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Corus Gas volume converter

Installation guide V2.6

TABLE OF CONTENTS 1

INTRODUCTION .......................................................................................................................................................... 3 1.1 1.2 1.3 1.4 1.5

2

SYNOPTIC OF THE PRODUCT ...................................................................................................................................... 8 2.1 2.2 2.3 2.4

3

FIRMWARE STRUCTURE ................................................................................................................................................................... 29 FIRMWARE IDENTIFICATION ............................................................................................................................................................. 30 FIRMWARE PROTECTION AND DATA CONTROL (CRC) ............................................................................................................................. 30 DATA PROTECTION – DATA ACCESS ................................................................................................................................................... 31 INDEX DISPLAY FORMAT .................................................................................................................................................................. 32

FUNCTIONAL DESCRIPTION .......................................................................................................................................33 8.1 8.2 8.3

9

FIXING ........................................................................................................................................................................................ 22 CONNECTORS AND TERMINALS ......................................................................................................................................................... 22 INSTALLATION OF THE SENSORS......................................................................................................................................................... 24 POWER SUPPLY ............................................................................................................................................................................. 25 PROGRAMMING............................................................................................................................................................................ 27 PRESSURE AND TEMPERATURE ADJUSTMENT ON SITE ............................................................................................................................. 28

MID: COMPLIANCE WITH WELMEC 7.2 GUIDE .........................................................................................................29 7.1 7.2 7.3 7.4 7.5

8

OPTICAL PORT .............................................................................................................................................................................. 19 RS232 PORT ............................................................................................................................................................................... 19 INTERNAL ATEX PSTN MODEM (OPTIONAL BOARD) ............................................................................................................................. 20 2-CHANNEL RS485 (OPTIONAL BOARD) ............................................................................................................................................ 20

INSTALLATION, COMMISSIONING AND MAINTENANCE ..........................................................................................22 6.1 6.2 6.3 6.4 6.5 6.6

7

TAMPER INPUT ............................................................................................................................................................................. 16 COHERENCE LF INPUT .................................................................................................................................................................... 16 ON/OFF INPUTS ............................................................................................................................................................................ 16 ON/OFF OUTPUTS ......................................................................................................................................................................... 17 INSTANTANEOUS FLOWS ................................................................................................................................................................. 18 SECOND PRESSURE (OPTIONAL BOARD) ............................................................................................................................................... 18

COMMUNICATION ....................................................................................................................................................19 5.1 5.2 5.3 5.4

6

TEMPERATURE MEASUREMENT ......................................................................................................................................................... 11 PRESSURE MEASUREMENT ............................................................................................................................................................... 11 COMPRESSIBILITY RATIO CALCULATION ............................................................................................................................................... 12 CONVERSION FACTOR CALCULATION .................................................................................................................................................. 13 VOLUMES METERING ..................................................................................................................................................................... 13

NON-METROLOGICAL MEASUREMENTS AND INPUTS/OUTPUTS............................................................................16 4.1 4.2 4.3 4.4 4.5 4.6

5

HARDWARE ARCHITECTURE ............................................................................................................................................................... 8 METROLOGICAL SEALING SCHEME ....................................................................................................................................................... 8 CUSTOMER SEALING......................................................................................................................................................................... 9 METROLOGICAL LABEL .................................................................................................................................................................... 10

METROLOGICAL MEASUREMENTS AND INPUTS/OUTPUTS .....................................................................................11 3.1 3.2 3.3 3.4 3.5

4

PRODUCT PRESENTATION .................................................................................................................................................................. 3 OPERATING PRINCIPLE ...................................................................................................................................................................... 3 MAIN CHARACTERISTICS.................................................................................................................................................................... 5 OVERALL DIMENSIONS (IN MM) .......................................................................................................................................................... 7 MAIN COMPONENTS ........................................................................................................................................................................ 7

DATABASE ................................................................................................................................................................................... 33 ALARMS ...................................................................................................................................................................................... 36 ALARMS RESET ............................................................................................................................................................................. 41

USER INTERFACE ........................................................................................................................................................42 9.1

KEYBOARD ................................................................................................................................................................................... 43

1

9.2

10

DISPLAY ...................................................................................................................................................................................... 43

SAFETY INSTRUCTIONS ..............................................................................................................................................53 10.1 GENERAL .................................................................................................................................................................................... 53 10.2 MARKING RELATIVE TO ATEX - ZONE ................................................................................................................................................ 53 10.3 SPECIFIC INSTRUCTIONS .................................................................................................................................................................. 53

11

MANUFACTURING .....................................................................................................................................................55

