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.

Electrical & mechanical installation manual 730962.31.00 page 4 of 52

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)

Electrical & mechanical installation manual 730962.31.00 page 5 of 52

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.

Electrical & mechanical installation manual 730962.31.00 page 7 of 52

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.

Electrical & mechanical installation manual 730962.31.00 page 9 of 52

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

Electrical & mechanical installation manual 730962.31.00 page 10 of 52

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").

Electrical & mechanical installation manual 730962.31.00 page 13 of 52

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

Electrical & mechanical installation manual 730962.31.00 page 14 of 52

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.

Electrical & mechanical installation manual 730962.31.00 page 15 of 52

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

OPTISONIC 7060

2.6 Event logging

Important system events (max. 250) are stored in a verification logbook. Each entry consists
of the event, time stamp and the valid volume counter value along with acknowledgement
status present at the time the event occurred. The events are logged continuously in the
order they occur and, each event can be acknowledged manually. Logbook queries provide
information on the number of registered events and the remaining memory space. The
entries are classified as follows:

• Active events

• Inactive acknowledged and unacknowledged events

• Acknowledged events

If there is no space left in the logbook, the logbook is closed and the system signals a fault.
Until the logbook is reset (deleted), the measured volumes are stored in the error volume
counters, in accordance with the direction of flow, irrespective of the measuring accuracy.

Overview of event entries

Name Class Description Value

(second line on the display)

Power On “I”

information

Change of
operating mode

Volume counter
reset
Error volume
counter reset
Counter overflow “I”

Logbook reset “I”

Set clock “I”

Check requested “W”

Output range “W”

Measurement
invalid

System error “E” error Safe operation of the system is not

“I”
information

“I”
information
“I”
information

information

information

information

warning

warning

“E” error More than one path must be substituted by

System is cold started or rebooted after a
watchdog reset.

System was changed to the configuration
mode after password input, or back from
the configuration mode to the
measurement mode. Parameter
modifications that affect the measured
values may have been carried out.
Resetting the volume counters to zero Reset volume

Resetting the error volume counters to zero Reset volume

One of the four volume counters completed
its counter range.
Entire logbook was deleted (“Reset” is
always the first entry and indicated the
point of time the logbook was opened.)
Date and/ or time register of the real time
clock was/ were changed.
The measured value of one path must be
substituted by the replacement value
calculation routine.
The current measured value can no longer
be represented by the pulse output,
because the maximum output frequency
was reached.

the replacement value calculation routine,
or the activated adaptive path failure
compensation is not yet active.

guaranteed.

Time stamp of the last counter value stored is
considered to be the time of the “Power off”
event.
Activated password level

Time stamp of the change

Path index and cause for deactivation

Value is assigned with the four path states

Cause for the fault

• CRC program code

• CRC parameter

• CRC counter value

• CRC replacement path weights

• Implausible parameter

• DSP malfunction

Electrical & mechanical installation manual 730962.31.00 page 17 of 52

OPTISONIC 7060

2.7 Configurations

Output Terminal Assignment
AO 0 31, 32 Measured value (current signal 4..20 mA) fault current signal at

DO 1 51, 52

DO 2 41, 42

DO 3 81, 82

configuration or malfunction

• Measured value (frequency signal)

• Direction of flow

• Malfunction

• Check requested

• Warning

• Measured value (frequency signal)

• Direction of flow

• Malfunction

• Check requested

• Warning

• Measured value (frequency signal)

• Direction of flow

• Malfunction

• Check requested

• Warning

Electrical & mechanical installation manual 730962.31.00 page 18 of 52

OPTISONIC 7060

3 Assembly and Installation

3.1 General Notes

3.1.1 Delivery

The OPTISONIC 7060 is delivered in a pre-assembled condition in robust packaging. When

unpacking the device,
check for possible damage in transit. Pay particular attention to the interior of the meter
body, any visible transducer components and the sealing surfaces of the flanges. Any
damage must be documented and reported to the manufacturer immediately.

Also check the consignment for completeness. The standard scope of delivery comprises:

¾ OPTISONIC 7060 measuring system (meter body with CONVERTER and transducers)
¾ Operating instructions (this document)
¾ Documentation CD
¾ Certificates

– OPTISONIC 7060 manufacturer information
– EC Declaration of Conformity

Important

Make sure the actual site conditions match the information provided on the labels at the
converter (see Fig. 3.1), in order to guarantee a safe operation of the measuring

IMPORTANT

equipment.

Fig. 3.1: OPTISONIC 7060 type plate label

Electrical & mechanical installation manual 730962.31.00 page 19 of 52

OPTISONIC 7060

3.1.2 Transport and Storage

Important

Only use the hoisting gear and auxiliaries (e.g. lifting straps) suitable for the weight to be

IMPORTANT

lifted. Max. load information can be found on the type plate of the hoisting gear. It is strongly
recommended to use the eye bolts supplied with the device only.

During OPTISONIC 7060 transport and storage operations, make sure that:

¾ The sealing surfaces of the flanges are protected with special caps
¾ The measuring device is firmly secures at all times
¾ Measures are taken to avoid mechanical damage
¾ Humidity and ambient temperature are within specified limits (see Section 2.2.4).

