Corus Gas volume converter
Installation guide V2.6
TABLE OF CONTENTS 1
INTRODUCTION .......................................................................................................................................................... 1.1 1.2 1.3 1.4 1.5
2
3
SYNOPTIC OF THE PRODUCT
7
...................................................................................................................................... 8
METROLOGICAL SEALING SCHEME ....................................................................................................................................................... 8 CUSTOMER SEALING......................................................................................................................................................................... 9 METROLOGICAL LABEL .................................................................................................................................................................... 10
............................................................................................................................................................... 8
METROLOGICAL MEASUREMENTS AND INPUTS/OUTPUTS .....................................................................................11 TEMPERATURE MEASUREMENT ......................................................................................................................................................... 11 PRESSURE MEASUREMENT ............................................................................................................................................................... 11 COMPRESSIBILITY RATIO CALCULATION ............................................................................................................................................... 12 CONVERSION FACTOR CALCULATION .................................................................................................................................................. 13 VOLUMES METERING ..................................................................................................................................................................... 13
NON-METROLOGICAL M EASUREMENTS AND INPUTS/OUTPUTS............................................................................16 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
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
7
HARDWARE ARCHITECTURE
5.1 5.2 5.3 5.4
6
3 5
2.2 2.3 2.4
4.1 4.2 4.3 4.4 4.5 4.6
5
3
2.1
3.1 3.2 3.3 3.4 3.5
4
3
PRODUCT PRESENTATION .................................................................................................................................................................. OPERATING PRINCIPLE ...................................................................................................................................................................... MAIN CHARACTERISTICS.................................................................................................................................................................... OVERALL DIMENSIONS (IN MM) .......................................................................................................................................................... MAIN COMPONENTS ........................................................................................................................................................................
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
FIRMWARE STRUCTURE ................................................................................................................................................................... 29 FIRMWARE IDENTIFICATION ............................................................................................................................................................. 30 FIRMWARE PROTECTION AND DATA CONTROL (CRC) ............................................................................................................................. 30 DATA PROTECTION – DATA ACCESS ................................................................................................................................................... 31
7.5
I
NDEX DISPLAY FORMAT .................................................................................................................................................................. 32
8
FUNCTIONAL DESCRIPTION .......................................................................................................................................33 8.1 8.2 8.3
9
DATABASE ................................................................................................................................................................................... ALARMS ...................................................................................................................................................................................... ALARMS RESET .............................................................................................................................................................................
33 36 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 Pb
Tb Zb Vm C Vm 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.
Pressure sensor type
Sensor : 7.2 – 80 bars abs. 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
: m , Cft
3
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 . 31 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 3
4 5 6
1 2 3 4 5 6
Keyboard Connection
Programming Connector
SRAM Memory
1 2
3
1 2 3 4
125mA 1
2 3 4 5 6
7 8 9 10
1 2 3 4 5
C
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…)
antamper 'I/O' board , that gathersinputs all terminals, the pressure temperature acquisition circuits, the LF and inputs, the digital and outputs, the RS232and 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/OU TPUTS
3.1
Temperature measurement
Corus is provided with a four-wire Pt1000 temperature sensor that is in accordance with IEC/EN 60751 (1000 Ώresistance 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 1.202 104 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
AGANX19 (Std. or Mod.)
AGA8 GM2
Prd
Trd
Full composition 16 coefficients
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.): < < < <
%CO2 < 30% %H2 < 10% SG < 0.9 Cv (kWh) < 13.33
AGA8 (Gross method):
0% 0% 0.55
< < <
%CO2 < 30% %N2 < 50% SG < 0.9
0%
<
C5H12
<
0,5%
0% 0.55 0.55
< < <
C6 C7
< < <
0,1% 0.05% 0.05%
0% 0% 0.55
< < <
%CO2 < 30% %N2 < 50% SG < 0.9
0%
<
CO2
0% 0% 0%
< < <
N2 H2 CO
AGA8 (Detailed method):
70%
<
CH4
<
100%
0% 0% 0%
< < <
C2H6 C3H8
< < <
10% 3,5% 1,5%
C4H10
C8+
< <
20% 20% < 10% < 3%
Table of Z: The 16 coefficients are provided by Itron according the required gas.
3.4
Conversion factor calculation
Corus calculates the conversion 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
The calculation is done according to the formula defined in EN 12405-1/A1: C
Pm Pb
Tb Zb Tm Zm
The reference pressure Pb and the reference temperature Tb must be programmed into the device.
3.5
Volumes metering
Corus manages two volume indexes and two under alarm volume counters: an unconverted index a converted index an under alarm unconverted counter a total converted counter
The two indexes are available in the 'INDEX' menu of the display, whereas the under alarm unconverted counter and the total converted counter can be found in the 'ALARM' menu (see §9.2).
13
3.5.1
Main LF input and unconverted volumes
Corus features a low frequency (LF) input that can work up to 2 Hertz and that is used to meter the unconverted volumes. The pulses sent by the meter on this input (called “main LF input” or LF1) are balanced by the input pulse weight and are added to the unconverted index. The input pulse weight can be chosen among the following values: 3 0.001 m /pulse 3 0.01 m /pulse
3
0.1 m 3 /pulse 1 m /pulse 3 10 m /pulse 3 100 m /pulse
The LF input can be associated to any gas meter that outputs LF signal or to any device that provides an electrically compliant interface: dry contact static relay open collector or open drain output
For its connection to the meter, it shares the same terminals (J3 and J4) and the same cable as the coherence LF input (see §4.1) and as the tamper input (see §4.2). Corus can be delivered with several different LF cables, in order to comply with all existing types of meter connections. All cables are available with length of 0.80m or 2.50m.
3.5.2
Converted volumes
After every conversion, Corus updates its converted volumes: the converted index and the total converted counter are increased by the unconverted volume metered since the last conversion balanced by the conversion factor.
3.5.3
Under alarm operation
As long as a metrological alarm is in progress, volumes are managed as specified in EN 12405-1/A1: the unconverted main index continues to be incremented the under alarm unconverted counter is incremented metering on the converted main index is stopped the total converted counter is incremented during the alarm using a conversion factor based on pressure and temperature back-up values, if this function is activated with programmed values.
Twelve monthly temperatures and one pressure back-up values are available. They can be either:
programmed by the user automatically calculated by Corus from stored data (using the database)
14
normal operation
operation under alarm
unconverted index
Incremented
Incremented
converted index
Incremented
Stopped
under alarm unconverted counter
Stopped
Incremented
total converted counter
Incremented
Incremented with back-up values
15
4
NON-METROLOGICAL MEASUREMENTS AND INPUTS/OU TPUTS
4.1
Tamper input
Corus manages an on/off tamper input that allows to detect any magnetic violation attempt on meters that are equipped with an anti-tampering reed contact. This input shares the same terminals (J3 and J4) and the same cable as the main LF input. Tamper input can be set to one of the following modes: disabled normally open (NO) normally closed (NC)
When the input is enabled and not in its normal state, the device generates a tamper alarm that is not metrological and that does therefore not impact the management of the unconverted and converted indexes.
