) : differential gas pressure Pa

Y1: MIN range of Calorific value (green)

Y2: MIN range of WI (light blue)

The key for switching screens.

Press this key to go to ALARM screen. Push this again to return.

3-10

Figure 3.12 Measuring Display

---CM6G---

ALARM

SYSTEM

PROCESS

* * * *

* *

STC EVENT

YOKOGAWA

CALC

SHIFT

FAIL

ALM

CLR

Left is ALARM screen you see when input or output is error. Do as *1 of Fiigure 3.12 to go to ALARM.

EVT

CLR

Figure 3.13 Alarm Display

ALARM items, such as X1 to X4,Y1 and Y2, are displayed.

F0517.ai

IM 11R02A01-02E 5th Edition : Dec. 28, 2016-00

<3.Construction and Function>

n Switching to alarm display

3-11

---CM6G---

TREND 3

18.00

35.00

1000.0

100.00

X3X1500.0

FAIL

ALM

90.00

37.67

23.02

ALARM

PROCESS SYSTEM

Push key

0.00

0.0

SHIFT

YOKOGAWA

14.65

23.02

(1) Measuring display (2) Alarm display

Figure 3.14 Switching operation to alarm display

n ConrmationofInput/outputdata

---CM6G---

TREND 3 Y1 Y2

FAIL

1000.0

100.00

ALM

90.00

500.0

37.67

23.02

Push key

SHIFT

with key.

18.00

35.00

---CM6G---

TUNING MENU

PID 1

PID 2

STC 1

STC 2

P&T REG

14.65

0.00

23.02

0.0

I/O DATA

FAIL

ALM

---CM6G---

CALC

EVENTSTC

SHIFT

YOKOGAWA

Push key

FAIL

ALM

CLR

EVT

CLR

F0518.ai

---CM6G---

I/O DATA

X1 X2 X3 X4 X5 X6 X7 X8

Y1 Y2 Y3 Y4 Y5 Y6

DI01

DI02

DI03

DI04

DI05

DI06

DI07

DI08

DI09

DI10

FAIL

ALM

90.00

500.0

0.500

18.00

-25.0

18.00

35.00

-6.3

0.0

DO01

DO02

DO03

DO04

DO05

DO06

DO07

DO08

DO09

DO10

DO11

0 0

DO12 DO13

DO14

DO15

DO16

SHIFT

YOKOGAWA

SHIFT

YOKOGAWA

(1) Measuring display

Figure 3.15 Switching operation to Input/output status display

SHIFT

YOKOGAWA

F0519.ai

(3) Input/Output status display(2) Tuning display

This screen is for confirming Input/Output status and for setting X1,X2 and X3. Displayed characters become bigger by pushing key.

IM 11R02A01-02E 5th Edition : Dec. 28, 2016-00

<3.Construction and Function>

n Parameter setting

3-12

---CM6G---

TUNING MENU

PID 1

PID 2

STC 1

STC 2

P&T REG

I/O DATA

YOKOGAWA

FAIL

ALM

Push key

SHIFT

---CM6G--- ---CM6G---

P&T REG 1/3

P01 P02 P03 P04 P05 P06 P07 P08 P09 P10 P11 P12 P13 P14 P15 P16 P17 P18 P19 P21 P22 P23 P24 P25 P26 P27 P28 P29 P30

YOKOGAWA

FAIL

ALM

60.00

2.500

0.00

100.0

7.00

100.0

7.00

5.00

0.0

SHIFT

Push key

(Press key to enlarge characters of parameter to set.)

P&T REG 1/3

P01 P02 P03 P04 P05 P06 P07 P08 P09 P10 P11 P12 P13 P14 P15 P16 P17 P18 P19 P21 P22 P23 P24 P25 P26 P27 P28 P29 P30

FAIL

ALM

60.00

2.500

0.00

100.0

7.00

100.0

7.00

5.00

0.0

SHIFT

YOKOGAWA

(1) Tuning display (2) Parameter setting display (3) Parameter setting display

Push key.

---CM6G---

TREND 3

18.00

Y2Y1X3X1500.0

35.00

YOKOGAWA

FAIL

ALM

90.00

1000.0

37.67

100.00

23.02

0.00

14.65

0.0

23.02

SHIFT

(5) Measuring display

Push key

SHIFT

with key twice.

The screen is for setting various parameters such as ZERO and SPAN.

In setting other parameters

Parameter setting is finished. Return to the measuring display.

(4) Input/Output status display

This screen is for confirming Input/Output status.

Select a parameter to confirm. Press key to enlarge the character to display.

---CM6G---

I/O DATA

X1 X2 X3 X4 X5 X6 X7 X8

Y1 Y2 Y3 Y4 Y5 Y6

DI01 DI02 DI03 DI04 DI05 DI06 DI07 DI08 DI09 DI10

By using and key, change the parameter value which becomes larger characters.

After returning to Tuning display (1) by pushing key, push key.

90.00

500.0

0.500

18.00

-25.0

18.00

35.00

-6.3

0.0

DO01

DO02

DO03

DO04

DO05

DO06

DO07

DO08

DO09

DO10

DO11

DO12

DO13

DO14

DO15

DO16

SHIFT

YOKOGAWA

FAIL

ALM

F0520.ai

Figure3.16FlowChartofVariousParameterSettingandConrmation

IM 11R02A01-02E 5th Edition : Dec. 28, 2016-00

<3.Construction and Function>

3.5.2 Contents of the Data Display

Contents of the data display are as follows:

Table 6.2 Contents of the data display

Kind Data abbreviated Data contents Data range

Input

Output Y

Variable data

X1 NON-CORR. WI [%] WI value before correction 0.0 to 100.0

X2 A-PRESS [Pa] Air di󰀨erential pressure 0.0 to 1000

X3 G-PRESS [Pa] Sample gas di󰀨erential pressure 0.0 to 1000

X4 SQT. DENSITY A square root of the sample gas

density

X5 TC or LOW ALARM *2[mV] Thermocouple electromotive force or

ame extinction alarm threshold value

X6~X8 Unused

cal [MJ/

Caloric value *1

]