12

APPENDIX 1: INITIAL ATEX CERTIFICATE ...................................................................................................................56

13

APPENDIX 2: EC DECLARATION OF CONFORMITY ....................................................................................................59

THIS MANUAL INCLUDES DOCUMENT D0214888 – AD PROVIDED FOR MID CERTIFICATION

ADDITIONAL INFORMATION CONCERNS THE NON METROLOGICAL PARTS

2

1

INTRODUCTION

1.1 Product presentation Corus is a type 1 gas volume converter that can be configured as a T, PT or PTZ version. It is designed to calculate gas volumes under base conditions, based on a volume at metering conditions, a temperature, a pressure and a compressibility factor. Its volume input is a low frequency one that can be connected to any Ex compliant gas meter that provides such information. Corus belongs to a new generation of volume converters that are designed to achieve a high level of performance thanks to powerful electronic equipment. Based on the use of flash memory, its architecture allows the download of a new firmware release through a laptop without board modification. Corus is approved according the new European directive (MID) based on standard EN 12405-1/A1 and can be used for commercial and fiscal gas transactions. According to the European regulation, it bears the CE marking and complies with the following directives:  89/336/EEC  94/9/EC  2004/22/EC

(electromagnetic compatibility directive) EMC (potentially explosive atmospheres directive) ATEX (metrology) (MID)

Corus provides the following functions:  acquisition and integration of the volume measured by the meter  measurement of gas temperature and gas pressure  calculation of the compressibility factor (PTZ version)  calculation of the conversion factor and of the volume in base conditions using a T, PT or PTZ conversion  calculation of the measured and converted flow rates  display of the measured and calculated data  management of alarms  management of a large database  multiple communication channels for local and remote operations  on/off inputs and outputs  optional slot for one ATEX additional board: Internal PSTN modem or double RS485 com ports board or second pressure input board (P2).

1.2 Operating principle The gas meter measures a volume of gas at metering conditions (Vm), under specific pressure (Pm) and temperature (Tm) conditions. This volume is converted into a volume at base conditions by Corus according to EN 12405:

Vb  where :  Vm  Vb  Tm

= = =

Pm Tb Zb    Vm  C  Vm Pb Tm Zm

Volume at measuring conditions Converted volume at reference (base) conditions Gas temperature at metering conditions

3

     

Tb Pm Pb Zm Zb C

= = = = = =

Reference (base) absolute temperature Gas absolute pressure at metering conditions Reference (base) absolute pressure Gas compressibility factor at metering conditions Gas compressibility factor at reference (base) conditions Conversion factor

4

1.3 Main characteristics Name

CORUS

Manufacturer

ITRON

Type

Gas volume conversion device - Type 1

Model

T, PT or PTZ

Metrology

Conform to EN12405-1/A1 MID test certificate: T10323 by NMI (module B) MID production approval by PTB (module D) PTZ model : Z computed according : 

S-GERG 88



AGANX19



AGANX19 mod.



Table of Z



AGA8 – Gross method 2 (GM2)



AGA8 – Detailed method (DM)

Ambient temperature range

[-25°C ; +55°C]

Gas temperature range

[- 30°C ; +70°C]

Reference conditions

Pb : from 0,9 bar to 2 bar Tb : from 0°C to 40°C

Protection class

IP65 according EN60529

Power Supply

Internal battery (16.5A.h) or external DC voltage

Internal power supply

Limits : 2.6V DC < Vint < 3.7V DC Nominal voltage : 3.3V DC

External power supply

Limits : 6 V DC < Vext < 12 V DC Nominal voltage : 10V DC

Pressure ranges

Number : 3 

Sensor : 0.9 – 10 bars abs.



Sensor : 3 – 30 bars abs.



Sensor : 7.2 – 80 bars abs.

Pressure sensor type

External Piezo-resistive sensor

Temperature probe

Platinum probe - PT1000 class A according EN60751

Metering input (volume)

Low frequency type (2Hz max.)

Cables length

LF volume

: 0.8 m or 2.5 m

5

Pressure

: 0.8 m or 2.5 m

Temperature : 0.8 m or 2.5 m ‘CE’ marking

Conformity to : -

EMC directive (89/336/EEC)

-

ATEX directive (94/9/EC)

-

MID directive

(2004/22/EC)

Electromagnetic class

E2

Mechanical class

M2

Humidity

Designed for non-condensing humidity

ATEX classification

II1G ia IIC T4

Enclosure material

Poly-carbonate

Enclosure dimensions (cm)

22.2 x 14.5 x 8.6

Total weight (approx.)

