9.17.075
Instruction Manual
CORI-FILL™
Setting-up (mini) CORI-FLOW™
instruments for filling applications
Doc. no.: 9.17.075B Date: 09-12-2015
ATTENTION
Please read this Instruction Manual carefully before installing and operating the instrument. Not
following the guidelines could result in personal injury and/or damage to the equipment.
Bronkhorst®
Disclaimer
Because of the various hardware and software environments into which Bronkhorst software may be put, this software and
the accompanying files are "as is" and without warranties as to performance of merchantability or any other warranties
whether expressed or implied.
Bronkhorst is not responsible for lost profits or revenue, loss of use of the software, loss of data, costs of re-creating lost
data, the cost of any substitute equipment or program, or claims by any party other than you.
Although the equipment is thoroughly tested, Bronkhorst takes no responsibility for hardware or software failures which
could result in personal injury and/or damage to any customer equipment.
Bronkhorst strongly recommends a backup to be made before any software is installed.
Although every attempt has been made to make Bronkhorst software virus free there is no warranty for software viruses.
The fact that you are using the program indicates that you understand and agree to these terms.
Copyright
All rights reserved. This documentation is protected by copyright.
Subject to technical and optical changes as well as printing errors. The information contained in this document is subject to
change at any time without prior notification. Bronkhorst® reserves the right to modify or improve its products and modify
the contents without being obliged to inform any particular persons or organizations. The device specifications and the
contents of the package may deviate from what is stated in this document.
Symbols
Important information. Discarding this information could cause injuries to people or damage to the Instrument or
installation.
Helpful information. This information will facilitate the use of this instrument.
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Additional info available on the internet or from your local sales representative.
Receipt of equipment
Check the outside packing box for damage incurred during shipment. When the packing box is damaged, then the local
carrier must be notified at once regarding his liability, if so required. At the same time a report should be submitted to your
local sales representative.
Carefully remove the equipment from the packing box. Verify that the equipment was not damaged during shipment.
Should the equipment be damaged, then the local carrier must be notified at once regarding his liability, if so required. At
the same time a report should be submitted to your local sales representative.
Check the packing list to ensure that you received all of the items.
Do not discard spare or replacement parts with the packing material and inspect the contents for damage.
Refer to "Removal and return instructions" about return shipment procedures.
Equipment storage
The equipment should be stored in its original packing in a cupboard warehouse or similar. Care should be taken not to
subject the equipment to excessive temperatures or humidity.
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Warranty
Bronkhorst products are warranted against defects in material and workmanship for a period of three years from the date
of shipment provided they are used in accordance with the ordering specifications and not subjected to abuse or physical
damage. Products that do not operate properly during this period may be repaired or replaced at no charge. Repairs are
normally warranted for one year or the balance of the original warranty, whichever is the longer.
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See also paragraph 9 of the Conditions of sales:
http://www.bronkhorst.com/files/corporate_headquarters/sales_conditions/en_general_terms_of_sales.pdf
The warranty includes all initial and latent defects, random failures, and undeterminable internal causes.
It excludes failures and damage caused by the customer, such as contamination, improper electrical hook-up, physical shock
etc.
Re-conditioning of products primarily returned for warranty service that is partly or wholly judged non-warranty may be
charged for.
Bronkhorst® or affiliated company prepays outgoing freight charges when any part of the service is performed under
warranty, unless otherwise agreed upon beforehand, however, if the product has been returned collect to our factory or
service center, these costs are added to the repair invoice. Import and/or export charges, foreign shipping methods/carriers
are paid by the customer.
