Promesstec MDW 500 User manual

promesstec GmbH I Niedersachsenstraße 4 I D-48465 Schüttorf I Tel.:+49 (0)5923/ 90 229 0 I Fax:+49 (0)5923/ 90 229 29

E-Mail: office@promesstec.com I Internet: www.promesstec.com

User manual

Flow meter MDW / MDH 500

version 2.1.1

promesstec GmbH I Niedersachsenstraße 4 I D-48465 Schüttorf I Tel.:+49 (0)5923/ 90 229 0 I Fax:+49 (0)5923/ 90 229 29

E-Mail: office@promesstec.com I Internet: www.promesstec.com

Content

1. General................................................................................................................ 4

1.1 Description measuring principle......................................................................4

1.2 Drawings, shortcut..........................................................................................4

2. Transport, Packaging, Storage............................................................................ 5

2.1 Transport........................................................................................................5

2.2 Packaging.......................................................................................................5

2.3 Storage...........................................................................................................5

3. Safety instructions.............................................................................................. 5

3.1 Intended use of the product............................................................................5

3.2 Stuff qualification............................................................................................6

3.3 Special hazards..............................................................................................6

4. Starting, operation.............................................................................................. 7

4.1 feature............................................................................................................7

4.2 Installation in pipeline.....................................................................................7

4.3 Outdoor conditions .........................................................................................7

4.4 Disturbance sources.......................................................................................7

4.4.1 Vibrations.................................................................................................8

4.4.2 Proper location.........................................................................................8

4.4.3 Installation examples ...............................................................................9

4.4.4 Recommendation...................................................................................10

4.4.5 Compact construction of the meter........................................................10

4.4.6 Installation in pipeline.............................................................................11

4.5Wiring...........................................................................................................19

4.5.1 Meter wiring ...........................................................................................19

4.5.2 Assignment M12 plug ............................................................................21

4.6 Power supply cover sheet ............................................................................22

4.7 Impulse output / Flow Switch contact OUT1 / OUT2 ....................................23

4.8 Current output...............................................................................................25

4.9 Control input.................................................................................................26

4.10 Data output...................................................................................................26

4.11 Protection degree.........................................................................................26

4.12 Replacement of tube fuse in the meter.........................................................27

4.13 Wiring check.................................................................................................27

5. Putting into operation........................................................................................ 28

promesstec GmbH I Niedersachsenstraße 4 I D-48465 Schüttorf I Tel.:+49 (0)5923/ 90 229 0 I Fax:+49 (0)5923/ 90 229 29

E-Mail: office@promesstec.com I Internet: www.promesstec.com

5.1 Meter status..................................................................................................28

6. Technical specifications.................................................................................... 29

6.1 Factory settings............................................................................................31

6.2 Adjusting and control of the meter MDW/ MDH 500.....................................32

6.3 Instruction manual MDW / MDH 500............................................................33

7. Application information..................................................................................... 65

7.1 Disassembly and assembly of PCB..............................................................66

7.2 Basic sensor sizes........................................................................................67

7.3 Reduction in DN pipe....................................................................................71

7.4 Faults and their symptoms during measurement..........................................71

8. Dismounting, Return, Cleaning, Disposal......................................................... 72

8.1 Dismounting .................................................................................................72

8.2 Return...........................................................................................................72

8.3 Cleaning.......................................................................................................72

8.4 Disposal........................................................................................................72

promesstec GmbH I Niedersachsenstraße 4 I D-48465 Schüttorf I Tel.:+49 (0)5923/ 90 229 0 I Fax:+49 (0)5923/ 90 229 29

E-Mail: office@promesstec.com I Internet: www.promesstec.com

1. General

1.1 Description measuring principle

The MDW/MDH 500 meter is based on measurement principle by a well-known Far-

aday's electromagnetic induction law according to which an electric voltage is in-

duced during the flow of a conductive liquid through the flow meter magnetic field.

This is picked up by two electrodes in direct contact with the measured medium and

evaluated in the electronic unit.

The MDW/MDH 500 type of induction meters are suitable exclusively for measure-

ment of volumetric flow of electrically conductive liquid substances with a minimum

conductivity of 20 µS/сm (at a lower conductivity, upon agreement with the manu-

facturer).

Meters are designed for flow measurement where the velocity of liquid is in the range

of 0.01 - 12 m/s. The best measurement accuracy can be obtained in the range of

1 - 10 m/s.

1.2 Drawings, shortcut

Warning!

A non-observance can cause injuries to persons and/or the demoli-

tion of the device. There can be a dangerous to life.

Attention!

A non-observance can cause a faulty operation of the device or lead

to property damage.

Information!

A non-observance can have influence on the operation of the device

or cause unintentional reactions of the device.

Danger!

When not observing the safety instructions, there is a risk of serious

or fatal injuries caused by electrical power.

Warning!

Possibly a dangerous situation can occur, which results in burns be-

cause of hot surfaces or liquids, if not avoided.

