FCRCGM-03 User Manual - Queen's

FCRCGM-03 User Manual - Queen's
FUEL CELL RESEARCH CENTRE
Gas Blending System Model FCRCGM-03
User Manual
QUEEN'S - RMC FUEL CELL RESEARCH CENTRE
FCRCGM-03
945 Princess Street • 2nd Floor
Kingston, ON K7L 3N6
Phone (613) 547-6700 • Fax (613) 547-8125
Table of Contents
System Overview ....................................................................... 1 System Layout ................................................................................. 2 Front ......................................................................................................... 2 Top ........................................................................................................... 3 Back.......................................................................................................... 4 General ............................................................................................ 5 Plumbing .......................................................................................... 5 Plumbing Diagram .................................................................................... 5 Controls ........................................................................................... 6 Safety system .................................................................................. 6 System Installation ..................................................................... 6 Wiring ............................................................................................... 6 External flow control and monitoring ........................................................ 7 E-stop system expansion ......................................................................... 8 Gas Connections ............................................................................. 8 Safety considerations ...................................................................... 8 System Operation ...................................................................... 9 Gas Type Selection and Correction Factors .................................... 9 Mass Flow control ............................................................................ 9 Local set point control............................................................................... 9 External analog control ........................................................................... 10 Flow override .......................................................................................... 10 RS-232 computer control........................................................................ 10 Gas source and blending control ................................................... 10 Inlet gases .............................................................................................. 11 Metered gas streams – Straight out or mixed......................................... 11 Maintenance ............................................................................ 12 Troubleshooting ............................................................................. 12 Spare Parts .................................................................................... 14 System Specifications .............................................................. 16 Omega Process Controllers ..................................................... 18 Parameter Settings ........................................................................ 18 Parameter ........................................................................................ 18 Setting............................................................................................. 18 OEM Documentation ................................................................ 20 Document Listing ........................................................................... 20 Document ....................................................................................... 20 Website ........................................................................................... 20 Notes: ....................................................................................... 21 F C R C G M - 0 3
U S E R
M A N U A L
System Overview
Four channel gas control and blending.
T
he FCRCGM-03 is a four channel gas delivery and blending system. This manual details
the use, capabilities, specifications and care of the system.
I C O N
K E Y
1 Valuable information
G
Safety Information
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System Layout
Front
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
Function
Common Inlet
MFC 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
E-stop reset button and status indicator
Temperature limit switch override
Temperature limit switch
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Top
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Function
MFC 1 Inlet selection ball valve
MFC 1 Outlet selection ball valve
MFC 2 Inlet selection ball valve
MFC 2 Outlet selection ball valve
MFC 3 Inlet selection ball valve
MFC 3 Outlet selection ball valve
MFC 4 Inlet selection ball valve
MFC 4 Outlet selection ball valve
MFC 1 Omega process controller
MFC 2 Omega process controller
MFC 3 Omega process controller
MFC 4 Omega process controller
MFC 1 Flow override switch and indicators
MFC 2 Flow override switch and indicators
MFC 3 Flow override switch and indicators
MFC 4 Flow override switch and indicators
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Back
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
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
Mixed gas outlet
MFC 4 gas outlet
MFC 3 gas outlet
MFC 2 gas outlet
MFC 1 gas outlet
Cabinet ventilation outlet
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General
The FCRCGM-03 gas delivery and blending system can be used as a stand-alone unit, or connected
to a computer or 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 is 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
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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 etc.
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 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
G
Note: The e-stop circuit is bypassed for MFC’s under RS-232 control.
System Installation
Wiring
Electrical connections to the system are used for e-stop expansion, external gas control and
monitoring, and MFC calibration.
6
1
2
3F C R 4C G M5 - 0 36
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8 M A9N U10
11
A L
U S E R
12 13 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 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
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Connection
MFC 1 negative set point signal (4-20 mA)
MFC 1 positive set point signal (4-20 mA)
MFC 2 negative set point signal (4-20 mA)
MFC 2 positive set point signal (4-20 mA)
MFC 3 negative set point signal (4-20 mA)
MFC 3 positive set point signal (4-20 mA)
MFC 4 negative set point signal (4-20 mA)
MFC 4 positive set point signal (4-20 mA)
MFC 1 process value (0-10 VDC)
MFC 2 process value (0-10 VDC)
Common (for process values)
Common (for process values)
MFC 3 process value (0-10 VDC)
MFC 4 process value (0-10 VDC)
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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.
Pins 3 and 4 are connected to a safety relay contact. The contact is open when the system is in an estop condition, and closed when the safety system is out of e-stop and reset. This contact can be
used as a switch for external devices such as solenoids, lights, alarms etc. This relay output is rated:
Output Rating AC:
Output Rating DC:
Inductive AC, 3 A/230 VAC
Inductive 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 ¼” 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.
G
The RS-232 connections to the MFC’s bypass the E-stop circuitry. For applications requiring the estop system to be enabled, analog control (either local or remote) must be used.
