Common CGR-01 Series User manual

COMMON S.A.
ul. Aleksandrowska 67/93
91-205 Łódź, Poland
Tel: [phone]
Fax: [phone]
ROTARY GAS
METERS
Type
CGR-01
MANUAL
CGR / IU09
Łódź2009
PLEASE READ THIS MANUAL BEFORE INSTALLING THE ROTARY
GAS METER AND PUTTING IT INTO OPERATION

1
TABLE OF CONTENTS
Page
I. PURPOSE AND CONDITIONS OF USE 2
II. CONSTRUCTION AND OPERATING PRINCIPLE 6
III. METER OUTPUT 8
IV. GAS METER MARKING 12
V. PACKING, TRANSPORTATION AND STORAGE 14
VI. METER INSTALLATION AND PUTTING INTO OPERATION 17
VII. INSPECTION & MAINTENANCE, MALFUNCTIONS, REPAIRS 23
VIII. ACCESSORIES 25

2
I. PURPOSE AND CONDITIONS OF USE
Rotary gas meter purpose
CGR-01 rotary gas meters are electromechanical pressure devices designed for the
measurement of gas volume passing through the installation. Standard version of CGR-01 is
suitable for installation in areas where explosion atmospheres are possible, as the result of
mixture of gases classified as explosion class IIA and IIB, with air. Special version of
CGR-01, can be installed in areas where explosion atmospheres may be possible, as the result
of mixture of gases classified as explosion class IIC, with air. Physical parameters of most
popular gases and gas mixtures that can be measured by CGR-01 are presented in table 1. The
maximum design pressure for housings of CGR-01 rotary gas meters is:
-1,6 MPa for gas meters with PN16 connections,
-2 MPa for gas meters with PN20 (ANSI150) connections.
Rotary gas meters can be installed both indoors (inside rooms with stabilized
temperature) and outdoors. In the case of outdoors installation, it is recommended to protect
the gas meter from direct influence of atmospheric conditions (using containers, roofs,
covers, closets, etc.). Ambient temperature range: from -25
°
C to +70
°
C. Measured gas
temperature range: from -20
°
C to +60
°
C. Storage temperature range: from -30
°
C to +70
°
C.
Conditions of use of rotary gas meter.
1. Compliance with the requirements of directive 2004/22/WE MID:
-certificate PL – MI 002 – 1450CL0002
-CE markings 1450, Oil and Gas Institute
- ambient temperature range -25° C ≤Ta ≤+70° C
- measured gas temperature range from -20° C to +60° C
- storage temperature range from -30
o
C to +70
o
C
- maximum working pressure p
max
= 1,6 MPa
- mechanical environment class M2
- electromagnetic environment class E2
-metrological parameters Table 2.
-metrological accuracy class 1,0
-gas meter working position HV,
-harmonized standards EN 12480:2002, EN 12480:2002/A1:2006,
2. Compliance with the requirements of directive 94/9/WE ATEX:
-certificate KDB 04ATEX034,
-CE markings 1453, Central Mining Institute, KD”Barbara”
-conditions of use standard version: II 2G EEx ia IIB T4
special version: II 2G EEx ia IIC T4
- index housing protection IP66/IP67,
3. Compliance with the requirements of directive 97/23/WE PED:
-certificate 67/JN/2004-002/3,
-CE markings 1433, Office of Technical Inspection
-maximum design pressure for PN16 flanges: PS = 16 bar,
for PN20 (ANSI150) flanges: PS = 20 bar.
- ambient temperature -25° C ≤Ta ≤+70° C
Mxx