1.5 kg

Display

Graphic

Keyboard

5 keys

Communication ports

Standard : RS232 & Optical Option

Communication protocols

: RS485 – 2 channels or PSTN modem

IFLAG (based on IEC 62056-21 also know as EN61107) Modbus RTU Slave mode for both protocols

Nature of measured gas

Fuel gases of the first and second family according EN437

Units of main data

Pressure (absolute): bar, Psi, kPa

Firmware

Temperature

: °C , °F

Volume

: m3, Cft

Compliant with WELMEC 7.2 guide according following modules: - ‘P’ : Embedded software - ‘I’ : Instrument specific requirements (converter) - ‘S’ : Software separation -------------------------------------------------------------------2 separate micro-controllers (µC) :  M16C µC (CPU board)  Metrological kernel  Non-metrological application  XEMICS µC (I/O board)  Metrological firmware (analogue measurements)

6

1.4 Overall dimensions (in mm)

1.5 Main components

Programming Programming Switch Connector

Display

Fuse

Battery Connector

Battery

A m 0 5 2 EULAV rab 8 9 6 .5 1 C° 5 . 3 1 5 3 00 . 1 4 5 46 . 5 3 h /3 m 6 5 .4 5 5 1 h / mN 6 9 .3 4 8 1

= P = T = 0Z/Z = C = mQ = bQ

Customer Switch

Metrology Shield

1 2

1 2

Keyboard Connection

3

4 5 6

3 4

5 6

1 2

1 2 3

3

125mA

4

1

2 3 4

5 6

7 8

9 10

1 2

3 4 5

C Programming Connector

SRAM Memory

Extension Slot (J3 Connector) Flash Memory Optional board Fixing

7

2

SYNOPTIC OF THE PRODUCT Corus is delivered as an IP65 wall-mountable device designed in a tight polycarbonate enclosure. A hinge on the left of the box makes any operation in the field very easy, providing a clear access to all major parts of the product (terminals, switches, internal battery…) Corus features three electronic boards:  a display board, that includes the liquid crystal display  a 'CPU' board that holds the heart of the product (the microcontroller and its direct peripherals: RAM and flash memories…)  an 'I/O' board , that gathers all terminals, the pressure and temperature acquisition circuits, the LF and tamper inputs, the digital inputs and outputs, the RS232 port and the internal battery. Note: two components in Corus integrate firmware:  one micro-controller on the CPU board  one specific chip on the I/O board that is dedicated to pulse acquisition, pressure and temperature measurement.

2.1 Hardware architecture

2.2 Metrological sealing scheme The metrological sealing protects the access:  to all metrological components  to all connections to the sensors and to the meter  to the prog switch that is used to configure the access to metrological data (see §6.4)

8

The standard sealing is made up of two plates that cover respectively the CPU board and the metrological part of the I/O board. These plates can be sealed as indicated below:

1: metrological plate protected by seal 2: metrological plate protected by seal 3: inviolable metrological label

2.3 Customer sealing It is possible to place on the top-right corner and/or on the bottom-right corner of the box a nonmetrological seal (called customer seal) to prevent any access to the inside of the enclosure of Corus. Any attempt to open the box lets permanent visible marks on the seal or on the enclosure. This seal notably protects the access to:  the non-metrological interfaces  the customer switch that is used to configure the access to customer data (see §6.4)  the battery

1: customer seals

9

2.4 Metrological label A label is provided on the top of the product for the metrological marking and the CE marking. This label is inviolable: it cannot be unstuck without being destroyed. This label provides the following data:  product name  name of the manufacturer (Itron)  serial number of the device  manufacturing date  ambient temperature range  operating gas pressure range  gas temperature range  reference pressure  reference temperature  data related to MID metrological approval  data required by the potentially explosive atmospheres regulation  IP protection level  CE marking

Marking related to MID : Manufacturing year

M08

0102

T10323

Notified body number (Module D) Corus MID certificate number

Marking related to ATEX : 0081

II1G Ex ia IIC T4 - LCIE 03 ATEX 6165X

with internal optional PSTN modem:

0081

II 1/2 G Ex eiamb IIC T4 - LCIE 03 ATEX 6165X

10

3

METROLOGICAL MEASUREMENTS AND INPUTS/OUTPUTS

3.1 Temperature measurement Corus is provided with a four-wire Pt1000 temperature sensor that is in accordance with IEC/EN 60751 (1000Ώresistance at 0°C). Its four-wire mounting provides a high accuracy by eliminating the resistance of the cable. The temperature sensor has an IP67 protection level according to EN 60529 and is delivered with a cable length of either 2.50m or 0.80m. Its operating range (gas temperature range) is [-30°C ; +70°C]. The temperature measurement period is programmable from 1 to 30 seconds. When the display is ‘On’, this period is forced to 1 second. Whenever the temperature measurement goes beyond the operating range defined by two minimal and maximal temperature thresholds or whenever a temperature sensor failure is detected, a temperature metrological alarm is generated (see § 8.2.2).

