YOKOGAWA Rotamass Intense, Rotamass series, Rotamass Hygienic, Rotamass Supreme, Rotamass Giga General Instruction Manual

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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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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").

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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

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

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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.

-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.

Fig.2: Coriolis forces and measuring tube deformation

1 Measuring tube mount A

Rotational axis 2 Fluid F1, F2 Coriolis forces 3 Measuring tube α Torsion angle

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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

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

Fig.3: Phase shift between output signals of S1 and S2 pick-offs

Δφ ~ FC ~

Phase shift

m Dynamic mass t Time dm/dt Mass flow F

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.

Fig.4: Resonance frequency of measuring tubes

A Measuring tube displacement

Resonance frequency with fluid 1

Resonance frequency with fluid 2

ρ = + ß

Fluid density

Resonance frequency of measuring tubes

α, β

Device-dependent constants

Measuring principle and flow meter design

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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.

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

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

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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

- - -

- /-

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 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

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

3 4

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

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

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

2016-03-15

Update 1: Update 2:

2 3

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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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.

- - - - /-

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

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

6 7

3 8

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

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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)

General Instruction Manual

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].

Installation instructions

General Instruction Manual

Installation

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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.

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.

Sensor installation

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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.

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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6.3.2 Installation in pipe

Depending on process connections, the sensor is connected to the pipe by means of flanges, terminals or thread. The model 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 fluid flows through the pipe is indicated by an arrow on the

flow meter. The sensor must be installed in accordance with the flow direction indicated 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.

Fig.21: Clamp connection

1 Terminal 2 Gasket 3 Terminal connector

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Fixing the flange

▶ Use screws and nuts suitable for the flanges.

▶ In case the nominal width of the piping deviates from the flow meter, use the appropri-

ate reductions.

▶ Inner gasket diameters should not fall below the inner diameters of the flange.

Fig.22: Fixing the flange

1 Pipe flange 2 Gasket 3 Sensor flange 4 Bolt 5 Nut

Internal thread connection

For process connections with an internal thread, the connection must be installed in accordance with the following figure.

Fig.23: Internal thread connection

1 Sensor 2 Gasket (not use in case of NPT) 3 Pipe

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NOTICE

Use of seal tape for installation

In case of process connection with internal thread NPT you have to use a seal tape for installation.

6.3.3 Installation Rotamass Nano (Option PD)

For the Rotamass Nano the sensor can be installed on a DN50 (2") pipe by using a bracket and U-bolt assy (model code position 15, option PD).

NOTICE

The bracket contains vibration dampers, but for extreme cases of vibration stronger damping arrangements may be necessary to ensure best performance.

Fig.24: 2" fixing device option /PD for Nano

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6.3.4 Installation recommendation for viscosity measurements

For the Rotamass sensor this function can only be used if it is present an external differential pressure transmitter (to order separately) measuring the pressure difference at the flow line. The accuracy of the estimated viscosity is strongly depending on the accuracy of the pressure transmitter and the correct position and implementation of the pressure taps.

NOTICE

The needed pressure taps have to be placed at the flow line at approximately 4D … 5D upstream and downstream of the Rotamass sensor. The differential pressure transmitter is directly connected via analog input to the Rotamass transmitter (analog input function must be available).

Fig.25: Positioning of pressure taps

① Mounting flanges ④ Differential pressure transmitter ② Pressure taps ⑤ HART communication ③ Rotamass Total Insight

x = approx. 4 to 5 x D

x Flow line upstream or downstream of the Rotamass Total Insight sensor D Inner diameter of process line

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6.4 Insulation and heat tracing

6.4.1 Heat tracing

The majority of applications do not require or provide insulation or heat tracing for the sensor. Product versions with insulation and/or heat tracing are available for specific technical applications, see applicable General Specifications. Starting with fluid temperatures of approx. 80 °C above or below the ambient temperature, insulating the sensor is recommended if the goal is to maintain utmost accuracy. These measures are also sensible with increased requirements for fluid temperature stability.

The sensor is heated by means of heat tracing via a heat transfer fluid running through stainless steel pipes. The heat transfer fluid is supplied through process connections that can be selected. The operator is responsible for temperature control of the heat carrier. Here the specifications for pressure and the temperature of the heat transfer fluid must be met, see applicable General Specifications.

Heat tracing is only available for the remote type of flow meter and must be selected by including an appropriate device option when placing the order, see applicable General Specifications.

WARNING

Risk of overheating the transmitter due to increased ambient temperature

Failure of measuring electronics

▶ Observe the maximum allowable ambient temperature for the transmitter.

▶ Install the transmitter at a sufficient distance from heat sources.

6.4.2 Customer-supplied insulation

For insulation provided by the customer it is important to select a sensor with the appropriate design type (remote type, sensor with long neck). The space between upper insulation edge and lower edge of the sensor's terminal box must be at least 40 mm.

Recommended insulation thickness is 80 mm and recommended heat transfer coefficient

0.4 W/m² K.

min. 40 mm

Fig.26: Customer-supplied insulation

1 Insulation box

DANGER

When installing in hazardous areas, the applicable Explosion Proof Type Manual must be considered.

Transmitter installation

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6.5 Transmitter installation

6.5.1 Rotating and replacing the display

The transmitter display can be oriented in line with the flow meter installation position.

NOTICE

The following instruction must only be performed at the following ambient conditions:

▶ at temperatures up to 31°C: relative humidity maximum 80 %

▶ at temperatures between 31°C and 40°C: from 80 % linearly decreasing to 50 % of

maximum relative humidity

1. Switch off power supply.

2. Using an Allen wrench (size: 3.0), turn the locking screw on display screw plug clockwise to remove.

3. Unscrew display cover from transmitter housing.

4. Remove the two screws from the display.

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5. Remove the display from housing by pulling forward.

6. Rotate display and push back into housing in the orientation desired.

NOTICE

The display can be removed and replaced by loosening the connector.

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7. Tighten screws.

8. Screw display cover back onto transmitter housing.

9. Using an Allen wrench (size: 3.0), turn the locking screw on display screw plug counter-clockwise to tighten.

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6.5.2 Rotating transmitter housing (integral type)

The transmitter housing can be installed in any one of four orientations.

WARNING

Short-circuit hazard caused by penetrating water

Failure of measuring electronics

▶ In order to prevent any water from penetrating the flow meter by way of the cable,

install the transmitter in a way so that the cable gland is not pointed upward.

WARNING

Insufficient sensor grounding connection

Electric shock and ignition in hazardous areas

▶ Use a minimum torque of 4.3 Nm when tightening the screws.

NOTICE

Damage to flow meter

Rotating the transmitter housing several times in the same direction may damage the connection between sensor and transmitter.

▶ Do not turn transmitter housing more than 270° in the same direction.

1. By using an Allen wrench (size: 5.0), remove the four fixing screws.

2. Lift transmitter housing.

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3. Rotate transmitter housing at angles of 90°, 180° or 270°.

4. Place transmitter housing.

5. Tighten the four fixing screws.

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6.5.3 Rotating the terminal box (remote type)

The terminal box can be installed in any one of four orientations.

1. Loosen the four fixing screws and remove the cover.

2. Remove the cables so that none of the cables inside can accidentally become trapped and damaged.

3. By using an Allen wrench (size: 5.0), remove the bottom fixing screws and rotate the terminal box at an angle of 90°, 180° or 270°.

4. Place the terminal box and tighten the bottom fixing screws using a minimum torque of 7.4Nm.

5. Attach the cover and tighten the fixing screws using a minimum torque of 7.4Nm.

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6.5.4 Installing transmitter on pipe (remote type)

WARNING

Risk of overheating the transmitter due to increased ambient temperature

Failure of measuring electronics

▶ Observe the maximum allowable ambient temperature for the transmitter.

▶ Install the transmitter at a sufficient distance from heat sources. Also note the tem-

perature of the fixing pipe.

WARNING

Short-circuit hazard caused by penetrating water

Failure of measuring electronics

▶ In order to prevent any water from penetrating the flow meter by way of the cable,

install the transmitter in a way so that the cable gland is not pointed upward.