If the device is to be stored outside for more than one day, sealing surfaces of the flanges
and the interior of the meter body must be protected from corrosion, e.g. with Anticorit spray
(not required for stainless steel meter bodies). The same measure shall be taken if the
device is to be stored in dry condition, but for more than a week.

Note Due to natural temperature fluctuation in the course of a day, or if the measuring device is
transported to a place with different temperature and humidity, moisture will condense on
any material. Carbon steel surfaces may corrode if left unprotected.

3.2 Assembly

Generally, the installation arrangement is specified during the project planning phase, i.e.
before installation of the system. Nominal width, material and type of flange should therefore
be defined in accordance with the design of the existing plant. It is particularly important that
the internal diameters of the meter body and adjacent pipelines are identical.

Fixing bolts, nuts and flange seals used must be suited to the operational conditions, and
comply with legal regulations and relevant standards.

Note Any deviation from the planned design of the OPTISONIC 7060 and installation arrangement
shall be agreed with the supplier and documented prior to installing the measuring device.

Measuring location

• The OPTISONIC 7060 can be installed in customary straight inlet and outlet pipes. The
adjacent pipes must have the same nominal width as the meter body. The internal
diameter can be derived from the marked flange standard and the type key information
(Appendix, Table 8.2). Any welding beads on the flanges of the inlet pipe shall be
flattened.

• The meter body may be installed in horizontal or vertical position. In case of horizontal
installation, make sure that the meter body is adjusted so that the measuring planes are

in horizontal position. This aims to prevent dirt or moisture in the pipeline from entering the

transducer ports. Vertical installation is only possible if the measuring system is used for dry,
noncondensing gases. The gas flow must be free from any foreign material, dust and liquids.

Otherwise, filters and traps shall be used.

• Avoid installations which may adversely affect the gas flow to be mounted directly
upstream the OPTISONIC 7060.

• Seals at the flange connections between meter body and pipeline must not protrude into
the pipeline. Otherwise, the flow profile and thus the measuring accuracy may be
adversely affected.

• Temperature measuring devices shall be fitted in the outlet pipe no closer than 1.5x DN,
or – in case of nominal widths of ≥

DN 400 – no closer than 300 mm.

Electrical & mechanical installation manual 730962.31.00 page 20 of 52

OPTISONIC 7060

Typical installation configuration:

Fig. 3.2: OPTISONIC 7060 installation in the pipeline for unidirectional use

1. Temperature measurement point

The choice of the installation configuration depends on type and extent of the flow
disturbance at the installation position (according to TR G13).

Type of disturbance Possible installation configuration

None
Elbow, reducer

Configuration 1 (fig. 3.2)
Double elbow out of plane, T piece
Gas pressure controller with/ without muffler
Diffuser
Diffuser with swirling flow

Configuration 1 (fig. 3.2), >= 20 DN distance

from device and not “in sight” of the flowmeter

For bidirectional use, inlet and outlet section at both sides of the meter body shall be of
identical, independent of the configuration used (see Fig. 3.3). The temperature
measuring point shall in this case be installed at a distance of 5x DN to the meter body
(configuration 1),

Fig. 3.3: OPTISONIC 7060 installation in the pipeline for bidirectional use

1. Temperature measurement point

3.3 Mechanical Installation

Work on the pipelines in preparation to installing the gas flow meter is not included in the
scope of delivery.

It is recommended to use the following tools and auxiliaries for proper installation of the
OPTISONIC 7060:

• Hoisting gear or fork lift (load capacity according to the weight information given on the

type plate)

• Suitably sized ring wrench for flange mounting

• Sealing and separating agents

• Bolt lubricant

• Leak detection spray

Electrical & mechanical installation manual 730962.31.00 page 21 of 52

OPTISONIC 7060

Warning

• Always observe the general safety regulations and safety instructions given in Section 1

when carrying out any assembly work.

WARNING

• The OPTISONIC 7060 must only be mounted to pressure-free and vented pipelines.

• Take appropriate measures to avoid potential local or plant-specific dangers.

3.3.1 Choosing flanges, seals and other parts

Use pipeline flanges, bolts, nuts, and seals that withstand the maximum operational
pressure and temperature, as well as ambient and operational conditions (external and
internal corrosion) for the flange connections. For installation lengths and flange dimensions,
see Section 8.1.

Important

including the connection of several pressure components set forth in the Pressure

IMPORTANT

• Always strictly observe the safety instructions for the installation of pressure equipment

Equipment Directive 97/23/EC.

• Installation staff must be familiar with the directives and standards applicable for pipeline

construction.

3.3.2 Mounting the OPTISONIC 7060 to the pipeline

An arrow on the meter body indicates the main direction of flow. It is recommended to install
the OPTISONIC 7060 as indicated by this arrow id the device is to be used for unidirectional
flow applications. If the device is to be used in the bidirectional mode, the arrow indicates
the positive direction of flow.

Installation work to be carried out

¾ Take the OPTISONIC 7060 in the right position of the pipeline using the hoisting gear. Only
use the hoisting eyes provided to lift and transport the device. If you use lifting straps,
wrap them around the meter body.

