YOKOGAWA Rotamass Intense, Rotamass series, Rotamass Hygienic, Rotamass Supreme, Rotamass Giga General Instruction Manual
...
User's Manual
IM 01U10B00-00EN-R
IM 01U10B00-00EN-R, 3rd edition, 2018-07-09
ROTA
MASS
Total Insight
Coriolis Mass Flow and Density Meter
General Instruction Manual
Table of contents
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IM 01U10B00-00EN-R, 3rd edition, 2018-07-09
Table of contents
1 Introduction................................................................................................................................................ 4
1.1 Scope of application ......................................................................................................................... 4
1.2 Target group ..................................................................................................................................... 4
1.3 Applicable documents....................................................................................................................... 4
1.4 Explanation of safety instructions and symbols................................................................................ 5
2 Safety.......................................................................................................................................................... 6
2.1 Intended use..................................................................................................................................... 6
2.2 Technical conditions ......................................................................................................................... 6
2.3 General safety instructions ............................................................................................................... 7
3 Warranty ..................................................................................................................................................... 9
4 Product specification ................................................................................................................................ 10
4.1 Scope of delivery .............................................................................................................................. 10
4.2 Measuring principle and flow meter design ...................................................................................... 11
4.2.1 Measuring principle.............................................................................................................. 11
4.2.2 Flow meter ........................................................................................................................... 13
4.3 Identification...................................................................................................................................... 14
4.3.1 Nameplates.......................................................................................................................... 14
4.3.2 Model code .......................................................................................................................... 17
4.4 Flow meter components ................................................................................................................... 17
4.5 Mechanical specification................................................................................................................... 18
5 Transport and storage .............................................................................................................................. 19
5.1 Transport .......................................................................................................................................... 19
5.2 Storage ............................................................................................................................................. 20
6 Installation.................................................................................................................................................. 21
6.1 Installation instructions ..................................................................................................................... 21
6.1.1 Installation dimensions......................................................................................................... 21
6.1.2 Installation site ..................................................................................................................... 21
6.1.3 Instructions........................................................................................................................... 22
6.1.4 Installation position .............................................................................................................. 23
6.1.5 Sanitary Installation.............................................................................................................. 24
6.2 Installation instructions ..................................................................................................................... 26
6.3 Sensor installation ............................................................................................................................ 27
6.3.1 General installation rules ..................................................................................................... 27
6.3.2 Installation in pipe ................................................................................................................ 28
6.3.3 Installation Rotamass Nano (Option PD) ............................................................................. 30
6.3.4 Installation recommendation for viscosity measurements ................................................... 31
6.4 Insulation and heat tracing................................................................................................................ 32
6.4.1 Heat tracing.......................................................................................................................... 32
6.4.2 Customer-supplied insulation............................................................................................... 32
6.5 Transmitter installation...................................................................................................................... 33
6.5.1 Rotating and replacing the display....................................................................................... 33
6.5.2 Rotating transmitter housing (integral type) ......................................................................... 36
6.5.3 Rotating the terminal box (remote type)............................................................................... 38
6.5.4 Installing transmitter on pipe (remote type).......................................................................... 39
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6.6 Installation check list......................................................................................................................... 41
7 Wiring ......................................................................................................................................................... 42
7.1 General wiring rules.......................................................................................................................... 42
7.2 Grounding connections and sensor circuits...................................................................................... 44
7.3 Connecting cable installation............................................................................................................ 45
7.3.1 Connection terminals ........................................................................................................... 46
7.3.2 Connecting the connecting cable to sensor ......................................................................... 49
7.3.3 Connecting the connecting cable to transmitter................................................................... 50
7.4 Transmitter........................................................................................................................................ 51
7.4.1 Connection terminals ........................................................................................................... 51
7.4.2 HART communication .......................................................................................................... 52
7.4.3 MODBUS communication .................................................................................................... 52
