Handbook © KROHNE 06/05 7.02233.24.
Contents 1 MECHANICAL INSTALLATION 1.1 General principles 1.1.1 Transport and Lifting 1.2 OPTIMASS 7000 Single Straight Tube Meter 1.2.1 Specific Installation Guidelines 1.2.2 Ambient / Process temperatures 1.2.3 Pressure Equipment Directive (PED) requirements 1.2.4 Secondary Pressure containment 1.2.5 Pressure de-rating 1.2.6 Hygienic Applications 1.2.7 Heating and insulation 1.2.8 Purge Port Meters and Burst Disk Meters 1.2.9 Technical Data 1.2.10 Weights & Dimensions 9 9 9 9 10 10 13 14 18 19 20 1.
PROGRAMMING THE CONVERTER MFC 050/051 4.1 Operating and check elements 4.2 OPTIMASS MFC 050/051 Operating Concept 4.3 Key functions 4.3.1 How to enter programming mode 4.3.2 How to terminate Programming mode 4.4 Table of programmable functions 4.5 Reset / Quit Menu - Totalizer reset and status indication acknowledgement 52 52 53 54 55 55 58 67 5 DESCRIPTION OF FUNCTIONS 5.1 Menu 1 - Initial Start up 5.2 Menu 2 – Functional Checks 5.3 Menu 3- Configuration Menu 5.4 Menu 4 - I/O Configuration 5.
How to use these installation and operating instructions Congratulations on purchasing this high quality product. To get the best out of your mass flowmeter, please take some time to read through the instructions. This instruction handbook is comprehensive and describes the many features and options available with this mass flow meter. Please refer to the index for a list of detailed topics. Note: If applicable, a separate document is supplied that describes all ATEX hazardous area information.
Unpacking the meter When unpacking your meter, please ensure that no visible damage has occurred during transportation. If damage has occurred, please contact the carrier for claims. Your high quality instrument has been fully tested and checked before shipping. The following items should be included with your instrument unless otherwise requested: 1. 2. 3. 4. 5. 6. 7. 8.
1 Mechanical Installation 1.1 General principles The OPTIMASS mass flow meters provide high accuracy and excellent repeatability. Narrow band pass digital filtering, and the mathematically modelled internal primary head design with AST (Adaptive Sensor Technology) for the OPTIMASS sensor family provide exceptional immunity to external vibratory disturbances from nearby process equipment. The accuracy of the flow meter is not affected by velocity profile.
Examples Vertical mounting Horizontal mounting Upward sloping installation Avoid mounting the meter with long vertical drops after the meter. This could cause siphoning and cause measurement errors. Avoid mounting the meter at the highest point in the pipeline.
1.1.1 Transport and Lifting As the larger meters are heavy, care should be taken when lifting to install. • Meters should be lifted or suspended using a well maintained sling. • The meters should under no circumstances be lifted by the electronics housings. • The meters can be lifted and suspended from the spigots as shown.
1.2 OPTIMASS 7000 Single Straight Tube Meter 1.2.1 Specific Installation Guidelines • Tighten flange bolts evenly. • Observe min and max pipe end loads at end of this section. The use of reducers at the flanges is allowed. Extreme pipe size reductions should be avoided due to possibility of cavitation and degassing. There are no additional installation requirements for the OPTIMASS 7000 sensors. Fixing of flexible hoses directly on the meter is allowed. 1.2.
1.2.4 Secondary Pressure containment The OPTIMASS 7000 meters are supplied with secondary pressure containment as standard. Allowable maximum secondary containment pressures are 63 bar at 20°C or 914 psig at 70°F If the user suspects that the primary tube has failed, the unit must be depressurised and removed from service as soon as possible.
Pressure/Temperature de-rating for SS and Hast. C22 Metric DIN 2501 PN 40 Secondary Pressure Containment 316 L 70 65 60 55 50 Pressure (bar) 45 40 35 DN100 PN40 Flange 30 Secondary Pressure Containment 304 L and flanges DIN 2501 PN 40 25 20 15 10 5 0 0 10 20 30 40 50 60 70 80 90 100 Temperature Deg. C Pressure/Temperature de-rating for Titanium Gr.
Pressure/Temperature de-rating for SS and Hast. C22 ANSI 150 and 300 lbs Secondary Pressure Containment 316 L 950 900 850 800 ANSI 300 lbs 750 Pressure in psi 700 650 600 550 500 Secondary Pressure Containment 304 L 450 400 350 300 250 200 ANSI 150 lbs 150 100 50 0 30 50 70 90 110 130 150 170 190 210 Temperature in Deg.
1.2.6 Hygienic Applications The OPTIMASS 7000 series is available with a variety of hygienic process connectors. When using / installing meters with hygienic process connectors, care should be taken to ensure the meter is well supported / clamped, as the meters are heavy and could injure when disconnected from the adjacent pipe work. The recommended method of installation is to mount the meter against a support / wall with the body of the meter supported / clamped.
1.2.7 Heating and insulation There are several methods to heat the meter. In most cases heating is unnecessary as the meter is designed as such that very little heat is lost or gained through the outer cylinder. Insulation Where insulation is required a variety of materials may be used to insulate the meter. Care must be taken not to insulate the meter above the halfway mark of the electronics support post as shown in the sketch. Do not insulate above this line.
Liquid / Steam heating jacket The meter can be supplied with a heating jacket. This jacket is designed to minimise the differential stress across the meter where differences in temperature between outer cylinder and measuring tube exist. The connections to the heating jacket are NPT or Ermeto sockets. It is recommended that reinforced flexible hoses be used to connect the heating jacket to the heat source. Important: Always heat jacket to working temperature before flowing product in measuring tube.
OPTIMASS T10 to T25 - Heating Times 160.0 312 Measuring Tube (centre) temperature (°C) 272 252 120.0 232 100.0 212 192 80.0 172 152 60.0 132 112 40.0 92 72 20.0 Measuring Tube (centre) temperature (°F) 292 140.0 52 0.0 0.00 32 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00 Time (hours) OPTIMASS T 40 to T 80 - Heating Times 160.0 310 290 270 Measuring Tube (centre) temperature (°F) Measuring Tube (centre) temperature (°C) 140.0 250 120.0 230 100.0 210 190 80.0 170 150 60.
