KROHNE OPTIMASS-1000 User Manual
Handbook
Handbook
OPTIMASS 1000
OPTIMASS 1000
OPTIMASS 1000OPTIMASS 1000
HandbookHandbook
Sensor for mass flow
The documentation is only complete when used in combination with the relevant
documentation for the signal converter.
© KROHNE 04/2011 - 4000977901 - MA OPTIMASS 1000 R01 en
: IMPRINT :::::::::::::::::::::::::::::::::::::::
All rights reserved. It is prohibited to reproduce this documentation, or any part thereof, without
the prior written authorisation of KROHNE Messtechnik GmbH.
Subject to change without notice.
Copyright 2011 by
KROHNE Messtechnik GmbH - Ludwig-Krohne-Str. 5 - 47058 Duisburg (Germany)
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OPTIMASS 1000
CONTENTS
1 Safety instructions 5
1.1 Software History ............................................................................................................... 5
1.2 Intended use ..................................................................................................................... 5
1.3 CE certification ................................................................................................................. 5
1.4 Associated documents ..................................................................................................... 6
1.5 Pressure Equipment Directive (PED)............................................................................... 7
1.6 Safety instructions from the manufacturer ..................................................................... 8
1.6.1 Copyright and data protection ................................................................................................ 8
1.6.2 Disclaimer ............................................................................................................................... 8
1.6.3 Product liability and warranty ................................................................................................ 9
1.6.4 Information concerning the documentation........................................................................... 9
1.6.5 Warnings and symbols used................................................................................................. 10
1.7 Safety instructions for the operator............................................................................... 10
2 Device description 11
2.1 Scope of delivery............................................................................................................. 11
2.1.1 Meters with hygienic connections ........................................................................................ 12
2.2 Nameplates .................................................................................................................... 12
2.3 CSA Dual Seal................................................................................................................. 12
2.4 Temperature differential and thermal shock ................................................................ 14
3 Installation 15
3.1 Notes on installation ......................................................................................................15
3.2 Storage ........................................................................................................................... 15
3.3 Handling.......................................................................................................................... 16
3.4 Installation conditions ....................................................................................................18
3.4.1 Supporting the meter............................................................................................................ 18
3.4.2 Mounting the meter .............................................................................................................. 19
3.4.3 Cross talk .............................................................................................................................. 20
3.4.4 Flange connections............................................................................................................... 20
3.4.5 Maximum pipework forces (end loadings) ........................................................................... 21
3.4.6 Pipework reducers................................................................................................................ 22
3.4.7 Flexible connections ............................................................................................................. 22
3.4.8 Hygienic installations............................................................................................................ 22
3.4.9 Heating and insulation .......................................................................................................... 23
3.4.10 Purge ports ......................................................................................................................... 25
3.4.11 Zero calibration................................................................................................................... 25
3.4.12 Sunshades........................................................................................................................... 26
4 Electrical connections 27
4.1 Safety instructions.......................................................................................................... 27
4.2 Electrical and I/O connections ....................................................................................... 27
5 Service 28
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CONTENTS
OPTIMASS 1000
5.1 Spare parts availability...................................................................................................28
5.2 Availability of services .................................................................................................... 28
5.3 Returning the device to the manufacturer..................................................................... 28
5.3.1 General information.............................................................................................................. 28
5.3.2 Form (for copying) to accompany a returned device............................................................ 29
5.4 Disposal .......................................................................................................................... 29
6 Technical data 30
6.1 Technical data................................................................................................................. 30
6.2 Measuring accuracy ....................................................................................................... 36
6.3 Guidelines for maximum operating pressure................................................................ 37
6.4 Dimensions and weights ................................................................................................ 39
6.4.1 Flanged versions................................................................................................................... 39
6.4.2 Hygienic versions .................................................................................................................. 43
6.4.3 Heating jacket version .......................................................................................................... 47
6.4.4 Purge port option .................................................................................................................. 48
7 Notes 49
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OPTIMASS 1000
1.1 Software History
Release date Software version Documentation
Aug 2008 V2.2.xx MA MFC 300 R02
1.2 Intended use
This mass flowmeter is designed for the direct measurement of mass flow rate, product density
and product temperature. Indirectly, it also enables the measurement of parameters like total
mass, concentration of dissolved substances and the volume flow. For use in hazardous areas,
special codes and regulations are also applicable and these are specified in a separate
documentation.