3
Table 1. Physical properties of most popular gases and gas mixtures that may be measured
with the CGR-01 Rotary Gas Meters. Density specified at 101,325 kPa and 20°C .
Gas or gas
mixture
Chemical
symbol
formula
Density
ρ
[kg/m
3
]
Density
related to air
ρ
w
Gas meter
version
Argon Ar 1,66 1,38 standard IIB
Nitrogen N
2
1,16 0,97 standard IIB
Butane C
4
H
10
2,53 2,1 standard IIB
Carbon dioxide CO
2
1,84 1,53 standard IIB
Ethane C
2
H
6
1,27 1,06 standard IIB
Ethylene C
2
H
4
1,17 0,98 standard IIB
Natural gas ≈CH
4
about 0,75 about 0,63 standard IIB
Helium He 0,17 0,14 standard IIB
Methane CH
4
0,67 0,55 standard IIB
Propane C
3
H
8
1,87 1,56 standard IIB
Carbon monoxide CO 1,16 0,97 standard IIB
Acetylene C
2
H
2
1,09 0,91 special IIC
Hydrogen H
2
0,084 0,07 special IIC
Air - 1,20 1 standard IIB
Essential metrological parameters of CGR-01 rotary gas meters are presented in
table 2. Please note that table 2 should not be used as our offer; for our offer please contact
our company (telephone numbers are given on the front page).
The gas meter causes inevitable pressure loss. The value of pressure loss, for each
meter size, was determined at Qmax maximum flow (for air at atmospheric conditions and
density ρ
ρρ
ρ
0
= 1,2 kg/m
3
), and is listed in table 2.
Please use the following formula in order to determine the pressure loss ∆p
rz
[Pa] in operating
conditions:
ρ
w
= ρ/ ρ
0
– relative gas density (relative to air) according to table 1,
p
a
- atmospheric pressure (p
a
≅101 [kPa] ),
p - gauge pressure before meter inlet [kPa],
Wpd – pressure loss coefficient according to figure 1,
∆p - pressure loss at Qmax – from table 2 [Pa].
∆ ·W pd ·∆p
pp p
p
rz
a
a
=
+
ρ
ρρ
ρ
w

4
Figure 1. Pressure loss coefficient as a function of relative flow Q/Qmax.

5
Table 2. Essential metrological parameters of CGR-01 rotary gas meters.
DN
nominal
diameter
G
meter size
Q
max
maximum
flow
Q
min
minimum flow [m
3
/h ]
LF
pulser constant
HF
pulser constant
(approximately)
V
cyclic
volume
∆p
pressure loss
at Q
max
Series
[mm] [m
3
/h]
turn down ratio (rangeability)
[pulses/m
3
] [pulses/m
3
] [dm
3
]
[Pa] [-]
1:50 1:65 1:100 1:160 1:200 1:250
40/50 G10p 16 0,3 0,25 0,16 - - - 10 15459 0,23 110 / 85 „171”
40/50 G16p 25 0,5 0,4 0,25 0,16 - - 10 15459 0,23 185 / 140 „171”
40/50 G16w 25 0,5 0,4 0,25 0,16 - - 10 11470 0,31 105 / 80 „171”
40/50 G25s 40 0,8 0,65 0,4 0,25 0,2 0,16 10 15459 0,23 375 / 280 „171”
40/50 G25p 40 0,8 0,65 0,4 0,25 0,2 0,16 10 11470 0,31 240 / 180 „171”
40/50 G25w 40 0,8 0,65 0,4 0,25 - - 10 7111 0,50 110 / 80 „171”
40/50 G40s 65 1,3 1,0 0,65 0,4 0,3 0,25 10 11470 0,31 480 / 360 „171”
40/50 G40p 65 1,3 1,0 0,65 0,4 0,3 0,25 10 7111 0,50 280 / 210 „171”
40/50 G40w 65 1,3 1,0 0,65 0,4 - - 10 4390 0,81 195 / 150 „171”
50/80 G65s 100 2,0 1,6 1,0 0,65 0,5 0,4 10 7111 0,50 420/320 „171”
50/80 G65p 100 2,0 1,6 1,0 0,65 0,5 0,4 10 4390 0,81 325/290 „171”
50/80 G65w 100 2,0 1,6 1,0 0,65 - - 10 2867 1,24 245/200 „171”
50/80 G100s 160 3,2 2,5 1,6 1,0 0,8 0,65 1 4390 0,81 570 / 430 „171”
50/80 G100p 160 3,2 2,5 1,6 1,0 0,8 0,65 1 2867 1,24 505 / 395 „171”
80/100 G100p 160 3,2 2,5 1,6 1,0 0,8 0,65 1 1654 1,29 220 / 160 „241”
80/100 G100w 160 3,2 2,5 1,6 1,0 - - 1 1067 2,00 180 / 135 „241”
80/100 G160s 250 5,0 4,0 2,5 1,6 1,3 1,0 1 1654 1,29 530 / 400 „241”
80/100 G160p 250 5,0 4,0 2,5 1,6 1,3 1,0 1 1067 2,00 370 / 280 „241”
80/100 G160w 250 5,0 4,0 2,5 1,6 - - 1 639 3,34 270 / 210 „241”
100 G250s 400 8,0 6,5 4,0 2,5 2,0 1,6 1 1067 2,00 660 „241”
100 G250p 400 8,0 6,5 4,0 2,5 2,0 1,6 1 639 3,34 510 „241”
Meter size: p – basic version,
w – low speed version (bigger sizes, lower pressure drop, lower noise level),
s – high speed version (smaller sizes, higher pressure drop, higher noise level).

