KROHNE OPTISONIC 6400 Handbook
Handbook
Handbook
OPTISONIC 6400
OPTISONIC 6400
OPTISONIC 6400OPTISONIC 6400
HandbookHandbook
Portable ultrasonic clamp-on flowmeter
Electronic Revision:
ER 1.1.0_
(SW.REV 01.01.01)
© KROHNE 08/2011 - 4000972602 - MA OPTISONIC 6400 R02 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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OPTISONIC 6400
CONTENTS
1 Safety instructions 5
1.1 Intended use ..................................................................................................................... 5
1.2 Certification ...................................................................................................................... 5
1.3 Safety instructions from the manufacturer ..................................................................... 6
1.3.1 Copyright and data protection ................................................................................................ 6
1.3.2 Disclaimer ............................................................................................................................... 6
1.3.3 Product liability and warranty ................................................................................................ 7
1.3.4 Information concerning the documentation........................................................................... 7
1.3.5 Warnings and symbols used................................................................................................... 8
2 Device description 9
2.1 Scope of delivery............................................................................................................... 9
2.2 Nameplates .................................................................................................................... 10
3 Installation 12
3.1 General safety instructions ............................................................................................ 12
3.2 Installation requirements .............................................................................................. 13
3.2.1 Inlet, outlet and recommended mounting area ................................................................... 13
3.2.2 Long horizontal pipes ........................................................................................................... 14
3.2.3 Vertical pipelines .................................................................................................................. 14
3.2.4 Open feed or discharge......................................................................................................... 15
3.2.5 Down going pipeline over 5 m / 16 ft length......................................................................... 15
3.2.6 Position of control valve........................................................................................................ 15
3.2.7 Position of pump ................................................................................................................... 16
3.3 Installation procedure for flow measurement .............................................................. 17
3.3.1 Step 1: check required parts ................................................................................................ 17
3.3.2 Step 2: select proper installation position ........................................................................... 18
3.3.3 Step 3: determine dimensions of pipe.................................................................................. 18
3.3.4 Step 4: initialise the UFC 400 P converter............................................................................ 18
3.3.5 Step 5: program the units in the converter .......................................................................... 19
3.3.6 Step 6: program the converter ............................................................................................. 20
3.3.7 Step 7: mount the sensor rails ............................................................................................. 21
3.3.8 Step 8: connect the sensor cable .........................................................................................27
3.3.9 Step 9: start flow measurement...........................................................................................28
3.3.10 Error messages .................................................................................................................. 29
3.4 Installation procedure for energy measurement .......................................................... 31
3.4.1 Step 1: selecting the necessary tools for energy measurement ......................................... 32
3.4.2 Step 2: what to do before setting up the energy units ......................................................... 34
3.4.3 Step 3: setting up the units ................................................................................................... 35
3.4.4 Step 4: set up I/O input for energy measurement................................................................ 35
3.4.5 Step 5: Set up process input for energy measurement ....................................................... 35
3.4.6 Step 6: set up counters for energy .......................................................................................37
3.4.7 Step 7: How to read energy measurement........................................................................... 37
4 Electrical connections 39
4.1 Safety instructions.......................................................................................................... 39
4.2 Location of connectors at the converter ........................................................................ 39
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CONTENTS
OPTISONIC 6400
4.3 Power supply .................................................................................................................. 40
4.4 Signal cable .................................................................................................................... 40
4.5 USB connector................................................................................................................ 41
4.6 I/O cable.......................................................................................................................... 42
4.7 Connection diagrams ..................................................................................................... 44
4.8 I/O configuration............................................................................................................. 49
5 Operation 50
5.1 Display configuration......................................................................................................50
5.1.1 Step 1: how to set up the display for showing measured values ......................................... 50
5.1.2 Basic settings of display ....................................................................................................... 51
5.2 Menu description ............................................................................................................ 51
5.3 How to set up data logging............................................................................................. 62
5.3.1 Step 1: how to set up the data logger................................................................................... 62
5.3.2 Step 2: how to start data logging.......................................................................................... 64
5.3.3 Step 3: how to view logged data............................................................................................ 65
5.4 How to transfer data to a PC .......................................................................................... 65
5.4.1 Site files................................................................................................................................. 65
5.4.2 Log files................................................................................................................................. 66
5.4.3 Managing your files from your pc.........................................................................................67
6 Service 68
6.1 Spare parts availability...................................................................................................68
6.2 Availability of services .................................................................................................... 68
6.3 Returning the device to the manufacturer..................................................................... 68
6.3.1 General information.............................................................................................................. 68
6.3.2 Form (for copying) to accompany a returned device............................................................ 69
6.4 Disposal .......................................................................................................................... 69
7 Technical data 70
7.1 Measuring principle........................................................................................................70
7.2 Technical data................................................................................................................. 71
7.3 Dimensions and weights ................................................................................................ 77
7.3.1 Clamp-on sensor .................................................................................................................. 77
7.3.2 Converter............................................................................................................................... 78
7.3.3 I/O box ................................................................................................................................... 79
7.3.4 Trunk on wheels.................................................................................................................... 80
8 Notes 81
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OPTISONIC 6400
1.1 Intended use
The OPTISONIC 6400
OPTISONIC 6400 portable clamp-on flow meter is designed for measurement of liquid flows
OPTISONIC 6400OPTISONIC 6400
in full pipes, datalogging and transfer of logged results to the PC. The portable clamp-on flow
meter makes it possible to measure the flow on places temporary or you can make use of it if
you want to compare the output with other measurement devices. If an inline measurement
device is broken and you are in need of the information the OPTISONIC 6400 might be the
solution for you.