Y2 WI Wobbe index *1

Y3 Option Option *1

Y4 BIAS CHECK Preheating check output 0.0 to 100.0 Y5, Y6

Unused

P01 ZERO Zero adjustment 0.0 to 100.0

P02 SPAN Span adjustment *1

P03 BIAS Preheating adjustment 0.0 to 100.0

P04 A-CORR. RATE [%] Air di󰀨erential pressure signal

computing correction rate

P05 A-TIME [sec] Time constant of air di󰀨erential

pressure signal delay time

P06 G-CORR. RATE [%] Sample gas di󰀨erential pressure

signal computing correction rate

P07 G-TIME [sec] Time constant of sample gas

di󰀨erential pressure signal delay time

P08 PRESS ALARM SET [%] Di󰀨erential pressure warning setting 0.0 to 100.0

P09 to P30 Unused

3-13

0 to 30.0

0.0 to 200.0

0.0 to 100.0

0.0 to 200.0

0.0 to 100.0

*1: Di󰀨ers depending on each specication. *2: Press “METER” to switch.

IM 11R02A01-02E 5th Edition : Dec. 28, 2016-00

<3.Construction and Function>

3.5.3 Correcting Computation

CM6G sets the di󰀨erential pressure of both sample gas (∆Pg) and air (∆Pa) to 500 Pa. In order to correct the indication error due to the variation of the di󰀨erential pressure (Flow rate), the

correcting computation is practiced.

The detection signal is obtained through the measurement with the standard di󰀨erential pressure of 500 Pa, but if each di󰀨erential pressure change to ∆Pg and ∆Pa (≠500 Pa), the detection

signal shall be changed from Eo to E’o.

3-14

E’o = Eo

Therefore, if you multiply the detection signal E’o by

∆ Pg

•

∆ Pa

, you can correct to the value

∆Pg∆Pa

(3.1)

at the standard di󰀨erential pressure.

In the computing program, each di󰀨erential pressure is root-extracted and provides a di󰀨erential

pressure correcting computation. The signal after the correction is range suppressed (ZERO)

and to further extended to SPAN. 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 caloric signal, the following density correction is

necessary:

K = C(WI)

•

(3.2)

Also it is necessary for each signal to operate with a timing matched with the signal of the caloric

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:

•

∆θ = C1

•

H : Pre-heat calorie

1, C2 : Constant

g : Density of the gas

∆ Pg

∆ Pa

+ C

•

∆ Pa

(3.3)

If the correction computation of the di󰀨erential pressure is provided to ∆θ in the formula (6.3), it is

shown as per the following formula:

∆θ (3.4)

= C1

∆ Pa

∆ Pg

•

• ρ

+ C

•

∆ Pg

The second clause of the right part in the formula (3.4) represent the preheat calorie, which, as you can see in the formula (3.4), the matters concerning the preheating is varied according to the

change of di󰀨erential pressure (∆Pg).

In this computing program, if there is preheating circuit, multiply the constant by the di󰀨erential pressure signal, and after correcting the di󰀨erential pressure to the preheating, the deduction of

the preheat calorie is computed.

IM 11R02A01-02E 5th Edition : Dec. 28, 2016-00

<3.Construction and Function>

3-15

(G-CORR. RATE)

(G-TIME)

Gas differential pressure signal

DYNAMIC CHAR.

FUNCTION

CORRECTION

Air differential

pressure signal

DYNAMIC CHAR.

FUNCTION

CORRECTION

(A-CORR. RATE) (A-TIME)

Extraction Extraction

Calorie detector signal

(ZERO)

(SPAN)

Correction of density

density

signal

Extraction

Remarks: ( ) is variable constant.

WI signal

Calorific signal

Figure3.17ComputingBlockDiagram(PreheatingCircuitDoesNotExist)

F0521.ai

Gas differential

pressure signal

(G-CORR.RATE)

(G-TIME)

DYNAMIC CHAR.

FUNCTION

CORRECTION

(BIAS)

Remarks: ( ) is variable constant.

Root Extraction

(SPAN)

(ZERO)

Air differential

pressure signal

DYNAMIC CHAR.

FUNCTION

CORRECTION

Root Extraction

(A-CORR.RATE) (A-TIME)

Calorie detector signal

Correction of density

Density

signal Root Extraction

Pre-heat temperature

check signal

Calorie signalWI signal

Figure3.18ComputingBlockDiagram(PreheatingCircuitExists)

F0522.ai

IM 11R02A01-02E 5th Edition : Dec. 28, 2016-00

<3.Construction and Function>

3.6 Density Meter

The GD400G is used for gas density meter.

Regarding GD400G Gas density meter, refer to attached Instruction Manual IM 11T3B1-01E.

3-16

IM 11R02A01-02E 5th Edition : Dec. 28, 2016-00

<4. Preparation of Operation>

4. Preparation of Operation

CAUTION

Before starting operation, check outside wirings or pipings and conrm if no gas leakage is found.

See Figure 3.2, 3.3 and 3.4.

4.1 Sampling Section (Outside panel)

● If the drain pot is located outside the panel, supply water fully until the water overows from

the drain outlet.

● Open the gate valve when it is in the sample line.

● If two fulo lters are located in parallel on the sample line, one of them is not used.

4.2 Status of Valves

4-1

See the following table, Table 4.1 and Table 4.2 to open/close valves.

Table 4.1 For town gas use

Valve No. Open or Close Valve No. Open or Close

V-1 V-2 V-3 V-4 V-5 V-6 V-7 V-8

Remarks: Valves with the mark * are the ow adjustment use and preliminary adjusted. They don’t need to be adjusted.

Table 4.2 For steel mill use

Valve No. Open or Close Valve No. Open or Close

V-1 V-2 V-3 V-4 V-5 V-6 V-7 V-8

Close Open Open Close * Open Close Close

Close * * Close Close Open Close Close

V-9 V-10 V-11 V-12 V-13 V-14 V-15 V-15

Close Close Open Open * Close Open *

Close Close * * Close Close Open *

Remarks: Valves with the mark * are the ow adjustment use and preliminary adjusted. They don’t need to be adjusted.