7.4.4 Assignment of inputs and outputs........................................................................................ 53
7.4.5 Output signals ...................................................................................................................... 55
7.4.6 Input signals......................................................................................................................... 61
7.4.7 Power supply ....................................................................................................................... 62
7.4.8 Connecting power supply and external devices................................................................... 63
7.5 Wiring check list................................................................................................................................ 66
8 Commissioning.......................................................................................................................................... 67
9 System configuration and operation ....................................................................................................... 68
9.1 Operating options ............................................................................................................................. 68
9.2 Display.............................................................................................................................................. 68
9.3 Default settings................................................................................................................................. 72
9.3.1 Setting display language...................................................................................................... 72
9.3.2 Setting date.......................................................................................................................... 73
9.3.3 Setting time .......................................................................................................................... 73
9.3.4 Setting zero point ................................................................................................................. 74
9.3.5 Performing autozero ............................................................................................................ 74
9.4 Advanced settings ............................................................................................................................ 75
9.4.1 Setting hardware write-protection ........................................................................................ 75
9.4.2 MODBUS hardware setting.................................................................................................. 77
10 Troubleshooting ........................................................................................................................................ 80
10.1 Malfunction of operation ................................................................................................................... 80
10.2 Zero point unstable ........................................................................................................................... 81
10.3 Display deviating............................................................................................................................... 82
11 Maintenance and repair ............................................................................................................................ 84
11.1 Exterior cleaning ............................................................................................................................... 85
11.2 Recalibration and calibration service ................................................................................................ 85
11.3 Impairment of the display.................................................................................................................. 85
11.4 List of replacement parts .................................................................................................................. 85
12 Dismantling and disposal ......................................................................................................................... 86
12.1 Decontamination and return shipment .............................................................................................. 86
12.2 Disposal ............................................................................................................................................ 86
13 Specifications ............................................................................................................................................ 88
13.1 Ambient conditions ........................................................................................................................... 88
General Instruction Manual
Introduction
Scope of application
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1 Introduction
1.1 Scope of application
These instructions apply to the following Rotamass Total Insight product families:
▪ Rotamass Nano
▪ Rotamass Supreme
▪ Rotamass Giga
▪ Rotamass Prime
▪ Rotamass Intense
▪ Rotamass Hygienic
▪ Rotamass Total Insight transmitter in combination with any Rotamass Total Insight
sensor.
1.2 Target group
The following persons are the target group of this manual:
▪ Technicians
▪ Engineers
This manual along with its applicable documents enable the target group to complete the
following steps:
▪ Installation
▪ Commissioning
▪ Configuration (parametrization)
▪ Integration of the flow meter into a process control system
▪ Troubleshooting
▪ Maintenance and repair
▪ Dismantling and disposal
1.3 Applicable documents
The following documents supplement this manual:
▪ Explosion Proof Type Manual (Ex-IM) IM01U10X␣␣-00␣␣-R
▪ Software Instruction Manual (SW-IM) IM01U10S␣␣-00␣␣-R
▪ General Specifications (GS) GS01U10B␣␣-00␣␣-R
Explanation of safety instructions and symbols
General Instruction Manual
Introduction
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1.4 Explanation of safety instructions and symbols
Signal words
Warning notices are intended to alert users to potential hazards when working with the
flow meter. There are four hazard levels that can be identified by the signal word:
Signal word Meaning
DANGER
Identifies a high-risk hazard resulting in death or severe injury
unless avoided.
WARNING
Identifies a fluid-risk hazard that may lead to death or severe injury unless avoided.
CAUTION
Identifies a low-risk hazard that may lead to minor or moderate
injury unless avoided.
NOTICE Identifies a hazard resulting in property damage.
Explanation of
symbols
Symbols in this
document
Meaning
Indicates a hazard, documentations must be consulted.
Indicates important information.
IM01U10S01-00␣␣-R
The ␣␣ symbols in the document numbers are placeholders,
here, for example, for the corresponding language version (DE,
EN, etc.).
Symbols on the
nameplates
Meaning
Warning that requires reading the documentation
RCM marking
CE marking
ATEX explosion protection marking
,
EAC and EAC Ex marking
,
Korean (KC and KCs) marking
FM/CSA marking
NEPSI marking
INMETRO marking
DNV GL type approval marking
3-A Sanitary approval marking
China RoHS marking
General Instruction Manual
Safety
Intended use
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2 Safety
2.1 Intended use
The flow meter described in this user's manual is intended to measure mass flow of fluids
and gases while simultaneously also capturing their density and temperature. These values form the basis for calculating additional measured quantities, such as volume flow
and concentration of fluids.
The flow meter uses the Coriolis principle (see Measuring principle [}11]) and can be
used in process automation for a wide range of flow rate measurements. It allows for
measuring various fluids, e.g.:
▪ Oils, grease
▪ Gases, liquid gases
▪ Acids, solutions, solvents
▪ Emulsions and suspensions
Use of the flow meter is limited primarily by the necessary homogeneity of the fluid and
chemical resistance of the wetted parts. Details can be obtained from the responsible
Yokogawa sales organization. Operational safety cannot be ensured in the event of any
improper or not intended use. Rota Yokogawa is not liable for damage arising from such
use.
The flow meter described in this user’s manual is a class A device according to
EN 61326-1 and may only be used in an industrial environment.