4.2
Coherence LF input
Corus features a second LF input called “coherence LF input” or LF2. This input shares the same terminals (J3 and J4) and the same cable as the main LF input. It allows checking of good operation of the metering function and of the pulse emitter of the meter. If this function is activated, Corus constantly compares the number of pulses metered on both LF inputs and generates a coherence alarm as soon as the spread between both inputs exceeds a programmable threshold within a programmable period of time. The coherence LF input and the coherence alarm are not metrological: they have no effect on the unconverted and converted indexes.
4.3
On/off inputs
Corus features two on/off inputs that can be connected to different types of intrinsically safe interfaces: reed contact static relay open collector or open drain output
The field of use of these inputs includes the connection to a safety valve to a delta pressure filter status or to a station door opening contact. On/Off inputs can be set to one of the following modes: disabled normally open (NO) normally closed (NC)
When any on/off input is enabled and not in its normal state, the device generates a non-metrological alarm.
16
4.4
On/off outputs
Corus features two on/off outputs that can be each configured: as an unconverted volume pulse output as a converted volume pulse output as a total converted counter pulse output as an alarm output (standard mode) as an alarm output (limited mode) as a 4/20 mA output (with external F/I converter) 1Hz clock signal “End of period” signal
4.4.1
Volume pulse output mode
When configured as unconverted or converted volume or total converted counter pulse outputs, on/off outputs behave like the LF outputs of a meter: they are individually characterized by a pulse weight that can be configured to any value greater than or 3 3 3 equal to the input pulse weight (see §3.5.1) among 0.001 m /pulse, 0.01 m /pulse, 0.1 m /pulse, 1 3 3 3 m /pulse, 10 m /pulse, 100 m /pulse they generate a pulse every time the corresponding (unconverted or converted) index gets increased by a value equal to the selected output pulse weight.
The closing time of the volume pulse outputs can be programmed (default value is 250ms). Maximal frequency of outputs is 2Hz. Base volume outputs are automatically disabled as long as any metrological alarm is active.
4.4.2
Alarm output mode
Each alarm can be individually configured to activate the alarm outputs when triggered. The activation duration of the alarm outputs can be selected. The alarm outputs can remain active: either as long as any alarm is active (standard mode) or as long as any alarm is active with a duration limit of 30 minutes (limited mode)
4.4.3
4-20mA mode
The On/Off outputs of CORUS can be configured as 4/20mA outputs. This option requires the use of an ® external frequency to current converter (model KFU8-UFC-EX1D from Pepperl&Fuchs ) and an external power supply for Corus.
The analogue measurement to be transmitted can be selected among:
Pressure
Temperature
Unconverted flow rate
Converted flow rate
Only one of the above analogue measurements can be transmitted per output. A more detailed installation guide can be provided for this function.
17
4.4.4
1Hz clock signal
When selected, the Corus provides permanently a 1Hz square signal (50% duty-cycle) on the corresponding output. Caution: It is recommended to use this function with an external power supply or during a short period if the Corus is powered by its internal battery only.
4.4.5
End of period signal
When selected, the Corus provides on the selected output a pulse (duration programmable from 1 to 60 seconds) at each completion of a database period (programmable among Interval, Hourly, Daily, Monthly)
4.5
Instantaneous flows
Corus calculates every second the gas instantaneous unconverted and converted flows: the unconverted flow is derived from the incoming main LF signal the converted flow is calculated from the unconverted flow balanced by the conversion factor
Theses flows are indicative, not metrological. If the function is activated, every time they are updated, the instantaneous flows are compared respectively to: a minimal and maximal unconverted flow threshold a minimal and maximal converted flow threshold
When a flow rate leaves the range defined by the corresponding threshold, a flow alarm gets active.
4.6
Second pressure (optional board)
A Second pressure board can be used in hazardous area. This pressure measurement is not metrological. The sensors managed by this board are:
CORUS sensor 0.9-10 bara
CORUS sensor 3-30 bara
CORUS sensor 7.2-80 bara
Other compatible gauge or absolute sensors compliant with the ATEX parameters of this board.
18
5
COMMUNICATION Corus provides two (2) communication ports that can be used simultaneously: an optical port a RS232 port
Optionally, a board can be plugged on the CPU board slot. Following communication boards (ATEX) are available : an internal PSTN modem a 2-channel RS485 board
For more details, please refer to the corresponding operating manuals for each optional board. Additional board operation with communication ports (modem or RS485) can operate simultaneously. RS232, internal PSTN modem and RS485 ports can communicate with both protocols IFLAG and Modbus RTU (both in slave mode). IFLAG is always activated and is used also for the communication on the optical port. Modbus protocol can be activated separately for each of above mentioned ports. Both protocols can be active on the same port. Corus is able to identify the protocol that the master is using to communicate.
5.1
Optical port
Corus provides an asynchronous serial optical port that is compliant with the optical head used with existing Itron gas products. This port can be used for serial asynchronous (start-stop) half-duplex communications. It operates at 1200 baud, 2400 baud, 4800 baud, 9600 baud. A disc made into a magnetic material is fixed under the cover and allows the mechanical fixing of the optical head. The presence of an optical head is magnetically detected. This allows the optical port to be by default in a power-down mode and to wake up automatically when necessary. In case of failure, the magnetic detection can be overridden by turning on the user interface.
5.2
RS232 port
Corus features an insulated RS232 port that can be used for: local communication with a laptop through an intrinsic safe isolation remote communication through an external modem (either through an IS associated modem or through an IS barrier connected to a standard modem)
The RS232 port provides the following signals: transmitted data (TxD) received data (RxD)
data terminal ready (DTR) As it is insulated, it needs to be externally supplied by a voltage between 6V and 12V. The terminals (J6) that correspond to the serial port are located in the customer area:
19
J6.1
TxD
J6.2
RxD
J6.3
DTR
J6.4
Supply+
J6.5
Supply-
The RS232 port can be used for serial asynchronous (start-stop) full-duplex communications. It operates at 300 baud, 1200 baud, 2400the baud, 4800 baud, 9600 baud, a19200 baud. The RS232 port is by default in aa power-down mode. When connected device initiates communication, it has to take into account wake up time of a few milliseconds. The intrinsic safety interface for the RS232 of Corus, proposed by Itron, is the ISB+. For more details see the manual of this product.
5.3
Internal ATEX PSTN modem (optional board)
Corus internal modem board is ATEX certified (approved according to 94/9/EC directive related to introduction of material in explosive atmosphere area). Corus equipped with its internal modem board is approved as category 2 equipment and is then suitable for use in zone 1. The main characteristics of the internal modem board are:
ATEX internal PSTN Modem for Corus Connection to the optional slot (J3 – CPU board) Chip Modem V32 bis (max.14400 bauds) Communication protocol depending on the application
The modem can be used when Corus is powered by battery or external power supply.