1.2 Certification
In accordance with the commitment to customer service and safety, the device
described in this document meets the following safety requirements:
• EMC Directive 2004/108/EC 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)
SAFETY INSTRUCTIONS 1
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1 SAFETY INSTRUCTIONS
1.3 Safety instructions from the manufacturer
1.3.1 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.
OPTISONIC 6400
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.
1.3.2 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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OPTISONIC 6400
1.3.3 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.
1.3.4 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
1.3.5 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 6400
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.
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OPTISONIC 6400
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.
CAUTION!
The device arrives in a plastic trunk on wheels.
DEVICE DESCRIPTION 2
Figure 2-1: Scope of delivery
1 Product documentation, factory calibration report
2 Trunk on wheels
3 Carrying bag
4 1 or 2 rail(s) per tray
5 Metal / textile straps for mounting rail(s) and converter
6 Sensor(s) with fixing units (small version 1, medium version 2 sensors)
2 Transducers (small versions: 2 MHz, medium version: 1 MHz), including 3 m cable, coupling grease
7 Power adapter including plugs for EU, UK, US and AUS
8 USB memory stick, measure band
optionally I/O box and/or temperature sensors, PC connection cable
9 Signal converter UFC 400 P
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2 DEVICE DESCRIPTION
2.2 Nameplates
Figure 2-2: 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 Name and address of the manufacturer
OPTISONIC 6400
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Figure 2-3: Nameplate
1 Name and address of the manufacturer
2 Device type
3 Manufacturing year
4 Serial number
5 Protection class and temperature data
6 Treat device as electronic garbage according WEEE rules.
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OPTISONIC 6400
DEVICE DESCRIPTION 2
Figure 2-4: I/O box, standard version
Figure 2-5: I/O box with 2 OPTITEMP TT 30 C included.
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3 INSTALLATION
3.1 General safety instructions
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.
Specific for sensors:
WARNING!
•
Be careful when locking the rail back on to the mounting units as your fingers may get stuck
between rail and pipe it is mounted on. This may cause injury.
•
Be careful when mounting the fixation units using the metal strap. The edge of the strap may
cause injury.
CAUTION!
•
Do not bend the metal mounting strap. This may cause improper mounting of the fixation
units of the sensor rails.
•
Protect the pipe contact side of the transducer. Scratches or other damages may have a
negative impact on its proper functioning.
•
Before fitting the transducer to the transducer knob in the sensor rail, check the connection
groove of the transducer cover for damages or dirt. Clean or replace when dirty or damaged.
•
Check sensor cabling with regular intervals for damages and wear as this may cause
improper functioning. Replace when necessary.
•
Check presence of sufficient grease on the transducer pipe contact side in case of acoustic
signal failure.
•
Check the sensor rail sliding area regularly for dirt or other pollution or excess coupling fat,
that may cause improper functioning.
•
Excess of coupling fat may be removed from the sensor rails and transducers with a dry piece
of cloth. Coupling fat on the converter housing may be removed using soapy water.
OPTISONIC 6400
Specific for converters:
WARNING!
Be careful moving the handle of the converter, as your fingers may get stuck between the handle
and the housing of the converter. This may cause injury.
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OPTISONIC 6400
CAUTION!
•
In order to comply with the EMC directive 2004/108/EC, I/O cables that provide a galvanic
connection to the UFC 400 P should have a maximum total length of 3 meter.
•
When not used, put the connector covers of the connectors on the bottom side of the
converter in place. This to prevent improper functioning caused by dust/dirt.
•
When the sensor cables are connected while the converter is positioned on a flat surface,
turn the handle fully backwards (towards the housing) in order to prevent excess stress on
the sensor cables.
•
With an empty main battery, the backup battery of the real time clock may run empty when
this is the case for a period longer than one year.
•
The protection degree of the battery charger / mains adapter is IP 40 / NEMA 1. It should be
protected against moisture entering.
