YOKOGAWA Rotamass Nano, Rotamass Giga, Rotamass Prime, Rotamass Intense, Rotamass Hygienic Quick Reference Instruction Manual
...
User's
Manual
IM01U10A00-00EN-R, 2nd edition, 2017-08-29
ROTA
MASS
Total Insight
Coriolis Mass Flow and Density Meter
Quick Reference Instruction Manual
Table of contents
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IM01U10A00-00EN-R, 2nd edition, 2017-08-29
Table of contents
1 Introduction....................................................................................................................................................4
1.1 Scope of application ............................................................................................................................... 4
1.2 Applicable documents............................................................................................................................. 4
1.3 Contact information................................................................................................................................. 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
5 Transport and storage ................................................................................................................................11
5.1 Transport .............................................................................................................................................. 11
5.2 Storage ................................................................................................................................................. 12
6 Installation....................................................................................................................................................13
6.1 Unpacking............................................................................................................................................. 13
6.1.1 Installation dimensions........................................................................................................... 13
6.1.2 Instructions............................................................................................................................. 13
6.1.3 Installation position ................................................................................................................14
6.2 Sensor installation ................................................................................................................................ 16
6.2.1 General installation rules .......................................................................................................16
6.2.2 Installation in pipe ..................................................................................................................17
6.2.3 Installation Rotamass Nano (Option PD) ............................................................................... 19
6.3 Insulation and heat tracing.................................................................................................................... 20
6.3.1 Heat tracing............................................................................................................................ 20
6.3.2 Customer-supplied insulation................................................................................................. 20
6.4 Transmitter installation.......................................................................................................................... 21
6.4.1 Integral type ...........................................................................................................................21
6.4.2 Remote type........................................................................................................................... 23
6.5 Installation check list............................................................................................................................. 28
7 Wiring ...........................................................................................................................................................29
7.1 General wiring rules.............................................................................................................................. 29
7.2 Grounding connections and sensor circuits.......................................................................................... 31
7.3 Connecting cable .................................................................................................................................. 32
7.3.1 Connection terminals of connecting cable .............................................................................33
7.4 Transmitter............................................................................................................................................ 35
7.4.1 Connection terminals .............................................................................................................35
7.4.2 HART communication ............................................................................................................ 36
7.4.3 MODBUS communication ...................................................................................................... 36
7.4.4 Assignment of inputs and outputs..........................................................................................37
7.4.5 Output signals ........................................................................................................................ 39
7.4.6 Input signals...........................................................................................................................45
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7.4.7 Connecting power supply and external devices..................................................................... 46
7.5 Wiring check list.................................................................................................................................... 49
8 Commissioning............................................................................................................................................50
9 Troubleshooting ..........................................................................................................................................51
9.1 Malfunction of operation ....................................................................................................................... 51
9.2 Zero point unstable ............................................................................................................................... 52
9.3 Display deviating................................................................................................................................... 52
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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
1.2 Applicable documents
The following documents supplement this manual:
▪ Ex Instruction Manual (Ex-IM) IM01U10X␣␣-00␣␣-R
▪ Software Instruction Manual (SW-IM) IM01U10S␣␣-00␣␣-R
▪ General Specifications (GS) GS01U10B␣␣-00␣␣-R
1.3 Contact information
For more information or questions, contact your local Yokogawa sales organization.
Additional information available at http://www.yokogawa.com or on back page.
Explanation of safety instructions and symbols
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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 medium-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
transmitter
Meaning
Warning that requires reading the documentation
ATEX explosion protection marking
CE marking
RCM marking
DNV GL type approval marking
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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 and can be used in process automation for a
wide range of flow rate measurements. It allows for measuring various media, 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 medium
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
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Safety
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2.3 General safety instructions
DANGER
Use of media that are a health hazard may result in caustic burns or
poisoning
▶ When removing the flow meter, avoid touching the medium and breathing gas
residues left in the sensor.
▶ Wear protective clothing and a breathing mask.
WARNING
High medium 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 Ex in-
struction 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").
▶ 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 media 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.
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Safety
General safety instructions
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▶ 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.
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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 MS 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 medium, 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.
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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 according to MS 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
Ex instruction manual.
2 units 2 units
Cable glands for connecting cable between sensor
and transmitter, metal (pre-installed)
- 2 units
Assembly set for shortening connecting cable, including instructions (not with option L␣␣␣)
- 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
MS code)
1 folder 1 folder
Transport
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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.1: 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 of -40–60 °C
(-35 – 80 °C for fire resistant cable option Y␣␣␣).
▶ 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 heating connections (if applicable), and thoroughly
clean the flow meter.
Unpacking
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6 Installation
6.1 Unpacking
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.
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 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.2: 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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Installation
Unpacking
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6.1.3 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
medium 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.3: 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.4: Horizontal installation, measuring tubes downward
Fig.5: Horizontal installation, measuring tubes upward
Unpacking
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Fig.6: 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.7: Vertical Installation
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Installation
Sensor installation
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6.2 Sensor installation
6.2.1 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.8: Avoid: Slope and mismatch
▶ Avoid fixing anything directly to the sensor. Doing so may result in increased devia-
tions.
1
1
2
Fig.9: 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.
Sensor installation
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6.2.2 Installation in pipe
Depending on process connections, the sensor is connected to the pipe by means of
flanges, terminals or thread. The MS code provides information on the process
connections selected.
DANGER
Risk of injury due to escaping fluids and damage, if fixing materials are inappropriate or not professionally installed
▶ Fixing materials (screws, nuts, terminals, terminal connectors, gaskets, etc.) are not
included in the delivery and must be provided by the customer. The operator is responsible for selecting suitable gaskets and defining corresponding torque values.
▶ Protective materials such as protective stickers or caps on process connections must
be removed immediately before installation.
▶ The direction in which the medium flows through the pipe is indicated by an arrow on
the flow meter. The sensor must be installed in accordance with the flow direction in-
dicated to ensure optimal measuring results for density measurements.
Otherwise, the parameter flow direction in the transmitter menu must be changed,
see applicable software instruction manual.
Clamp connection
The clamp connection must be installed as shown in the figure below.
3
2
1
Fig.10: Clamp connection
1 Terminal
2 Gasket
3 Terminal connector
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