5.4
2-Channel RS485 (optional board)
The RS485 board can be used in hazardous area and up to 4 Corus can be connected to the same bus (for RTU, modem, gas analyzer…). The maximal distance between the modem (or RTU) in safe area and Corus, depends on the number of Corus (1 to 4) and the electrical characteristics of the cable (linear L, C) and is, in any case, 200m at the most. The user can select the speed and other communication parameters for each of the two ports, including the choice of the protocol (Modbus, I-Flag). The board can be used when Corus is powered by battery or external power supply.
Main characteristics: ATEX internal board with two independent RS485 ports ATEX compatibility with a maximum of 4 Corus connected on the same RS485 bus and a maximum distance of 200m with the IS interface Connection on the optional slot (J3 – CPU board)
20
Two wires passive RS485 ports half-duplex Simultaneous communication on all ports without restrictions Configurable speed up to 38400 bauds Communication protocol depending on the application
The two ports are passive meaning that they must be powered by the intrinsic safety interface that will be connected on Corus. Each port is isolated separately and can be connected to two different types of devices (modems, RTUs, PCs, etc). Suggested intrinsic safety interfaces are: ISB+ (Itron) for both data signals and port powering
or
the barrier Z961 (from Pepperl &Fuchs) for data signals the BXNE31 (from Georgin) power supply for powering the port.
A separate power supply and barrier must be used for the second port.
21
6
INSTALLATION, COMMISSIONING AND MAINTENANCE
6.1
Fixing
Corus enclosure features four lateral holes (diameter 5.2mm) for wall-mounting or for mounting on special plate. Product shall be installed in a place protected from direct exposure to sunlight and rain. Following the installation procedure, Corus has to be carefully closed using the four screws placed on each corner. All cable glands have moreover to be tightened enough. These two actions are mandatory to achieve a correct water tightness of the enclosure.
Important notice: Cable glands must be screwed exclusively by hand.
6.2
Connectors and terminals
r o s n e s 2 P r o s u b
: t u p n i l a n o it p
r o s n e s T
r o s n e s P
le b a c r e p m a t d n a F L
5 8 4 S R r o
O
1 # t u p t u o e ls u P
). t p o ( y l p p u s r e
2 # t u tp u o e ls u P
–
S R
w o p l a n r e t x E
–
ff O / n O
2 3 2
ff /O n O
e n li
N T S P
J3 Meter
J1 T sensor d e h S 1
e h
d e 2
d e
3
1
4
2 n P
e h
5
3 w o e Y
d e h S 1
5 n w o B
P sensor J2
1
6 e h
n e e G
2
2 w o e Y
d e h S
e G
B
6
4 e G
nw o
3 e h
5
3
Meter J4
6
J
1 2 3 4 5 6 7 8 9 10
4 n P
J
n e e
T
T
T
T
T E
1 2 3 4 5 T E
D T
D
T D
V
V
G
On / Off Inputs
On / Off Outputs
Ext. Pow.
RS 232
22
6.2.1
Pressure and temperature sensor J1.1
6.2.2
6.2.3
6.2.4
shield (T sensor)
J2.1
pink (P sensor)
J1.2
red (T sensor)
J2.2
yellow (P sensor)
J1.3
white (T sensor)
J2.3
gray (P sensor)
J1.4
red (T sensor)
J2.4
brown (P sensor)
J1.5
white (T sensor)
J2.5
white (P sensor)
J1.6
shield (P sensor)
J2.6
green (P sensor)
J3.1
Tamper + (brown)
LF cable
J3.2
Tamper (gray) –
J3.3
shield (LF cable)
J4.1 J4.2
LF1 + (yellow) LF1
– (white)
J4.3
LF2 + (pink)
J4.4
LF2 – (green)
On/off inputs, on/off outputs, external power supply J5.1
on/off in1+
J5.2
on/off in1-
J5.3
on/off in2+
J5.4
on/off in2-
J5.5 J5.6
on/off out1+ on/off out1-
J5.7
on/off out2+
J5.8
on/off out2-
J5.9
ext.supply+
J5.10
ext.supply-
J6.1
TxD
RS232 interface
J6.2
RxD
J6.3
DTR
J6.4 J6.5
Supply+ Supply-
23
6.3
Installation of the sensors
6.3.1
Temperature sensor
The temperature sensor has to be placed into a protective thermowell at a point of the pipe where the measured temperature is representative of the gas temperature through the meter. The generally accepted installation conditions are: distance from the meter: less than 1 meter position: downstream for turbines immersion : 1/3 to 2/3 of the internal diameter of the pipe
The presence of a second thermowell located close to the first one is recommended to check Corus temperature measurement, using a reference thermometer, without having to remove the probe.
6.3.2
Pressure sensor
The pressure sensor connector has a G1/4 (BSP) male terminal. It must be preferentially screwed to the "Pr" reference pressure tap of the meter: either directly (through a mechanical adapter if necessary) or through a 3-way valve (which will avoid any modification of the installation during the periodical check of the sensor)
If a failure of the pressure sensor makes it mandatory to change it, the pressure coefficients have to be reprogrammed with the ones delivered with the new sensor. If Corus is in operation during the change, a pressure alarm will be generated. The pressure sensor features two (2) holes allowing the sealing the sensor with the meter installation.
Important notice: - The pressure sensor has a gland for its cable which shall not be screwed or unscrewed by the user. Any additional screwing can damage the wires of the cable. - When connecting the sensor on the meter, the cable of the sensor shall not be twisted. Twisting the cable can damage the wires of the sensor permanently. Sensors shall be mounted either by using an adaptor which allows the sensor to be screwed without turning its body, either by dismounting the sensor from Corus, screwing it to the meter (by turning the body of the sensor together with the cable), then reconnecting it to the Corus. 6.3.3
LF cable
The LF cable provided with the CORUS has to be connected directly to the LF output plug of the gas meter. The various LF cable (Binder plug ) available are :
Type 1 :
Type 2 :
Type 3 :
Type 4 :
Pins 1-4 : LF1 Pins 2-5 : LF2
Pins 4-6 : LF1 Pins 3-5 : LF2
Pins 1-2 : LF1 Pins 5-6 : LF2
Pins 1-4 : LF1 Pins 2-5 : LF2
Pins 3-6 : Strap
Pins 1-2 : AT
Pins 3-4 : AT
Pins 3-6 : AT
Each LF cable binder plug features two (2) holes allowing sealing the CORUS cable to the meter installation.
24
6.4
Power supply
Corus can be supplied either: by its internal battery by an external power supply
6.4.1
Internal battery
Corus is delivered with a 16.5A.h D-size lithium battery that provides autonomy for 5 years in average conditions. This battery includes all protections required by intrinsic safety and cannot be changed for a different type. When the battery reaches the end of its life, it has to be replaced according to the following procedure that ensures a non-stop operation of the product: do not provoke short-circuits on the new battery : it would be definitively damaged check the voltage of the new battery : it should be above 3.6V open the cover of Corus box connect the new battery on the free battery connector (J7 or J8) disconnect the old battery and remove it from the battery support put the new battery into the battery support reprogram the battery life to its nominal value (1825 days) close the enclosure and check Corus
6.4.2
External power supply
Corus can also be supplied by an external intrinsic safety associated module from: a 220 VAC mains a 24 VDC mains
The corresponding module has to be connected to the right hand side of the terminal J5 (J5.9 and J5.10). The converter must then be configured in the 'external power supply' mode. In this mode, the internal battery has to remain plugged in case of external power cut. For safety reasons, it is strictly forbidden to use other modules than those specified by 'Itron'.