G
Gases connected to the FCRCGM-03 such as fuels and Oxygen should have a flame arrestor
installed at the cylinder.
G
MFC 3 and it’s associated components have been cleaned for Oxygen service. Do not flow
hydrocarbons through MFC 3. Doing so could damage the sensor element in the MFC.
Check all gas connections for leaks prior to running the system.
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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 2nd: 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 2nd if FlowDDE is already
communicating with another MFC)
- Select the active curve with FlowView. If the desired gas type calibration curve 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 the pre-installed calibration curves for each MFC can be found in
the System Specifications section of this manual.
1
G
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
scenario, always set the flow override 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 are 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 is set for local
manual control. Press the up or down arrows on the process controller to adjust the set point.
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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 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:
FlowDDE: Software tool to establish communications between Windows and an MFC
FlowDDE 2nd: 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’s.
1
Note: Currently the RS-232 connections only support two MFCs at one time from a single
computer. Run FlowDDE and FlowDDE 2nd 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.
1
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.
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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
MFC, either to the mixed gas manifold, or straight out of the system. 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.
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Maintenance
With normal use, no routine maintenance is required. For applications requiring precise flow
control, gas flows can be verified using a Molbloc (or similar) flow meter.
MFC gas lines may be flushed with clean, dry inert gas.
Troubleshooting
Symptom
Possible Cause
No flow when commanded Unit in e-stop
(local set point on Omega
process controller(s)
Resolution
-
No gas supply to
MFC
-
Flow
override
switch is in the
wrong position
-
Excessive
pressure
-
back
MFC
Control
Switch is in the
wrong position
-
Blown MFC fuse
-
12
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
are connected.
Press green reset button
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
Move the flow override switch to the
middle position (orange LED will
light)
Ensure the outlet ball valve is in the
correct position to direct flow to the
desired outlet port.
Check external gas connections for
blockage
Set the MFC control switch to the
down position (“MN” will display on
MFC)
Replace fuse (400 mA fuse)
F C R C G M - 0 3
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24 VDC power
supply failure
-
Check 24 VDC power supply fuse.
No power
electronics
to
-
Omega process controller(s) Blown controller
not powered
fuse(s)
-
Plug unit into 115 VAC
Check main power fuse (integrated
into power socket on rear panel
Replace fuse(s)
Flow override will not force 10V signal not
full flow through MFC
reaching MFC
-
Check 10V regulator board for proper
output
-
See “No flow when commanded”
symptom in this troubleshooting guide
Check set point wiring connections on
Pheonix connector at rear panel
Ensure hardware used to send set
point is functioning properly
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
are connected.
Press green reset button
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
Move the flow override switch to the
middle position (orange LED will
light)
System will not turn on
Other
No flow when commanded Set point not
(external 4-20 mA set point)
received by MFC
Unit in e-stop
-
No gas supply to
MFC
-
Flow
override
switch is in the
wrong position
-
Excessive
pressure
-
back
-
13
Ensure the outlet ball valve is in the
correct position to direct flow to the
desired outlet port.
Check external gas connections for
blockage
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Flows not at expected values
MFC
Control
Switch is in the
wrong position
-
Set the MFC control switch to the up
position (“MN” will NOT display on
MFC)
Blown MFC fuse
-
Replace fuse (400 mA fuse).
24 VDC power
supply failure
-
Check 24 VDC power supply fuse.
Incorrect
calibration curve
loaded on MFC
-
Inlet to outlet
pressure
difference
to
small
-
Connect to MFC via FlowView and
select the proper calibration curve.
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.
A delta P of ??? from inlet to outlet is
required for the MFC to operate
properly.
Check for sufficient inlet pressure
Check for excessive backpressure
Calibrate MFC
MFC
requires
calibration
Spare Parts
Description
Supplier
-
Part Number
MFC fuses ( Fast 400mA Short Digi-Key
UL TE5)
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
Digi-Key # WK4340BK-ND
Manufacturer # 39504000440
SS-4C-1/3
Note: The #3 gas line is cleaned for O2
service. The part number for the check
valve in this line is SS-4C-1/3-SC11
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System Specifications
Electrical
Voltage
110 – 120 VAC 60Hz
Operating Current Draw (Max) Approx 3.6A
Operating Environment
Temperature
Humidity
Storage temperature
0 to 70 deg C
0 to 90% RH, non-condensing
-40 to 85 deg C
Plumbing
Tubing material
Tubing Size
Check valves
316 Stainless Steel
¼” O.D, 0.035” wall thickness
1/3 PSI cracking pressure
Ball valves
0.35 Cv
MFC’s General
Manufacturer
Model
Input pressure Maximum
Accuracy
Warm-up time
Plumbing connections
Material (wetted parts)
Seals
Communication
Inrush could exceed max
Seal material:
Fluorocarbon FKM
Bronkhorst
EL-Flow
100 bar
Calibrated to 5 bar
±1% FS for ranges > 3ml/min
±2% FS for ranges < 3ml/min
30 min. for optimum accuracy
2 min. for ±2% FS
¼” Swagelok compression
Stainless steel 316L
Viton
RS-232, Analog 0-10VDC
Note:
Omega
process
controllers that send external
set point to MFCs require 4-20
mA signal in.
