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Spirax Sarco ELM Installation, Operating And Maintenance Instructions Download Page 1

IM-P309-02 

 MI Issue 2

1

IM-P309-02

 

MI Issue 2

3090050/1

© Copyright 2014

Printed in GB

ELM

ElectroMagnetic Inductive Flowmeter

Installation, Operating and Maintenance Instructions

1. Introduction

2.  Safety information

3.  General product information
4.  Steps prior to operation
5. Applications
6.  Operational mode

 

and system design

7.  Performance characteristics 

and environmental conditions

8.  Installation / conditions for use
9.  Maintenance and repair
10. Dimensions and weight
11. Commissioning
12. System design

13. Configuration and operation

14. Operating modes

15. ELM functions

16. Standard operating mode
17. Standards & Directives
18. Maintenance

19. Decontamination certificate 

 

for device cleaning

Summary of Contents for ELM

Page 1: ...on 4 Steps prior to operation 5 Applications 6 Operational mode and system design 7 Performance characteristics and environmental conditions 8 Installation conditions for use 9 Maintenance and repair 10 Dimensions and weight 11 Commissioning 12 System design 13 Configuration and operation 14 Operating modes 15 ELM functions 16 Standard operating mode 17 Standards Directives 18 Maintenance 19 Decon...

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Page 3: ...ith the operating instructions General installation and safety instructions for pipeline and plant construction as well as the proper use of tools and safety equipment must also be complied with Supplier Spirax Sarco Limited Charlton House Charlton Kings Cheltenham Glos GL53 8ER The product is designed and constructed to withstand the forces encountered during normal use Use of the product for any...

Page 4: ...d herein and are to read and understand the contents of the present operating instructions before working with the device 2 1 Hazard warnings The purpose of the hazard warnings listed below is to ensure that device operators and maintenance personnel are not injured and that the flowmeter and any devices connected to it are not damaged The safety advisories and hazard warnings in the present docum...

Page 5: ...ion measures removal operations and the like that are attributable to inadequate cleaning of the device Any device sent in for servicing is to be accompanied by a certificate as specified in Section 18 The device is to be accompanied by a document describing the problem with the device Please include in this document the name of a contact person that our technical service department can get in tou...

Page 6: ...at the product is suitable for the intended use application The product listed complies with the requirements of the European Pressure Equipment Directive 97 23 EC carries the mark when so required The product falls within the following Pressure Equipment Directive categories Product Group 1 Gases Group 2 Gases Group 1 Liquids Group 2 Liquids ELM DN50 2 ELM DN150 DN200 2 i The ELM flow meter range...

Page 7: ...t is sent elsewhere to be installed the original packaging and transport protection inserts should be used 2 10 Returning the device for repair and servicing Note According to German waste disposal legislation it is the owner s or customer s responsibility to dispose of hazardous waste Thus any devices sent tous for servicing including their crevices and cavities must be devoid of any such materia...

Page 8: ...parts such as pipe lining material of electrodes and seal T m Medium temperature range T amb Ambient temperature range C Sensor constant Degrees of protection Degrees of protection in accordance with DIN EN 60529 2000 3 1 Manufacturer Manufactured for Spirax Sarco by Heinrichs Messtechnik GmbH Robert Perthel Str 9 D 50739 Köln Telephone 49 221 49708 0 Fax 49 221 49708 178 Internet http www heinric...

Page 9: ...to the applicability of the present document for any purpose other than that described We plan to optimize and improve the products described and in so doing will incorporate not only our own ideas but also and in particular any suggestions for improvement made by our customers We reserve the right to change the technical data in this manual in the light of any technical progress that might be mad...

Page 10: ...y v and a flow rate Q flowing through a tube 1 with an insulating lining 2 produces a measuring circuit voltage Um at the two electrodes 4 at right angles to the direction of flow and the magnetic field B generated by the field coils 3 The strength of this measuring circuit voltage is proportional to the mean flow velocity and therefore the volume flow rate 6 2 System design The electromagnetic EL...

Page 11: ...et section of 5 x DN 7 2 Fluid conductivity 5 µS cm 20 µS cm for demineralized water 7 3 Influence of ambient temperature 20 C to 60 C 7 4 Ambient temperature 20 Celsius to 60 Celsius 4 F to 140 F below 0degC the readability of the LC display will be limited 7 1 Measuring accuracy 7 1 1 Measured error 0 3 of actual value 0 0001 Q at 10 m s 7 Performance characteristics and environmental conditions...