Important

– The hoisting eyes are designed for transporting the measuring device only. Do not lift
the OPTISONIC 7060 using these eyes when additional loads (such as blind covers, filling

IMPORTANT

for pressure tests) are attached.
– Never attach hoisting gear to the signal processing unit or its mounting bracket and
avoid contact between these parts and the hoisting gear.
– The OPTISONIC 7060 must not turn over or swing while being transported. Flange sealing
surfaces, CONVERTER housing and transducer cover caps may be damaged when the device
is hoisting gear is not attached properly.
– Do not remove the caps protecting the sealing surfaces of the meter body flanges before
necessary.
– Take suitable measures to prevent damage to the measuring device when carrying out
any work (welding, painting) in the vicinity of the OPTISONIC 7060.

¾ Check the correct seat of the flange seals after inserting the first fixing bolts on both sides.

¾ Align the OPTISONIC 7060 so that the mismatch between inlet pipe, meter body and outlet

pipe becomes as small as possible.

¾ Insert the remaining fixing bolts and tighten the nuts cross-wise. Make sure to apply the
tightening torque specified in the project planning.

¾ Mount the pressure line between pressure tap and pressure transmitter.

¾ Fill the pipeline and check the OPTISONIC 7060 installed for leaks.

Note It is recommended to perform a leak test in accordance with the relevant regulations and
standards after completion of the mechanical installation.

Electrical & mechanical installation manual 730962.31.00 page 22 of 52

OPTISONIC 7060

3.3.3 CONVERTER alignment

The CONVERTER can be turned to a position which provides a good view on the display and good
conditions for cable routing (see Fig. 3.4). A stop on the housing prevents the CONVERTER from
being turned more than 330 . This aims to protect the cables from the meter body from
damage.

Fig. 3.4: Positioning the CONVERTER

1. Loosen the Allen screw, use 3 mm Allen key

2. Position the converter housing

3. Tighten the Allen screw

Note Do not forget to tighten the Allan screw after positioning the CONVERTER.

Electrical & mechanical installation manual 730962.31.00 page 23 of 52

OPTISONIC 7060

3.4 Electrical Installation

3.4.1 General information

Pre-requisites

Wiring work (laying and connecting the power supply and signal cables) as a part of installing
the gas flow meter is not included in the scope of delivery. The mechanical installation
described in Section 3.3 must be completed. Comply with the minimum requirements of the
cable specs in accordance with Section 3.4.2.

Notes on cable laying

• Cables shall be laid in conduits or on cable trays to provide protection from mechanical

damage.

• Observe the permitted bending radiuses (generally, min. six times the cable diameter for

multi-lead cables).

• Connections outside of conduits shall be as short as possible.

Warning

• Always observe the general safety regulations and safety instructions given in Section 1

when carrying out any installation work.

WARNING

• Installation work shall only be carried out by trained staff and in accordance with the

relevant regulations issued by the operating company.

• Take appropriate measures to avoid potential local or plant-specific dangers.

3.4.2 Cable specs

Power supply 12 … 24 V DC

Type of cable Tow leads Connect shielding (if present) to

Min./ max. cross-

sectional area

Maximum cable length Depending on loop resistance; min.

Cable diameter 6 ... 12 mm Fixing range of the cable glands

Specification Notes

0.5 mm² / 1.5 mm²

input voltage at the OPTISONIC 7060:
12 V

Digital output / current output

Specification Notes

Type of cable Twisted pair, shielded Connect shielding at other end to

Min./ max. cross-

sectional area

Maximum cable length Loop resistance under load ≤ 250 Ω

Cable diameter 6 ... 12 mm Fixing range of the cable glands

2 / 0.5 mm² Do not connect unused lead pairs

ground terminal

Peak current 150 mA

ground terminal

and prevent them form accidental
short-circuit.

Electrical & mechanical installation manual 730962.31.00 page 24 of 52

OPTISONIC 7060

Serial port

(RS485)

Type of cable Twisted pair, shielded, impedance

Min./ max. cross-

sectional area

Maximum cable length 100 m at 0.5 mm²

Cable diameter 6 ... 12 mm Fixing range of the cable glands

Specification Notes

Connect shielding at other end to

approx. 120 Ω
2 x 0.5 mm2

200 m at 1.5 mm²

ground terminal

Do not connect unused lead pairs
and prevent them from accidental
short-circuit.

Electrical & mechanical installation manual 730962.31.00 page 25 of 52

OPTISONIC 7060

3.4.3 Checking the cable loops

To verify the cables to be correctly connected, check the cable loops. Proceed as follows:

• Disconnect both ends of the cable of the loop to be tested.

• This is to prevent connected devices from interfering with the measurement.

• Test the entire cable loop between CONVERTER and final device by measuring the loop

resistance.

• If you want to test the insulation resistance as well, you must disconnect the cables at

the electronics unit before using the insulation resistance tester.
Important

The test voltage applied would seriously damage the electronics unit!

IMPORTANT

• Reconnect all cables after the loop resistance test.

Important

hazardous areas and connect/ disconnect cables when the system is disconnected from

IMPORTANT

the power supply.

• In non-intrinsically safe installations, only open the terminal boxes protected for use in

• The front housing cover (with viewing panel) must only be opened when the system is

disconnected from the power supply and no less than 10 minutes after the system has
been switched off.

• Incorrect cabling may cause the OPTISONIC 7060 to fail.
This will lead to the annulment of any warranty claims. The manufacturer excludes any
liability for consequential damage.