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Table of contents
1
. . .description
.........................................................................................................5
General
1.1
CORI-FILL™
. . . . with
. . . . . .shut-off
. . . . . . . . .valve
.........................................................................................6
1.2
CORI-FILL™
. . . . with
. . . . . .proportional
. . . . . . . . . . . . . valve
.....................................................................................6
1.3
CORI-FILL™
. . . . with
. . . . . .pump
..................................................................................................6
2
..........................................................................................................7
System. .requirements
2.1
Personal. . Computer
..........................................................................................................7
2.2
Software
. . on
. . . .Personal
. . . . . . . . . Computer
.............................................................................................7
3
. . . . . . . and
. . . . . startup
. . . . . . . . . .of
. . .FlowPlot
. . . . . . . . . . . and
. . . . . FlowDDE
...................................................................8
Installation
3.1
Getting. started
...........................................................................................................8
3.2
Installation
............................................................................................................8
3.3
Main window
. . . . . . . layout
. . . . . . . .FlowDDE
.............................................................................................8
4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Operation
4.1
Main window
. . . . . . . . .layout
. . . . . . .FlowPlot
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5
. . . . .in
. . .mass
. . . . . . flow
. . . . . . or
. . . volume
. . . . . . . . . .flow
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Readout
5.1
Adjust. instrument
. . . . . . . . . . . . unit
. . . . .type
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.2
Adjust. instrument
. . . . . . . . . . . . capacity
. . . . . . . . . (FS
. . . .range)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.3
Setting. .instrument
. . . . . . . . . . . .flow
. . . . . range
. . . . . . .and
. . . . filters
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6
. . . . . . .the
. . . . counter
. . . . . . . . . . for
. . . . batch
. . . . . . . .counting/dosing
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Preparing
6.1
Analog. .operation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7
. . . . . . . . .using
.......a
. . shut-off
. . . . . . . . . . Valve
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
On-off. .dosing
7.1
Using .hold
. . . . .current
. . . . . . . .for
. . . energy
. . . . . . . . saving
. . . . . . . .with
. . . . .shut-off
. . . . . . . . .valves
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
8
. . . . . . . . . . filling
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Proportional
8.1
Proportional
. . . . . . . filling
. . . . . . . example
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8.2
Controller
. . . . .options
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.3
Parameter
. . . . .settings
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8.4
FlowPlot
. . . settings
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
9
. . . . . . .batch
. . . . . . . dosing
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Very small
10
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Troubleshooting
11
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Service
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CORI-FILL™
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General description
CORI-FILL technology, integrated in (mini) CORI-FLOW instruments is based on Coriolis instruments firmware with additional
batch counter facilities. The instrument uses its integrated PID-controller and batch counter to directly control, shut-off
valves, proportional valves or pumps to enable compact, accurate filling applications.
CORI-FILLTM basic setup
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1.1
CORI-FILL™ with shut-off valve
CORI-FILL™ using shut-off valve
Features:
· Less supply pressure needed as for proportional valves due to large
orifices
· Low dead volume between sensor and valve
· Fast (up to < 0.5 sec. dosing time)
· Adaptive overrun correction
· Optimal accuracy after a few batches
· Adjustable correction factor for faster or slower overrun correction
· Cost effective and very compact
· Also useable for on-off switching of pumps
· Electrical as well as pneumatically shut-off valves available
1.2
CORI-FILL™ with proportional valve
CORI-FILL™ using proportional valve
Features:
· “First time right” batch (no overrun correction needed)
· Suitable for longer dosing times (> approx. 5 seconds)
· Will need at least same pressure drop as over Coriolis sensor for stable
control, only to be used if supply pressure is sufficient
· Also usable for pump control
· Adjustable P-action on batch counter
1.3
CORI-FILL™ with pump
CORI-FILL™ with a pump can be used with either the proportional filling
method by controlling the pump in speed (via integrated U/f-converter) or
by just switching the pump on and off using the shut-off filling method. It
will follow the features for the according filling method.
(Liquid) pumps can be used in stead of valves by just connecting the
instrument controller output signal (voltage or current) to an analog input
signal at the valve for speed control (if available for the pump) or use a
relay to switch the pump using the controller output signal.
The controller output signal can drive up to 4 Watt of energy.
For speed control of pumps a 300 Ohm resistor parallel to the analog input
is advised. Your local sales representative can provide more information
about this.
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System requirements
2.1
Personal Computer
Minimum requirements:
Pentium PC - 700 MHz / 32 MB internal RAM
20 MB free disk space for program files
1024 x 768 x 256 color display
Operating system: Windows 2000 UK, Windows XP UK or Windows Vista UK 32-bit, Windows7.
The regional settings for numbers have to be set to the values in the table below.
Operating System regional number settings
Decimal symbol
. (point)
Digit grouping symbol
, (comma)
Note: The digit grouping symbol of currency must always differ from the numbers decimal symbol (see Microsoft’s
KB198098). Having equal symbols is not valid and will cause problems, not just for this program but for other programs as
well. In this situation check that the digit grouping symbol of currency does not contain a . (point). If so, choose any other
character.