4.3 Water Supply (For Steel Mill Use)

● Open valve V-13 and supply water until it overows from the drain exhaust outlet of the

washing bubbler (3-2) and the pressure regulating pot (3-4). (Refer to Figure 3.4).

● The owmeter (6-1) indicates the ow rate of approx. 0.2 l/min.

IM 11R02A01-02E 5th Edition : Dec. 28, 2016-00

<4. Preparation of Operation>

4.4 Supply of the Air

Open valve V-14 and supply the air. The normal pressure is as under mentioned:

Table 4.3

Pressure Gauge Normal pressure

Pressure gauge of air set Pressure gauge (2-3)

When the pressure is not normal, adjust it by the following procedures.

1) Adjust the pressure gauge of the air set to approx. 200 kPa, using the air set valve (2-1).

Turn the valve to the right to increase the pressure.

2) Adjust the pressure gauge (2-3) to about 20 kPa, using the pressure reducing valve (2-2)

and V-16. Turn the pressure reducing valve to the right to increase the pressure.

approx. 200 kPa approx. 20 kPa

4.5 Supply of Power

1) Set the positions of each switch on the front panel of the calorie detector to the followings:

Table.4.4

4-2

Switch Position

POWER

SAFE EV METER

2) Turn on the switches of the following components in the switch box.

• Calorie Detector

• Orice Assembly (NFB)

• Pre-heater (NFB)

• Computing station

• Density meter (With density compensation)

• Dehumidier (For steel mill use )

3) When you turn on the “POWER” switch on the front of the calorie detector, both ”POWER”

and “ALARM” lamps are lit to show an alarm status.

4) When the power is supplied to the computing station, the alarm lamp on the front (yellow) lit

on, but this does NOT indicate “out of order.”

5) Turn on “POWER” in gas density meter (for the one with a gas density meter attached)

6) Approx. 60 minutes later, the lamp of the orice assembly starts ashing and the

temperature of the orice constant chamber becomes stable.

OFF SET

P.MEAS

4.6 TheZeroAdjustmentoftheDi󰀨erential

Pressure Transmitter

1) Remove the impulse lines from transmitters.

2) Turn on the main breaker of the switch box and the calorie detector switch.

3 Turn on the POWER switch on the front panel of the calorie detector.

IM 11R02A01-02E 5th Edition : Dec. 28, 2016-00

<4. Preparation of Operation>

4) Measure each of the output terminals on the terminal block with a voltmeter. Use the “zero

adjustment screw” on the di󰀨erential pressure transmitter to adjust the voltage to 1 V.DC.

The terminal number assigned for gas is 15 and 16, and one for air is 17 and 18.

5) Use a at-head screwdriver to make the adjustment. Turn the screw clockwise to increase

the output, and counterclockwise to decrease. The adjustment amount of the zero point

varies depending on how quickly the zero adjustment screw is turned. To make a ne adjustment, turn the screw slowly, and to make a rough adjustment, turn the screw quickly.

6 When the adjustment is completed, connect the impulse lines while making sure there is no

leakage.

CAUTION

● Be sure to make this adjustment every time the installation location of the panel is changed.

● Power is supplied to the di󰀨erential pressure transmitter from the calorie detector. To

operate the di󰀨erential pressure transmitter, turn on the calorie detector switch of the switch box and the POWER switch on the front panel of the calorie detector.

● After the zero-point adjustment is completed, do not turn o󰀨 the transmitter immediately. If

the power is turned o󰀨 within 30 seconds after the completion of the adjustment, the value

will return to the last one before the adjustment takes place.

4-3

Screw

Figure4.1Di󰀨erentialPressureTransmitter

F0401.aiZero Adjustment

4.7 AirDi󰀨erentialPressureAdjustment

1) Switch the computing station to the Input/Output status display (refer to Figure 3.15) and

check X2 (A-PRESS).

2) Adjust V-16 so that the indicated value becomes “500.”

3) If the indicated value of the pressure gauge (2-3) has deviated from 20 kPa, set the value to 20 kPa using the pressure reducing valve (2-2) and make the adjustment described in (2)

again.

4.8 Pressure Adjustment of the Gas Line

The pressure adjustment of the gas line uses air.

n For town gas use

1) Close V-6 and connect the one touch coupler (2-5).

2) Open V-7 and V-8.

IM 11R02A01-02E 5th Edition : Dec. 28, 2016-00

<4. Preparation of Operation>

3) Turn the switch “SAFE EV” of the calorie detector to “RELEASE”. The solenoid valve of the gas line opens and the alarm is released.

4) Adjust the owmeter (3-3) to approx. 10L/min by using the pressure reducing valve (4-1) and V-13. The pressure gauge (3-2) indicates 8 to 18 kPa.

5) Adjust the pressure gauge (3-5) to approx. 3 kPa. by using the pressure reducing valve (3-

4).

When a density meter is attached, adjust the throttle valve of the owmeter (5-3) to 0.5 to 1 l/min.

Set the indication of the computing station to Input/Output status display and check X3 (G-PRESS).

8) Adjust by pressure reducing valve (3-6) so that “X3” indicates “500”. When the value on the pressure gauge (3-5) deviates from about 3 kPa, repeat the procedure (5), then conduct the

adjustment.

9) When the adjustment is completed, close V-8, V-7, separate the one touch coupler (2-5), and open V-6.

10) Set the “SAFE EV” switch of the calorie detector to “SET”.

n For steel mill use

1) Close V-4, connect the one touch coupler (2-5) and open V-5 and V-8.

2) Set the switch “SAFE EV” of the calorie detector to “RELEASE”. The solenoid valve of the gas line opens and the alarm is released.

4-4

3) Adjust the ow rate of the owmeter (4-2) to about 10 l/min by using the pressure reducing valve (4-1). The pressure gauge (3-1) indicates approx. 6 kPa.

4) When the density meter is attached, adjust the owmeter (5-3) to 0.5 to 1 l/min by using

V-11.