Electrical & mechanical installation manual 730962.31.00 page 26 of 52

OPTISONIC 7060

3.4.4 Terminal box on the CONVERTER

Open the rear housing cover.

• Loosen the securing bracket using a 3 mm Allan key.

• Turn the rear housing cover in a counter-clockwise direction and take it off.

A schematic wiring diagram is provided on the inside of the rear housing cover (see also
Appendix, Section 8.3).

Fig. 3.6: CONVERTER housing, opening the cover

1. Housing cover

2. Securing bracket

Electrical & mechanical installation manual 730962.31.00 page 27 of 52

OPTISONIC 7060

Fig. 3.7: Terminal box on the rear of the CONVERTER

1. Power supply, 2x1,5mm2 (UYCY or equivalent)

2. Digital output / current output, 4 x 2 x 0,5 mm2 (UYCY [TP] or equivalent)

3. Modbus, 4 x 2 x 0,5 mm2 (UYCY [TP} or equivalent)

4. HSK-K cable glands, M20 x 1,5 plastic (EU) or ½ In NPT (North America)

5. Cabel entry for internal 10-wire cable

6. 10-connection terminal strip for singal inputs and outputs

Electrical & mechanical installation manual 730962.31.00 page 28 of 52

OPTISONIC 7060

x

3.4.5 Connecting the OPTISONIC 7060 for use in non-hazardous areas

Assign the terminals in the CONVERTER terminal box (see Fig. 3.7) in accordance with the

following table.

Terminal bo

Power supply

Field connections (10-channel terminal strip)

Fig. 3.8: Terminal assignment for use in non-hazardous areas

No. Connection for Function Terminal Value Notes

1 Power supply 1+, 2- 12 ... 24 (+20 %) V DC
2 Analog output Passive 31, 32
3 Serial port Modbus

33, 34 9600 Baud, 8 data bits, no parity, 1 stop bit Baud rate to be set

(RS 485)

4 Digital output D0 1 Passive 51, 52

f

= 6 kHz, pulse duration 0.05 s - 1 s

max

Range:
Freely selectable number of pulses per volume unit
“closed”:
0 V ≤ U

≤ 2 V, 2 mA ≤I

CEL

≤ 20 mA (L=Low)

CEL

through software
With NAMUR
contact for
connection to
switching amplifier
(to DIN 19234)

“open”:
16 V ≤ U

≤ 30 V, 0 mA ≤ I

CEH

≤ 0.2 mA (H =

CEH

High)

5 Digital output D0 2 Passive 41, 42 “closed”:

0 V ≤ U

≤ 2 V, 2 mA ≤I

CEL

≤ 20 mA (L=Low)

CEL

“open”:
16 V ≤ U

≤ 30 V, 0 mA ≤ I

CEH

≤ 0.2 mA (H =

CEH

High) “Check requested”

6 Digital output D0 3 Passive 81, 82 “closed”:

0 V ≤ U

≤ 2 V, 2 mA ≤I

CEL

≤ 20 mA (L=Low)

CEL

“open”:
16 V ≤ U

≤ 30 V, 0 mA ≤ I

CEH

≤ 0.2 mA (H =

CEH

High)
“Direction of flow”
(alternative “Warning”)

Electrical & mechanical installation manual 730962.31.00 page 29 of 52

OPTISONIC 7060

3.4.6 Operation in hazardous areas in accordance with Directive 94/9/EC (ATEX)

The power supply and field connections are designed with the increased type of protection
("e"). The transducer connections are of an intrinsically safe design ("ia").

All screw-type terminals as well as air and creepage distances of the OPTISONIC 7060 comply
with EN 50019.

Connection characteristics

Power supply connection Field connections

Separate terminal box, separated from the field
connections with partition wall in the housing
and cover to EN 50020.
Cable routing via EExe cable gland, M5 ground

Separate terminal box, separated from the
power supply connections with partition wall in
the housing and cover to EN 50020.
Cable routing via 2x EExe cable gland

terminal integrated into housing section (cast).

Connection variants

The protection concept for the OPTISONIC 7060 permits the following connection variants:

• Power supply connection and field connections with increased type of protection ("e")

• Intrinsically safe power supply connection and field connections ("i")

• Power supply connection with increased type of protection ("e"), where the field

connections are intrinsically safe ("i")

The user must decide which variant to use, taking into account EN 60079-14.

A combination of intrinsically safe and non-intrinsically safe circuits is not permitted in the
terminal box for the field connections.

The rated voltage of non-intrinsically safe circuits is U

= 253 V.

M

Requirements regarding cabling in hazardous areas (Europe)

• The cables must fulfill the requirements to EN 60079-14.

• Cables that are subject to exceptional thermal, mechanical, or chemical loads must be

specially protected (e.g. laid in open-ended conduits).

• Cables that are not fire protected must be verified to DIN VDE 0472, Part 804, test type
B with regard to fire resistance.

• Attach ferrules to the wire ends to ensure that they do not split up.

• The applicable requirements regarding air and creepage distances must be observed in

accordance with EN 50019. The available air and creepage distances in the terminal box
must not be reduced when connecting the cables.

• Unused cable glands must be replaced by the EExe plugs supplied.