2.2
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Software on Personal Computer
Advised software: download the latest version of FlowPlot and FlowDDE form our website
FlowPlot: http://downloads.bronkhorst.com/select.asp?title=flowplot
FlowDDE: http://downloads.bronkhorst.com/select.asp?title=flowdde
CORI-FILL™
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3
Installation and startup of FlowPlot and FlowDDE
3.1
Getting started
Make sure your instrument is powered and connected to your
PC with a special RS232 (split-) cable like in the picture below.
Note:
use a 15...24Vdc power supply.
3.2
Installation
Follow the on-screen instructions when installing FlowPlot and FlowDDE.
The default installation folder is: C:\Program files\Bronkhorst\FlowPlot and C:\Program files\Bronkhorst\FlowDDE.
3.3
Main window layout FlowDDE
First start-up FlowDDE, than start-up FlowPlot.
Start FlowDDE through the Start
menu: Start >> Programs >>
Bronkhorst >> FlowDDE
When FlowDDE is started and
indicating that it is ready for any
client, the main window is shown.
Select: Communication >>
Communication Settings and
select the COM-port on your PC
which is connected to the
instrument.
Select: Communication >> Open
communication and wait until the
message “Server is active and
ready for any client” appears on
the screen.
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Figure 1 - The FlowDDE main window for communication between instrument and
MS-Windows environment.
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Start FlowPlot through the Start
menu: Start >> Programs >>
Bronkhorst >> FlowPlot
At the screen “Select parameters”
connect the colored lines to:
· FlowDDE/FlowDDE2
· channel number (typically = 1)
· parameter number
e.g. like in picture on the right.
It is possible to use up to 8 plotlines in different (pre-defined) colors to watch the dynamic behavior of these signals in time.
Mode 18. RS232 (or mode 0 : bus & RS232) should be selected to enable your PC to take over setpoint control for the Coriolis
instrument.
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For more detailed information about FlowPlot and FlowDDE see:
· FlowPlot manual
http://www.bronkhorst.com/files/downloads/manuals_english/917030manual_flowplot.pdf
· FlowDDE manual
http://www.bronkhorst.com/files/downloads/manuals_english/917067manual_flowdde.pdf
Press OK to go to Main screen.
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Operation
4.1
Main window layout FlowPlot
In the beginning this screen is empty
This screen shows the selected parameter value sizes as a function of the time to get an impression of the dynamic flow
(and other parameter) behavior.
Counter value (100% is counter limit)
Density (100% = 2000 kg/m3 - 0% = 0 kg/m3 )
Temperature (percentage = °C)
Setpoint (wanted value; 100% = FS = capacity)
Measure (actual flow; 100% = FS = capacity)
Controller output value
Pressing “Instrument settings” will pop-up another screen for adjusting the instrument settings.
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Readout in mass flow or volume flow
5.1
Adjust instrument unit type
At the Tab “Basic” it is possible to prepare the instrument for mass flow readout, like e.g. g/h or kg/h or volumetric readout
values like e.g. l/min or ml/h. The counter will automatically switch to similar units like g or ml etc.
As the sensor can measure actual density, batch size can be given in mass and volume. To measure in volume, select
“Volume Flow”, the density should be specified manually.
When “Actual Volume Flow” is selected, the actual density will be used to convert mass flow to volume flow.
Normal Volume Flow and Standard Volume Flow are typical gas (mass)flow units. It will be necessary to enter the density at
normal (0 °C) and 1 atm. or at standard (20 °C) and 1 atm. conditions to be able to get the correct volumetric readout.
In order to change filter settings please see section 5.3.
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5.2
Adjust instrument capacity (FS range)
To adjust the filling speed of the CORI-FILL™ system, the instrument capacity
can be adjusted easily.
At [Capacity and unit] a full scale value can be entered with digits or by using
the slider. Depending on the instrument the full scale value will be a value
between a minimum and a maximum capacity.
The full scale value will be indicated as 100% value in FlowPlot.
(Mini) CORI-FLOW™ instruments are extremely linear and can be easily
rescaled.
Analog output signals will be re-scaled for this new capacity.
E.g. 4-20mA: 20 mA corresponds to FS capacity value (100%).
The flow value to be used for filling can be calculated as follows:
Flow speed = batch / dosing time.