6.4.3
Autonomy
The table below shows indicative (see notes) autonomy of CORUS in years when using the battery mode, according the 3 main parameters: Acquisition period, Retransmissions, Communication.
25
Retrans
No Retrans.
F = 0,1 Hz
F = 0,5 Hz
F = 1 Hz
F = 2 Hz
Acq. Period 1 second
5 seconds
10 seconds
15 seconds
20 seconds
30 seconds
Comm. Duration
1
1
1
0,9
0,8
15min./ month
1
1
1
0,9
0,8
15min./ week
3,7
3,6
3,2
2,7
2,1
15min./ month
3,7
3,6
3,1
2,7
2,1
15min./ week
5,7
5,4
4,4
3,6
2,7
15min./ month
5,6
5,3
4,4
3,6
2,6
15min./ week
6,9
6,4
5,1
4,1
2,9
15min./ month
6,7
6,3
5,0
4,0
2,9
15min./ week
7,7
7,1
5,6
4,3
3,0
15min./ month
7,5
6,9
5,4
4,2
3,0
15min./ week
8,7
8,0
6,1
4,7
3,2
15min./ month
8,4
7,8
5,9
4,6
3,1
15min./ week
The same table can be given in number of days. The user must set the starting value of the counter of battery life time into Corus according to the corresponding conditions of use. By default the value programmed is 1825 days, meaning 5 years.
Retrans
No Retrans.
F = 0,1 Hz
F = 0,5 Hz
F = 1 Hz
F = 2 Hz
Acq. Period 1 second
5 seconds
10 seconds
15 seconds
20 seconds
30 seconds
Comm. Duration
365
365
365
329
292 15min./ month
365
365
365
329
292 15min./ week
1351
1314
1168
986
767 15min./ month 767 15min./ week
1351
1314
1132
986
2081
1971
1606
1314
2044
1935
1606
1314
949 15min./ week
2519
2336
1862
1497
1059 15min./ month
2446
2300
1825
1460
1059 15min./ week
2811
2592
2044
1570
1095 15min./ month
2738
2519
1971
1533
1095 15min./ week
3176
2920
2227
1716
1168 15min./ month
3066
2847
2154
1679
1132 15min./ week
986 15min./ month
26
Note 1: The values provided in this table correspond to typical values in average conditions of use. They are calculated with a 30% margin to take in account the possible variations of operating conditions that could affect the consumption of the product (temperature, humidity, self-discharge of the battery…)
Note 2: The frequency of retransmissions indicated in the table corresponds to average frequency on both outputs, when both channels are configured for pulses.
Note 3: In case of activation of a digital output as ALARM output, the consumption of the device can be impacted, especially in ‘Standard’ mode for which the output is activated as long as the alarm is active. Then, it is recommended to use preferably the ‘limited’ mode or to use CORUS with an external power supply module if ‘Standard mode’ is required.
Note 4: The values provided in this table correspond to a Corus without any optional board.
Note 5: The use of AGA8 detailed formula reduces the battery life time, due to increased calculation time necessary for this formula.
6.5
Programming
To program/modify parameters protected by the ‘programming’ switch, the following procedure has to be followed: Open CORUS Remove the seal of the white metrological cover, placed on the left part of the I/O board Put the ‘programming’ switch ‘On’ Program the required parameters (Keyboard or communication) Put the ‘programming’ switch ‘Off’ Place the metrological cover and seal it Close CORUS
To program/modify parameters protected by the ‘Client’ switch, the following procedure has to be followed:
Open CORUS Put the ‘Client’ switch ‘On’ Program the required parameters (keyboard or communication) Put the ‘Client’ switch ‘Off’ Close CORUS
27
6.6
Pressure and temperature adjustment on site
It is possible to adjust the pressure and temperature values through a “linearization function” available within Wincor software tool.
P’ = (a x P) + b T’ = (c x T) + d The coefficients a, b, c, d can be introduced in Corus, after an on-site verification, performed on 2 different operating measurement values.
P(theoretical_1) => P(measured_1) P(theoretical_2) => P(measured_2)
T(theoretical_1) => T(measured_1) T(theoretical_2) => T(measured_2)
=> Determination of ‘a’ and ‘b’
=> Determination of ‘c’ and ‘d’
The use of this function is subject to national regulations. Refer to your local authorities before using it.
28
7
MID: COMPLIANCE WITH WELMEC 7.2 GUIDE Corus complies with MID directive (2004/22/EC) and consequently to the corresponding harmonized standard, EN12405-1/A1. Additionally, the internal firmware of the product complies with the WELMEC 7.2 guide. This document provides guidance for software-equipped measuring instruments within the scope of the MID directive. Corus complies with the following requirement sets of this guide:
‘P’ : Embedded software
‘I’
‘S’ : Software separation
7.1
: Instrument specific requirements (converter)
Firmware structure
Corus firmware is split in to 2 separate microcontrollers but must be considered functionally as based on 3 parts:
F1: One metrological firmware dedicated to analogue measurements on the I/O board (‘metrol’). F2: One metrological firmware (‘kernel’) that controls the heart of the product and ensures the integrity of all metrological functions. F3: One non-metrological firmware managing all non-metrological functions (called ‘application’ ).
F2 and F3 are included into the same microcontroller on the CPU board.
µC1
F2 firmware (‘kernel’)
µC2
F1 firmware (‘metrol’.)
F3 firmware (‘application’)
CPU board
I/O board
So, the part of firmware which contains all legally relevant functions is clearly separated from other parts of firmware. The Kernel “manages” the non-legally relevant firmware tasks and the priority is given to the metrological tasks. Application firmware can be updated without breaking the metrology seals.
The Kernel integrates:
Metrological functions.
Management and protection of the metrological parameters.
Management and protection of the measurement data.
29
7.2
Protected interface with other parts of the firmware.
Backup of the metrological parameters and measurement data.
Verification of the kernel, parameters and data integrity.
Display of metrological measurements and parameters.
Firmware identification
It is possible to get information (version, date) related to the 3 different firmware versions in the first INDEX sub-menu. INDEX
VALUE
ALARM
DATA
CONFIG
06/09/2008 14:00:00 Kernel : Kr1.00 13/04/ 07 Metrol : Met1.00 19/02/03 Appli : Ver5.00 12/08/08
7.3
Firmware protection and data control (CRC)
To ensure the integrity of metrological firmware and associated parameters, Corus manages 4 CRC (cyclic redundancy code):
Metrological firmware CRC check (‘Metrol’ and ‘Kernel’) : Corus checks every hour the CRC of the 2 metro logical firmware parts (‘Metrol’ and ‘Kernel’) and displays the CRC value. If the result is not OK, a specific icon (
CRC
) is displayed.