• The equipotential bonding must be in accordance with EN 60079-14.

• The meter body and CONVERTER housing must be connected to the potential equalizer.

• In intrinsicallysafe circuits, install potential equalizers along the wiring runs of the current

outputs.

• The applicable national specifications must also be observed.

Electrical & mechanical installation manual 730962.31.00 page 30 of 52

OPTISONIC 7060

Terminal assignment

Assign the terminals in the CONVERTER terminal box (see Fig. 3.7) in the same way as for the
OPTISONIC 7060 in non-hazardous areas (see table in Section 3.4.5).

Important

The protective conductor must not be connected within the hazardous area. For
measurement reasons, the equipotential bonding must, as far as possible, be identical to

IMPORTANT

the pipeline potential. Additional grounding with the protective conductor PE via the
terminals is not permitted!

Notes for safe operation in hazardous areas

Approval of the
ultrasonic transducers
in zone 0 only valid for

In the extended temperature range from -40 C to +60 C, only use metal cable glands.

operation under
atmospheric conditions.

circuits, it is recommended to replace these with the light-blue cable connections (RAL

• Protection against explosion: II 2G EEx de ib [ia] IIC T4 or II 2G EEx de ib [ia] IIA T4

• Ambient temperature: -20°C to +60°C

• The cable glands delivered are black. If connections are wired with intrinsically safe

5015) provided.

• For the temperature class according to the ambient and media temperature, see the EC
Type Examination Certificate.

• The type of protection for the field and power supply connections is determined by the
external circuits that are connected (for options see "Connection variants").

• Safety-relevant data for intrinsically safe circuits is provided in the EC Type Examination
Certificate.

• Ensure that the power supply connection cover is properly sealed. In intrinsically safe
installations, the terminal box can be opened and cables connected and disconnected
while the system is live.

• If the meter body is insulated, the CONVERTER housing must not be insulated.

Important

IMPORTANT

Always observe the temperature specifications for use in hazardous areas.

Electrical & mechanical installation manual 730962.31.00 page 31 of 52

OPTISONIC 7060

Fig. 3.9: Explosion protection of the OPTISONIC 7060 components

1. Power supply

2. I/O connections

Electrical & mechanical installation manual 730962.31.00 page 32 of 52

OPTISONIC 7060

Safety-relevant data of inputs and outputs

Output circuit Intrinsically safe EEX ia IIA / IIB / IIC Non-intrinsically

safe U
Active current output
Terminals 31/32

[mA]

Po

[mW]

Uo = 22.1 V

EEx ia IIA EEx ia IIC Io

C

[nF] Lo [mH] Co [nF] Lo [mH]

o

= 18 V

U

B

I

= 35 mA

B

M

155 / 155 857 / 857 4100 7 163 1
Characteristic curve: linear
Internal capacity C

= 4 nF, internal inductance LI = 0.075 mH

I

Only for connection to passive, intrinsically safe circuits or intrinsically safe

= 30 V

I

CI = 4 nF

= 0.075 mH

L

I

CI = 4 nF

= 0.075 mH

L

I

UI = 10 V
I

= 275 mA

I

= 1420 mW

P

I

U

= 30 V

B

= 35 mA

I

B

U

= 30 V

B

= 100 mA

I

B

U

= 5 V

B

= 175 mA

I

B

Passive current
output
Terminals 31/32

Digital output
Terminals 51/52,
41/42, 81/82
RS 485
Terminals 81/82

PROFIBUS PA
Terminals 33/34

circuits with the following maximum values: U
UI = 30 V

= 100 mA

I

I

P

= 750 mW

I

UI = 30 V

= 100 mA

I

I

P

= 750 mW

I

Characteristic curve: linear

= 5.88 V

U

o

I

= 313 mA

o

= 460 mW

P

o

C

= 1000 µF/43 µF

o

= 1.5/0.2 mH

L

o

UI = 30 V

= 100 mA

I

I

P

= 750 mW

I

EEx ia IIA EEx ia IIB EEx ia IIC Ultrasonic
transducer
connections

Characteristic curve: linear
Max. transmission voltage U
Short-circuit current I
P

= 1444 mW

o

= 300 nF

C

o

= 95 mA

o

= 60.8 V

o

Uo = 51.2 V
I

= 80 mA

o

= 1024 mW

P

o

C

= 187 nF

o

= 38.9 V

U

o

I

= 60 mA

o

= 584 mW

P

o

C

= 34 nF

o

Special conditions

For connection to a NAMUR amplifier, the digital output (terminals, 51/52, 41/42,
81/82) can be wired internally as a NAMUR contact by setting a jumper (for details see
Service manual). Open Collector or NAMUR configuration is carried out at the factory in
accordance with the order details. If no configuration was specified in the purchase order,
the digital output is configured as Open Collector.

Digital output as Open Collector Digital output in accordance with NAMUR

= 253 V

Fig. 3.10: Wiring digital outputs

Electrical & mechanical installation manual 730962.31.00 page 33 of 52

IMPORTANT

OPTISONIC 7060

3.4.7 Operation in hazardous areas to North American Guidelines (CSA)

The system must be installed as shown in Fig. 8.3 to Fig. 8.5 in the appendix. The notes
provided in Fig. 8.3 and Fig. 8.4 must be observed at all times.