MFC 1
Gas cal. curves pre-loaded
Flow Range
500 mls/min
500 mls/min
500 mls/min
500 mls/min
H2,
CO2
CO
N2
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MFC 2
Gas cal. curves pre-loaded
H2,
CO2
CO
N2
Flow Range
250 mls/min
250 mls/min
250 mls/min
250 mls/min
O2
CO2
CO
Flow Range
100 mls/min
100 mls/min
100 mls/min
H2,
CH4
C2H6
C3H8
C3H6
C2H4`
Flow Range
50 mls/min
50 mls/min
50 mls/min
45 mls/min
50 mls/min
50 mls/min
MFC 3
Gas cal. curves pre-loaded
MFC 4
Gas cal. curves pre-loaded
Process Controllers
Manufacturer
Model
Omega
CN63300-R1-R2-F3-RSP
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Omega Process Controllers
Parameter Settings
Mnemonic Parameter
CN63300 Configure Input 1-INP
tYPE
Input Type
dCPt
Decimal Point
rnd
Rounding Element
FLtr
Digital Filtering
dSP1
Display Value #1
InP1
Signal Input Value #1
dSP2
Display Value #2
InP2
SPLO
SPHI
Setting
Volt
0.0
0.1
1
0
0
MFC 1: 500
MFC 2: 250
MFC 3: 100
MFC 4: 50
10
0
MFC 1: 500
MFC 2: 250
MFC 3: 100
MFC 4: 50
0
RSP
Signal Input Value 2
Setpoint Lower Limit
Setpoint Upper Limit
SPrP
Setpoint Ramp Rate
InPt
User Input
CN63300 Configure Output 1-OP
CYCt
Cycle Time
OPAC
Output Control Action
OPLO
Output Lower Limit
OPHI
Output Upper Limit
OPdP
Output Power Dampening
CHYS
ON/OFF Control Hysteresis
tcod
Auto-Tune Dampening Code
ANtP
Linear Output Range
ANAS
Linear Output Source
ANUt
Linear Output Update Time
ANLO
Linear Output Scale Point Low
ANHI
Linear Output Scale point High
0
REV
0
100
1
0.1
0
0-10
SP
0
0
MFC 1: 500
MFC 2: 250
MFC 3: 100
MFC 4: 50
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Configure Lockouts 3-LC
SP
Access Setpoint
OP
Access Output Power
dEv
Access Deviation Display
UdSP
Access Display Units
Code
Access Code Number
PId
Access PID Values
AL
Access Alarm(s) Values
ALrS
Enable Reset Alarm(s)
SPSL
Enable Remote/Local Transfer
trnF
Enable Auto/Man Transfer
tUNE
Enable Auto-tune
Configure Alarms 4-AL
Act1
Alarm 1 Action Mode
rSt1
Alarm 1 Reset Mode
Stb1
Alarm 1 Standby Enabled
AL-1
Alarm 1 Value
Act2
rSt2
Stb2
AL-2
Ent
LOC
RED
RED
2
LOC
LOC
LOC
LOC
LOC
LOC
Alarm 2 Action Mode
Alarm 2 Reset Mode
Alarm 2 Standby Enabled
Alarm 2 Value
AHYS
Alarm Hysteresis Value
Configure Remote Setpoint 7-rS / 7-n2
dSP1
Remote Setpoint Display Value #1
INP1
Remote Setpoint Input Value #1
dSP2
Remote Setpoint Display Value #2
INP2
FLtr
bAnd
trnF
Remote Setpoint Input Value #2
Remote Setpoint Filter Time Constant
Remote Setpoint Filter Band
Local/Remote Transfer Options
19
b-ot
Auto
yes
MFC 1: 50
MFC 2: 25
MFC 3: 10
MFC 4: 5
b-ot
Auto
yes
MFC 1: 550
MFC 2: 225
MFC 3: 110
MFC 4: 55
0.1
0
4
MFC 1: 500
MFC 2: 250
MFC 3: 100
MFC 4: 50
20
1
0.5
NOR
OEM Documentation
For further information on the components within the FCRCGM-03, consult
the following documents and websites:
Document Listing
Component(s)
Document
Bronkhorst MFCs Bronkhorst Doc. No. 9.17.022O
Omega
process CN63100/63300
Series
1/16
DIN
controllers
Temperature/Process Controllers User’s Guide
Watlow
Watlow Doc. No. 0600-0044-0001 Rev. G
Series L User’s Manual
Sti
SR103AM SR103AM Spec sheet
Safety Relay
24VDC
Power Type SPD 60W power supply spec sheet
supply
Swagelok
components
20
Website
www.bronkhorst.com
www.omega.com
www.watlow.com
www.sti.com
www.gavazzionline.com
www.swagelok.com
Notes:
Keep operating and maintenance notes here
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