2.2 Technical conditions
At normal conditions, the flow meter does not release any poisonous gases or substances.
If the flow meter is operated in faulty conditions, its safety and function may be impaired.
For this reason, the following must be observed:
▶ Operate the flow meter only when in good working order.
▶ If its operational performance changes unexpectedly, check flow meter for faults.
▶ Do not undertake unauthorized conversions or modifications on the flow meter.
▶ Eliminate faults immediately.
▶ Use only original spare parts.
General safety instructions
General Instruction Manual
Safety
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2.3 General safety instructions
DANGER
Use of fluids that are a health hazard may result in caustic burns or
poisoning
▶ When removing the flow meter, avoid touching the fluid and breathing gas residues
left in the sensor.
▶ Wear protective clothing and a breathing mask.
DANGER
Use of unproper materials through the customer may result in heavy corrosion and/or erosion
▶ The medium temperature / pressure ranges are calculated and approved without cor-
rosion or erosion.
▶ The customer is fully responsible to select proper materials to withstand his corrosive
or erosive conditions.
▶ In case of heavy corrosion and/or erosion the instrument may not withstand the pres-
sure and an incident may happen with human and / or environmental harm.
▶ Yokogawa will not take any liability regarding damage caused by corrosion / erosion.
▶ If corrosion / erosion may happen, the user has to check periodically if the necessary
wall thickness is still in place.
WARNING
High fluid temperatures may result in hot surfaces and therefore a risk of
burns
▶ Apply thermal insulation to sensor.
▶ Attach warning labels to the sensor.
▶ Wear protective gloves.
WARNING
Risk of injury from electrical shock due to inadequate clothing
▶ Wear protective clothing as required by regulations.
WARNING
Risk of injury from electrical shock at the transmitter
▶ Avoid handling the transmitter with wet hands.
▶ Wear protective gloves.
The following basic safety instructions must be observed when handling the flow meter:
▶ Carefully read the user's manual prior to operating the flow meter.
▶ When using the flow meter in areas at risk of explosion, compliance with the Explo-
sion Proof Type Manual is mandatory.
▶ Only qualified specialist personnel must be charged with the tasks described in this
user's manual.
▶ Ensure that personnel complies with locally applicable regulations and rules for work-
ing safely.
▶ Do not remove or cover safety markings and nameplates from flow meter.
▶ Replace soiled or damaged safety markings on the flow meter. For replacing please
contact the Yokogawa Service Center.
▶ If Rotamass Total Insight is used to measure safety-related quantities, ensure that the
transmitter does not display any error messages and, if applicable, the total health
check function is performed at regular intervals (see applicable General Specifications GS01U01B␣␣-00␣␣-R, chapter "Options").
General Instruction Manual
Safety
General safety instructions
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▶ Avoid erosion and corrosion as they reduce accuracy and resistance to temperature
and pressure. Over time, calibration constants change as a result of erosion and corrosion, therefore requiring recalibration. Rota Yokogawa does not assume any guaranty or liability with respect to corrosion resistance of wetted parts in any specific
process. The user is responsible for selecting the appropriate materials. Rota Yokogawa provides support in clearing up the question of corrosion resistance of the materials used (special fluids but also cleaning agents). Minor changes in temperature,
concentration or pollution degree in the process may result in differences in terms of
corrosion resistance. In case of corrosion or erosion, the pipes must be checked periodically to ensure necessary wall thickness. This can be accomplished by using, for
example, the tube health check function (see applicable General Specifications
GS01U01B␣␣-00␣␣-R, chapter "Options").
▶ When performing welding tasks on the pipe, it is important not to ground the welding
equipment by way of the flow meter. Soldering and welding work on parts of the flow
meter is prohibited.
▶ Continuous temperature fluctuations in excess of 100 °C may result in tube failure
due to material fatigue and therefore must be avoided.
▶ The operator is responsible for ensuring that design limits (pressure, temperature) are
not exceeded in the event unstable fluids decay.
▶ External influences may result in failure of threaded connections. The operator is re-
sponsible for providing suitable protective measures.
▶ Compression and shock waves in pipes can cause damage to the sensor. For this
reason it is important to avoid exceeding the design limits (pressure, temperature).
▶ Fires may result in increased process pressure (caused by temperature-related vol-
ume changes) and failure of gaskets. The operator is responsible for taking suitable
measures to prevent fire-related damage.
▶ Manufacturing methods and technologies have been successfully field-tested for
decades. Erosion and/or corrosion are not taken into account.
▶ Removal of material from the flow meter with power tools such as drills or saws is not
permitted.
