KROHNE OPTISONIC-7060 User Manual
© KROHNE 10/2006 730962.31.00
Ultrasonic
Flowmeters
OPTISONIC 7060
Electrical
& mechanical
installation
manual
OPTISONIC 7060
TABLE OF CONTENTS
1 Safety Instructions ............................................................................................. 6
1.1 Intended Use of the Equipment ...............................................................................6
1.2 Authorized Staff.........................................................................................................6
1.3 General Safety Instructions and Protective Measures..........................................6
1.3.1 Danger Due to Hot, Corrosive and Explosive Gases and High Pressure ......................... 7
1.3.2 Dangers Due to Heavy Loads Overhead........................................................................... 7
2 Product Description ........................................................................................... 8
2.1 Features and Applications .......................................................................................8
2.2 Conformity, Configuration, Technical Data............................................................9
2.2.1 CE Certificate..................................................................................................................... 9
2.2.2 Technical Data................................................................................................................... 9
2.3 System Components ..............................................................................................11
2.3.1 Meter Body....................................................................................................................... 11
2.3.2 Ultrasonic Transducers.................................................................................................... 12
2.3.3 Signal Processing Unit (CONVERTER) .......................................................................... 12
2.4 Operating modes and signal output......................................................................14
2.5 Self-diagnosis..........................................................................................................16
2.6 Event logging ..........................................................................................................17
2.7 Configurations.........................................................................................................18
3 Assembly and Installation ............................................................................... 19
3.1 General Notes.......................................................................................................... 19
3.1.1 Delivery............................................................................................................................ 19
3.1.2 Transport and Storage..................................................................................................... 20
3.2 Assembly .................................................................................................................20
3.3 Mechanical Installation...........................................................................................21
3.3.1 Choosing flanges, seals and other parts ......................................................................... 22
3.3.2 Mounting the OPTISONIC 7060 to the pipeline............................................................... 22
3.3.3 CONVERTER alignment.................................................................................................. 23
3.4 Electrical Installation ..............................................................................................24
3.4.1 General information ......................................................................................................... 24
3.4.2 Cable specs .....................................................................................................................24
3.4.3 Checking the cable loops................................................................................................. 26
3.4.4 Terminal box on the CONVERTER ................................................................................. 27
3.4.5 Connecting the OPTISONIC 7060 for use in non-hazardous areas................................ 29
3.4.6 Operation in hazardous areas in accordance with Directive 94/9/EC (ATEX) ................ 30
3.4.7 Operation in hazardous areas to North American Guidelines (CSA) .............................. 34
4 Operation of the converter............................................................................... 35
4.1 Operation and menu structure of the CONVERTER with LCD............................35
4.1.1 Operation ......................................................................................................................... 35
4.1.2 Menu structure................................................................................................................. 36
4.1.3 Definition of measured value displays ............................................................................. 39
4.1.4 Definition of log book entries ........................................................................................... 40
4.1.5 Acknowledgement of a log book entry............................................................................. 41
4.1.6 Resetting the error volume counters ............................................................................... 41
5 Verification and Commissioning..................................................................... 42
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OPTISONIC 7060
5.1 Verification...............................................................................................................42
5.1.1 Examining the condition................................................................................................... 42
5.1.2 Testing the functions........................................................................................................ 42
5.2 Commissioning .......................................................................................................42
5.2.1 Installation........................................................................................................................ 42
5.2.2 Checking the functions .................................................................................................... 42
5.2.3 Pressure testing of a gas pipeline with liquid (water) ...................................................... 43
6 Maintenance...................................................................................................... 44
6.1 General.....................................................................................................................44
6.2 Routine checks........................................................................................................44
7 Troubleshooting ............................................................................................... 46
8 ATEX / CSA converter terminal assignment .................................................. 47
8.1 Converter terminal assignments ATEX.................................................................47
8.2 Converter terminal assignments CSA...................................................................48
Product Liability and warranty
Responsibility for suitability and intented use of these ultrasonic flowmeters rests solely with the
operator.
