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Operating Instructions

OIO 23en  Edition 10/2017 

37

Possible faults

Troubleshooting

Troubleshooting

Faults can have different causes. The following tables list the symptoms of a fault, the possible causes 
and measures for troubleshooting.

Possible faults

Troubleshooting

Fault

Cause/Remedy

□

Flowmeter leaks

1, 2, 6

□

No flow rate

3, 7, 8, 20, 22, 23

□

Flowmeter does not generate a pulse

3, 4, 5, 6, 8, 11, 18, 20, 22, 23

□

Pressure loss too high

9, 12, 20, 21

□

Measured values not realistic

3, 4, 5, 7, 10, 13, 14, 15, 16, 17, 18, 19, 20, 21

No.

Cause

Remedy

1

Seal preload too low

► Preload the screws.

2

Seal damaged

► Replace the seal.
► Check the chemical resistance of the seal.

3

Foreign bodies in the liquid and/or 
flowmeter

► Dismantle the flowmeter and clean it.
► Use the commissioning filter.

4

Pick up not connected correctly

► Check the supply voltage for the pick up, while 

observing the pick up operating instructions.

5

Pick up defective

► Check the function of the pick up, while observing 

the pick up operating instructions.

6

Dry sleeve destroyed

► Replace the dry sleeve, contact the manufacturer for 

information.

7

Liquid lubricates too little

► Use the OMK series.

8

Feed pressure too low

► Increase the feed pressure.

9

Viscosity of the liquid too high

► Increase the temperature, while observing the 

permissible temperature range.

10

Viscosity of the liquid too low

► Use the OMK series.

11

Flow rate too low

► Increase the flow rate.

- or -
► Use a suitable flowmeter size.
- or -
► Use linearization, while observing the 

electronic operating instructions.

12

Flow rate too high

► Reduce the flow rate.

- or -
► Use a suitable flowmeter size.

13

Airlocks

► Deaerate the system and check for leaks.

14

Outgassing

► Increase the system pressure.
► Reduce the temperature.

15

Pulsations too high

► Use another feed pump.
► Carry out changes to the system.

16

Back pressure too low

► Increase the back pressure.

Summary of Contents for OMP 13

Page 1: ...www kral at Operating Instructions KRAL Flowmeter OMP Series OIO 23en Edition 10 2017 Original instructions ...

Page 2: ... instructions for installation and removal 22 Installing the flowmeter 22 Installation types 22 Preferred installation variant 23 Recommendations for alternative installation variants 23 Protect the flowmeter against soiling 24 Connecting the flowmeter to the pipe system 24 Electrical installation 25 Safety instructions for electrical installation 25 Connection for the pick ups 25 Removing the flo...

Page 3: ...s available at the system site for future reference Ensure that employees read and observe these instructions and the associated documents in particular the safety instructions and warnings Observe additional system specific directives and regulations Specialist personnel fitters Read observe and follow these instructions and the associated documents in particular the safety instructions and warni...

Page 4: ... Potentially dangerous situation Slight personal injury Caution Potentially dangerous situation Material damage Calibration certificate Declaration of conformity according to EU Directive 2006 42 EC Declaration of conformity according to EU Directive 2014 34 EU ATEX supplementary instructions for operation in potentially explosive areas Manufacturer s declaration according to EU Directive 2014 68 ...

Page 5: ...ructions Read the operating instructions carefully and observe them The operator owner is responsible for the observance of the operating instructions Installation removal and installation work may only be carried out by specialist personnel Flowmeters wear to different degrees depending on the respective operating conditions pulsations temperature Do not continue to use flowmeters that are operat...

Page 6: ...ogy A Without flow direction detection B With flow direction detection C Without flow direction detection with temperature compensation D With flow direction detection with temperature compensation X Special design 5 Material of bearing B Hybrid 6 Material of seal A FPM FKM B FFPM C Low temperature FPM D EPDM X Special design 7 Mechanical connection A Pipe thread connection BSPP B Flange connectio...

Page 7: ...IO 23en Edition 10 2017 7 Rating plate Identification Rating plate 1 Serial number 2 Year of construction 3 K factor 4 Preferred flow direction 5 Maximum temperature 6 Type 7 Maximum pressure Fig 2 Rating plate R 1 2 3 4 5 6 7 ...

Page 8: ... In addition the operational limits of the corresponding completion of the sealing material and of the pick up are to be observed Tab 1 Maximum values Strong pressure pulses in the system can reduce the lifetime of the flowmeter Fig 1 Pressure pulses Unit OMP 13 OMP 20 OMP 32 OMP 52 Flow rate Qmax l min 15 45 150 525 Qnom 10 30 100 350 Qmin 0 1 0 3 1 0 3 5 Max pressure bar 40 Temperature min max C...

