KROHNE OPTISWIRL 4200 Operating Manual
OPTISWIRL 4200
OPTISWIRL 4200
OPTISWIRL 4200OPTISWIRL 4200
Vortex flowmeter
Electronic revision: ER 1.0.6_
Handbook
Handbook
HandbookHandbook
© KROHNE 08/2016 - 4003930803 - MA OPTISWIRL 4200 R03 en
:
IMPRINT
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All rights reserved. It is prohibited to reproduce this documentation, or any part thereof, without
the prior written authorisation of KROHNE Messtechnik GmbH.
Subject to change without notice.
Copyright 2016 by
KROHNE Messtechnik GmbH - Ludwig-Krohne-Str. 5 - 47058 Duisburg (Germany)
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OPTISWIRL 4200
CONTENTS
1 Safety instructions 6
1.1 Software history ............................................................................................................... 6
1.2 Intended use ..................................................................................................................... 7
1.3 Certifications .................................................................................................................... 9
1.4 Safety instructions from the manufacturer................................................................... 10
1.4.1 Copyright and data protection .............................................................................................. 10
1.4.2 Disclaimer ............................................................................................................................. 10
1.4.3 Product liability and warranty .............................................................................................. 11
1.4.4 Information concerning the documentation......................................................................... 11
1.4.5 Warnings and symbols used................................................................................................. 12
1.5 Safety instructions for the operator............................................................................... 12
2 Device description 13
2.1 Scope of delivery............................................................................................................. 13
2.2 Device versions............................................................................................................... 13
2.2.1 Devices with connection flange ............................................................................................ 14
2.2.2 Devices in sandwich version ................................................................................................. 14
2.2.3 Dual version and twofold reliability...................................................................................... 15
2.2.4 Remote version ..................................................................................................................... 15
2.2.5 Devices with integrated nominal diameter reduction.......................................................... 16
2.2.6 Device description................................................................................................................. 16
2.2.7 Free air delivery measurement - FAD (optional) ................................................................. 17
2.2.8 Gross heat quantity calculation (optional)............................................................................ 18
2.2.9 Net heat quantity calculation (optional) ............................................................................... 19
2.2.10 Dual seal.............................................................................................................................. 20
2.3 Nameplate ...................................................................................................................... 21
3 Installation 22
3.1 General notes on installation ......................................................................................... 22
3.2 Storage ........................................................................................................................... 22
3.3 Transport ........................................................................................................................ 22
3.4 Installation conditions ....................................................................................................23
3.4.1 Prohibited installation when measuring liquids .................................................................. 24
3.4.2 Prohibited installation when measuring steam and gases.................................................. 25
3.4.3 Pipelines with control valve .................................................................................................. 25
3.4.4 Preferred mounting position ................................................................................................ 26
3.5 Minimum inlet sections.................................................................................................. 27
3.6 Minimum outlet sections................................................................................................ 28
3.7 Flow straightener ........................................................................................................... 28
3.8 Installation...................................................................................................................... 29
3.8.1 General installation notes..................................................................................................... 29
3.8.2 Installing devices in sandwich design .................................................................................. 30
3.8.3 Installing devices in flange design ....................................................................................... 31
3.8.4 Mounting the field housing, remote version ........................................................................ 32
3.9 Heat insulation................................................................................................................ 33
3.10 Turning the connection housing................................................................................... 34
3.11 Turning the display .......................................................................................................35
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CONTENTS
OPTISWIRL 4200
4 Electrical connections 36
4.1 Safety instructions.......................................................................................................... 36
4.2 Connecting the signal converter .................................................................................... 37
4.3 Electrical connections .................................................................................................... 38
4.3.1 Power supply......................................................................................................................... 38
4.3.2 Current output ...................................................................................................................... 38
4.3.3 Current input......................................................................................................................... 39
4.3.4 Binary output......................................................................................................................... 39
4.3.5 Limit switch output ............................................................................................................... 40
4.3.6 Pulse output / Frequency output ..........................................................................................42
4.3.7 Status output......................................................................................................................... 43