CAUTION

Risk of injury and damage to the flow, meter if it is insufficiently attached to the pipe

▶ Observe the installation notes below.

▶ Tighten screws by using a minimum torque of 7.4 Nm.

NOTICE

Installation at high vibration levels

The mounting bracket for the pipe installation of the transmitter may not be suitable for installation environments with very high levels of vibration. In this case the user is advised to employ more rugged methods of fixation using the threaded bottom holes directly.

If it is a remote type transmitter, it can be mounted to a pipe size DN50 (2") using the angle bracket and retaining clip included in the delivery.

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1. Screw angle bracket to bottom of transmitter.

2. Place retaining clip around pipe and slide through drill holes on angle bracket.

3. Fasten retaining clip to bracket using the nuts.

Installation check list

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6.6 Installation check list

The following checks must be performed once the flow meter is installed in the pipe:

Check Performed?

State and specification of device

▪ Flow meter checked for external damage?

▪ Does flow meter meet the specifications of the measuring point

(process fluid temperature, process pressure, ambient temperature, measuring range, etc.)?

Installation

▪ Does flow direction on flow meter correspond to the actual flow di-

rection in the pipe?

▪ If not, has the appropriate parameter in the transmitter menu been

switched?

▪ Do measuring point number and nameplate labeling match the in-

stallation site?

▪ Do mounting position and installation match usage (measurement

of gas, liquid) in the process environment and under process conditions?

▪ Is meeting the permissible ambient temperature for the transmitter

ensured?

Process environment and conditions

▪ Is the flow meter protected from environmental influences (precipi-

tation, direct insolation)?

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7 Wiring

7.1 General wiring rules

Be sure to handle the transmitter cover carefully so that there are no damages and foreign matter adhesion at its thread and O-ring when it is opened or attached.

DANGER

Life-threatening injuries from electric shock

▶ Switch off power supply.

▶ Secure power supply against inadvertent switch-on.

▶ Check that power supply is free of voltage.

DANGER

Life-threatening injuries from ignition of explosive atmospheres

▶ Wait 20 minutes before opening the housing until the capacitors have discharged

and components have cooled off.

▶ Avoid electrostatically charging the device, e.g. by rubbing it with dry cloths.

DANGER

Explosion hazard from electrostatic discharge or brush discharge

Life-threatening injuries or ignition of explosive atmospheres

▶ Avoid actions that could lead to electrostatic discharges. For example, do not wipe

the coated surface of the transmitter using a piece of cloth.

DANGER

When connecting flow meters in hazardous areas, the applicable Explosion Proof Type Manual must be observed.

WARNING

Risk of injury due to electrical shock

▶ Only have skilled personnel to connect the flow meter.

▶ Do not perform wiring outdoors if it is raining.

WARNING

Risk of injury due to electrical shock, as well as sparking and damage to the flow meter, if an inappropriate connecting cable is used

▶ It is imperative to adhere to the cable diameter of 0.5 – 2.5 mm for sensor and trans-

mitter connection terminals. When using Litz wire, it must be combined with wire end ferrules.

▶ The outer cable diameter must meet the specification of the cable glands used.

▶ Install cables tension-free.

WARNING

Risk of sparking and damage to the flow meter due to incorrect wiring

▶ Observe connection diagram for the connecting cable according to chapter Connec-

tion terminals [}46] and Connection terminals [}51].

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WARNING

Risk of injury due to electrical shock, as well as damage to the flow meter due to insufficient clamping of the connecting wires

▶ Completely open connection terminal by using the operating tool.

▶ Insert connecting wires with wire end ferrules into the corresponding connection ter-

minal up to the stop.

▶ Close connection terminal.

CAUTION

Don't install the connecting cable at ambient temperatures below -10 °C.

NOTICE

Wiring Work must only be performed at max. 80 % humidity and temperatures up to 31°C, linearly decreasing to 50 % relative humidity at 40°C.

NOTICE

Be aware that conducted and radiated electromagnetic emission may effect the EMC of adjacent areas.

NOTICE

Be aware that improper earthing, false wiring and use of cable out of specification may lead to instrument damage and/or disturbance of other sensitive electrical equipment due to increased electromagnetic emissions/immunity.

NOTICE

Be aware that wrong input voltage may lead to disturbance of other sensitive electrical equipment due to increased electromagnetic emissions.

▶ The applicable national standards must be considered for installation.

▶ Only sensors and transmitters with compatible model codes may be interconnected. If

these instructions are not observed, flawless function of the flow meter cannot be guaranteed.

▶ In case of cabling in pipes (Conduit), guide the pipe through the opening in the wiring

and use watertight gaskets to avoid that water runs in. Install the installation pipe at an angle, as shown in the figure below. Install a drain valve in the bottom end of the vertical pipe and regularly open that valve.

Drain valve

▶ Unused cable entries must be closed using blind plugs.

▶ Install cables hanging down to prevent water from flowing along the cable into the

flow meter.

▶ The electrical connection between potential equalization system and grounding

connection must be safe, see Grounding connections and sensor circuits [}44].

▶ Ensure that housing gaskets are positioned in the lining grooves and not damaged.

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7.2 Grounding connections and sensor circuits

WARNING

Risk of injury from electrical shock due to inadequate grounding

▶ Perform potential equalization at the grounding terminals provided for this purpose

according to the figure “Grounding connections on transmitter and sensor”.

Fig.27: Grounding connections on transmitter and sensor

1 Grounding screw in transmitter terminal box for grounding conductor 2 Grounding terminal on transmitter for potential equalization 3 Grounding terminal on sensor for potential equalization

D +

D -

S1 +

S1 -

S2 +

S2 -

TP1

TP2

TP3

D +

D -

S1 +

S1 -

S2 +

S2 -

TP1

TP2

TP3

COM

3 2 1

1 2 3 4 5 6

Fig.28: Connection terminal circuits (transmitter on the left side, sensor on the right side)

1 Driver circuit (D+/D-) 4 Signal grounding 2 Sensor circuits (S1+/S1-, S2+/S2-) 5 Transmitter 3 Temperature measurement circuit

(TP1, TP2, TP3)

6 Sensor

Connecting cable installation

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7.3 Connecting cable installation

With remote type flow meters, sensors and transmitters are connected by means of connecting cables.

CAUTION

Risk of damage to the flow meter due to incorrect sealing

In case of metric cable entry ensure appropriate IP rating and suitability of O-ring of used accessory (e.g. cable glands).

In case of NPT cable entry ensure appropriate sealing measures (e.g. use of sealing tape).

In order to obtain optimum measuring results and ensure compliance with the specification, it is imperative that an original connecting cable and original glands from Rota Yokogawa are used. In order to ensure the IP code, the cable must be professionally installed at the entries. If necessary, the cable may be shortened using the enclosed termination kit. Refer to the cable termination instructions enclose to each termination kit that is attached to each cable.

1 2 3

7 8

Fig.29: Cable gland parts mounting

1 Cap nut 5 Outer cable shield 2 Connecting cable 6 Outer cone part 3 Plastic part 7 Mounting thread 4 Inner cone part 8 Housing cable entry

If the connecting cable, included in the delivery, is too short, additional lengths can be procured through the Yokogawa sales organization.

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7.3.1 Connection terminals

The delivery includes an operating tool for connecting the connecting cable to the connection terminals.