Page 9: ... not installed at the factory The customer can optionally fit OMP series KRAL flowmeters with a trace heating system The manufacturer recommends heating systems for high viscosity liquids that do not flow sufficiently if not heated because bearing damage and destruction of the device may otherwise result Trace heating system Contact the manufacturer before installing a trace heating system Unit OM...

Page 10: ...e pick up temperature sensor junction box and corresponding cables above the temperature specified in the associated operating instructions G M16x1 M18x1 G1 4 D L1 L2 L3 L4 T Pipe thread Pick up hole Mounting connection element Temperature sensor hole Outer diameter Total length Flowmeter length without connections Flange thickness Max screw in depth Fig 3 Dimensional drawing OMP with pipe thread ...

Page 11: ... sensor hole Outer diameter Total length Flowmeter length without connections Flange thickness Pitch circle Fig 4 Dimensional drawing OMP with DIN flange Unit OMP 13 OMP 20 OMP 32 OMP 32 OMP 52 DN 15 20 25 32 40 Pressure stage bar 40 40 40 40 40 D mm 95 105 115 140 150 L1 mm 115 125 180 190 240 L2 mm 64 85 0 140 0 140 0 185 5 L3 mm 25 5 20 20 25 32 L4 mm 25 5 20 0 20 0 25 0 22 5 TK mm 65 75 85 100...

Page 12: ...ing connection element Temperature sensor hole Outer diameter Total length Flowmeter length without connections Flange thickness Pitch circle Fig 5 Dimensional drawing OMP with ANSI flange Unit OMP 20 OMP 32 OMP 52 DN inch 3 4 1 1 1 2 Class 300 300 300 D mm 117 5 123 8 155 6 L1 mm 134 195 245 L2 mm 85 0 140 0 185 5 L3 mm 24 5 27 5 32 0 L4 mm 24 5 27 5 27 5 TK mm 82 5 88 9 114 3 Weight kg 6 0 12 5 ...

Page 13: ...ole Mounting connection element Temperature sensor hole Outer diameter Total length Flowmeter length without connections Flange thickness Pitch circle Fig 6 Dimensional drawing OMP with JIS flange Unit OMP 20 OMP 32 OMP 52 DN 20 25 40 Pressure stage 16K 16K 16K D mm 100 125 140 L1 mm 125 190 260 L2 mm 85 140 215 L3 mm 20 0 25 0 22 5 L4 mm 20 0 25 0 22 5 TK mm 75 90 105 Weight kg 4 5 12 2 19 0 DN G...

Page 14: ...s reduce the durability A Short time operation B Continuous operation C Pressure loss D Flow rate E Qnom 20 18 16 14 12 2 4 6 8 10 0 A B 1000 h 30000 h 10000 h 5000 h 100000 5 10 50 200 500 1000 2000 5000 10000 50000 100 mm2 s C bar bar C 2 3 0 1 100000 5000 10000 50000 5 10 50 200 500 1000 2000 100 mm2 s 2 3 4 10 9 8 7 6 5 0 1 1 15 14 13 12 11 E D l min 100 50 150 D l min 50 45 40 30 25 20 15 10 ...

Page 15: ...ability A Short time operation B Continuous operation C Pressure loss D Flow rate E Qnom 20 18 16 14 12 2 4 6 8 10 0 A B 1000 h 30000 h 10000 h 5000 h 100000 5 10 50 200 500 1000 2000 5000 10000 50000 100 mm2 s C bar bar C 2 3 0 1 100000 5000 10000 50000 5 10 50 200 500 1000 2000 100 mm2 s 6 9 12 30 27 24 21 18 15 0 3 3 45 42 39 36 33 E D l min 100 50 150 D l min 50 45 40 30 25 20 15 10 5 1 35 10 ...

Page 16: ...ability A Short time operation B Continuous operation C Pressure loss D Flow rate E Qnom 20 18 16 14 12 2 4 6 8 10 0 A B 1000 h 30000 h 10000 h 5000 h 100000 5 10 50 200 500 1000 2000 5000 10000 50000 100 mm2 s C bar bar C 2 3 0 1 100000 5000 10000 50000 5 10 50 200 500 1000 2000 100 mm2 s 20 30 40 100 90 80 70 60 50 1 10 150 140 130 120 110 E D l min 100 50 150 D l min 50 45 40 30 25 20 15 10 5 1...