4.4 Connection of remote version ........................................................................................ 43
4.5 Grounding connections................................................................................................... 45
4.6 Ingress protection .......................................................................................................... 46
5 Start-up 47
5.1 Start-up screen .............................................................................................................. 47
5.2 Operation ........................................................................................................................ 47
6 Operation 48
6.1 Display and operating elements .................................................................................... 48
6.1.1 Display for selection of submenu and functions, 3 lines ..................................................... 49
6.1.2 Display when setting parameters, 4 lines ............................................................................ 50
6.1.3 Display when previewing parameters, 4 lines...................................................................... 50
6.2 Basic principles of operation.......................................................................................... 51
6.2.1 Functional description of the keys........................................................................................ 51
6.2.2 Switch from measuring mode to menu mode...................................................................... 51
6.2.3 Change the settings in the menu..........................................................................................51
6.2.4 Character selection in change mode.................................................................................... 52
6.2.5 Units, figures and factors ..................................................................................................... 53
6.2.6 Security and permissions ..................................................................................................... 53
6.3 Overview of the most important functions and units..................................................... 55
6.4 Menu languages .............................................................................................................55
6.5 Gas options for gas measurement................................................................................. 56
6.6 Units................................................................................................................................ 57
6.7 Menu structure............................................................................................................... 60
6.7.1 Menu overview "A Quick Setup"............................................................................................60
6.7.2 Menu overview "B Test"........................................................................................................ 61
6.7.3 Menu overview "C Setup"...................................................................................................... 62
6.7.4 Menu description "A Quick Setup"........................................................................................ 66
6.7.5 Menu description "B Test".................................................................................................... 74
6.7.6 Menu description "C Setup".................................................................................................. 74
6.8 Setting examples ............................................................................................................ 83
6.8.1 Settings for free air delivery measurement - FAD............................................................... 83
6.8.2 Gross heat measurement ..................................................................................................... 84
6.8.3 Net heat measurement......................................................................................................... 85
6.9 Status messages and diagnostic information................................................................ 86
6.10 A12 plausibility checks ................................................................................................. 91
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CONTENTS
7 Service 92
7.1 Replacing signal converter / LC display ........................................................................ 92
7.2 Maintaining the O-rings.................................................................................................. 93
7.3 Spare parts availability...................................................................................................94
7.4 Availability of services .................................................................................................... 94
7.5 Returning the device to the manufacturer..................................................................... 94
7.5.1 General information.............................................................................................................. 94
7.5.2 Form (for copying) to accompany a returned device............................................................ 95
7.6 Disposal .......................................................................................................................... 95
8 Technical data 96
8.1 Functional principle........................................................................................................ 96
8.2 Technical data................................................................................................................. 97
8.3 Dimensions and weights .............................................................................................. 102
8.3.1 Flange versions................................................................................................................... 102
8.3.2 Sandwich version ................................................................................................................ 109
8.3.3 Dimensions of remote version............................................................................................ 111
8.4 Flow tables ................................................................................................................... 112
9 Notes 115
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1
SAFETY INSTRUCTIONS
1.1 Software history
The "Electronic Revision" (ER) is consulted to document the revision status of electronic
equipment according to NE 53 for all devices. It is easy to see from the ER whether
troubleshooting or larger changes in the electronic equipment have taken place and how that
has affected the compatibility.
Changes and effect on compatibility
1 Downwards compatible changes and fault repair with no effect on operation (e.g. spelling
mistakes on display)
2-_ Downwards compatible hardware and/or software change of interfaces:
HART
®
H
P Profibus
F Foundation Fieldbus
3-_ Downwards compatible hardware and/or software change of inputs and outputs:
CO Current output
FO, POFrequency output / pulse output
OPTISWIRL 4200
SO Status output
LS Limit switch
CI Current input
D Display
Release date Electronic revision Changes and compatibility Documentation
2014-12-10 ER 1.0.0_ - MA OPTISWIRL 4200 R01
2015-01-07 ER 1.0.1_ 1; 2-H MA OPTISWIRL 4200 R01
2015-02-04 ER 1.0.2_ 1; 3-PO MA OPTISWIRL 4200 R01
2015-03-04 ER 1.0.3_ 1; 2-H; 3-CO; 3-PO; 3-CI; 3-D MA OPTISWIRL 4200 R01
2015-09-07 ER 1.0.4_ 1; 2-H; 3-D MA OPTISWIRL 4200 R01
2016-04-18 ER 1.0.5_ 1; 3-PO; 3-SO MA OPTISWIRL 4200 R02
2016-08-19 ER 1.0.6_ 1; 3-D MA OPTISWIRL 4200 R03
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1.2 Intended use
CAUTION!