100.0 212 90.0 192 Measuring Tube (centre) temperature (°C) 80.0 172 70.0 152 60.0 132 50.0 112 40.0 92 30.0 72 20.0 52 10.0 0.0 Measuring Tube (centre) temperature (°F) OPTIMASS H & S 40 Heating Time 32 0.00 2.00 4.00 6.00 8.00 10.00 12.00 14.00 Time (hours) 100.0 210 90.0 190 80.0 170 70.0 150 60.0 130 50.0 110 40.0 90 30.0 70 20.0 50 10.0 0.0 0.
1.2.8 Purge Port Meters and Burst Disk Meters Purge Port Options If the purge port option was selected at time of order, then your meter will be fitted with ½” NPT female connections – these will be clearly identified. These connections are sealed with NPT plugs and PTFE tape. Important: Do not remove these plugs. The meter is factory sealed with a dry nitrogen gas fill and any ingress of moisture will damage the meter.
1.2.9 Technical Data Nominal Flow Rates 06 Kg/h 950 Lbs/min 35 10 2,700 100 15 11,250 400 25 34,500 1,250 40 91,500 3,350 50 180,000 6,600 80 430,000 15,800 Maximum flow rate Typically 130 % of the nominal flow rate for the sensor size depending on application. Minimum flow rate Depending on measuring error required. Tube materials: • Titanium Gr. 9, • Hastelloy C22 and • SS 318. The meter size has a prefix T, H, or S indicating the tube material.
1.2.10 Weights & Dimensions Weights Weight of OPTIMASS 7000 sensor fitted with a typical standard flange in kg (lbs) Size Kg lbs 06 16 35 10 20 44 15 23 51 25 35 77 40 80 176 50 145 319 80 260 572 Flanged versions Dimensions mm inches Meter Size 06 10 15 25 40 50 80 06 10 15 25 40 50 80 øA B C std C Ex 102 102 102 115 170 220 274 4.0 4.0 4.0 4.5 6.7 8.7 10.8 312 312 312 319 346 371 398 12.3 12.3 12.3 12.6 13.6 14.6 15.7 104 104 104 104 104 104 104 4.1 4.1 4.1 4.1 4.1 4.1 4.
Meter 6 10 15 25 40 50 80 connection size DN10 1/2" DN10 DN10 1/2" DN10 DN10 1/2" 10A DN15 DN15 3/4" DN15 DN15 3/4" 15A 1" 1" 1" 1" DN25 DN25 1.5" 1.5" DN25 DN25 1.5" 1.5" 1.5" 1.5" 1.
Heating Jacket Dimensions HJ mm inches Meter Size 10 15 25 40 50 50 80 10 15 25 40 50 50 80 Connection Size 1/2"(12 mm) 1/2"(12 mm) 1/2"(12 mm) 1/2"(12 mm) 1/2"(12 mm) 1"(25 mm) 1"(25 mm) 1/2"(12 mm) 1/2"(12 mm) 1/2"(12 mm) 1/2"(12 mm) 1/2"(12 mm) 1"(25 mm 1"(25 mm øA 115±1 115±1 142±1 206±1 254±1 254±1 305±1 4.5±0.04 4.5±0.04 5.6±0.04 8.1±0.04 10.0±0.04 10.0±0.04 12.0±0.04 B 312 312 319 346 371 371 398 12.3 12.3 12.6 13.6 14.6 14.6 15.7 Titanium C1 36±1 51±1 100±1 130±1 180±1 175±2 385±2 1.4±0.04 2.
1.3 OPTIMASS 3000 (7100) Single Z Shaped Tube Meter 1.3.1 Specific Installation Guidelines When installing, please observe the following: • Four holes are provided in the base plate and all four should always be used. • The plastic inserts in the base plate mounting holes are important to ensure a rigid and stable connection to the mounting structure. • It is important to mount on a firm and rigid structure to obtain a stable zero condition.
Flanged and Tri-clamp Meters When installing these meters ensure that the pipework is supported behind the process flange, so that no unnecessary stress is applied to the meter flanges. 1.First fix meter to firm support 2.Carefully align process flanges and connect 3.Support process pipe close to flanges – do not pull pipe with clamps 4.
1.3.4 Secondary Pressure containment The OPTIMASS 3000 (7100) meters are supplied with secondary pressure containment as standard. Allowable maximum secondary containment pressures are 30 bar at 20°C or 435 psig at 70°F, and is derated as follows : 20 °C 30 bar 50°C 28.5 bar 100°C 26.1 bar 150°C 24 bar The de-rating is based on the reduction of material strength with temperature for 316L (W No. 1.4404) material from DIN 17456. Heating jacket is rated to 10 bar at 150°C or 145 psig at 300°F.
1.3.6 Heating and insulation All secondary containment and heated jacket parts are 316L, except the 1/4" NPT Female connections, which are 316. Max heating medium pressure and temperature is 10 bar at 150°C or 145 psig at 300°F. The max secondary containment pressure on the OPTIMASS 3000 (7100) when fitted with a heating jacket is 10 bar at 150°C or 145 psig at 300°F.
1.3.8 Technical Data Nominal Flow Rates 01 Kg/h 15 Lbs/min 0.5 03 100 3.5 04 350 12.5 Maximum flow rate Typically 130 % of the nominal flow rate for the sensor size depending on application. Minimum flow rate Depending on measuring error required. Tube materials: • S 316L • Hastelloy C22 The meter size has a prefix S or H indicating the tube material. Secondary pressure containment • All OPTIMASS 3000 (7100) Series meters have secondary containment rated to 30 bar or 435 psi.
1.3.9 Weights & Dimensions Weights Weight of OPTIMASS 3000 (7100) sensor fitted with a typical standard connection in kg (lbs) Size Kg lbs 01 12 26.4 03 12 26.4 04 12 26.