▶ Any repair, modification, replacement or installation of replacement parts is permitted
only so long as it is in keeping with this user's manual. Other work must be first authorized by Rota Yokogawa. Rota Yokogawa does not assume liability for damage
caused by unauthorized work on the flow meter or by improper use.
General Instruction Manual
Warranty
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3 Warranty
Please contact the Yokogawa sales organization if the device needs to be repaired.
The warranty terms for this device are described in the quotation.
If a defect for which Yokogawa is responsible occurs in the device during the warranty
period, Yokogawa will repair that defect at its own cost.
If you believe that the device is defective, please contact us and provide a detailed description of the problem. Please also tell us how long the defect has already occurred and
list the model code and serial number. Additional information, such as drawings, simplifies the identification of the cause and repair of the defect.
Based on our test results, we determine whether the device can be repaired at Yokogawa’s expense or at the expense of the customer. If, for example, the Yokogawa calibration device for the water flow rate confirms a deviation of the output signal from the
stated flow rate accuracy of the device, the device is deemed defective.
The warranty does not apply in the following cases:
▪ If the adhesion, blockage, deposit, abrasion or corrosion is the result of the device’s
actual use.
▪ If the device is mechanically damaged through solids in the fluid, hydraulic shock, or
similar influences.
▪ If the instructions in the corresponding General Specifications or user's manual that
must be met have not been followed.
▪ In case of problems, errors or damage that result from unprofessional installation by
the customer, for example due to insufficient tightness of the pipe fittings.
▪ In case of problems, errors or damage that result from operation, handling or storage
in rough ambient conditions that are beyond the specifications of the device.
▪ In case of problems, errors or damage that result from unprofessional or insufficient
maintenance by the customer, for example, if water or foreign particles enter the device due to opening the device cover.
▪ In case of problems, errors or damage that result from use or from performing mainte-
nance work on the device in a location other than the installation location specified by
Yokogawa.
▪ In case of problems, errors or damage that result from modification or repair work that
was not performed by Yokogawa or by a person authorized by Yokogawa.
▪ In case of problems, errors or damage that result from unprofessional installation, if
the location of the device has been changed.
▪ In case of problems, errors or damage that result from external factors, such as other
devices that are connected to this device.
▪ In case of problems, errors or damage that result from catastrophic external influ-
ences, such as fire, earthquake, storm, flooding or lightning.
General Instruction Manual
Product specification
Scope of delivery
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4 Product specification
4.1 Scope of delivery
The scope of delivery of the flow meter must be checked for completeness using the following list:
Integral type Remote type
Sensor
1 unit
1 unit
Transmitter 1 unit
Connecting cable -
Length accord-
ing to model
code
Operating tool for terminals 2 units 2 units
2-inch pipe mounting bracket set
▪ Sheet metal console (bracket)
▪ Mounting bracket (U-bracket)
▪ Fixing materials (2 nuts, 2 washers, 4 Allen
screws)
- 1 set
Pipe installation set for sensor (with device option PD)
▪ Sheet metal console (bracket)
▪ Mounting bracket (U-bracket)
▪ Fixing plate
▪ Fixing materials (14 nuts, 6 washers, 4 bolts, 8
notched washers, 4 rubber buffers)
- 1 set
Cable glands are included for a device with metric
cable entries and without Ex approval.
Please note:
▪ No cable glands are included for a device with
cable entries other than metric.
▪ For a device with Ex approval the inclusion of ca-
ble glands may vary. Please refer to the applicable
Explosion Proof Type Manual.
2 units 2 units
Cable glands for connecting cable between sensor
and transmitter, metal (pre-installed)
- 2 units
Termination kit for shortening the connecting cable
(not with option L000 or Y000), including instruction
booklet.)
- 1 set
Document folder with this content:
▪ Product CD/DVD (includes the complete product
documentation)
▪ Quick reference guide
▪ Safety Regulations Manual
▪ Further documents like certificates (depending on
model code)
1 folder 1 folder
Measuring principle and flow meter design
General Instruction Manual
Product specification
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4.2 Measuring principle and flow meter design
4.2.1 Measuring principle
The measuring principle is based on the generation of Coriolis forces. For this purpose, a
driver system (E) excites the two measuring tubes (M1, M2) in their first resonance frequency. Both pipes vibrate inversely phased, similar to a resonating tuning fork.