6
II. CONSTRUCTION AND OPERATING PRINCIPLE
Rotary gas meter is the volume machine, rotational, working on the basis of
proportionality between number of (rotors) rotation and the actual gas volume, which passes
through the gas meter at a given pressure and temperature. Gas passing into the meter
(figure 2) fills the measurement chamber and the pressure on the inlet causes rotors to rotate
and transports portion of gas to the meter outlet. Gears and magnetic coupling transfer
rotational movement of rotors to the index. Index mechanism sums the volume, which passed
through the meter, and that value is presented on the counter (the counter is of drums design).
Figure. 2. The working principle of CGR-01 rotary gas meter.
Rotary gas meter (figure 3) consists of four major units:
External housing. External housing consists of the main body, front cover and back cover.
Both covers are mounted to the main body by screws and secured by seals. In the main body
there are sockets (including pockets) for gas pressure and gas temperature measurement, and
also two jointing faces, including threaded holes, for mounting the gas meter to the piping. In
the front cover there is a hermetic barrier separating the gas part from outer environment, and
also there are: oil fill plug and oil level sight glass.
Measuring unit. The measuring unit is mounted between the covers of external housing by
the use of elastic sealing inserts. It consists of measurement chamber (where the rotors are
rotating) and two side chambers, separated by internal covers. The rolling bearings of the
rotors are fixed in mentioned internal covers. In both side chambers, there is oil for lubrication
of bearings and toothed gears of measuring unit. Lubrication takes place through oil mist
produced by rotating plates fixed on the rotors’ shafts.
Drive transmission unit. The drive transmission unit is mounted on the front cover of
external housing. This unit provides transmission of the rotational movement of rotors from
the measuring unit to the index, through gas tight barrier. It consists of toothed gear and
magnetic coupling. The inductor for the HF pulser can be fixed on the drive part of the
magnetic coupling.
Index. There is further reduction of rotational speed in this unit (by the worm gear and
cylindrical gear) in order to drive the mechanical counter and inductor elements for low
frequency pulse generators (pulsers). In the index there are also sockets allowing low
frequency and high frequency pulse outputs from the gas meter.

7
Figure 3. The intersection of CGR-01 rotary gas meter.

8
III. METER OUTPUT
The CGR-01 meter outputs are: mechanical counter, electrical signals outputs, output
for pressure measurement and optional output for temperature measurement. Mentioned
outputs allow controlling the meter and connecting external devices to the meter. The location
of meter outputs is presented on the figure 4.
Mechanical counter is located inside the index and is visible through polycarbonate sight
glass. It allows direct visual readout of actual gas volume, which passed through the gas meter
at given pressure and given temperature. The index can be rotated around horizontal axis of
the gas meter, with the range of 350
o
, which allows convenient visual readout of the counter
from almost any direction.
Figure 4. The location of meter outputs of the CGR-01 rotary gas meter.
Electrical signals outputs. There can be two types of electrical signals outputs: LF-low
frequency and HF-high frequency. The index can be equipped with maximum two sockets and
six pulse generators (pulsers):
-two LFK low frequency, reed contact pulse generators,
-two LFI low frequency, inductive (gap type) pulse generators,
-two HF high frequency, inductive (proximity type) pulse generators,
and AFK control circuit (normally closed read contact), or interchangeably any other pulse
generator.

