FCRCGM-03 User Manual - Queen's
Contents
1. FCRCGM 03 USER MANUAL Top Item Function 1 MFC 1 Inlet selection ball valve 2 MFC 1 Outlet selection ball valve 3 MFC 2 Inlet selection ball valve 4 MFC 2 Outlet selection ball valve 5 MFC 3 Inlet selection ball valve 6 MFC 3 Outlet selection ball valve 7 MFC 4 Inlet selection ball valve 8 MFC 4 Outlet selection ball valve 9 MFC 1 Omega process controller 10 MFC 2 Omega process controller 11 MFC 3 Omega process controller 12 MFC 4 Omega process controller 13 MFC 1 Flow override switch and indicators 14 MFC 2 Flow override switch and indicatots 15 MFC 3 Flow override switch and indicatots 16 MFC 4 Flow override switch and indicatots FCRCGM 03 USER MANUAL Back Item Function AC power connector Thermocouple input for over temp shutoff Power switch Cabinet ventilation inlet E stop extension connector Analog signal connector MFC 1 control switch MFC 2 control switch MFC 3 control switch MFC 4 control switch Ria Sala o ojujaja a eN e Mixed gas outlet N MFC 4 gas outlet Go MEC 3 gas outlet jak A MFC 2 gas outlet on MEC 1 gas outlet nN Cabinet ventilation outlet FCRCGM 03 USER MANUAL General The FCRCGM 03 gas delivery and blending system can be used as a stand alone unit or connected to a computer or2. MFC2 M EST ye NP MFC 2 Out Ll Lk L M 5 Lk 1 AN 1 J gt A MFC 1 In c MFC 1 c A JAN EN X i Eom I d a cK ENA H gt MFC 1 Out E Common Purg AAA 4 Gas In FCRCGM 03 USER MANUAL Controls The MFC s in the system can be controlled by four methods manually specifying a set point via the Omega process controllers local control an external analog 4 20mA signal a flow override switch forcing zero or full flow or RS 232 control using a PC and Bronhorst Flow View or Flow Plot Read back of the MFC process value in all modes of control is available in the top section of the Omega process controllers The MFC process values can also be connected to external devices for data logging ete Safety system An expandable hard wired safety system is included with the FCRCGM 03 The safety system monitors e stop trigger devices and halts flow through the MFC s if a problem is detected There are two on board e stop triggers an e stop button and a Watlow temperature switch used with an external K type thermocouple The temperature switch can also be bypassed if this control is not applicable to the application Additional e stop devices may be added to the e stop loop and a relay e stop status output is available to external devices The system must be out of e stop in order to flow gases in either local or external analog control To get the system out of e stop Ensure all external e stop devices are in a
3. sssssssessssrsrrrrrrrrrrrrrrrrrrrrnnn rn nn nn nn 10 lnlet gases ier te ee tbe pite ptem 11 Metered gas streams Straight out or mixed 11 MA ei o cet Re 12 TrOUDISSIODHITO oer seed id iia 12 Spare Pan Satta datos nes bed prs vali dd curabit E n nd 14 System Specifications ssec 16 Omega Process ControllerS o ccconnoncccnnccnoocccccccccnnnanncnnnnnnnns 18 Parameter Settings M iin ai ei oi 18 Parainetet ss ces dea ds ce A ck Seas Tee 18 SCN C 18 OEM DocurmefitallOD dete edi d a renen kanse DR dE Ex 20 Document Lislg 2 tst th ieee telnet Rit aii 20 Documenti xn Ee 20 Website A ioi eain 20 FCRCGM 03 USER MANUAL System Overview Four channel gas control and blending he FCRCGM 08 is a four channel gas delivery and blending system This manual details the use capabilities specifications and care of the system ICON KEY 7 Valuable information d Safety Information FCRCGM 03 USER MANUAL System Layout Front Item Function Common Inlet MEC 1 Inlet MFC 2 Inlet MFC 3 Inlet MFC 4 Inlet MFC 1 RS 232 data connection MFC 2 RS 232 data connection MFC 3 RS 232 data connection MFC 4 RS 232 data connection E stop button Ri Zi is ojo oja u a o E stop reset button and status indicator N Temperature limit switch override Oo Temperature limit switch