Examples:
If you would like to dose a batch of 10 g in 2 seconds, the flow speed will
need to be:
Flow = (10 g / 2 sec) * 3600 sec = +/- 18000 g/h (M14)
If you would like to dose a batch of 500 mg in 10 seconds, the flow speed will
need to be:
Flow = (0.005 g / 10 sec) * 3600 sec = +/- 180 g/h (M13)
Please mind that this is a theoretical approach, it is meant to give you an indication of the full scale value. In practice the
full scale value will need to be a little higher, because of the opening and closing time of the actuator.
The “counter control gain” value will also influence the total dosing time. This function is explained in section 8.
Please note this can only be used for proportional filling.
When a shut-off valve is used, the inlet pressure will determine the flow rate. Therefore it is very important to use a correct
and stable inlet pressure.
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5.3
Setting instrument flow range and filters
In the Tab “Basic” it is possible to (re)range the instrument. Just set the desired range at “Full scale value” or use the slider. A
value between minimum and maximum indicated values can be entered.
If needed the controller speed can be easily adjusted at “Speed”. More advanced controller settings can be adjusted at the
Tab “Controller”.
The picture below shows the full factory FlowPlot version. Please note that FlowPlot customer versions will show less Tab
options.
Auto zero:
Before starting up a dosing process, it is important to auto-zero the
instrument before using it.
Auto-zero the instrument by using FlowPlot. Mind that the instrument should
be powered on for at least 30 minutes before doing an auto-zero, as the
instrument will warm up and this influences the measure value.
Before doing an auto-zero, make sure the tube is filled totally with fluid.
Therefore, give a setpoint for a few seconds. Make sure all gas bubbles are
purged out of the liquid or all liquid drops are purged out of the gas (when
using gas). Then, put the setpoint back to zero and make sure there is no flow.
If possible close other (manual) valves in the flow line. Now press the autozero button in FlowPlot or on the instrument.
Filters:
Instrument filter settings can be adjusted (if needed).
All filters have values between 0…1. Low values mean more filtering. Filter is
switched off when value = 1.0.
The value(s) at “Sensor filter” will also influence the batch counter and the
controlling behavior. “Exponential” is to be set as follows:
· 0.1 : normal value
· < 0.1 : when more dampening is needed (e.g. noise or vibrations);
will slow down measuring signal
· 0.1…0.5 : when faster signal is needed (e.g. for step responses < 0.5 sec.)
“Adaptive” setting is between 0…1 for CORI-FLOW series and not used (=0) for
mini CORI-FLOW series.
The values at “Output filter”: “Dynamic and Static” can be used to smoothen-up the flow value on the display or in the
graph and will not influence the batch counter.
Typical values are 1.0E-3 for both dynamic and static filter parts. Making these values lower will slow down the signal
(more filtering). Making them higher will speed up the signal (less filtering).
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For more detailed information see:
· FlowPlot manual
http://www.bronkhorst.com/files/downloads/manuals_english/917030manual_flowplot.pdf
CORI-FILL™
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6
Preparing the counter for batch counting/dosing
After setting the counter mode in “up to limit” and giving the right limit
(=batch), the overrun correction and counter control gain need to be entered,
depending on short time dosing using a shut-off valve or proportional filling
(see subsequent sections 7 and 8).
The counter control gain is of no influence when the dosing is performed
with a shut-off valve.
‘New setpoint on limit’ should be enabled. The ‘New setpoint’ value will
normally be = 0% (= setpoint when reaching the batch).
‘Output’ can be set as shown left, but will not have any effect on batching.
‘Reset’ will determine the enabled sources for resetting the counter.
Following options are available:
· FLOW-BUS(Bus and RS232)
· Keyboard (using the button on the instrument)
· Ext. (external input on optional pc-board)
· Analog setpoint (external setpoint input)
6.1
Analog operation
CORI-FILL can also be used in analog mode. The setpoint will be determined by analog signals like
0..5V/0..10V/0..20mA/4..20mA.
The counter will be reset by an analog signal of 0V or 0mA. Any analog signal > 0 (over 2%) will restart the next batch.
When using this option in on-off dosing mode (with shut-off valves) the setpoint value is irrelevant, as long as it is >2%. For
proportional filling with a proportional valve the setpoint value is important!
Example analog operation:
Analog setpoint
change for reset
and starting next
batch
or
Correct
settings
via RS232
(just once)
Flow rate
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CORI-FILL™
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On-off dosing using a shut-off Valve
Dosing example:
Counter limit = 10.00g.