Responsibility for the use of the measuring devices with regard to suitability, intended use and
corrosion resistance of the used materials against the measured fluid lies solely with the
operator.
INFORMATION!
This device is a Group 1, Class A device as specified within CISPR11:2009. It is intended for use in
industrial environment. There may be potential difficulties in ensuring electromagnetic
compatibility in other environments, due to conducted as well as radiated disturbances.
INFORMATION!
The manufacturer is not liable for any damage resulting from improper use or use for other than
the intended purpose.
The vortex flowmeters are used for flow measurement of gases, vapours and liquids.
The devices are particularly suitable for the measurement of:
• Clean liquids with low viscosity (< 10 cP)
• Hydrocarbons with low viscosity (< 10 cP)
• Water
• Chemicals with low corrosiveness
• Saturated steam
• Superheated steam, including CIP and SIP applications in the food industry
SAFETY INSTRUCTIONS
1
®
• The flow sensors are made from stainless steel 316 L (1.4404) or Hastelloy
• In your project planning, please observe the data given in the corrosion tables.
• The pressure-bearing parts have been designed and rated for stationary operation taking into
account the maximum pressure and temperature.
• Observe the data indicated on the nameplate for PS, TS and PT (PED 97/23/EC).
• External forces and moments, caused e.g. by pipe stresses, have not been taken into account.
Primarily, volumetric flow and temperature are measured, with pressure measurement as an
option. From these parameters the measuring device calculates the mass flow or standard
volumetric flow using pre-programmed density data and then exports the measured values via
various communication interfaces.
C22.
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1
SAFETY INSTRUCTIONS
The devices are rated for the following flow velocities:
OPTISWIRL 4200
Liquids:
DN15...DN300
Gases and
steam:
DN15 V
DN15C V
DN25 V
DN25C V
V
: 0.25 m/s 0.8 ft/s 1
min
V
: 10 m/s 32 ft/s 2
max
: 3 m/s 10 ft/s 1
min
V
: 45 m/s 147 ft/s 2
max
: 3 m/s 10 ft/s 1
min
V
: 55 m/s 180 ft/s 2
max
: 2 m/s 6.6 ft/s 1
min
V
: 70 m/s 229 ft/s 2
max
: 2 m/s 6.6 ft/s 1
min
V
: 80 m/s 262 ft/s 2
max
DN40...
DN300
V
: 2 m/s 6.6 ft/s 1
min
V
: 80 m/s 262 ft/s 2
max
1 Use the larger value, according to the amount.
2 Use the smaller value, according to the amount.
INFORMATION!
DN15C and DN25C have a robust flow sensor (signal pick-up) for harsh measuring conditions
and higher maximum velocity compared to the standard version.
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OPTISWIRL 4200
1.3 Certifications
CE marking
The device fulfils the statutory requirements of the following EU directives:
• Pressure equipment directive
• EMC directive
• Devices for use in hazardous areas: ATEX directive
as well as
• EN 61010
• NAMUR recommendations NE 21 and NE 43
SAFETY INSTRUCTIONS
1
The manufacturer certifies successful testing of the product by applying the CE marking.
A CE declaration of conformity regarding the directives in question and the associated
harmonised standards can be downloaded from our internet site.
DANGER!
For devices used in hazardous areas, additional safety notes apply; please refer to the Ex
documentation.
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SAFETY INSTRUCTIONS
1.4 Safety instructions from the manufacturer
1.4.1 Copyright and data protection
The contents of this document have been created with great care. Nevertheless, we provide no
guarantee that the contents are correct, complete or up-to-date.
The contents and works in this document are subject to copyright. Contributions from third
parties are identified as such. Reproduction, processing, dissemination and any type of use
beyond what is permitted under copyright requires written authorisation from the respective
author and/or the manufacturer.
The manufacturer tries always to observe the copyrights of others, and to draw on works created
in-house or works in the public domain.
The collection of personal data (such as names, street addresses or e-mail addresses) in the
manufacturer's documents is always on a voluntary basis whenever possible. Whenever
feasible, it is always possible to make use of the offerings and services without providing any
personal data.