Installation in Division 1 / Zone 0 / Zone 1

The following applies to devices installed in this area and that are connected to the
UFC 060 electronics installed in Division 1 / Zone 1:
The maximum device voltage must not exceed 125 V.

You must observe the applicable national regulations, such as:
– In the USA, the device must be installed in accordance with NEC (ANSI/NFPA 70 and
ANSI/ISA RP 12.6.)
– In Canada, the conditions according to CEC part 1 apply.

Exchanging components impairs the intrinsic safety.

In intrinsically safe installations (Entity system), only equipment certified to CSA safety
barriers, or other CSA equipment that fulfills requirements regarding the Entity system,
must be used (Voc ≤ Vmax, Isc ≤ Imax.,
Ca ≥ Ci + Ccable, La ≥ Li + Lcable).

Installation in Division 2 / Zone 2

Installation to CEC or NEC

Important

Danger of explosion: Do not loosen any components without switching the power supply
off beforehand or where it states that the area is potentially explosive.
Exchanging components affects compatibility with Class 1, Division 2.

Electrical & mechanical installation manual 730962.31.00 page 34 of 52

OPTISONIC 7060

4 Operation of the converter

4.1 Operation and menu structure of the CONVERTER with LCD

4.1.1 Operation

The current measurement, volume counter, and diagnosis values can be displayed on the
two-line LCD on the front of the CONVERTER. You can select the values you want to display using

a magnetic pen while the front cover is kept closed or using the buttons while the front cover

is open (see Fig. 8.2).
Important

When the CONVERTER housing is open, there is no EMC protection or protection against electric

IMPORTANT

shock!

Fig. 4.1 : Front panel with LCD

1. Selected measured value / device status

2. Current measured value

3. Control area for operation by a magnetic pin

The control panels and buttons have the following functions:

• C/CE control panel/ button
Used to call up the menu from the measured value display. Within the menu, you can go
back a level, or return from the top level menu to the measured value display.

Electrical & mechanical installation manual 730962.31.00 page 35 of 52

OPTISONIC 7060

• STEP control panel/ button
Used to scroll forward in the menu.

• DATA control panel/ button
Used to scroll backward in the menu.

• ENTER function
Used to select a menu level, to acknowledge log book entries and to reset the error
volume counter.
– Magnetic pen operation:
The ENTER function is executed when you hold the pen on the DATA/ENTER control
panel for at least 2 s.
– Button operation:
The ENTER function is executed by pressing STEP and DATA simultaneously.
Alternatively, you can press the DATA button for at least 2 s.

4.1.2 Menu structure

You can call up information, acknowledge logged events and reset the error volume
counters in the display menu, using the control panels and buttons described
above.

Electrical & mechanical installation manual 730962.31.00 page 36 of 52

OPTISONIC 7060

Electrical & mechanical installation manual 730962.31.00 page 37 of 52

OPTISONIC 7060

Electrical & mechanical installation manual 730962.31.00 page 38 of 52

OPTISONIC 7060

4.1.3 Definition of measured value displays

Each line of the LCD can be configured separately as regards the measured value shown.
In addition, the display lines may be configured with a multiplex layout (shifted LCD content).
If this configuration is active, the two display contents are shown alternately (display
changes every 5 s).

Display

Operating volume flow rate
“>” forward

>Qv 1000.0 m3/h

“<” reverse

Forward volume counter value

>V 1234567 m3/h

Reverse volume counter value

<V 1234567 m3/h

Forward error volume counter value

>EV 1234567 m3/h

Reverse error volume counter value

<EV 1234567 m3/h

Average flow velocity (velocity of gas)

VOG 20.23 m/s

Average velocity of sound (speed of sound)

SOS 343.15 m/s

Electrical & mechanical installation manual 730962.31.00 page 39 of 52

OPTISONIC 7060

4.1.4 Definition of log book entries

1. Classification

The entries are distinguished into three classes and identified by the initial character in the
first line.

• “I” Information

• “W” Warning

• “E” Error/ malfunction

2. Type of occurrence

• “S+” Point in time of the event identifying the beginning of a state

• “S-” Point in time of the event identifying the end of a state

3. Overview of event entries

Name Class Description Value

Power on

I Power supply
April 18, 2003
12:13

I System is cold started or rebooted after a watchdog

reset.

Time stamp of the last stored
counter value is considered to
be the time of the “Power off”
event.

Change of
operating mode

I Operation S+
Password 2

I System was changed to the configuration mode after

password input, or back from the configuration mode to
the measurement mode.
Parameter modifications that affect the measured
values may have been carried out.

Activated password level.

Set clock

I Real time clock
April 18, 2003
12:13

I Date and/or time register of the real time clock

was/were changed.

Time stamp of the change.

Volume counter
reset

I Reset V S+

Error volume
counter reset

I Reset V S+

Counter overflow

I Overflow S+

Log book reset

I Reset Log S+

Check requested

W Check re. S+
Path no.

I Resetting the volume counters to zero. Counter value at the time of

the event.

I Resetting the error volume counters to zero. Counter value at the time of

the event.

I One of the four volume counters has run through

completely.

I Entire log book was deleted

(“Reset” is always the first entry and indicates the point
in time the log book was opened.)

W The measured value of one path must be substituted by

Path index

the replacement value calculation routing.

Electrical & mechanical installation manual 730962.31.00 page 40 of 52

OPTISONIC 7060

r

Name Class Description Value

Output range

W Output S+

W The current measured value can no longer be

represented by the pulse output, because the maximum
output. frequency was reached.

Measurement
invalid

E Measurement
S+
Path

System error

E System S+
Paramete

4.1.5 Acknowledgement of a log book entry

E More than one path must be substituted by the

replacement value calculation routine, or the activated
adaptive path failure compensation is not yet active.

E Safe operation of the system is not guaranteed. Cause of the fault

• CRC program code

• CRC parameters

• CRC counter value

• CRC replacement path

weights

• Parameters (implausible)

• DSP

4.1.6 Resetting the error volume counters

Electrical & mechanical installation manual 730962.31.00 page 41 of 52

OPTISONIC 7060

5 Verification and Commissioning

5.1 Verification

5.1.1 Examining the condition

The following conditions must be fulfilled before you can start the verification procedure for
the OPTISONIC 7060:

o CONVERTER: Make sure there is no visible sign of damage, in particular to the sealing surfaces

and the internal contours of the connection flanges.

o The meter body must be approved for the max. test pressure that is to be applied.

5.1.2 Testing the functions

Check that the OPTISONIC 7060 is properly installed mechanically and electrically, as detailed
in Section 3, to ensure successful commissioning.

The major system parameters have been configured at the factory. The default settings
should allow trouble-free operation of the ultrasonic gas flow meter.

Checking without PC and MEPAFLOW IV control and diagnosis software
The information listed below is shown directly on the LCD of the OPTISONIC 7060 (for details
on the menu structure and operation with a magnetic pen, see chapter 4).

5.2 Commissioning

5.2.1 Installation

Install the OPTISONIC 7060 in the line at the measurement position after completion of the
calibration. The necessary working steps are detailed in Section 3. Observe the safety
instructions provided in that Section.

5.2.2 Checking the functions

The current values of the operating volume counters (forward and reverse) are shown on
the LCD (see Appendix, Section 6.2.2). If these values are displayed continuously, the
OPTISONIC 7060 is working correctly. A flashing display indicates a warning state or fault, which
should be analysed as described in Section 6.

Fasten the magnetic pen which is part of the measuring system and which is used to
operate the LCD on the CONVERTER using the strap provided on the OPTISONIC 7060 so that it

cannot be lost.

Electrical & mechanical installation manual 730962.31.00 page 42 of 52

OPTISONIC 7060

5.2.3 Pressure testing of a gas pipeline with liquid (water)

For example when a pipeline in which the OPTISONIC 7060 is installed will be pressure tested with
a liquid (water) the following precautions must be taken to prevent the transducers from getting wet:

• The transducers must be removed.

• Blindstops must be fitted in the tranducer positions. A set of blindstops can be ordered at

KROHNE.

For the detailed procedure to remove and refit the transducers, consult the service manual.

Electrical & mechanical installation manual 730962.31.00 page 43 of 52

OPTISONIC 7060

6 Maintenance

6.1 General

The OPTISONIC 7060 does not contain any components that move mechanically. Meter body
and ultrasonic transducers are the only components that come into contact with the
gaseous media. Titanium and high-quality stainless steel ensure that these components are
resistant to corrosion, provided that the device is implemented in accordance with the
relevant specifications. This means that the OPTISONIC 7060 is a low-maintenance system.
Maintenance essentially involves routine checks to determine the plausibility of the
measured and diagnosis values calculated by the system.

It is recommended to record a diagnosis and status log on a regular basis (see software
manual) and compare these values with the initial situation when the system was
commissioned. The operating conditions (gas composition, pressure, temperature, flow
velocity) of the individual logs should be comparable or documented separately and taken
into account when the comparison is evaluated.

6.2 Routine checks

You can check the front panel of the OPTISONIC 7060 to ensure that the system is
functioning properly (see Section 4.3).

The routine checks relate to the following values (see also the table below and Section 6).
Velocity of sound

The velocity of sound measured is usually highly stable. Sudden changes in the measured
value can indicate signal detection problems, which can affect propagation time
measurements, or changes in the gas composition. A theoretical velocity of sound value can
be calculated by analysing the gas or recording the pressure and temperature during log
measurement. Implausible measurements can then be indicated by comparing theoretical
and measured velocity of sound values and identifying any marked discrepancies. The
velocity of sound values in the paths should also be approximately equal.

Number of rejected measurements

The number of rejected measurement (% inaccurate measurement) for the measuring
path(s) should be as close to 0 % as possible, although this largely depends on the flow
velocity. With high flow velocities, the figure can be as high as 50% without affecting
accuracy. Marked discrepancies in the values under similar conditions (pressure,
temperature, gas flow rate, gas composition) indicate that changes have been made to the
device or plant (e.g. malfunctions caused by a valve that is not fully open).

Receiving sensitivity

The receiving sensitivity set by the device largely depends on the process pressure. Under
normal conditions, this value is highly stable. The difference between the ultrasonic
transducers for a measuring path is small, although it can increase with greater velocities.
Significant fluctuations in the receiving sensitivity indicate a low-quality receiving signal. A
significant increase under similar process conditions is normally caused by contamination
on the ultrasonic transducers (for instructions on cleaning them, see the service manual).