Improper installation and operation of the flowmeters (systems) may lead to loss of warranty.
In addition, the “General conditions of sale” forming the basis of the purchase contract are applicable.
If flowmeters need to be returned to KROHNE, please note the information given on the last-but-one
page of these instructions. KROHNE regret that they cannot repair or check your flowmeter(s) unless
accompanied by the completed form sheet.
Electrical & mechanical installation manual 730962.31.00 page 3 of 52
OPTISONIC 7060
About this document
This manual describes the measuring system OPTISONIC 7060 used to determine the actual
volume flow, actual volume and the velocity of sound in gases transported in pipelines. It
provides general information on the measuring method employed, design and function of
the entire system and its components, and on planning, assembly, installation,
commissioning, maintenance and troubleshooting. Contrasting characteristic properties of
available system variants aims to facilitate a decision on a configuration that is ideally
adapted to the measuring task already in the planning phase.
This manual covers standard applications which conform with the technical data specified.
Additional information and assistance for special applications is available from your KROHNE
representative.
This manual is part of the OPTISONIC 7060 documentation package. This package includes the
following documents:
• Operating Instructions OPTISONIC 7060 (this document)
• Documentation CD
Option, for trained staff only:
• Service Manual OPTISONIC 7060
• Software Manual MEPAFLOW IV
Symbols used in this document
Important information, in particular regarding safety, are highlighted in this document to
facilitate quick reference. Such information is provided where necessary within each section
of this manual.
Note To provide information about special features of the device/ system and further
recommendations.
Important
IMPORTANT
WARNING
Note Always read this manual carefully before carrying out any work on the equipment. Always comply
To indicate potential dangers to the equipment and possible functional impairment.
Warning
To indicate potential dangers to the operating staff, in particular due to electrical equipment
and improper use of the device/ system. Always observe such warnings, as they aim to
protect you from serious injuries.
with any safety instructions and warnings.
Any obligation of KROHNE are set forth in the relevant purchase agreement. This agreement
also includes the complete and solely valid warranty conditions.
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OPTISONIC 7060
Abbreviations used in this manual
act. actual (operating condition)
ANSI American National Standards Institute
ASCII American Standard Code for Information Interchange
ASME American Society of Mechanical Engineers
CSA Canadian Standards Association
DC Direct Current
DIN Deutsches Institut für Normung (German Industrial Standard)
DN NominalDiameter (internal)
DSP Digital Signal Processor
EC European Community
EN Euro Norm (European Standard)
Ex Potentially explosive atmosphere (hazardous area)
HART Communication interface
IEC International Electrotechnical Commission
norm. normalised (standard condition)
LED Light Emitting Diode
MEPAFLOW Menu-assisted Parameterisation and Diagnosis for OPTISONIC 7060
NAMUR Normenarbeitsgemeinschaft für Mess- und Regeltechnik in der chemischen
Industrie (now "Interessengemeinschaft Prozessleittechnik der chemischen
und pharmazeutischen Industrie"; ~ Association for Instrumentation and
Control Standards in the Chemical Industry)
PC Personal Computer
VDE Verband der Elektrotechnik Elektronik Informationstechnik (~ Association of
German Electrical Engineers)
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OPTISONIC 7060
1 Safety Instructions
1.1 Intended Use of the Equipment
The OPTISONIC 7060 measuring system was designed to determine the actual volume flow
rate of gases transported in pipelines. The OPTISONIC 7060 measuring system can further be
used to measure the actual volume and velocity of sound in gases.
The measuring system shall only be used as specified by the manufacturer and as set forth
below. Always observe the following points:
• Make sure the use of the equipment complies with the technical data, information about
the permitted use, assembly and installation specifications and ambient and operating
conditions. Any relevant information is provided in the order documentation, type plate,
certification documents and this manual.