Dimensions 7100 mm inches Flange Size None ANSI 150 ANSI 300 ANSI 600 DIN15 PN40 DIN15 PN63 DIN10 DIN 32676 1/2" TRI CLOVER None ANSI 150 ANSI 300 ANSI 600 DIN15 PN40 DIN15 PN63 DIN10 DIN 32676 1/2" TRI CLOVER øA 256 286±2 286±2 295±2 286±2 295±2 N/A N/A 10.1 11.3 11.3 11.6 11.3 11.6 N/A N/A B std 104 104 104 104 104 104 104 104 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 B Ex 120 120 120 120 120 120 120 120 4.7 4.7 4.7 4.7 4.7 4.7 4.7 4.
1.4 OPTIMASS 8000 / 9000 Meter with Twin U Measuring Tubes 1.4.1 Specific Installation Guidelines • Tighten flange bolts evenly. • Do not stress the sensor mechanically. Clamp and support the connecting pipework accordingly. • It is permissible to support the weight of the meter on the square body. • Cavitation and Mechanical vibration should be avoided. • Use of standard pipework reducers at the flange is allowed. Avoid extreme changes in pipe size (step changes).
1.4.4 Secondary Pressure containment The OPTIMASS 8000/9000 series sensors do not have certified secondary containment. If the user suspects that the primary tube has failed, the unit must be depressurised and removed from service as soon as possible. 1.4.5 Pressure de-rating Meter data plates are stamped with maximum pressure rating (at max. operating temperature) of connection, primary tube or secondary pressure containment (whichever is the lower). Higher pressures may be possible at lower temperatures.
ANSI flanges to ASME B16.5. Note also pressure / temperature limits for measuring tubes above. 3500 3000 Pressure (psi) 2500 Flange ASME B16.5 Class 150 Flange ASME B16.5 Class 300 Flange ASME B16.5 Class 600 Flange ASME B16.5 Class 900 Flange ASME B16.5 Class 1500 2000 1500 1000 500 0 -300 -200 -100 0 100 200 300 400 500 600 700 Temperature ('F) JIS flanges to 2220 B. Note also pressure / temperature limits for measuring tubes above.
1.4.6 Hygienic Applications The OPTIMASS 8000/9000 series is available with a variety of hygienic process connectors. When using / installing meters with hygienic process connectors, care should be taken to ensure the meter is well supported / clamped, as the meters are heavy and could injure when disconnected from the adjacent pipe work. The recommended method of installation is to mount the meter against a support / wall with the body of the meter supported / clamped.
1.4.7 Heating and insulation Insulation OPTIMASS 8000 Where insulation is required a variety of materials may be used to insulate the meter. Care must be taken not to insulate the meter above the halfway mark of the electronics support post as shown in the sketch. Do not insulate above this line. Strongly recommended > 100°C Above 150°C, recommended to use factory supplied option.
1.4.8 Purge Port Meters and Burst Disk Meters Purge Port Options If the purge port option was selected at time of order, then your meter will be fitted with 1/4" NPT female connections – these will be clearly identified. These connections are sealed with NPT plugs and PTFE tape. Important: Do not remove these plugs. The meter is factory sealed with a dry nitrogen gas fill and any ingress of moisture will damage the meter.
Flanged & Hygienic Connections Dimension A EN 1092-1 MATERIAL PN40 PN 63 PN100 1500lb SIZE 80 SIZE 100 DN40 DN40 DN50 DN80 DN80 DN100 DN100 DN150 S/S 370 370 500 500 600 600 610 1000 1000 1100 1100 HAST - 390 500 520 - 620 620 1000 1000 - - S/S - - - - - 620 620 - - - - HAST - - - - - - - - - - - S/S 380 390 520 560 620 660 730 - - - - HAST - - - - - - - - - - - 150 lb 900 lb SIZE 40 DN25 MATERIAL 600lb SIZE 25 D
Triclamp DIN32676 & ISO2852 Triclover Triclamp DIN 11851 Male Material SIZE 15 SIZE 25 SIZE 40 DN25 DN40 DN50 DN65 DN100 S/S 370 500 600 600 1020 Material SIZE 15 SIZE 25 SIZE 40 1" 1 1/2" 2" 3" 4" S/S 370 500 600 600 1020 Material SIZE 15 SIZE 25 SIZE 40 SIZE 80 DN25 DN40 DN50 DN100 380 510 600 1050 S/S SIZE 80 SIZE 80 Other major external dimensions (for all process connections) SIZE B C D E F G H J K Std K Ex 15 272 212 180 368 429 80 60
Insulated / Heated Jacket Meters Major external dimensions of insulating and heating jacket options.
2 Electrical Installation 2.1 Location and connecting cables Location Do not expose the compact flow meter to direct sunlight in hot climates. Install a sunshade if necessary. Connecting cables To conform to protection category requirements, observe the following recommendations: • Fit blanking plug and apply sealant to unused cable entries. • Do not kink cables directly at cable entries. • Provide water drip point (U bend in cable). • Do not connect rigid conduit to cable entries.
2.2.3 Power Supply Wiring MFC 051 Ex Slide the cover to the left to expose the power terminals. Power supply terminals covered. Terminal designation as per section 2.2.2. 2.3 Connection of remote meters The OPTIMASS meter can be supplied as a remote meter with up to 300 m or 1000 ft distance between sensor and converter. Connect cable marked A, B, +, - to corresponding terminals in remote junction box as per sketch below.
Shield is connected through the cable gland. 2.4 Hazardous Area requirements • Hazardous Area Installation. • For further information please see supplementary installation and operating instructions. • Please follow these guidelines explicitly for mechanical and electrical connections. • General cabling guidelines. To maintain the IP 67 / NEMA 4x protection it is necessary to ensure that the correct size cable is used for the cable glands. Please ensure that the cable glands are well tightened.
Output Option 1 Active status O/P 24V DC Pulse O/P (Passive) Input < 24V DC 4-20 mA Common Active Status Output The status output can be programmed to provide a constant 24V (20mA maximum) which can be used as the power source for the pulse output and control input. Set Menu 4.6.1 to OFF Set Menu 4.6.2 to ACTIVE LOW Example Circuits V < 24 V DC R> V 0.