Page 17: ...rt time operation B Continuous operation C Pressure loss D Flow rate E Qnom 20 18 16 14 12 2 4 6 8 10 0 A B 1000 h 30000 h 10000 h 5000 h 100000 5 10 50 200 500 1000 2000 5000 10000 50000 100 mm2 s C bar bar C 2 3 0 1 100000 5000 10000 50000 5 10 50 200 500 1000 2000 100 mm2 s 70 105 140 350 315 280 245 210 175 3 5 35 525 490 455 420 385 E D l min 100 50 150 D l min 50 45 40 30 25 20 15 10 5 1 35 ...

Page 18: ...hing sections in its supply and discharge Depending on the customer requirements the flowmeters can be equipped with suitable end connections for connection to various flanges Rolling bearings The measuring unit is maintained without contact and with a low degree of friction in the housing of the flowmeter by means of precision rolling bearings Depending on the respective size the following bearin...

Page 19: ...for the flow rate being measured is then determined by means of linear interpolation between the two nearest interpolation values The viscosity dependence of the K factors must also be taken into account These are determined during calibration at a viscosity of approximately 4 2 mm s The influence of the flow rate on the K factor decreases at higher viscosities so that the mean K factor can then a...

Page 20: ...nally packed in hermetically sealing anti corrosion paper Observe the chapters Storage and Preservation Preservation Preservation has to be carried out additionally under the following conditions Tab 1 Check table for preservation Preserving the flowmeter 1 Close a connection of the flowmeter with a blind flange 2 Position the flowmeter vertically 3 Fill non corrosive and resin free oil up to appr...

Page 21: ... oil or Rinse the flowmeter with pumped liquid Disposal Aids Solvents or industrial cleaners suitable for the pumped liquid 1 Disassemble the flowmeter 2 Clean residues of the pumped liquid from the individual parts 3 Separate sealing elements made of elastomer from the flowmeter and dispose of them in the residual waste 4 Recycle cast iron and steel parts WARNING Risk of injury through emitted pr...

Page 22: ...lation Put the protective caps on the dry sleeves during removal During installation only remove the screw plugs in order to insert the temperature sensor Screw in the screw plugs again after the temperature sensor has been removed If installing a trace heating system pick up temperature sensor junction box and corresponding cables have to be free of heat insulation see Trace heating system page 9...

Page 23: ...e by routing the piping upwards No vertical installation with open outlet Measuring error through free flowing of the liquid out of the flowmeter Horizontal flow Ensure that the liquid does not flow freely out of the flowmeter for example by routing the piping upwards No horizontal installation at the highest point in the pipe system Avoid measuring error through formation of an air pocket in the ...

Page 24: ...allation of the flowmeter at the highest point of the pipe system an air pocket can arise that results in measuring errors Vent the pipe system thoroughly before commissioning At a vertical installation of the flowmeter and the flow direction from top to bottom ensure that the liquid does not flow freely out of the flowmeter for example by routing the pipe upwards or by reducing the pipe diameter ...

Page 25: ...depends on the preferred direction of flow in accordance with the arrow on the rating plate see Fig 2 page 7 In the case of a direction of flow contrary to the preferred direction of flow the connections have to be swapped in order to obtain a correct signal Observe the corresponding operating instructions for pick ups Removing the flowmeter Prerequisite System switched off Aids Vessel to collect ...

Page 26: ...the bypass 3 Dismantle the flowmeter 4 Apply the protective cover 5 Observe the chapters Storage and Preservation on the subject of storing the flowmeter WARNING Risk of injury through emitted hot poisonous or corrosive pumped liquid when removing the flowmeter Observe the safety regulations for handling dangerous liquids Ensure that the flowmeter is not under pressure Collect the emitted pumped l...

Page 27: ...ata page 8 Flowmeter correctly installed into the pipe system see Installing the flowmeter page 22 Flowmeter connection to the pipe system is free of mechanical stress Pipe system is free of contamination Pipe system vented Shut off devices in the supply and discharge lines opened CAUTION Damage to equipment through usage of an incorrect rinsing liquid Under no circumstances may water or superheat...

Page 28: ...t any time CAUTION Measuring error through gas inclusion in the pipe system Before commissioning make sure that the flowmeter is filled Vent the pipe system CAUTION Increased wear and or blocking of the flowmeter due to solid particles or abrasive fine particles in the liquid Protect the flowmeter by a correspondingly dimensioned operating filter in the pipe system Pay attention to the following w...

Page 29: ...n of the flowmeter the manufacturer recommends carrying out the first re calibration after about one year of operation The results reveal any wear starting on the measuring unit The interval at which recalibration is actually required depends strongly on the operating conditions of the device The manufacturer provides the factory calibration as standard If higher requirements are placed on the mea...