• Any actions aiming at maintaining the value of the equipment, e.g. service and inspection,
transport and storage etc., shall be performed as specified.
• Do not expose the equipment to mechanical stress, such as pig cleaning.
1.2 Authorized Staff
Persons responsible for safety issues shall ensure the following points:
• Any work on the measuring system shall only be carried out by qualified persons and
must be checked by responsible skilled persons.
Due to their professional training, knowledge and vocational experience, as well as their
knowledge of the relevant standards, regulations, health and safety regulations and
equipment conditions, qualified persons shall be assigned by the person responsible for
personal and plant safety to carry out such work. Qualified persons must be able to
identify possible dangers and to take preventive action in due time.
• Skilled persons shall have precise knowledge of process-specific dangers, e.g. due to the
effects of hot, toxic and pressurised gases, gas-liquid mixtures and other process media,
and of the design and working principle of the measuring system and shall have received
appropriate training.
• In hazardous areas, wiring and installation shall only be carried out by staff trained
according to EN 60079-14 and according to national regulations.
1.3 General Safety Instructions and Protective Measures
Using the equipment for any other purpose than intended, and improper operation may
result in personal injuries and damage to the equipment. Read this section and the notes
and warnings in the individual sections of this manual carefully and observe the instructions
given therein when carrying out any work on the OPTISONIC 7060 measuring system.
Generally,
• Always comply with the statutory provisions and the associated technical rules and
regulations relevant for the present equipment when preparing and carrying out any work
on the measuring system. Pay particular attention to potentially hazardous parts of the
equipment, such as pressure pipes and explosion protection zones. Always observe the
relevant regulations.
• Always consider local and equipment-specific conditions and process-specific dangers
when carrying out any work on the equipment.
• Operating and service instructions and equipment documentation shall always be
available on site. Always observe the safety instructions and notes on the prevention of
injuries and damage given in these manuals.
• Make sure appropriate protective accessories are available in sufficient number. Always
use such protective accessories. Check that appropriate safety devices are fitted and
working correctly.
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OPTISONIC 7060
1.3.1 Danger Due to Hot, Corrosive and Explosive Gases and High Pressure
The OPTISONIC 7060 measuring system is directly integrated into gas-carrying pipelines.
The operating company shall be responsible for safe operation and for complying with
additional national and company-specific regulations.
Warning
In plants with toxic and explosive gases, high pressure or high temperatures, the OPTISONIC 7060
WARNING
vented or when the plant is not working.
measuring system shall only be mounted and dismounted when the pipelines are
The same applies to repair and service work which involves opening measuring channel or
the explosion-protected measuring transducer (CONVERTER).
Note Design, manufacture and inspection of the OPTISONIC 7060 measuring system are performed
in compliance with the safety requirements set forth in the European Pressure Equipment
Directive 97/23/EC. Any relevant information has been taken into account for the particular
application as specified in the technical information questionnaire filled out by the customer
before commencing order processing.
1.3.2 Dangers Due to Heavy Loads Overhead
IMPORTANT
The OPTISONIC 7060 measuring system must be safely attached to the lifting gear when being
transported and installed.
Important
¾ Only use the hoisting gear and auxiliaries (e.g. lifting straps) suitable for the load to be lifted.
Max. load information can be found on the type plate of the hoisting gear.
¾ The eye bolts attached to the equipment are suitable for the transport of the measuring
device. However, additional loads (e.g. blind covers, filling for pressure tests) must not be
lifted and transported together with the measuring system.
¾ Never attach hoisting gear to the measuring transducer or its mounting bracket and avoid
contact between these parts and the hoisting gear.
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OPTISONIC 7060
2 Product Description
2.1 Features and Applications
System features
The OPTISONIC 7060 measuring system is a compact gas meter used for ultrasonic
volumetric gas flow measurements. The measuring system is characterised by the following
features:
• Specially designed, compatible assemblies
• Ultrasonic sensors integrated into the meter body
• Concealed cabling
As a result, this measuring system is extremely robust and provides maximum accuracy,
even under extremely harsh operating conditions. Its compact design also provides
protection from mechanical damage, thereby ensuring a long-term stable gas measurement
that is insensitive to mechanical or electrical interference.