Page 12: ... water or product might seep through the wire sheath into the terminal compartment in the housing Warning Electromagnetic compatibility is only achieved if the electronics housing is closed Leaving the enclosure open can lead to electromagnetic disturbances 7 5 Ambient temperature range 20 Celsius to 60 Celsius 4 F to 140 F In the case of an outdoor installation the device must be protected agains...

Page 13: ...mit The data sheet rating plate of the connected transmitter must be observed 7 8 6 Pressure loss The data sheet rating plate of the connected transmitter must be observed 7 8 7 Empty pipe detection Transmitters which are equipped with a control unit BE3 have an on and off switch able empty pipe detection The operating reliability depends on the conductivity of the liquid medium and the cleanlines...

Page 14: ...und both process connections Do not use chains as these can damage the surface coating and the housing When transporting devices without lugs and when looping the slings around the flow tube the center of gravity of the entire device can be higher than both attachment points of the slings When transporting the device ensure that it does not rotate or slip accidentally This could cause injury Senso...

Page 15: ...he sensor with an arrow When mounting sensors always observe the specified screw torques The electrical system can be taken into operation when the sensor and the cables have been installed and connected In order to prevent measuring errors caused by gas pockets in the fluid and damage lining of the sensor caused by negative pressure the following points must be observed 8 2 1 Long pipe systems As...

Page 16: ...3 2 Horizontal and vertical installation The flowmeter can be installed wherever required whereby the intended x y electrode axis should run almost horizontal A vertical Electrode axis should be avoided as otherwise the accuracy could be affected by the gas pockets or the solid particles in the fluid Incorrect installation for horizontal pipe system Correct installation system 8 3 Installation Scr...

Page 17: ...ters long In case of fall pipes that are more than five meters long arrange for a syphon or a venting valve in order to avoid a negative pressure in the pipe and damage to the lining In addition this measure prevents the flow from stopping so that air pockets can be avoided Highest point in pipe system Air bubbles will accumulate in the tube Incorrect measurement Caution There is the danger of acc...

Page 18: ...entical to the potential of the fluid The grounding cable should not transmit any interference voltage For this reason do not ground other electrical devices with this cable at the same time The measuring signal tapped at the electrodes is only a few millivolts Correct grounding of the electromagnetic flowmeter is therefore an important prerequisite for exact measurement The transmitter requires a...

Page 19: ...ssue 2 19 8 3 3 1 Grounding the ELM flowmeter Earth bonding Uninsulated metal pipes only not required for plastic pipe installations Ground Wire Min 4mm2 Cu Protective Earth Seal Pipe Flanges Seal Pipe Pipe ELM Fig 13 ...

Page 20: ...required torque should be reached and for the second time the torque should be 80 The required torque should reach 100 when the nuts are tightened for the third time For higher torques it is advisable to use protectors The following tables state the maximum torques Nominal size mm DIN Pressure rating bar Studs Maximum torques Nm DN25 PN40 4 x M12 25 DN32 40 PN40 4 x M16 45 DN50 PN40 4 x M16 65 DN6...

Page 21: ...does not drop below the upper range value of 0 5 m s In case of fluids with solid particles the flow velocity should range between 3 m s and 5 m s in order to prevent sedimentation in the sensor 8 4 Wiring Caution Installation and wiring may only be performed when the auxiliary power is switched off Non compliance can result in electric shock and irreparable damage to electronic parts Size Litres ...

Page 22: ...ditions Ambient temperature range For fluid temperatures 60 C As the sensors are an element of the pipe these are normally thermally isolated when installed to save energy and prevent accidental physical contact Due to the process temperature heat is introduced through the support for securing the integral mount transmitter or the terminal box For this reason the thermal insulation of the sensor s...

Page 23: ...sed for connection must comply with the specified outer diameter for the cable glands used Tighten the cable glands firmly Loop the cable in front of the cable gland Any moisture running along the cable can then drip off and not penetrate the device Always install the device so that the cable gland does not face upwards Any unused cable glands must be closed with a plug which is suitable for the r...