9
LFK reed contact pulse generators are intended for cooperation with volume converters
(both battery supplied or with external power supply) situated close to the gas meter (up to
about 2 meters). Inductive pulse generators, both LFI low frequency and HF high frequency,
can send signals for much higher distances (up to about 200 meters, depending on local
conditions). Because of higher energy consumption, they can cooperate only with volume
converters with external power supply. The gas volume corresponding to one pulse of LF
pulser is presented in table 2. The amount of HF pulses corresponding to one m
3
of gas is
determined individually for each gas meter, and is given on the nameplate. The HF output is
particularly useful for tracking the current flow of gas passing through the meter.
All pulse generators located in the index are connected to “Tuchel”
C091 31N006 100 2 sockets, placed on the backside of the index. For connections to those
sockets please use plugs with 6 pins: “Tuchel” C091 31H006 100 2. The “Tuchel” connectors
used in CGR-01 rotary gas meters are IP67. Possible connections of pulse generators with
corresponding sockets are presented in table 3.
Table 3. Possible connections of pulsers with sockets.
PIN polarity LFK 1 LFK 2 AFK LFI 1 LFI 2 HF 1 HF 2
1 − S O
4 + S O
Socket 1 2 − O P P O O
5 + O P P O O
3 − O P
6 + O P
1 − P O
4 + P O
Socket 2 2 − O O P O
5 + O O P O
3 − O P
6 + O P
S - standard connection
P - preferred connection
O – alternative connection
In the standard version of CGR-01 gas meter there is only one LFK 1 low
frequency reed contact pulse generator.
One of the HF pulsers installed in the index can act as the test element in CGR-01 gas
meter. If the index is not equipped with HF pulser, than for the time of tests the gas meter can
be equipped with the external test element (please refer to chapter VII). As the external test
element please use HF inductive pulser type Bi1-EG05-Y1, manufactured by Hans Turck
GmbH. The values of HF1 and HF2 pulsers’ constants are given on the nameplate, and also
apply to the pulser of the test element. After disconnecting the external test element the
connection socket is closed tightly and sealed (Figure 9).

10
According to conditions of use, CGR-01 gas meters should be equipped with pulsers
(pulse generators) which assure the safety level of at least II 2G Ex ib IIC T4. That
condition is met by the following example of pulsers mounted in the index:
-HF type Bi1-EG05-Y1 manufactured by Hans Turck GmbH; II 1G Ex ia IIC T6.
-LFI type Si5-K09-Y1-LF manufactured by Hans Turck GmbH; II 1G Ex ia IIC T6.
-LFK type CLFK-02 manufactured by Common S.A. II 2G Ex ia IIC T6.
Parameters of intrinsically safe circuits
HF LFI LFK
U
i
= 20 V DC U
i
= 20 V DC U
i
= 15,5 V DC
I
i
= 60 mA I
i
= 60 mA I
i
= 52 mA
P
i
= 80 mW P
i
= 130 mW P
i
= 169 mW
L
i
= 150 µH L
i
= 350 µH L
i
≈0
C
i
= 150 nF C
i
= 250 nF C
i
≈0
Parameters of intrinsically safe circuits of the pulse generators (pulsers) used in the gas
meter are specified on the nameplate.
Rated parameters of pulsers used in the gas meter:
reed contact CLFK-02:
closed contact resistance R
z
= 100Ω÷ 2 kΩ,
open contact resistance R
o
> 100 MΩ,
maximum switching frequency f
p
= 2 Hz .
inductive Si5-K09-Y1-LF Bi1-EG05-Y1
maximum switching frequency f
p
= 2 Hz, f
p
= 5 kHz.
Other rated parameters of pulsers used in the gas meter are in compliance with the
requirements of PN-EN 60947-5-6:2002.
Meter outputs for pressure measurement.
Meter outputs for pressure measurement (pressure tappings) are located on both sides
of the external housing (figure 4). The pressure tappings holes are threaded NPT 1/4
(figure 5).
a .) b .)
Figure 5. Pressure tappings NPT ¼
Those outputs can be used for pressure transducer connection: directly to the connector
(figure 5b), or using the three-way valve. Unused outputs are plugged (figure 5a). Both plugs
and connectors can be secured by seals.