5) Adjust, by using V-12, the number of bubbles that come out of pipe A of the pressure regulating pot (3-4). The number of bubbles has to be 3 to 6 pcs/sec. However, if no bubbles come out, when low calorie gas is being used, open V-12 fully,

6) Set the indication of the computing station to Input/Output status display and check X3 (G-PRESS).

7) Adjust the pressure to “500” by using the pressure reducing valve. “X3” the pressure reducing valve (3-6), adjust the indication “X3” to become “500”. When the number of bubbles from pipe A uctuates, adjust the number by using V-12, then carry out the

adjustment.

8) When completing the adjustment, close V-8 and V-5. Separate the one touch coupler (2-5), and open V-4.

9) Turn the switch “SAFE EV” of calorie detector to “SET”.

IM 11R02A01-02E 5th Edition : Dec. 28, 2016-00

<5. Operation>

5. Operation

5.1 Start Operation

WARNING

 Conrm the air is supplied before starting operation.  Conrm that the ventilation system is running before introducing the gas.

n Introduction of the Sample Gas

l For town gas use

1) Open V-1 fully.

2) When the pump is attached, turn ON the power supply before proceeding to (3).

5-1

3) When the pressure is increased by the pump, adjust the pressure by V-5 so that the

pressure gauge (3-2) indicates 8 to 18 kPa. When the pressure is reduced by the pressure

reducing valve, adjust the pressure by the pressure reducing valve (3-8) so that the

pressure gauge (3-2) indicates 8 to 18 kPa, .

l For steel mill use.

1) When you use the standard pressure, open V-4. When the pressure is increased by the pump, open V-1, V-4 respectively.

2) When the pump is attached, turn on the power supply switch of the pump at this time.

3) Use V-3 for standard pressure or use V-2 and V-3 for the pressure raised by pump to make

the pressure gauge indicate approx. 6kPa.

n Start Operation of the Calorie Detector

Conrm the switch “SAFE EV” is set at “SET” then push the switch “START”.

n Di󰀨erentialPressureReadjustment

When the burner is ignited and the output becomes stable (after 20 to 30 min.), adjust again the

di󰀨erential pressure.

l For town gas use

1) When the pressure gauge (3-5) does not indicate approx. 3 kPa, adjust the pressure by the

pressure reducing valve (3-4).

2) When the density meter is attached and the owmeter (5-3) indicates out of 0.5 to 1 l/min,

adjust its indication again.

3) Set the computing station to Input / Output status display. 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 5th Edition : Dec. 28, 2016-00

<5. Operation>

l For steel mill use

1) When the density meter is attached, adjust again the indication of the owmeter (5- 3) by

V-11.

2) When the number of bubbles coming out from the pipe A is not constant, adjust it by V-12.

3) Set the computing station to Input / Output status display. If either the indication of “X2 (A-PRESS)” or “X3 (G-PRESS)” is not ”500”, adjust each with the pressure reducing valve

(3-6) and V-16.

5.2 Stopping Operations

n Long Time Stopping

1) Close V-1. To stop standard pressure gas for the steel mill use, close V-4. But when a pump

is attached, turn o󰀨 the power of pump in advance.

2) When the gas supply is suspended and the burner is extinguished, the lamp “MEAS” of the calorie detector is lit o󰀨 and the lamp “ALARM” on.

3) Switch the calorie detector from “SAFE EV” to “RELEASE”.

4) To stop the ow of a town gas , close V-6 and open V-7, V-8. To stop the ow of steel mill gas, close V-4 and open V-5, V-8. The sample gas in the gas line should be blown o󰀨 by the

air then the subtle sample gas will be emitted

5-2

5) After continuing the blow for 3 to 5 min., turn o󰀨 the “POWER” switch of the calorie detector.

If the density meter is attached, cut the power supply inside the density meter.

6) Turn o󰀨 all switches of the switch box.

7) Lastly, close V-14 and stop the air supply.

n Short Time Stopping

Same as mentioned above, the mode suspends the supply of sample gas only.

If this state is kept on hold, you can skip the warm-up time before another operation starts.

IM 11R02A01-02E 5th Edition : Dec. 28, 2016-00

<6. Calibration>

6. Calibration

For calibration, zero and span gases are necessary. Use the gas with the specications as near

to each measuring range for both lower and upper limit as possible.

6.1 Supply of the Calibration Gas

6.1.1 For Town Gas Use

Refer to Figure 3.2 and 3.3.

1) Close V-6 and open V-7. At this time, the ame of burner is extinguished. But if the pump is attached, turn o󰀨 the power supply of the pump rst, then close V-6 and open V-7.

2) Adjust the secondary pressure of the pressure reducing valve for calibration gas cylinder, to

approx. 200 kPa.

3) Open V-9 or V-10 and introduce the calibration gas.

4) Adjust the indication of the owmeter (3-3), by the pressure reducing valve (4-1), to become about 10 l/min. In case of only indication check, the adjustment to approximately 2 to 3 l/min

is permissible.

5) Push the “START” switch of the calorie detector to ignite.

6-1

6) Set the computing station to Input/Output display screen. 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.

7) In the case of the density meter being attached, conrm and readjust (if necessary) the indication of the owmeter (5-3).

8) When the calibration is completed, close V-9, V-10, V-7, and open V-6. When a pump is attached, turn on the power of pump now.

9) Push the “START” switch of the calorie detector to ignite.

10) Conrm and readjust (if necessary) the gas di󰀨erential pressure and the ow rate to the

density meter.

11) Do not forget to close the root valve of the calibration gas cylinder.

IM 11R02A01-02E 5th Edition : Dec. 28, 2016-00

<6. Calibration>

6.1.2 For Steel Mill Use

Refer to Figure 3.4 Flow Sheet (Steel Mill Use).

1) Close V-4 and open V-5. The burner is extinguished. However, if the pump being attached, turn o󰀨 the power supply of it in advance.

2) Set the secondary pressure of the pressure reducing valve for calibration gas cylinder to

approx. 200 kPa.

3) Open V-9 or V-10 and introduce the calibration gas.

