Common CMK-03 User manual

CMK-03 GAS VOLUME CONVERTER
OPERATING INSTRUCTION
Edition: CMK3 / 102U
Firmware version: 2.2.39-39-2.7.8
Lodz, June 2016
Technical specification and construction may change due to improvement. This publication serves as general information only, and all specifi-
cations are subject to confirmation by COMMON S.A.

COMMON S.A. OPERATING INSTRUCTION CMK-03
CONTENTS
1. INTRODUCTION 5
2. SAFETY AND OPERATION 5
2.1 Transportation 5
2.2 Storage 5
2.3 Periodical inspections 5
2.4 Warranty repairs 6
2.5 List of components and additional accessories 6
3. CONSTRUCTION 9
4. TECHNICAL DATA , CONDITIONS OF USAGE, MEASUREMENT INPUTS 10
4.1 Product code and version of execution 10
4.2 Technical data 12
4.3 Intrinsically safe parameters 17
5. ASSEMBLY AND INSTALLATION 19
5.1 Clamps and outputs 20
5.1.1 TUCHEL port 20
5.1.2 Internal clamps 21
5.2 Cables for intrinsically safe circuits 22
5.2.1 Requirements of cables 22
5.2.2 Parameters and cable types 22
5.3 Protective grounding 26
5.4 Connecting the temperature sensor 27
5.4.1 Connecting the thermometer to the volume converter 27
5.4.2 Connecting the thermometer to the piping 28
5.5 Connection the pressure sensor P1 and P2 29
5.6 Connection the external pressure CPC-03 converter 30
5.6.1 Mechanical installation 30
5.6.2 Electrical connection of CPC-03 30
5.7 Connecting the LF input to the gas meter 31
5.8 Mechanical installation of the CMK-03 —appendix 1 32
5.9 Battery 32
5.9.1 Main battery 32
5.9.2 Battery of LCD backlight 33
5.10 Conditions of safety usage 34
6. GAS VOLUME CORRECTION 34
6.1 Principles of operation 34
6.2 Algorithms 36
6.3 Bio-Gas configuration 37
7. ENERGY CONVERSION 38
8. METROLOGICAL MARKS, PROTECTION SEALS, NAME PLATES 39
8.1 Metrological marks –Seal 1 and Mark IV 39
8.2 Manufacturer protection seals –Seal 2 39
8.3 User protection seals –Seal 3 39
8.4 Marking of name plate 40
8.5 Diagram of sealing 41

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8.6 Identification of software 43
9. MID ALARMS 43
9.1 Principle of operation and list of alarms 43
9.2 Signalling, authorization and alarm acknowledgement 45
9.3 Principle of operation in the Vbe emergency conditions 45
10. MID INTERFERENCES (CONFIGURATION CHANGES) 46
10.1 Principle of operation and list of parameters 46
10.2 Signalling, authentication and alarms acknowledgment 47
11. LOCAL SERVICE 47
11.1 LCD menu structure 47
11.1.1 Menu Measure 51
11.1.2 Menu Archive 53
11.1.3 Menu Clock 57
11.1.4 Menu Name plate 57
11.2 Menu Settings 57
11.2.1 Configuration after installation 57
11.2.2 Parameters settings –general information 58
11.2.3 Log in 59
11.2.4 Settings of COM Ports parameters 60
11.2.5 Registration 62
11.2.6 Gas meter 62
11.2.7 Measure 62
11.2.8 Limits and “gas guard” function 64
11.2.9 Gas 66
11.2.10 Simulation 67
11.2.11 Inputs IN 68
11.2.12 Outputs OUT 69
11.2.13 Control of odorizing unit, OUT1 output proportional to Vbs 70
11.2.14 LCD 71
11.2.15 Users 71
11.2.16 Clock 72
12. SETTINGS OF EXTENDED FUNCTIONALIETIES 73
12.1 Summary alarms 73
12.2 Control of the gas meter FF/LF constant error 73
12.3 Operating below Qmin of the gas meter –in range QmSTOP <–> QmMIN 74
12.4 LCD power supply 74
12.5 Reserve1 configuration in GAZ-MODEM 74
12.6 Activity time of OPTO-GAZ port 75
13. REMOTE CONTROL OF CMK-03, USERS, AUTHORIZATION 75
13.1 CCTool configurator 75
13.1.1 Connection by using COGUSB-03 76
13.1.2 Users and authorization 77
14. DATA REGISTRATION, READING AND CONFIRGURATION IN TELEMETRIC SYSTEMS 78
14.1 Registered data 78
14.1.1 Data registered with registration period and and daily registered data 79

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14.1.2 Events 81
14.2 Reading and configuration in the telemetric systems 82
15. ENVIRONMENTAL PROTECTION 83
15.1 Packaging waste 83
15.2 Disposal of used batteries and devices after life-time 83
16. HISTORY OF THE DOCUMENTATION CHANGES 84
17. NOTES 84