OPTISWIRL 4200
We draw your attention to the fact that data transmission over the Internet (e.g. when
communicating by e-mail) may involve gaps in security. It is not possible to protect such data
completely against access by third parties.
We hereby expressly prohibit the use of the contact data published as part of our duty to publish
an imprint for the purpose of sending us any advertising or informational materials that we have
not expressly requested.
1.4.2 Disclaimer
The manufacturer will not be liable for any damage of any kind by using its product, including,
but not limited to direct, indirect or incidental and consequential damages.
This disclaimer does not apply in case the manufacturer has acted on purpose or with gross
negligence. In the event any applicable law does not allow such limitations on implied warranties
or the exclusion of limitation of certain damages, you may, if such law applies to you, not be
subject to some or all of the above disclaimer, exclusions or limitations.
Any product purchased from the manufacturer is warranted in accordance with the relevant
product documentation and our Terms and Conditions of Sale.
The manufacturer reserves the right to alter the content of its documents, including this
disclaimer in any way, at any time, for any reason, without prior notification, and will not be liable
in any way for possible consequences of such changes.
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1.4.3 Product liability and warranty
The operator shall bear responsibility for the suitability of the device for the specific purpose.
The manufacturer accepts no liability for the consequences of misuse by the operator. Improper
installation or operation of the devices (systems) will cause the warranty to be void. The
respective "Standard Terms and Conditions" which form the basis for the sales contract shall
also apply.
1.4.4 Information concerning the documentation
To prevent any injury to the user or damage to the device it is essential that you read the
information in this document and observe applicable national standards, safety requirements
and accident prevention regulations.
If this document is not in your native language and if you have any problems understanding the
text, we advise you to contact your local office for assistance. The manufacturer can not accept
responsibility for any damage or injury caused by misunderstanding of the information in this
document.
This document is provided to help you establish operating conditions, which will permit safe and
efficient use of this device. Special considerations and precautions are also described in the
document, which appear in the form of icons as shown below.
SAFETY INSTRUCTIONS
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SAFETY INSTRUCTIONS
1.4.5 Warnings and symbols used
Safety warnings are indicated by the following symbols.
DANGER!
This warning refers to the immediate danger when working with electricity.
DANGER!
This warning refers to the immediate danger of burns caused by heat or hot surfaces.
DANGER!
This warning refers to the immediate danger when using this device in a hazardous atmosphere.
DANGER!
These warnings must be observed without fail. Even partial disregard of this warning can lead to
serious health problems and even death. There is also the risk of seriously damaging the device
or parts of the operator's plant.
OPTISWIRL 4200
WARNING!
Disregarding this safety warning, even if only in part, poses the risk of serious health problems.
There is also the risk of damaging the device or parts of the operator's plant.
CAUTION!
Disregarding these instructions can result in damage to the device or to parts of the operator's
plant.
INFORMATION!
These instructions contain important information for the handling of the device.
LEGAL NOTICE!
This note contains information on statutory directives and standards.
• HANDLING
HANDLING
HANDLINGHANDLING
This symbol designates all instructions for actions to be carried out by the operator in the
specified sequence.
i RESULT
RESULT
RESULTRESULT
This symbol refers to all important consequences of the previous actions.
1.5 Safety instructions for the operator
12
WARNING!
In general, devices from the manufacturer may only be installed, commissioned, operated and
maintained by properly trained and authorized personnel.
This document is provided to help you establish operating conditions, which will permit safe and
efficient use of this device.
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OPTISWIRL 4200
2.1 Scope of delivery
INFORMATION!
Inspect the packaging carefully for damages or signs of rough handling. Report damage to the
carrier and to the local office of the manufacturer.
INFORMATION!
Do a check of the packing list to make sure that you have all the elements given in the order.
INFORMATION!
Look at the device nameplate to ensure that the device is delivered according to your order.
Check for the correct supply voltage printed on the nameplate.