Note: when this screen is active, it is possible to proceed to a “live” CRC calculation check by pressing the “OK” key for 2 seconds. The upload of the ‘Kernel’ and ‘Metrol’ firmware is protected by the programming switch. Then, no change of the metrological firmware is possible without breaking the metrological seal. In case of error, a CRC alarm is generated and the corresponding event is provided to the application for storage.
Parameters CRC check : Corus manages a CRC related to all metrological parameters (P & T thresholds, input pulse weight…). This CRC is checked every 10 minutes or is recalculated automatically when the value of such parameters is modified on request. In case of error, a CRC alarm is generated and the corresponding event is provided to the application for storage.
30
Index CRC check : Corus manages a CRC related to index & counters (converted and unconverted). This CRC is checked every second, corresponding to the refreshment period of the index. In case of error, a CRC alarm is generated and the corresponding event is provided to the application for storage.
INDEX
VALUE
ALARM
DATA
CONFIG
Kernel C RC : 0CAFE M e t rol C R C : 310EF Param CRC : F E4 7 Index CRC : OK Prog. switch : On Cust. s witch : Off Alarm P: Off Alarm T: Off
7.4
Data protection – Data access
All parameters and index access can be protected by a hardware and/or software protection, except main index (unconverted and converted), which are protected by hardware programming switch in any case. The read access is free and the write access can be protected by different means. The access level of each parameter is defined in a table called “Table protect”. The ‘table protect’ itself is protected by the programming switch, meaning that it is notossible p to modify
an access right without breaking the metrological seal of the product. Hardware protection:
Programming switch
This switch has to be turned ON before any change on parameters declared as protected by this switch. Access to this switch is protected by metrological seal and then prevent unauthorized access to metrological data
Client switch
This switch has to be turned ON before any change on parameters declared as protected by this switch. Access to this switch is protected by client seal (if any).
Software protection: Software protection modes are approved according MID requirements. This includes flexible management of password/keys/user groups for reading and programming. For more information please contact your local Itron office.
31
7.5
Index display format
In order to comply with the MID requirement stating that “the display shall have a sufficient number of digits to ensure that both unconverted and converted index incremented during 8000 hours at maximum conditions (Qmax, Cmax) do not return to its initial value ”, Corus display format is as follows, depending dynamically on the index value itself.
3
Value (m )
Format
00000000.000 000000000.00
Max < 99999999 99999999 < Max < 999999999 999999999 < Max < 9999999999
0000000000.0
9999999999 < Max < 99999999999
00000000000
99999999999 < Max < 999999999999
000000000000
Note : The raw and base indexes are displayed on the first screen. This screen is updated every second.
INDEX
VALUE
ALARM
DATA
CONFIG
Unconverted index :
00012345.000m3 Converted index :
00054321.100Nm3
32
8
FUNCTIONAL DESCRIPTION
Note:
The legally relevant firmware (‘Kernel’ & ‘Metrol’) is then approved under MID/ Welmec 7.2. Through the application of the ‘S’ requirements set, the rest of the firmware (‘Appli.) has no influence on metrology and can be adapted to various markets requirements (e.g : database, non-metrological alarms, communication protocol, display of non-metrological items, digital I/Os management, etc…)
8.1
Database
Corus manages six logs : an hourly log a daily log a monthly log an interval log an events log a parameters log
8.1.1
Hourly Log
The hourly log contains up to 1440 records (2 months data) that include:
the date and time the hourly unconverted consumption the hourly converted consumption the hourly under alarm unconverted consumption the hourly total converted consumption the value of unconverted index (end of period) the value of converted index (end of period) the value of under alarm unconverted counter (end of period) the value of total converted counter (end of period) the minimum, maximum and average gas temperature the minimum, maximum and average gas pressure the minimum, maximum and average second gas pressure (if P2 optional board) the minimum, maximum and average unconverted flow rate the minimum, maximum and average converted flow rate the status of the converter during the hour (presence of metrological alarms, Date/Time change)
8.1.2
Daily Log
The daily log contains up to 124 records (4 months data) that include: the date and time the daily unconverted consumption the daily converted consumption
33
the daily under alarm unconverted consumption the daily total converted consumption the value of unconverted index (end of period) the value of converted index (end of period) the value of under alarm unconverted counter (end of period) the value of total converted counter (end of period) the minimum, maximum and average gas temperature the minimum, maximum and average gas pressure the minimum, maximum and average second gas pressure (if P2 optional board) the minimum, maximum and average unconverted flow rate the minimum, maximum and average converted flow rate
the status of the converter during the day (presence of metrological alarms, Date/Time change) The user can introduce a "gas hour" in Corus. All daily consumptions are stamped from the gas hour to the gas hour of the next day.
8.1.3
Monthly Log
The daily log contains up to 24 records (2 years data) that include: the date and time the monthly unconverted consumption the monthly converted consumption the monthly under alarm unconverted consumption the monthly total converted consumption the minimum, maximum and average gas temperature the minimum, maximum and average gas pressure the minimum, maximum and average second gas pressure (if P2 optional board) the minimum, maximum and average unconverted flow rate the minimum, maximum and average converted flow rate the status of the converter during the month (presence of metrological alarms, Date/Time change) the value of the main unconverted index at the end of the month the value of the main converted index at the end of the month the value of the unconverted counter at the end of the month the value of the converted counter at the end of the month the maximum unconverted consumption during the month (interval) with corresponding date/time the maximum converted consumption during the month (interval) with corresponding date/time
The user can introduce a "Gas day" in Corus. All monthly consumptions are stamped from the gas day (at the gas hour) to the gas day of the next month (at the gas hour). The user can select the items to store in calendar logs (Hourly, Daily, Monthly) for each record. However some items will always be recorded and the user can’t unselect them. By reducing the number of items, the number of database records is increased. The fixed part of the databases includes: For the hourly and daily logs the unconverted consumption the converted consumption the under alarm unconverted consumption
34
the total converted consumption date/time and status
For the monthly log date/time and status the monthly unconverted consumption the monthly converted consumption the monthly under alarm unconverted consumption the monthly total converted consumption the value of the main unconverted index at the end of the month
the value of the main converted index at the end of the month
It’s to be noted that the user can select to store only the integer part of index values to save space in database.
8.1.4
Interval Log
This log is also made up of two parts: a fixed one a configurable one
The configurable part allows the user to build his own database structure according to his needs. The fixed part includes the following data: the date and time the interval unconverted consumption the interval converted consumption
the interval under alarm unconverted consumption the interval total converted consumption a status of the converter (presence of metrologic alarms, Date/Time change)
In the configurable part, the user can select the following fields: the minimum, maximum and average gas temperature the minimum, maximum and average gas pressure the minimum, maximum and average unconverted flow rate the minimum, maximum and average converted flow rate the value of unconverted index (end of period) the value of converted index (end of period) the value of under alarm unconverted counter (end of period) the value of total converted counter (end of period) the minimum, maximum and average second gas pressure (if P2 optional board)
The value of the interval is programmable among 1, 2, 3, 4, 5, 10, 15, 20, 30 and 60 minutes. The capacity of the interval log extends from 3100 (all optional fields selected) to 5900 (no optional field selected).