4) Using the pressure reducing valve (4-1), adjust the indication of the owmeter (4-2) to become about 10 l/min. In case of only indication check, the adjustment to approximately 2

to 3 l/min is permissible.

5) Push the “START” switch of the calorie detector to ignite.

6) Set the computing station to Input/Output status display. The indication of “X3 (G-PRESS)”

is adjusted to ”500” with the pressure reducing valve (3-6). In the case of the density meter

being attached, conrm and readjust the ow rate.

7) Conrm “X2 (A-PRESS)” in Input/Output status display and adjust “X2” to “500” by using

V-16.

8) When the calibration is completed, close V-9, V-10, V-5 and open V-4. When the pump is attached, turn on the power of the pump.

6-2

9) Push the “START” switch of the calorie detector to ignite.

10)

Readjust both the gas di󰀨erential pressure and the ow rate to the density meter.

11)

Do not forget to close the root valve of the calibration gas cylinder.

6.2 Span Adjustment of the Calorie Detector

This adjustment is not necessary for the usual calibration. This adjustment is held when replacement such as the thermocouple of the burner unit takes place. This adjustment is

di󰀨erent depending upon if the preheating circuit exists or not. This adjustment is to be held after regulating each di󰀨erential pressure to “500”.

n WhennoPreheatingCircuitExist

1) Set the computing station to Input/Output status display with X1 (NON-CORR. WI%).

2) Introduce the span gas and after ignition, wait until the indication “X1” becomes stable.

3) Adjust the indication, using the “SPAN” potentiometer on the front side of the calorie detector, to become the specied value (x%). WI is used to nd out the x value. Example: WI value of the span gas = 59.00 WI WI value of the upper range = 60.00 WI

59.00

x =  100 = 98.3%

60.00

n WhenPreheatingCircuitExists

1) Suspend the supply of the sample gas.

2) Same as the gas line pressure adjustment explained in paragraph 4.8), introduce the air to the gas line.

3) 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 e󰀨ect of the preheating is detected by the thermocouple.

IM 11R02A01-02E 5th Edition : Dec. 28, 2016-00

<6. Calibration>

4) Switch the “METER” switch of the calorie detector to “P.MEAS” and measure X5 of the

computing station. Wait until the indicated value is stabilized and then record the value. (E0 mV)

5) Switch the “SAFE EV” switch of the calorie detector to “SET.”

6) Stop the air supply to the gas line, supply the span gas, and start the ignition action.

7) Measure X5 of the computing station. Wait until the indicated value is stabilized and then

record the value. (Ec mV)

8) Set the computing station to Input/Output status display and adjust the “SPAN” potentiometer of the calorie detector so that “X1” will show the specied value (x%). WI is to be used to nd out the value of x.

For example:

WI value of the upper range = 5.00 WI WI value of the span gad = 4.90 WI Eo = 4 mV, Ec = 19 mV

x =  100 = 98.4 %

(19-4) x

5.00

4.9

100

+ 4

6-3

NON-CORR. WI [%]

WI value of the span gas: Wc WI value of the upper range: Ws

x =

(Ec – Eo) + Eo

Figure6.1HowtoFindOutxWhenPreheatingCircuitExists

Ws Wc

 100

output (mV)

Thermocouple

WI value of the span gas

WI value of the upper range

WOBBE INDEX [WI]

F0703.ai

IM 11R02A01-02E 5th Edition : Dec. 28, 2016-00

<6. Calibration>

6.3 Calibration of the Computing Station

This chapter explains an ordinary calibration of the computing station. The calibration is

conducted as follows according to the type of the output.

• WI output .............. Calibrate with WI value.

• WI calorie output .. Calibrate with WI value and conrm the caloric value.

• Calorie output ....... Calibrate with caloric value.

In case of existing the preheating, the bias adjustment is carried out rstly.

n Bias Adjustment

This adjustment is carried out only when the preheating circuit exists.

1) Suspend the supply of the sample gas, and introduce the air to the gas line.

2) Set the “SAFE EV” switch of the calorie detector to “RELEASE”.

3) Set the computing station to Input/Output status display. After the indication Y4 (BIAS

CHECK) becomes stable (20 to 30 minutes), adjust the (Y4) value of the P03(BIAS) will

become [0.0] by the data setting key.

Note) When you perform a ne adjustment on a potentiometer, select alternatively between (Y4) and (P03) and display

4) When the adjustment is completed, turn the switch “SAFE EV” of the calorie detector to “SET”, and suspend the air supply to the gas line.

6-4

n Zero and Span Adjustment

1) Introduce the zero gas and ignite.

2) 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 calibration gas).

3) Change from zero gas to span gas, when, if let the span gas start owing 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.

4) 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 caloric value of the calibration gas. (Display P02, adjust by the data setting key). (Conrm the result of the adjustment after displaying it as WI or cal)

5) Repeat 2 or 3 times the above adjustments.

6) When complete the adjustment, suspend the supply of the calibration gas.

n Other Adjustment

The adjustment of P04 (A-CORR, RATE), P06 (G-CORR, RATE) and P05 (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 is required. For the adjustment in

detail, consult our service personnel.

]” (WI value or the caloric value of the

6.4 Calibration of the Density Meter

Regarding GD400G Gas density meter, refer to an attached Instruction Manual IM 11T3B1-01E.

IM 11R02A01-02E 5th Edition : Dec. 28, 2016-00

<7. Maintenance>

F11-1.ai

7. Maintenance

7.1 Daily Check

7.1.1 Air,GasDi󰀨erentialPressureAdjustment

Conrm the air or gas di󰀨erential pressure or adjust the indication of X2 (A-PRESS), X3 (G-PRESS) to “500”. Refer to the paragraph 4.7 or 4.8 then follow the instruction on the

adjustment.

7.1.2 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. After the drain is taken out, be sure to close the valve.

7.1.3 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

7-1

GAUGE FOR SECONDARY PRESSURE

DRAINAGE KNOB

Figure 7.1 Air Set

IM 11R02A01-02E 5th Edition : Dec. 28, 2016-00

<7. Maintenance>

7.2 Regular Check

Refer to Figure 3.2 , 3.3 and 3.4. The ow sheet depends on the specication.