A
E
F1
S1
S2
F2
M1
Q
M2
-F1
-F2
-A
inlet
outlet
Fig.1: Coriolis principle
M1,M2 Measuring tubes E Driver system
S1, S2 Pick-offs A Direction of measuring tube
vibration
F1, F2 Coriolis forces Q Direction of fluid flow
Mass flow
The fluid flow through the vibrating measuring tubes generates Coriolis forces (F1, -F1
and F2, -F2) that produce positive or negative values for the tubes on the inflow or outflow side. These forces are directly proportional to the mass flow and result in deformation (torsion) of the measuring tubes.
1
3
1
2
3
A
E
A
E
F1
F2
α
Fig.2: Coriolis forces and measuring tube deformation
1 Measuring tube mount A
E
Rotational axis
2 Fluid F1, F2 Coriolis forces
3 Measuring tube α Torsion angle
General Instruction Manual
Product specification
Measuring principle and flow meter design
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The small deformation overlying the fundamental vibration is recorded by means of pickoffs (S1, S2) attached at suitable measuring tube locations. The resulting phase shift Δ
φ
between the output signals of pick-offs S1 and S2 is proportional to the mass flow. The
output signals generated are further processed in a transmitter.
Δφ
S1
S2
y
t
Fig.3: Phase shift between output signals of S1 and S2 pick-offs
Δφ ~ FC ~
dt
dm
Δ
φ
Phase shift
m Dynamic mass
t Time
dm/dt Mass flow
F
c
Coriolis force
Density
measurement
Using a driver and an electronic regulator, the measuring tubes are operated in their resonance frequency ƒ. This resonance frequency is a function of measuring tube geometry,
material properties and the mass of the fluid covibrating in the measuring tubes. Altering
the density and the attendant mass will alter the resonance frequency. The transmitter
measures the resonance frequency and calculates density from it according to the formula below. Device-dependent constants are determined individually during calibration.
A
t
ƒ
2
ƒ
1
Fig.4: Resonance frequency of measuring tubes
A Measuring tube displacement
ƒ
1
Resonance frequency with fluid 1
ƒ
2
Resonance frequency with fluid 2
ρ = + ß
ƒ
2
α
ρ
Fluid density
ƒ
Resonance frequency of measuring tubes
α, β
Device-dependent constants
Measuring principle and flow meter design
General Instruction Manual
Product specification
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Temperature
measurement
The measuring tube temperature is measured in order to compensate for the effects of
temperature on the flow meter. This temperature approximately equals the fluid temperature and is made available as a measured quantity at the transmitter as well.
4.2.2 Flow meter
The Rotamass Total Insight Coriolis mass flow and density meter is offered in several
families (Nano, Supreme, Giga, Prime, Intense and Hygienic). It consists of the following
main components:
▪ Sensor
▪ Transmitter
In the integral type, sensor and transmitter are firmly connected.
1
2
3
3
Fig.5: Design of the Rotamass Total Insight integral type (Rotamass Supreme as an example)
1 Transmitter
2 Sensor
3 Process connections
When the remote type is used, sensors and transmitters are linked via connecting cable.
As a result, sensor and transmitter can be installed in different locations.
4 53
1
23
5
3
2
1
4
3
Fig.6: Design of the Rotamass Total Insight remote type (left: Rotamass Supreme, right: Rotamass
Nano)
1 Transmitter 4 Sensor terminal box
2 Sensor 5 Connecting cable
3 Process connections
General Instruction Manual
Product specification
Identification
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General
specifications
All available properties of the Rotamass Total Insight Coriolis mass flow and density meter are specified by means of a model code.
The position of the model code relevant to the respective property is depicted and highlighted in blue.
U S 36 40H BA1 0 2 C5 A NN00 2 JA 1
P8
- - -
- /-
RC
1 2 3 4 6 75 9 10 11 12 13 14 158
Fig.7: Example of an model code
A complete description of the model code is included in the General Specifications (GS)
of the corresponding product family.
4.3 Identification
The model code can be used to identify the flow meter along with its specification. The
model code is located on each main nameplate.
4.3.1 Nameplates
The sensor as well as the transmitter each contain a main nameplate and an additional
nameplate that feature different information.
NOTICE
For individual applications (e.g. marine applications with option MC␣) additional limitations to those on the nameplate may apply according to the respective applicable regulations.
The variants of the nameplates are described below.