Page 24: ... components of working equipment must be provided with guards which prevent physical contact of workers with the respective parts For this reason and also to save energy in practical applications at temperatures of 60 C all pipes and installed measuring instruments are normally thermally insulated Refer to Section 8 6 for information on the relation between the fluid temperature and the ambient te...

Page 25: ...10 Process terminals Terminals located at the rear side of the transmitter s housing Mains 24 Vdc 15 Power input 10 VA Fuse 5x20mm DIN 41571 3 Voltage 24 Vdc Current 1 AT Rated voltage 250 Vac Breaking capacity 80A 250Vac e g Fa Wickmann series 201 Fig 17 ...

Page 26: ...be displayed Frequency fmax 1 kHz Pulse value 1 pulse unit The pulse value can be multiplied by a factor between 0 001 and 100 0 in decade increments of the selected units e g m3 Status output for forward and reverse flow MIN and MAX flow rate or alarm 8 11 4 Failure signal A failure in the meter can be indicated via the current output or the status output The current output can be set to alarm of...

Page 27: ...nal Label Polarity Function 1 PE Protective conductor 2 N Mains 3 L Mains 4 Pulse Pulse output passive 5 Pulse Pulse output passive 6 Status Status output passive 7 Status Status output passive 8 Current Out Current output active 9 Current Out Current output active Loop Loop Status Status Pulse Pulse Fuse Fig 18 ...

Page 28: ...r cable specification see section 8 16 The outer shield has to be connected to the metalized cable glands at both ends The inner shields are connected to each other and are plugged into the terminal labeled Schirm shield They are related to the potential of the function earth FE See also section 11 2 Potentials Note terminal diagram Schematic representation of a wiring between flow sensor and remo...

Page 29: ... Electrode cable and field coil cable as shielded twisted pair In order to protect the cable from external interference the twisted pair wires are covered by an additional overall shield e g LIYCY CY TP 2 x 2 x 0 25 mm At cable length more than 10m a wire cross section of at least 0 75 mm is required e g SLIYCY C11Y 2 x 2 x 0 75 mm The outer shield is grounded by means of special EMC compliant cab...

Page 30: ... in the power can be switched on again 9 3 Exchange of transmitter electronic The transmitter electronic may be exchanged only as complete module With the exchange of individual components the transmitter is afterwards no longer calibrated neither regarding its measuring characteristics nor its analog outputs The exchange has to be done as described in the following Mains power off Unclamp the 6 p...

Page 31: ...C D Weight kg approximate values PN40 ASME Class 300 DN25 1 284 72 104 4 4 DN32 1 82 DN40 1 290 92 DN50 2 295 5 107 5 4 PN16 ASME Class 150 DN65 2 307 127 5 4 DN80 3 313 138 6 4 DN100 4 323 162 DN150 6 351 218 134 10 4 DN200 8 379 274 219 12 4 205 108 ØA D 115 B Ø110 ØC M20 X 1 5 cable entry point 2 ...

Page 32: ...ation of the magnetic inductive flow sensor the instructions and notes of the assembly instructions and operating manuals have to be followed Also observe the grounding potential equalization and internal grounding guidelines 11 2 Potentials All outputs are electrically isolated from the auxiliary power the sensor circuit and from each other The housing and the interference suppression filters of ...

Page 33: ...e the device is put into operation and before any regular operations are carried out Zero point calibration is to be carried out using a fluid The zero calibration procedure is as follows Install the sensor as described in the manufacturer s instructions Check to ensure that the sensor is completely filled with fluid and that there are no gas bubbles in the flow tubes Define the process conditions...

Page 34: ...o configure comfortable and simple the transmitter without any other tool 12 3 Optional equipment 12 3 1 HART Interface An analog 0 4 20 mA output is a standard feature and digital data transmission via HART protocol as an optional feature of the device A retrofit by customer is not possible 12 3 2 Empty pipe detection Transmitters which are equipped with a control unit BE3 have an on and off swit...

Page 35: ... values stored in the DSM Thus the DSM offers maximum safety and high comfort when exchanging device components Electronic Power supply board ELM Slot DSM At any exchange watch the polarity of the memory chip Pin 1 is signed by a dot or a notch 12 3 4 Safety of operation A comprehensive self monitoring system ensures maximum safety of operation Potential errors can be reported immediately via the ...

