KROHNE OPTISONIC 6300 Operating Manual

Handbook
Handbook
OPTISONIC 6300
OPTISONIC 6300
OPTISONIC 6300OPTISONIC 6300
HandbookHandbook
Ultrasonic clamp-on flowmeter
ER 3.4.0_
© KROHNE 07/2009 - 4000263902 - HB OPTISONIC 6300 R03 en
: IMPRINT ::::::::::::::::::::::::::::::::::
Subject to change without notice.
Copyright 2009 by KROHNE Messtechnik GmbH & Co. KG - Ludwig-Krohne-Straße 5 - 47058 Duisburg
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OPTISONIC 6300
CONTENTS
1 Safety instructions 6
1.1 Software history ............................................................................................................... 6
1.2 Intended use ..................................................................................................................... 6
1.3 Certification ...................................................................................................................... 6
1.4 Safety instructions from the manufacturer ..................................................................... 8
1.4.1 Copyright and data protection ................................................................................................ 8
1.4.2 Disclaimer ............................................................................................................................... 8
1.4.3 Product liability and warranty ................................................................................................ 9
1.4.4 Information concerning the documentation........................................................................... 9
1.4.5 Warnings and symbols used................................................................................................. 10
1.5 Safety instructions for the operator............................................................................... 10
2 Device description 11
2.1 Scope of delivery............................................................................................................. 11
2.2 Device description .......................................................................................................... 12
2.3 Nameplates .................................................................................................................... 13
2.3.1 Overview ................................................................................................................................ 13
2.3.2 Flow sensor........................................................................................................................... 13
2.3.3 Signal converter.................................................................................................................... 14
2.3.4 Electrical connection data of inputs/outputs (example of basic version)............................ 15
3 Installation 16
3.1 Notes on installation ......................................................................................................16
3.2 Storage ........................................................................................................................... 16
3.3 Transport ........................................................................................................................ 16
3.4 Pre-installation requirements ....................................................................................... 16
3.4.1 Environmental requirements ...............................................................................................16
3.4.2 Installation requirements signal converter ......................................................................... 17
3.5 Installation requirements sensor .................................................................................. 17
3.5.1 Inlet, outlet and recommended mounting area ................................................................... 18
3.5.2 Long horizontal pipes ........................................................................................................... 18
3.5.3 Open feed or discharge......................................................................................................... 19
3.5.4 Down going pipeline over 5 m /16 ft length.......................................................................... 19
3.5.5 Position of control valve........................................................................................................ 19
3.5.6 Position of pump ................................................................................................................... 20
3.5.7 Pipe diameters and sensor construction ............................................................................. 20
3.5.8 Pipe and media parameters ................................................................................................. 20
3.6 Installation of the flowmeter.......................................................................................... 21
3.6.1 General mechanical installation........................................................................................... 21
3.6.2 Installation instructions for small and medium version...................................................... 23
3.6.3 Installation instructions for large version............................................................................ 25
3.7 Mounting of converter .................................................................................................... 27
3.7.1 Mounting of UFC 300 F.......................................................................................................... 27
3.7.2 Turning the display of the field housing version .................................................................. 27
3.7.3 Mounting of UFC 300 W......................................................................................................... 28
4 Electrical connections 29
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CONTENTS
OPTISONIC 6300
4.1 Safety instructions.......................................................................................................... 29
4.2 Construction of the various housing versions ............................................................... 29
4.2.1 UFC 300 F .............................................................................................................................. 29
4.2.2 UFC 300 W ............................................................................................................................. 30
4.3 Electrical connection......................................................................................................31
4.3.1 Signal cable to flow sensor................................................................................................... 31
4.3.2 Signal cable and power supply signal converter.................................................................. 33
4.3.3 Laying electrical cables correctly......................................................................................... 35
4.4 Description of the electrical symbols ............................................................................ 36
4.5 Basic inputs and outputs ................................................................................................ 37
4.5.1 Fixed, non-alterable input/output versions.......................................................................... 38
