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Operating Instructions DB05 - PKP Prozessmesstechnik GmbH

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1. Chapter 50 09 Dimensions 10 Dimensions Dimensions G1 4 1 Bri 68 8 G1 4x 12 G1 4 x 12 Mounting Fixation Ansicht A View Vue With manual valve 35 106 5 119 162 12 5 Chapter Page 10 51 Dimensions Dimensions G1 4 68 8 12 Ansicht A View A Vue Chapter Page 10 52 Dimensions Dimensions G1 2 Befestigung Mounting Fixation Ansicht A View A Vue A Ansicht B View B Vue B Dimensions G1 2 Befestigung Mounting Fixation Ansicht A View A Vue A Ansicht B View B Vue B Chapter Page 10 53 11 Annexe Annexe Pressure Loss Pressure loss Typ 500 e 2 Nitrogen Ar Argon so He Helium Ed E 8 8 0 100 200 0 mln min 300 400 500 Pressure loss Typ 500 3 5 3 e Nitrogen Ar Argon 25 He Helium 2 E 5 fs 15 Q 1 0 5 0 0 100 200 Q min min 300 400 500 Pr
2. 1 5 of full scale 0 5 of full scale 3 5 100 within specified accuracy Cut off 296 of full scale 1 100 within specified accuracy Cut off 0 1 of full scale lt 1 of rate year 2 typical 2 0 1 of setpoint Up to 10 bar 0 50 C 1x10 mbar 1 5 He 1x10 mbar 1 5 He 30 min for max accuracy Aluminum Stainless Steel PBT Epoxy and Silicon Viton optional EPDM or PTFE Up to 50In min 61 4 up to 200In min G1 2 female inlet and outlet optional with fittings 9 pin sub D connector male IP 50 24 5 10 max 100 mA max 250 mA 0 5V 1 5V 0 10V 0 20 mA or 4 20 mA 500 Ohm RS 485 Modbus RTU protocol Freely adjustable by digital communication Chapter Page 03 8 Technical Informations Measurement Ranges The DB05 massflow meters and controllers are normally supplied with one of the following standard measuring ranges for air Optional the instruments are available with a customer specific range and calibrated for a different gas Standard ranges Code Range Unit Code Range Unit A1 25 min min C2 5 In min A2 50 min min C3 10 In min A3 100 min min C4 20 In min A4 200 min min C5 50 In min 5 500 min min D2 50 In min B2 500 min min D3 100 In min B3 1000 min min D4 200 In min B4 2000 min min B5 5000 min min Pin Configuration 1 Ground Analoge Signale Common 2 Ground Supply 0 Vac 5 9 3 Supply 24 Supply 4
3. Comms converter RS232 RS485 Sub D plug 9 pole female 2 OVdc brown 3 24Vdc white 6 Tx green 7 Tx yellow 8 Rx grey 9 Rx pink Screen violet Chapter Page 09 48 Connection examples Connection of one meter or controller PC RS232 Operation with analog signals 24Vde Pluggable screw terminals setpoint signal 0 Vac output powered by PSD power supply 05 Accessories Powered by PSD power supply 2805 Chapter Page 09 49 Jojeuiuua sng Wvg Accessories Wad 49 sjuawWn Sul 0 iojesedas Jamod uM 54 JO an 5181104 02 10 19j3W ajdi jnui 1 55 2 4 UIIMJIG UOISUIXF 239 Les 06 02 60 mm 20444 palaMod jJ G9VSU ZETSH Ava 54 20 2 5 2 I M le I a 3pArc 2 Ol Ajddns 254 Wad 7 find Aq 9048
4. Analogue inputs and outputs for set and actual value serial interface e Turndown ratio up to 100 1 e Materials aluminium or stainless steel Description The 0804 thermal mass flowmeter and controller is modular system for measuring and regulating the flow of gases The device can be supplied as a pure flowmeter or with an integrated control valve with PI control function In series production the DBO5 has analogue current signals for the momentary flow and the set flow as well as a serial interface via which the device can be programmed with user friendly Windows software A variety of non aggressive gases can be measured in measuring ranges from 0 25 ml min to O 200 l min BEE PKP Process Instruments Inc 10 Brent Drive Hudson 01749 1 978 212 0006 amp 1 978 568 0060 Email info pkp eu Internet www pkp eu As a result of its modular structure and due to the fact that it can be installed in any position and can be easily cleaned without the need for recalibration the 0805 is suitable for the most varied applications such as analysis devices in the semiconductor industry for pneumatic installations lasers welding systems or fuel cells Depending on the area of application the device can be supplied with an aluminium or stainless steel casing as well as with a measuring accuracy or 1 5 or as a precision instrument with an accuracy of 0 5 PKP Prozessmesstechnik GmbH 5 10 Bors
5. Due to the flow end values the correspondingly applied control valve and the pressure ratios _ these sets receive different values for the parameters P I D F and N We will discuss the function of the individual parameters later on in this manual The aim is to provide the controller with the following different properties with the three sets U Fast response time with the corresponding overshooting fast response V Medium response time with a low overshooting tendency standard setting w SION yesponse Ume UT overshooting slow response Value uint16 consists of two uint8 uint8 bit 15 8 selects the control parameter set for control and activates it The default set is the manufacturer control parameter set V Selection Type User control parameter set A User control parameter set B User control parameter set U User control parameter set V default User control parameter set W 255 not allowed Data Out Of Range error Chapter Page 06 30 Digital Communication m 1 Power up alarm 0 4040 Activation of the power up alarm function If the alarm is deactivated the instrument behaves according to its standard or EPPROM settings after an operational disruption or reset The following operations are performed in case of an operational disruption or reset if the power up alarm is activated The power up alarm setpoint register
6. Chapter Page 00 3 01 Introduction Welcome With DBO5 you get the latest most modern CMOS sensor technology CMOSens is a technology label and stands for a modern process in which the sensor and the signal processing are combined on a highly integrated chip This manual will familiarize you with the installation and operation of your DBO5 We therefore ask you to read this manual carefully and to contact your sales partner with any questions or doubts We have prepared this manual very carefully in order provide you with appropriate and precise information and instructions However no liability is assumed for any errors User Benefits Ultimately a technology only represents a means to an end Therefore all of our efforts are aimed at the requirements and wishes of the user of this instrument and his measurement and regulation tasks Compact easy to install measurement or regulation unit Normalised input and output signals Normalised supply voltage Serial communication CE approved Measurement of the gas temperature Easy maintenance and service Easy expansion of functionality 3 year guarantee Top performance in response dynamics and accuracy Matching options and accessories Service and Quality We continuously improve the quality of our products and services Only with use does it ultimately become clear whether the right product has been selected Thus we at
7. Value float32 White Not possible Read Measured value analog input 0x0008 0x0009 Analog setpoint input the controller Manufacturer configuration as voltage V current mA The converted input value is always loaded into the register whether the controller works in analog or digital mode Value float32 Value float32 voltage or current signal Chapter Page 06 23 Digital Communication Valve control signal 0x000a 0x000b User i Contains the actual control value for the valve whether the control value is generated from the controller automatic mode or manually set via Modbus If the register control mode 0x 0006 is defined as mode 10 the control value is immediately loaded into the register In any other modes the value is stored in a buffer and becomes active when control mode 10 has been activated _ tis possible to adjust directly the position of the control valve If the value is outside of the normal range the error message Data Out Of Range is generated Value float32 valve control signal in percent 0 10096 Alarm messages 0x000c i Indicates the alarm messages in a bit map The bit pattern depends on the status of the instrument and the detected alarms If an alarm condition is no longer valid the corresponding bit is automatically erased Value uint16 bits 15 0 Bit Description Bit 0 Indicates a neg
8. PKP Process Instruments Inc 10 Brent Drive Hudson MA 01749 Tel 1 978 212 0006 Fax 1 978 568 0060 PKP Prozessmesstechnik GmbH Borsigstrasse 24 D 65205 Wiesbaden Nordenstadt Tel 06122 7055 0 Fax 06122 7055 50 Operating Instructions Thermal mass flowmeter and Controller for gases 01 02 03 04 05 06 07 08 09 10 11 Table of Contents Introduction User Benefits Service and Quality Guarantee Tips and warnings Mode of Operation Measurement Principle CMOS Technology Technical Information General Specifications Physical Specifications Electrical Specifications Measurement Ranges Pin Configuration Analog Signals Serial Communication Calibration Conversion Factors for other Gases Pressure Loss Temperature Compensation Pressure Compensation Response Time Control Caracteristics Mounting amp Installation General Tips Mounting Piping Electrical Connection Gas Supply Operation amp Service Heat Up Time Zero Point Check Service Cleaning in the Case of Contamination Returns Digital Communication Type of Communication Modbus RTU Different Memories Control Characteristics Backflow Detection Software Installation Functions Direct help Troubleshooting Accessories Cables Modules amp Power Supply Circuit Diagramm Signal Flow amp Connection Examples Dimensions Annex Drop of Pressure Gas Conversion Factors 4 11 13 18 39 40 44 51 54
