KROHNE OPTIMASS-2000 User Manual

Handbook

OPTIMASS 2000

OPTIMASS 2000OPTIMASS 2000

HandbookHandbook

Sensor for bulk mass flow

Software revision: V2.2.xx

The documentation is only complete when used in combination with the relevant documentation for the converter.

: IMPRINT ::::::::::::::::::::::::::::::::::

Subject to change without notice.

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OPTIMASS 2000

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 ................................................................ 13

3 Installation 14

3.1 Notes on installation ......................................................................................................14

3.2 Storage ........................................................................................................................... 14

3.3 Handling.......................................................................................................................... 15

3.4 Installation conditions ....................................................................................................17

3.4.1 Supporting the meter............................................................................................................ 17

3.4.2 Mounting the meter .............................................................................................................. 18

3.4.3 Side mounting ....................................................................................................................... 19

3.4.4 Cross talk .............................................................................................................................. 19

3.4.5 Flange connections............................................................................................................... 20

3.4.6 Maximum pipework forces (end loadings) ........................................................................... 20

3.4.7 Pipework reducers................................................................................................................ 21

3.4.8 Flexible connections ............................................................................................................. 21

3.4.9 Hygienic installations............................................................................................................ 22

3.4.10 Heating and insulation ........................................................................................................ 22

3.4.11 Purge ports ......................................................................................................................... 24

3.4.12 Burst discs .......................................................................................................................... 24

3.4.13 Zero calibration................................................................................................................... 25

3.4.14 Sunshades........................................................................................................................... 26

4 Electrical connections 27

4.1 Safety instructions.......................................................................................................... 27

4.2 Electrical and I/O connections ....................................................................................... 27

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CONTENTS

OPTIMASS 2000

5 Service 28

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 Measuring principle (twin tube) ..................................................................................... 30

6.2 Technical data................................................................................................................. 32

6.3 Measuring accuracy ....................................................................................................... 37

6.4 Guidelines for maximum operating pressure................................................................ 38

6.5 Dimensions and weights ................................................................................................ 40

6.5.1 Flanged versions................................................................................................................... 40

6.5.2 Hygienic versions .................................................................................................................. 45

6.5.3 Heating jacket version .......................................................................................................... 47

6.5.4 Purge port option .................................................................................................................. 48

7 Notes 49

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OPTIMASS 2000

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 2000 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 2000

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OPTIMASS 2000

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 2000

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 2000

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 2000

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

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 2000

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 2000

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 2000C S250 - LIQUID)

LiquidsLiquids

Pressure and temperature data:

Pressure and temperature data:Pressure and temperature data:

OPTIMASS 2000 / 2300 / 2010 -45°C...+130°C and 100...14000 kPa

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.

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.

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.

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OPTIMASS 2000

If the meter remains in <Startup> mode you MUST assume that the primary seal (tube) has failed and the appropriate action MUST be taken.

DEVICE DESCRIPTION 2

Gases

Gases (Example model code: OPTIMASS 2000C S250

GasesGases

Pressure

Pressure / temperature data:

Pressure / temperature data:Pressure / temperature data:

OPTIMASS 2000 / 2300 / 2010 -45°C...+130°C and 500...14000 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.

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.

emperature data:

/ t

- GAS)

2.4 Temperature differential and thermal shock

Temperature differential

Temperature differentialTemperature differential

The maximum difference between ambient temperature and process (operating) temperature is

100°C / 212°F.

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 S100 +90°C / +194°F (+110°C / +230°F with a maximum operating pressure of 40 barg / 580 psig) S150 +80°C / +176°F S250 +50°C / +122°F

Maximum temperature shift

Maximum temperature shiftMaximum temperature shift

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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3 INSTALLATION

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.

OPTIMASS 2000

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OPTIMASS 2000

3.3 Handling

Using a sling to lift and carry the meter

INSTALLATION 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.

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3 INSTALLATION

Standing the meter before installation

1 When standing the meter prior to installation, use blocks or similar to keep the meter upright. 2 NEVER stand the meter upright without blocks (or similar) .

OPTIMASS 2000

1 If the meter is not blocked it can roll over 2 This can cause severe damage to the meter, or injury to personnel

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