D +

D -

S1 +

S1 -

S2 +

S2 -

TP1

TP2

TP3

D +

D -

S1 +

S1 -

S2 +

S2 -

TP1

TP2

TP3

COM

3 2 1

1 2 3 4 5 6

Fig.30: Connection terminal circuits (transmitter on the left side, sensor on the right side)

1 Driver circuit (D+/D-) 4 Signal grounding 2 Sensor circuits (S1+/S1-, S2+/S2-) 5 Transmitter 3 Temperature measurement circuit

(TP1, TP2, TP3)

6 Sensor

Installation of standard connecting cable option L

␣␣␣

Fig.31: Transmitter and sensor interconnection diagram

1 Sensor 2 Transmitter 3 Potential equalization system

Connecting cable installation

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green

red

blue

white brown yellow

drain wire

Fig.32: Terminated standard connecting cable L␣␣␣, transmitter side

Connection scheme of standard connecting cable option L␣␣␣

Standard connecting cable option L

␣␣␣

Signal Coaxial wire

Coaxial wire pair colour Wire type Wire colour

D+

green

Core wire transparent

D- Shield black

S1+

red

Core wire transparent

S1- Shield black

S2+

blue

Core wire transparent

S2- Shield black

Standard connecting cable option L

␣␣␣

Signal Single wire

Wire type Wire colour

TP1

Conductor

white

brownTP2

TP3 yellow

COM

Drain wire

–

Present only at transmitter side

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Installation of fire retardant connecting cable option Y

␣␣␣

1 2

D+

D– S1+ S1– S2+ S2–

TP1 TP2 TP3

D+ D– S1+ S1– S2+ S2– TP1 TP2 TP3

COM

Fig.33: Transmitter and sensor interconnection diagram

1 Sensor 2 Transmitter 3 Potential equalization system

Shield wire

Fig.34: Terminated fire retardant connecting cable Y␣␣␣, transmitter side

Connection scheme of fire retardant connecting cable option Y␣␣␣

␣␣␣

-cable

Signal Conductor pair number

Conductor colour

D+

white

D- blue

S1+

white

S1- blue

S2+

white

S2- blue

TP1

white

TP2 blue

TP3 5 white

COM

Shield wire

–

Conductor pair number refers to the numbers printed on the single conductors

Present only at transmitter side

Connecting cable installation

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7.3.2 Connecting the connecting cable to sensor

NOTICE

Use the cable end without shield wire to connect to the sensor (observe labeling).

NOTICE

If the cable is not terminated or was shortened, observe the separate instructions in the included terminating set.

1. Loosen the four screws from the neck cover and remove cover.

2. Remove connector nut from cable gland and pull out clamped insert.

3. Push cable through connector nut and clamped insert.

4. Remove precut outer casing of cable.

5. Pull back outer shield of cable over clamped insert.

6. Feed cable through cable entry into sensor.

7. Use the operating tool to connect wires to connection terminals in accordance with terminal diagram Connection terminals [}46].

8. Assemble the cable gland and tighten connector nut.

9. Place cover onto sensor and fasten with four screws.

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7.3.3 Connecting the connecting cable to transmitter

1. Loosen the four screws from the sensor connection cover and remove cover.

2. Remove connector nut from cable gland and pull out clamped insert.

3. Push cable through connector nut and clamped insert.

4. Remove precut outer casing of cable.

5. Pull back outer shield of cable over clamped insert.

6. Feed cable through cable entry into transmitter.

7. Use the operating tool to connect wires to connection terminals in accordance with terminal diagram (Connection terminals of connecting cable).

8. Assemble the cable gland and tighten connector nut.

9. Place sensor connection cover onto transmitter and fasten with four screws.

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7.4 Transmitter

7.4.1 Connection terminals

WARNING

Risk of injury from electrical shock due to inadequate grounding

▶ Use grounding screw to connect the grounding conductor.

▶ Use an M4 ring-type or forked cable lug for the grounding conductor of the connect-

ing cable.

L/+ N/-

8 7 6 5

Fig.35: Terminal box for I/O outputs and transmitter power supply

1 Power supply connection terminals 6 Connection terminals for I/O2 +/2 Grounding screw for connecting

grounding conductor

7 Connection terminals for I/O3 +/-

3 Grounding terminal for potential

equalization

8 Connection terminals for I/O4 +/-

4 Locking screw 9 WP: Write-protection terminal 5 Connection terminals for I/O1 +/-

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7.4.2 HART communication

For devices with HART communication, the HART interface, along with the analog signal, is available at the output Iout1. A load resistance of 230 – 600Ω at Iout1 is recommended.

How to connect to the communication tools is described in the applicable Software Instruction Manual.

7.4.3 MODBUS communication

Modbus interface

Modbus interface of Rotamass Total Insight is implemented in accordance with "MODBUS over serial line specification and implementation guide V1.02", for details of instrumentation see website of the Modbus organization (http://www.modbus.org/).

Modbus connections

Terminal Description

I/O3 - Modbus C (Common)

I/O4 + Modbus B (D1)

I/O4 - Modbus A (D0)

MODBUS_B

MODBUS_A

MODBUS_C

IO4+

IO4-

IO3-

RD+

RD-

GND

RS485

ROTAMASS

Modem

Fig.36: MODBUS communication

Modbus cable

3-Wire cable (twisted pair (D0, D1) and Common) with shield should be used. Wire gauge should be AWG24 or wider.

Rotamass Total Insight has a RS485 electrical interface, operating in slave mode and communicating with the following default specification:

Default Modbus setting

▪ Modbus baud rate: 19200 bps ▪ Modbus transfer mode: RTU ▪ Modbus parity: Even ▪ Modbus stop bit: 1 stop bit

For further details, see applicable software instruction manual (SWIM).

Balanced Pair

Master

Pull Up

Pull Down

LT: Line Termination

Common

Slave n

ROTAMASS

Fig.37: Modbus connection

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7.4.4 Assignment of inputs and outputs

The table below shows possible connection terminal assignments for I/O outputs depending on model code Position 13.

The following figure shows the relevant position of the model code:

- - - - /-

1 2 3 4 6 75 9 10 11 12 13 14 158

Configuration of input/output terminals for HART communication

HART I/O

Model code

Position 13

Connection terminal assignment

I/O1 +/- I/O2 +/- I/O3 +/- I/O4 +/- WP

Iout1

Active

P/Sout1

Passive

– – Write-protect

Iout1

Active

P/Sout1

Passive

P/Sout2

Passive

Iout2

Active

Write-protect

Iout1

Active

P/Sout1

Passive

Sin

Iout2

Active

Write-protect

Iout1

Active

P/Sout1

Passive

Sout

Passive

P/Sout2

Passive

Write-protect

Iout1

Active

P/Sout1

Passive

Sin

P/Sout2

Passive

Write-protect

Iout1

Active

P/Sout1

Passive

Sin

P/Sout2

Active

Internal pullup resistor

Write-protect

Iout1

Active

P/Sout1

Passive

Sin

P/Sout2

Active

Write-protect

Iout1

Active

P/Sout1

Passive

Iout2

Passive

Iin

Active

Write-protect

Iout1

Active

P/Sout1

Passive

P/Sout2

Passive

Iin

Active

Write-protect

Iout1

Active

P/Sout1

Passive

Sin

Iin

Active

Write-protect

Iout1

Active

P/Sout1

Passive

Iout2

Passive

Iin

Passive

Write-protect

Iout1

Active

P/Sout1

Passive

P/Sout2

Passive

Iin

Passive

Write-protect

Iout1

Active

P/Sout1

Passive

Sin

Iin

Passive

Write-protect

Iout1

Passive

P/Sout1

Passive

Iout2

Passive

– Write-protect

Iout1

Passive

P/Sout1

Passive

Iout2

Passive

P/Sout2

Passive

Write-protect

Iout1

Passive

P/Sout1

Passive

NAMUR

Iout2

Passive

– Write-protect

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Model code

Position 13

Connection terminal assignment

I/O1 +/- I/O2 +/- I/O3 +/- I/O4 +/- WP

Iout1

Passive

P/Sout1

Passive

NAMUR

Iout2

Passive

P/Sout2

Passive

NAMUR

Write-protect

Iout1 Analog current output with HART communication

Iout2 Analog current output

Iin Analog current input

P/Sout1 Pulse or status output

P/Sout2 Pulse or status output

Sin Status input

Sout Status output

Configuration of input/output terminals for Modbus communication

Modbus I/O

Model

code

position

Connection terminal assignment

I/O1 +/- I/O2 +/- I/O3 + I/O3 - I/O4 + I/O4 - WP

M0 –

P/Sout1

Passive

– Modbus C Modbus B Modbus A

Writeprotect

Iin

Active

P/Sout1

Passive

– Modbus C Modbus B Modbus A

Writeprotect

P/Sout2

Passive

P/Sout1

Passive

– Modbus C Modbus B Modbus A

Writeprotect

P/Sout2

Active

P/Sout1

Passive

– Modbus C Modbus B Modbus A

Writeprotect

P/Sout2

Active

Internal pull-up resistor

P/Sout1

Passive

– Modbus C Modbus B Modbus A

Writeprotect

Iout1

Active

P/Sout1

Passive

– Modbus C Modbus B Modbus A

Writeprotect

Iin

Passive

P/Sout1

Passive

– Modbus C Modbus B Modbus A

Writeprotect

Iout Analog current output, no HART

Iin Analog current input

P/Sout1 Pulse or status output

P/Sout2 Pulse or status output

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7.4.5 Output signals

Galvanic isolation

All circuits for inputs, outputs and power supply are galvanically isolated from each other.