9. power supply 24Vde Circuit diagram Signal flow Supply Signal gt Setpoint Chapter Page 09 46 328 2160 0 5m 328 2161 2 0m 328 2162 5 0m 328 2163 BTM 328 2139 Accessories Bus Extension Cable Extension cable for digital communication and analog signals Signal flow lt gt Power lt gt Bus Output gt Setpoint Bus Feeder Cable 2 0 Junction cable PCU DB05 Fixing screws om both sides Signal flow Power lt gt Bus Output gt Setpoint Bus Terminator Modul Termination resistor for bus communication Chapter Page 09 47 PDC 328 2164 328 2165 Accessories Power Analog Cable 3 0m Plug type power supply 24V 0 35A 8W Secondary side plug dia 2 1 5 5mm PVC Cable grey 3m 5 0 25 shielded stripped wire 10cm OVdc 24Vde Setpoint cable length 3 0m Signal 0 4 Output Abschirmung Sub D plug 9 pole female 2 OVdc brown 3 24Vdc white 1 Signal 0Vdc grey 4 Output green 5 Selpoint yellow Screen violet Power Digital Cable 3 0m Plug type power supply 24V 1 25A 30W Secondary side plug dia 2 1 5 5mm PVC Cable grey 3m 6x0 25mm shielded stripped wire 10cm OVdc 24Vde RX RX TX TX Abschirmung cable length 3 0m female O
10. Euro Version Plug type power supply 24V 0 35A 8W Secondary side plug dia 2 1 5 5mm Power Supply Device Euro Version Plug type power supply 24V 1 25A 30W Secondary side plug dia 2 1 5 5mm Chapter Page 09 44 Accessories Cables amp Modules Circuit Diagramm Signal Flow 328 2150 BAM 328 2151 Power Digital Module 1 5m Communication cable PC DB05 passive level converter RS232 RS485 Power Supply with PSD Einspeisung 24Vde Kabell nge 1 5m Signal flow L p Supply Bus digital Communication Bus Analog Module 0 1m Digital communication combined with pluggable screw terminals for analog signals Pluggable screw Type Phoenix 3 MCVR 1 5 3 ST 3 81 contact spacing 3 81mm 3 pole max cable cross section 1 5mm Signal flow dt Supply 4 Bus digital Communication Output Selpoint Chapter Page 09 45 PSM 328 2152 PAM 328 2153 Accessories Power Separator Module Power module with power separator for additional power supply PSD Einspeisung 24Vde HET gt Signal flow gt Power Bus digital Communication Power Analog Module Operation with analog signals only pluggable screw terminals Powered by power supply PSD Pluggable screw Type Phoenix 3 MCVR 1 5 3 ST 3 81 contact spacing 3 81mm 3 pole max cable cross section 1 5mm
11. contact your service representative Send in the instrument for repair or obtain a new control valve cartridge Check the setpoint default Check the control parameters and use one of the provided standard sets for control purposes Check the gas type specified on the type plate If it does not correspond to the one that is actually used you have to consider the corresponding conversion factor You can check the programmed gas type with he software Contamination Open the pipe system and check it for possible contaminations including the installed filters If you detect contamination check the instrument as well In case of contamination in the flow division section the displayed flow is higher than the actual one vice versa when the measuring channel is contaminated If you think the valve is contaminated as well contact your service representative Send in the instrument for repair or obtain a new Control valve cartridge Do not use any liquid leak detector liquids for determining leaks inside the instrument Helium leak detectors or gas sniffers are ideal If you suspect a leak inside the measuring instrument contact your service representative or send in the instrument for repair Chapter Page 08 42 Troubleshooting Wrong parameter set Select the correct parameters sets Substantial heat build up Setpoint default without Try to avoid this state over longer periods if on t
12. 0x4041 0x4042 is used as the new setpoint The last normal setpoint is overwritten in this process The power up alarm bit is set to one in the register hardware error 0x 0004 a these operations are only performed when the control mode register 0x 0002 is set to 1 digital Otherwise only the alarm flag is set _ In each case the power up alarm bit remains on 1 until it is explicitly deleted see description Value uint16 Value Description 0 Deactivates the power up alarm 1 Activates the powerupalarm 1 Write Read User Power up alarm setpoint 0x4041 0x4042 Defines the setpoint which i is sto be set automatically after a an operational disruption ora reset of the instrument if the power up alarm was configured accordingly If this value is changed and the instrument is already in power up alarm mode the changed alarm setpoint first becomes effective after the next operational disruption or reset Value 132 alarm setpoint in min min between 0 and end value Read i User Totaliser function 0x4043 Defines the totaliser function This register i is bit coded Value ui uint16 bit15 0 whereby each bit stands for a certain totaliser function Bit Value Description 0 0 Deactivates the totaliser function 1 Activates the totaliser function If flow gt zero is totalled 1 15 No function Totaliser scaling factor 0x4046 0x4047 The read out c
13. 24 Vdc 4 4 Analog output Output 4 3 5 Analog setpoint Setpoint 2 7 6 RS 485 Output Y Tx4 15485 Y 6 7 RS 485 Output Z Tx 15485 2 8 RS 485 Input B Rx RS485 B 9 RS 485 Input A Rx RS485 A Analog Signals The analog output signal linear to the mass flow is available between pins 4 and 1 The analog setpoint signal linear to the mass flow is applied between pins 5 and 1 Note Use separate cables for signal ground pin 1 and power supply ground pin 2 to avoid interference problems Voltage signals have to be specified on order or configured by an authorised sales partner The voltage output signal is generated by a 250 Ohm shunt resistor Serial Communication Serial communications with Modbus protocol are a standard feature for the configuration and readout of the instruments Note The power supply for the analog signals and digital communications must have a common ground potential Calibration Each instrument is tested and calibrated on a fully automatic calibration equipment traceable to european and american standards and the calibration data are stored in the non volatile memory As standard the calibration gas is air Please consult your sales partner for calibrations with other gases The configuration and calibration data of each individual instrument are available on request Chapter Page 03 9 Technical Informations Conversion Factors for other Gases For gases othe
14. Page 02 6 Mode of Operation The digital intelligence linked with the CMOSens sensor permits the emission of a fully calibrated temperature compensated output signal The CMOSens intelligence integrated onto the chip thus facilitates an extremely simple processing of the emitted measurement data CMOS is a standard technology for the manufacture of integrated circuits CMOS chips are generally known as semi conductor chips silicon chips or computer chips They are widely used in PCs mobile telephones and many other information technology devices gt Turbulence filter cce Figure 2 Block diagram of the hardware Chapter Page 02 7 03 Technical Informations General Specifications Accuracy Standard Hi Performance Dynamic range Standard Hi Performance Repeatability Longterm stability Temperature sensitivity Pressure sensitivity Control stability Operating pressure Operating temperature Leak integrity Inboard outboard Control valve Warm up time Physical Specifications Materials of construction Model code A Alu Model code E SS Sensor Seals Mechanical connection Electrical connection Ingress protection Electrical Specifications Supply voltage Supply current Massflow meter Massflow controller Analog setpoint Voltage Current Max load Digital communication Control parameters Technical Informations
15. Possible formats 4 20 1 5 V 2 10 V signal analog output im 40 20 0 20 40 60 80 100 example 18 effective mass flow Range If the condition for setting alarm flag 1 is fulfilled the analog output is set to half the value of the minimum output value Accuracy The accuracy of the backflow detection switching threshold of alarm flag 1 directly depends on the symmetry of the sensor characteristics curve as well as the offset trimming The sensor is only calibrated for the positive flow range This inevitably results in an inaccuracy for measuring in the negative range Chapter Page 06 38 07 Soflware Software This software is a configuration software that lets you control and change instrument parameter easily In addition you can check your interface cabling with 2805 map the bus structure and modify instrument addresses if required The software works on IBM compatible computer systems with the operating Installation After inserting the CD you can select which programs or manuals you want to install and or open With a manual installation proceed as follows The enclosed CD contains a directory called Open this directory and start the program setup exe Menus guide you through the installation Functions The software provides the following function blocks Configuration of the serial computer interface Settin
16. a zero drift This alarm is only active if the instrument is a flow controller No gas jammed valve alarm Raised if at a valve control signal of 100 valve electrically fully open no gas flow is measured This alarm is only active if the instrument is a flow controller No reaction Raised if the valve control signal is raised or lowered and no variation of the gas flow is measured Possible causes are Jammed valve changed pressure conditions or valve too small after a change of gas This alarm is only active if the instrument is a flow controller Sensor communication error Raised if a communication problem occurs between the sensor and the electronic module In this case the measurements are probably wrong Raised if the cyclic RAM check fails Possible cause Defective memory EPROM access check Raised if access errors to the EPROM are detected In this case the correct function of the instrument is no longer guaranteed Totaliser memory corrupted Raised if the storage of the total value is no longer possible In this case the totaliser always starts from 0 at power on Invalid contents in EPROM or empty FPROM Current input overload gt 25mA Chapter Page 06 25 Controller Mode 0x000e Digital Communication Selection of the controller mode and the source of the setpoint Value uint16 _ Attempting to write another value results in the error message D