Page 36: ...data and settings can be read directly from this display The LCD display is designed be operated at temperatures ranging from 20 C to 60 C 4 F to 140 F without incurring any damage However at freezing or near freezing temperatures the display becomes slow and readability of the measured values is reduced At temperatures below 10 C 14 F only static values parameter settings can be displayed At temp...

Page 37: ...isplays and parameters are shown in logical groups Beneath this is the menu level which lists all measured value displays or the headings for their underlying parameters parameter level All functional classes are interlinked horizontally while all subpoints that are assigned to a functional class are displayed beneath the relevant class 14 Operating modes 14 1 2 The keys and their functions There ...

Page 38: ... to the parameter level You confirm all entries with the key 14 1 3 Functional classes functions and parameters Functional classes are written in all upper case letters headings The functions beneath each functional class are written in upper and lower case The various functional classes and functions are describes in Section 15 11 UMF2 B transmitter functions The lower lines contain the following...

Page 39: ... Operating modes which means that a correct password see 14 1 3 3 Passwords and 15 2 PASSWORD functional clas must be entered To move the cursor from one decimal place to the next use the or keys To increase the value of the decimal place just under the cursor by 1 use the key and use key to lower the number by 1 To change the minus and plus sign place the cursor in front of the first digit To con...

Page 40: ... The software functions of the ELM transmitter are divided into functional classes are arrayed in a circle and can be navigated by using the or cursor keys To go back to your starting point the measured values functional class press Esc Fig 26 ...

Page 41: ...sing the customer password are described Functions that are only accessible to the vendor service functions are not described in the present document 15 1 Measured values functional class The measured values functional class contains all functions for displaying the measured values Fig 27 ...

Page 42: ... as a daily counter If you select the function forward flow counter 2 the following will be displayed example Counter 2 forw 000001 0 l The LCD shows the current value of forward flow counter 2 You define the display unit in the functional class COUNTERS using the function unit of counter 15 1 4 Reverse flow counter If you select the function reverse flow counter the following will be displayed ex...

Page 43: ...fined in the functional class FLOW using the function volume flow unit The unit of the counter is defined in the functional class COUNTER using the function counter unit 15 1 8 QV Forward flow counter 2 If the function QV forward flow counter 2 is selected in the first line the content of the actual flow will be displayed XXX X l XXX XX l h In the second line the LCD shows the current value of the...

Page 44: ...forward flow Counter 2 forward flow Counter reverse flow Velocity QVabs QVrel QV counter 1 QV counter 2 QV velocity and raw values 15 1 11 Raw values The Raw value display supports fault diagnostics and trouble shooting Please inform our service department about the clear text error messages and contents of the Raw value display xxx xxx ggooo iiii gguuu The displayed values are decimals and have t...

Page 45: ...c 15 2 1 Customer password After selecting the Customer password function and pressing enter the following will be displayed Password 0000 According to the description in Section 14 1 3 2 Input window modify a value the password can be changed If the entered password is correct the following message will be displayed Password valid If the entered password is not correct the following message will ...

Page 46: ... you may change the existing password and enter a new one After selecting the Change customer password function and pressing enter the following will be display Enter New password 0000 According to the description in Section 1 2 3 2 value the current value can be changed Press to confirm and save the new password Make sure that you entered the desired password A copy of the password should be kept...

Page 47: ...onal class The counters functional class is comprised of the following functions To change the current settings enter the customer password Otherwise the settings can only be displayed but not changed To cancel the current action press Esc Fig 29 ...

Page 48: ...sense if density factor has been programmed for mass flow calculation Press to confirm and save the selection Forward and reverse counters will now show the selected unit 15 3 2 Reset counter The ELM has 3 independent totalizing counters Counter 1 and Counter 2 for forward flow and a reverse flow counter Each of them can be reset individually on the initial value 0 00 To reset one of the totalizin...

Page 49: ...rement processing functional class is comprised of all functions that affect the processing of the measured values To change the current settings enter the customer password Otherwise the settings can only be displayed but not changed To cancel the current action press Esc Fig 30 ...

Page 50: ...be set from 0 to 20 in 1 percent increments After choosing the Low flow cut off function and pressing enter the following selection field will be displa Low flow cut off 00 The low flow volume will be displayed According to the description in Section 14 1 3 2 Input window modify a value the current value can be changed After setting the new low flow volume you confirm your entry with en 15 4 3 Low...