4.5.2 Basic inputs/outputs ............................................................................................................. 40
4.5.3 HART
®
connection ................................................................................................................ 43
4.6 Modular Inputs and Outputs........................................................................................... 44
4.6.1 Alterable input/output versions............................................................................................ 44
4.6.2 Modular inputs/outputs and bus systems............................................................................ 46
4.6.3 HART
®
connection ................................................................................................................ 54
5 Start-up 56
5.1 General instructions for programming.......................................................................... 56
5.2 Start measurement of small / medium version ............................................................ 60
5.3 Start measurement of large version.............................................................................. 61
5.4 Mechanical installation for large version ...................................................................... 63
6 Operation 73
6.1 Menu overview................................................................................................................ 73
6.2 Menu structure............................................................................................................... 74
6.2.1 Quick setup............................................................................................................................ 74
6.2.2 Test........................................................................................................................................ 76
6.2.3 Setup ..................................................................................................................................... 78
6.2.4 Customize settings ............................................................................................................... 85
6.3 Function description.......................................................................................................86
6.4 Error messages.............................................................................................................. 93
7 Service 95
7.1 Periodic maintenance..................................................................................................... 95
7.1.1 Regreasing of transducers ................................................................................................... 95
7.2 Cleaning.......................................................................................................................... 96
7.3 Exchange of electronics unit .......................................................................................... 96
7.3.1 Field version.......................................................................................................................... 97
7.3.2 Wall version........................................................................................................................... 99
7.4 Replacing the mains fuse............................................................................................. 102
7.4.1 Field version........................................................................................................................ 103
7.4.2 Wall version......................................................................................................................... 103
7.5 Spare parts availability................................................................................................. 104
7.6 Availability of services .................................................................................................. 104
7.7 Returning the device to the manufacturer................................................................... 104
7.7.1 General information............................................................................................................ 104
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7.7.2 Form (for copying) to accompany a returned device.......................................................... 105
CONTENTS
7.8 Disposal ........................................................................................................................ 105
8 Technical data 106
8.1 Measuring principle...................................................................................................... 106
8.2 Technical data............................................................................................................... 107
8.3 Dimensions and weights .............................................................................................. 115
8.3.1 Housing ............................................................................................................................... 115
8.3.2 Clamp-on sensor and cable box ......................................................................................... 116
8.3.3 Mounting plate, field housing ............................................................................................. 118
8.3.4 Mounting plate, wall-mounted housing ............................................................................. 118
9 Notes 119
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1 SAFETY INSTRUCTIONS
1.1 Software history
For all GDC devices, the "Electronic Revision" (ER) is consulted to document the revision status of the electronics according to NE 53. It is easy to see from the ER whether any fault repairs or major changes to the electronic equipment have taken place and what effect they have had on compatibility.
Changes and effect on compatibility
1 Downwards compatible changes and fault repair with no effect on operation (e.g. spelling
mistakes on display)
2-_ Downwards compatible hardware and/or software change of interfaces:
HART
®
H
P PROFIBUS
F Foundation Fieldbus
M Modbus
X all interfaces
3-_ Downwards compatible hardware and/or software change of inputs and outputs:
I Current output
F, P Frequency / pulse output
S Status output
C Control input
CI Current input
X all inputs and outputs
4 Downwards compatible changes with new functions
5 Incompatible changes, i.e. electronic equipment must be changed.
OPTISONIC 6300
INFORMATION!
In the table below, "x" is a placeholder for possible multi-digit alphanumeric combinations, depending on the available version.
1.2 Intended use
The overall functionality of the clamp-on flowmeter is the continuous measurement of actual volume flow, mass flow, flow speed, velocity of sound, gain, SNR and diagnosis value.
1.3 Certification
In accordance with the commitment to customer service and safety, the device described in this document meets the following safety requirements:
EMC Directive 89 / 336 / EEC and 93 / 68 / EEC in conjunction with EN 61326-1 (1997) and A1 (1998), A2 (2001)
Low-Voltage Directives 73 / 23 / EEC and 93 / 68 / EEC in conjunction with EN 61010-1 (2001)
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All devices are based on the CE marking and meet the requirements of NAMUR Guideline NE 21 / 04.
DANGER!
For devices used in hazardous areas, additional safety notes apply; please refer to the Ex documentation.