Contact Input <24V DC 0V DC Fig 5 : Binary input Fig 6 : Binary input status powered < 24V DC > I500Ω Contact Contact Pull down IKΩ 0V DC Fig 7 : Binary input status powered Fig 8 : Binary input external powered < 24V DC Output ETC. Output ETC. Relay Relay Fig 9 : Pulse relay status powered ; 24v DC <20mA relay Fig 10 : Pulse relay, external powered ; 24VDC <150mA Output ETC.
Output Option 2 Modbus Current Output Refer to communications handbook for details of Modbus connections Output Option 3 A Pulse 2 B Pulse 1 B LAGS A BY 90° Common 0 V Common 0 V Phase shifted pulse (Passive) for Custody Transfer applications Alternative to drive 2 pulse outputs. Note: It is not possible to provide two independently assignable and scaleable frequency outputs for two separate measurements. Pulse output is passive. Refer to Figs. 2 & 10 for circuit examples.
Output Option 5 Status Output (Passive) Control Input (Passive) Current Output 2 Current Output 1 Common 0 V <24 V DC V < 24 V DC > IK5R Output ETC.
2.5.2 Inputs / Outputs MFC051 The MFC 051 offers galvanically separated outputs in the non-hazardous area version and intrinsically safe outputs for the Hazardous area approved version (see Supplementary Installation and Operating Instructions). All outputs are passive. The converter is shipped from the factory with the required output option fitted and configured. These cannot be changed in the field as the modules are soldered in place.
Output Option 3 In addition to the 1st 4...20mA, a control or binary input can be wired as shown. 5 … 30 V DC Contact 0 V DC Output Option 4 In addition to the 1st 4...20 mA, a status or alarm output can be wired as shown. 5 … 30 V DC 300 R Status 0 V DC Output Option 5 The Profibus communication output available on this converter can be wired as shown in addition to a 4...20mA output.
2.6 Compact to Remote / Remote to Compact conversion instructions Conversion of the mounting of the signal converter from compact to remote, or vice-versa, is possible under certain circumstances, using a kit of parts. A change from compact to remote or vice versa in the field is possible in safe areas, for hazardous areas only in the workshop. Contact your local KROHNE Company and provide the serial number of the meter for further details. 2.7 Technical Data 2.7.
2.7.2 MFC051 Power Supply Operating Voltage : 100 – 230V AC (+10% / -15%) 24V DC (+/- 30%) Power consumption : AC – 18VA DC – 10W Inputs and Outputs Current (mA) output Function : Level : External Power supply : Passive (externally powered) 4 … 20mA 8 … 30V DC Pulse Output Function : Maximum Frequency : Pulse width : External power supply : Maximum circuit current : Passive (externally powered) open collector transistor switch Frequency – 1300Hz, Pulse – 10 KHz 0.
3 Start-Up 3.1 Factory Set Parameters The mass flow meter leaves the factory ready to be used. All process data has been programmed according to the customer order. When no process details were supplied at the time of order, the mass flow meter is programmed to a standard default set of values and functions. The current and pulse outputs treat all flows as positive. The actual flow and quantity is thereby measured independent of the flow direction.
3.3 Zero point adjustment After installation adjust the zero point. To do this, the primary head must be completely filled with the liquid product without gas or air inclusions. This is best obtained by allowing the liquid product to flow through the primary head for approx. 2 minutes at a throughput rate of greater than 50% of rated flow. Subsequently ensure that flow comes to a complete stop in the primary head (see Section 1.
4 Programming the Converter MFC 050/051 4.1 Operating and check elements The operating elements are accessible after removing the cover of the electronics section using the special wrench. The converter is also programmable with magnetic sensors and a bar magnet without removing the covers of the electronic housing. Caution: Do not damage the screw thread and the gasket, never allow dirt to accumulate, and make sure they are well greased at all times.
4.
4.3 Key functions Function of the keys Cursor The location of the cursor on the display is indicated by flashing characters. This could be a single digit when entering number; numeric sign ( + or -) ; measurement units (g, kg, t etc.); or any other text field. Throughout this manual the location of the cursor, in programming examples, will be indicated by parentheses ( ) around the flashing characters. Select or Up Key. This key changes the field/digit under the cursor.
4.3.1 How to enter programming mode To start: Display Fct. 1 OPERATION or CodE 1 --------- Comments If this appears, see box: ”Function of the keys ” in 4.3. 1st - 8th place (key) CodE 1 ∗∗∗∗∗∗∗∗- Each keystroke acknowledged by " * " in display. 9th place (key) Fct. 1 OPERATION If this appears, see box: ”Function of the keys ” in 4.3. XXXXX CODE WRONG A wrong Supervisor CodE 1 was keyed in. Press any key and set the correct 9-keystroke Supervisor CodE 1.
Examples The cursor (flashing part of display) has a grey background in the following examples: To start programming Measurement mode 1 3. 5 m 3 / Programming mode 7 1 → F c h r t. 1. 0 O P E R A T I O N Note: When ”yes” is set under Fct. 3.5.1 SUPERVISOR, the following will appear in the display after pressing the → key: CodE 1 - - - - - - - - -. The 9-stroke entry code must now be entered. Factory setting: → → → ↵ ↵ ↵ ↑ ↑ ↑. Each keystroke is acknowledged by an ” * ” in the display.
To change numeric values Increase numeric value 2 1 0 k g / . 5 0 m i n ↑ 2 1 k 0 . 6 0 g / m i n 2 1 . 6 0 k g / m i n 2 1 . 6 0 k g / m i n To move the cursor (flashing digit) To move to the right 2 1 0 k g / . 6 0 m i n → 0 To move the decimal point To move to the right 2 1 k g / .