•
To prevent damage due to vibrations, do not firmly attach the converter to or place it on top of
a vibrating object.
3.2 Installation requirements
3.2.1 Inlet, outlet and recommended mounting area
INSTALLATION 3
To perform an accurate flow measurement preferably mount the sensor rail at least 10 DN
downstream of a flow disturbance like elbow, valve, header or pump. Please follow the
installation recommendations in the next installation position examples.
Figure 3-1: Inlet, outlet and recommended mounting area
1 Min. 10 DN
2 Min. 5 DN
3 OK, 120°
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3 INSTALLATION
3.2.2 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.
Figure 3-2: Long horizontal pipes
3.2.3 Vertical pipelines
OPTISONIC 6400
CAUTION!
•
Ensure that the pipe is fully filled at all times.
•
Both ascending and descending flow direction is measurable.
•
Observe the required in- and outlets.
Figure 3-3: Mounting on vertical pipelines is possible
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OPTISONIC 6400
3.2.4 Open feed or discharge
Install meter on a lowered section of the pipe to ensure a full pipe condition through the meter.
Figure 3-4: Open feed or discharge
3.2.5 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 3-5: Down going pipeline over 5 m / 16 ft length
3.2.6 Position of control valve
Always install control valves downstream of flowmeter in order to avoid cavitation or distortion
of flow profile.
Figure 3-6: Position of control valve
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3 INSTALLATION
3.2.7 Position of pump
CAUTION!
Never install flowmeter at a pump suction side in order to avoid cavitation or flashing in the
flowmeter.
Figure 3-7: Position of pump
OPTISONIC 6400
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OPTISONIC 6400
3.3 Installation procedure for flow measurement
3.3.1 Step 1: check required parts
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.
CAUTION!
The device arrives in a plastic trunk on wheels.
INSTALLATION 3
Figure 3-8: Scope of delivery
1 Product documentation, factory calibration report
2 Trunk on wheels
3 Carrying bag
4 1 or 2 rail(s) per tray
5 Metal / textile straps for mounting rail(s) and converter
6 Sensor(s) with fixing units (small version 1, medium version 2 sensors)
2 Transducers (small versions: 2 MHz, medium version: 1 MHz), including 3 m cable, coupling grease
7 Power adapter including plugs for EU, UK, US and AUS
8 USB memory stick, measure band
optionally I/O box and/or temperature sensors, PC connection cable
9 Signal converter UFC 400 P
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3 INSTALLATION
3.3.2 Step 2: select proper installation position
3.3.3 Step 3: determine dimensions of pipe
• Use the supplied tape measure to find the outside diameter of the pipe.
• Use a pipe wall thickness gauge, or pipe tables to find the pipe wall thickness.
• Establish the pipe material.
• Is the pipe lined, find out what the liner and material thickness is.
3.3.4 Step 4: initialise the UFC 400 P converter
OPTISONIC 6400
1
2
123
ABC DEF
456
GHI JKL MNO
789
PQRS TUV WXYZ
+/- 0
A/a
EXP
-
I/O
DISPLAY
LOGGER
MENU
3
4
5
Figure 3-9: Keys UFC 400 P
1 TFT Display
2 Navigation keys
3 Quick access keys
4 Text and numerical keypad
5 On / off button
Turn on the converter by pressing the on / off button for one second. Wait until the menu
appears, this will take approximately 30 seconds.
When the UFC 400 P converter is started the first time the startup menu will be shown. In this
menu you can set the language, time and date. This menu will be shown only once. You can
activate the menu to be shown again at the next startup by selecting "Settings and information
Device Start-up sequence?".
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OPTISONIC 6400
Menu
Language English
Time and date
Units
Continue
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If the device has been used before, the screen will look like the figure below.
Menu
Installation
Measurement
View logged data
File Management
Settings and information
Settings and information
Settings and information Settings and information
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INFORMATION!
You can still change the language, time and date and units from other parts of the menu.
INSTALLATION 3
Use the following keys to navigate through the menu:
Back Back one page
∧ Up Up one line
∨ Down Down one line
Forward Enter item to edit or to select it
When editing only the Back and Forward buttons are functional:
Back Delete previous character or leave item
Forward Move cursor right, accept item when at
unchanged when at position one
last position
3.3.5 Step 5: program the units in the converter
If you use the converter for the first time, it will prompt you for the unit setting automatically.
Otherwise go to menu number 2.4.1 ("Measurement Setup Units")
Choose in each line the required unit with the buttons as shown in the previous section.
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3 INSTALLATION
3.3.6 Step 6: program the converter
CAUTION!
Because the converter remember most of its previous settings, you may wish to reset the
converter before installing at a new location to prevent unexpected behavior. To reset the
converter, enter the "Settings and information" menu and select "Load factory settings".