7.2.1 CleaningoftheOricePlateandReplacementof

O-ring

When something like dust adhere to the orice holes, the output declines. Follow the instruction as below to clean.

CROTCHET JOINT

7-2

HOLDING SCREW

ORIFICE ASSEMBLY

O-RING (P16)

O-RING (P20)

ORIFICE PLATE

COVER PLATE

HEX. HOLE SCREW

F10-2.ai

Figure7.2OriceSystem

1) Suspend the supply of the sample gas, then blow the gas line with the air.

2) Remove the crotchet joint.

3) Turn the holding screw and take out.

4) Pull out slowly to the direction as shown on Figure 10.2.

5) Loosen the set screw by using the hexagonal wrench attached to take out the orice plate together with the cover plate. The following is part number of the orice plate.

Oricehole(Ø) Part number Oricehole(Ø) Part number

0.35 G7025XJ 0.80 G7034XJ

0.40 G7026XJ 0.85 G7035XJ

0.45 G7027XJ 0.90 G7036XJ

0.50 G7028XJ 1.0 G7037XJ

0.55 G7029XJ 1.1 G7038XJ

0.60 G7030XJ 1.2 G7039XJ

0.65 G7031XJ 1.3 G7040XJ

0.70 G7032XJ 1.4 G7041XJ

0.75 G7033XJ 1.5 G7042XJ

6) For the cleaning use something like a supersonic cleaner and never insert into the orice

holes anything like a stick or rod.

7) When the O-rings are worn out, replace them with the spare parts. Part number of O-rings are Y9114XB (P16) and L9817MT (P20).

8) After the cleaning and replacement are completed, assemble the parts in the reverse order of the disassembly as mentioned above.

IM 11R02A01-02E 5th Edition : Dec. 28, 2016-00

<7. Maintenance>

NOTE

The orice system is temperature-controlled by a plate heater, so better nish the cleaning and

replacement as swiftly as possible.

7.2.2 Fulo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 follows. Same process applies to the option fulo lter whose element (50µm) is G7057XJ in the part number.

1) Turn the nut and remove the cover.

2) Pull out the element and clean or replace.

3) Assembly is carried out in contrary order to above.

4) When the packing or gasket is worn out, replace it. We provide a packet which contains 4

pieces of packing and a gasket. (G7086XL)

PACKING GASKET ELEMENT PACKING

7-3

NUT

COVER

Figure7.3FuloFilter

TENTION BOLT

CASE

F0703.ai

7.2.3 Line Filter (For Town Gas Use)

Disassemble 3 screws, and open the cover, there inside exist an element (G7005XJ.) If it is stained, replace by a new one. Also if the O-ring (Y9116XB) is fatigued, replace it with new one.

SCREW

O-RING

GAS INLET

FILTER

ELEMENT

GUIDE

BODY

Figure 7.4 Line Filter

IM 11R02A01-02E 5th Edition : Dec. 28, 2016-00

<7. Maintenance>

7.2.4 Washing Bubbler or Pressure Regulating Pot

If inside of case becomes dirty by the weeds grown in the water, pull the plug at the bottom of the

bubbler to drain and rell it with clean water. If inside the bubbler is stained, remove the cover and

clean inside of the bubbler. Be careful not to scatter the water around the panel when you drain the water.

When the water level becomes higher than the drain outlet position, there would be a possible

contamination in the exhaust pipe line, so the cleaning is necessary.

7-4

Figure 7.5 Washing Bubbler and Pressure Regulating Pot

7.2.5 Dehumidier(ForSteelMillUse)

The washing bubbler cannot eliminate all of the naphthalene if it is contained too much in a

sample gas. The naphthalene may be crystallized and clog the piping inside of dehumidier. In such a case, stop the sample gas ow, remove the 4 pipes at the top of the dehumidier and

introduce hot water of 70°C to 80°C. The naphthalene is dissolved into the hot water and is eliminated.

F12-6.ai

PRESSURE REDUCING VALVE

FULFLO FILTER

POWER

COOL

TERMINAL BLOCK

CIRCUIT BREAKER

POWER LAMP

COOL LAMP

DRAIN (TO PRESSURE REGULATING POT)

(ORIFICE ASSEMBLY)

DENSITY METER

Figure7.6Dehumidier

7.2.6 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.

F11-7.ai

IM 11R02A01-02E 5th Edition : Dec. 28, 2016-00

<7. Maintenance>

7.3 Check at the Regular Service

7.3.1 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 ame.

• The shape of the ame for the complete combustion is as shown in Figure 7.7 - (A) of a shape sharply outlined, and the height of the inner ame is about a half size of the outer ame.

• When the primary air is too much, the ame becomes, as shown in Figure 7.7 - (B), ickering and when the secondary air is not su󰀩cient, the ame outline becomes like (B) as

well.

• When the primary air is not su󰀩cient, the color of the ame is clear yellow (C) and

sometimes soots come out.

• When there is any blockade or leakage is the air line, the ame becomes like the shape as

shown in Figure 7.7 - (D).

OUTER FLAME

INNER FLAME

7-5

（A）（B）（C）（D）

F11-8.ai

Figure 7.7 Burner Flames

Check the ames 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.

1) Remove the screw (4 pcs) xing the external pipe, then remove the connectors to the

terminal of the hot junction detecting point.

2) Disassemble the external pipe and take out the jet plate by pulling upward. (The direction to

pull for removal is shown in Figure 7.8 by the sign of arrow).

3) Insert the attached mirror herewith into the ventilator.

4) When you ignite, the ame reected on the above mirror can be observed from slanting

upside.

5) Assemble the burner by following the procedures above in the reverse order.

IM 11R02A01-02E 5th Edition : Dec. 28, 2016-00

<7. Maintenance>

Connector

Detector for

Hot Junction

Exhaust Pipe

Terninal Board

7-6

Detector for

Cold Junction

Burner Unit

Ventilator

Secondary Air

Throttle Screw

Primary Air

Throttle Screw

Figure 7.8 Flame Checking

Screw(4pcs)

Mirror

Jet Plate

Combustion Pipe

Ignition Trans Assembly

Relay ( A1574MR)

External Pipe

Constant-Voltage Power Supply Transformer

F0708.ai

7.3.2 ZeroAdjustmentoftheDi󰀨erentialPressure

Transmitter

Adjust according to the procedure described in paragraph 4.6.