4. am Fuel Cell F RC Research Centre FUEL CELL RESEARCH CENTRE Gas Blending System Model FCRCGM 03 User Manual QUEEN S RMC FUEL CELL RESEARCH CENTRE FCRCGM 03 945 Princess Street 21d Floor Kingston ON K7L 3N6 Phone 613 547 6700 Fax 613 547 8125 Table of Contents System VETIVIGW A reren 1 E A b ibus od eode qur 2 FOP tC 2 TOD usici iudice la eam RU ata etait EE INT hata 3 Back oeste Meo d Cet E 4 Generale d rcs e ota eec etu bs ees 5 PLUTNID IN G ros sens oo e NO Lr 5 Plumbing Diag am et ede ds Rin 5 As eret ep Le EM dre edt 6 Safety SV SIC IN p T 6 System Installation ie ed e redondas PE Ho teet 6 Ms ee ts e SR ERE 6 External flow control and monitoring sse 7 E stop system expansion ccccecceceeee cece cae ae eee eeeeeeeeeeeeeeeeseeeeeeeeeeeeeeeeeees 8 Gas Connections icd ge tete uet iet ter ut dese tee es ae e 8 Safety considerations eee tardas 8 O coche e iod e re sens ccc bre eua ad 9 Gas Type Selection and Correction Factors 9 Mass Flow COOL 2 556205 p Iota si 9 Local set point Control aseinaan ceeeeeeeaeeeeeeececeeeeceeeeeeeeeeeenenenees 9 External analog control ite nee ag eee 10 Flow oVertlde eio d tra ep be ti eae iet Tues 10 RS 232 computer CONtlOl sssssseersrrrssrrssensnnnrernsrrrsn enas nr rrrrr rr r rr ann nr nn nn nan 10 Gas source and blending CONtrOl
5. closed switch state If no external e stop devices are present ensure the external e stop jumper is installed If an external thermocouple is connected ensure the temperature limit override switch is up not bypassed and press the Reset button on the Watlow temperature switch If no external thermocouple is used set the temperature limit override switch to the down position to bypass the circuit Ensure the red e stop button is pulled out Press the green e stop reset button The button should illuminate indicating the system is out of e stop and ready to control gas flow Note The e stop circuit is bypassed for MFC s under RS 232 control System Installation Wiring Electrical connections to the system ate used for e stop expansion external gas control and monitoring and MFC calibration tcrtom of uder manu M12 B 14 External flow control and monitoring To externally control and monitor gas flow with analog signals use the 14 pin phoenix connector at the back of the system External set points to the MFC s are sent via 4 20mA signals corresponding to 0 to full scale flow of the MFC Note that these connections DO NOT share a common ground reference The process value actual flow achieved through each MFC is available at the phoenix connector as 0 10 VDC signals representing zero to full flow The process value signals do share a common ground reference Cables connected to the 0 10 VDC signals should be shielded with an earth
6. ground connection to the shield at only one end of the cable The shielding of these cables will reduce the effect of outside electrical noise on the signals to external monitoring equipment Cable length should be as short as possible to reduce voltage loss due to cable resistance Terminal number Connection 1 MEC 1 negative set point signal 4 20 mA 2 MEC 1 positive set point signal 4 20 mA 3 MFC 2 negative set point signal 4 20 mA 4 MFC 2 positive set point signal 4 20 mA 5 MFC 3 negative set point signal 4 20 mA 6 MEC 3 positive set point signal 4 20 mA 7 MEC 4 negative set point signal 4 20 mA 8 MEC 4 positive set point signal 4 20 mA 9 MEC 1 process value 0 10 VDC 10 MFC 2 process value 0 10 VDC 11 Common for process values 12 Common for process values 13 MFC 3 process value 0 10 VDC 14 MEC 4 process value 0 10 VDC FCRCGM 03 USER MANUAL E stop system expansion The four pin connector at the back of the system is used for e stop expansion Pins 1 and 2 of the connector are an extension of the e stop device loop These pins should be jumpered when no additional e stop devices are connected Any additional e stop devices to be added to the loop must be switched output devices with the output contacts closed when the measured levels of the device are within operating limits Output Rating AC Inductive AC 3 A 230 VAC Output Rating DC Ind
7. s Note Currently the RS 232 connections only support two MFCs at one time from a single computer Run FlowDDE and FlowDDE 2 with one instance for each MFC to communicate with two instruments Bronkhorst may release additional DDE s to support more simultaneous connections in the future Check www bronckhorst com for updates If more than two MFCs must be controlled via RS 232 it is possible to use two computers or upgrade the MFC hardware to include a FlowBus communications card Note The MFC Control type is set using FlowView Setting this parameter to RS 232 will disable analog control through the Omega process controllers This also bypasses the e stop circuitry Gas source and blending control Ball valves on the top panel are used to direct inlet and outlet gas streams 10 FCRCGM 03 USER MANUAL Inlet gases Each of the four MFC s in the system is connected to a dedicated gas inlet port and a common inlet manifold This selection between the two inlet sources for each MFC is done via the four ball valves on the left side of the top system panel If the valve handle is pointing down the MFC inlet is connected to the common manifold If the valve handle is pointing up the MFC inlet is connected it s own inlet port Metered gas streams Straight out or mixed The four ball valves in the centre of the top panel are used to specify the outlet direction for each MEC either to the mixed gas manifold or straight out of the syst
8. signal in MFC 1 Gas cal curves pre loaded Flow Range H2 500 mls min CO2 500 mls min CO 500 mls min N2 500 mls min FCRCGM 03 USER MANUAL MFC 2 Flow Range H2 250 mls min Gas cal curves pre loaded CO2 950 cals mn CO 250 mls min N2 250 mls min MFC 3 Flow Range Gas cal curves pre loaded O2 100 mls min CO2 100 mls min CO 100 mls min MFC 4 Flow Range H2 50 mls min CH4 50 mls min Gas cal curves pre loaded C2H6 bU mals dd C3H8 45 mls min C3H6 50 mls min C2H4 50 mls min Process Controllers Manufacturer Omega Model CN63300 R1 R2 F3 RSP FCRCGM 03 USER MANUAL Omega Process Controllers Parameter Settings Mnemonic Parameter Setting CN63300 Configure Input 1 INP tYPE Input Type Volt dCPt Decimal Point 0 0 rnd Rounding Element 0 1 FLtr Digital Filtering 1 dSP1 Display Value 1 0 InP1 Signal Input Value 1 0 dSP2 Display Value 2 MFC 1 500 MFC 2 250 MFC 3 100 MFC 4 50 InP2 Signal Input Value 2 10 SPLO Setpoint Lower Limit 0 SPHI Setpoint Upper Limit MFC 1 500 MFC 2 250 MFC 3 100 MFC 4 50 SPrP Setpoint Ramp Rate 0 InPt User Input RSP CN63300 Configure Output 1 OP CYCt Cycle Time 0 OPAC Output Control Action REV OPLO Output Lower Limit 0 OPHI Output Upper Limit 100 OPdP Output Powe
9. Digi Key Digi Key WK4340BK ND UL TE5 Manufacturer 39504000440 Omega controller fuses 5x20mm GY 250mA 24 V power supply fuse 5x20mm GY 2A STi SR 103 safety relay fuse 5x20mm GY 150mA Watlow LV series fuse 5x20mm GY 200mA 1 3 PSI Check valve Swagelok SS 4C 1 3 Note The 3 gas line is cleaned for O2 setvice The part number for the check valve in this line is SS 4C 1 3 SC11 FCRCGM 03 USER MANUAL FCRCGM 03 USER MANUAL System Specifications Electrical Voltage 110 120 VAC 60Hz Operating Current Draw Max Approx 3 6A Inrush could exceed max Operating Environment Temperature 0 to 70 deg C Humidity 0 to 90 RH non condensing Storage temperature 40 to 85 deg C Plumbing Tubing material 316 Stainless Steel Tubing Size V4 O D 0 035 wall thickness Check valves 1 3 PSI cracking pressute Seal material Fluorocarbon FKM Ball valves 0 35 Cv MFC s General Manufacturer Bronkhorst Model EL Flow Input pressure Maximum 100 bar Calibrated to 5 bar Accuracy 1 FS for ranges gt 3ml min 20 ES far ranaes lt Aml min Warm up time 30 min for optimum accuracy 2 min for 2 FS Plumbing connections V4 Swagelok compression Material wetted parts Stainless steel 316L Seals Viton Communication RS 232 Analog 0 10VDC Note Omega process controllers that send external set point to MFCs require 4 20 mA
10. analog controller for external control An integrated E stop circuit allows analog set point control only when applicable safety criteria are met Plumbing Gas flow through the system 1s controlled by four Mass Flow Controllers herein referred to as MFC1 MFC2 MFC3 and MFC4 Refer to the System Specifications section of this manual for the specifications of each MFC There are five inlet gas connections at the front of the machine The first gas input line connects to a manifold available to each of the four mass flow controllers in the system This port is referred to as the Common inlet The remaining four gas inlet connections correspond their relative mass flow controllers The inlet gas to each MFC is selected from either the common manifold or the inlet connection specific to the MFC The outlets of the MFC s are in a similar configuration to the inlets Five outlet ports are located at the back of the system one outlet for each MFC and one outlet common to all MFC s used for gas blending This configuration is meant to provide versatility in that the each MFC can provide gas blending capability or simply be used to control a single gas flow Plumbing Diagram A A AA nar i DH MFC 4 In A gt MFC4 c wi E i ea 3x be AN MFC 4 Out LA Ed DK A O 4 MFC 3 In a MFC 3 Ew L N MFC 3 Out Ga Se ce uae i t IA Fa P Mixed Gas Out DK i 4 up i MFC 2 In i
11. e pre installed calibration curves for each MFC can be found in the System Specifications section of this manual Mass Flow control Note The system must be out of E stop to enable set point signals to be sent to the MFC s in Manual set point control External analog control and Flow override modes MFCs should never be commanded a set point when source gas is not available or a gas exit path is blocked These conditions can cause the MFC valve to over heat and lose calibration due to the fact the valve tries to keep opening to get the actual gas flow to meet the set point To avoid this scenatio always set the flow ovetride switches to the down position red LEDs lit and move the switches of only active MFCs to the middle position orange LEDs lit when you ate ready to flow gas Local set point control To use this function set the corresponding control switch at the back of the unit to the down position The Omega process controller will display MN indicating that the unit 1s set for local manual control Press the up or down atrows on the process controller to adjust the set point a FCRCGM 03 USER MANUAL Finally set the flow override switch to the middle position The orange LED will illuminate indicating that the MFC is set for set point control External analog control To use this control type set the MFC control switch to the up position The Omega process controller should NOT show MN The flow override
12. em If the valve handle is pointing down the MFC outlet is connected to the common mixed gas manifold If the valve handle is pointing up the MFC inlet is connected it s own outlet port Check valves from each MFC to the mixed line prevent backflow from the mixed gas manifold FCRCGM 03 USER MANUAL Maintenance With normal use no routine maintenance is required For applications requiring precise flow control gas flows Troubleshooting can be verified using MEC gas lines may be flushed with clean dry inert gas Molbloc ot similar flow meter Symptom Possible Cause Resolution No flow when commanded local set point on Omega process controller s Unit in e stop Check e stop devices Pull e stop button out Ensure over temp limit switch override is engaged if a thermocouple is not connected Reset over temp limit switch if a thermocouple is connected Ensure e stop expansion connector is jumpered if no external e stop devices ate connected Press green reset button No gas supply to MFC Ensure gas is connected with a pressure of 35 PSIG Check that the gas is connected to the proper inlet port Check the inlet ball valve is connecting the MFC to the correct inlet port Flow ovettide switch is in the wrong position Move the flow override switch to the middle position orange LED will light Excessive back pressure Ensure the outlet ball valve is in the correct position t
13. l bAnd Remote Setpoint Filter Band 0 5 tenF Local Remote Transfer Options NOR OEM Documentation For further information on the components within the FCRCGM 03 consult the following documents and websites Document Listing Component s Document Website Bronkhorst MFCs Bronkhorst Doc No 9 17 0220 www bronkhotst com Omega process CN63100 63300 Series 1 16 DIN www omega com controllers Temperature Process Controllers User s Guide Watlow Watlow Doc No 0600 0044 0001 Rev G www watlow com Series L User s Manual Sti SR103AM SR103AM Spec sheet www sti com Safety Relay 24VDC Power Type SPD 60W power supply spec sheet www gavazzionline com supply Swagelok www swagelok com components 20 Notes Keep aperating and maintenance notes bere 21 22
14. o direct flow to the desired outlet port Check external gas connections for blockage MFC Control Switch is in the wrong position Set the MFC control switch to the down position MN will display on MFC Blown MFC fuse Replace fuse 400 mA fuse FCRCGM 03 USER MANUAL 24 VDC power supply failure Check 24 VDC power supply fuse System will not turn on No power to electronics Plug unit into 115 VAC Check main power fuse integrated into power socket on rear panel Omega process controller s not powered Blown controller fuse s Replace fuse s Flow override will not force full flow through MFC 10V signal not reaching MFC Check 10V regulator boatd for proper output Other See No flow when commanded symptom in this troubleshooting guide No flow when commanded external 4 20 mA set point Set point not received by MFC Check set point wiring connections on Pheonix connector at rear panel Ensure hardware used to send set point is functioning propetly Unit in e stop Check e stop devices Pull e stop button out Ensure over temp limit switch override is engaged if a thermocouple is not connected Reset over temp limit switch if a thermocouple is connected Ensure e stop expansion connector is jumpered if no external e stop devices ate connected Press green reset button No gas supply to MFC Ensure gas is connected with a pre
15. r Dampening 1 CHYS ON OFF Control Hysteresis 0 1 tcod Auto Tune Dampening Code 0 ANtP Linear Output Range 0 10 ANAS Linear Output Source SP ANUt Linear Output Update Time 0 ANLO Linear Output Scale Point Low 0 ANHI Linear Output Scale point High MFC 1 500 MFC 2 250 MFC 3 100 MFC 4 50 FCRCGM 03 USER MANUAL Configure Lockouts 3 LC SP Access Setpoint Ent OP Access Output Power LOC dEv Access Deviation Display RED UdSP Access Display Units RED Code Access Code Number 2 Pld Access PID Values LOC AL Access Alarm s Values LOC ALS Enable Reset Alarm s LOC SPSL Enable Remote Local Transfer LOC trnF Enable Auto Man Transfer LOC tUNE Enable Auto tune LOC Configure Alarms 4 AL Act Alarm 1 Action Mode b ot rSt1 Alarm 1 Reset Mode Auto Stb1 Alarm 1 Standby Enabled yes AL 1 Alarm 1 Value MFC 1 50 MFC 2 25 MFC 3 10 MFC 4 5 Act2 Alarm 2 Action Mode b ot rSt2 Alarm 2 Reset Mode Auto Stb2 Alarm 2 Standby Enabled yes AL 2 Alarm 2 Value MFC 1 550 MFC 2 225 MFC 3 110 MFC 4 55 AHYS Alarm Hysteresis Value 0 1 Configure Remote Setpoint 7 1S 7 n2 dSP1 Remote Setpoint Display Value 1 0 INP1 Remote Setpoint Input Value 1 4 dSP2 Remote Setpoint Display Value 2 MFC 1 500 MFC 2 250 MFC 3 100 MFC 4 50 INP2 Remote Setpoint Input Value 2 20 FLtr Remote Setpoint Filter Time Constant i
16. rbons through MFC 3 Doing so could damage the sensor element in the MFC Check all gas connections for leaks prior to running the system FCRCGM 03 USER MANUAL System Operation Gas Type Selection and Correction Factors Four DB9 connectors are available at the front panel of the system for communication to Bronkhorst EL Flow MFC s The EL Flow series of MFC s is capable of storing up to eight calibration curves for various gases Four software programs from Bronkhorst are used to communicate to the MFC s FlowDDE Software tool to establish communications between Windows and an MFC FlowDDE 2 Software tool to establish communications between Windows and an MFC FlowPlot Software for monitoring and optimizing digital instruments parameters FlowView Software to operate Bronkhorst digital instruments and select gas calibration curves Connect the appropriate DB9 on the instrument to an x86 Windows based computer using a standard RS 232 extension cable To select the active calibration curve Establish communications using FlowDDE or FlowDDE 2 if FlowDDE is already communicating with another MFC Select the active curve with FlowView If the desired gas type calibration cutve is not listed in flow view the curve can be added or a gas conversion factor can be applied to estimate actual flow Further details about calibration and installing additional gas curves are contained the Maintenance section of this manual A list of th
17. ssure of 35 PSIG Check that the gas is connected to the proper inlet port Check the inlet ball valve is connecting the MFC to the correct inlet port Flow ovettide switch is in the wrong position Move the flow override switch to the middle position orange LED will light Excessive back pressure Ensure the outlet ball valve is in the cotrect position to direct flow to the desired outlet port Check external gas connections for blockage FCRCGM 03 USER MANUAL MFC Control Set the MFC control switch to the up Switch is in the position MN will NOT display on wrong position MFC Blown MFC fuse Replace fuse 400 mA fuse 24 VDC power Check 24 VDC power supply fuse supply failure Flows not at expected values Incorrect Connect to MFC via FlowView and calibration curve select the proper calibration curve loaded on MFC Note if the desired calibration curve is not available in the MFC memory additional curves can be added up to eight on each MFC A correction factor can also be applied to estimate actual flow Inlet to outlet A delta P of from inlet to outlet is pressure required for the MFC to operate difference to properly small Check for sufficient inlet pressure _ Check for excessive backpressure MFC requires Calibrate MFC calibration Spare Parts Description Supplier Part Number MFC fuses Fast 400mA Short
18. switch must also be in the middle position with the orange LED lit The MFC can now be controlled via a 4 20 mA signal connected to the analog signal connector at the back of the system See the System Installation Wiring section of this manual for details on external analog signal connections Flow override Flow override of no flow or full scale flow is set with the flow override switch to the right of each process controller This is a three position switch that will stop gas flow red LED lit allow set point control orange LED lit or send a full flow command to the MFC green LED lit RS 232 computer control Computer control using Bronkhorst software is achieved by connecting a PC serial port to the MFC RS 232 connectors located at the front of the machine Four software programs from Bronkhorst are used to communicate to the MFC s HowDDE Software tool to establish communications between Windows and an MFC FlowDDE 2 Software tool to establish communications between Windows and an MFC FlowPlot Software for monitoring and optimizing digital instruments parameters FlowView Software to operate Bronkhorst digital instruments and select gas calibration curves Connect the appropriate DB9 on the instrument to an x86 Windows based computer using a standard RS 232 extension cable FlowDDE and or FlowDDE 2nd must be started to establish communications with the MFC s FlowView or FlowPlot can then be used to control the MFC
19. uctive DC 2 A 24 V Gas Connections Gas connections to the system are shown in the system overview layout pictures front and back Use Swagelok 4 connectors for all tubing in and out of the system Take care not to over tighten these connections as it will reduce the number of times the tube connectors can be used without leakage The MFC s have been calibrated with an input pressure of 5 bar If a higher input pressure is required the MFC s should be re calibrated to the applicable pressure Safety considerations Operators of this system must fully read and understand this manual An integrated E stop system included with the FCRCGM 03 Tied into this e stop system is a Watlow LV temperature limit controller This controller should be enabled when gases controlled through the system are fed to external setups that have the possibility of over temperature conditions requiring fuel flow shutoff Similarly the external e stop loop connection should be connected if there are any setup specific conditions possible that would require gas flow shutoff The RS 232 connections to the MFC s bypass the E stop circuitry For applications requiring the e stop system to be enabled analog control either local or remote must be used Gases connected to the FCRCGM 03 such as fuels and Oxygen should have a flame arrestor installed at the cylinder MFC 3 and it s associated components have been cleaned for Oxygen service Do not flow hydroca
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