Flow meter MDW/ MDH 500

promesstec GmbH I Niedersachsenstraße 4 I D-48465 Schüttorf I Tel.:+49 (0)5923/ 90 229 0 I Fax:+49 (0)5923/ 90 229 29

E-Mail: office@promesstec.com I Internet: www.promesstec.com

2. Transport, Packaging, Storage

2.1 Transport

Check the instrument for any damage that may have been caused during transpor-

tation. If, report them immediately. The temperature during transportation and stor-

age of the meter must be within the range of -10 °C to 50 °C.

2.2 Packaging

Do not remove packaging until just before mounting. Keep the packaging as it will

provide optimum protection during transport (e.g. change in installation site, sending

back).

2.3 Storage

For longer term storage avoid the following influences:

1. Direct sunlight or proximity to hot objects

2. Mechanical vibration, mechanical shock (putting it hard down)

3. Soot, vapour, dust and corrosive gases

If possible store the device in its original package or an equivalent one

3. Safety instructions

More important safety instructions can be found in the individual

chapters.

3.1 Intended use of the product

The sensor has been designed and built solely for the intended use described here

and may only be used accordingly. The technical specifications contained in these

operating instructions must be observed. Improper handling or operation of the in-

strument outside of its technical specifications requires the instrument to be taken

out of service immediately and an inspection by the manufacturer. When the instru-

ment is transported from a cold into a warm environment, the formation of conden-

sation may result in the instrument malfunctioning. Before putting it back into oper-

ation, wait for the instrument temperature and the room temperature to equalise.

The manufacturer shall not be liable for claims of any type based on operation con-

trary to the intended use.

promesstec GmbH I Niedersachsenstraße 4 I D-48465 Schüttorf I Tel.:+49 (0)5923/ 90 229 0 I Fax:+49 (0)5923/ 90 229 29

E-Mail: office@promesstec.com I Internet: www.promesstec.com

3.2 Stuff qualification

Improper handling can result in considerable injury and damage to

equipment. The activities described in these operating instructions

may only be carried out by skilled stuff who have the qualifications

described below. Keep unqualified stuff away from hazardous areas.

For installation and starting of the flow-meter the stuff has to be familiar with the

relevant regulations and directives of the country and must have the qualification

required. They must have knowledge on measurement and control technology, have

to be acquainted with electric circuits, are capable of carrying out the work described

and can independently recognize potential hazards. Depending on the operation

conditions of the application they have to have the corresponding knowledge, e.g.

of aggressive media.

3.3 Special hazards

For hazardous media such as oxygen, acetylene, flammable or toxic

gases or liquids, refrigeration plants, compressors, etc., in addition to

all standard regulations, the appropriate existing codes or regulations

must also be followed. If you do not observe the appropriate reg-

ulation, serious injuries and/or damage can occur!

A protection from electrostatic discharge (ESD) is required. The

proper use of grounded work surfaces and personal wrist straps is

required when working with exposed circuitry (PCB, printed circuit

boards), in order to prevent static discharge from damaging sensitive

electronic components.

There is a danger of death caused by electric current. Upon contact

with life parts, there is a direct danger of death. Electrical instruments

may only be installed and connected by skilled electrical personnel.

Operation using a defective power supply unit (e.g. short circuit from

the mains voltage to the voltage output) can result in life-threatening

voltages at the instrument.

Residual media in dismounted instruments can result in a risk to per-

sonnel, the environment and equipment. Take sufficient precaution-

ary measures. Do not use this instrument in safety or Emergency

Stop devices. Incorrect use of the instrument can result in injury.

Should a failure occur, aggressive media with extremely high tem-

perature and under high pressure or vacuum may be present at the

instrument.

promesstec GmbH I Niedersachsenstraße 4 I D-48465 Schüttorf I Tel.:+49 (0)5923/ 90 229 0 I Fax:+49 (0)5923/ 90 229 29

E-Mail: office@promesstec.com I Internet: www.promesstec.com

4. Starting, operation

4.1 feature

4.2 Installation in pipeline

In case of detached design, the cable must not be extended or cut

short.

4.3 Outdoor conditions

It is necessary to ensure that the flow sensor is not exposed to weather effects and

that the measured medium cannot freeze in the flow sensor as it would damage the

measuring tube.

In case of outdoor location of the electronic evaluation unit, the manufacturer rec-

ommends using a protective box or a roof to avoid direct solar exposure so that the

evaluation electronics cannot get overheated.

4.4 Disturbance sources

These are the sources disturbing the steady flow of a liquid:

-Pumps and bends or elbows located closely in series in various planes.

These elements should be at a distance of at least 20´d (“d” stands for inside

diameter of the sensor in mm) before the flow sensor.

-Sudden variations in the pipe sectionunless constructedas a cone with angle

α ≤ 16° (where αis the angle between the bevelled walls of the pipe adapter).

-Incorrectly centred seal, the seal with a mall internal diameter, or the seal

made of soft elastic materials which penetrate into internal section of the pipe

after the flanges have been tightened.

-Anything that interferes with the flow of liquid, e.g. the thermometer well.

-Branches, T-pieces, bends, elbows, slide valves, taps, and throttles. Shut-off

valves, control valves, butterfly valves, and check valves. Pipe outlets from

tanks, heat exchangers, and filters.