COMMON S.A. OPERATING INSTRUCTION CMK-03
5
1. INTRODUCTION
The CMK-03 Gas Volume Converter is a Type 1 converter (according to EN12405-1 + A2:2010) which fully meets
the requirements of the MID Directive.
2. SAFETY AND OPERATION
The following warning marks are used in this manual:
ATEX Directive requirements (intrinsic safety)
installation and usage
MID Directive requirements
Packaging Regulations requirements (used accumulators and
devices after their life time).
recyclable packages
The installation and connection of the CMK-03 requires to follow according to recommendations of this operating
instruction. The device should be used according with the regulation and rules of the explosion hazard safety.
The CMK-03 can be installed and operate in explosion hazard zone 1 or 2. The device can
cooperate with the intrinsically safe circuits on security level “ia”or “ib”. The subgroup
conformity of the potentially gas mixture has to be maintained with the subgroup of device
circuits (IIA or IIB) and temperature T4 class.
The CMK-03 can be connect to the intrinsically safe circuits of other devices, only ac-
cordingly to the safety rules of usage which are contained in the certificates and manu-
facturer instructions of this devices. The conformity of the intrinsically safe parameters
has to be maintained for connected devices.
2.1 Transportation
The transportation should be carried out in the original packaging, which secures the device against the mechani-
cal damage and assure a proper level of protection.
2.2 Storage
The elements of the CMK-03 should be storage in the original package in room with temperature from -20°C till
+60°C and humidity which does not exceeding 80%, without vapour and chemically active compounds.
2.3 Periodic inspections
The CMK-03 is dedicated to installation and operation in the explosion hazard zones. To be sure that device and
the installation system allows for safety usage, it is necessary to implement a regular periodical inspections or
assure a continuous supervision by the qualified personnel. The proper services should be carried out in every
necessary case.
The detailed guidelines regarding to the control frequency and control level can be found in the standard EN
60079-14:2008.
The devices with "X" sign in the certificate number have a special condition of usage, which are precisely de-
scribed in the certificate documentation.

COMMON S.A. OPERATING INSTRUCTION CMK-03
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2.4 Warranty repairs
The manufacturer or a recommended authorized workshops should perform warranty re-
pairs of the CMK-03. The method of usage after warranty repairs and post-warranty repairs,
should be consistent with the regulations of the country where the device is installed.
The CMK-03 should be disassembled from the operating point in case of doubt regarding the correctness of
instrument indications. The device should be pass to the appropriate laboratory for checking and verification. The
checking may be carried out by means of control instruments without damage or removing the manufacturer's
protection seals.
WARNING !
The removing or damage of manufacturer protection seal means the loss of guarantee
and loss of intrinsically safe characteristic.
2.5 List of components and additional accessories
List of components:
CMK-03 Gas Volume Converter operating instruction
guarantee card
initial verification certificate (if there is present a mark of the initial verification)
gasket of pressure connection M12 thread (type O-ring, dimensions 9,3x2,4mm)
transporting cover of the pressure converter (plug P1, P2)
cable glands plugs in dimension 6mm and 8mm
sealed, protective covers for the PT1000, LF and HF clamps
Table 2.1 Additional Accessories
NR
additional accessories, set name: example drawing
1
cable sleeves for finishing the wires assembled on clamps:
size 0,25mm2/ 8-10mm- 100 pcs.
size 0,34mm2/ 8-10mm- 100 pcs.
size 0,5mm2/ 8-10mm- 100 pcs.
size 0,75mm2/ 8-10mm- 100 pcs.
2
Assembly set through the holes in the housing
Part name
Quantity
bolt (cylinder type) M5x45
4
washer M5
4
nut M5
4
see part 5.8.1

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3
Assembly set: O-Type, flat handles
Part name
Quantity
O-Type, flat handle
4
bolt (cylinder type) M5x40
4
bolt (cylinder type) M5x12
4
washer M5
4
nut M5
4
see part 5.8.2
4
Assembly set: L-Type, flat handles, the replacement
of the CMK-02
Part name
Quantity
L-Type, flat handle
4
bolt (cylinder type) M5x40
4
bolt (cylinder type) M5x12
4
washer M5
4
nut M5
4
see part 5.8.3
5
Assembly set with the universal hangers
Part name
Quantity
left hanger universal set
1
right hanger universal set
1
universal strip of pipe holder
2
bolt M8x16
4
washer M8
4
nut M8
4
see part 5.8.4
6
Assembly set with the pipe holders
Part name
Quantity
DN50
DN80
pipe holder M8 x 61 (2")
2
-
pipe holder M8 x 89 (3")
-
2
connector of pipe holder ŁC8.61
2
-
connector of pipe holder ŁC10.89
-
2
washer M8
4
4
nut M8
4
4
see part 5.8.5
7
Assembly set with the pipe clamp
Part name
Quantity
DN100
DN150
DN200
clamping ring with bolt
DN100
2
-
-
clamping ring with bolt
DN150
-
2
-
clamping ring with bolt
DN200
-
-
2
base of band clip DN100
2
-
-
base of band clip DN150-200
-
2
-
base of band clip DN150-200
-
-
2
bolt M8x16
4
4
4
washer M8
4
4
4
nut M8
4
4
4
see part 5.8.5