Active current output lout

One or two current outputs are available depending on model code position 13.

Depending on the measured value, the active current output delivers 4 – 20 mA.

It may be used for output of the following measured values:

▪ Flow rate (mass, volume, net partial component flow of a mixture) ▪ Density ▪ Temperature ▪ Pressure ▪ Concentration

For HART communication devices, it is supplied on the current output lout1. The current output may be operated in compliance with the NAMUR NE43 standard.

Value

Nominal output current 4 – 20 mA

Maximum output current range 2.4 – 21.6 mA

Load resistance ≤ 750Ω

Load resistance for secure HART communication 230–600 Ω

Additive maximum deviation 8 µA

Additive output deviation for deviation from 20 °C ambient temperature

0.8 µA/ °C

Iout+

Iout-

ROTAMASS

Fig.38: Active current output connection lout HART

① Receiver

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Passive current output lout

Value

Nominal output current 4 – 20 mA

Maximum output current range 2.4 – 21.6 mA

External power supply 10.5–32 V

Load resistance for secure HART communication

230–600 Ω

Load resistance at current output ≤ 911 Ω

Additive maximum deviation 8 µA

Additive output deviation for deviation from 20 °C ambient temperature

0.8 µA/ °C

R =

U - 10.5 V

0.0236 A

911

U in V

10.5

R in Ω

Fig.39: Maximum load resistance as a function of an external power supply voltage

R Load resistance U External power supply voltage

The diagram shows the maximum load resistance R as a function of voltage U of the connected voltage source. Higher load resistances are allowed with higher power supply values. The usable zone for passive power output operation is indicated by the hatched area.

Iout+

Iout-

ROTAMASS

Fig.40: Passive current output connection lout

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Active pulse

output P/Sout

Connection of an electronic counter

Maximum voltage and correct polarity must be observed for wiring.

Value

Load resistance > 1 kΩ

Internal power supply 24 VDC ±20 %

Maximum pulse rate 10000 pulses/s

Frequency range 0 – 12.5 kHz

P/Sout+

P/Sout-

24 V

0 V

ROTAMASS

Fig.41: Active pulse output connection P/Sout

① Load resistance ② Electronic counter

Connection of an electromechanical counter

Value

Maximum current 150 mA

Average current ≤ 30 mA

Internal power supply 24 VDC ±20 %

Maximum pulse rate 2 pulses/s

Pulse width 20, 33, 50, 100 ms

P/Sout+

P/Sout-

24 V

0 V

ROTAMASS

Fig.42: Active pulse output P/Sout connection with electromechanical counter

① Protective diode ② Electromechanical counter

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Active pulse

output P/Sout

with internal

pull-up resistor

Value

Internal power supply 24 VDC ±20 %

Internal pull-up resistor 2.2 kΩ

Maximum pulse rate 10000 pulses/s

Frequency range 0 – 12.5 kHz

P/Sout+

P/Sout-

24 V

0 V

ROTAMASS

Fig.43: Active pulse output P/Sout with internal pull-up resistor

① Electronic counter

Passive pulse

output P/Sout

Maximum voltage and correct polarity must be observed for wiring.

Value

Maximum load current ≤ 200 mA

Power supply ≤ 30 V

Maximum pulse rate 10000 pulses/s

Frequency range 0 – 12.5 kHz

ROTAMASS

P/Sout+

P/Sout-

Fig.44: Passive pulse output connection P/Sout with electronic counter

① Passive pulse or status output ② Load resistance ③ Electronic counter

ROTAMASS

P/Sout+

P/Sout-

Fig.45: Passive pulse output P/Sout connection with electromechanical counter

① Passive pulse or status output ② Protective diode ③ Electromechanical counter

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Active status output P/Sout

Since this is a transistor contact, maximum allowed current as well as polarity and level of output voltage must be observed during wiring.

Value

Load resistance > 1 kΩ

Internal power supply 24 VDC ±20 %

P/Sout+

P/Sout-

24 V

0 V

ROTAMASS

Fig.46: Active status output connection P/Sout

① External device with load resistance

Active status

output P/Sout

with internal

pull-up resistor

Value

Internal pull-up resistor 2.2 kΩ

Internal power supply 24 VDC ±20 %

P/Sout+

P/Sout-

24 V

0 V

ROTAMASS

Fig.47: Active status output P/Sout with internal pull-up resistor

① External device

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Passive status output P/Sout or Sout

Value

Output current ≤ 200 mA

Power supply ≤ 30 V

P/Sout+ or Sout+

P/Sout- or Sout-

ROTAMASS

Fig.48: Passive status output connection P/Sout or Sout

① External device

P/Sout- or Sout-

P/Sout+ or Sout+

ROTAMASS

Fig.49: Passive status output connection P/Sout or Sout for solenoid valve circuit

① Relay ② Solenoid valve ③ Magnetic valve power supply ④ Protective diode

A relay must be connected in series to switch alternating voltage.

Passive pulse

or status output

P/Sout (NAMUR)

Output signals according to EN 60947-5-6 (previously NAMUR, worksheet NA001):

10kΩ

1kΩ

ROTAMASS

P/Sout+

P/Sout-

Fig.50: Passive pulse or status output with switching amplifier connected in series

① Passive pulse or status output ② Switching amplifier

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7.4.6 Input signals

Active current input lin

An individual analog power input is available for external analog devices.

The active current input lin is provided for connecting a two-wire transmitter with an output signal of 4–20 mA.

Value

Nominal input current 4 – 20 mA

Maximum input current range 2.4 – 21.6 mA

Internal power supply 24 VDC ±20 %

Internal load resistance Rotamass ≤ 160 Ω

Iin+

Iin-

24 V

ROTAMASS

0 V

Fig.51: Connection of external device with passive current output

① External passive current output device

Passive current input lin

The passive current input lin is provided for connecting a four-wire transmitter with an output signal of 4 – 20 mA.

Value

Nominal input current 4 – 20 mA

Maximum input current range 2.4 – 21.6 mA

Maximum input voltage ≤ 32 V

Internal load resistance Rotamass ≤ 160 Ω

Iin+

Iin-

ROTAMASS

Fig.52: Connection of external device with active current output

① External active current output device

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Status input Sin

Do not connect a signal source with electric voltage.

The status input is provided for use of voltage-free contacts with the following specification:

Switching status Resistance

Closed < 200 Ω

Open > 100 kΩ

ROTAMASS

Sin+

Sin-

Fig.53: Status input connection

7.4.7 Power supply

Power supply

Alternating-current voltage (rms):

▪ Power supply1): 24 VAC +20 % -15 % or 100–240 VAC +10 % -20 % ▪ Power frequency: 47–63Hz

Direct-current voltage:

▪ Power supply1): 24 VDC +20 % -15 % or 100–120 VDC +8,3 % -10 %

for option MC␣ (DNV GL approval) supply voltage is limited to 24 V

Power consumption

P ≤ 10 W (including sensor)

Power supply failure

In the event of a power failure, the flow meter data are backed up on a non-volatile internal memory. In case of devices with display, the characteristic sensor values, such as nominal diameter, serial number, calibration constants, zero point, etc. and the error history are also stored on a microSD card.