Fig. 2.1: OPTISONIC 7060
The OPTISONIC 7060 is ideally suited for a wide range of applications in process measurements,
Applications
such as
¾ Chemical and petrochemical industries
¾ Power stations and other gas-consuming installations
¾ Compressed air distribution systems.
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OPTISONIC 7060
2.2 Conformity, Configuration, Technical Data
2.2.1 CE Certificate
The OPTISONIC 7060 has been developed, manufactured and tested in accordance with the
following EC directives:
• Pressure Equipment Directive 97/23/EC
• Directive 94/9/EC (ATEX100)
• EMC Directive 89/336/EC
Conformity with above directives has been verified and the equipment given the CE label.
2.2.2 Technical Data
Flow rate range
Meter size
DN 50 2"
DN 65 2,5"
Max gas
velocity
Max flowrate
[m/s] [ft/s] [m3/h] [ft3/h] [m3/h] [ft3/h] [m3/h] [ft3/h]
57 187 402 14197 212 7486,74 7,1 249
57 187 680 24014 357 12607,4 11,9 417
Max flowrate @
30m/s
Minimum flowrate
DN 80 3" 57 187 1000 35315 540 19070 18 630
DN 100 4" 53 174 1600 56503 900 31783 30 1050
DN 150 6" 45 148 3000 105944 2000 70629 67 2345
DN 200 8" 43 141 4800 169510 3360 118657 112 3920
DN 250 10" 45 148 7800 275454 5220 184342 174 6090
DN 300 12" 32 105 7800 275454 7380 260622 246 8610
DN 400 16" 30 98 12000 423776 12000 423776 400 14000
DN 450 18" 30 98 17170 606353 17170 606353 572 20020
DN 500 20" 30 98 21200 748761 21200 748761 707 24745
DN 600 24" 30 98 30550 1078993 30550 1078993 1018 35630
• Any flow rates given above are also valid in the bidirectional mode.
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OPTISONIC 7060
Other information
Meter characteristics
Number of measuring paths < DN80 (4”): 1; >= DN80: 2
Min. Gas velocity 1 m/s (for standard accuracy)
V
min/vmax
Min.: 1:30
Measuring medium
Gas process gas, air
Pressure range From ambient pressure to 103 bar; higher pressure on request
Temprature range Standard: -25 °C to + 100 °C
Extended: -25 °C to +180 °C
Measuring accuracy
Reproducibility < 0.2 of the measured value
Typical measuring uncertainty * < ± 1% of measured value for a flowspeed > 1 m/s (3 ft/s) (2 acoustic path's)
< ± 2% of measured value for a flowspeed > 1 m/s (3 ft/s) (1 acoustic path)
Outputs
Measuring quantities Act. volume flowrate, act. volume, gas velocity, velocity of sound
Pulse and status outputs Passive; electrically isolated; open collector; U
kHz, pulse width = 0.05…1 s or in accordance with NAMUR (EN50227)
Measuring rate 20 measurements /s
Interfaces
MODBUS (RS 485) ASCII protocol, for parameterisation, measured value inquiry and diagnosis
(9600,8, N.1)
Explosion protection
Europe II 2G EEx de ib [ia] IIA or IIC T4 in accordance with RL94/9/EG (ATEX) **
Ultrasonic signal converter intrinsically safe “ia”
Power supply
Operating voltage
Voltage limits
When supplied through solar-
U
= 12 V DC, U
min
= 28.8 V DC
max
Start-up voltage: 11.8V
Turn-off voltage for integrated total discharge protection: 10.8V
panel-fed battery
Typical power consumption <1 W (approx. 37 mA at 24 V DC, approx. 66 mA at 12 V DC)
Ambient conditions
Temperature range ATEX: - 20 °C to + 60 °C (- 40 °C to + 60 °C on request)
CSA: - 40 °C to + 60 °C
Storage temperature - 40 °C… + 60 °C
Type of protection IP 67
Relative humidity < 95 %
* Related to the measured value in the range 0.1…1 Qmax with min. straight inlet length of 10
Important
When used in hazardous areas, comply with the required type of explosion protection during
IMPORTANT
installation (intrinsically safe or increased safety)!