DEVICE DESCRIPTION
2
Figure 2-1: Scope of delivery
1 Measuring device in ordered version
2 Product documentation
3 Certificates, calibration report and parameter data sheet
4 CD with complete documentation
5 Bar magnet
6 Centering rings (only for sandwich devices)
7 Handle to pull off the display
8 Key for opening the front and rear cover
2.2 Device versions
The devices are delivered in the following variants:
• Signal converter with display
• Flow sensor in flanged design, flow sensor F
• Flow sensor in sandwich design, flow sensor S
• Remote version - Flow sensor with separated remote signal converter
• Dual version with two flow sensors and two signal converters
The following designs are available as options:
• With pressure sensor - with or without shut-off valve
• Flange version, flow sensor with single reduction F1R
• Flange version, flow sensor with double reduction F2R
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2
DEVICE DESCRIPTION
2.2.1 Devices with connection flange
Figure 2-2: Flanged devices with display
1 Version with temperature sensor
2 Version with temperature sensor and optional pressure sensor
3 Version with temperature sensor, optional pressure sensor and shut-off valve
4 Version with temperature sensor, flow sensor with integrated reducer
OPTISWIRL 4200
2.2.2 Devices in sandwich version
The sandwich version features 2 centering rings to aid with installation.
Figure 2-3: Sandwich versions with display
1 Version with temperature sensor
2 Version with temperature sensor and optional pressure sensor
3 Version with temperature sensor, optional pressure sensor and shut-off valve
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2.2.3 Dual version and twofold reliability
DEVICE DESCRIPTION
2
This is a genuine redundant system with two
independent flow sensors and two signal
converters.
This provides twofold functional reliability and
availability of the measurement. This variant
is ideally suited for measurements in multiproduct pipelines. In such pipelines, two
different products are moved through one
after the other. One signal converter can be
programmed for one product, and the other
signal converter for the other product.
2.2.4 Remote version
Figure 2-4: Remote version
1 Flow sensor connection box
2 Flow sensor
3 Signal converter
4 Wall mount bracket connection box
With the remote version, the flow sensor and signal converter are installed separately in
different places. The 6-pin, shielded connection cable is available with a length up to 50 m /
164 ft.
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2
DEVICE DESCRIPTION
2.2.5 Devices with integrated nominal diameter reduction
The device versions F1R and F2R offer an integrated nominal diameter reduction up to two
nominal diameter sizes to assure best results in accuracy and optimum measuring ranges; even
in pipelines with large diameters, which have been designed for a low pressure loss.
OPTISWIRL 4200
Nominal
Nominal size of process connections
diameter of flow
sensor
DN15 DN25 DN40 DN50 DN80 DN100 DN150 DN200 DN250 DN300
DN15 StV
DN25 - StV
DN40 --StV
DN50 ---StV
DN80 ----StV
DN100 -----StV
DN150 ------StV
DN200 -------StV
DN250 --------StV
DN300 ---------StV
1 Standard version
1
F1RF2R-------
1
F1RF2R------
1
F1RF2R-----
1
F1RF2R----
1
F1RF2R---
1
F1R F2R - -
1
F1R F2R -
1
F1R F2R
1
F1R
1
2.2.6 Device description
16
Figure 2-5: Device description
1 Signal converter
2 Cable feed through
3 Pressure sensor, optional
4 Shut-off valve, optional
5 Flow sensor
6 Centering ring
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OPTISWIRL 4200
2.2.7 Free air delivery measurement - FAD (optional)
To create compressed air, a compressor draws in air from the ambient atmosphere,
compresses it and delivers it at the required pressure. Since the ambient atmosphere also
contains water vapour, what the compressor draws in is a mixture of air and water vapour. In
addition to the moisture in the air, the ambient temperature and pressure conditions on the inlet
side and the process conditions on the outlet side also influence compressor capacity.
That is why most manufacturers specify compressor capacity as free air delivery at standard
intake conditions. To compare the capacity of different compressors or to compare the capacity
of a compressor at different points in time, the measurement of the air conveyed by the
compressor must be purged of the influences of the process and of the environment and
converted to these standardised suction conditions.
The vortex flowmeter with optional FAD function (FAD - Free Air Delivery) can measure the free
air delivery online, regardless of its function as standard flowmeter. For this the device needs
the process and ambient conditions, as well as the compressor data. When installed on the
outlet side, it measures the air volume generated by the compressor and the process conditions.