8.1.5
Events Log
Corus logs the occurrence of all main events (alarms, reset, switches change, programming…). For each event, the following data are available: Date and time of the event Nature of the event
35
Specific value (for some events only) Status
The events log has a capacity of 800 events and cannot be reset. It is circular: when it is full, every new event replaces the oldest one.
8.1.6
Parameters Log
Corus logs the modifications of the following key parameters: temperature specific data: alarm thresholds, … pressure specific data: alarm thresholds, coefficients, …
compressibility ratio specific data: gas composition, calorific value, … conversion specific data : formula, … volume specific data: index, input pulse weight, … database specific or related data: interval duration, gas hour and day…
In case of modification of one of the above parameters, the following information is stored: date and time nature of the parameter former value of the parameter new value of the parameter values of the unconverted and converted indexes
The parameters log has a capacity of 200 modifications and cannot be reset. It is circular: when it is full, every new modification replaces the oldest one.
8.2
Alarms
Metrological part of Corus manages alarms as described below. Others types of alarms depend on the application (non-metrological alarms) :
s m r la a l a c i g lo ro t e m
. p m e t
T low threshold T high threshold T sensor failure
e r u s s e r p
P low threshold P high threshold P sensor failure
s m r la a l e rn e k
l e rn e k
CRC 'Metrol' firmware CRC 'Kernel' firmware CRC 'Parameters' CRC 'Index' Metrol task
36
The rest of the alarms that are managed are:
s ld o h s r e th g in n r a W
. p m e t
T low threshold T high threshold
r u s s e r p
P low threshold P high threshold
d n o c e s
re u s s re p s t u p n i
s m r a l a r e h t O
P2 low threshold P2 high threshold P2 sensor failure pulse inputs coherence tamper input on/off input #1 on/off input #2
. v n o c
C factor low threshold C factor high threshold
.l o v
base cons. high threshold
w lfo
y l p p u s
unconv. flow flow high low threshold unconv. threshold base flow low threshold base flow high threshold remaining battery life alarm external power supply
37
8.2.1
Pressure alarms
Pressure alarms occur: when the gas pressure is out of the operating range [Pmin ; Pmax] when the pressure sensor is out of order.
Corus manages three pressure alarms: a pressure low threshold alarm a pressure high threshold alarm a pressure sensor failure alarm
These alarms are automatically disabled when a T conversion is used. When a pressure alarm occurs: the alarm icon and the 'P' icon are displayed (blinking while the alarm is active) the incrementing of the main converted index is stopped if the alarm is due to a pressure sensor failure : – pressure, compressibility and conversion factor are set to "not-available" on the display the total converted counter is incremented based on the back-up pressure value (if existing) the on/off outputs activated as alarm outputs are switched 'on' , if the corresponding alarms were configured for the alarm output the corresponding alarm is set into the 'ALARM' menu and is stamped in the events log
8.2.2
Temperature alarms
Temperature alarms occur: when the gas temperature is out of the operating range [Tmin ; Tmax]
when the temperature sensor is out of order. Corus manages three temperature alarms: a temperature low threshold alarm a temperature high threshold alarm a temperature sensor failure alarm
When a temperature alarm occurs: the alarm icon and the 'T' icon are displayed (blinking while alarm is active) the incrementing of the main converted index is stopped if the alarm is due to a temperature sensor failure : – temperature, compressibility and conversion factor are set to "not-available" on the display the total converted counter is incremented based on the back-up temperature value (if existing) the on/off outputs activated as alarm outputs are switched 'on' , if the corresponding alarms were configured for the alarm output the corresponding alarm is set into the 'ALARM' menu and is stamped in the events log
38
8.2.3
Kernel alarms
The kernel firmware manages 5 alarms related to the control of firmware and metrological parameters integrity:
Alarm ‘CRC Metrol’ : active if the CRC of the ‘Metrol’ firmware is not correct Alarm ‘CRC Kernel’ : active if the CRC of the ‘Kernel’ firmware is not correct Alarm ‘CRC Param’ : active if the CRC of the metrological parameters is not correct Alarm ‘CRC Index’ : active if the CRC of the Index is not correct Alarm ‘Metrol. task’ : active if the kernel metrological task duration is higher than 1 second. In any case, after 1 second, priority is given to the kernel and the corresponding application task is stopped.
8.2.4
Warning threshold alarms
Warning for pressure, temperature and second pressure input have no impact to the operation of Corus and their thresholds have no connection with thresholds for metrological P and T alarms. Warnings are set to monitor the functional operation of the station and therefore have no connection with metrology.
8.2.5
LF coherence alarm
This alarm can be enabled or disabled by programming. The user can program a number of pulses (Np) and duration (Dp). If the difference between the number of pulses on input LF1 and input LF2 is higher or equal to Np during a period Dp expressed in days (see §4.2), Corus generates an alarm. This alarm is not metrological, meaning that it does not impact the management of the unconverted and converted indexes. When the alarm occurs: the alarm icon is displayed the on/off outputs activated as alarm outputs are switched 'on', if the LF coherence alarm was configured for the alarm output the LF coherence alarm is set into the 'ALARM' menu and is stamped in the events log
8.2.6
Tamper alarm, on/off1 alarm, on/off2 alarm
These alarms can be enabled or disabled by programming. When enabled, the tamper input and the on/off inputs can be set as normally open or normally closed (see §4.1). Then, when Corus detects that an input is not in its normal state, the corresponding alarm is generated. When such an alarm occurs: the alarm icon is displayed the on/off outputs activated as alarm outputs are switched 'on', if the alarm was configured for alarm output the alarm is set into the 'ALARM' menu and is stamped in the events log
39
8.2.7
Conversion factor alarm
If this function is activated, Corus generates this alarm when the computed conversion factor gets out of a programmed range [Cmin ; Cmax]. This alarm is not metrological and is dedicated to the control of the whole metering chain. Corus manages two conversion factor alarms: conversion factor low threshold alarm conversion factor high threshold alarm
When a conversion factor alarm occurs: the alarm icon is displayed the on/off outputs activated as alarm outputs are switched 'on', if the alarm was configured for the alarm
output the conversion factor alarm is set into the 'ALARM' menu and is stamped in the events log
8.2.8
Converted consumption alarm
Corus sets this alarm when the converted consumption during a given interval is higher than a programmed threshold. The interval can be selected among: the current database interval the ongoing hour the ongoing day the ongoing month.