COMMON S.A. OPERATING INSTRUCTION CMK-03
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8
Assembly set with the band clips
Part name
Quantity
DN250
DN300
band clip with lock
2
2
base of band clip DN250-300
2
2
bolt M8x16
4
4
washer M8
4
4
nut M8
4
4
see part 5.8.5
9
Assembly set with bars mounted into collar
Part name
Quantity
assembly bars into collar
2
bolt (cylinder) M5x45
2
washer M5
2
nut M5
2
bolt (cylinder type) M5x12 (assembly of the
CKMT valve)
2
see part 5.8.6
10
grounding clamp elements: plate + spring washer + bolt (available in
the CMK-03 set; spare part)
11
The assembly set of thermometer in the thermowell; the set is
adapted to sealing by the cord –bolt nut, washer, seal
see part 5.4.2
12
The tightening nut M12x1,5 of the pressure measurement pipe,
sleeve, pulse pipe.
The length and material (cooper or acid-resistant stainless steel)
have to be indicate by the order.
13
The CKMT three way manometrical valve.
The detailed information are contained in the service manual and
the technical documentation of this device —available on the web
site: www.common.pl
14
The CPC-03 Pressure Converter
The selected information about converter are described in the Table
4.5 —“The measuring converters of the CMK-03".
The detailed information are contained in the service manual and
the technical documentation of this device —available on the web
site: www.common.pl

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15
The CZAK-03 Communication and Signal Barrier
The detailed information are contained in the manual instruction and
the technical documentation of this device —available on the web
site www.common.pl
16
Optical communications interface COGUSB-03.
Detailed information contains manual instruction and technical doc-
umentation of the device available on web site: www.common.pl
17
The female, TUCHEL contact, C091D Type (to the COM1 trans-
mission port)
3. CONSTRUCTION
The CMK-03 Gas Volume Converter is a measuring and accounting instrument which fulfills the requirements of
MID Directive. The device is dedicated to operate on the measuring and reducing & measuring gas stations. It
can be used with any of the gas meter (turbine, rotor or ultrasonic) which provides information about measured
volume in the pulses.
The CMK-03 is a battery power supplied instrument with possibility to operate on the external power supply. The
installed batteries provide continuous and service less data registration for a minimum 6 years.
The CMK-03 is a volume converter of the gas Type 1. This is complete measurement system, equipped in the
pressure converters, the temperature converters, the input of pulses/volume of the meter and the algorithms for
converting the measured volume of gas to the basic conditions.
The construction of the CMK-03 has an additional inputs and outputs, which allow for a usage to the technological
purpose and to the control and measurement processes. The inputs and outputs are listed below:
control inputs LFb and LFc
Encoder input,
HF transmitter input in NAMUR standard
double ExtCPC input for external technological CPC-03 converters,
double-state, signal outputs OUT
double-state, signal inputs IN
input IN in NAMUR standard
The data reading and also the CMK-03 power supply are carried out by using three independent communication
ports in the RS-GAZ2 standard: COM1 ("Tuchel/OPTO-gas"), and COM2 and COM3.
The housing is made from the aluminum what assure durability, resistance and a high level of waterproofness —
IP66/67. The opening of the cover is a hinge with the limiter what allows for easy access to the wire clamps and
the battery unit.
The LCD display with keyboard, the port OPTO-GAZ port and the RS-GAZ2 (TUCHEL) port are located in the
device cover. There are maximum two pressure converters P1 and P2 which are built in the housing base.
The P1 Converter occurs also as an external version which is constant connected via a cable with the CMK-03.
The metal cable glands are located in the base of the housing. They are adapted for the shielded cables. This
solution raises the resistance of the device electrical circuits against the electromagnetic interference.

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The CMK-03 is equipped in the LCD display with graphical-text menu. The LCD is readable in the entire tempera-
ture range. The display backlight is supported by the additional battery which is independent of the converter
main battery.
The protection level of housing will be preserved if the conditions will be filled as listed
below:
appropriate diameters of the connection cables
correct tightening of the cable gland,
proper positioning of the gaskets and tightening of the housing cover
4. TECHNICAL DATA, USAGE CONDITIONS, MEASUREMENT INPUTS
4.1 Product code and version of the execution
Table 4.1 Code of product and versions