17. accuracy 1 596 f s d CS Flowmeter and controller standard accuracy 1 5 f s d Flowmeter increased accuracy 0 3 of end value and 0 5 of actual value CH Flowmeter and controller increased accuracy 0 3 of end value and 0 5 of actual value Measuring range air 01 0 25 Nml min G 1 4 female 02 0 50 Nml min G 1 4 female 03 0 100 Nml min 1 4 female 04 0 200 Nml min G 1 4 female 05 0 500 Nml min G 1 4 female 06 O 1 Ni min G 1 4 female 07 0 2 Ni min G 1 4 female 08 0 5 G 1 4 female 09 0 10 G 1 4 female 10 0 20 G 1 4 female 11 0 50 Ni min G 1 4 female 12 0 50 Ni min G 1 2 female 13 0 100 G 1 2 female 14 0 200 Nl min G 1 2 female Material Aluminium casing E Stainless steel casing Options O without EPDM seals IA Actual value output deviating from standard 4 20 mA SA Set value input deviating from standard 4 20 mA ES Real gas calibration Medium L Standard medium air N Standard medium N2 O Standard medium O2 S Other media please indicate in block letters Technical data Max pressure 10 bar Medium temperature 0 50 C lt 150 ms DB05 C lt 50 ms 0 05 Voltage supply 24V DC 5 10 Electrical connection D sub plug 9 pin up to 5 bar any position ove
18. for damage Should the packing be damaged immediately notify the local carrier and inform your sales partner Carefully check if the goods correspond to the packing list and that there are no missing or damaged parts For best performance carefully read the following recommendations Check the instrument label and make sure that the massflow meter controller suits the application Caution The maximum working pressure must always be lower than specified test pressure Mounting The preferred mounting position is horizontal up right or hanging For pressures gt 5bar a vertical mounting position may cause an offset Avoid the installation in proximity of any source of thermal or electric radiation Avoid vibrations and mechanical stress Do not install the instrument at the lowest point of the piping to avoid an eventual backflow of liquids Pipin piping is very important the performance of measurement Therefore carefully check the following points The piping must be absolutely clean The piping must conform in pressure and corrosion resistance Always fix the instrument on the body by means of fixing screws Avoid abrupt angles on the inlet If this is not possible contact your sales partner Use appropriate fittings with O ring seals and do not tighten the fittings holding the instrument by the cover Never use liquid sealing as it may flow into the instrument Do allow a sufficient upstream buffer volume betw
19. is perfectly suited for the measurement of gas flows One of the significant advantages is that the measurement is largely independent of pressure and temperature By contrast to volumetric principles pressure and temperature do not have to be additionally measured Although the principle yields mass as a measurement result e g g min most devices are calibrated to standard volumes e g In min One possible explanation is the fact that the comparability of the measurement results with other principles is given with this Since the thermal flow measurement depends on the type of gas in addition to the specific heat the standard density 0 C 1 01325 bar the conversion to standard volume is also used With all design options of the measuring principle there is always a heater and one or more temperature measurement points and the gasflow draws heat from the heater With the DBO5 mass flow meter a constant heating power ensures a temperature difference that is directly proportional to the gas flow rate In the flume a temperature measurement is followed by a heater and then a temperature measurement again The figure below illustrates this process If the flow rate 0 the heater H uniformly distributes the heat for which the temperature difference T1 T2 equals zero Two effects occur with the flow rate that lead to a temperature difference First the temperature sensor T1 at the entrance detects a lower temperature This happens beca
20. 0 4 Chapter Digital Communication Page 06 33 Digital Communication E pons Read User User Delay hardware error 0x4087 Sets then minimum n time in ec nda dm which a plausibility e error r has to occur r constantly in in operation before the corresponding error bit is set the register hardware error 0x 00 0d If normal status returns before the end of this time the time starts at t 0s again at the next occurrence of the same error The following errors are checked for their plausibility during operation A flow larger than zero is measured despite a set value of 0 No flow is measured despite a set value of 10096 Setpoint was increased still flow does not increase These three errors correspond to the error bits 2 4 in the register hardware error So if one of these errors persists longer than the defined time the corresponding error bit i 5 set Value uint16 the value is interpreted in seconds The admissible input range is 0 600 seconds If the value zero is set the corresponding error bit is set as soon as an error occurs The maximum delay is approx 16 ms Please note that different effects inertia of the control valve pressure build up etc cause an undesired error indication _ Default 10 seconds Write Not possible Implement functions 0x4128 0x04129 Read User The individual bits of th
21. 5 130 of the determined value 195 255 Backflow Detection General A function is implemented as of firmware version 3 1 5 which allows the detection of negative mass flows This function is intended for measuring instruments and only makes little sense in control operation Function description If this function is activated the mass flow metre behaves as follows Negative flows are detected and the corresponding alarm flags set with and w o hysteresis Negative flows are detected and signalled with the analog signal output with hysteresis Setting the alarm threshold With the ModReg backflow detection you can set an alarm threshold in the range from 096 to 2096 of the maximum flow see ModReg reference Digital signalling The alarm can be queried with the help of the ModReg alarm messages The register shows the current state of the negative mass flow with the two flags 0 and 1 alarm treshold Alarmflag 0 Hi 0 Alarmflag 1 Hi Lo os 40 20 0 20 40 60 80 100 example 18 effective mass flow Range Here the alarm threshold that can be adjusted by the user influences the hysteresis behaviour of the alarm flag 1 Chapter Page 06 37 Digital Communication Analog signalling The analog measuring value output is also influenced in addition to alarm flag 1 Signalling with the analog output signal is only possible if a suitable signal format was selected
22. ata Out Of Range The following options are possible Value 0 20 21 22 23 30 31 Description Automatic setpoint selection The source of setpoint is automatically selected i e As standard the analog setpoint voltage or current signal is active If a digital setpoint is sent Modbus automatically the DBO5 switches to Digital mode and the analog setpoint is disabled Digital setpoint Activates the digital setpoint via Modbus Analog setpoint standard setting Selects the analog signal as setpoint source Direct adjustment of the valve signal Deactivates the automatic control mode Sets the valve control to the value of register valve control signal 0x000a 0x000b Setpoint 0 Sets the setpoint to 0 The serial communication is ready for a new digital setpoint Setpoint 100 Sets the setpoint to 100 The serial communication is ready for a new digital setpoint Valve fully closed Deactivates the automatic control mode Sets the valve control to 0 Valve fully closed Valve fully open Deactivates the automatic control mode Sets the valve control signal to 100 Valve fully open Test mode analog output Deactivates the automatic control mode and sets the valve control to 0 Forces the analog output signal to the value in the register Analog output manual 0x0028 Test mode for the DAC of the current output Chapter Page 06 26 Digital Comm
23. ative flow flow value 0 Bit 1 Indicates a negative flow exceeding the backflow setpoint The bit remains set until a positive flow is detected Bit 2 14 Not used Bit 15 Hardware error Indicates a hardware error register 0x 00 04d This bit is therefore an OR function of all hardware errors Chapter Page 06 24 Hardware error 0x000d Digital Communication Read User Indicates eventual malfunctions during operation of the instrument This Information persists even the problem has been solved and has to be reset with the parameter Reset hardware error All alarm messages are reset if the instrument is switched off and activated again at power on if _ alarm persists Value uint16 bits 15 0 The following table explains the individual error bits Bit 0 9 10 Description Power up alarm If the instrument is switched off with activated Power up alarm and switched on again then the active setpoint will be the readjusted power up setpoint see parameter power up alarm setpoint This status will only be checked at power up Alarm analog setpoint Raised if the analog setpoint is outside the valid range This alarm is only active if the instrument is a flow controller Zero point or leakage alarm Raised If at a valve control signal of 0 Valve electrically closed a flow is measured Possible causes are An incompletely closed valve internal leakage or
24. control parameter set is displayed G s Value float32 gain factor K without unit Default 100 The value must be positive The error Data Out Of Range is generated when trying to define values outside of the admissible range User Time constant Tv 0x0030 0x0031 i Read Time constant T of the PI controller The logic operation function of this emnet is described further down in this manual The following formula shows the meaning of Tw in the PI controller G s Kp x sTy 1 sT A smaller Tu value makes the controller more exact faster more aggressive and more prone to _ oscillations A larger value makes it slower and less sensitive time constant of the presently selected control parameter seti is displayed Value float32 time constant Tw in seconds Default 0 1 s The value must be larger than 0 0 The error Data Out Of Range is generated when trying to define values outside of the admissible range i User User Write Feed forward F i 0x0032 Read Feed forward share of a controller The parameters ar are stated i in 18 breakdown The logic operation function of this parameter is described further down in this chapter Value uint16 bits 15 8 always zero Chapter Page 06 29 Digital Communication Non linearity N 0x0033 User Offset compensation share non linear part N of a controller The parameters a