Transmitter

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7.4.8 Connecting power supply and external devices

WARNING

Risk of sparking and damage to the flow meter due to incorrect sealing

▶ In case of metric cable entry ensure appropriate IP rating and suitability of O-ring of

used accessory (e.g. cable glands).

▶ In case of NPT cable entry ensure appropriate sealing measures (e.g. use of sealing

tape).

NOTICE

Risk of damage to the flow meter due to incorrect power supply

▶ The specified power supply must be observed (see General Specifications).

▶ The power-supply cable must be designed for the power supply used with a

minimum diameter of 0.5 mm.

1 Transmitter back cover 2 Power supply cable gland

WARNING

Risk of injury due to electrical shock

▶ The transmitter must be assigned an external, fixed-mount power switch or automatic

circuit breaker in order to disconnect the transmitter from the power grid (compliant with IEC60947-1 and IEC60947-3). Power switch or automatic circuit breaker must disconnect all lines under current, but cannot disconnect the grounding conductor under any circumstances.

▶ The power switch of automatic circuit breaker must be installed near the transmitter

and easily accessible. The "OFF" switch position must be clearly recognizable.

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1. Switch off power supply.

2. Using an Allen wrench (Size: 3.0), tighten the locking screw on the back cover in clockwise direction.

3. Unscrew back cover from transmitter housing in counter-clockwise direction.

4. Attach cable glands.

5. Connect wires to connection terminals.

NOTICE

Connect the grounding conductor to the grounding screw (see chapter Connection terminals [}51], figure, point 2).

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6. Fit grounding conductor with a terminal lug and affix to grounding conductor.

7. Screw cable gland on tightly.

8. Screw back cover onto transmitter housing in clockwise direction.

9. Using an Allen wrench (Size: 3.0), loosen the locking screw in counter-clockwise direction.

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Wiring check list

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7.5 Wiring check list

The following checks must be performed once the flow meter is connected electrically:

WARNING

Risk of injury from electrical shock due to insufficiently closed housing

▶ Before switching on the power supply, check that the housing covers of the transmit-

ter have been properly installed.

WARNING

Risk of sparking and damage to the flow meter due to missing locking screw

▶ After wiring work, check that the housing cover has been installed and the locking

screws have been tightened.

NOTICE

Risk of damage to the flow meter due to insufficiently secured cable inlets

▶ Install cables tension-free.

▶ Fit any unused cable entries with blind plugs.

▶ Completely install cable glands and screw together tightly.

NOTICE

Be aware that improper treatment of cable entry and/or cable terminal may lead to disturbance of other sensitive electrical equipment due to increased electromagnetic emissions.

Check Performed?

Are cables intact?

Are power-supply and signal cables connected correctly?

Do the cables have a lower point where liquid can drip immediately before they enter the cable glands?

Are the cables installed tension-free?

Is the power supply within the range specified on the nameplate?

Are any unused cable entries fitted with blind plug?

Are cable glands installed completely, tightly secured and watertight?

Are housing covers installed and locking screws tightened?

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8 Commissioning

1. Activate external power switch.

2. Perform check of piping installation.

3. Check flow meter for device errors, warnings or alarms, see chapter on Troubleshooting [}80].

4. Configure the transmitter, and perform autozero, see chapter on Default settings [}72].

ð Flow meter is ready for operation.

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Operating options

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9 System configuration and operation

9.1 Operating options

The Rotamass Total Insight can be operated in different ways:

▪ IR (Infra-Red) switches on the display ▪ Digital communication (e.g. HART or Modbus)

The section below describes how to operate the system using the IR switches on the display.

The display is a device option and therefore not always available.

For more information on how to operate the transmitter and its functions, and on digital communication, see applicable software instruction manual.

NOTICE

Be aware that all covers are closed before operating in order to prevent disturbance of other sensitive electrical equipment due to increased electromagnetic emissions.

9.2 Display

All of the functions described here are also available via digital communication. Numerical values that are entered via the display are limited to 6 digits.

1 2

Fig.54: Display layout

1 Measured quantities and units 4 IR switches 2 Status icon and time 5 Alarm symbol 3 Measured quantity abbreviation

Display

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The controls on the display are IR switches. They respond as soon as an object, such as a finger, is in close proximity. It is not necessary to apply pressure to the display surface.

NOTICE

Impairment of the display

If the device is operated for a longer period and is subjected to high temperatures or high humidity in the process, the display may be impaired.

▶ Replace display unit as described in Rotating and replacing the display [}33]

Observe the following instructions to ensure that the IR switches are functional:

▶ Keep the display glass clean.

▶ Avoid exposure to direct sunlight.

▶ To increase the reflectivity of fingers (e.g. if they are very dirty) place some white tape

on the fingertip.

IR switch functions

IR switch Display Function

SET ► SET

▪ Apply setting ▪ Enter data ▪ Apply parameter

SHIFT SHT

▪ Move cursor right or to the next position ▪ Change function and display of SET and ▼

▼ INC

▪ Increment parameter or value ▪ Change position of the decimal point ▪ Select next menu item

The IR switch function changes as follows when used with the SHIFT key:

Key combinations

Display Function

SHIFT + SET ► ESC

▪ Cancel and switch to parent menu

SHIFT + ▼ DEC

▪ Decrement parameter or number ▪ Select previous menu item

Status icons

Status icon

Description Status

icon

Description

System alarm tripped Process alarm tripped

Settings alarm tripped Warning tripped

Write protection disabled Write protection enabled

Device error (no write access) Device busy (no write access)

microSD card ready Access to microSD card

Error accessing microSD card Process variable has bad status

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Status icon

Description Status

icon

Description

Upload parameter enabled Download parameter enabled

Total health result: good

(only indicated when display total health result is active)

Total health result: warning

(only indicated when display total health result is active)

Total health result: bad state

(only indicated when display total health result is active)

Tube health check with result: OK

Tube health check with result: warning

Tube health check with result: error

Stop batch Resume batch

Batch running SIL mode

Total health result: good

(only indicated when display total health result is active)

Total health result: warning

(only indicated when display total health result is active)

Total health result: bad state

(only indicated when display total health result is active)

Tube health check with result: OK

Tube health check with result: warning

Tube health check with result: error

For status icon placement on the display see figure at Display [}68], No. 1, 2 or 5.

Measured quantities and identifications

List of measured quantity abbreviations and identification on the display

Tab.1: Regular display

Abbreviation Measured quantity or identification

MFL Mass flow

DNS Density

TMP Temperature

VFL Volume flow

RFD Reference density

RLD Relative density

CVF Corrected volume flow

PRS Pressure

TT1 – TT6 Totalizer 1 – 6

TAG Customer-Device identification

LTG Customer-Device identification, long version

VEL Velocity

CNC Concentration

NM1, NM2 Net mass flow rate 1, 2

Display

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Abbreviation Measured quantity or identification

NV1, NV2 Net volume flow rate 1, 2

NCV Corrected net volume flow rate

DRC Drive current

VSC Viscosity

HT1 24hours totalizer 1

HT2 24hours totalizer 2

HT3 24hours totalizer 3

GVF Gas void fraction

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Default settings

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The following values are only available for the trend display to record data on the microSD card. Additional information about data recording can be found in the applicable software instruction manual.

Only use the microSD card included with the Rotamass Total Insight. Functionality of the device cannot be guaranteed if other cards are used.

Tab.2: Trend display

Abbreviation Measured quantity or identification

MFL Mass flow

DNS Density

TMP Temperature

VFL Volume flow

PRS Pressure

CNC Concentration

NM1 Net mass flow rate 1

NV1 Net volume flow rate 1

PHS Phase shift

FRQ Resonance frequency

DRG Drive gain

DRC Driving current

MBT Transmitter temperature

VSC Viscosity

9.3 Default settings

9.3.1 Setting display language

1. Press [SET] switch for 2 seconds to enter [Operation level].

2. Press [▼] switch 1 time to enter [Operator].

3. Press [SET] switch to enter [Device setup].

4. Press [▼] switch until [Lang] is selected.

5. Press [SET] switch to enter the [Lang] menu.

6. Press [▼] switch repeatedly until the desired language appears.

7. Press [SET] switch to select the desired language.

8. Press [SET] switch to confirm the language selected.

ð Display switches to the next higher menu level.