SAFETY INSTRUCTIONS 1
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1 SAFETY INSTRUCTIONS
1.4 Safety instructions from the manufacturer
1.4.1 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 German 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.
OPTISONIC 6300
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.
1.4.2 Disclaimer
The manufacturer will not be liable for any damage of any kind by using its product, including, but not limited to direct, indirect, incidental, punitive 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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1.4.3 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.
1.4.4 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
1.4.5 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.
OPTISONIC 6300
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.
1.5 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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OPTISONIC 6300
2.1 Scope of delivery
INFORMATION!
Check the packing list to check if you received completely all that you ordered.
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!
The device will arrive in two cartons. The square carton contains the converter. The rectangular carton contains the transducer set.
DEVICE DESCRIPTION 2
Figure 2-1: Scope of delivery
1 Signal converter, wall version or field version 2 Quick Start 3 CD-ROM (including Handbook, Quick Start, Technical Datasheet, Support database, movie) 4 Factory calibration report 5 Sensor plus cover (stainless steel / XT version without cover) 6 Metal strap
7 Mineral coupling grease (standard versions) or high temperature contactgel Pyrogel 8 Signal cable plus connector cap (XT versions have a protection sleeve around the signal cable).
®
(XT versions)
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2 DEVICE DESCRIPTION
Additionally for large version:
1 2nd sensor plus cover 2 90 degree screw driver 3 4 fixing units 4 Positioning tool 5 2 metal straps 6 Signal cable plus connector cap 7 Cable box plus signal cable
INFORMATION!
No special tools, no training required!
OPTISONIC 6300
2.2 Device description
The ultrasonic clamp-on flowmeter can be fitted on the outside of piping to measure the flow rate of liquids. The device is a combination of one up to two clamp-on sensor(s) and one ultrasonic flow converter.
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Figure 2-2: System configuration possibilities
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OPTISONIC 6300
The underneath accessories can be ordered optionally:
GDC interface set
SoundCheck
Coupling grease; mineral (standard versions)
High temperature contact gel Pyrogel
2.3 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.
2.3.1 Overview
®
(XT versions)
DEVICE DESCRIPTION 2
Figure 2-3: Visual check
1 Flow sensor 2 Signal converter
2.3.2 Flow sensor
Figure 2-4: Nameplate flow sensor
1 Ambient temperature operating range 2 Protection category 3 Calibration number 4 Process temperature (-40...+200°C for XT version) 5 Manufacturing year 6 Serial number 7 Device type (yyy = small, medium or large) 8 Manufacturer
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2 DEVICE DESCRIPTION
2.3.3 Signal converter
OPTISONIC 6300
Figure 2-5: Nameplate
1 Manufacturer 2 Device type 3 Manufacturing year 4 Serial number sensor 1 + short code flow sensor 5 Serial number sensor 2 + short code flow sensor 6 Empty
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OPTISONIC 6300
DEVICE DESCRIPTION 2
2.3.4 Electrical connection data of inputs/outputs (example of basic version)
Figure 2-6: Example of a nameplate for electrical connection data of inputs and outputs
1 Power supply (AC: L and N; DC: L+ and L-; PE for 24 VAC; FE for 24 VAC and DC) 2 Connection data of connection terminal D/D- 3 Connection data of connection terminal C/C- 4 Connection data of connection terminal B/B- 5 Connection data of connection terminal A/A-; A+ only operable in the basic version
A = active mode; the signal converter supplies the power for connection of the subsequent devices
P = passive mode; external power supply required for operation of the subsequent devices
N/C = connection terminals not connected
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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 flowmeter in a dry and dust-free location.
Avoid lasting direct exposure to the sun.
Store the flowmeter in its original packing.
OPTISONIC 6300
3.3 Transport
No special requirements.
3.4 Pre-installation requirements
INFORMATION!
To assure a quick, safe and uncomplicated installation, we kindly request you to make provisions as stated below.
3.4.1 Environmental requirements
Pollution degree 2
Protection class I
Humidity: 5...80 % RH
Temperature: 40+60°C / -40+140°F operating and 50+70°C / -58+158°F storage
Suitable for indoor and outdoor use and certified for operating up to an altitude of
2000 m / 6562 ft
IP class 66/67
CAUTION!