Page 51: ...will be display 0 00 l h cal no According to the description in Section 14 1 3 2 Selection window make a selection yes or no can be selected By pressing Esc or toggling to no the operator can cancel the current action Enter yes to have the zero point recalibrated 15 4 5 Filter For a noise reduction of the actual readings a signal filter can be used Following settings are available none weak mid st...

Page 52: ...ured flow rates In Programming mode see section 14 Operating modes i e after a password has been entered see 14 1 3 3 Passwords 15 2 PASSWORD functional class the operator can change the settings regarding flow To change the current settings enter the customer password Otherwise the settings can only be displayed but not changed To cancel the current action press Esc Fig 31 ...

Page 53: ...r range value will scale the current and frequency outputs assigned to volume flow After choosing the Volume flow lower range value function and pressing enter the following selection field will be display QV LRV 0 XXXXX XX l h The current lower range value for volume flow will be displayed According to the description in Section 14 1 3 2 Input window modify a value the current value can be change...

Page 54: ...is limit value the status output will be set in case the corresponding assignment has been made If the alarm function has also been activated for the current output the applied current will change to 3 2 mA or 20 5 mA 22 mA After choosing the Volume flow limit MAX function and pressing enter the following selection field will be display Volume flow limit MAX 90 The current MAX upper range value fo...

Page 55: ...e will be displayed According to the description in Section 14 1 3 2 Input window modify a value the current value can be changed The value of the density is not measured It is a parameter 15 5 8 Volume flow LSL information field This value represents the minimum lower range value based on the inside diameter of the sensor This value is normally set for a flow velocity of 0 25 m s QV LSL XX XXX l ...

Page 56: ...IM P309 02 MI Issue 2 56 15 6 Pulse output functional class The pulse output functional class is comprised of the functions regarding the pulse output Fig 32 ...

Page 57: ...error message Pulse width too large or Inconsistent parameter will be displayed Press to display the current setting Output of Pulses According to the description in Section 14 1 3 1 Selection window make a selection the operator can toggle between frequency and pulse output default setting 15 6 2 Pulse output unit This function allows the operator to define the unit to be counted After selecting ...

Page 58: ...tion field Pulse width 0050 0 ms The current pulse width will be displayed As mentioned in Section 14 1 3 2 Input window modify a value the operator can change the current value The maximum output frequency can be calculated from the following formula If connecting to electrical counter relays we recommend pulse widths greater than 4 ms for electromechanical counter relays the preset value should ...

Page 59: ...tive closed As mentioned in Section 14 1 3 1 Selection window make a selection the operator can choose between the following settings closed open 15 7 2 Status output assignment This function allows the operator to define to which event the status output is to be assigned The most general assignment is the reverse flow assignment After selecting the Status output assignment function press to displ...

Page 60: ... 60 15 8 Current output functional class The current output functional class allows the operator to perform the settings for the current outputs of the transmitter The current output is always assigned to volume flow Fig 34 ...

Page 61: ...put current 0 20 21 5 mA 4 20 5 mA and 4 21 6 mA 15 8 1 Current output 0 4 20 mA The Current output 0 4 to 20 mA function allows the operator to define the range in which the current output is to be operated Within the range from 0 to 21 6 mA 0 110 HART communication is not possible The range from 4 to 20 5 mA follows the NAMUR recommendation and covers the range from 0 to 104 of the measuring ran...

Page 62: ... Simulation can also be activated and controlled via HART commands 15 9 1 Simulation on off The Simulation on off function allows the operator to activate or deactivate simulation If simulation is activated all output signals will be generated based on the selected type of simulation The peripherals connected to the device can be tested without a flowing product Press to display the current status...

Page 63: ...an then be purposefully changed during simulation Simulation will be deactivated automatically if the operator switched the device off or did not touch any control unit keys for about 10 minutes 15 9 3 Simulation measured flow Q If the operator selected the setting QVabs described in Section 15 9 2 the following settings of a volume flow will affect the output behavior during measured value simula...

Page 64: ...the operator to define a frequency to be assigned to the pulse output After selecting this function and pressing enter the following selection field will be display Set frequency 0210 0 Hz This field shows the current frequency As mentioned in Section 14 1 3 2 Input window modify a value the definable frequency ranges from 6 Hz to 1100 Hz 15 9 7 Current output simulation This function allows the o...