When the alarm occurs: the alarm icon is displayed the on/off outputs activated as alarm outputs are switched 'on', if the alarm was configured for the alarm output the alarm is set into the 'ALARM' menu and is stamped in the events log
8.2.9
Flow-rate alarms
Corus manages four flow alarms: unconverted flow low threshold alarm unconverted flow high threshold alarm converted flow low threshold alarm converted flow high threshold alarm
Every time the unconverted and converted instantaneous flows are calculated, their values are compared to four thresholds that are programmable by the user. If the function is activated, an alarm among the above list is set, if the corresponding flow-rate gets higher or lower than the threshold. When such an alarm occurs: the alarm icon is displayed the on/off outputs activated as alarm outputs are switched 'on', if the alarm was configured for the alarm output
the alarm is set into the 'ALARM' menu and is stamped in the events log
8.2.10 Battery alarm Every 24 hours, the internal battery counter is decreased of one day. When the counter reaches 10% of the nominal battery life (about 6 month (182 days) for a 5 years battery life), the battery alarm is generated.
40
When changing the battery, the battery counter has to be re-programmed so as to acknowledge the battery alarm. When the battery alarm occurs: the alarm icon is displayed the on/off outputs activated as alarm outputs are switched 'on', if the alarm was configured for the alarm output the alarm is set into the 'ALARM' menu and is stamped in the events log
The battery alarm is not metrological, meaning that when the battery alarm occurs, Corus keeps working until the battery is fully discharged.
8.2.11 External power supply alarm When Corus is supplied through external power, it is able to detect a mains cut. Then, this alarm is set as long as the external supply is not present. During the mains cut, the internal backup battery will ensure the normal operation of Corus and the battery counter will be decreased as described in the "battery alarm" chapter. When such an alarm occurs: the alarm icon is displayed the on/off outputs activated as alarm outputs are switched 'on', if the alarm was configured for alarm output The alarm is set into the 'ALARM' menu and is stamped in the events log
8.3
Alarms Reset
The alarms can be reset either via keyboard, or via software. This action is allowed according to data access rights that have been programmed in CORUS (see §7.4). Through keyboard : Go to the menu ‘ALARM’ Select reset Select all alarms Press OK to confirm
Through software Go to the ‘Reset alarms’ menu of the configuration tool Select type of alarm to be reset : Metrologic (P or T) and/or Non metrologic Click on ‘Prog’ button
Note 1: it is not possible to reset an active alarm, except the ‘Coherence’ alarm and the ‘Consumption threshold’ alarm.
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9
USER INTERFACE Corus features a graphic liquid crystal display and a five-key keyboard. The five keys allow scrolling through the various menus as described below. The interface architecture is based on five main menus: INDEX, VALUE and ALARM menus are always displayed. DATA and CONFIG menus can be displayed or not according configuration. INDEX
VALUE
ALARM
DATA
CONFIG
Also, Corus manages the following icons:
the turbine icon is refreshed every second and is: on if any pulse has been metered since the last screen refresh off otherwise
the bell icon: blinks when any alarm is active is on when any alarm is memorized but none is active is off when all alarms are off (neither active nor memorized)
the pressure icon: blinks when any pressure alarm is active is on when any pressure alarm is memorized but none is active is off when all pressure alarms are off (neither active nor memorized)
the temperature icon: blinks when any temperature alarm is active is on when any temperature alarm is memorized but none is active is off when all temperature alarms are off (neither active nor memorized)
the phone icon is: on when any communication is ongoing off otherwise
the plug icon: is off when CORUS is used in battery operating mode is on when CORUS is used in external supply mode and main power is present blinks when CORUS is used in external supply mode and main power is not present
the inner bar graph of the battery icon is set according to the remaining battery life time ratio in battery and external power mode (if there is a mains cut). it blinks when the battery alarm is active
the key icon:
is blinking when the shunt of optical port detection is activated.
is off otherwise
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9.1
Keyboard
The left/right arrow keys allow scrolling through the menus. Items can be selected using the 'OK' key. When the display is off, any press on a key puts the display on. Access to the DATA and CONFIG menus can be restricted according the application and the display configuration which is selected. After 2 minutes with no action on the keyboard, the display switches off. When pressing a key, the display automatically starts on the INDEX menu. When the display is on, the acquisition of pressure, temperature and the calculation of compressibility and conversion factor is performed every second.
9.2
Display
Below is shown the display sequence managed directly by the Kernel. Content and access to other(s) menu(s) depend on the application and the display configuration which is selected.
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Kernel Stand alone
INDEX
VALUE
ALARM
DATA DATA
CONFIG
Unconverted index :
00012345.000 m3 Conver ted index :
00054321.100 Nm3
VALUE
ALARM
Ke r ne l CR C Met r ol CR C Pa r a m CR C
DATA
INDEX INDEX
CONFIG
: 0CA FE : 31 0EF : F E4 7
2s
VALUE
ALARM
DATA DATA
ALA RM
DA T A
CON FI G
= 15. 698 bar = -13.5 °C = 1. 0035 = 5. 6454 = 250 days
Non-Metrological Add
Non-Metrological
CONFIG CONFIG
Kernel : Kr1.00 V1.00 13/04 Kernel: 13/04/07 /07 Metrol : Met1. V1.0000 08/07/02 19/02/03 App 3.00 25/1 2/0 7 Appllii : Ver Ve r5.00 12/08 /08
Non-Metrological Add
OK
OK INDEX
ALARM ALARM
13/04/07 06/09/2008 07:18:00 14:00:00
OK
In dog e x. C RiCtc h ::OK Pr sw On Cus t. switc h : Off Alarm P: Off Alarm T : Off
VALUE VALUE
VALUE
P T Zb/Z C Bat
OK
OK INDEX
INDEX
DATA
CONFIG
Serial N°: SC08000001234 ----------------P Serial N°: KB08060123 Pmin : 0.90000 bar Pmax: 10.00000 bar -----------------
Non-Metrological Add
T Serial N°: CB05080546
OK
Test LCD
9.2.1
'INDEX' menu
This menu provides access to the following items:
display of unconverted and converted index
adjustment of the contrast of the display.
display of date and time
display firmware versions and associated dates
display of the 4 CRCs managed by the kernel
status of metrological alarms (P and T)
status of ‘Prog.’ And ‘Client’ switches
display of main parameters (sensors serial numbers, P and T thresholds, type of conversion, input pulse weight,….)
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display test
When associated to an application, this menu (and associated sub-menus) can be enhanced with other(s) data.
9.2.2
'VALUE' menu
This menu displays the instantaneous values that are measured or calculated by Corus: pressure temperature compressibility factor
conversion factor battery life
When associated to an application, this menu can be enhanced with others data (flow-rates, second pressure P2,…), display of a graph, …
9.2.3
'ALARM' menu
The content of this menu depends on the application and the associated display configuration which is selected. As an example, this menu usually allows to: get information related to active alarms get information related to memorized alarms get information related to under alarm counters reset alarms
Active alarms The active alarms submenu displays the list of all active alarms. Using the up/down arrows and the OK keys, it is possible to get more details about a given active alarm (Start time-stamping)
Memorized alarms The memorized alarms submenu displays the list of all memorized alarms. Using the up/down arrows and the OK keys, it is then possible to get more details about a given memorized alarm (Start and End timestamping)
Under alarm counters This submenu displays the under alarm unconverted counter and the total converted counter.