Page 30: ...sleeve 115 1 Flange 115 2 Flange 128 Measuring housing 672 1 Measuring screw large 672 1 Measuring screw small 739 1 O ring 739 2 O ring 817 1 Deep groove ball bearing 817 2 Deep groove ball bearing 817 3 Deep groove ball bearing 817 4 Deep groove ball bearing 915 5 Socket screw 915 5 115 1 128 115 2 115 1 739 1 128 039 128 817 3 817 4 672 2 817 1 672 1 817 2 039 ...

Page 31: ...device Installing seals and bearings Prerequisites Replacement parts available 1 Place the O rings 739 1 and 739 2 onto both sides of the measuring housing 128 2 Press the ball bearings 817 1 and 817 2 onto the measuring screw large 672 1 and the ball bearings 817 3 and 817 4 onto the measuring screw small 672 2 Notice Press the ball bearings on only over the inner ring 3 Place the flange 115 2 on...

Page 32: ...uring screw large 672 1 Measuring screw small 739 1 O ring 739 2 O ring 817 1 Deep groove ball bearing 817 2 Deep groove ball bearing 817 3 Deep groove ball bearing 817 4 Deep groove ball bearing 869 2 Circlip 869 4 Circlip 904 1 Wedge lock washer 904 2 Wedge lock washer 915 1 Socket screw 915 2 Socket screw 915 6 Socket screw 915 7 Socket screw 915 1 115 1 128 115 2 915 2 739 2 115 1 739 1 039 12...

Page 33: ... 817 1 and 817 2 onto the measuring screw large 672 1 and the ball bearings 817 3 and 817 4 onto the measuring screw small 672 2 Notice Press the ball bearings on only over the inner ring 3 Pull the wedge lock washers 904 1 and 904 2 and support rings 064 1 and 064 2 onto the sockets screws 915 6 and 915 7 Overview see Fig 10 page 32 Notice Ensure that the wedge lock washers are positioned correct...

Page 34: ...s OMP 52 Fig 12 Fig 13 Fig 14 Fig 15 Fig 16 Fig 17 115 1 115 2 915 1 915 2 739 1 739 2 080 1 915 3 739 3 128 739 4 080 2 915 4 739 3 080 1 128 915 6 904 1 064 1 915 7 904 2 064 2 080 1 057 2 057 1 080 1 904 2 915 7 064 2 818 2 868 4 817 2 057 2 672 2 869 4 672 1 817 1 868 2 869 2 904 1 064 1 915 6 818 1 057 1 054 ...

Page 35: ... using an extractor 6 Screw out the threaded rings 057 1 and 057 2 of the bearing cover see Fig 16 page 34 For allen key widths see Tab 2 page 36 7 Take the spacer 054 out and pull the bearings 818 1 and 818 2 out of the bearing cover using an extractor 8 Remove the O ring 739 3 9 Remove the circlips 869 2 and 869 4 and support rings 868 2 and 868 4 from the measuring screws see Fig 17 page 34 10 ...

Page 36: ...er 904 2 and supporting ring 064 2 onto the socket screw 915 7 Notice Ensure that the wedge lock washers are positioned correctly wedge surface to wedge surface see Fig 18 page 35 8 Mount the socket screw 915 7 with Loctite 242 applied with mounted washer and ring onto the measuring screw small 672 2 and tighten with torque see Tab 6 page 47 9 Pull the wedge lock washer 904 1 and supporting ring 0...

Page 37: ...age for the pick up while observing the pick up operating instructions 5 Pick up defective Check the function of the pick up while observing the pick up operating instructions 6 Dry sleeve destroyed Replace the dry sleeve contact the manufacturer for information 7 Liquid lubricates too little Use the OMK series 8 Feed pressure too low Increase the feed pressure 9 Viscosity of the liquid too high I...

Page 38: ...r type 19 Strongly deviating operating data Use a suitable flowmeter type Adapt the operating data to the flowmeter 20 Wear at the measuring unit and bearing Renew the measuring unit Replace the bearing Filter out the abrasive materials 21 Sluggishness through deposits Disassemble the flowmeter and clean it carefully 22 Flow impaired at the system end Check whether the fluid flows in the system pu...

Page 39: ...parts and are only supplied complete Tab 1 Maintenance kit OMP 13 Fig 1 Maintenance kit OMP 13 Qty Item No Part Qty Item No Part 1 739 1 O ring 1 817 2 Deep groove ball bearing 1 739 2 O ring 1 817 3 Deep groove ball bearing 2 739 5 O ring 1 817 4 Deep groove ball bearing 1 817 1 Deep groove ball bearing 739 2 739 1 869 4 817 4 817 2 869 2 817 3 817 1 739 5 597 1 ...