DN and min. straight outlet length of 5 D, for calibrated measuring system
= 30 V, I
Imax
= 100 mA, f
Imax
max
= 6
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OPTISONIC 7060
2.3 System Components
The OPTISONIC 7060 measuring system consists of the hardware components,
• Meter body
• Ultrasonic transducers
• CONVERTER (signal processing unit)
Fig. 2.3: OPTISONIC 7060
1. Converter
2. Flange
3. Flowmeter body
4. Indication of positive flow direction
5. Transducer holder
2.3.1 Meter Body
The meter body consists of a section for mounting the ultrasonic transducers and flanges
used for installing in the pipeline.
Standard meter bodies are available in carbon steel and stainless steel.
The meter bodies can be delivered in several nominal sizes (see Section 2.2.4).
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OPTISONIC 7060
2.3.2 Ultrasonic Transducers
The OPTISONIC 7060 ultrasonic transducers are optimised to suit the system requirements.
The high quality of the transducer parameters provides the basis for accurate and highly
stable propagation time measurements with nanosecond precision. The ultrasonic
transducers are of an intrinsically safe design (class "ia").
2.3.3 Signal Processing Unit (CONVERTER)
The CONVERTER contains all the electrical and electronic components required for controlling the
ultrasonic transducers. It generates transmission signals and uses the received signals to
calculate the measured values. The CONVERTER also contains several interfaces for
communication
with a PC, or standardised process control system.
Event logging The current volume counter value, fault, warning, and power failure alarms are stored in a
see Section battery-buffered data memory (FRAM) along with the time of day. On system restart, the
2.7 counter value that was last saved is restored as the start value for the volume counter. The
FRAM back-up provides an unlimited number of writing cycles and protects the saved data
for at least 10 years.
The CONVERTER is supplied with a front panel containing a two-line LCD to display current
measured
values, diagnosis and logbook information (see Fig. 2.4). You can select the values you
want to display using a magnetic pen while the front cover is kept closed (for details on
operation and menu structure see Section 8.2 in the appendix).
Fig. 2.4: Front panel for the OPTISONIC 7060 CONVERTER
1. Selected measured value / device status
2. Current measured value
3. Control area for operation by a magnetic pin
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OPTISONIC 7060
The connection terminals for the power supply and field connections are located on the
back of the CONVERTER in a separate terminal box (see Section 3.4.4).
The electronics units are mounted in a housing certified to EN 50018 or IEC 60079-1 with
type of protection "d" (flameproof enclosure). The transducer circuits are of an intrinsically
safe design (type "ia").
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OPTISONIC 7060
2.4 Operating modes and signal output
The OPTISONIC 7060 measuring system has the following operating modes:
¾ Measurement
Normal, fault-free system operation. The pulse and switching outputs, as well as the current
output are updated periodically. The “Warning” status signal may be set automatically
by the system in the course of the self-diagnosis (for details see Section 2.6).
¾ Check requested
This mode is active for multipath flowmeters only, if one measuring path has failed and the
adaptive path failure compensation has been activated. The measuring system compensates
for this failure but the measurement accuracy can be slightly reduced.
¾ Configuration
Mode for changing parameters and performing system tests. When this mode is active,
the measured values are considered to be invalid, although all the measurements and
calculations are carried out as in the "Measurement" mode (except system tests).
¾ Malfunction
This mode is activated when faults occur that prevent the system from measuring accurately.