The device should be protected from corrosive chemicals or gases and dust / particles accumulation.
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3.4.2 Installation requirements signal converter
Allow 10…20 cm / 3.97.9" of space at the sides and rear of the signal converter to permit
free air circulation.
Protect signal converter against direct solar radiation, install a sunshield if necessary.
Signal converters installed in switchgear cabinets require adequate cooling, e.g. by fan or
heat exchanger.
Do not expose the signal converter to intense vibration.
INFORMATION!
For detailed information please also refer to Housing on page 115
3.5 Installation requirements sensor
INFORMATION!
To avoid measuring errors and malfunctioning of the flowmeter due to gas or air inclusions or an empty pipe, please observe the following precautions.
INSTALLATION 3
.
CAUTION!
Since gas will collect at the highest point of a pipe, installation of the flowmeter at that location should be avoided at all times. Also installation in a down going pipe should be avoided since a completely filled pipe may not be guaranteed due to cascading effects. Additionally flow profile distortion is possible.
CAUTION!
If you program the diameter, please note that you use the outer diameter of the pipe.
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3 INSTALLATION
3.5.1 Inlet, outlet and recommended mounting area
Figure 3-1: Inlet, outlet and recommended mounting area
1 Min. 10 DN 2 Min. 5 DN 3 OK, 120°
OPTISONIC 6300
CAUTION!
Especially for XT (eXtended Temperature) versions:
Always install the sensor at a non-insulated part of the pipe. Remove any insulation if necessary!
Bend radius of cable plus connection box needs 10 cm / 4" additional non insulated pipe section.
Always wear protections gloves.
3.5.2 Long horizontal pipes
Install on slightly ascending pipe section.
If not possible, ensure adequate velocity to prevent air, gas or vapor from collecting in upper
part.
In partially filled pipes, the clamp-on flowmeter will report incorrect flow rates, or not measure.
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Figure 3-2: Long horizontal pipes
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OPTISONIC 6300
3.5.3 Open feed or discharge
Install meter on a lowered section of the pipe to ensure a full pipe condition through the meter.
Figure 3-3: Open feed or discharge
3.5.4 Down going pipeline over 5 m /16 ft length
Install air vent downstream of the flow meter to prevent vacuum. Although this will not harm the meter, it may cause gases to come out of solution (cavitate) and interfere with proper measurements.
INSTALLATION 3
Figure 3-4: Down going pipeline over 5 m /16 ft length
3.5.5 Position of control valve
Always install control valves downstream of flowmeter in order to avoid cavitation or distortion of flow profile.
Figure 3-5: Position of control valve
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3 INSTALLATION
3.5.6 Position of pump
CAUTION!
Never install flowmeter at a pump suction side in order to avoid cavitation or flashing in the flowmeter.
Figure 3-6: Position of pump
3.5.7 Pipe diameters and sensor construction
OPTISONIC 6300
Figure 3-7: Measuring modes
1 Z-mode 2 V-mode 3 W-mode
3.5.8 Pipe and media parameters
INFORMATION!
Detailed databases of most pipe and media parameters are on the supplied CD.
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OPTISONIC 6300
3.6 Installation of the flowmeter
3.6.1 General mechanical installation
Installation of the rails with the metal straps
Installation of the rails with the metal straps
Installation of the rails with the metal strapsInstallation of the rails with the metal straps
INSTALLATION 3
8: Repeat steps 1...7 at the other side of the rail.
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3 INSTALLATION
Change the position of the transducer
Change the position of the transducer
Change the position of the transducerChange the position of the transducer
Unlock the floating transducer 2 by turning the locking knob 1 counter clockwise.
Slide the transducer 2 to the advised mounting distance 3 (menu X9.4).
Lock the transducer by turning the locking knob 1 clockwise.
Greasing the transducer surfaces
Greasing the transducer surfaces
Greasing the transducer surfacesGreasing the transducer surfaces
OPTISONIC 6300
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OPTISONIC 6300
INFORMATION!
Not applicable for stainless steel / XT versions. These are delivered without cover.