7.3.3 Others

If necessary, conduct each regular check mentioned in paragraph 7.2.

IM 11R02A01-02E 5th Edition : Dec. 28, 2016-00

<8. Troubleshooting>

8-1

8. Troubleshooting

Two major factors are considered to make large di󰀨erence between current measuring result and normally expected ones. One factor is that the process condition is changed, which leads to the

change of gas component . The other one is that the measuring system has some errors. If the measuring system has some errors, carry out the following troubleshooting in this chapter.

8.1 Gas Sampling Pressure Regulating Section

n For Town Gas Use

1) See Figure 3.2 and 3.3 Flow Sheet. Check if any blockade or leakage exist in the sampling

line up to the panel.

→If any blockade is found, blow the sampling line by air.

2) Check the lter element of the line lter. →According to the paragraph 7.2.3, clean or replace.

3) If conditions above mentioned are 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 opening V-5 fully, the decrease of the suction ability of the pump might be a cause of the trouble.

→If 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 have a defect.

When introducing the check gas, conrm the indication of the owmeter (3-3) is about 10 l/min. If you need to check only an indication, adjust the owmeter to approximately 2 to 3 l/min. →It is due to a defect of the pressure regulator that the ow rate cannot be successfully

set by the pressure regulator (4-1).

5) Conrm the pressure gauge (3-5) indicate approx. 3 kPa. →If the pressure cannot be satisfactorily set by the pressure reducing valve (3-4), it may

have a defect.

When the density meter is attached, conrm the indication of the owmeter (5-3) is 0.5 to 1 l/min. →It may be due to the clogging of the gas pipe inside the density meter that no indication appears on the owmeter.

7) Conrm the indication of the computing station is about “500”, after setting the indication to “X3 (G-PRESS)”. →When the di󰀨erential pressure setting cannot be executed with the pressure reducing

valve (3-6), it is due to a defect of the pressure reducing valve.

8) For all gas lines, check any leakage at each joint connection.

IM 11R02A01-02E 5th Edition : Dec. 28, 2016-00

<8. Troubleshooting>

n For Steel Mill Use

See Figure 3.4 Flow Sheet. The sampling system here (outside the panel) refers to the one we recommend.

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 clogging, accumulation of dust or leakage in the pipings between the probe

(7-1) and the fulo lter (7-2) equipped outside. →When there is any clogging, blow by the air. →When the piping has any U bending, tilt the piping so that the water ows smoothly.

3) Check the element of the outside fulo lter (7-2). →When you nd any clogging, clean or replace as according to the paragraph 7.2.2.

4) Check the indication of the pressure gauge (3-1) is approx. 6 kPa. → If there is no water accumulated in the washing bubbler, no indication appears on the

pressure gauge. Supply water to the washing bubbler.

→ If the pump is attached, and its suction ability decreases,the pressure gauge may 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 owmeter (4-2) is approx. 10 l/min.

→ When the pressure valve (4-1) cannot adjust it, there is a high chance that the pressure

reducing valve has a defect.

8-2

6) Check the element of the fulo lter (3-3). →If it is stained, clean or replace as according to the paragraph 7.2.2.

7) Check the water level of the pressure regulating pot.

→If necessary, supply water or clean.

8) Check if the bubbles are coming out 3 to 6 pcs/sec from the pipe A of the pressure regulating pot.

→ When V-11, V-12 fail to adjust, clean the piping inside the dehumidier as according to

the paragraph 7.2.5. But no bubbles are coming out, when you use low calorie gas.

When the density meter is attached, check if the indication of the owmeter (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)”. → When the adjustment is impossible even by using the pressure reducing valve (3-6), there

is a high chance that pressure reducing valve has a defect.

11) For all gas lines, check the leakage at each joint connection.

8.2 Air Pressure Adjustment Section

1) Check the pressure gauge of the air set (2-1) is about 200 kPa → When the primary pressure of the instrument air is normal, but the adjustment of the air

set is impossible, there is a high chance that the air set has a defect.

2) Check the pressure gauge (2-3) indicates approx. 20 kPa. → If you cannot adjust it when even using the pressure reducing valve (2-2), there is a high

chance that the pressure reducing valve has a defect.

3) If the above are found normal, we can adjust by using V-16 the air di󰀨erential pressure to

“500”.

8.3 Di󰀨erentialPressureTransmitterSection

1) Check the orice section of the orice assembly. →When the orice plate is contaminated, clean it as according to the paragraph 7.2.1.

IM 11R02A01-02E 5th Edition :Dec. 28, 2016-00

<8. Troubleshooting>

2) Check any leakage in the pressure transmission pipe of each di󰀨erential pressure

transmitter.

3) Check the temperature (thermistor resistance value) setting of orice assembly. →If the resistance value is not 3.6 to 4.2 kΩ, the temperature controller may have a failure.

8.4 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 measure X5 of the computing station. If preheating is not required, the appropriate output is approximately 0 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 0 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, if the sample gas is 80 WI, the voltage output is about 16 mV (when no preheating circuit).

→Although both the gas pressure control section and the di󰀨erential pressure are normal,

the voltage output might be much varied. In this case there is a high chance that some

blockade exist in the air ow distribution line of the burner unit. Check the burner ame as

mentioned in paragraph 7.3.1.

8-3

→When the gas ame is coming out of the burner but the voltage output is very low , there

is a high chance that the wire is disconnected in thermocouple.

2) Measure 3 (+) and 4 (-) on the terminal board of the calorie detector. The normal voltage

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).

3) Measure 17 (+) and 18 (-) on the terminal block of the calorie detector. The appropriate value is 23 V ±1%.

→It is due to a defect of the distributor in the calorie detector that the value is not normal.

4) Measure 15 (+) and 16 (-) on the terminal block of the calorie detector. The appropriate value is 23 V ±1%.