1.3 CE certification
CE marking
SAFETY INSTRUCTIONS 1
MA OPTIMASS 1000 R01
This device conforms with the following EC directives:
• EMC Directive 2004/108/EC
• ATEX Directive 94/9/EC
• Low Voltage Directive 2006/95/EC
• Pressure Equipment Directive 97/23/EC
The manufacturer declares conformity and the device carries the CE mark.
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1 SAFETY INSTRUCTIONS
1.4 Associated documents
This handbook should be read in conjunction with relevant documents in relation to:
• hazardous areas
• communications
• concentration
• corrosion
OPTIMASS 1000
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OPTIMASS 1000
1.5 Pressure Equipment Directive (PED)
LEGAL NOTICE!
The Pressure Equipment Directive places legal requirements on both the manufacturer and the
end user. Please read this section carefully!
Visual check
XXXXX
To ensure the PED integrity of the meter, you MUST check that the serial numbers on the
converter nameplate and the sensor nameplate are the same.
To comply with the requirements of the Pressure Equipment Directive (PED) the manufacturer
provides all the relevant technical data in the technical data section of this handbook. In addition
to which, the following should also be noted:
SAFETY INSTRUCTIONS 1
• Secondary pressure containment is NOT supplied as standard.
• The non PED / CRN approved outer cyclinder has a typical burst pressure greater than
100 barg / 1450 psig at 20°C / 68°F.
• The wiring feedthrough is made of Epoxy, PPS or PEEK with two O-rings made from FPM /
FKM & Hydrogenated Nitrile.
• If the measuring tube/s fails, the O-ring and feedthrough will be in contact with the process
product.
• You MUST make sure that the O-ring ring and feedthrough material is suitable for the
application.
• Alternative O-ring materials are available on request.
Secondary pressure containment
Where the meter is being used to measure high pressure gases and / or gases kept as liquids by
high pressure and / or where there is a risk of tube failure because of the use of corrosive or
erosive fluids, frequent pressure and / or thermal cycling, seismic or other shock loading, a
secondary containment option MUST be purchased
Where the above situation applies and the process pressure exceeds the secondary pressure
containment (please refer to technical data) or where secondary pressure containment is not
available, the burst disc option MUST also be purchased. For more information, please contact
your nearest representative.
DANGER!
If it is suspected that the primary measuring tube has failed, de-pressurise the meter and
remove it from service as soon as it is safe to do so.
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1 SAFETY INSTRUCTIONS
1.6 Safety instructions from the manufacturer
1.6.1 Copyright and data protection
The contents of this document have been created with great care. Nevertheless, we provide no
guarantee that the contents are correct, complete or up-to-date.
The contents and works in this document are subject to copyright. Contributions from third
parties are identified as such. Reproduction, processing, dissemination and any type of use
beyond what is permitted under copyright requires written authorisation from the respective
author and/or the manufacturer.
The manufacturer tries always to observe the copyrights of others, and to draw on works created
in-house or works in the public domain.
The collection of personal data (such as names, street addresses or e-mail addresses) in the
manufacturer's documents is always on a voluntary basis whenever possible. Whenever
feasible, it is always possible to make use of the offerings and services without providing any
personal data.
OPTIMASS 1000
We draw your attention to the fact that data transmission over the Internet (e.g. when
communicating by e-mail) may involve gaps in security. It is not possible to protect such data
completely against access by third parties.
We hereby expressly prohibit the use of the contact data published as part of our duty to publish
an imprint for the purpose of sending us any advertising or informational materials that we have
not expressly requested.
1.6.2 Disclaimer
The manufacturer will not be liable for any damage of any kind by using its product, including,
but not limited to direct, indirect or incidental and consequential damages.
This disclaimer does not apply in case the manufacturer has acted on purpose or with gross
negligence. In the event any applicable law does not allow such limitations on implied warranties
or the exclusion of limitation of certain damages, you may, if such law applies to you, not be
subject to some or all of the above disclaimer, exclusions or limitations.
Any product purchased from the manufacturer is warranted in accordance with the relevant
product documentation and our Terms and Conditions of Sale.
The manufacturer reserves the right to alter the content of its documents, including this
disclaimer in any way, at any time, for any reason, without prior notification, and will not be liable
in any way for possible consequences of such changes.
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OPTIMASS 1000
1.6.3 Product liability and warranty
The operator shall bear responsibility for the suitability of the device for the specific purpose.