Measured counter value = 9.98g
Counter value line in FlowPlot = 99.8%
Give a setpoint of any value, a shut-off valve will either be open or
closed, so setpoint value is irrelevant.
Please use a correct and stable inlet pressure
Because of the self learning principle (overrun correction) the requested
counter value will always be very accurate.
The Counter control gain option has no influence on dosing with a
shut-off valve. This formula is explained in section 8.
Overrun correction (on-off control):
A correction value between 0 and 1 can be entered. Therefore, when a
value is entered, the system will close the valve a fraction earlier or later,
depending on the overrun (or underrun). An overrun correction of 0.8
has proven to be a proper functioning value. The closing value for the
valve is calculated by the following formula:
Closing value = Limit value – (Overrun correction *
(Last actual dosing value – Limit value)).
For example: if the last limit value for the dosing was 10g and the actual measured value was 10.50g, considering a overrun
correction factor of 0.8, for the next dosing the valve will close at: 10 – ( 0.8 * (10.5 – 10) ) = 10 – 0.40 = 9.60g
This correction is a continuous process, therefore it ensures that the requested dosing value will come to 10g.
Lower correction values can be used to filter instabilities in supply pressures, this will result in more cycles before the
requested batch is reached. Higher values result in fast correction and less cycles before final batch is reached.
PID settings can't be used in combination with shut-off valves!
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Flow speed:
When using shut-off valves the flow speed needs to be controlled by either the supply pressure or a manual needle valve.
In many cases the supply pressure will only be gravimetric by having a supply vessel at a certain level.
This means this supply pressure will not be very high.
Bronkhorst instrument sizing tool CoriCalc is needed to calculate the pressure drop across the Coriolis instrument. The
correct inlet pressure and consistency will have a positive influence on the batch accuracy.
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CoriCalc is a Coriolis Calculation routine, integrated in Bronkhorst's online software tool "FLUIDAT on the Net"
www.fluidat.com (free registration for users of Bronkhorst instruments)
It is important that the maximum flow does not exceed 130% of the maximum FS of the instrument. Values above 130% of
the full scale value will not be measured. If this is the case, there are a few possibilities to adjust this:
· The pressure could be lowered
· The flow could be restricted by using a manual valve
If the “measure” line (green) exceeds 130% of the set full scale (e.g. 10 kg/h), but not exceeds the max. full scale (e.g. 30 kg/h),
it won’t have any influence on the counter. Please keep in mind that this specific 130% rule will only work for filling
applications using the up to limit mode (counter).
Green sensor signal ‘clips’ at 130% -> however the counter line (grey) has a constant upward trend.
By increasing the full scale value the measure line will be visible.
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After increasing the FS value, the flow signal can be measured and be shown correctly in the plotted graph.
The batch value of the counter (grey line) remains 100% as shown in both plots.
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7.1
Using hold current for energy saving with shut-off valves
The yellow lines show the controller output signals to the valve. After 1 sec. opening current valve switches to hold current
to save energy and to avoid heat dissipation at electrical coils.
In order to open the valve (open current) the output signal can be set at [valve
powers] Max. The hold signal (current) can be separately set at [valve powers]
Open.
These values might differ for each type of valve, depending on e.g. the coil.
Using the energy saving option will result in less power dissipation at the valve
and thus in lower temperatures. For fluids sensitive to evaporation/boiling, this
option might be very useful.
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8
Proportional filling
In the “Alarm & Count” tab, the counter setting can be found. The counter will count the total amount of flow passing
through the instrument. The counter has three modes: [Off], [Up] and [Up to limit]. For filling applications, the [Up to limit]
has to be selected. In order to perform a dosage a setpoint value (e.g. 100%) has to be selected. The setpoint value is related
to the full scale value. Setpoint can be changed once the limit has been (or will be) reached. By enabling [new setpoint on
limit] and set it at 0.0%, the dosing set-up is created. Select [reset counter] to perform a dosage. (When the desired limit has
been reached, setpoint will be set to zero).
Counter control gain (proportional filling):
In this mode the PID-controller will be used. This function will work as follows:
The counter starts running up to limit until a certain moment where the controller
starts to slow down. This is needed in order to approach the limit carefully which
will avoid overshoots. The point of slowing down can be set by means of counter
control gain. This value can be changed from 1…100.