3.2 Pressure measurement 3.2.1

T version

When used as a T converter, Corus uses a fixed pressure that is calculated according to the following formula:





pressure  1.01325 bara  gas.rel.press  1.202  104 bar/m  altitude where:  pressure  gas.rel.press  altitude 3.2.2

= = =

fixed pressure used for the T conversion gas fixed relative pressure to be programmed into the device altitude of the installation to be programmed into the device

PT and PTZ versions

When used as a PT or PTZ converter, Corus is provided with an external absolute piezo-resistive pressure sensor providing a rangeability higher than 11. Three (3) operating pressure ranges are available: 

0.9 bara to 10 bara



3 bara to 30 bara



7.2 bara to 80 bara

The sensor is enclosed into a stainless steel enclosure and has an IP66 protection level according to EN 60529. It can withstand an overpressure of 1.25 times its maximal pressure (12.5, 37.5 or 100 bara) for 30 minutes. It is equipped with a G1/4 (BSP) male terminal that allows its direct connection to the gas meter or to the gas pipe. It is delivered with a cable length of either 2.50m or 0.80m. All pressure sensors are delivered with their own characterization coefficients (12) that must be programmed into the converter so that the accuracy required by EN 12405-1/A1 can be reached over the whole pressure and temperature range.

11

The pressure measurement period is programmable from 1 to 30 seconds. When the display is ‘On’, this period is forced to 1 second. Whenever the pressure measurement goes beyond the operating range defined by two minimal and maximal pressure thresholds or whenever a pressure sensor failure is detected, a pressure metrological alarm is generated (see §8.2.1).

3.3 Compressibility ratio calculation Corus can be programmed to display either Zb/Zm or Zm/Zb (this choice is a metrological parameter). 3.3.1

T and PT versions

When configured as a T or PT converter, Corus uses a constant value as compressibility factor. This value (Zb/Zm or Zm/Zb fixed ratio) can be set by the user. 3.3.2

PTZ version

Corus calculates the compressibility factor:  every 1s to 30s (programmable period) if the display is off (same period than for P and T acquisition)  every second if the display is on When configured as a PTZ converter, Corus computes the compressibility ratio of the gas using one of the following formulas:  S-GERG88  AGANX19 standard  AGANX19 modified  AGA8 Gross method 2  AGA8 Detailed method  16 Coefficients (Table of Z) According to the selected formula, the following data are necessary and must be programmed into the device:

S-GERG %CO2



%N2 %H2 HSV (Cv) Specific gravity Prd Trd Full composition 16 coefficients

  

AGANX19 (Std. or Mod.)

AGA8 GM2

 

 



  

AGA8 Detailed

Table of Z

 

12

According the selected formula, gas composition has to be compatible with the following ranges: S-GERG:    

0% 0% 0.55 5.27

AGANX19 (Std or mod.): < < <
16:00 14:00 > 15:00 13:00 > 14:00 12:00 > 13:00 11:00 > 12:00 14/08/2002

previous record back to date selection

choose selected record

back to date selection

next record

2/24

Data INDEX

VALUE

Time UV CV UV (Al) CV (Al)

ALARM

DATA

CONFIG

: 60 mn : 152.000 m3 : 165.395 Nm3 : 0.000 m3 : 165.395 Nm3

Hourly 16/08/2002 21:00 > 22:00

scroll up

back to record selection

back to record selection

scroll down

1/18

50

CONFIG MENU Config menu INDEX

VALUE

ALARM

DATA

CONFIG

Communication Volume Metrology Date/Time Supply Output 1 Output 2

Communication

OK for modification

Selection with up and down keys + OK

Selection of the digit with left and right keys Adjustment of value with up and down keys

Volume INDEX

VALUE

ALARM

DATA

CONFIG

INDEX

VALUE

ALARM

DATA

CONFIG

Current value UV Index : 000143.000 m3 è

Pulse weight : 1.000 m3 è UV Index : 000143.000 m3 CV Index : 000165.321Nm3

è

000185.000

OK for validation

Selection with up and down keys + OK

Selection of the digit with left and right keys Adjustment of value with up and down keys