In the menu "Settings and information Device Password" a password can be set. In
measuring mode the password blocks the measurement mode after the display sleep time has
passed. The measurement mode can only be left after typing the password.
Select "Installation" from the main menu, then press "" and select the desired configuration.
1.2
Pipe tag
Outer diameter
Material
Wall thickness
Liner material
< Previous | Next >
< Previous | Next >
< Previous | Next > < Previous | Next >
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OPTISONIC 6400
Pipe1
100.00 mm
Carbon steel
5.00 mm
None
Pipe tag Give the pipe a name
Press again "" and "".
Outer diameter Use the outside diameter
Material Choose the right material
Wall thickness Fill in the pipe wall thickness material
Liner material Select whether there is a liner or not
Choose next
CAUTION!
Inaccurate input of the outside diameter will affect the accuracy of the measured flow rate.
1.3
Fluid
VoS Fluid
Viscosity
< Previous | Next >
< Previous | Next >
< Previous | Next > < Previous | Next >
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Water
1485.0 m/s
2
/s
1 mm
20
Fluid Give the right liquid from the table. If the liquid is unknown,
choose water. The correct value will be measured.
VoS Fluid Velocity of Sound. Only change it if it is well known.
Viscosity Only change it if it is well known.
Choose next
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OPTISONIC 6400
3.3.7 Step 7: mount the sensor rails
1.7
Transducer set
Calibration number
Number of traverses
< Previous | Next >
< Previous | Next >
< Previous | Next > < Previous | Next >
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Transducer set Fill in the value given on the label on the transducer cable
Calibration number Fill in the value given on the label on the transducer cable
Number of traverses Z mode = 1 traverse
The best suitable sensor is automatically selected from a list of three available sensor types and
the appropiate number of traverses is indicated.
INSTALLATION 3
Ta
522505050
V mode = 2 traverses
W mode = 4 traverses
Pipe Available sensor Traverse mode
DN15...150 Small 2 MHz, 1 rail
DN50...250 Medium 1 MHz, 1 rail
DN200...750 Medium 1 MHz, 2 rails
DN400...1500 Medium 1 MHz, 2 rails
Choose the right traverse mode. For recommendations please see examples above.
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3 INSTALLATION
V mode;1 rail (DN15...250)
Press " "
Read from the display of the signal converter what rail configuration is required and what the
correct sensor distance is.
1.8
Advised sensor position
34.30 mm
Signal quality
< Previous | Next >
< Previous | Next >
< Previous | Next > < Previous | Next >
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Please follow up the instructions for the application.
One rail with 2 transducers in V mode: Put the first transducer at position "0", the other one at
the recommended distance, shown on the screen (in this example 34.30 mm).
OPTISONIC 6400
78%
• Unlock the transducer by turning the locking knob 2 counter clockwise.
• Slide the transducer 1 to the new position 3.
• Lock the transducer by turning the locking knob 2 clockwise.
V mode; 2 rails (DN200...750)
INFORMATION!
For V mode with 2 rails you must install the DOWN rail in line with UP rail. It is easier to install
than the Z mode, but you need more free pipe length.
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OPTISONIC 6400
Z mode; 2 rails (DN400...1500)
Measure the outer diameter of the pipe with the measuring band. Install the DOWN rail at the
opposite location of the pipe.
• Mount the DOWN rail in such a way that the transducer is at the marked location.
INSTALLATION 3
Figure 3-10: Mounting second rail in Z mode (1 traverse) using a reference point
1 Measure the distance between the transducer of the UP rail and the reference point.
2 Add the advised distance to determine the position of the second transducer.
Figure 3-11: Mounting second rail in Z mode (1 traverse) without using a reference point
1 Advised distance 1 = 2 + 3
W mode; 1 rail (DN15...150)
Follow the instructions as given in "V mode; 1 rail
V mode; 1 rail".
V mode; 1 railV mode; 1 rail
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3 INSTALLATION
Installation with metal straps (DN15...250)
On request it is possible to use the large rail of the OPTISONIC 6300 with 0,5 MHz transducers.
Using this you can measure up to DN4000.
Put the metal straps around the pipe. Put the sensor rail(s) on the pipe including the transducers
with fixed cables.
OPTISONIC 6400
24
• 8: Repeat steps 1...7 for the second strap.
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OPTISONIC 6400
Installation with textile straps (> DN250)
Installation with textile straps (> DN250)
Installation with textile straps (> DN250)Installation with textile straps (> DN250)
INSTALLATION 3
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3 INSTALLATION
Regreasing of transducers
Set the sensors to the proper sensor distance. Unlock and tilt the rail by pushing the buttons of
the fixing units. Then put some coupling fat on the transducers and put the rail back by clicking.
OPTISONIC 6400
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