The menu-driven, user-friendly software prompts the operator to enter the following values:
DEVICE DESCRIPTION
2
• Ambient temperature (inlet)
• Atmospheric pressure (inlet)
• Air humidity (inlet and outlet)
• Motor speed (rated speed and actual speed)
• Pressure loss of the air filter
The FAD value is calculated from the measured and entered parameters using the vapour and
compressibility tables stored in the measuring device.
INFORMATION!
FAD measurement is an optional feature which can be unlocked in menu "C6.3 Extras".
Please contact the manufacturer to obtain the four digit code required to enable this feature.
For programming example refer to Settings for free air delivery measurement - FAD on page 83
.
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2
DEVICE DESCRIPTION
2.2.8 Gross heat quantity calculation (optional)
This feature enables the calculation of the heat flow volume in systems where hot water,
saturated or superheated steam is used for heating.
The determination of gross heat is based on the relation between the temperature-dependent
enthalpy of steam and mass flow. The enthalpy tables are permanently programmed in the
device memory.
The calculated density-compensated mass flow is multiplied by the correct enthalpy in order to
obtain gross heat flow.
OPTISWIRL 4200
Gross power [Q
The absolute hot water and steam consumption, as well as the energy, can be monitored
internally via a totalizer, which enables an integration of the measured heat flow over time.
] = mass flow [Qm] x enthalpy [H]
H
INFORMATION!
Gross heat quantity calculation is an optional feature, which can be unlocked in menu "C6.3
Extras". Please contact the manufacturer to obtain the four digit code required to enable this
feature.
For programming example refer to Gross heat measurement on page 84
.
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OPTISWIRL 4200
2.2.9 Net heat quantity calculation (optional)
When measuring the net heat, the energy consumption of steam and hot water can be exactly
determined. To do this, the vortex flowmeter is built into the inlet run of the plant component to
be measured. An additional temperature sensor is installed in the return flow and then
connected to the signal converter, either via an additional current input or via HART
DEVICE DESCRIPTION
®
.
2
Figure 2-6: Measuring heat difference
1 Flowmeter with built-in temperature sensor
2 Temperature sensor
3 Heat exchanger
4 Heat flow
The measuring device can now determine the gross heat and measure the net heat from the
temperature difference determined by the second temperature sensor.
INFORMATION!
Net heat quantity calculation is an optional feature which can be unlocked in menu "C6.3 Extras".
Please contact the manufacturer to obtain the four digit code required to enable this feature.
For programming examples refer to Net heat measurement on page 85
.
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2
DEVICE DESCRIPTION
2.2.10 Dual seal
To comply with the requirements of ANSI/ISA 12.27.01 "Requirements for Process Sealing
Between Electrical Systems and Flammable or Combustible Process Fluids", a membrane vent
is integrated in the neck of the device. This vent is located between the primary seal (process)
and the secondary seal (electronics compartment) and works to prevent pressure build-up in the
device neck, thus preventing product from penetrating the electronics compartment in the
unlikely event of a leak in the primary seal.
OPTISWIRL 4200
Figure 2-7: Dual Seal
1 Membrane vent
The seal between the pick-up and the measuring tube is considered as the primary seal. The
material used for this is always the same as that used for the measuring tube itself (e.g.
®
1.4435/316L for measuring tube made of stainless steel 1.4404/316L or Hastelloy
®
measuring tube made of Hastelloy
C22). When selecting the material, corrosion resistance
C276 for
depending on process parameters (product, temperature) must be taken into account.
By using the membrane vent, all requirements for a "DUAL SEAL" version in terms of the above
mentioned standards are met.
• It protects the electronics from the process media.
• Any leak in the primary seal can be detected.
Even though there is no reason to expect the seal to fail, regular visual checks should still be
carried out to detect any possible leak as early as possible.
In the event of a leak, contact the manufacturer's service department to service or replace the
device.
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2.3 Nameplate
INFORMATION!
Check the device nameplate to ensure that the device is delivered according to your order. Check
for the correct supply voltage printed on the nameplate.