→It is due to a defect of the distributor in the calorie detector that the value is not normal.

5) Measure 8 (+) and 7 (-) on the terminal block of the calorie detector. The appropriate value is 3 V ± 0.2 V.

→If the measured value varies much in spite of the air pressure control section being

normal, there is a high chance that the di󰀨erential pressure transmitter has a defect.

6) Measure 6 (+) and 7 (-) on the terminal block of the calorie detector. The appropriate value is 3 V ± 0.2 V.

→ If the measurement value is greater than the appropriate value, even though the gas

pressure controller is normal, the di󰀨erential pressure transmitter is considered to have a

defect.

7) When the density meter is attached, measure 3 (+) and 4 (-) of the density meter terminals. Compare the gas density meter and the voltage output, then obtain an appropriate value , while reviewing the characteristics of gas density meters.

. →If the appropriate value is out of data in spite of no leakage, calibrate as according to the

paragraph 6.4.

IM 11R02A01-02E 5th Edition : Dec. 28, 2016-00

<8. Troubleshooting>

8-4

CALORIE DETECTOR

DIFFERENTIAL PRESSURE TRANSMITTER (GAS)

DC 4~20mA

(+)

(–)

DC 4~20mA

(+)

(–)

DIFFERENTIAL PRESSURE TRANSMITTER (AIR)

15(+) 16(–)

17(+) 18(–)

DENSITY METER

Figure 8.1 Signal Circuit Diagram

1 2 3 4 5 6 7 8 9

3(+) 4(–)

5(+)

6(+) 7(–)

8(+)

3(+)

4(–)

DC 1~5V

DC 0~20mA

DC 1~5V

250 Ω

COMPUTING STATION

1(+) 2(–)

20(–) 19(+)

22(+) 23(–)

5(+)

24(+)

6(–)

25(–)

4(–)

26(+)

3(+)

27(–)

7(+)

8(–)

DC 4~20mA

DC 1~5V

CALORIFIC OUTPUT

WI OUTPUT

OPTIONAL OUTPUT

10 11121314 15 16 17 18

19 20 212223242526 27

Figure 8.2 Terminal Block of the Calorie Detector

IM 11R02A01-02E 5th Edition :Dec. 28, 2016-00

<8. Troubleshooting>

8.5 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

NON-CORR. WI % *

A-PRESS Pa 500 ± 50

G-PRESS Pa 500 ± 50

SQT. DENSITY Same as density meter

*: When pre-heating circuit does not exist, 0 to 100% is almost in proportion to 0 to “the highest level WI value in the measurement

range.”

When preheating exists, about 20 to 100% is almost in proportion to 0 to “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 o󰀨. But in this case, the computing inside the station keeps working. Change to Alarm display and examine the cause of the alarm.

2) 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 hold output has a tendency of decreasing gradually as time proceeds. When the fail lamp is on, the display of fail will be shown. The alarm lamp lights for the abnormal operation of the pressure adjustment for the gas or air line. The lighting when other than under the time of measurement is not abnormal.

8-5

8.6 Other Troubleshooting

Check and deal with measures mentioned in paragraph 8.1 to 8.5. As to the trouble not mentioned in this manual, contact our service personnel and describe how the inspection goes, and if you have any record..

IM 11R02A01-02E 5th Edition : Dec. 28, 2016-00

Blank Page

Revision Information

l Title : Model CM6G Gas Calorimeter

l Manual No. : IM 11R02A01-02E

May 2019/6th Edition

Corrections (p. 1-2. 1-3)

Dec. 2016/5th Edition

Full revision. Changed chapter order. Deleted contents described in the former Chapter 12 of and

CMPL.

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.

Subsection 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 :Su󰀩x 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, length 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. Thermal 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)&b),

6.1.8 town gas g)&h), steel mill f)&g) and 6.2.3 both of c)

Range of ow 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)&g), 7.2.1 a)&b), 7.2.2 h), 7.3.1 c), 7.3.2 b)&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: P05 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 ow 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”.

Section 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

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.

IM 11R02A01-02E 5th Edition : Dec. 28, 2016-00

Section 9.5: Item 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 1st Edition :Dec. 28, 2016-00

YOKOGAWA CM6G User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

u Introduction

u Safety Precautions

1. Outline

1.3 Standard Systems for Each Application

1.5 Principle of Measurements

2. Installation, Piping, Wiring

2.1 Installations

3. Construction and Function

3.1 Air Pressure Regulating System

3.2 Gas Pressure Control Section

3.4 Calorie Detector

3.4.1 Burner Unit

3.4.2 High/Low Alarm Action

3.4.3 Ignition

3.5 Computing Station

3.5.1 Display

3.5.2 Contents of the Data Display

3.5.3 Correcting Computation

3.6 Density Meter

4. Preparation of Operation

4.1 Sampling Section (Outside panel)

4.2 Status of Valves

4.3 Water Supply (For Steel Mill Use)

4.4 Supply of the Air

4.5 Supply of Power

4.8 Pressure Adjustment of the Gas Line

5. Operation

5.1 Start Operation

5.2 Stopping Operations

6. Calibration

6.1 Supply of the Calibration Gas

6.1.1 For Town Gas Use

6.1.2 For Steel Mill Use

6.2 Span Adjustment of the Calorie Detector

6.3 Calibration of the Computing Station

6.4 Calibration of the Density Meter

7. Maintenance

7.1 Daily Check

7.1.2 Take Out the Water Out of the Drain Pot (Pump for Steel Mill Use)

7.1.3 Take Out the Drain from the Air Set

7.2 Regular Check

7.2.3 Line Filter (For Town Gas Use)

7.2.4 Washing Bubbler or Pressure Regulating Pot

7.2.6 Density Meter

7.3 Check at the Regular Service

7.3.1 Check the Burner Flame

7.3.3 Others

8. Troubleshooting

8.1 Gas Sampling Pressure Regulating Section

8.2 Air Pressure Adjustment Section

8.4 Signal Section

8.5 Computing Station

8.6 Other Troubleshooting

Revision Information