No strong electromagnetic field must take effect close to the inductive flow sensor

(pick-up).

promesstec GmbH I Niedersachsenstraße 4 I D-48465 Schüttorf I Tel.:+49 (0)5923/ 90 229 0 I Fax:+49 (0)5923/ 90 229 29

E-Mail: office@promesstec.com I Internet: www.promesstec.com

4.4.1 Vibrations

We recommend you to support the connecting pipes at both sides of the meter to

partially eliminate vibrations. The level and range of vibrations must be below 2.2g

within frequency range of 20 - 50 Hz according to IEC 068-2-34 standard.

4.4.2 Proper location

The flow sensor must not be at the top of the pipeline where air intake occurs or in

the declining and also in horizontal pipeline with open end where air may penetrate.

Sedimentation of impurities may occur during a long-run measurement of very low

flow rates Q < 0.1 m/s. The site where the flow sensor is installed there must be a

sufficient pressure so that vapour or gas bubbles cannot be discharged from the

liquid. The tiny bubbles occurring in liquids all the time can accumulate at any of the

electrodes and they can cause incorrect function of the meter. The gas bubbles are

discharged from liquids also during a sudden drop of pressure. Therefore, the con-

trol butterfly valves and similar components should be inserted behind the flow sen-

sor. For the same reason, the flow sensor should not be installed at the suction side

of the pump. To prevent the bubbles from accumulating in the flow sensor while the

flow is slow, it is useful for the pipeline either to be slightly ascending or the sensor

is put into the vertical part of the pipeline.

If the meter is populated with measuring electrodes only (2 or 3 electrodes located

beyond the upper profile of the tube), itis necessary for proper function of the meter,

to fill up the flow sensor with the fluid to be measured so that erroneous measure-

ment of quantity of liquid passing through the meter can be avoided when the pipe

is empty. It is necessary to select the location of the meter in such a way that the

flow sensor aeration is avoided. In the case of an open system, the flow sensor is

placed in the bottom position of the U-profile, ensuring that the fluid will not flow out

of the sensor. In the case that the sensor is equipped with an empty pipe test elec-

trode (3rd or 4th electrode in the upper part of the measuring tube profile), there is

no risk of erroneous measurement of quantity of liquid passing through the meter

due to aeration of measuringelectrodes. This function must be activated in PARAM-

ETERS (EMPTY TUBE TEST) menu. If it be to the contrary, the same conditions

stand good as if the testing electrode is not populated.

promesstec GmbH I Niedersachsenstraße 4 I D-48465 Schüttorf I Tel.:+49 (0)5923/ 90 229 0 I Fax:+49 (0)5923/ 90 229 29

E-Mail: office@promesstec.com I Internet: www.promesstec.com

4.4.3 Installation examples

Trouble-free and exact operation of the meter is dependent on its correct location in

the system. The most frequent methods of the placement are shown in the following

figures:

Recommended installation locations Downtake pipe

Horizontally laid pipeline Long pipeline

Free inlet or outlet Pumps

Bubbles are accumulated in the

pipeline; erroneous measurement

Install an air bleed valve after

the sensor 

Place the sensor in a slightly as-

cending pipeline

Pipeline is

empty; er-

roneous

measure-

ment

Correct loca-

tion

Install controls and shut-off valves al-

ways after the sensor

Built in the U-shaped pipeline

The flow meter must not be installed in the

suction side of the pump

promesstec GmbH I Niedersachsenstraße 4 I D-48465 Schüttorf I Tel.:+49 (0)5923/ 90 229 0 I Fax:+49 (0)5923/ 90 229 29

E-Mail: office@promesstec.com I Internet: www.promesstec.com

The flow of liquid flow in the flow sensor should be steady and free of whirling. For

this reason, straight sections of pipeline with the same ID as that of the flow meter

before and after the flow sensor (with permissible deviation of +5%). Recom-

mended minimum length of straight sections is 5xd before the flow sensor and 3xd

after the flow sensor where d is the inside diameter of the meter in millimetres. The

same principles apply before and after the flow sensor in case of bi-directional flow

measurement.

4.4.4 Recommendation

When the flow is whirled up, increase the stabilizing sections of the pipe or install

the flow conditioner. When mixtures are blended, it is necessary to install the flow

meter either before the blending spot or at a sufficient distance behind it (30xd min.)

otherwise it may result in unstable readouts. The grounding rings are necessary

when plastic or metal pipes with the internal non-conductive layer are used.

4.4.5 Compact construction of the meter

For the compact design, the following points should be particularly noted:

- The maximum temperature of the medium (max. +90° C, attention see here-for

data sheet Lining). If the temperature is exceeded, this can lead to a faulty meas-

urement or even to the destruction of the device. With the PTFE-lining CIP-clean-

ing processes are possible.

- When installing the device, do not pick up or hang up the flow meter on the eval-

uation unit (connection head).

- If the flowmeter is exposed to high vibrations, do not use a compact version.

The user is responsible for the proper use of the meter.

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