DEVICE DESCRIPTION
2
Figure 2-8: Example of nameplate
1 Meter type
2 Manufacturer
3 Flow sensor
S - Sandwich
F - Flange
F1R - Flange, single reduction
F2R - Flange, double reduction
4 Notified bodies for PED & ATEX (only available if this option was ordered)
5 Connection data: nominal diameter and pressure rating
6 PED data
7 Ex data (only available if this option was ordered)
8 Electrical connection data
9 Tag no. - Measuring point identifier
Figure 2-9: Example of nameplate
1 Serial number
2 Order number
3 Production order number
4 Type code
5 Article code
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3
INSTALLATION
3.1 General notes on installation
INFORMATION!
Inspect the packaging carefully for damages or signs of rough handling. Report damage to the
carrier and to the local office of the manufacturer.
INFORMATION!
Do a check of the packing list to make sure that you have all the elements given in the order.
3.2 Storage
• Store the device in a dry, dust-free location.
• Avoid extended direct exposure to the sun.
• Store the device in the original packaging.
• The permissible storage temperature for standard devices is -40...+85°C / -40...+185°F.
OPTISWIRL 4200
3.3 Transport
• Use lifting straps wrapped around both process connections for transport.
• Do not lift measuring devices by the signal converter housing for transport.
• Never lift the measuring device by the pressure sensor.
• Do not use lifting chains as they may damage the housing.
Figure 3-1: Transport instructions
CAUTION!
Non-secured devices can pose risk of injury. The centre of mass of the device is often higher
than the point at which the lifting straps are attached.
Prevent the measuring device from sliding or rotating accidentally.
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OPTISWIRL 4200
3.4 Installation conditions
INFORMATION!
For accurate volumetric flow measurement the measuring device needs a completely filled pipe
and a fully developed flow profile.
CAUTION!
Any vibration will distort the measuring result. That is why any vibrations in the pipeline must be
prevented through suitable measures.
CAUTION!
Procedures to carry out before installing the device:
•
Nominal diameter of connection pipe flange = nominal flange diameter of pipe!
•
Use flanges with smooth holes, e.g. welding neck flanges.
•
Align carefully the holes of the connecting flange and the flowmeter flange.
•
Check the compatibility of the gasket material with the process product.
•
Make sure that the gaskets are arranged concentrically. The flange gaskets must not project
into the pipe cross-section.
•
The flanges have to be concentric.
•
There must not be any pipe bends, valves, flaps or other internals in the immediate inlet run.
•
Devices in sandwich version may only be installed using centering rings.
•
Never install the device directly behind piston compressors or rotary piston meters.
•
Do not lay signal cables directly next to cables for the power supply.
•
At product temperatures or ambient temperatures >+65°C / +149°F, a connection cable and
cable glands with a minimum service temperature of +80
INSTALLATION
°
C / +176°F must be used.
3
INFORMATION!
If there is a risk of water hammers in steam networks, appropriate condensate separators must
be installed. Suitable measures must be taken to avoid water cavitation if it is a possible risk.
Sunshades
Figure 3-2: Installation recommendations
1 Horizontal mounting
2 Vertical mounting
The meter MUST be protected from strong sunlight.
A sunshade is available from the manufacturer as an option.
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INSTALLATION
3.4.1 Prohibited installation when measuring liquids
Figure 3-3: Upper pipe bend
CAUTION!
Prohibited: Installing the device in an upper pipe bend 1, because there is a risk of gas bubbles
2 forming. Gas bubbles can lead to pressure surges and inaccurate measurement.
OPTISWIRL 4200
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Figure 3-4: Downstream pipe and outlet
CAUTION!
Installing the device in a downstream pipe 3 or upstream pipe of an outlet 4. There is the risk of
partially filled pipes leading to inaccurate measurements.
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OPTISWIRL 4200
3.4.2 Prohibited installation when measuring steam and gases
1 Lower pipe bends
2 Condensate
DANGER!
Prohibited: Installing the device in a lower pipe bend 1, because there is a risk of condensate
forming 2.
Condensate can lead to cavitation and inaccurate measurement. Under certain circumstances
the device can be destroyed and the measured medium can leak.
INSTALLATION
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3.4.3 Pipelines with control valve
INFORMATION!
To ensure smooth and correct measurement, the manufacturer recommends not installing the
measuring device downstream from a control valve. This would run the risk of vortex formation,
which would distort the measuring result.
Figure 3-5: Pipeline with control valve
1 Recommended: installing the device before the control valve at a distance of ≥ 5 DN
2 Not recommended: Installing the flowmeter directly downstream of control valves, due to vortex formation.
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INSTALLATION
3.4.4 Preferred mounting position
Preferred mounting position
OPTISWIRL 4200
Figure 3-6: Mountig position
1 Above a horizontal pipe
2 Underneath a horizontal pipe (not permitted with lines at risk of condensate forming)
3 On a vertical pipe
4 Horizontal pipeline with signal converter-orientation 90° to the side
INFORMATION!
Depending on the installation position, you may have to rotate the display and/or the connection
housing.
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OPTISWIRL 4200
3.5 Minimum inlet sections
INSTALLATION
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Figure 3-7: Inlet sections
1 General inlet section without disturbing flow ≥ 15 DN
2 After a control valve ≥ 50 DN
3 After a pipe diameter reduction ≥ 20 DN
4 After a single bend 90° ≥ 20 DN
5 After a double bend 2x90° ≥ 30 DN
6 After a double three-dimensional bend 2x90° ≥ 40 DN
7 Outlet section: >5 DN
INFORMATION!
The nominal diameter of the flange is significant for the determination of the minimum inlet and
outlet sections for the nominal diameter reduced versions of vortex flowmeter versions F1R and
F2R.
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INSTALLATION
3.6 Minimum outlet sections
OPTISWIRL 4200
Figure 3-8: Minimum outlet sections
1 Upstream of pipe expanders, pipe bends, control valves, etc. ≥ 5 DN
2 Upstream of measuring points ≥ 5 DN
INFORMATION!
The interior of the pipe at the metering points must be free of burrs and other flow impediments.
The measuring device has an internal temperature sensor. The distance from external
temperature measuring points must be ≥ 5 DN. Use flow sensors that are as short as possible to
avoid disturbances of the flow profile.
3.7 Flow straightener
If, due to the type of installation, the required inlet sections are not available, the manufacturer
recommends using flow straighteners. Flow straighteners are installed between two flanges
upstream of the device and shorten the required inlet section.
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Figure 3-9: Flow straightener
1 Straight inlet section upstream of straightener ≥ 2 DN
2 Flow straightener
3 Straight pipe run between flow straightener and device ≥ 8 DN
4 Minimum straight outlet section ≥ 5 DN
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OPTISWIRL 4200
3.8 Installation
3.8.1 General installation notes
CAUTION!
Installation, assembly, start-up and maintenance may only be performed by appropriately
trained personnel. The regional occupational health and safety directives must always be
observed.
The following procedures have to be carried out before installing the device:
• Ensure that the gaskets have the same diameter as the pipelines.
• Note the correct flow direction for the device. This is indicated by an arrow on the neck of the
flow sensor.
• On measuring points with varying thermal loads, the devices have to be mounted with stress
bolts (DIN 2510).
• Stress bolts or bolts and nuts are not included in the scope of delivery.
• Ensure that the measuring flange is concentrically fitted.
• Note the exact installation length of the measuring device when preparing the measuring
point.
INSTALLATION
3
Figure 3-10: Preparing the metering point
1 Installation length of measuring device + thickness of gaskets.
CAUTION!
The internal diameter of the pipelines, the flow sensor and the gaskets must match. The gaskets
may not protrude into the flow.
Figure 3-11: Inner diameter
1 Inner diameter of connection pipe
2 Inner diameter of flange and gasket
3 Inner diameter of flow sensor
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INSTALLATION
3.8.2 Installing devices in sandwich design
OPTISWIRL 4200
Figure 3-12: Installation using centering ring
1 Flow sensor
2 Centering ring
3 Bolts with fixing nuts
4 Drill hole
5 Sealing
• Push the first bolt 3 through the hole 4 of both flanges.
• Screw on the nuts and washers to both ends of the bolt 3 but do not tighten them.
• Install the second bolt through the holes 4.
• Place the flow sensor 1 between the two flanges.
• Insert the gaskets 5 between flow sensor 1 and flanges and align them.
• Check that the flange is concentric.
• Install the remaining bolts, washers and nuts. Do not yet tighten the nuts.
• Turn the centring ring 2 in a counter-clockwise direction and align the device.
• Check that the gaskets 5 are concentric; they must not protrude into the pipe cross-section.
• Now tighten all nuts bit by bit alternately across the diagonal.
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