9.2.4
Alarms reset
This submenu allows to reset all memorized alarms and/or the under alarm counters (according to the status of the prog switch for metrological alarms)
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9.2.5
'DATA' menu
The content of this menu depends on the application and the associated display configuration which is selected. For each active log, it is possible to consult the content of each record stamped in the corresponding log of the product.
9.2.6
'CONFIG' menu
The content of this menu depends on the application and the associated display configuration which is selected. This menu allows the user to program the main parameters of Corus, allowing a basic commissioning without laptop: Authorization to modify a parameter’s value through keyboard is related to the access rights (see §7.4)
Communication
Volume
Metrology
Date / Time
Supply
: Mode (battery, external) , autonomy
Digital Output 1
: Activation/Deactivation , type (pulse, alarm,4/20mA) , parameters
Digital Output 2
: Activation/Deactivation , type (pulse, alarm,4/20mA) , parameters
: Modbus protocol activation and communication parameters for each com port : Input pulse weight, unconverted Index, converted Index : Pbase, Tbase, Gas composition (according formula) : Current date / time
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INDEX MENU
Index menu INDEX
VALUE
ALARM
DATA
CONFIG
contrast+
Unconverted index :
m3 00012345.000 Converted index : 00054321.100 Nm3
config menu
Date / Time Versions
value menu
contrast-
Date / Time and Versions menu INDEX
VALUE
ALARM
DATA
CONFIG
06/09/2008 14:00:00
config menu
Status
value menu
Kernel : Kr1.00 13/0 4/07 Metrol : Met1.00 19/02/03 Appli : Ve r5.00 12 /08/08
Main metrology parameters (press 2s )
Status menu INDEX
VALUE
ALARM
DATA
Add. Board Conversion type On/off1 On/off2 Tamper Prog. switch Cust. switch
CONFIG
None SGERG Normal Normal Alarm On On
config menu
Index menu
value menu
config menu
LCD Test (press 2 s)
value menu
Display test (progressing test)
Index menu
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VALUE MENU
INDEX
VALUE
P T Zb/Z C Qm Qb Bat
= = = = = = =
ALARM
DATA
C ON F I G
previous item
15.698 bar -13.5 °C 1.0035 5.6454 152.5 m3/h 153.9 Nm3/h 250 days
Index menu
show Graph
Alarm menu
next item
Value menu
Graph INDEX
VALUE
ALARM
DATA
C ON F I G
previous item graph
4.2 Index menu
4.0 P (bar)
Value menu
Alarm menu
next item graph
4.025 Instantaneous value
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ALARM MENU Alarm menu I N DE X
VAL U E
ALARM
DAT A
C O NF I G
Alarms: 02active activealarms alarms 02 00 memorized alarms
Under alarm counters Reset List of alarms I N DE X
VAL U E
ALARM
Reset DAT A
C O NF I G
V AL UE
see details for selected alarm
DAT A
CO N F I G
I N DE X
V A LU E
ALARM
DAT A
C O NF I G
Under alarm counters: Unconverted : 00000012.000 m3 Converted : 00000018.567 Nm3
1/2
previous alarm back to alarms menu
Under alarm counters
ALARM
Reset: alarms AllAll alarms Under alarm counters
Pressure sensor failure Tamper
Active alarms
I N DE X
upper item back to alarms menu
back to alarms menu
reset selected item
next alarm
back to alarms menu
lower item
Details of selected alarm I NDE X
V A L UE
ALARM
DA T A
Confirmation screen CO NF I G
V AL UE
ALARM
DATA
C ON FI G
Warning:
Pressure sensor failure start: 14/08/2002 16:03:41 end : --/--/---- --:--:-Active alarms
I ND E X
1/2
All alarms will be reset. Press OK to confirm. back to reset menu back to reset menu
confirm reset
back to reset menu
back to reset menu
I N DE X
V A LU E
ALARM
DAT A
CO NF I G
Alarms reset : Completed
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DATA MENU Data menu I ND E X
VALU E
A LARM
DATA
CONFIG
upper menu item
Hourly log Daily log Monthly log Interval log Event log Parameters log
alarms menu
enter selected submenu
config menu
lower menu item
Date selection I ND E X
V A LU E
A L ARM
DATA
CONFIG
previous date
14/08/2002 13/08/2002 12/08/2002 11/08/2002 10/08/2002 09/08/2002 Hourly log
back to database menu
display records on date
back to database menu
next date
1/60
Hour selection I ND E X
V AL U E
A LA RM
DATA
CONFIG
16:00 > Now 15:00 > 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 I ND E X
V AL U E
Time UV CV UV (Al) CV (Al)
AL ARM
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
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CONFIG MENU Config menu INDEX
VAL UE
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
V AL UE
AL ARM
DATA
CONFIG
Pulse weight : 1.000 m3 UV Index : 000143.000 m3 CV Index : 000165.321Nm3
IN DE X
V A LU E
A LA R M
DATA
CONFIG
Current value UV Index : 000143.000 m3
000185.000 Selection with up and down keys + OK
OK for validation
Selection of the digit with left and right keys Adjustment of value with up and down keys
Metrology I N DE X
V A LU E
A LA R M
DATA
CONFIG
Pb : 1.01325 bar Tb : 273.15 K Gas rel. density : 0.57000 C02 : 1.8 % N2 : 0.6%
IN DE X
V A LU E
A LA R M
DATA
CONFIG
Current value Gas rel. density : 0.57000
OK for validation
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
VAL UE
AL ARM
DATA
CONFIG
Date: 07/06/2003 07:43:00
VAL UE
AL ARM
DATA
CONFIG
Current value Date : 07/06/2003 07:43:00
07/ 06/2003
OK for validation
07:43:00 OK
Selection of the digit with left and right keys Adjustment of value with up and down keys
Supply INDEX
VAL UE
AL ARM
DATA
CONFIG
Battery : 1794 days Mode : Battery
INDEX
VAL UE
AL ARM
DATA
CONFIG
Current value Mode : Battery
Battery
Selection with up and down keys + OK
OK for validation
Selection with up and down keys
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Output 1 or 2 INDEX
VAL UE
AL ARM
DATA
CONFIG
Mode : Unconv. Pulse Pulse Weight : 1.000 m3 Time closed : 250 ms
INDEX
VAL UE
AL ARM
DATA
Current value Pulse Weight : 1 m3
1.000 m3
Selection with up and down keys + OK
CONFIG
OK for validation
Selection of the digit with left and right keys Adjustment of value with up and down keys
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10
10.1
SAFETY INSTRUCTIONS
General
Corus gas volume converter is approved according to 94/9/CE directive (ATEX) relative to introduction of material in explosive atmosphere area. st
The respect of this directive is mandatory (from July, 1 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
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►
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
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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.
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12
APPENDIX 1: INITIAL ATEX CERTIFICATE
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13
APPENDIX 2: EC DECLARATION OF CONFORMITY
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60
61
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