Mounting the cover
Mounting the cover
Mounting the coverMounting the cover
INSTALLATION 3
3.6.2 Installation instructions for small and medium version
Figure 3-8: Procedure for installation of small or medium version
1 Rail, small version 2 Rail, medium version 3 Choose for V-mode or ... 4 Choose for W-mode 5 Make settings in converter
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3 INSTALLATION
OPTISONIC 6300
Figure 3-9: Device versions
1 Small version: single pipe / single path 2 Medium version: single pipe / single path 3 Small version: single pipe / dual path 4 Medium version: single pipe / dual path 5 Small version: dual pipe / single path 6 Medium version: dual pipe / single path
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3.6.3 Installation instructions for large version
INSTALLATION 3
Figure 3-10: Procedure for installation of large version
1 Enter the values for the installation menu, X1...X9.8.4 2 Read the advised mounting distance in menu X9.8.5 3 Choose for Z-mode (default) or ... 4 Choose for V-mode 5 Finish the installation menu
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3 INSTALLATION
OPTISONIC 6300
Figure 3-11: Device versions
1 Single pipe, single path 2 Single pipe, dual path 3 Dual pipe
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OPTISONIC 6300
3.7 Mounting of converter
CAUTION!
Always use the supplied signal cable. Keep the distance between the sensor and the signal converter as short as possible.
3.7.1 Mounting of UFC 300 F
Perform the following procedures:
Mount converter with mounting plate on wall or standpipe.
Observe maximum allowed length of 30 m / 98.4 ft for the signal cable
3.7.2 Turning the display of the field housing version
INSTALLATION 3
Figure 3-12: Turning the display of the field housing version
The display of the field housing version can be turned in 90° increments.
1 Unscrew the cover from the display and operation control unit. 2 Using a suitable tool, pull out the two metal puller devices to the left and right of the display. 3 Pull out the display between the two metal puller devices and rotate it to the required position. 4 Slide the display and then the metal puller devices back into the housing. 5 Re-fit the cover and tighten it by hand.
CAUTION!
The ribbon cable of the display must not be folded or twisted repeatedly.
INFORMATION!
Each time a housing cover is opened, the thread should be cleaned and greased. Use only resin­free and acid-free grease. Ensure that the housing gasket is properly fitted, clean and undamaged.
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3 INSTALLATION
3.7.3 Mounting of UFC 300 W
Perform the following procedures:
Remove aluminium mounting plate from rear of the signal converter, and attach to wall or
standpipe.
Mount signal converter.
Position lock washers and nuts on the housing bolts, tighten nuts slightly.
Align housing, tighten nuts firmly.
Observe max. allowed length of 30 m / 98.4 ft for the signal cable.
OPTISONIC 6300
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4.1 Safety instructions
DANGER!
All work on the electrical connections may only be carried out with the power disconnected. Take note of the voltage data on the nameplate!
DANGER!
Observe the national regulations for electrical installations!
DANGER!
For devices used in hazardous areas, additional safety notes apply; please refer to the Ex documentation.
WARNING!
Observe without fail the local occupational health and safety regulations. Any work done on the electrical components of the measuring device may only be carried out by properly trained specialists.
ELECTRICAL CONNECTIONS 4
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.
4.2 Construction of the various housing versions
4.2.1 UFC 300 F
The terminal compartments are accessible after unscrewing cover 2 and 6.
Figure 4-1: Construction (field version)
1 Cover, electronics compartment 2 Cover, terminal compartment for power supply and inputs/outputs 3 Cable entry for power 4 Cable entry for inputs/outputs 5 Cable entry for sensor cable 6 Cover, sensor terminal compartment
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4 ELECTRICAL CONNECTIONS
4.2.2 UFC 300 W
The terminal compartments are accessible after opening cover 2.
Figure 4-2: Construction of remote version
1 Cover, electronics compartment 2 Cover for the three separate terminal compartments for power, sensor connection and inputs/outputs 3 Locking screw, 1/2 turn left/right to open/close cover 2 4 Sensor terminal compartment 5 Terminal compartment for inputs/outputs 6 Power terminal compartment, open separate shock-hazard protection cover
OPTISONIC 6300
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