Page 40: ...re Qty Item No Part Qty Item No Part 1 597 1 Screw plup 1 817 2 Deep groove ball bearing 1 739 1 O ring 1 817 3 Deep groove ball bearing 1 739 2 O ring 1 817 4 Deep groove ball bearing 2 739 5 O ring 1 869 2 Circlip 1 817 1 Deep groove ball bearing 1 869 4 Circlip 739 2 739 1 869 4 817 4 817 2 869 2 817 3 817 1 739 5 597 1 739 2 739 1 869 4 817 4 817 2 869 2 817 3 817 1 739 5 597 1 ...

Page 41: ...017 41 Spare parts Appendix Fig 4 Maintenance kit OMP 52 Fig 5 Maintenance kit OMP 52 high temperature 739 1 739 2 739 3 739 4 817 1 869 2 869 4 817 2 818 2 818 1 739 5 597 1 739 1 739 2 739 3 739 4 817 1 869 2 869 4 817 2 818 2 818 1 739 5 597 1 ...

Page 42: ...bearings 1 739 3 O ring 1 869 2 Circlip 1 739 4 O ring 1 869 4 Circlip 2 739 5 O ring 1 870 1 Circlip 1 817 1 Deep groove ball bearing 1 870 2 Circlip Fig 6 Junction box Fig 7 Connection circuit diagram junction box Fig 8 OMP 32 with installed junction box standard Fig 9 OMP 32 with installed junction box high temperature 1 Output 2 Sensor inputs 2 1 BEG 1 BEG 2 EET BEM 1 0 V Q 1 24 V Q 2 9 8 Com ...

Page 43: ... junction boxes are offered in two variants Tab 4 Junction box variants Tab 5 Junction box usage and electrical specification Unit Junction box standard Junction box high temperature Article no UZA 56 UZA 57 UZA 59 UZA 60 UZA 83 UZA 84 UZA103 UZA104 UZA 92 Housing material Aluminium Steel Aluminium Connection thread M6 M6 Fastening type With base plate With fastening angle Used pick up BEG 56A BEG...

Page 44: ...ut the hexagon 3 of the pick ups 4 Place the washers 4 of the junction box over the pick up inserts 5 5 Slide the base plate 6 of the junction box under the washers 4 screw the hexagon 3 back in 6 Plug the connectors 2 of the pick ups back in Mounting the junction box on OMP 13 52 1 Cable pick up and temperature sensor 2 Connector pick up 3 Hexagon pick up 4 Washer junction box 5 Pick up inserts 6...

Page 45: ...r 3 3 Slide the amplifier 3 in the cut out of the fastening angle 1 Ensure that the hexagon nuts lie above and below the fastening angle 4 Tighten the hexagon nuts Connecting the junction box Mounting the junction box for OMP 13 52 high temperature 1 Fastening angle 2 Hexagon nut amplifier 3 Amplifier 4 Cable temperature sensor and pick up 5 Pick up insert Fig 11 Example OMP 32 1 Junction box lid ...

Page 46: ...nection cable of the junction box beyond a maximum length of 100 m Extension cable as well as cable plug and cable box are available as accessories from the manufacturer 1 Solder cable plug to the sensor cable 2 Solder cable box to the extension cable 3 Connect sensor cable and extension cable 4 Connect extension cable in accordance with the connection circuit diagram Extension cable Unit Length m...

Page 47: ...70 Property class 80 Thread Galvanized stainless steel M 3 0 6 1 5 1 2 1 5 1 1 G 1 8 13 M 4 1 4 2 9 4 1 2 3 3 2 G 1 4 30 M 5 2 7 6 0 8 0 4 8 6 0 3 9 3 5 4 7 G 3 8 60 M 6 4 7 9 5 14 7 6 10 3 6 9 6 8 G 1 2 80 M 8 11 3 23 1 34 18 4 25 17 16 22 G 3 4 120 M 10 23 46 68 36 8 47 33 32 43 G 1 200 M 12 39 80 117 64 84 56 56 75 G 1 1 4 400 M 14 62 127 186 101 133 89 G 1 1 2 450 M 16 96 194 285 155 204 136 1...

Page 48: ... Bildgasse 40 Industrie Nord 6890 Lustenau Austria Tel 43 55 77 8 66 44 0 Fax 43 55 77 8 84 33 www kral at E Mail kral kral at www kral at KRAL AG 6890 Lustenau Austria Tel 43 5577 86644 0 E Mail kral kral at ...

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