If the cause for the fault ceases to exist, the system returns to "Measurement"
mode automatically.
Any operating modes are recorded in the logbook together with their respective activation
and deactivation time.
Output value in operating mode
Output, signal
Measurement Check requested Configuration Malfunction
“Measured value” Frequency signal proportional to the volumetric flow “open”, measurement fault *
“Check requested” *
Status signal
“open”
Measurement valid
“closed”
Compensation of a faulty
“undefined” “undefined”
path (reduced accuracy)
“Direction of flow” *
Status signal
“open”
positieve direction of
flow;
“closed”
“open”
positieve direction of flow;
“closed”
negative direction of flow
“undefined” “undefined”
negative direction of
flow
“Warning” If “Warning” active,
then digital output
“closed”, else “open”
LCD
>V 123456 m3
<V 1234 m
3
Serial port RS485
• Measured value, diagnosis information and parameters
If “Warning” active, then
digital output “closed”,
else “open”
>V 123456 m3
<V 1234 m
3
Display flashing
“undefined” “undefined”
OPTISONIC
7060
>V 123456 m3
<V 1234 m
Display flashing
• Measuring data logging, diagnosis and parameterisation
• Connection with external process control equipment through implemented MODBUS protocol
(data polling)
* Output value can be changed by test commands.
3
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OPTISONIC 7060
The digital output 2 is assigned at the factory with the status signal “Check requested”, and
digital output 3 the status signal “Direction of flow”.
As a standard, the LCD shows the two major counters, one for each direction of flow.
Changes in the logbook status are indicated by a flashing character at the far right end of
the first line of the display. The character depends on the status:
• “I” for information
• “W” for warning
• “E” for error
The character will disappear after acknowledgement. For details on reading the logbook
contents, acknowledgement and menu structure, refer to Section 8.2.4.
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OPTISONIC 7060
2.5 Self-diagnosis
In the measurement mode, the ratios of sound and path velocities, amplification settings,
and signal-to-noise are continuously monitored. If these parameters deviate from a preset
range, a warning signal is generated. This enables immediate measures to be taken to
prevent possible system malfunctions.
During commissioning or operation, you can adjust the signalling threshold values to suit
individual application requirements. This enables you to create the most effective status
warning system.
Note The "Warning" status signal does not affect the device function.
Parameter Default
threshold
value
Velocity of
sound
Reception
gain
If one of the alarms is triggered by a path, this can indicate a malfunction
Signal-tonoise ratio
< 5 m/s Warning SOS
< 6 dB Warning AGC
< 93 dB Warning AGC
< 13 dB Warning SNR This alarm is activated when the signal-to-noise ratio is too small.
Warning
message
Deviation
Deviation
Limit
Notes
This message is produced when the current measured path velocity of
sound deviates from the mean value of the mean velocities of sound
calculated for all the paths by more than the specified threshold value.
The current flow velocity is used as a weighting factor, so that
temperature stratification is disregarded at very low flow velocities. Used
to indicate whether or not the path is measuring the correct propagation
time.
Note
When setting the parameters, take into account plausible conditions for
normal operation (in particular temperature stratification).
The absolute difference between both path gain factors is evaluated and
must remain below the threshold value.
Important
High flow rates can also increase the difference in gain.
The absolute value of the reception gain is monitored.
Important
The current receiving sensitivity largely depends on the current process
pressure (inversely proportional in initial approximation, that is, when the
pressure doubles, the required receiving sensitivity is halved).
in the ultrasonic transducers, electronics, probe cables or parameter
settings (signal models, standard threshold values).
Reasons for this include interference noise caused by fittings in the
pipeline, valves that are not fully open, sources of noise near the
measuring location, or defective ultrasonic transducers.
Additional signal and system diagnosis functions monitor the accuracy of the measured
values, by checking the plausibility of the ultrasonic signals received and the ultrasound
signal propagation times calculated from them.
Electrical & mechanical installation manual 730962.31.00 page 16 of 52
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