Metrology INDEX

VALUE

ALARM

DATA

CONFIG

INDEX

VALUE

ALARM

DATA

CONFIG

Current value Gas rel. density : 0.57000

OK for validation

0.57000 è

C02 : 1.8 % N2 : 0.6%

è

Pb : 1.01325 bar Tb : 273.15 K

è Gas rel. density : 0.57000

Selection with up and down keys + OK

Selection of the digit with left and right keys Adjustment of value with up and down keys

Date/Time INDEX INDEX

VALUE

ALARM

DATA

CONFIG

è Date: 07/06/2003 07:43:00

VALUE

ALARM

DATA

CONFIG

Current value Date : 07/06/2003 07:43:00

07/ 06/2003 07:43:00 è

OK for validation

OK

Selection of the digit with left and right keys Adjustment of value with up and down keys

Supply INDEX

VALUE

ALARM

DATA

CONFIG

Battery : 1794 days è Mode : Battery

INDEX

VALUE

ALARM

DATA

CONFIG

Current value Mode : Battery è

OK for validation

è

Battery

Selection with up and down keys + OK

Selection with up and down keys

51

Output 1 or 2 INDEX

VALUE

ALARM

DATA

CONFIG

Mode : Unconv. Pulse è Pulse Weight : 1.000 m3

VALUE

ALARM

DATA

Current value Pulse Weight : 1 m3 è

Time closed : 250 ms

INDEX

OK for validation

è

1.000 m3

CONFIG

Selection with up and down keys + OK

Selection of the digit with left and right keys Adjustment of value with up and down keys

52

10

SAFETY INSTRUCTIONS

10.1 General Corus gas volume converter is approved according to 94/9/CE directive (ATEX) relative to introduction of material in explosive atmosphere area. The respect of this directive is mandatory (from July, 1st 2003) and is included in the 'CE' marking. Thus, 'CE' marking of Corus implies now conformity with the following directives: 94/9/EC (ATEX), 89/336/EEC (EMC) and 2004/22/EC (MID).

10.2

Marking relative to ATEX - Zone

CORUS is approved as category 1 equipment and is thus suitable for use in zone 0 (areas with permanent presence of gas). The corresponding marking is:

0081 LCIE 03 ATEX 6165X

II1G Ex ia IIC T4

The ambient temperature range for operation is: -25°C; +55°C

10.3

Specific Instructions

►

To avoid erroneous operations, it is recommended to read the whole operating manual before commissioning.

►

Corus is suitable for being used with gases belonging to ‘IIA’, ‘IIB’ and 'IIC' classification gases, but : 

Use with hydrogen is forbidden. (Hydrogen implies specific tightness elements).



Use with oxygen is strictly forbidden. (Oxygen is not covered by ATEX)

►

The connection of Corus to any other instrument or device must be done in accordance to the electrical parameters indicated on the certificate.

►

It has to be noted that the directive 1999/92/EEC ("Installation / Users") has also to be respected for the commissioning of the device.

►

When Corus is used in the external power supply mode, the supply has to be provided through an intrinsically safe module with electrical compatible parameters; Use of any other type of module is strictly forbidden. In this mode, the main battery remains plugged inside Corus in case of external mains failure.

►

When using the battery mode, it is allowed to change the battery on site, by plugging the new battery on the free connector (J7 or J8 of the I/O board) and then, removing the old battery. It’s strictly forbidden to leave Corus with two batteries permanently plugged in hazardous area.

Caution: The battery of Corus includes all protections required for intrinsic safety. Thus, it is strictly forbidden to replace the battery unit by any battery other than the one specified by Itron (reference: LS33600 from Saft , SL2780 from Sonnenschein or TD5930 from Tadiran) ►

Battery warning : The battery of Corus contains Lithium :  Fire, explosion and severe burn hazard

53

   ►

Do not recharge, short-circuit, crush, disassemble, heat above 100°C (212°F), incinerate or expose contents to water Do not solder directly to the cell Respect storage recommendations (-30°C ; +60°C)

To prevent any damage, the following operations are recommended to limit electrostatic discharges on the enclosure of Corus : -

wipe only with a wet cleaning rag

-

the person carrying out the installation can discharge himself/herself by touching the potential equalization line

54

11

MANUFACTURING

Corus is manufactured by : Itron GMBH Hardeckstrasse 2 76185 Karlsruhe Germany

The site has ISO9001, ISO14401 certifications as well as certifications to produce Corus with ATEX and MID markings.

55

12

APPENDIX 1: INITIAL ATEX CERTIFICATE

56

57

58

13

APPENDIX 2: EC DECLARATION OF CONFORMITY

59

60

61

62