Default settings

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9.3.2 Setting date

1. Press [SET] switch for 2 seconds to enter [Operation level].

2. Press [▼] switch until the [Maintenance] menu is selected.

3. Press [SET] switch to enter the [Device setup] menu.

4. Press [▼] switch until the [Detailed setup] menu is selected.

5. Press [SET] switch to enter the [Detailed setup] menu.

6. Press [▼] switch until the [Date/Time] menu is selected.

7. Press [SET] switch to enter the [Date/Time] menu.

ð Menu [Date] is preselected.

8. Press [▼] switch until the menu [Set date] is selected.

9. Press [SET] switch to enter the menu [set date].

ð Date on display is flashing.

10. Press [▼]switch until the desired year is displayed.

11. Press [SHIFT] switch to switch to the display of the month.

12. Press [▼] switch until the desired month is displayed.

13. Press [SHIFT] switch to switch to the display of the day.

14. Press [▼]switch until the desired day is displayed.

15. Press [SET] switch to apply the date set.

16. Press [SET]switch to confirm the date set.

ð Display switches to the next higher menu level.

9.3.3 Setting time

1. Press [SET]switch for 2 seconds to enter [Operation level].

2. Press [▼] switch until the [Maintenance] menu is selected.

3. Press [SET] switch to enter [Device setup].

4. Press [▼] switch until the [Detailed setup] menu is selected.

5. Press [SET] switch to enter [Detailed setup].

6. Press [▼] switch until the [Date/Time] menu is selected.

7. Press [SET] switch to enter [Date/Time].

8. Press [▼] switch until the [Set time] menu is selected.

9. Press [SET] switch to enter [Set time].

ð Time on display is flashing.

10. Press [▼] switch until the desired number for the hour is displayed.

11. Press [SHIFT] switch to set the minutes.

12. Repeat the two previous steps for minutes and seconds.

13. Press [SET] switch to apply the time set.

14. Press [SET] switch to confirm the time set.

ð Display switches to the next higher menu level.

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System configuration and operation

Default settings

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9.3.4 Setting zero point

In order to avoid systematic flow rate measurement deviations, performance of a zero point adjustment is recommended before starting measuring operations. For two- or multiphase fluids, the factory-set zero point value is preferable to a manual zero point adjustment.

1. Flush flow meter with fluid and check valves for tightness.

2. Close valves in front of and after the flow meter and stop the flow.

3. Wait until density, temperature and pressure are stabilized.

4. In case of fluids, compare the density displayed on the Rotamass Total Insight with the fluid density in order to rule out gas accumulations in the measuring tube.

5. In applications with increased process pressure, ensure that the process pressure and its unit of measurement are set correctly.

6. Perform autozero.

9.3.5 Performing autozero

To ensure ideal measuring results, performance of a second autozero process is recommended after several days of operation and stabilization of the installation conditions.

1. Press [SET] switch for 2 seconds to enter [Operation level].

2. Press [▼] switch until the [Operator] menu is selected.

3. Press [SET] switch to enter [Device setup].

4. Press [▼] switch until the [Diag/Service] menu is selected.

5. Press [SET] switch to enter [Diag/Service].

6. Press [▼] switch until the [AZ] menu is selected.

7. Press [SET] switch to enter [AZ].

ð Menu [Exe] is preselected.

8. Press [SET] switch to enter [Exe].

ð Parameter [Not exe] appears.

9. Press [▼] switch until [Exe] is selected.

10. Press [SET] switch.

ð Parameter [Exe] flashes.

11. Press [SET] switch to start autozero.

ð Progress bar appears to indicate status of autozero, after completion display

switches to next higher menu level.

Advanced settings

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9.4 Advanced settings

DANGER

Explosion hazard

▶ When the housing is opened in hazardous areas, the applicable Explosion Proof

Type Manual must be observed, see chapter Operation, maintenance and repair.

9.4.1 Setting hardware write-protection

The flow meter can be protected from unauthorized access. If the software write-protection via password is not adequate, an additional hardware write-protection can be set on the main board of the transmitter. With the write-protection active, the transmitter display can still be operated, any changes to settings or parameters are not saved and therefore not effective.

Write-protection can also be activated without removing the display. To do this, remove the jumper from the write-protection terminal (see Connection terminals [}51]).

It is not possible to release the hardware write-protection via HART, Modbus or other communication software.

1. Switch off power supply.

2. Loosen the locking screw by turning it clockwise with an Allen wrench (size: 3.0).

3. Unscrew display cover from transmitter housing.

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Advanced settings

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4. On the main board, set DIP switch 2 to the ON position using a sharp-pointed object.

OFF

1 2

SW1

5. Screw display cover back onto transmitter housing.

6. Tighten the locking screw by turning it counterclockwise with an Allen wrench (size:

3.0).

ð Symbol appears in the top right corner of the display.

Setting the Burnout mode

The flow meter is equipped with a Burnout function. The Burnout mode can be set via DIP SW1-1 behind the display.

Factory setting

The factory setting of the Burnout mode is High.

SW1-1 position Burnout mode Output value if Burnout

in mA

High 21.6

Low 2.4

Advanced settings

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9.4.2 MODBUS hardware setting

Switch settings

1. Switch off power supply.

2. Loosen the locking screw by turning it clockwise with an Allen wrench (size: 3.0).

Fig.55:

3. Unscrew display cover from transmitter housing.

4. Remove 2 screws from the display.

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Advanced settings

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5. Remove the display from housing by slowly pulling forward.

ð The switch can be seen.

6. Set the desired address.

OFF

1 2

H L

SW1

127

Address

1 2

OFF

1 2

SW2SW3

7. Push display into housing.

8. Fasten the display with 2 screws.

9. Screw display cover back onto transmitter housing.

10. Tighten the locking screw by turning it counterclockwise with an Allen wrench (size:

3.0).

Advanced settings

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Default settings

Switches

Address SW 3 SW 2

0 ON OFF

Address switch

SW (ADDRESS: 7)

Device address Position Description

Hardware 1

Address SW” settings between position 0 and 6 are the device address.

Software 0

Parameter value setting is the device address.

Factory setting

SW (ADDRESS: 0-6)

Hardware address can be set from 1 to 127.

e.g.: If only address switch "6" is set to 1, the resulting address is 64.

(1 * 26 + 0 * 25 + 0 * 24 + 0 * 23 + 0 * 22 + 0 * 21 + 0 * 20)

Address has to be set always between 1 and 127. If address switch is set to 0, address is automatically converted to 1.

When hardware switch is active, then address value based on the hardware address is stored in the device.

SW2

Line termination of two ends on the bus are required to communicate Modbus. One termination mode can be selected by SW2, see below table for setting.

Termination mode Configuration

Bus end

Available when both SW2-1 and SW2-2 are “ON” (Resistance is 150 Ω)

Not bus end Available when both SW2-1 and SW2-2 are “OFF”

Both SW2-1 and SW2-2 have to be set at the same position.

SW3

When bus is idle state, it becomes unstable in potential without pull up to D1 and pull down to D0. SW3 can be set, see below table for setting.

Pull up and Pull down mode Configuration of Pull up and Pull down

Used

Available when both SW3-1 and SW3-2 are “ON” (Resistance is 600 Ω)

Not used Available when both SW3-1 and SW3-2 are “OFF”

Both SW3-1 and SW3-2 have to be set at the same position.

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Troubleshooting

Malfunction of operation

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10 Troubleshooting

All error messages and error codes that may appear in operation are described in the software instruction manual. Possible malfunctions that may occur during commissioning are explained below and remedying them is explained. If you cannot remedy the malfunction using these explanations, contact the Yokogawa service center.