Flow value where counter will start to force the setpoint down can be calculated
as follows:
(1 - 1/x ) * 100%. (x = counter control gain value).
In the example to the left, the counter control gain = 2, which means that setpoint
value will go downwards after reaching 50% of the limit (10 g). So at 5g, the
counter will force the controller to decrease its setpoint. Setpoint will decrease
down to 2% (automatically controlled by an additional P- controller for the
counter). The last part of the batch will be dosed at 2% flow rate of the capacity.
An example is shown at the following page.
Note: Fast and accurate proportional filling is possible, therefore it is important to set a few controller options, such as FS
value, counter control gain and the PID-Kp value. Please see section 8.2 & 8.3 for controller options and findings in
practice.
Counter control gain (X)
Counter value where controller will slow down
0
No slowing down; controller stops if limit has been reached
1
0%, so immediately when counter starts running
2
50% of max. limit of counter
3
67% of max. limit of counter
4
75% of max. limit of counter
5
80% of max. limit of counter
10
90% of max. limit of counter
50
98% of max. limit of counter
100
99% of max. limit of counter
Please try to make sure that the last phase of dosing will be performed at 2% setpoint, otherwise there could be an overdose.
If this cannot be avoided or when dosing at 2% will still give an overdose, you might consider for enabling the overrun
correction. Both mechanisms can be active at the same time with proportional filling.
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8.1
Proportional filling example
Test instrument: M14 with Tuthill DGS.23 gear pump; 100% = 30 kg/h water.
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8.2
Controller options
Controller options should be set for fast response. Below typical (fast response) settings for a pump controlled by a mini
CORI-FLOW instrument.
Valve powers, with the learn open function the instrument will
determine what the opening voltage of the used actuator is
(e.g. a valve or a pump).
After this value is known the opening response will be adapted to
decrease the dead time during setpoint steps from zero.
Setpoint slope. Normally = 0, except when PID-Td > 0.
PID-Kp: Typical = 10. Increase in range 10…100 to make controller
faster. Decrease to slow down.
PID-Ti: Typical = 0.1. Decrease in range 0.02..0.1 to make controller
faster. Increase from 0.1…2 to slow down.
PID-Td: Typical = 0. Increase a little (0…2 sec.) to differentiate dead
volume if necessary.
Special adjustment for PID-Kp at certain situations for extra
speeding up or slowing down.
i
www
For more detailed information about FlowPlot see:
· FlowPlot manual
http://www.bronkhorst.com/files/downloads/manuals_english/917030manual_flowplot.pdf
Extra information
The PID scale can be adjusted by double clicking the highest value on the scale as shown below.
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8.3
Parameter settings
Test performed with a M14 and Tuthill DGS.23 gear pump. Used liquid = water.
·
·
·
·
·
The first table will give an indication of the full scale value (kg/h) in relation with the desired batch in grams.
The second table shows the fastest dosing time in seconds, with a dosing accuracy better than 0.5%.
The overrun correction is set to zero. When using the overrun correction, dosing will be more accurate!
The counter control gain (CCG) has to be adjusted to the batch size.
The PID controller settings vary per application.
Please note that these values are indicative, it can vary per application. In section 8.4 the FlowPlot settings are shown for a
batch of 20 gram.
Full scale value in kg/h
Dosing accuracy better than 0,5%
2g
5g
10g
15g
20g
30g
40g
50g
75g
100g
150g
200g
500g
2,5
6
11
15,5
19
26,5
30
30
30
30
30
30
30
M12
M13
M14
M15
M54
M55
Dosing time in seconds
Dosing accuracy better than 0,5%
2g
5g
10g
15g
20g
30g
40g
50g
75g
100g
150g
200g
500g
5,5
5,5
5
5,5
5,5
6
7
8
11
14
20
26
62
M12
M13
M14
M15
M54
M55
CCG
2,5
3
4
4
4
4
4,5
5,3
8
11
16
22
50
PID-Kp
25
25
25
25
25
25
25
20
20
20
20
20
20
PID-Ti
0,08
0,08
0,08
0,07
0,08
0,08
0,1
0,1
0,1
0,1
0,1
0,1
0,1
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Important settings:
For fast and accurate proportional dosing
it is import to create a small overshoot, like
10% as shown on the left. By doing this
the Coriolis instrument has more time to
control the requested dosage.