Page 65: ...s comprised of the functions relating to the self test of the sensor The diagnostic functions of the transmitter which monitor the proper functioning of the electronics and the software are always active and cannot be switched off The excitation current can be monitored in addition Fig 37 ...

Page 66: ...s between 35 seconds and 999 seconds Self test STP 040 s This field shows the current self test period As mentioned in Section 14 1 3 2 Input window modify a value the current value can be changed 15 10 2 Reference calibration on off With the help of the function Reference calibration on off the periodic recalibration of the transmitter can be activated or deactivated The objectives of the functio...

Page 67: ...off continuous empty pipe detection can be activated or deactivated After selecting this function and pressing enter the following selection field will be display Empty pipe detection off According to the description in Section 14 1 3 1 Selection window make a selection the operator can toggle between on and off If switched on the empty pipe detection will be done periodically 15 10 5 Empty pipe d...

Page 68: ...ter Inside diameter 0125 5 mm Language Language LAnguage English _________________ German English Excitation frequency Excitation frequency Excitation frequency 6 25 Hz _________________ 1 56 3 125 6 25 12 5 25 Mains frequency Mains frequency Mains frequency 50 Hz _________________ 50 60 Flow direction Flow direction Flow direction forward reverse _________________ forward reverse forward reverse ...

Page 69: ...f the plus or minus sign of the sensor constant is then changed without changing the actual value a plus sign will again be displayed No changes need be made in the disposition of the electrical connections wires 15 11 2 Sensor type The function Sensor type contains the type of the sensor with which the transmitter has been delivered The distinction is necessary and required because the flow rate ...

Page 70: ...on frequency defaults to 6 25 Hz Excitation frequency 6 25 Hz The selection is confirmed and taken over with the key Caution If the excitation frequency is changed then a reference calibration Section 15 10 2 Reference calibration on off must be accomplished Otherwise the measuring accuracy is not ensured 15 11 6 Mains frequency In order to ensure with mains frequency 50 Hz or 60 Hz per second opt...

Page 71: ...verse After selecting the Flow direction function press to display the current setting Flow direction forward As mentioned in Section 14 1 3 1 Selection window make a selection the operator can choose between forward reverse forward reverse 15 11 8 Software version information field After selecting this function the version of the transmitter software will be shown example 1 06 Version of ELM 001 ...

Page 72: ... automatically after the error usually of very brief duration is eliminated 15 11 11 Reset system error Before resetting a system error manually we advise that you contact our technical service department For further information see Section 16 1 2 Display of system error Reset error no If the operator toggles to yes and confirms the action according to the description in Section 14 1 3 1 Selection...

Page 73: ...rcuit in the connection of excitation coil All signal outputs will be set to no flow Check the wiring between transmitter and sensor Messkreis überst meas circ sat The flow measurement circuit is overloaded The measured electrode voltage is too high All signal outputs will be set to no flow Flow rate exceeds the upper range value URL High electrostatic voltage at the electrodes Strom überst curr s...

Page 74: ...y that the combination fits for all measured values ext EEPROM fehlt missing EEPROM The data memory module DSM with the calibration data of the sensor and the customer specific settings of the transmitter is not plugged in Insert the data storage module DSM in the socket on the power supply board UMF2 20 Information Error message Parameter is inconsistent system error 0x0400 To generate a list of ...

Page 75: ...set system error After the fault recovery the displayed system error message can be reset For this purpose the customer password has to be entered Refer to 15 2 1 Customer password Select the function Show system error Refer to 15 11 10 Show system error Analyse the fault and repair the transmitter or sensor Finally reset the system error message Refer to 15 11 11 Reset system error General standa...

Page 76: ...M P309 02 MI Issue 2 76 18 Maintenance The device requires no maintenance if used according to its intended purpose Cleaning might be necessary due to deposits and dirt on the electrodes or the flow tube ...

Page 77: ...ollowing fluid In as much as this fluid is water hazardous toxic corrosive combustible we have done the following Checked all cavities in the device to ensure that they are free of fluid residues Washed and neutralized all cavities in the device cross out all non applicable items We hereby warrant that no health or environmental hazard will arise from any fluid residues on or in the enclosed devic...

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