11
Meter outputs for temperature measurement.
Temperature measurement in CGR-01 rotary gas meter is optional; it is not supplied as
standard.
Meter outputs for temperature measurement are located on both sides of the external
housing (figure 4). Temperature pockets are fixed in holes in the external housing (figure 6)
and their length is: L=110mm for “171” meter series and L=120mm for “241” meter series.
The socket of a temperature pocket is threaded G ½” (special version: M12x1,5).
Thermometer’s tip or temperature transducer’s tip is immersed in silicon oil inside the
temperature pocket. Unused temperature pockets are plugged (figure 6a). Unused temperature
outputs are plugged, with a plug which is threaded NPT ¼” (figure 5a).
a ) Plugged temperature pocket b ) Temperature pocket with a thermometer
Figure 6. Temperature pockets

12
IV. GAS METER MARKING
Information about basic technical parameters of the gas meter, its serial number and the
year of production are specified on nameplates (figure 7 & figure 8), which are fixed by
screws to the index.
Figure 7. Nameplates for a standard version of a gas meter (“IIA” & “IIB”)
Figure 8. Nameplate for a special version of a gas meter (“IIC”)

13
On the upper part of the external housing there are markings informing about flow direction
and pressure tappings (figure 4).
Each gas meter, after calibration in authorized manufacturer’s laboratory, is secured by
seals located in points presented on the figure 9. The marks of initial verification or
reverification are located on P1 seal, while security marks are located on P2, P3, P4, P5, P6,
P7 seals. Upon customer’s request, gas meter calibration can be documented by Examination
Certificate.
Figure 9. Sealings location points on CGR-01 rotary gas meter.
The validity of initial verification depends on local metrology law in the country.
Before the validity of verification expires, the gas meter should be presented to authorized
laboratory for reverification (please take into account the time needed by the laboratory).
Common S.A. offers reverification, and if needed, also regulation and repairs of the gas
meters.
Preservation of the seal with initial verification marks (or reverification marks) is
required for the gas meter to be legally controlled measuring instrument.

14
V. PACKING, TRANSPORTATION AND STORAGE
The gas meter is supplied in the manufacturer’s package which provides suitable
protection during transportation and storage (figure 10 & 11). The package consists of
pasteboard box and shaped Styrofoam inserts. On the package there is suitable marking
concerning its contents, limitations in loading/unloading and transportation. There are
handholds for carrying the box located on the sides of the package. Gas meters sent for repair
or reverification should be delivered in manufacturer’s package, or other package which
provides same or better protection during transportation.
Each rotary gas meter manufactured by Common S.A. is delivered with the following
equipment:
-plug: 6-PIN “Tuchel” C091 31H006 100 2, which can be used for connecting a
volume converter or data logger to the low frequency electrical output of the meter
(unless the volume converter is already attached to the meter by the manufacturer);
-bottle of oil for lubrication;
-set of items for fixing the meter to the pipeline: hexagon socket set screws with flat
point M16x70 according to ISO 4026:2003, nuts and washers;
-manual.
The rotary gas meter is very precise measuring device and should be handled with care.
During transportation and storage please follow these rules:
1. During transportation it is not allowed to throw the meter, roll the meter, or subjecting it to
strong shocks (for example by fast ride on the cart with no springing suspension).
2. It is not allowed to carry the meter by holding the index.
3. Covers and other shields fixed by the manufacturer on meter’s holes should be removed
no sooner but directly before installing the gas meter.
4. The storage place should protect the meter from precipitation and dampness.
5. Please take care of seals installed on the gas meter. Breaking the seals may result in
losing the warranty and legal consequences between the supplier and consumer of
measured gas.
6. During storage it is not necessary to fill the meter with oil.