The manufacturer accepts no liability for the consequences of misuse by the operator. Improper
installation and operation of the devices (systems) will cause the warranty to be void. The
respective "Standard Terms and Conditions" which form the basis for the sales contract shall
also apply.
1.6.4 Information concerning the documentation
To prevent any injury to the user or damage to the device it is essential that you read the
information in this document and observe applicable national standards, safety requirements
and accident prevention regulations.
If this document is not in your native language and if you have any problems understanding the
text, we advise you to contact your local office for assistance. The manufacturer can not accept
responsibility for any damage or injury caused by misunderstanding of the information in this
document.
This document is provided to help you establish operating conditions, which will permit safe and
efficient use of this device. Special considerations and precautions are also described in the
document, which appear in the form of underneath icons.
SAFETY INSTRUCTIONS 1
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1 SAFETY INSTRUCTIONS
1.6.5 Warnings and symbols used
Safety warnings are indicated by the following symbols.
DANGER!
This information refers to the immediate danger when working with electricity.
DANGER!
This warning refers to the immediate danger of burns caused by heat or hot surfaces.
DANGER!
This warning refers to the immediate danger when using this device in a hazardous atmosphere.
DANGER!
These warnings must be observed without fail. Even partial disregard of this warning can lead to
serious health problems and even death. There is also the risk of seriously damaging the device
or parts of the operator's plant.
OPTIMASS 1000
WARNING!
Disregarding this safety warning, even if only in part, poses the risk of serious health problems.
There is also the risk of damaging the device or parts of the operator's plant.
CAUTION!
Disregarding these instructions can result in damage to the device or to parts of the operator's
plant.
INFORMATION!
These instructions contain important information for the handling of the device.
LEGAL NOTICE!
This note contains information on statutory directives and standards.
• HANDLING
HANDLING
HANDLINGHANDLING
This symbol designates all instructions for actions to be carried out by the operator in the
specified sequence.
i RESULT
RESULT
RESULTRESULT
This symbol refers to all important consequences of the previous actions.
1.7 Safety instructions for the operator
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WARNING!
In general, devices from the manufacturer may only be installed, commissioned, operated and
maintained by properly trained and authorized personnel.
This document is provided to help you establish operating conditions, which will permit safe and
efficient use of this device.
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OPTIMASS 1000
2.1 Scope of delivery
Compact version
1 Mass flowmeter.
2 Carton.
3 Documentation.
4 2.5 mm and 5 mm hex head tools.
5 CD-ROM and calibration certificate.
DEVICE DESCRIPTION 2
Remote version
1 Mass flowmeter.
2 Converter. This will be either: field (as shown), wall or rack.
3 Carton.
4 2.5 mm and 5 mm hex head tools.
5 CD-ROM and calibration certificate.
6 Documentation.
If any items are missing, please contact the manufacturer.
If your meter has flange connections, the flange specification is stamped on the outer edge of the
flange. Check that the specification on the flange is the same as your order.
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2 DEVICE DESCRIPTION
2.1.1 Meters with hygienic connections
1 Fully welded - the O-rings between the meter and the process pipework are not supplied as standard but can be or-
dered.
2 DIN 11864-2 Form A - the O-rings between the Form A and Form B parts of the connection are not supplied as standard
but can be ordered.
3 The 11864-2 Form B is not supplied as part of this connection but it can be ordered.
2.2 Nameplates
INFORMATION!
Look at the device nameplate to ensure that the device is delivered according to your order.
Check for the correct supply voltage printed on the nameplate.
OPTIMASS 1000
2.3 CSA Dual Seal
To comply with the requirements of ANSI/ISA -12.27.01-2003 “Requirements for process Sealing
Between electrical systems and Flammable or Combustible process Fluids” a secondary seal is
incorporated into all OPTIMASS / GAS products. If the primary seal fails, the secondary seal will
prevent escaping fluid reaching the electronic compartment.
Pressures and / or temperatures are limited by tube, temperature, connection and Ex limits.
Check the meter nameplates and relevant documentation for full details. On all meters
operating on gas measurement, the casing of the meter is fitted with a burst disc. If the primary
seal (tube) fails leakage will occur from the burst disc. Install the meter so that the burst disc is
pointing away from personnel.