Signal-to-noise ratio

These values are typical for the plant and do not change, providing the conditions remain
the same. A reduction in the signal-to-noise ratio with similar reception sensitivity indicates
sources of acoustic interference (e.g. pressure regulator) near the measuring location.

Electrical & mechanical installation manual 730962.31.00 page 44 of 52

OPTISONIC 7060

Overview of the typical values

Parameter Standard value Error Comments

Velocity of sound

Signal-to-noise ratio ~20 dB

Receiving sensitivity /
AGC level

Number of rejected
measurements

Deviation from the
theoretical velocity of
sound less than ± 0.3 %

The differences
between the velocities
of sound in the paths
should not be greater
than ± 1.5 m/s.

This depends on the
nominal width of the
meter body and the
current process
pressure.

This depends on the
nominal width of the
meter body and the
current process
pressure.

< 5 % with zero point
< 35 % with flow

Greater than ± 0.3 % When calculating the

theoretical velocity of
sound, you must take
special care to ensure
that the gas
composition, pressure
and, in particular, the
temperature are the
same as at the
measuring location
when the log was
recorded.

Greater than ± 1.5 m/s Temperature

stratification can occur
with low flow rates.

Permanently less than
10 dB

Significant deviations
(greater than 50%) from
the historical data with
similar process
pressures

Permanently greater
than 50%

Possible sources of
interference include
electrical noise caused
by bad contacts on the
connectors or sources
of acoustic interference,
such as control valves
or very high flow
velocities.
The receiving sensitivity
is inversely proportional
to the process
pressure: when the
pressure doubles, the
sensitivity halves.

Deviations from the standard values specified in the table can indicate a malfunction. In
addition to diagnosing the error (as described in Section 6), you can also create a diagnosis
and status log and send this to KROHNE for analysis (see software manual).

Electrical & mechanical installation manual 730962.31.00 page 45 of 52

OPTISONIC 7060

7 Troubleshooting

If the routine checks described in Section 5.2 or the functional checks described in Section

4.1.2 indicate that the device is not functioning properly, the following table will help you

diagnose the fault. If you still cannot find the cause for the fault, you can use the
ALTO IV program to carry out a more detailed fault diagnosis (see software manual, service
manual).

Display, parameter Possible cause Corrective action

• No display

• No pulse frequency

• No active status

signal

“Warning” on the
LCD

Different velocities of
sound in the
individual paths

Implausible sound
velocity

• Lower signal-to-

noise ratio and
reception sensitivity

• Increased number

of rejected
measurements in
individual paths

sensitivity

Increased number of
rejected
measurements in all
paths
Gas velocity outside

Faulty power supply

Defective device Contact the manufacturer
Transducer(s) are
dirty
Transducer(s) are
defective
Cabling swapped
when transducer was
cleaned
Transducer or
electronics fault

Gas analysis,
pressure or
temperature
measurement
incorrect
Transducer(s)
damaged during
maintenance
Additional sources of
noise due to a valve
that is not fully open,
fittings, noise sources
near the device
Different gas
composition or
process pressure
Transducer(s) are
dirty
Additional noise
sources

the measurement
range

• Check the input voltage at terminals 1 and 2

• Check cables and terminal connections

Important

Take the relevant safety precautions!

Clean the transducer(s)

Replace the transducer(s) (see service manual)

Check and, if necessary, correct

Replace the transducer(s) (see service manual)
Note
Temperature stratification can result in differences
between the individual paths, especially with very low
flow (higher temperatures generate higher velocities of
sound). Even when the plant is being filled or when it is
shut down, different velocities of sound can occur on
the individual paths as a result of gas stratifications.

Replace the transducer(s) (see service manual)

Check the measurement plausibility and number of
rejected measurements and, if necessary, remove
noise sources.

No work required on the device Increased reception

Clean the transducer(s)

Remove noise sources

Electrical & mechanical installation manual 730962.31.00 page 46 of 52

OPTISONIC 7060

8 ATEX / CSA converter terminal assignment

8.1 Converter terminal assignments ATEX

Fig. 8.1: Terminal assignment in accordance with ATEX IIA

Fig. 8.2: Terminal assignment in accordance with ATEX IIC

Electrical & mechanical installation manual 730962.31.00 page 47 of 52

OPTISONIC 7060

8.2 Converter terminal assignments CSA

Fig. 8.3: Terminal assignment in accordance with CSA Group D

Fig. 8.4: Terminal assignment in accordance with CSA Group BCD

Electrical & mechanical installation manual 730962.31.00 page 48 of 52

OPTISONIC 7060

Fig. 8.5: Control drawing CSA 781.00.02 (page 1)

Electrical & mechanical installation manual 730962.31.00 page 49 of 52

OPTISONIC 7060

Fig. 8.6: Control drawing CSA 781.00.02 (page 2)

Electrical & mechanical installation manual 730962.31.00 page 50 of 52

OPTISONIC 7060

Fig. 8.7: Control drawing CSA 781.00.02 (page 3)

Electrical & mechanical installation manual 730962.31.00 page 51 of 52

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A

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Subject to change without notice