Sensor
Main sensor
nameplate
1
5
4
3
2
6
7
11
10
9
8
12
1 Model code 7 Warning that requires reading the
documentation
2 Serial number 8 Area for conformity marking
3 Year of manufacture 9 Manufacturer's address
4 Ambient temperature range 10 Test pressure
5 Kind of material 11 Maximum allowed working pres-
sure at room temperature
6 Direction of flow 12 Maximum allowed process temper-
ature
Identification
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Additional sensor
nameplate
i
3
4
1
2
35
16.8
144
1 Calibration constants of sensor 3 Warning that requires reading the
documentation
2 Customer-Device location
identification (option BG)
4 Space for Ex marking (see Explo-
sion Proof Type Manual)
Transmitter
Main transmitter
nameplate
8
1
2
3
4
5
6
7
i
RCES34S-50BD40-OE70- -4-JA1
1234567
2015
24VAC or 100...240VAC, 50/60Hz
24VDC or 100...120VDC; 10W
-40...+60 oC
1 Model code 5 Ambient temperature range
2 Serial number 6 Warning that requires reading the
documentation
3 Year of manufacture 7 Area for conformity marking
4 Power supply range 8 Manufacturer's address
Additional
transmitter
nameplate
i
3
2
1
1 Customer-Device location identification (option BG)
2 Space for Ex marking (see Explosion Proof Type Manual)
3 Warning that requires reading the documentation
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Product specification
Identification
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Label transmitter
3
1 2
1 Transmitter
2 Transmitter back cover
3 Label
SERIAL No.:
CPU FW :
DSP FW :
HMI FW :
HW :
Date :
Ex works:
D1xxxxxxxx
xx.xx.xx
xx.xx.xx
xx.xx.xx
xx.xx.xx
2016-03-15
Update 1: Update 2:
1
2
3
4
5
6
1 Serial number 4 Indicator software revision
2 Main software revision 5 Hardware revision
3 Sensor software revision 6 Date of Ex works/ Update
NOTICE
Software revisions are also shown on the Indicator after power on, with the following
designations:
▶ "CPU FW" indicated as "Main"
▶ "DSP FW" indicated as "Sensor"
▶ "HMI FW" indicated as "Indicator"
Flow meter components
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Product specification
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4.3.2 Model code
The model code of the Rotamass Total Insight is explained below.
Items 1 through 14 are mandatory entries and must be specified at the time of ordering.
Device options (item 15) can be selected and specified individually by separating them
with slashes.
- - - - /-
RC
1 2 3 4 6 75 9 10 11 12 13 14 158
1. Transmitter
2. Sensor
3. Meter size
4. Material wetted parts
5. Process connection size
6. Process connection type
7. Sensor housing material
8. Process fluid temperature range
9. Mass flow and density accuracy
10. Design and housing
11. Ex approval
12. Cable entries
13. Communication type and I/O
14. Display
15. Options
4.4 Flow meter components
Integral type
4
5
2
5
1
5
1
3
6
1 Process connections
2 Back cover for inputs and outputs, and power supply
3 Display cover
4 Power supply cable entry
5 Blind plug
6 Inputs/outputs cable entry
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Product specification
Mechanical specification
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Remote type
4
6
7
7
9
10
3
1
21
3
8
5
1 Process connections
2 Terminal box
3 Cable entry for connecting cable
4 Display cover
5 Sensor connection cover
6 Back cover for inputs and outputs, and power supply
7 Blind plug
8 Inputs/outputs cable entry
9 Power supply cable entry
10 Connecting cable
4.5 Mechanical specification
Mechanical specifications are defined in the related General Specifications (GS):
see GS01U10B0␣␣-00␣␣-R
Transport
General Instruction Manual
Transport and storage
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5 Transport and storage
5.1 Transport
The following rules apply when transporting the flow meter:
▶ Observe the transport-related instructions on packaging.
▶ In order to avoid damage, do not unpack the flow meter until it is at the installation
site.
▶ Do not remove protective materials, such as protective stickers or covers from
process connections during transport.
▶ Starting at a weight of 15 kg, have at least two persons and/or use suitable tools
(shoulder straps, lifting device, cart) to lift and transport the flow meter.
WARNING
Risk of injury from slipping or falling flow meter
▶ Ensure that suspension points of the ropes are located above the flow meter's center
of gravity.
▶ Use a lifting device meeting local regulations.
▶ Attach lifting ropes to process connections.
▶ Do not suspend flow meter from transmitter housing, neck of sensor or flange holes.
The lifting ropes must always be attached to the sensor at the process connections (except for the Rotamass Nano). The depictions that are crossed out in the figure below
show impermissible attachment types. This applies to the remote type, the remote type
with long neck and the integral type, independent of the design. If the process
connections are others than flanges, the holding ropes must be secured against slipping,
if necessary (for example, for the Rotamass Hygienic).
Fig.8: Attachment of the transport ropes to the sensor independent of the design (impermissible attachment types are crossed out)
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Transport and storage
Storage
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5.2 Storage
Please note the following rules apply when storing the flow meter:
NOTICE
Risk of damage to the flow meter due to storage in a damp environment
▶ Protect flow meter from rain and humidity.