Liquids
Liquids (Example model code: OPTIMASS 1000C S25 - LIQUID)
LiquidsLiquids
Pressure and temperature data:
Pressure and temperature data:
Pressure and temperature data:Pressure and temperature data:
OPTIMASS 1000 / 1300 / 1010 -40°C...+130°C and 100...10000 kPa
Pressures and/or temperatures may be further limited by tube, temperature, connection and Ex
limits. Consult the meter nameplate and relevant documentation for full details.
If the primary seal fails, the casing of the meter will fill with liquid and the meter will stop
working. The meter will notify the operator by going into <Startup> mode and a diagnostic error
will be shown on the converter or PLC display. This is an indication that the primary seal (tube)
has failed and the status of the meter should be checked.
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Meter status:
Meter status:
Meter status:Meter status:
The meter will also go into <Startup> mode if the primary seal (tube) fails, or if they are not
completely filled with fluid. For example, if the meter is drained or re/filled.
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OPTIMASS 1000
To check the status of the meter, drain and re/fill with fluid and note the converter or PLC
display. See the relevant section of the converter handbook for a list of status messages and
diagnostics information.
If the meter remains in <Startup> mode you MUST assume that the primary seal (tube) has failed
and the appropriate action MUST be taken.
Gases
Gases (Example model code: OPTIMASS 1000C S25 - GAS)
GasesGases
Pressure / temperature data:
Pressure / temperature data:
Pressure / temperature data:Pressure / temperature data:
-40°C...+130°C and 500...10000 kPa
Pressures and/or temperatures may be further limited by tube, temperature, connection and Ex
limits. Consult the meter nameplate and relevant documentation for full details.
On all meters operating on gas measurement the casing of the meter is fitted with a burst disc. If
the primary seal (tube/s) fails leakage will occur from the burst disc. Install the meter so that the
burst disc is pointing away from personnel.
DEVICE DESCRIPTION 2
Regular maintenance of the burst disc:
Regular maintenance of the burst disc:
Regular maintenance of the burst disc:Regular maintenance of the burst disc:
Carry out regular maintenance checks on burst discs for leakage and/or blockages. On all
OPTIMASS meters, the primary seal is considered to be the measuring tube of the meter. The
materials of construction of the measuring tube/s are described within the relevant sections of
this handbook and the customer’s product and any other fluid flowing through the tube must be
compatible with the material of construction. If failure of the primary seal is suspected then the
process line should be de-pressurised and the meter removed as soon as it is safe to do so.
Please contact customer service for servicing or replacement of the meter.
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2 DEVICE DESCRIPTION
2.4 Temperature differential and thermal shock
Temperature differential
Temperature differential
Temperature differentialTemperature differential
The maximum difference between ambient temperature and process (operating) temperature is
110°C / 230°F.
Thermal shock
Thermal shock
Thermal shockThermal shock
Thermal shock occurs when there is a sudden and extreme change (shift) in process
temperature. To avoid thermal shock, refer to the following table for the maximum temperature
shift.
Meter
Meter Maximum temperature shift
MeterMeter
S15 +80°C / +176°F
S25
S40 +110°C / +230°F
S50
Maximum temperature shift
Maximum temperature shiftMaximum temperature shift
OPTIMASS 1000
CAUTION!
Operation outside these limits may result in shifts in density and mass flow calibration. Repeated
shocking may also lead to premature failure of the meter! However, higher thermal shocks are
possible at lower working pressures. For more information, please contact your nearest
representative.
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OPTIMASS 1000
3.1 Notes on installation
INFORMATION!
Inspect the cartons carefully for damage or signs of rough handling. Report damage to the
carrier and to the local office of the manufacturer.
INFORMATION!
Check the packing list to check if you received completely all that you ordered.
INFORMATION!
Look at the device nameplate to ensure that the device is delivered according to your order.
Check for the correct supply voltage printed on the nameplate.
3.2 Storage
• Store the device in a dry and dust-free location.
• Avoid direct exposure to the sun.
• Store the device in its original packing.
• Do not allow the ambient temperature to fall below -50°C / -58°F or rise above +85°C /
+185°F.
INSTALLATION 3
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3 INSTALLATION
3.3 Handling
Using a sling to lift and carry the meter
1
OPTIMASS 1000
2
3
1 Use a well maintained sling to lift the meter by the spigots.
2 DO NOT lift the meter with the sling part way along the outer cylinder.
3 DO NOT lift the meter using the flange bolt holes.
4 DO NOT lift the meter by the converter housing or the electronics stem.
4
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