4.4 Table of programmable functions Fct. No 1 1.1 1.1.1 Text Description and settings OPERATION ZERO CALIB. AUTO. CALIB. 1.1.2 MANUAL CAL. 1.1.3 1.2 DISP. ZERO INST. STATE 1.3 1.3.1 1.3.2 1.3.3 DENSITY.CAL DISP. PT. 1 DISP. PT. 2 1 POINT.CAL. 1.3.4 2 POINT.CAL. 1.3.4 CALIB. OK. 2 POINT.CAL 1.3.5 CALIB. OK FACTORY.SET Main menu 1 Operation Submenu 1.1 Zero adjustment Automatic zero adjustment *1) Select: SURE YES or NO *2) If YES: Calibration (approx. 30 sec.
Fct. No 2 2.1 Text Description and settings TEST DISPLAY. 2.2 CUR. OUT. 1 2.3 CUR. OUT. 2 2.4 CUR. OUT. 3 2.5 PULSE OUT. 2.6 FREQ. OUT. 2.7 ALARM OUT. 2.8 CONTROL.INP 2.9 2.9.1 DIAGNOSE TUBE TEMP. 2.9.2 STRAIN M.T. 2.9.3 STRAIN I.C. 2.9.4 TUBE FREQ. 2.9.5 DRIVE.ENEGY. 2.9.6 2.9.7 SENSOR A SENSOR B 2.9.8 COMM.ERROR S 2.10 VERSIONS BACKEND.SW Main Menu 2. Test functions Carry out display test * SURE (NO). Use the ↑ key to select YES, then press ↵ (Duration of test approx.
Fct. No 3 3.1 3.1.1 Text Description and settings CONFIG BASIS.PARAM L.F. CUTOFF 3.1.2 TIME CONST. 3.1.3 FLOW MODE 3.1.4 FLOW DIR. 3.1.5 PIPE DIAM. 3.1.6 ADD. TOTAL 3.1.7 ERROR MSG 3.1.8 PRESS TIME 3.1.9 PRESS CUTOF 3.2 3.2.1 DISPLAY CYCL. DISP. 3.2.2 MASS FLOW 3.2.3 TOTAL MASS. 3.2.4 VOLUME.FLOW 3.2.5 VOL.TOTAL 3.2.6 TEMPERATUR. 3.2.7 DENSITY 3.2.8 CONC. FLOW 3.2.9 CONC. TOTAL 3.2.10 CONC.BY. MASS Main menu 3 Configuration Submenu 3.
Fct. No 3.2.11 Text Description and settings CONC.BY.VOL. 3.2.12 VELOCITY 3.2.13 LANGUAGE 3.3 3.3.1 CONC. MEAS. CONC. MODE 3.3.2 ENABLE.CONC 3.3.2 OFFSET Monitor concentration by volume * Select OFF (no concentration by volume on display or * PERCENT V Monitor flow velocity * Select OFF (no flow velocity on display or) * m/sec * ft/sec Language for display text * ENGLISH * FRANCAIS * ESPANOL * DEUTSCH Submenu 3.
Fct. No 4 4.1 Text Description and settings I.O. CONFIG I.O. FITTED Main menu 4 Input/output configuration Submenu 4.
Fct. No 4.5 Text Description and settings PULSE OUT. Submenu 4.5 Pulse/frequency output 4.5.1 FUNCTION Function pulse/frequency output P * OFF (Output = 0V DC) * MASS FLOW (Frequency output 0 to MAX Freq. Hz = Mass Flow in range: MIN. FLOW to MAX FLOW as set in Fct. 4.5.2 and 4.5.3) * DENSITY (Frequency output 0 to MAX Freq. Hz = Density in range: MIN.DENSITY to MAX.DENSITY as set in Fct. 4.5.2 and 4.5.3) * MASS TOTAL(1 pulse = fixed mass as set in Fct 4.5.2) * VOLUME.
Fct. No 4.6 4.6.1 Text Description and settings ALARM. OUT FUNCTION 4.6.2 LOW LIMIT Sub menu 4.6 Process alarm output Function for alarm output * OFF (Output goes to its inactive state) * MASS FLOW (Alarm active if mass flow goes outside limits as set in Fcts. 4.2 to 4.5) * DENSITY (Alarm active if density goes outside limits as set in Fcts. 4.2 to 4.5) * MASS TOTAL (Alarm active if totaliser goes outside limits as set in Fcts. 4.2 to 4.5) * VOLUME.
Fct. No 4.8 4.8.1 Text Description and settings SYS.CTROL FUNCTION 4.8.2 CONDITION 4.8.3 LOW LIMIT 4.8.4 HIGH LIMIT 4.9 4.9.1 COMM.MODULE PROTOCOL 4.9.2 ADDRESS 4.9.3 4.9.4 4.10 4.10.1 4.10.2 4.10.3 4.10.4 4.10.5 4.10.6 BAUDRATE SER.FORMAT CALIB I I 1 5 mA I 1 18 mA I 2 5 mA I 2 18 mA I 3 5 mA I 3 18 mA Submenu 4.8 System control Function for system control * OFF (System control inactive) * FLOW = 0 (Mass flow readings forced to zero, totaliser frozen) * FLOW = 0/RST.
Fct. No 5 5.1 5.1.1 5.1.2 5.1.3 5.1.4 5.1.5 5.1.6 5.1.7 5.1.8 5.1.9 5.1.10 5.1.11 5.1.12 5.1.13 5.1.14 5.1.15 5.1.16 5.1.17 5.1.18 5.1.19 5.1.20 5.1.21 5.2 5.2.1 5.2.2 5.2.3 5.2.4 5.3 5.3.1 5.3.2 5.4 5.4.1 5.4.2 5.5 5.5.1 5.5.2 5.5.3 5.5.4 Text Description and settings FACTORY.SET CALIBRATED CF1 CF2 CF3 CF4 CF5 CF6 CF7 CF8 CF9 CF10 CF11 CF12 CF13 CF14 CF15 CF16 CF17 CF18 CF19 CF20 METER CORR. METER METER TYPE METER SIZE MATERIAL TUBE AMP TEMP.LIMITS MAX. TEMP. MIN. TEMP. TEMP. HIST. MAX. TEMP. MIN. TEMP.