10.1 Malfunction of operation

Malfunction Possible causes Remedy

Display on transmitter not functioning

Power supply disconnected

– Ensure that the unit is connected to the

power supply, see [}63]

Settings cannot be made via IR switches

– Check cable connections between

display and main board and connect properly, if necessary.

Settings cannot be made via IR switches

Incorrect settings in write-protect menu item

– Switch off write-protect menu item via

digital communication or hardware switch.

Field communicator is not detected

HART or Modbus DD not installed on field communicator

– Save HART or Modbus DD file on field

communicator.

Field communicator not connected

– Connect field communicator with

Rotamass Total Insight, see software instruction manual.

Zero point unstable

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10.2 Zero point unstable

Malfunction Possible causes Remedy

Zero point unstable

Measuring tube not completely filled with fluid

– Check that the measuring tube in the

sensor is completely filled with fluid. Correct installation, see [}21].

Bubbles or solids in the fluid

– Check pipe and sensor installation,

see [}27].

– Correct installation, see [}21].

No electrical grounding

– Ground transmitter and sensor,

see [}44], and [}63].

– Check correct connection of connecting

cable shield on transmitter.

Flow meter installed in proximity to facilities with strong electromagnetic field

– Ground transmitter and sensor,

see [}44], and [}63].

– Install flow meter as far away as possible

from these electric devices.

Mechanical strain from traction or pressure

– Eliminate cause for mechanical tension.

Terminal board or connection terminals of transmitter or sensor soiled or damp

– Clean terminal board and connection

terminals.

– Clean transmitter and/or sensor.

– Dry transmitter and/or sensor.

– Seal transmitter and/or sensor tightly.

Influence of external vibration

– Install mechanical dampers.

– Increase parameter mass flow damping

(see applicable software instruction manual).

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Display deviating

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10.3 Display deviating

Malfunction Possible causes Remedy

Flow rate displayed deviates from actual flow rate

Zero point set incorrectly

– Set zero point, see [}74]

Highest and lowest value for mass flow set incorrectly

– Match settings of flow meter and reading

system.

– Check LRV and URV process parame-

ters, see software instruction manual.

Measuring tubes not completely filled with fluid

– Correct installation, see [}27]

Bubbles in fluid

– Check pipe and installation, see [}27].

– Correct installation, see [}27]

Connecting cable incorrectly connected for remote type

– Check cable connections and correct, if

necessary, see [}46].

Density displayed deviating from actual density

Density unit, highest and lowest value for density set incorrectly

– Match settings of flow meter and reading

system.

– Check LRV and URV process parame-

ters, see software instruction manual.

Fixed density

– Check whether the Val sel parameter is

set correctly. If a fixed value is selected, ensure that the parameter Fix val is set correctly, see software instruction manual.

– Set parameter Val sel to Meas val,

see software instruction manual.

Analog output trim was performed incorrectly

– Correctly perform trimming, see

applicable software instruction manual.

No electrical grounding

– Ground transmitter and sensor,

see [}44].

– Check correct connection of connecting

cable shield on transmitter.

Bubbles in fluid

– Check pipe and installation, see [}27].

Connecting cable incorrectly connected for remote type

– Check cable connections and correct, if

necessary, see [}46].

Faulty temperature measurement

– Check temperature measurement circuits

TP1 – TP3 of connecting cable.

Corrosion and erosion

– If corrosion or erosion due to corrosive

fluids is suspected, contact Yokogawa and have density and mass flow recalibrated, if necessary.

Contaminated measuring tubes

– Clean measuring tubes.

Display deviating

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Malfunction Possible causes Remedy

Temperature displayed deviating from actual temperature

Temperature unit, highest and lowest value for temperature set incorrectly

– Match settings of flow meter and reading

system.

– Check LRV and URV process parame-

ters, see software instruction manual.

Non-adjustable temperature

– Check whether the Func sel parameter is

set correctly. If a fixed value is selected, ensure that the Fix val is set correctly, see software instruction manual.

– Set parameter Func sel to Inter val.

Analog output trim was performed incorrectly

– Correctly perform trimming (see applica-

ble software instruction manual).

Connecting cable incorrectly connected for remote type

– Check cable connections and correct, if

necessary, see [}46].

Incorrect temperature measurement with remote type

– Check temperature measurement circuit

by measuring resistance between TP1/ TP2 and TP1/TP3. Each value must be between 50 – 200 Ω.

– Check temperature measurement circuit

TP2/TP3 and make sure that resistance is < 10 Ω.

– Connect Pt100 simulator and check

temperature measurement.

Output signal deviating from measured quantity

Incorrect parameter

– Check parameter LRV and URV of the

corresponding output signal, and correct, if necessary.

Incorrect measured quantity

– Check measured quantity output and, if

necessary, correct; check parameter Sel, see software instruction manual.

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Maintenance and repair

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11 Maintenance and repair

Applicable country-specific regulations for opening and repairing electrical devices must be observed.

DANGER

Risk of injury and damage to the flow meter due to ignition after sparking, if there is mechanical impact

▶ Avoid strong mechanical impacts on the flow meter during maintenance work.

WARNING

Risk of injury due to electrical shock, as well as damage to the flow meter, due to insufficiently trained personnel

▶ Only have skilled personnel maintain and repair the flow meter.

WARNING

Risk of injury due to electrical shock, as well as damage to the flow meter

▶ Do not perform maintenance outdoors during rain.

WARNING

Risk of injury from slipping or falling flow meter

▶ Observe notes about the transport of the flow meter in chapter Transport [}19];

these also apply accordingly during maintenance work.

WARNING

Risk of injury due to electrical shock, as well as damage to the flow meter, due to maintenance work in areas at risk of explosion

▶ When maintaining the flow meter in areas at risk of explosion, compliance with the

applicable Explosion Proof Type Manual is mandatory.

WARNING

Risk of injury from electrical shock due to insufficiently closed housing

▶ After completion of the maintenance work, check that the housing covers of the

transmitter have been properly installed.

WARNING

Risk of open/ close the transmitter cover

▶ Please be sure to handle the transmitter cover carefully so that there are no dam-

ages and foreign matter adhesion at its thread and O-ring when it is opened or closed. Keep checking their condition and clean the threads in case of adhering the foreign matter. Replace the cover in case the threads receive damages. Replace the O-ring if there is any scarring or transformation and apply silicone based grease at the O-ring in case of the shortage and exhaustion of grease.

NOTICE

Risk of damage to the flow meter due to electrostatic discharge (ESD)

▶ When performing maintenance work on the flow meter, appropriate ESD protective

measures must be taken.

NOTICE

Be aware that all covers are closed before operating in order to prevent disturbance of other sensitive electrical equipment due to increased electromagnetic emissions.

The need for maintaining the Rotamass Total Insight depends on process and environmental conditions. Maintenance-free operation is possible for many processes. Contact the responsible Yokogawa sales organization for details.

Exterior cleaning

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11.1 Exterior cleaning

WARNING

Risk of injury due to electrical shock, as well as damage to the flow meter, due to unskilled cleaning

▶ For CIP or SIP cleaning, limit the steam temperature to max. 230°C.

▶ Observe the maximum permissible ambient temperature for the transmitter during

cleaning (especially for the integral type).

1. Regularly remove soiling on display glass pane or nameplate by using a soft, dry cloth.

2. Use only cleaning agents that do not corrode the surface of the flow meter.

11.2 Recalibration and calibration service

For recalibration, flow meters should be sent to the manufacturer Rota Yokogawa GmbH in Wehr/Germany. The option of having on-site calibration performed by a Yokogawa technician is available in some countries. For additional information regarding service products and their availability, go to the Yokogawa homepage or contact a local Yokogawa sales partner.

11.3 Impairment of the display

NOTICE

Impairment of the display

If the device is operated for a longer period and is subjected to high temperatures or high humidity in the process, the display may be impaired.

▶ Replace display unit as described in Rotating and replacing the display [}33]

11.4 List of replacement parts

Replacement parts may be reordered using the Customer Maintenance Part List (CMPL), which is available on the included CD/ DVD.