25. de the valve cable into the recess of the sensor carrier With the metal part affix the valve cable in this sector Reinsert the valve electronically Please make sure that the valve cable is not squashed in the area of the duct recess when assembling the electronics casing After assembly of the control valve it may be necessary to readjust individual control parameters especially the parameter non linearity N Chapter Page 05 16 Operation amp Service Returns With the return of a measurement or regulation device use the original packaging if possible or other appropriate packing Please inform us of the reason for the return in order to spare any unnecessary callbacks and delays Should the device come in contact with dangerous substances please clean the device carefully notify us and pack the device tightly Please fill out the contamination statement You will find this in the chapter 11 annex or on the enclosed CD If you have any further questions please contact your sales partner Chapter Page 05 17 06 Digital Communication Digital Communication The digital communication with a 0805 mass flow meter or controller offers the following advantages More informations Besides the mass flow you can read the gas temperature total flow alarm status serial number etc Acc
26. een the pressure regulator and the instrument especially with higher flow rates Do not use too small diameter piping as this creates a high pressure loss and may impare the performance of the instrument Carefully check the piping for possible leaks The instruments have a flow rectifier at the inlet For flow rates gt 50In min a straight tube of 10 times diameter is recommended For critical applications uninterrupted gas supply we recommend to install a bypass system to allow service on an instrument Electrical Connection We strongly recommend our standard cables Please consult your sales partner If you install your own cables carefully read the connection instructions The installation has to comply with all relevant safety and EMC regulations We recommend the use of an EMC filter if the power supply cable exceeds 3m Avoid earth loops The power supply voltage must be 24Vdc 10 Use cable of sufficient size to minimize the voltage drop Chapter Page 04 12 Mounting amp Installation Gas Supply Make sure your gas supply is absolutely clean i e free from dust oil water etc If necessary install an upstream and eventually a downstream filter to avoid any damage to the instrument The capacity of the supply should be at least 2 times of the max flow range Carefully choose your pressure controller and do not install your DBO5 directy to it The pressure must be sufficient to cover all press
27. egister is first output via the current interface upon activation register control mode 0x000e 30 In order to return to the output of the current actual value via the analog current interface the register control mode 0x000 must be Teset accordingly _ Value float32 current value i in mA Chapter Page 06 28 za Communication Scanning 5 0x002d With a setpoint as of 2 Zero the valved is s accessed continuously and linear until a How sets ir in Afterwards the instrument switches back to normal control It is possible to change the speed of this continuous linear scanning process which is proportional to the value set here smaller value is set the scanning process takes longer On the other hand the overshoot tendency is lesser with smaller setpoint defaults vice versa with large values Value uint16 bits 15 8 always zero uint8 bits 7 0 admissible range 1 255 Gain factor Ke 0x002e 0x002f i Read User Gain factor Ke of the PI controller The S Inde operation function of this is described further down in this manual The following formula shows the meaning of K in the PI controller Ky x sT 1 sT A larger Ke value makes the controller more exact faster more aggressive and more prone to oscillations A smaller value makes it slower and less sensitive The gain factor of the presently selected
28. embly rinse the 0805 once again with dry inter gas By means of empirical values check the correct function of the cleaned measuring instrument e g by checking the zero point 2 S N DS N Ld D Disassembly of the control valve also see sketch on the next page Disassemble the gas and the electric connections Make sure that there is no gas pressure in the pipe system or the instrument itself In order to clean the measuring part first dismantle the central fastening of the electronics casing with an Allen key 4 mm Slightly lift up the red casing on the screw side and press it towards the electronics plug Now carefully pull out the valve plug Make sure you do not touch any electronic components on the circuit board Loosen the two Allen screws 6 which hold the U shaped clamp 7 at the valve After you have removed the screws you can pull the clamp away towards the gas output Slightly loosen the Allen screws 8 so that you can turn the metal part 9 diagonally to the outside Chapter Page 05 15 Operation amp Service Carefully pull the valve insert 10 upwards Slight diagonal turning supports the dismantling process Carefully reinstall the new valve insert with the cable outlet towards the electronic circuit board Please be careful not to damage the O ring seals on the valve insert Assemble the U shaped retaining clamp with the 2 screws Gui
29. equence of faulty operating states If you want to reset an error bit in the register hardware error 00004 the corresponding bit is set here i in this register 0x4 04 f bit remains on zero the error biti is also not changed Value uint16 bit15 0 whereby each bit stands for a specific error to be deleted Bit reset to mee the corresponding error bit i is not modified th Storage mode E PROM 0 4050 rl Defines whether the registers date can be saved i in EPROM a are MIN HMM saved when writing or not If this function is activated the register is saved in the non volatile memory with each change of the corresponding registers If this function is not activated changed register contents are only permanently saved if save take place explicitly with the command register E PROM actualisation Value uint16 Value Description 0 No automatic saving 1 Automatic saving activated Chapter Page 06 32 Write User Read Backflow detection 0x4052 0x04053 oo Defines the limit in percent of the measuring range as of which a negative flow is detected by the sensor If the negative flow exceeds this mark the corresponding alarm flag is set see ModReg alarm messages and the analog output is set to 10 of the respective maximum range 0 5 V with Vmax 5 V 2 mA with Imax 20 mA In order for the value set here to have an effect the instrument function backflow detectio
30. es of the different parameters Type Value Description uint4 0 7 unsigned integer 4 bits uint8 0 255 unsigned integer 8 bits uint16 0 65536 unsigned integer 16 bits Often used to define two 8 bit values uint32 0 429496729 unsigned integer 32 bits int16 32768 32767 signed integer 16 bits Chapter Page 06 21 Digital Communication Parameter table Name DESCHD ON OM register u Gasflow Measuredvave 000000001 Temperature i Measured value 0x0002 0x0003 __ Setpoint gas flow ME Measured v value analog input Measured value of analog input port 0 0008 0 0009 Valve control signal Actual value of the valve control signal u X000a 0x0000 0 Hardware error _ Indicator for possible malfunction 2 _0x000d TRE Instrument address Sets the Modbus instrument address u 0 001 3 Unit of measured value Engineering unit of measured vate 0x0016 0x0019 Name of fluid of the measured gas EE Serial number hardware _ Serial number of the electronic module 0x001e 0x001f Version number software e Development stage of the software 200021 PROM actualisation Stores the settings in the non volatile memory _ 0022 nn Instrument name Nameoftheinstrument 0 0023 0 006 Manual settin of the analo out ut 8 0x0029 Time constant Tv _______ C
31. ese register represent different functions this instrument has If a biti is 5 set 1 the corresponding function is available if the bit is deleted 0 the corresponding function is not available on this instrument The functions visible here depend directly on the installed software version If a new software version is installed which offers additional new functions the corresponding bits are set here With the registers Available instrument functions for users you can block or release individual basically available functions for users A No Wrote Access error is generated when attempting to write in these registers These two registers can also be read written individually 2 x uinti 6 uint 32 consisting of 32 bits bit 31 0 Value Description 0 Controller is available 1 Totaliser is available 2 Backflow detection Calibration data set 0x4139 Read Not possible a Up to three different calibration data sets can be saved in the instrument These may have _ different pressures end values or media Value uint16 Specifies which data set is to be used Value Description 1 Internal data set do not use 2 Standard data set 3 First optional data set 4 Second optional data set Values outside of 1 4 generate Data Out Of Range error _ Chapter Page 06 34 Digital Communication Different Memories The controller has three differen
32. ess to control functions Allowing you to adapt the controller behavior Save cost Due to a bus structure within a system of several instruments Higher RFI immunity Type of Communication DB05 mass flow meters and controllers work on a serial communication RS 485 with protocol Modbus RTU A 2 or 4 wire connection is possible T R R T R R Master R 5 R T e R R R T e T T T R R T T 4 wire communication 2 wire communication Using a RS 485 RS 232 converter the instruments can also be connected to a RS 232 port of a PC The converter should be galvanically isolated With a special cable according to the diagram in chapter 9 accessories a DB05 connects directly to the RS 232 port of your PC This item is also available from your sales partner Notes The special cable contains a resistor network to adapt the signal level to the RS 232 port In some cases it may impair the function of the serial port Each 0805 must be set to an individual address between 1 and 246 in order to communicate properly with your PC With the free software you can check the bus read and if necessary change the address of an instrument Chapter Page 06 18 Digital Communication Modbus RTU The Modbus protocol is a communication structure for a master slave communication between intelligent instruments It is used world wide and supported by most manufacturers of measurement and con
33. essure loss Typ 500 e N2 Nitrogen MH Ar Argon He Helium E E amp Q 0 100 200 Q min min 300 400 500 Chapter Page 11 54 Delta P mbar mio sek mE o m Boo o oo o S 5 e Pressure mbar Annexe Pressure loss 200 In min Q in In min Chapter Page 11 55 Symbol _ Gas Conversion Factors Name Chem 02 Nitrogen N2 Helium He Argon Ar Carbondioxide C02 Hydrogen H2 Methane CH4 Propane C3H8 Nitrousoxide N20 Sulfur Hexafluoride 5 6 Propylene C3H6 Carbonmonoxide CO Butane C4H10 Valve with EPDM seals Annexe Density g l 1 293 1 429 1 250 0 1785 1 784 1 977 0 08991 0 7175 2 012 1 978 6 626 1 915 1 25 2 705 a M Conversion factor Comments 0 992 absolutely free from oil amp grease 1 ca 9 1 27 0 70 ca 10 0 32 The conversion factors given are approximative values and should only be used to determine a new range Example New range Conversion factor Equivalent range with air 3 In min C02 3 0 7 4 28 In min Chapter Page 11 56 Flow Metering and Monitoring Systems 0805 Thermal mass flowmeter and controller for gases Pressure and temperature independent measurement Compact design no need for straight pipe runs High degree of precision short response time
34. f the measured gas The temperature variations are detected by the sensor Based on a three dimensional correction table the microprocessor then automatically corrects the output The temperature is measured with an accuracy of 0 5 C and can be read out over the serial link Pressure Compensation Each individual instrument is calibrated for the specified working pressure Changing pressure conditions degrade the accuracy Note The proper function of a flow controller is not guaranteed if the pressure drop is too high or too small Response Time A unique feature of the CMOS sensor is the extremely fast response time of 5ms After 10ms the measured value is within its standard accuracy of 2 After 1 25 the maximum accuracy is attained Chapter Page 03 10 Technical Informations Control Caracteristics The control caracteristics of the 0805 massflow controllers can be adapted to the application 3 sets of control parameters are factory programmed for the following control response Parameter setU Fast response with overshoot Parameter set V Optimal response with slight overshoot standard Parameter set W Slow response without overshoot 2 additional sets of control parameters are user programmable should none of the preprogrammed ones be acceptable Chapter Page 03 11 04 Mounting amp Installation Mounting and Installation General Informations Check the packing box
35. g the program language Scanning and mapping the bus structure Integrating individual instruments into the bus structure Reading out the instrument specific hardware and software versions Displaying the measuring value the totaliser and the temperature of a instrument Setting setpoint values Resetting the totaliser Selecting the control parameter sets Setting the Pl control parameters and checking their function mode Selecting the corresponding calibration data record Optional data recording Direct help The functions within the program are described in the help menu Chapter Page 07 39 08 Troubleshooting Troubleshooting In the following table we have compiled possible error situations their causes and possible remedies If the error on your measuring or control instrument is not listed please contact your distribution partner or return the instrument Please observe the recommendations in the chapter Returns If you need to open the pipe system due to the suggested measures observe all required rinsing processes and the hazard potential of systems under pressure in general In the chapter Operation and Maintenance you will find illustrated instructions about disassembling and cleaning the instruments Observe the proper procedure Error Possible cause Output signal remains at gas 4mAor 1V Measures Check s the gas supply working Are all sh
36. h uint16 consists of two uint8 char8 Default value 0 zero for all characters 0x001a contains the first two characters 0x 001d contains the last two characters All four registers be read independently of each other hot posso m Read User Serial number hardware 0x001e 0x001f Clear and unique ser a number of the electronic part of the measuring instrument print Value uint32 _ Possible range 0 2 x 10 1 Ta Read Version number hardware 0 0020 Different development stages of the print ar are e documented with unequivocal version n numbers Value Chapter Page 06 27 Digital Communication Version number software 0x0021 me i Read User i Different development stages of the software are e documented with unequivocal v version numbers Value uintte Write User EPROM actualisation 0 0022 Bun Read User En Al settings made v via i modbus are saved 10 a volatile memory RAM n automatic save Register 0x4050 storage mode of the non volatile memory is activated the settings are saved immediately when written also in the non volatile memory There are two different types of settings parameters 1 Settings which are only saved as long as the instrument runs connected to the supply When next turning the instrument on off the default values are activated again These setting
37. he control casing gas supply possible Your instrument might get damaged in the long run Control parameters Check the control parameters and use one of the provided standard sets for control purposes Chapter Page 08 43 09 Accessories Cables amp Modules Type Part Number PDM 328 2150 BAM 328 2151 PSM 328 2152 PAM 328 2153 BEC 328 2160 0 5m 328 2161 2 0m 328 2162 5 0m 328 2163 BTM 328 2139 328 2164 PDC 328 2165 Power Supply PSD 328 2231 PSD 328 2232 Accessories Description Lenght Use Power Digital Module 1 5m Communication cable PC DB05 passive level converter RS232 RS485 Bus Analog Module 0 1m Digital communication combined with pluggable screw terminals for analog signals Power Separator Module Power module with power separator for additional power supply PSD Power Analog Module Operation with analog signals only pluggable screw terminals Powered by power supply PSD Bus Extension Cable Extension cable for digital communication and analog signals Bus Feeder Cable 2 0m Junction cable PCU DB05 Fixing screws om both sides Bus Terminator Module Termination resistor for bus communication Power Analog Cable 3 0m Loose ends For analog operation of the controller Power Digital Cable 3 0m Loose ends For analog and digital operation of meter or controller with external converter RS232 RS485 Power Supply Device
38. hole Typical Valve characteristics curve 140 120 i max possible flow De 100 80 ya Delta P klein E Delta P gross 5 60 40 20 0 0 10 20 30 40 50 60 70 80 90 100 110 manipulated variable in min possible flow Da Function of the individual parameters Non linearity N A linear controller PI only functions as intended when the distance to be controlled behaves approximately linear in the entire work section As described above this is not the case here The parameter non linearity N compensates the dead zone in the area 0 to Da This compensation only takes place with a setpoint default larger than zero With setpoint defaults larger than zero a value generated by N is added to the controlling signal generated by the linear control algorithm Naturally the value N may never be larger or equal the value Da in Different pressure ratios and temperature changes move the value Da Chapter Page 06 35 Digital Communication Minimum scanning speed S With a setpoint jump away from zero the valve tension has to be increased with a certain speed after reaching the N value This speed can be influenced with this parameter The following correlation applies The larger the set value the faster the valve reaches its actual opening point which increases the likelihood of producing an overshoot with smallest setpoint defaults Therefore the value should rep
39. igstraBe 24 D 65205 Wiesbaden 49 0 6122 7055 0 amp 49 0 6122 7055 50 Email info pkp de Internet www pkp de Versions DB05 MS Mass flowmeter Standard accuracy 1 5 f s d Mass flowmeter and controller Standard accuracy 1 596 f s d DB05 MH Mass flowmeter ncreased precision 0 5 f s d DB05 CH Mass flowmeter and controller ncreased precision 0 5 f s d DBO05 CS Measuring ranges and dimensions Version Con A B D E F G nection GIG mm mm mm mm mm mm mm DBOS M 1 4 94 87 25 25 69 25 44 DBOS M 1 2 145 87 35 25 79 35 44 DBOS C 1 4 124 117 25 25 69 25 44 DBOS C 1 2 170 117 35 25 79 35 44 flow Materials DB05 x x A Aluminium casing PBT sensor Viton seal DB05 x x E Stainless steel casing electropolished PBT sensor Viton seal Options B EDPM seals Actual value output and set value input 0 20 mA 0 5 V 1 5 V 0 10 V 4 20 mA Namur Special measuring range for medium air N2 O2 B Special measuring range for medium air N2 O2 with real gas calibration Other media with air calibration Other media with real gas calibration PKP Prozessmesstechnik GmbH Borsigstra e 24 D 65205 Wiesbaden 49 0 6122 7055 0 amp 49 0 6122 7055 50 Email info pkp de Internet www pkp de Ordering Code Order no 9805 MS 01 A 0 Thermal mass flowmeter and controller for gases Version MS Flowmeter standard
40. irst dismantle the central fastening of the electronics casing with an Allen key 4 mm 2 Slightly lift up the red casing on the screw side and press it towards the electronics plug The L shaped sensor carrier is screwed onto the body with four Allen screws 4 mm 3 Once you have loosened the screws you can lift the carrier off the body Please note that there are two O ring seals on the bottom side of the sensor carrier 4 Now clean the measuring unit by letting dry gas flow into one of the measuring channel openings sealed by the O rings 5 or carefully rinse the channel with a suitable solvent e g IPA When doing so hold the complete sensor carrier in such a way that liquid can never penetrate the system After cleaning the system make sure to rinse it with dry gas until the measuring channel is also completely dry Chapter Page 05 14 Operation amp Service Cleaning the body also see sketch below n case the body is contaminated dismantle the instrument as described for dismantling the flow module and the measuring unit and clean this also Please make sure that no residues of cleaning liquids and cleaning cloths etc remain in the body With the subsequent assembly of the sensor carrier observe the correct position of the two 0 ring seals between the sensor carrier and the body under all circumstances 4 Make sure to screw in the flow module 1 up to the mechanical stop After correct ass
41. n must be previously set in the ModReg available instrument functions for users The value of this register can therefore also be written and read if this function was not activated As the instrument cannot be calibrated for negative mass flows it is not possible to detect negative flows Only the sensor characteristics curve is reflected and the characteristics curve is assumed to be symmetric which is of course not exactly the case If invalid values are written in this register Data Out Of Range error is generated float32 the value is interpreted in percent Jo of the maximum flow value The admissible value range is 0 20 Yo 20 l ot ice Signal type analog measuring m Mito Not possible value Read User Defines the output value of the analog measuring value output Value uint16 The error message Data Out Of Range is generated when writing other values The following possible defaults are available Value Description 0 0 20 mA 0 5 V linear 1 4 20 mA 1 5 V linear 2 4 20 mA to Namur NE43 i ite Not possible Sets the format of the analog setpoint input Value 16 _ The error message Data Out Of Range is generated when writing other values _ The following possible defaults are available Value Description 0 0 20 mA 0 5 V linear 1 4 20 mA 1 5 V linear 2 4 20 1
42. ontrlparameterintegraltime 0x0030 0x0031 ___ Feed forward F Control parameter feed forward 00082 s Non linearity N Control parameter valve offset compensation 000838 _ Soft reset Resets all parameters to the power on status 0 0034 Set of control parameters mm Selection of predefined control parameters EM UCM Power up alarm Activation of the power up alarm function 0X4040 u Power up alarm setpoint wai Setpoint of power up alarm nn Lu 0x4042 Y Totaliser function Function of the totaliser 0x4043 Totaliser unit _ Engineering unit of total 7 0x4048 0x404b Zero point suppression _ u Zero point suppression DIO nen Automatic storage B PROM _ Storage r mode of the non volatile memory mM 0x4050 Backflow detection Indicates a negative flow o 0X4052 0X4053 ss Signal type analog out ut Signal type of the analog measured value output ____0 4084 Delay hardware error Delay time for the plausibility check 0x4087 Implemented functions Implemented functions options 0x4128 0x4129 ss ACCOFdIng to the type of instrument Calibration data set Selection of the calibration data set 0x4139 Chapter Page 06 22 Digital Communication Detailed explanation of parameters EET EMI Read _ Measured value gas flow 0x0000 0x0001 Measured value of the gas flow in Scaling according to customer specification adjustable by manufact
43. r 5 bar horizontal Response time Installation position PKP Process Instruments Inc 10 Brent Drive Hudson 01749 1 978 212 0006 9 1 978 568 0060 Email info pkp eu Internet www pkp eu
44. r than air the calibration data are automatically converted to the requested gas If the measured gas differ from the one the instrument has been calibrated for the correct output signal can be calculated by means of the relevant conversion factor see chapter 11 Note Depending on the gas measured conversion factors may introduce considerable inaccuracies The reconfiguration to an other gas is more accurate by using the software supplied with each instrument The software reads the calibration data from the instrument converts them to the new gas and reloads them to the instrument Pressure Loss The pressure loss in a thermal massflow meter is very small and depends on the gas the operating pressure and the actual flow rate The graphs in chapter 11 annex show typical values for different gases at 20 C and 1013 mbar The pressure loss for a gas other than air is calculated according to the following formula p required bd AP x 1 250 Note that insufficient tube diameter or unsuitable fittings may cause a high pressure loss The pressure loss in a massflow controller mainly depends on the control valve The control valve must operate with the specified pressure drop for proper operation The graphs in chapter 11 annex show the typical pressure loss in massflow meters of different sizes and with different gases Temperature Compensation Thermal massflow meters are almost unaffected by temperature and pressure variations o
45. re stated with 8 bit breakdown The logic operation function of these parameters is described further down in this chapter Remark _ The N share is only active when the set setpoint is larger than zero Value uintt6 uint8 bits 15 8 always zero uint8 bits 7 0 N share of the currently selected controller 0 4 Soft reset 0x0034 Not possible A software reset of the measuring or control instrument takes place if any chosen value is written in this register This returns the instrument to the state it had after its last activation Attention The soft reset is first performed after the response to this command was returned to the master _ _ Value uint16 Any value triggers reset ad User Selection of the control 0x0035 Write E i The controller consists of altogether 5 complete control parameter sets see the corresponding documentation Three of these sets were defined by the manufacturer and cannot be changed by _ the user so called manufacturer control parameter sets Two sets can be changed at wish by the user so called user control parameter sets One set is used for the current control This setting can be saved in E PROM and is available again with the next activation This set can be read changed and re written modbus access Afterwards the controller immediately works with the modified set Function of the pre defined control parameter sets
46. resent an optimum between the setpoint step height and the opening speed Feed forward share F This share effects that the setpoint has a direct influence on the control value It does not contribute to the control signal if the setpoint is zero If the setpoint is larger than zero this value is directly multiplied with the F share and the result us added to the control value If all remaining shares of the controller were set to zero and only the feed forward share F used a direct control of the control valve results The setpoint would simply control the valve in the range 0 100 opening Of course the effect of F strongly depends on the pressure as pressure changes also change the valve characteristics curve This way one can largely realise a high control speed F share with a high control accuracy slow share Controller setting We recommend setting the individual controller parameters according to the following procedure 1 Non linearity N 2 Minimum scanning speed S 3 Gain factor 4 Fime constant Tx 5 Feed forward share F Setting the non linearity N 1 Connect the controller electrically warm up time and establish the operating conditions pressure ratios if possible With the software you have access to the control parameter sets A and B Set the control parameters to the following values S 0 Ke 0 001 0 02 N 0 Set the setpoint to 596 of the final value Increase the parameter N in steps of 5
47. routine service at all If the measurement value is in a quality relevant range e g ISO 9001 we recommend a periodic check of calibration The interval depends strongly on use Cleaning in the Case of Contamination Should there be suspicion of contamination sudden deviation of measurement value in familiar processes visible traces in the piping etc try flushing the device with a dry inert gas Depending on the contamination it may be necessary to dismantle the device Tips Use only designated tools Handle the device and individual components with extreme care Ensure that the dismantling area is clean The guarantee lapses at all events with the dismantling of the device Never loosen a torx screw Do not touch the electronic circuit board or electronic components under any circumstances After the cleaning you should have the device checked by your sales partner at the first opportunity Dismantling the flow module also see sketch on the next page Dismantle the gas and the electric connections On the feed side carefully turn out the flow divider together with the flow resistor 1 The construction does not have any O ring seals in this section You can now clean the complete flow module with a light solvent e g IPA Please make sure that the drill holes are all absolutely clean dry and patent Dismantling the measuring unit also see sketch on the next page n order to clean the measuring part f
48. ry Data Start Adr Hi Start Adr Lo No of Register Hi No of Register Lo Byte Count 1 Data N 8 Bit 8 Bit 8 Bit 8 Bit 8 Bit 8Bit 8Bit 8 Bit Start Adr Starting address of registers of Register Number of registers to be written in Byte Count Number of bytes to be transmitted Data N Register data Note The number of bytes to be transmitted is limited to 20 because of the limited storage capacity of the RAM Response Data Start Adr Hi Start Adr Lo No of Register Hi No of Register Lo 8 Bit 8 Bit 8 Bit 8 Bit Start Adr Starting address of registers of Register Number of registers to be written in END A message is terminated with a pause of min 3 5 Character times ca 4ms Parameter Measured value and setpoint of the mass flow meter or controller are available either as analog signals or directly in engineering units as digital signals The full functionality is only available in the digital mode The following parameters describe the functions accessible by the customer A series of other parameters are only accessible by the manufacturer The following example shows the structure of a parameter s nos Se Read _ Parameter name Register address Authorisation Description of the parameters Format interpretation of the parameter The following parameter table lists the Modbus registers In the detailed description you find the register addresses in HEX Number typ
49. s No Of Points Number of registers to be read Response Data Byte Count Data 1 Data Reg N 8 Bit n Bytes n Bytes n Bytes Byte Count Number of bytes retrieved Data Reg N Register data Function 06 Preset Single Register Writes data in a register of the slave Query Data Reg Adr Hi Reg Adr Lo Preset Data Hi PresetDataxN Preset Data Lo 8 Bit 8 Bit 8 Bit 8 Bit x N 8 Bit Reg Adr Register addess Preset Data Register data Response Data Reg Adr Hi Reg Adr Lo Preset Data Preset Data Lo 8 Bit 8 Bit 8 Bit 8 Bit Reg Adr Register adress Preset Data Register data Function 08 Diagnostics Used is only the Diagnostics function Return Query Data Code 00 This allows to test the Modbus The addressed slave returns the query without execution The function is called up with the subfunction 00 Query Data Subfunction Hi Subfunction Lo Data Hi Data Lo 8 Bit 8 Bit 8 Bit 8 Bit Subfunction Gall of diagnostic function Data Data Response Data Subfunction Hi Subfunction Lo Data Hi Data Lo 8 Bit 8 Bit 8 Bit 8 Bit Subfunction Gall of diagnostic function Data Data Chapter Page 06 20 Digital Communication Function 16 Preset Multiple Registers Writes data into multiple registers of a slave The number and the starting address of the registers are free However the number of bytes is limited to 20 address function data and CRC check Que
50. s are saved in the volatile memory 2 Settings which are also saved in case of an interruption of operations These settings are saved in the non volatile memory EPROM This command permanently saves all settings of all parameters of the second kind in EPROM If automatic save register 0x 4050 storage mode of the non volatile memory is deactivated this i is the only possibility to permanently Save the Settings to be Stored in EPROM Value uint16 Value Description 0 Save settings Writes the settings from the volatile to the non volatile memory gt 0 Re read settings Reads the settings of the memory and writes them back to the volatile memory Instrument name 0 0023 0 0026 Read s sr 5 2 of the instrument type 4 instrument code Value uint16 x 4 whereby each uint16 consists of two uint8 char8 Default value 0 zero for all characters 0x0023 contains the first two characters 0x 002 6 contains the last two characters All four registers can be read independently of each other Analog output manual 0 0028 0 0029 The analog power output i is manually set to a i certain current The possible range i is 50 21 6 mA Smaller or larger values are clipped according to these limits This function lets you check the connected evaluation of the of the analog measuring value It is possible to write and read in this register at all times The value set in this r
51. t memories respectively data sources PPROM configuration data etc RAM measuring values etc ROM fixed coded data in the program Saving data in the non volatile memory Certain register contents are saved in the non volatile memory E PROM By setting the parameter storage mode of the non volatile memory you can define whether changes to these registers are saved immediately and automatically or whether these are initially saved in RAM volatile memory first With the parameter update E7PROM you save all registers which can be deposited at all in the non volatile memory in EPROM Control characteristics Control circuit structure The controller consists of a linear and a non linear part The linear part of the controller consist of the following components Gain factor K Time constant The non linear part consists of two components Feed forward share F Offset compensation share N Scanning speed S Valve characteristics curve In its work range the valve characteristics curve has almost linear characteristics Here the valve does not use the entire adjustment value range from 096 to 10096 The operating points minimum possible flow and D max possible flow depend on the inlet pressure and the pressure difference across the valve As mentioned the valve behaves linear in the work range However because Da is not located at 0 adjustment value the valve behaves non linear when seen as a w
52. taminated as well contact your service representative Send in the instrument for repair or obtain a new control valve cartridge Check the control parameters and use one of the provided standard sets for control Check the gas supply for constant pressure or any elements that destabilise the system Did you observe the recommendations for dimensioning the pipe system _ Open the pipe system and check it for possible contaminations including the installed filters If you detect contamination check the instrument as well If you think the valve is contaminated as well contact your distribution partner Chapter Page 08 41 expectations Control unstable 0 0 Troubleshooting Gas supply Check the gas supply for constant pressure or any elements that destabilise the system Especially a too small dimensioned pressure reduction can produce very negative influences With very small flows with an oversized gas supply sporadic pressure changes ON OFF function pressure reduction can also lead to unstable pressure characteristics Did you observe the recommendations for dimensioning the pipe system Setpoint default unstable Control parameters Conversion factor not considered Open the pipe system and check it for possible contaminations including the installed filters If you detect contamination check the instrument as well If you think the valve is contaminated as well
53. tempt not only to propagate good service and high quality but to live it every day Guarantee The guarantee for DBO5 or gasflow products extends to material defects and production flaws The guarantee maximum is the replacement of the equipment at no cost Claims are omitted in the case of inappropriate use external effects in general excessive heat or dropping We are always grateful for information on existing defects for suggestions for improvements and for critiques Chapter Page 01 4 Introduction Tips and Warnings Before putting the instrument into use these operating instructions should be read thoroughly Improper use errors for lack of understanding and the consequences arising from this can lead to the destruction of the instrument or even the endangerment of personnel The equipment should be put into operation and serviced by appropriately qualified personnel only The proper handling of the products is an absolute requirement for its trouble free operation Electrostatic discharges can destroy electronic components of this measurement and regulation unit This manual aims at a safe operation of 2805 mass flow meters and controllers Each instrument is supplied full of charge with a CD containing the 2805 software as well as this manual Chapter Page 01 5 02 Mode of Operation A Bit of Theory Measuring Principle The principle of thermal mass flow measurement
54. than setpoint Actual value unstable Troubleshooting Defect circuit board Offset though installation position ne No gas Contamination Control circuit does not work properly Defect circuit board Gas supply Control parameters Contamination Send in the instrument for repair as described in chapter 5 s A zero point offset may occur with vertical installation position and higher pressures oo s the gas supply working Are all shut off valves open __ Are any filters clogged Open the pipe system and check it for possible contamination Separate the connection cables from the instrument and open the casing cover Check the correct position of the valve plug Then reinstall the valve plug and reassemble the casing If the actual value is zero now check the control parameters For control purposes select one of the provided standard sets Check the control parameters and use one of the provided standard sets for control purposes Send in the instrument for repair as described in chapter 5 Check the gas supply Does the pressure P1 specified on the type plate correspond to the actual one Did you observe the recommendations for dimensioning the pipe system Open the pipe system and check it for possible contaminations including the installed filters If you detect contamination check the instrument as well If you think the valve is con