4.5 Reset / Quit Menu - Totalizer reset and status indication acknowledgement Totalizer reset Button ↵ ↑→ Display 10.36 kg CodE 2 –– RESET.TOTAL Description Measurement mode Enter access Code 2 for reset/quit menu: ↑ → Totalizer reset menu If the additional totaliser is selected (Fct. 3.1.
5 Description of Functions In all the following examples, a short notation is used for the setting of the signal converter. Pushing a key several times is indicated by the number of times without the intermediate display messages. Only the final display output is listed. 5.1 Menu 1 - Initial Start up Zero Point Adjustment Fct. 1.1 When operating the system for the first time, it is necessary to set the zero point of the instrument.
Under certain conditions, it may not be possible to adjust the zero point, for instance when: • The medium is in motion, because the shut-off valves etc. are not functioning properly. • There are still gaseous inclusions in the primary head because it was flushed insufficiently. In such cases the zero point adjustment will not be accepted. If the zero adjustment was started by the binary input, the converter will show the message : ZERO.ERROR The converter also reports the ZERO.ERROR in the status list.
Note: When changing from STOP into STANDBY the instrument will run through the STARTUP mode. In addition to these 'standby' modes the SYSTEM CONTROL function provides a fully automated way of switching to similar modes using either the density or temperature of the process fluid as a control (see submenu 4.8). Density Calibration Fct. 1.3 Calibrating the points can only be done when product is in the meter. The two samples that the density has been calibrated at can be seen in the menu 1.3.
st First (1 ) Entered Sample Option: CAL Sample 1 Exit - Do not calibrate and exit (Does not change the calibration details) CAL Sample 1 This gives you a choice of the following products air, pure water, town water and other. Enter the product that is in the meter. PLEASE WAIT will be displayed. Response CALIB OK or CALIB FAIL. Once saved, the meter can be switched off and it will remember that point 1 of a 2 point calibration has been entered.
Density of water as a function of temperature Temperature in Density in 3 Temperature in Density in °C °F kg/m lb/ft3 °C °F kg/m3 lb/ft3 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8 8.5 9 9.5 10 10.5 11 11.5 12 12.5 13 13.5 14 14.5 15 15.5 16 16.5 17 17.5 18 18.5 19 19.5 20 20.5 21 21.5 22 32 32.9 33.8 34.7 35.6 36.5 37.4 38.3 39.2 40.1 41 41.9 42.8 43.7 44.6 45.5 46.4 47.3 48.2 49.1 50 50.9 51.8 52.7 53.6 54.5 55.4 56.3 57.2 58.1 59 59.9 60.8 61.7 62.6 63.5 64.4 65.3 66.2 67.1 68 68.9 69.
Temperature in Density in 3 Temperature in Density in °C °F kg/m lb/ft3 °C °F kg/m3 lb/ft3 45 45.5 46 46.5 47 47.5 48 48.5 49 49.5 50 50.5 51 51.5 52 52.5 53 53.5 54 54.5 55 55.5 56 56.5 57 57.5 58 58.5 59 59.5 60 60.5 61 61.5 62 62.5 113 113.9 114.8 115.7 116.6 117.5 118.4 119.3 120.2 121.1 122 122.9 123.8 124.7 125.6 126.5 127.4 128.3 129.2 130.1 131 131.9 132.8 133.7 134.6 135.5 136.4 137.3 138.2 139.1 140 140.9 141.8 142.7 143.6 144.5 990.2427 990.0341 989.8239 989.6121 989.3986 989.
5.2 Menu 2 – Functional Checks Menu 2.0. contains a number of test functions. These allow the current, frequency and alarm outputs to be driven at a number of fixed test levels, so that the communication between the converter and the customer's equipment can be verified. In addition, other functions allow various measured parameters from the primary head to be viewed directly for trouble shooting purposes. Testing the display Fct. 2.
Testing the pulse output Fct. 2.5 To test the pulse output, connect an external counter to the output terminals. When testing the pulse output, the operator has the choice of the following pulse widths: 0.4 ms, 1.0 ms, 10.0 ms, 100.0 ms and 500 ms. The operator should choose the pulse width that best matches the performance of his external pulse counter. Connect a pulse counter to the impulse output and proceed as follows: Display Key Line 1 Line 2 Fct. (2) TEST →↑ Fct. 2.(1) DISPLAY → Fct. 2.
Testing alarm output Fct. 2.7 This is a simple function that allows the alarm output to be tested at both its high and low states. Key →↑ → ↑x6 → ↑ ↵ Display Line 1 Fct. (2) Fct. 2.(1) Fct. 2.(7) ↑ Fct. 2.(7) ↵ Line 2 TEST DISPLAY Alarm out SURE (NO) SURE (YES) (Level Low) 0V on the output (Level High) +24V on the output * Alarm out * Actual voltage depends on supply if using a PASSIVE status output Testing control input Fct. 2.8 This function allows the state of the control input signal to be tested.
Viewing sensor signal conditions – Diagnose Fct. 2.9 Menu 2.9 allows the viewing of eight parameters Key Display Line 1 Line 2 Fct. 2.9 Diagnose Fct. 2.9.1 ↑ This displays the temperature of the measuring tube. By pressing the → key, the temperature will be indicated. By pressing the ↵ key, you will be returned to the Function display. Fct. 2.9.2 Strain M. T. ↑ This displays the strain value of the measuring tube stain gauge in ohms (where fitted). Fct. 2.9.3 Strain I. C.
5.3 Menu 3- Configuration Menu To access this menu, enter programming mode Key → ↑ ↑ → → Display Line 1 Fct. 1 Fct. 2 Fct. 3 Fct. 3.1 Fct. 3.1.1 Line 2 Operation Test Config. Basic Param. Low Flow cut off Low Flow Cut Off Fct. 3.1.1 If the flow mode in (Fct. 3.1.3. is set to Flow +/- then at zero flow small signal fluctuations will average out to nothing and the totaliser will remain static.
To set a time constant: e.g. 0.5 sec Key Display Line 1 Line 2 From 3.1.(2) Time. Const. (0)0.3 Time. Const. → (0).2 Time. Const. → 0.(2) Time. Const. → ↑ Repeat ↑ key till 5 is reached, then to accept the value. ↵ The standard range for the time constant is 0.2...20 seconds. The filtering only applies to mass and volume flow readings and any outputs programmed to these values. The mass totaliser, volume totaliser, density and temperature measurement outputs are independent of the programmed time constant.
Flow direction Fct. 3.1.4 This function allows the user to select the direction of the flow measurement in relation to the arrows on the Front End housing. (see section 1.1 General Principles). ‘Forward’ is selected if the flow is in the same direction as the + arrow and ‘Backward’ if the flow is in the reverse or negative direction, i.e. same direction as the – arrow.
Pressure Suppression Fct. 3.1.8 and 3.1.9 The Pressure Suppression feature eliminates any influences on the measurement result of sudden termination of flow, such as when a valve is shut. When this occurs the propagation of pressure waves along the pipe work and through the meter may produce an “Over-shoot” or “ringing” effect, where the flow rate will oscillate backwards and forwards until it settles to a stable zero flow condition, as is indicated in the diagram below.
Cyclic Display Fct. 3.2.1 The display can be programmed to cycle between all values or to remain static at the selected variable. To select an option: Key Display Line 1 From Fct. 3.2.1 STATIC DISPLAY → CYCLE DISPLAY ↑ STATIC DISPLAY ↑ Press ↵ to select the required option. Line 2 Cycle Disp. Mass Flow Fct. 3.2.2 The units and the measurement resolution can be set in this menu. Key Display Line 1 Line 2 From Fct. 3.2.2 Mass Flow. 00000.000 (kg) / min → Changes the eng. units selectable kg, t, oz, Ib, g.
Volume Total Fct. 3.2.5. Parameters for the volume totalizer are selected in this menu. Key Display Line 1 Fct. 3.2.5 Line 2 Volume Tot. (off) – default is off. Selects the totalizer display. 00000.000 (cm³) Selects the units. Selection of cm³, dm³, litre, m³, in³, ft³, US gal, ↑ Impgal, off. Allows the position of the decimal place to be changed. → When selection complete press ↵. From → ↑ Temperature Fct. 3.2.6. Selects the temperature units. Key From → ↑ ↵ Display Line 1 Fct. 3.2.
Velocity: Fct. 3.2.12 This function provides an additional measurement parameter. This is particularly useful when the velocity of hazardous materials is to be monitored where static build up is a danger. The mass flow meter will calculate the velocity based on the tube diameter and the mass flow rate. In this menu the units for velocity may be selected. Key From → ↑ ↵ Display Line 1 Fct. 3.2.12 Line 2 Velocity. (off) - default Selects the velocity units. Choose from m/sec, ft/sec and off.
Menu 3.5 Passwords This menu contains all the settings to protect the configuration of the instrument from accidental or deliberate changes. Key From → ↑ Display Line 1 Line 2 Fct. 3.5.1 Supervisor By pressing this button Enable PW appears. Selects further options, change PW or Exit. Enable password – press ↵. • Code 1 will appear with 9 open segments below. • Press a combination of → ↵ ↑ arrows as a pre-selected password.
Menu 3.6 Settings This menu allows a Tag or ID number to be programmed. A combination of alphanumeric characters is available. Key Display Line 1 Line 2 From Fct. 3.6.1 Tag ID Allows the programming of a Tag number. → The ↑ provides the selection of character required while the → allows the selection of the next character to be selected. When complete the ↵ button must be pressed. 5.4 Menu 4 - I/O Configuration The actual output configuration can be read out in Fct. 4.1 I.O. FITTED. The menu 4.
Range Fct. 4.2.2. This allows the setting of the measurement range of the output. Choose from the following: Key Fct. 4.2.2. Range 4-20 mA 4-20/2 mA 4-20/3.5 mA 4-20/22 mA 0-20 mA 0-20/22 mA defaults to 2 mA in case of a fault. defaults to 3.5 mA in case of a fault (required by some control systems). defaults to 22 mA in case of a fault. defaults to 22 mA in case of a fault. Low Limit Fct. 4.2.3. This menu allows the selection of the units as well as the minimum value for the function chosen.
Alarm Output – Menu 4.6 Function Fct. 4.6.1. Any one of the following may be programmed / selected for the alarm output. Key Fct. 4.2.1. Function Off Mass flow Density Mass total Volume flow Volume total Temperature Direction Severe Error All Errors I1 Sat. I2 Sat. I3 Sat. Pulse Sat. Any op. Sat.
System Control – Menu 4.8 This menu allows the setting up of certain instrument functions depending on the selected process condition. If a pre-determined condition arises (as selected in Fct. 4.8.2) then one of the following options can be selected. Function Fct. 4.8.1. Key Fct. 4.8.1. Off Flow = 0 Flow = 0 / RST Outputs off Function not activated If process condition arises, flow outputs will be forced to zero. Flow outputs are driven to zero and totalizer is reset. All outputs switched off.
Calibration – Menu 4.10 This menu allows the calibration of the current outputs. This is always factory set before shipment. It only requires performing if any of the configuration for outputs, or output modules have been changed. I1 5mA Fct. 4.10.1. Injects 5 mA on the output terminals for the first current output. I1 18mA Fct. 4.10.2. Injects 18 mA on the output terminals for the first current output.
5.5 Menu 5 - Factory Settings This menu allows the user to view certain information relating to the meter. E.g. calibration co-efficients, meter type, size, serial numbers etc. Fct. 5.1.1. through to Fct. 5.1.20. Read only transducer co-efficients. Meter Corr. Fct. 5.1.21. Correction factor if meter over or under reads in an application. If under reading, add the required value in + percent in this menu. If over reading, deduct the required percentage i.e. change sign to – and program the percentage error.
Serial numbers – Menu 5.5 All the components that make up the complete instrument have individual serial numbers. This menu displays the serial numbers of the individual components. These serial numbers are mainly used for service purposes. The system serial number is the only serial number that is required when communicating with the factory. Back end Fct. 5.5.1. Displays the back end or main signal converter serial number. Front end Fct. 5.5.2. Displays the front end serial number. Meter Fct. 5.5.3.
6 Service and Trouble Shooting 6.1 Diagnostic functions The following diagnostic functions are available in the submenu Fct. 2.9 DIAGNOSE: Temperature (menu 2.9.1): • Displays temperature in either °C or °F. The value should be stable. Strain (menu 2.9.2 Strain measuring tube / 2.9.3 Strain inner cylinder): • Value of strain in Ohms. The values should be in the range stated in the table in chapter 7.3.
6.2 Error Messages • Basic Errors: These errors are displayed independently of which error message function is selected. • Transducer Errors: These errors only occur when error massage function is set to TRANS.ERROR or ALL ERRORS • I/O Errors: These errors only occur when TRANS.
6.3 Functional Tests and Troubleshooting Min. and Max. recorded temperature (menu 5.4): Records the maximum values of temperature and strain as experienced by the transducer. Max.
Zero Problems • Perform auto zero, observe the displayed value, it should be stable and lower than +/- 0.5% • If the result is bad: Stop flow, set 3.1.1 Low flow cut off to 0, 3.1.3 Flow Mode to “+/-”, perform auto zero, and totalise over 2 minutes. Compare totalised flow to specified zero stability. For best process results, zero setting should be performed on process fluid at process temperature. High Zero’s can be caused by: Leaking valves, Air/Gas inclusions, Coating on tube.
OPTIMASS 8000 / 9000 OPTIMASS 8000 9000 Inductance (mH) Driver Sensor A/B 2.2 0.735 2.6 0.95 Resistance (Ohm) Driver Sensor A/B 38 12.5 67 25 • The above data are provided as a rough guide only. • Driver = White / Brown • Sensor A = Orange / Black. Sensor B = Grey / Blue • RTD = Red / Purple (108Ω at 20°C if PT100, 540Ω at 20°C if PT500). Compensation leg = Purple / Yellow • Resistance values outside these values could indicate a circuit failure.
6.4.2 Replacing the Back End Unscrew the front lid and undo the two screws holding the display in place. The two screws holding the converter in the housing can now be seen towards the rear on the steel frame. Take care not to damage any components while attempting to loosen these screws. The converter will slide out easily after disengaging from the rear terminals in the case of EX/FM converters.
6.5 Spares Description Converters Complete Display Ex + Non Ex Front end electronics (cast in SS lid) Front end gasket Converter electronics insert (see main price list) Part No X2132750100 X2134330100 X6870069989 Converter Output Modules (MFC 050 only) 1st current output module non GI I/O Module, (input/output contact & pulse output) *RS 485 Module (Modbus) Dual Frequency output (phase shifted) X2107010000 X2107030000 X2105850000 X2107620000 * Cannot work with HART module installed.
Terminal Labels for MFC 050 Housing Opt 1: 1 x 4-20 mA, 1 x Pulse, 1 x Control input, 1 x Status output-HART Opt 2: 1 x 4-20 mA, Modbus Opt 3: 1 x 4-20 mA, 1 x Control input, 1 x dual phase frequency output-HART Opt 4: 2 x 4-20 mA, 1 x Pulse, 1 x Control input-HART Opt 5: 2 x 4-20 mA, 1 x Status output, 1 x Control input-HART Opt 6: 3 x 4-20 mA, 1 x Pulse-HART Opt 7: 3 x 4-20 mA, 1 x Control input-HART Opt 8: 3 x 4-20 mA, 1 x Status output-HART Terminal Labels for MFC 051 Housing Opt 1: 2 x 4-20 mA, outputs
7 External Standards and Codes 7.1 Standards The OPTIMASS range of mass flow meters comply with some or all of the following standards or codes: 7.1.1 Mechanical Pressure Equipment Directive PED (acc. to AD2000 Regelewerk) Hygienic Protection Category IP67 (equiv. Nema 4x and 6) Insulation/Heating jacket on OPTIMASS 8000/9000 – IP54 Custody Transfer 97/23/EC ASME Bioprocessing ASME BPEa-2000 Addenda to BPE-1997 3A Dairy Products Standard (28-03) Authorization No. 1246 EHEDG TNO report No.
7.
7.
Installation and Operating Instructions OPTIMASS 104
8 Device Configuration sheet The following pages can be photocopied for your use when required. Serial No. Tag No. MENU 3 CONFIGURATION 3.1.1 L.F. CUTOFF 3.1.2 TIME CONST. 3.1.3 FLOW MODE 3.1.4 FLOW DIR. 3.1.5 PIPE DIAM. 3.1.6 ADD. TOTAL 3.1.7 ERROR MSG 3.1.8 PRESS TIME 3.1.9 PRESS CUTOF 3.2.6 TEMPERATUR. 3.2.7 DENSITY 3.2.8 CONC. FLOW 3.2.9 CONC. TOTAL 3.2.10 CONC.BY.MASS 3.2.11 CONC.BY.VOL. 3.2.12 VELOCITY 3.2.13 LANGUAGE 3.3 CONC. MEAS. 3.2.1 CYCL. DISP. 3.2.2 MASS FLOW 3.2.3 MASS TOTAL 3.2.
Notes Installation and Operating Instructions OPTIMASS 106
9 Declaration of Cleanliness Certificate Returning a device for testing or repair to KROHNE This device has been carefully manufactured and tested. If installed and operated in accordance with these operating instructions, it will rarely present any problems.
Australia KROHNE Australia Pty Ltd Quantum Business Park 10/287 Victoria Rd Rydalmere NSW 2116 TEL.: +61 2 8846 1700 FAX: +61 2 8846 1755 e-mail: krohne@krohne.com.au France KROHNE S.A.S. Les Ors BP 98 F-26103 ROMANS Cedex TEL.: +33(0)4-75 05 44 00 FAX: +33(0)4-75 05 00 48 e-mail: info@krohne.fr Austria KROHNE Austria Ges.m.b.H. Modecenterstraße 14 A-1030 Wien TEL.: +43(0)1/203 45 32 FAX: +43(0)1/203 47 78 e-mail: info@krohne.at Germany KROHNE Messtechnik GmbH & Co. KG Ludwig-Krohne-Str.