▶ Ensure that a relative humidity of 95 % is not exceeded.
NOTICE
Risk of damage to the flow meter due to mechanical wear during storage
▶ Store flow meter in a location that is secured against mechanical influences.
▶ Ensure compliance with the allowed storage temperature, see Specifications [}88].
▶ Protect flow meter against direct insolation to prevent exceeding the allowed storage
temperature.
▶ Protect flow meter from rain and inappropriate humidity.
▶ Keep protective materials such as protective stickers or covers on process
connections or re-apply them.
▶ Prior to storing a used flow meter, completely drain all fluids from the measuring tube,
as well as from the process and heat tracing connections (if applicable), and thoroughly clean the flow meter, see Dismantling and disposal [}86].
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6 Installation
6.1 Installation instructions
WARNING
Risk of injury during installation due to insufficiently trained personnel
▶ Only have skilled personnel install the flow meter.
NOTICE
Risk of damage to the flow meter due to excessive mechanical stress
▶ The flow meter must not be used as a support for climbing (e.g. during installation
work on the tube system). The flow meter must not be used to support external loads
(e.g. as a support for pipes) or as a surface for depositing heavy tools (e.g. during installation work on the pipe system).
▶ The weight of the flow meter may generate additional mechanical forces on the pip-
ing that might lead to tensions at process connections. Design measures must be
taken to prevent the above.
NOTICE
Risk of damage to the flow meter due to mechanical influences
▶ Protect the flow meter from vibration, shocks and mechanical strain.
NOTICE
Meet the environmental conditions of the respective General Specifications
(see GS01U10B0␣␣-00␣␣-R) to prevent disturbance of other sensitive electrical equipment due to increased electromagnetic emissions.
6.1.1 Installation dimensions
Dimensions and installation lengths of sensor and transmitter are listed in the General
Specifications of the corresponding Rotamass Total Insight family in the chapter Mechan-
ical specification.
6.1.2 Installation site
In order to ensure stability while operating the flow meter, the following rules regarding
placement must be followed:
CAUTION
Risk of injury during installation, if space for free movement is insufficient
▶ Select an installation site that offers enough space for installation, electrical installa-
tion, maintenance, etc.
NOTICE
Risk of damage to the flow meter due to extreme environmental conditions
▶ Do not install flow meter in locations subject to severe temperature fluctuations.
▶ Do not install flow meter in locations subject to direct insolation or install additional
sun protection.
▶ Avoid installation sites susceptible to cavitation, such as immediately behind a control
valve.
▶ Install flow meter far removed from motors, transformers or other transmitters.
▶ If the plan calls for installing two sensors of the same kind back-to-back, use a cus-
tomized design. Contact the responsible Yokogawa sales organization.
▶ Operate the flow meter below an elevation of 2000 m above sea level.
▶ If possible, avoid installing the flow meter at the end of a downpipe.
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▶ When installing in a hazardous area, the separate Explosion Proof Type Manual must
be considered.
▶ Install flow meter away from magnetic compasses as it contains no precaution to pre-
vent it from causing compass deviations.
▶ Density indication of the Coriolis flow meter depends on installation orientation and
has to be corrected. For vertical and horizontal orientation (maximum deviation ± 5°)
of the sensor this can be done by the transmitter automatically if the appropriate sensor orientation is selected. For other orientations (inclinations to vertical or horizontal
orientation ≥ 5°) this can not be automatically corrected and has to be taken into account. For highest density accuracy it is recommended to avoid sensor orientations
different to horizontal or vertical installation.
6.1.3 Instructions
Observe the following general installation instructions during installation:
▶ Install the flow meter avoiding shock and vibration as much as possible.
▶ Use closing valves and bypass line to facilitate zero point setting.
1
2
23
Fig.9: Closing valves and bypass line
1 Bypass valve
2 Closing valve
3 Coriolis flow meter
▶ For application involving fluids, avoid installation at highest point of piping. Formation
of gas bubbles and accumulation of gas in measuring tube may result in increased
measurement uncertainties.
▶ In case of gas measurements, avoid installation directly in front of lowest point in pip-
ing. Accumulation of fluids, such as condensate, may result in lower accuracy.
▶ Do not install immediately in front of a free pipe outlet in a downpipe.
▶ Avoid letting the sensor run idle while taking the measurement, e.g. when installed in
front of an air gap to containers in case of filling applications. Doing so may result in
incorrect measurements. To avoid this, install a restriction in the open downpipe or
use an orifice gauge with a diameter smaller than the nominal pipe width.
▶ Each device is tested for pressure prior to delivery.
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6.1.4 Installation position
Rotamass Total Insight Coriolis mass flow and density meters can be mounted horizontally, vertically and at an incline. The measuring tubes should be completely filled with the
fluid during this process as accumulations of air or formation of gas bubbles in the measuring tube may result in errors in measurement. Straight pipe runs at inlet or outlet are
not required.
Sideways position
The sideways position must be avoided when installing the flow meter, because this may
result in a deterioration of accuracy.
Fig.10: Installation positions to be avoided: Flow meter in sideways position
Horizontal
installation
▶ In case of fluids, install the measuring tubes downward so as to avoid gas accumula-
tion in case of a low flow rate.
▶ For gas applications, install the measuring tubes upward so as to avoid fluid accumu-
lation in case of a low flow rate.
Fig.11: Horizontal installation, measuring tubes downward
Fig.12: Horizontal installation, measuring tubes upward
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Fig.13: Risk of solid matter and/or gas accumulation
Vertical installation
(recommended)
▶ Draining the pipe is easier in case of maintenance, production start or product
change.
▶ Allows gas bubbles to escape more easily.
▶ Only one shut-off valve required to ensure zero flow rate when running autozero.
Fig.14: Vertical Installation
6.1.5 Sanitary Installation
EHEDG compliant installation
In order to comply with the requirements of the European Hygienic Engineering and Design Group (EHEDG), the following aspects need to be considered:
▶ The installation must ensure a self-draining of the device (see figure below). A vertical
installation is recommended.
▶ An EHEDG compliant process connection requires a combination of process
connections and gaskets according to the latest version of the EHEDG Position Paper: "Easy cleanable Pipe couplings and Process connections".
Fig.15: EHEDG compliant installation position
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3-A compliant installation
Remote transmitter
installation
▶ For compliance with 3-A sanitary standards, remote transmitter is restricted to hang-
ing installation, as shown in figure below.
NOTICE
Fixation of the transmitter
For fixation of the transmitter at the bracket either hexagon head srews (M6x10) or socket
head screws with rubber cap must be used.
Fig.16: Hanging installation for remote transmitter
Sensor installation
(remote or integral
version)
▶ For compliance with 3-A sanitary standards, a vertical installation of sensor with fluid
flowing upwards (self-draining) is recommended, as shown in figure below.
Fig.17: Vertical (self-draining) installation
▶ A horizontal installation of sensor with tubes down, as shown in figure below, shall be
drained via air purge.
Fig.18: Horizontal installation with tubes down
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▶ For Cleaning-In-Place (CIP) application, the standard minimum flow velocity of
1.5 m/s shall be used for cleaning the sensor. Volumetric flow shall be determined by
using the cross-sectional area at process connection.
Notes on fittings
and gasket
▶ General note: It must be ensured that the inner diameter (ID) of adjacent pipe
matches the ID of process connection of the sensor fitting to ensure 3-A compliance.
▶ For compliance of DIN 11851 process connection (process connection HS2) with 3-A
standards, a special sanitary gasket such as the k-flex gasket system by Kieselmann
GmbH, or similar must be used to retain 3-A compliance.
6.2 Installation instructions
Note the following rules prior to installation:
▶ Check packaging and contents for damage.
▶ Do not remove protective materials such as protective stickers or caps on process
connections until the start of the installation process.
▶ Dispose packaging materials in compliance with country-specific regulations.
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6.3 Sensor installation
6.3.1 General installation rules
DANGER
Risk of injury due to escaping fluids, if pipe connection is faulty
▶ Correct slope and mismatch of pipe connections before inserting the sensor.
Fig.19: Avoid: Slope and mismatch
▶ Avoid fixing anything directly to the sensor. Doing so may result in increased devia-
tions.
1
1
2
Fig.20: Installation to be avoided: Fixing the sensor
1 Pipe
2 Sensor
▶ Secure pipes before installing the flow meter.
▶ Avoid damaging the process connections.
▶ Flush new pipes before installing the flow meter to remove foreign matter, such as
shavings or other residues.
Avoiding creation of noise
Zero point stability is a prerequisite for exact mass flow measurement. Insufficient installation may lead to mechanical tensions or flow noise which impact zero point stability.
Countermeasures to help avoid noise creation:
▶ Support sensor weight by using soft coupling (silicone or other types of cushioning
materials).
▶ Avoid bending or tensioning the sensor while aligning the pipe.
▶ Avoid reductions or expansions in pipe directly up- or downstream of flow meter.
▶ Avoid placing control valves, apertures or other devices generating noise near the
sensor.
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