55. trol instruments Orginally it was introduced by MODICON For further informations see http www modbus org For further programming examples please contact your sales partner The hardware typically used for Modbus is RS 485 RS 422 or RS 232 A Modbus message from master to slave consists of Address command read or write data and checksum DB05 works on the following communication parameters Communication speed 9600 Baud Startbit 1 Databits 8 Stopbits 2 Parity none Bit Time 104 6us Character Time 11 Bit 1 1458ms Max buffer size 20 Byte Data Max number of units theortical 247 Structure START ADRESS FUNCTION CRCOHECK NDO 1 2 3 4 8 BITS 8 5 nx 8BITS 16 BITS T1 T2 T3 T4 START A message starts with a break of min 3 5 character times ca 4ms ADRESS Address range 01 247 Broadcast to all instruments 00 no answer from the instruments FUNCTION Overview Function 03 Read Holding Registers Function 06 Preset Single Register Function 08 Diagnostics Function 16 10H Preset Multiple Registers Chapter Page 06 19 Digital Communication DATA Function 03 Read Holding Register Reads the data from the following registers of a slave The number and the starting address of the registers are free Query Data Start Adr Hi Start Adr Lo No of Points Hi of Points Lo 8 Bit 8 Bit 8 Bit 8 Bit Start Adr Starting address of register
56. unication Instrument address 0x0013 Read Defines the instrument address with which the Instrument c can nbe addressed within a modbus structure Up to 247 different addresses can be assigned in a modbus system Attention In a system in which several instruments are connected with each other via modbus all _ instruments must have different addresses Otherwise communication errors occur and the System will no longer function Value uint16 consist of two uint8 uint8 bits15 8 are not used should always be 0 uint8 bits7 0 value of the instrument address Admissible values 1 247 Default 247 The error data out of range is generated when trying to define values outside of the admissible range Read User Measuring range 0x0014 0x0015 Range of the measurable mass wi in min min for which the instrument was calibrated value float32 ranga of the measurable mass s flow Unit ge value 0x0016 0x0019 Name of the measuring medium i in plain text Value uint16 x 4 whereby each uinti6 consists of two uint8 char8 Default value OV zero for all characters 0x0016 contains the first two characters 0x 0019 contains the last two characters All four registers can be read independently of each other Write Not possible Name of medium 0x001a 0x001d gest Read i Name of the measuring medium in plain text Value vint16 x 4 whereby eac
57. until a flow sets in 6 Set N to 80 of the detected value N remains identical for all sets Setting the gain factor 1 A setpoint jump from 0 to 50 is defaulted 2 Keis increased until the system becomes unstable with this setpoint jump non abating constant oscillation with period T oscillation 3 Keis now set to the following value Optimised control k 150 of the determined value Maximum speed k 180 of the determined value Maximum stability k 120 of the determined value Setting the time constant With the determined value for the oscillation period the time constant Tu to be set can be calculated as follows Optimised control Tu 1 12 Of Toscivation Maximum speed Tu 1 15 Of Toscivation Maximum stability Tu 1 9 Toscitation Setting the feed forward share F We recommend leaving this parameter at zero Chapter Page 06 36 Digital Communication Setting the minimum scanning speed S 1 A setpoint jump from 0 to 5 is defaulted 2 The minimum scanning speed is increased in steps of 5 until a slight overshoot sets in with the setpoint jump 3 The detected value can be left for an optimum control speed For maximum stability the set value should amount to 7096 of the detected value The following table applies for maximum speed Determined value in a range of Value to be set 0 50 200 of the determined value 51 100 150 of the determined value 101 19
58. ure losses in the piping fittings etc At very low flows the pressure controller might be oversized and work in an intermittent mode resulting in a strongly oscillating flow Do not apply pressure until the electrical connections are made When applying pressure to the system increase the pressure gradually and avoid pressure shocks If explosive or aggressive gases are to be used purge the process with dry inert gas like Nitrogen or Argon Chapter Page 04 13 A 05 Operation amp Service Operation and Service Heat Up Time Right when the device is turned on 0805 is ready for use For the most precise measurements however in 30 minutes option of external feed Before turning on please be sure that the wiring is correct and is installed according to the installation plan and that the gas connections are also mounted in accordance with the installation instructions of the manufacturer Zero Point Check Without any special specifications for the installation position of the device the zero point is aligned at operating temperature and horizontal installation position before delivery If the device is installed vertically a value can be read out at a zero flow rate according to operating pressure During the check be completely sure that no gas is flowing In the case of a shift in the zero point please contact your sales partner Service With proper operation DBO5 does not require any
59. urer or sales partner Value float32 Measured value temperature 0x0002 0x0003 Measured value of the gas temperature in C Value float32 Totaliser 0x004 0x0005 Ew Read i User i Total gas flow since last reset Internally totalised in may be scaled with an appropriate scaling factor according to the following formula F Scalingfactor Gas Gas mln Legend Total quantity of gas converted by the scaling factor OF Sscatingtactor I Scaling factor Definition according to register Scaling factor of the totaliser Total quantity of gas Any value can be written in this register including negative values The totaliser then starts from this value _ Value float32 The gas total may have any unit if properly scaled Preset value 0 With a scaling factor of 1 0 the unit of the gas total is mln Setpoint of gas flow 0x0006 0x0007 Setpoint of the controller in mIn min To activate the setpoint the controller mode register 0 000 has to be in mode 0 automatic or in mode 1 Modbus _ The controller operates only with this setpoint if the power up alarm register 0x 4040 is not active _ In this case the value is stored in the non volatile memory and is still present after a power loss With the power up alarm activated the setpoint will be lost at a power loss i
60. urrent integral i is s multiplied with this factor before the value is output via a the modbus This way it is possible to select any unit for the totaliser sum In local mode calculation takes place with mIn min Multiplication with the following factor is required in order to read out the totaliser value in Is min Deng 3 1 107 etter 1000 Value float32 Chapter Page 06 31 Communication Write Read Totaliser unit 0x4048 0x404b Engineering unit of the totalled totaliser value Value uint16 x 4 whereby each uint16 consists of two uint8 char8 Default ON zero for all characters 0x40468 contains the first two characters 0x404b contains the last two characters All four registers can be read independent of each other Fre Read Zero amt suppression 0x0x404c 0x404d Ther mass flow measured i in n be suppressed downwards with this register them mass value is smaller than the value set here zero is output instead of the measuring value This value must be larger than or equal zero If a negative value is entered Data Out Of Range error is Se Reset hardware error 0x404f Resets the alarm statuses of the instrument that occurred during operation The meaning of the individual error bits are described the register hardware errors 0 0004 Error bits cannot be set manually as they are always a cons
61. use of the cooling of the entering gas which theoretically drops to the ambient temperature respective of gas Secondly the gas flowing over the heater carries heat to the temperature sensor T2 located after the heater and thus increases this temperature The temperature difference is in direct proportion to the mass flow T2 mu AT H M gt flow T1 T2 m 0o v Ar Tenvironment AT v T1 Figure 2 Schematic illustration of how thermal mass measurement functions CMOS Technology 0805 measurement and regulation units feature a new basic technology that sets standards for maximum precision sensor systems The fusion of a semi conductor chip with sensor technology results in a highly integrated system solution that is impressive for its excellent sensor precision as well as digital intelligence and reliability The most notable advantages to the customer are the outstanding precision of the sensor the rapid response time and a dynamic measuring range that no system has attained up until now Thanks to the compact single chip design CMOSens based sensors are extremely resistant to electromagnetic interference EMI a significant technical advantage of this ultra modern sensor technology With CMOSens the sensor element amplifier and A D converter form a unit on the same silicon chip Chapter
62. ut off valves open Are any filters clogged Open the pipe system and check it for possible contamination Check Is the supply connected and OK 24 V DC Are connection cables interrupted With present digital evaluation Does the digital communication still work Make sure whether there is also no signal at the input of your evaluation Have you installed the shunt resistance 250 Ohm with 0 5 V layout for your evaluation nn 0 mA or 0 V Defect circuit board CE e of zero Control circuit does not work properly In case the digital evaluation still functions the error description can be specified further for the necessary repair Send in the instrument as described in chapter 5 The instrument or at least the is contaminated Open the pipe system and check it for possible contamination Contact your distribution partner Either send in the instrument for repair or exchange the control valve Conic Separate the connection cables from the instrument and open the casing cover Then pull out the valve plug replace the cover and reconnect the connection cable If the actual value is zero now check the control parameters For control purposes select one of the provided standard sets Wrong control parameters Check the parameter and reduce this if required Chapter Page 08 40 setpoint lager than zero Actual value smaller

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