This is especially important for small
dosages. The graph shows a dosage of 20
gram in 5.5 seconds. Please see the correct
settings on the next page.
An overshoot can be created by increasing
the PID-Kp and PID-Ti value.
8.4
FlowPlot settings
These settings are used to dose a batch of 20 gram.
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9
Very small batch dosing
Challenge:
· Dosing a very small batch (60 mg) in a short period (1 sec.)
Flow needed:
· 0.060 g * 3600 sec = 216 g/h (M13 using a shut-off valve)
Please keep in mind that the opening + closing will be around 0.5 seconds.
Total dosing time will be 1 + 0.5 = 1.5 sec.
Points of attention:
· Use a small dosing needle.
· To calibrate, handle weighing scale with care; dose under fluid level to avoid drops at the needle. Weighing scale should
have right resolution and should be mounted horizontally on spirit level.
· Monitor density and temperature to detect gas bubbles in the fluid. Make sure there are no gas bubbles in the fluid. They
will cause deviations in batches. Best is to use pressurized vessels without direct contact of the gas to the liquid to avoid
dissolution of gas in the liquid. E.g. vessel with diaphragm.
· Make sure pressure to vessel is very constant. Behavior of pressure controller can be seen in batch results. Better is to
pressurize the vessel and close the gas inlet valve to stabilize the pressure in the valve (this can only be done using low
flow rates).
· Make sure to have short line between valve and dosing spot (needle) as on the pictures.
· Make sure FlowDDE and FlowPlot polling/sampling time is fast enough. This is 100 msec. for standard. For this kind of
fast dosing tests, times should be set down to approx. 20..25 msec.
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10
Troubleshooting
Symptom
Possible cause
Action
Suddenly a wrong value will be
dosed among a sequence of right
values when using on-off dosing
with shut-off valves.
· (Back) pressure waves caused at
valve closing with high force
might give erratic reading at (mini)
CORI-FLOW.
· Sudden pressure in- or decrease.
Select a different valve type
Make sure to have some volume or
dampener between valve and meter
Monitor ‘hardware error’ at alarm info byte
at instrument interface to indicate this
Monitor ‘counter value’ at instrument
interface to detect this
Check inlet pressure
Even when dosing time is very short
flow signal is too slow
Filter settings might be not optimal.
Exponential smoothing filter value
probably too low.
Change exponential smoothing filter
setting. See section 5.
Large deviation on sequential
batches
Filter settings might be not optimal.
Exponential smoothing filter value
probably too high.
Change exponential smoothing filter
setting. See section 5.
Supply pressure not stable
Check and stabilize pressure
Controller settings not optimal
Increase control stability by optimizing PID
settings.
Pressure too high
Lower the supply pressure
Resistance of flow line too low
Restrict the flow by using a manual valve
PID-Kp too high
Select a lower Kp value
FS value (capacity) too low
Increase the FS (capacity) value
Flow signal is >130%
Dosed value is not accurate enough
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Flow meter has wrong zero point
Perform new auto-zero
Too many gas bubbles in liquid
Purge the flow meter
Vibrations disturbing the meter
Follow instructions for mounting
Flow signal >130%
Try to limit flow signal < 130%
Dosing time is too short
Increase dosing time
Proportional dosing is too fast
Adjust counter control gain to ensure last
part of dosing at 2%
Counter control gain too low
(Dosing too long at low flow)
Increase counter control gain to dose
longer at high flow (more accurate)
Reference instrument to check with is
not a weighing scale (e.g. volumetric
device)
Use a weighing scale and handle it
according to the instructions
Proportional dosing @2% gives too
much overshoot
Lower flow rate (dosing speed) or enable
overrun correction
Air in the system causes drifting
Try to purge the air out of the system
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11
Service
For current information on Bronkhorst High-Tech B.V. and service addresses please visit our website:
 http://www.bronkhorst.com
Do you have any questions about our products? Our Sales Department will gladly assist you selecting the right product for
your application. Contact sales by e-mail:
› [email protected]
For after-sales questions, our Customer Service Department is available with help and guidance.
To contact CSD by e-mail:
› [email protected]
No matter the time zone, our experts within the Support Group are available to answer your request immediately or ensure
appropriate further action. Our experts can be reached at:
 +31 859 02 18 66
Bronkhorst High-Tech B.V.
Nijverheidsstraat 1A
NL-7261 AK Ruurlo
The Netherlands
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