15
Figure 10. The package for CGR-01 series “171” rotary gas meters.

16
Figure 11. The package for CGR-01 series “241” rotary gas meters.

17
VI. METER INSTALLATION AND PUTTING INTO OPERATION
Before gas meter installation please check if it is in compliance with the operating
parameters of the installation. In particular please note the following information given on the
nameplate:
•Maximum allowed pressure inside the gas meter [MPa], marked as p
max
,
•Maximum actual flow [m
3
/h], marked as Q
max
.
It is allowed to exceed the Q
max
maximum actual flow of the gas meter
by not more than 25% , and for no more than 30 minutes.
CGR-01 rotary gas meters can operate in four positions, as shown below (figure 12 a, b, c, d):
Figure 12. Possible operating positions of CGR-01 rotary gas meter.
It is not allowed to install the meter in vertical position!
Figure 12 e) & f)
Figure 13. Maximum allowed deviation of the meter to horizontal axis.

18
The gas meter should not be installed in the lowest point of piping, because of possible
condensate and dirt located there.
Rotary gas meters can be installed both indoors (inside rooms with stabilized
temperature) and outdoors. In the case of outdoors installation, it is recommended to protect
the gas meter from direct influence of atmospheric conditions (using containers, roofs, covers,
closets, etc.).
The gas meter must be fixed between the pipes with proper nominal diameter; also, the
proper alignment between the meter and the pipes is necessary in compliance with regulations
of the gas industry. The maximum load on the gas meter body, caused by the piping, should
not be higher than specified in EN 12480:2002.
Dimensions given in table 4a and 4b, presented on figure 14, may be helpful during
designing the place of installation for the gas meter.
Table 4a. The main dimensions and weights of CGR-01 rotary gas meters.
DN n A B L Weight
Cyclic
volume
40 50 80 100 mm mm mm kg dm
3
G10p + + 4 165 171 277 10 0,23
G16p + + 4 165 171 277 10 0,23
G16w + + 4 184 171 296 12 0,31
G25s + + 4 165 171 277 10 0,23
G25p + + 4 184 171 296 12 0,31
G25w + + 4 225 171 337 14 0,50
G40s + + 4 184 171 296 12 0,31
G40p + + 4 225 171 337 14 0,50
G40w + + 4 295 171 407 19 0,81
G65s + 4 225 171 337 14 0,50
G65p + 4 295 171 407 19 0,81
G65w + 4 391 171 503 24 1,24
G100s + 4 295 171 407 19 0,81
G100p + 4 391 171 503 24 1,24
G100s + 8 295 171 407 19 0,81
G100p + 8 391 171 503 24 1,24
G100p + + 8 249 241 356 25 1,29
G100w + + 8 314 241 421 31 2,00
G160s + + 8 249 241 356 25 1,29
G160p + + 8 314 241 421 31 2,00
G160w + + 8 439 241 546 42 3,34
G250s + 8 314 241 421 31 2,00
G250p + 8 439 241 546 42 3,34
p – basic version;
w – low speed version (bigger sizes, lower pressure drop, lower noise level),
s – high speed version (smaller sizes, higher pressure drop, higher noise level).

19
Table 4b. Dimension: K (diameter of fixing bolts position)
DN40 DN50 DN80 DN100
PN 16 110 125 160 180
PN 20 (ANSI 150) 98,5 120,7 152,4 190,5
Dirt located in the gas and in the piping may damage the rotors and decrease the
measurement accuracy. Therefore, it is necessary to apply a filter of at least 10 µm, located
upstream from the gas meter (especially in the case of a very dirty gas). Moreover before
installing the gas meter, the upstream side of the piping should be thoroughly cleaned. It is
recommended to install the cone sieve on the inlet of the meter inlet run. The cone sieve
should be removed after 1 ÷2 months of operation. If the cone sieve is not to be removed,
please ensure the control of the cone sieve pollution by the measurement of the pressure drop
on the cone sieve, or by regular inspections of the cone sieve. Clogged cone sieve may be
damaged by the gas pressure, and its debris may damage the gas meter.
The gas meter’s manufacturer is not responsible for gas meter damage, or gas
meter blocking, caused by poor filtration of gas.
Figure 14. The main dimensions of CGR-01 rotary gas meters.
The end user should note the possible risk related to the change of the gas flow rate in
the piping. If, after the commissioning and startup, the gas flow was small for a long time,
then the dirt coming from the construction of piping (e.g. remains from welding) stayed
upstream from the meter. Only after big increase of the flow, the gas may carry along that dirt
and damage the gas meter. In that case the cone sieve may be useful, when the measurement