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Dismantling and disposal

Decontamination and return shipment

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12 Dismantling and disposal

12.1 Decontamination and return shipment

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.

Note the following items before returning the shipment:

▶ Clean flow meter thoroughly. No harmful chemicals must remain in or on the flow me-

ter. Rota Yokogawa only accepts completely drained and cleaned flow meters.

▶ The form "Decontamination Declaration" must be filled in completely and sent to

Yokogawa along with the flow meter.

▶ Package flow meter in a shockproof manner for transport. Use original packaging, if

possible.

12.2 Disposal

Prior to disposal of the flow meter, please take note of the following:

▶ Comply with the applicable national regulations in the event of disposal or recycling.

▶ Do not dismantle flow meter until all fluid residues have been removed and dispose

the parts individually.

ROTA YOKOGAWA GmbH & Co. KG Service & Repair Department Rheinstraße 8; D - 79664 Wehr Phone no.: +49 (0)7761-567-190 Fax no.: +49 (0)7761-567-285 e-Mail: services.flow@de.yokogawa.com

Declaration of Decontamination

Legal regulations for the safety of our employees and operating equipment determine that we need the declaration of decontamination before your order can be handled.

Please make sure to include it with the shipping documents, attached to the outside of the packaging you use for shipment.

Customer data

Company:

Address:

Contact person: E-Mail:

Phone no.: Fax no.:

Reference/Order no.:

Instrument data

Type:

Serial no.:

Type: Serial no.:

*If not enough, note on separate sheet

Process data

Process fluid:

Fluid is:

[ ] toxic [ ] corrosive [ ] explosive [ ] biological hazardous [ ] unknown if dangerous [ ] non hazardous

Remarks:

Cleaning agent:

Kind of cleaning :

Other remarks / Reason of retur

We hereby confirm that this statement is filled in completely and truthfully. The returned instruments were carefully cleaned and are thus free from product residue and dirt. I agree that if this arrangement does not match with the instruments, they will be sent back to the above mentioned customer address at our expenses.

Name Date Signature

General Instruction Manual

Specifications

Ambient conditions

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13 Specifications

Specifications for sensor and transmitter are listed in the General Specifications of the corresponding product family.

13.1 Ambient conditions

Rotamass Total Insight can be used at demanding ambient conditions.

In doing so, the following specifications must be taken into account:

As ambient temperature is intend the air surrounding the device.

Allowed ambient and storage temperature of Rotamass Total Insight depends on the below components and their own temperature limits:

▪ Sensor ▪ Transmitter ▪ Connecting cable between sensor and transmitter (for remote design type)

Ambient temperature

Maximum ambient temperature range

integral type: -40–60 °C (-40–140 °F)

remote type

with standard cable (option L␣␣␣):

Sensor2): -50–80 °C (-58–176 °F)

Transmitter: -40–60 °C (-40–140 °F)

with fire retardant cable

(option Y␣␣␣):

Sensor2): -35–80 °C (-31–176 °F)

Transmitter: -35–60 °C (-31–140 °F)

If the device is operating outdoors make sure that the solar irradiation does not increase the surface temperature of the transmitter higher than the allowed maximum ambient temperature. Transmitter display has limited legibility below -20 °C (-4°F)

Check derating for high fluid temperature, see Process fluid temperature range, Process conditions and Allowed ambient temperatures for sensor.

Lower temperature specification valid for fixed installation only

Storage temperature

Maximum storage temperature range

integral type -40–60 °C (-40–140 °F)

remote type

with standard cable (option L␣␣␣):

Sensor: -50–80 °C (-58–176 °F)

Transmitter: -40–60 °C (-40–140 °F)

with fire retardant cable (option Y␣␣␣):

Sensor: -35–80 °C (-31–176 °F)

Transmitter: -35–60 °C (-31–140 °F)

Further ambient conditions

Ranges and specifications

Relative humidity 0–95 %

IP code

IP66/67 for transmitters and sensors when using the appropriate cable glands

Allowable pollution degree in surrounding area acc. EN61010-1

4 (in operation)

Vibration resistance acc. IEC 60068-2-6

Transmitter: 10 – 500 Hz, 1g

Sensor: 25– 100 Hz, 4g

Ambient conditions

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Ranges and specifications

Electromagnetic compatibility (EMC)

▪ IEC/EN 61326-1, Table 2 ▪ IEC/EN 61326-2-3 ▪ NAMUR NE 21 recommendation ▪ DNVGL-CG-0339, chapter 14

This includes

▪ Surge immunity acc.:

– EN 61000-4-5 for lightning

protection

▪ Emission acc.:

– IEC/EN 61000-3-2, Class A

– IEC/EN 61000-3-3, Class A

– NAMUR NE 21 recommendation

– DNVGL-CG-0339, chapter 14

Immunity assessment criterion: The output signal fluctuation is within ±1% of the output span.

Maximum altitude

2000m (6600ft) above mean sea level (MSL)

Overvoltage category acc. IEC/EN61010-1 II

YOKOGAWA ELECTRIC CORPORATION

YOKOGAWA CORPORATION OF AMERICA

YOKOGAWA AMERICA DO SUL LTDA.

YOKOGAWA EUROPE B. V.

Euroweg 2, 3825 HD Amersfoort, THE NETHERLANDS Phone : 31-88-4641000 Fax : 31-88-4641111

YOKOGAWA INDIA LTD.

Plot No.96, Electronic City Complex, Hosur Road, Bangalore - 560 100, INDIA Phone : 91-80-4158-6000 Fax : 91-80-2852-1442

YOKOGAWA AUSTRALIA PTY. LTD.

Tower A, 112-118 Talavera Road, Macquarie Park NSW 2113, AUSTRALIA Phone : 61-2-8870-1100 Fax : 61-2-8870-1111

YOKOGAWA MIDDLE EAST & AFRICA B.S.C.(C)

P.O. Box 10070, Manama, Building 577, Road 2516, Busaiteen 225, Muharraq, Kingdom of BAHRAIN Phone : 973-17358100 Fax : 973-17336100

Headquarters

2-9-32, Nakacho, Musashino-shi, Tokyo, 180-8750 JAPAN Phone : 81-422-52-5555

Branch Sales Offices

Osaka, Nagoya, Hiroshima, Kurashiki, Fukuoka, Kitakyusyu

Head Office

12530 West Airport Blvd, Sugar Land, Texas 77478, USA Phone : 1-281-340-3800 Fax : 1-281-340-3838

Georgia Office

2 Dart Road, Newnan, Georgia 30265, USA Phone : 1-800-888-6400/ 1-770-253-7000 Fax : 1-770-254-0928

Praca Acapulco, 31 - Santo Amaro, Sáo Paulo/SP, BRAZIL, CEP-04675-190 Phone : 55-11-5681-2400 Fax : 55-11-5681-4434

YOKOGAWA ELECTRIC CIS LTD.

Grokholskiy per 13 Building 2, 4th Floor 129090, Moscow, RUSSIA Phone : 7-495-737-7868 Fax : 7-495-737-7869

YOKOGAWA CHINA CO., LTD.

3F Tower D Cartelo Crocodile Building, No.568 West Tianshan Road, Shanghai 200335, CHINA Phone : 86-21-62396262 Fax : 86-21-62387866Z

YOKOGAWA ELECTRIC KOREA CO., LTD.

(Yokogawa B/D, Yangpyeong-dong 4-Ga), 21, Seonyu-ro 45-gil, Yeongdeungpo-gu,

Seoul, 150-866, KOREA Phone : 82-2-2628-6000 Fax : 82-2-2628-6400

YOKOGAWA ENGINEERING ASIA PTE. LTD.

5 Bedok South Road, Singapore 469270, SINGAPORE Phone : 65-6241-9933 Fax : 65-6241-2606

ISO 9001

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YOKOGAWA Rotamass Intense, Rotamass series, Rotamass Hygienic, Rotamass Supreme, Rotamass Giga General Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual