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00809-0100-4761 DS-4125 English Rev. CA Product Discontinued ProBar® Flowmeter Installation and Operation Manual Product Manual ProBar® Flowmeter Installation and Operation Manual NOTICE Read this manual before working with the product. For personal and system safety, and for optimum product performance, make sure you thoroughly understand the contents before installing, using, or maintaining this product. Contact Dieterich Standard Inc. for technical support, quoting, and order-related questions: 1-303-530-9600 (7:30 a.m. to 5:00 p.m. MST). Within the United States, Rosemount Inc. has two toll-free assistance numbers. Customer Central: 1-800-999-9307 (7:00 a.m. to 7:00 p.m. CST) Technical support, quoting, and order-related questions. North American Response Center: 1-800-654-7768 (24 hours a day – Includes Canada) Equipment service needs. For equipment service or support needs outside the United States, contact your local representative. The products described in this document are NOT designed for nuclear-qualified applications. Using non-nuclear qualified products in applications that require nuclear-qualified hardware or products may cause inaccurate readings. For information on Rosemount nuclear-qualified products, contact your local sales representative. . Rosemount, the Rosemount logotype, PlantWeb, Fisher-Rosemount, and Managing the Process Better are marks of one of the Fisher-Rosemount group of companies. Coplanar, MV, and Multivariable are trademarks of Rosemount Inc. Mass ProBar, ProBar, and Annubar are registered trademarks of Dieterich Standard Inc. HART is a registered trademark of the HART Communications Foundation. Monel is a registered trademark of International Nickel Co. Teflon is a registered trademark of E. I. du Pont de Nemours & Co. Hastelloy C and Hastelloy C-276 are registered trademarks of Cabot Corp. Windows is a trademark of Microsoft Corp. All other marks are the property of their respective owners. Fisher-Rosemount satisfies all obligations coming from legislation to harmonize product requirements in the European Union. Dieterich Standard Inc. PR INT IN U. S. A. http://www.rosemount.com ED 5601 North 71st Street Boulder, CO 80301 Tel (303) 530-9600 Fax (303) 530-7064 Probar Flowmeter Installation and Operation Manual ii Table of Contents IMPORTANT Procedures and instructions in this manual may require special precautions to ensure the safety of the personnel performing the operations. Refer to the safety messages at the beginning of each section before performing any operations. SECTION 1: Introduction Using This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Installation Flowchart and Checklist . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 SECTION 2: Installation Location and Orientation Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Receiving and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ProBar Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Structural Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Functional Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Straight Run Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Environmental Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 ProBar Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Process Connections (Remote Mounted ProBar only) . . . . . . . . . 2-7 Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Bolt Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 SECTION 3: Hardware Installation for ProBar Regular (Threaded, Pak-Lok) ProBar Models PBR+15S/16S, 25S/26S, 35S/36S, 45S/46S . . . . . 3-1 Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ProBar Regular Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Step 1: Determine the Proper ProBar Orientation . . . . . . . . . . . . . . . 3-2 Liquid Service in a Horizontal Pipe . . . . . . . . . . . . . . . . . . . . . . . 3-2 Gas Service in a Horizontal Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Steam Service in a Horizontal Pipe . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Liquid or Gas Service in a Vertical Pipe . . . . . . . . . . . . . . . . . . . . 3-4 Steam Service in a Vertical Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Shipping Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Step 2: Drill the Hole in the Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Drill a Hole for Opposite-Side Support . . . . . . . . . . . . . . . . . . . . . 3-5 Step 3: Tack Weld the Fittings to the Pipe . . . . . . . . . . . . . . . . . . . . . 3-6 Step 4: Insert the ProBar into the Pipe . . . . . . . . . . . . . . . . . . . . . . . . 3-7 iii SECTION 4: Hardware Installation for ProBar Flanged ProBar Models PBF+15S/16S, 25S/26S, 25H/26H, 25M/26M, 35S/36S, 45S/46S, 45H/46H, 45M/46M . . . . . . . . . . . . . . . . . . . . . . 4-1 Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 ProBar Flanged Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Step 1: Determine the Proper Orientation of the ProBar . . . . . . . . . . 4-2 Liquid Service in a Horizontal Pipe . . . . . . . . . . . . . . . . . . . . . . . 4-2 Gas Service in a Horizontal Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Steam Service in a Horizontal Pipe . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Liquid Service in a Vertical Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Gas Service in a Vertical Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Steam Service in a Vertical Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Shipping Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Step 2: Drill the Hole in the Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Drill a Hole for Opposite-Side Support . . . . . . . . . . . . . . . . . . . . . 4-5 Step 3: Weld the Weld-Neck Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Step 4: Assemble the ProBar and Mounting Hardware . . . . . . . . . . . 4-5 Step 5: Check the Fit-Up of the ProBar to the Pipe . . . . . . . . . . . . . . 4-6 Check the Fit-Up of the ProBar with Opposite-Side Support . . . 4-7 Step 6: Tack Weld the Mounting Hardware . . . . . . . . . . . . . . . . . . . . 4-8 Tack Weld the Opposite-Side Support Fitting . . . . . . . . . . . . . . . 4-8 Step 7: Finish Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Step 8: Assemble the ProBar and Mounting Flange . . . . . . . . . . . . . . 4-9 Opposite-Side Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 SECTION 5: Hardware Installation for ProBar Flanged Flo-Tap ProBar Models PHF+15S, 25S, 25M, 35S, 45S, 45H, 45M . . . . . 5-1 Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 ProBar Flo-Tap Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Step 1: Determine the Proper Orientation of the ProBar . . . . . . . . . . 5-2 Liquid or Steam Service in a Horizontal Pipe . . . . . . . . . . . . . . . 5-2 Gas Service in a Horizontal Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Liquid or Gas Service in a Vertical Pipe . . . . . . . . . . . . . . . . . . . . 5-3 Steam Service in a Vertical Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Step 2: Obtain the Required Welding Equipment and Hardware . . . 5-4 Step 3: Prepare the Weld-Neck Flange Assembly . . . . . . . . . . . . . . . . 5-5 Step 4: Weld the Weld-Neck Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Step 5: Attach the Unit Isolation Valve . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Step 6: Attach the Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Step 7: Attach the Pressure Drilling Machine . . . . . . . . . . . . . . . . . . 5-6 Step 8: Drill the Hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Step 9: Remove the Drilling Machine . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Step 10: Install the Flo-Tap Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Step 11: Open the Isolation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Step 12: Tighten the Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Step 13: Insert the Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Standard Drive (IHR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Gear Drive (IHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Step 14: Check for Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Step 15: Retract the Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Standard Drive (IHR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Gear Drive (IHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Step 16: Close the Isolation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Step 17: Remove the Flo-Tap Assembly . . . . . . . . . . . . . . . . . . . . . . . 5-10 iv SECTION 6: Hardware Installation for ProBar Threaded Flo-Tap ProBar Models PHT+15S, 25S, 35S . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 ProBar Flo-Tap Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Step 1: Determine the Proper Orientation of the ProBar . . . . . . . . . . 6-2 Liquid or Steam Service in a Horizontal Pipe . . . . . . . . . . . . . . . 6-2 Gas Service in a Horizontal Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Liquid or Gas Service in a Vertical Pipe . . . . . . . . . . . . . . . . . . . . 6-3 Steam Service in a Vertical Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Step 2: Obtain the Required Welding Equipment and Hardware . . . 6-4 Step 3: Prepare the Weld-Neck Flange Assembly . . . . . . . . . . . . . . . . 6-5 Step 4: Attach the Unit Isolation Valve . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Step 5: Attach the Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Step 6: Attach the Pressure Drilling Machine . . . . . . . . . . . . . . . . . . 6-6 Step 7: Drill the Hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Step 8: Remove the Drilling Machine . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Step 9: Install the Flo-Tap Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Step 10: Open the Isolation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Step 11: Tighten the Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Step 12: Insert the Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Standard Drive (IHR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Gear Drive (IHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Step 13: Check for Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Step 14: Retract the Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Standard Drive (IHR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Gear Drive (IHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Step 16: Close the Isolation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Step 17: Remove the Flo-Tap Assembly . . . . . . . . . . . . . . . . . . . . . . . 6-10 SECTION 7: Hardware Installation for ProBar In-Line ProBar Models PNT+10S, PNW+10S, PNF+10S, 10H, 10M . . . . 7-1 Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 ProBar In-Line Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Liquid Service in a Horizontal Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Gas Service in a Horizontal Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Steam Service in a Horizontal Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Liquid Service in a Vertical Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Gas Service in a Vertical Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Steam Service in a Vertical Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 SECTION 8: ProBar Remote Mounting Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 ProBar Valves and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Impulse Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Equipment Required to Remote Mount the ProBar Electronics . . . . 8-4 Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Instrument Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Location for the ProBar Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Liquid Service up to 250 °F (121 °C) . . . . . . . . . . . . . . . . . . . . . . . 8-6 Gas Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Steam or Liquid Service above 250 °F (121 °C) . . . . . . . . . . . . . 8-10 v SECTION 9: ProBar Electronics Functions Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Commissioning the Flowmeter on the Bench . . . . . . . . . . . . . . . . . . . 9-2 Failure Mode Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 Failure Mode Alarm vs. Saturation Output Values . . . . . . . . . . . 9-2 Alarm and Saturation Values for Flowmeters Set to Burst Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Alarm Level Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Flowmeter Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 Commissioning the ProBar with a HART-Based Communicator . . . . 9-5 Setting the Loop to Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 Wiring Diagrams (Bench Hook-up) . . . . . . . . . . . . . . . . . . . . . . . . 9-5 Wiring Diagrams (Field Hook-up) . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 Review Configuration Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7 Check Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7 Process Variables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7 Sensor Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7 Basic Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 Set Process Variable Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 Set Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 Rerange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10 Damping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13 LCD Meter Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13 Detailed Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14 Local Span and Zero Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14 Diagnostics and Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14 Transmitter Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14 Loop Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15 Calibration Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16 Sensor Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18 Analog Output Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20 Advanced Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21 Saving, Recalling, and Cloning Configuration Data . . . . . . . . . . 9-21 Burst Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22 Multidrop Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22 SECTION 10: Field Wiring and Electrical Considerations Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 Wiring Diagrams (Field Hook-Up) . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 Electrical Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 Power Supply (4–20mA Electronics) . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 Hazardous Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 Grounding the Signal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 Grounding the ProBar Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 Environmental Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 Access Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 Process Flange Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 Housing Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 Terminal Side of the Electronics Housing . . . . . . . . . . . . . . . . . . 10-5 Circuit Side of the Electronics Housing . . . . . . . . . . . . . . . . . . . 10-5 Exterior of the Electronics Housing . . . . . . . . . . . . . . . . . . . . . . 10-5 Cover Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5 vi SECTION 11: Direct Mount ProBar Commissioning Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 Commissioning Direct Mounted ProBars . . . . . . . . . . . . . . . . . . . . . 11-2 Liquid Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2 Gas Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3 Steam Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4 SECTION 12: Remote Mount ProBar Commissioning Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1 Commissioning Remote Mounted Flowmeters . . . . . . . . . . . . . . . . . 12-2 ProBar Valve Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2 Zero the Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3 Check for System Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3 “Calibrate Out” Temperature Effects . . . . . . . . . . . . . . . . . . . . . 12-4 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5 Liquid Service Below 250 °F (121 °C) . . . . . . . . . . . . . . . . . . . . . 12-5 Gas Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6 Steam Service or Liquid Service above 250 °F (121 °C) . . . . . . . 12-7 SECTION 13: Installation Options Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1 Integral Zero and Span Adjustment Options . . . . . . . . . . . . . . . . . . 13-1 Disabling the Zero and Span Adjustments . . . . . . . . . . . . . . . . . 13-2 LCD Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2 Diagnostic Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4 SECTION 14: Maintenance for the Optional RTD ProBar RTD Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1 Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1 Replacing a Direct Mount RTD . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2 Replacing a Remote Mount RTD . . . . . . . . . . . . . . . . . . . . . . . . . 14-2 SECTION 15: Troubleshooting Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1 Before you Disassemble the ProBar Electronics . . . . . . . . . . . . . . . . 15-3 Remove the Flowmeter from Service . . . . . . . . . . . . . . . . . . . . . . . . . 15-4 Remove the Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4 Remove the Electronics Board . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5 Remove the Sensor Module from the Electronics Housing (For service-type ProBar UC, uncalibrated ProBar only) . . . . . . . . . 15-6 Attach the Sensor Module to the Electronics Housing Block . . . . . . 15-7 Attahc the Electronics Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-8 Install the Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-9 Returning Products and/or Materials . . . . . . . . . . . . . . . . . . . . . . . . 15-9 SECTION 16: Specifications and Reference Data Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1 Functional Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1 Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-3 Physical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-5 Flanged Pipe Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-6 vii APPENDIX A: HART Communicator Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Connections and hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7 Communicator Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9 Fast Key Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11 Menus and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-12 Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-12 Online Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-13 Diagnostic Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-14 APPENDIX B: Standard ODF Dimensions Standard ODF Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 APPENDIX C: Approval Drawings Approval Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1 INDEX Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1 viii Section 1 USING THIS MANUAL Introduction This product manual provides installation, configuration, calibration, troubleshooting, and maintenance instructions for the ProBar Flowmeter. This section contains an explanation of each section of the manual, a flowchart for using the manual, and an installation checklist. Section 2: Installation Location and Orientation explains initial inspection, operating limitations, and in what location and orientation to install the ProBar Flowmeter. Section 3: Hardware Installation for ProBar Regular (Threaded, Pak-Lok) explains how to install the direct mounted regular ProBar model for liquid, gas or steam service. Section 4: Hardware Installation for ProBar Flanged explains how to install the direct mounted flanged ProBar models for liquid, gas or steam service. Section 5: Hardware Installation for ProBar Flanged Flo-Tap explains how to install the direct mounted Flo-Tap ProBar models for liquid, gas or steam service. Section 6: Hardware Installation for ProBar Threaded Flo-Tap explains how to install the direct mounted Flo-Tap ProBar models for liquid, gas or steam service. Section 7: Hardware Installation for ProBar In-Line explains how to install the direct in-line series ProBar for liquid, gas or steam service. Section 8: ProBar Remote Mounting explains how to install the remote mounted ProBar series flowmeter electronics for liquid, gas or steam service. Section 9: ProBar Electronic Functions provides information for commissioning the electronics, including operation of the software functions, configuration parameters, and on-line variables of the flowmeter. Section 10: Field Wiring and Electrical Considerations provides electrical considerations and field wiring diagrams to wire the ProBar flowmeter. Section 11: Direct Mount ProBar Commissioning describes how to commission a direct mounted ProBar flowmeter after installation. 1-1 ProBar Flowmeter Section 12: Remote Mount ProBar Commissioning describes how to commission a remote mounted ProBar flowmeter after installation. Section 13: Installation Options provides information about LCD meters and zero and span adjustment options. Section 14: Maintenance for the Optional RTD provides information on how to wire your integral or remote RTD and maintenance for integral RTDs. Section 15: Troubleshooting provides troubleshooting techniques for common operating problems associated with the ProBar flowmeter. Section 16: Specifications and Reference Data provides specification and reference data for the ProBar flowmeter series. Appendix A: HART Communicator contains a communicator overview, a HART communicator menu tree for the ProBar model family, and a table of diagnostic messages associated with the communicator. Appendix B: Standard ODF Dimensions provides mounting height dimensions necessary for installing the ProBar flowmeter. Appendix C: Approval Drawings illustrates Factory Mutual (FM) and Canadian Standards Association (CSA) certified drawings. INSTALLATION FLOWCHART AND CHECKLIST 1-2 Figure 1-1 on page 1-3 shows an installation flowchart to provide guidance through the ProBar installation process. Following the figure, an installation checklist has been provided to verify that all critical steps have been taken in the installation process. The checklist numbers are indicated in the flowchart. Introduction FIGURE 1-1. ProBar Installation Chart 6WDUW 8QSDFN3UR%DU 5HYLHZ3URGXFW ,20DQXDO 5HYLHZ6HFWLRQ Steps 1, 2 ,QVWDOODWLRQ/RFDWLRQDQG 2ULHQWDWLRQWRYHULI\SURSHU ORFDWLRQRIWKHIORZPHWHU Step 3 +D]DUGRXV /RFDWLRQ" <HV 5HYLHZDSSURYDO GUDZLQJV$SSHQGL[' 1R 5HYLHZ6HFWLRQ3UR%DU %HQFK &RQILJXUH" <HV (OHFWURQLF)XQFWLRQVIRU PXOWLSRLQWIORZFDOLEUDWHGDQG QRQIORZFDOLEUDWHG3UR%DUV 1R 9HULI\3UR%DU Step 4 PRGHOLQGLFDWHG RQWDJ Steps 5–9 5HPRWH 0RXQWHG ,QVWDOOKDUGZDUHDFFRUGLQJWR <HV HOHFWURQLFV" 6HFWLRQV±EDVHGRQ 3UR%DUPRGHO ,QVWDOO(OHFWURQLFVDFFRUGLQJ 1R WR6HFWLRQ ,QVWDOOIORZPHWHU Steps 5–9 DFFRUGLQJWR 6HFWLRQV± EDVHGRQ3UR%DU PRGHO :LUH3UR%DU IORZPHWHU DFFRUGLQJWR 6HFWLRQ Steps 11–14 5HPRWH 0RXQWHG HOHFWURQLFV" &RPPLVVLRQ <HV 3UR%DUDFFRUGLQJ WR6HFWLRQ 1R Steps 11–14 &RPPLVVLRQ 3UR%DUDFFRUGLQJ WR6HFWLRQ )LQLVK 1-3 ProBar Flowmeter The following list is a summary of the steps required to complete a ProBar flowmeter installation. If this is an entirely new installation, begin with step 1. If the mounting is already in place, verify that the hole size and the fittings match the recommended specifications, and begin with step 5. 1. Determine where the ProBar is to be placed within the piping system. 2. Establish the proper orientation as determined by the intended ProBar service for the flowmeter. 3. Review Appendix C: Approval Drawings if the flowmeter is located in a hazardous location. 4. Confirm the ProBar configuration. 5. Drill the correct size hole in the pipe. • For ProBar models equipped with opposite-side support, drill a second, identical hole 180 degrees from the first hole. 6. Weld the mounting, and clean the burrs and welds. 7. Measure the pipe’s internal diameter (ID), preferably at 1 x ID from the hole (upstream or downstream). NOTE Providing the pipe internal diameter at the time of purchase is necessary to maintain published flowmeter accuracy. 8. Check the fit-up of the ProBar assembly to the pipe. 9. Install the flowmeter. 10. Wire the ProBar electronics. 11. Supply power to the flowmeter. 12. Perform a zero trim for mounting effects. 13. Check for leaks. 14. Commission the ProBar. 1-4 Section 2 Installation Location and Orientation This section describes the orientation, location, and alignment limits for installing the ProBar flowmeter. Read it thoroughly before any installation is performed. SAFETY MESSAGES Instructions and procedures in this section may require special precautions to ensure the safety of the personnel performing the operations. Please refer to the following safety messages before performing any operation in this section. Explosions could result in death or serious injury: • Do not remove the transmitter cover in explosive atmospheres when the circuit is alive. • Before connecting a HART-based communicator in an explosive atmosphere, make sure the instruments in the loop are installed in accordance with intrinsically safe or non-incendive field wiring practices. • Verify that the operating atmosphere of the transmitter is consistent with the appropriate hazardous locations certifications. • Both transmitter covers must be fully engaged to meet explosion-proof requirements. Failure to follow these installation guidelines could result in death or serious injury: • Make sure only qualified personnel perform the installation. RECEIVING AND INSPECTION ProBar flowmeters are available in different models and with different options, so it is important to inspect and know which model you have before beginning installation. Upon receipt of the shipment, check the packing list against the material received and the purchase order. All items are tagged with a model number, serial number, and customer tag number. Report any damage to the carrier. 2-1 ProBar Flowmeter FIGURE 2-1. ProBar Mounting Configuration Examples: A (Integral Mount) and B (Remote Mount). The ProBar is available in a variety of mounting configurations and has two methods of electronic mounting: integral mount (or, direct mount) and remote mount. An integrally-mounted ProBar may be shipped with the electronics already bolted directly to the sensor. ProBar Electronics ProBar Sensor Mounting Configuration ProBar Sensor Mounting Configuration ProBar Electronics A B The ProBar may be purchased as a multipoint flow calibrated unit for enhanced accuracy and turndown, or as a non-flow calibrated unit. The multipoint flow calibrated units are identified by a note (or in the model callout) which reads: NOTE Replacing the electronics may affect performance. STRUCTURAL LIMITATIONS Structural limitations are printed on the ProBar sensor tag. Exceeding the ProBar structural limitations may cause the sensor to fail. 2-2 8900-8900V30A, 8900_28A PROBAR CONFIGURATIONS Installation Location and Orientation FUNCTIONAL LIMITATIONS The ProBar best produces accurate and repeatable flow measurement under the following conditions: • The maximum differential pressure, as printed on the tag attached to the ProBar, is not exceeded. • The ProBar is not used for two-phase flow or for steam service below saturation temperature. Install the ProBar in the correct location within the piping branch to prevent measurement inaccuracies caused by flow disturbances. ProBar installation allows for a maximum misalignment of 3 degrees, as illustrated in Figure 2-2. Misalignment beyond 3 degrees will cause errors in flow measurement. FIGURE 2-2. Permissible Misalignment for the ProBar. 8900-8900V14A 3° max. 3° max. Straight Run Requirements 3° max. Use Table 2-1 to determine the proper ProBar straight run requirements. NOTES For gas service, multiply values from Table 2-1 by 1.5. If longer lengths of straight run are available, position the ProBar where 80% of the run is upstream of the ProBar and 20% is downstream. Information contained in this manual applies to circular pipes only. Consult the factory for instructions regarding ProBar use in square or rectangular ducts. Straightening vanes may be used to reduce the required straight run length and will improve performance. Row 6 in Table 2-1 applies to gate, globe, plug, and other throttling valves that are partially opened. If a “through-type” valve will remain open, use the values shown in Row 5. Refer to Row 6 for the straight run requirements of a ProBar located downstream of the control valve. 2-3 ProBar Flowmeter TABLE 2-1. Straight Run Requirements. Downstream Dimensions Upstream dimension 4. 5. 6. 2-4 1295-0573C 1295-0573D 1295-0573E 3. 1295-0573F 2. 1295-0573G 1. 1295-0573B Without vanes With vanes In plane A Out of plane A A’ C C’ 8 10 – – – 4 – – 8 4 4 4 11 16 – – – 4 – – 8 4 4 4 23 28 – – – 4 – – 8 4 4 4 12 12 – – – 4 – – 8 4 4 4 18 18 – – – 4 – – 8 4 4 4 30 30 – – – 4 – – 8 4 4 4 Installation Location and Orientation ENVIRONMENTAL CONSIDERATIONS Location of the ProBar in pulsating flow will cause a noisy signal. Vibration can also distort the output signal and compromise the structural limits of the flowmeter. Mount the ProBar in a secure run of pipe as far as possible from pulsation sources such as check valves, reciprocating compressors or pumps, and control valves. Mount the transmitter to minimize ambient temperature changes. Section 15: Specifications and Reference Data lists the temperature operating limits. Mount the transmitter to avoid vibration and mechanical shock; mounting will also avoid external contact with corrosive materials. See Section 8: ProBar Electronics Functions for environmental considerations. ProBar Orientation Proper venting or draining must be considered when selecting a ProBar location. For liquid service, mount the side drain/vent valve upward; this allows gases to vent. For gas service, mount the drain/vent valve down to allow any accumulated liquid to drain. In steam service, fill lines with water to prevent contact of the live steam with the electronics; condensate chambers are not needed because the volumetric displacement of the electronics is negligible. ProBar instrument head connections differ on horizontal and vertical pipes. Refer to the specification head code number to confirm the proper pipe orientation for your ProBar. Horizontal Pipe: Liquid or Steam Application Due to the possibility of air getting trapped in the probe, the ProBar should be located per the drawing below. The area between 0° and 50° (50° angle) should not be used unless full bleeding of air from the probe is possible. Figure 2-3 illustrates the recommended location of the flowmeter. FIGURE 2-3. Liquid or Steam Service in a Horizontal Pipe. 50° 80° (Recommended Zone) 8900-8900V15A 50° 2-5 ProBar Flowmeter Horizontal Pipe: Air and Gas Applications The ProBar should be located on the upper half of the pipe, at least 30° above the horizontal line. Figure 2-4 illustrates the recommended location of the flowmeter. FIGURE 2-4. Air and Gas Applications in a Horizontal Pipe. 30° The ProBar can be installed in any position around the circumference of the pipe, provided the vents are positioned properly for bleeding or venting. Vertical pipe installations require more frequent bleeding or venting depending on the location. Figure 2-5 illustrates the recommended location of the flowmeter. Flow FIGURE 2-5. Liquid, Air, and Gas Applications in a Vertical Pipe. 8900-8900V19A Vertical Pipe: Liquid, Air, Gas, and Steam Applications 30° 8900-8900V16A 120° (Recommended Zone) Opposite-Side Support 360° Remote mounting is required for steam installations; see Figure 2-6. ProBar Remote Head Instrument Valve 2-6 8900-8900_04A FIGURE 2-6. Steam Service in a Vertical Pipe. Installation Location and Orientation Process Connections (Remote Mounted ProBar only) The ProBar process connections on the electronics flange are ¼–18 NPT. Flange adapter unions with ½–14 NPT connections are supplied as standard with the remote mounted ProBar. The threads are Class 2; use your plantapproved lubricant or sealant when making the process connections. The process connections on the electronics flange are on 21/8-inch (54 mm) centers to allow direct mounting to a three-valve or five-valve manifold. Rotate one or both of the flange adapters to attain connection centers of 2 inches (51 mm), 21/8 inches (54 mm), or 2¼ inches (57 mm). Install and tighten all four flange bolts before applying pressure, or process leakage will result. When properly installed, the flange bolts will protrude through the top of the module housing. Do not attempt to loosen or remove the flange bolts while the ProBar is in service. Perform the following procedure to install adapters to a coplanar flange: 1. Remove the flange bolts. 2. Leaving the flange in place, move the adapters into position with the o-ring installed. 3. Clamp the adapters and the coplanar flange to the transmitter module using the larger of the bolts supplied. 4. Tighten the bolts. Refer to Mounting Bolts on page 2-8 for torque specifications. Failure to install proper flange adapter O-rings can cause process leaks, which can result in death or serious injury. The flange adapters require a unique O-ring, as shown below. Flange Adapter O-ring Unique O-ring Grooves When compressed, Teflon® O-rings tend to cold flow, which aids in their sealing capabilities. Whenever you remove flanges or adapters, visually inspect the Teflon O-rings. Replace them if there are any signs of damage, such as nicks or cuts. If they are undamaged, you may reuse them. If the you replace the O-rings, retorque the flange bolts after installation to compensate for cold flow. Refer to the process sensor body reassembly procedure in Section 15: Troubleshooting. 2-7 ProBar Flowmeter Mounting Bolts The following guidelines have been established to ensure a tight flange, adapter, or manifold seal. The ProBar is shipped with the Coplanar flange installed with four 1.75-inch flange bolts. The following bolts also are supplied to facilitate other mounting configurations: Bolt Installation Only use bolts supplied with the ProBar or sold by Rosemount Inc. as spare parts for the ProBar. Use the following bolt installation procedure: 1. Finger-tighten the bolts. 2. Torque the bolts to the initial torque value using a cross-pattern (see Table 2-2 for torque values). 3. Torque the bolts to the final torque value using the same cross-pattern. TABLE 2-2. Bolt Installation Torque Values. 2-8 Bolt Material Initial Torque Value Final Torque Value Carbon Steel (CS) 300 in-lb (34 N-m) 650 in-lb (73 N-m) Stainless Steel (SST) 150 in-lb (17 N-m) 300 in-lb (34 N-m) Section 3 PROBAR MODELS: PBR+15S/16S PBR+25S/26S PBR+35S/36S PBR+45S/46S Hardware Installation for ProBar Regular (Threaded, Pak-Lok) This section provides hardware installation instructions for the ProBar Regular (Threaded, Pak-Lok) for service in either a horizontal or vertical pipe. Installation procedures are similar for all services. Service-specific instructions are provided where necessary; otherwise, all instructions in this section apply to all services. If remote mounting of the electronics is required, use this section for hardware installation. Then, see Section 8: ProBar Remote Mounting for electronics installation. • The direct mount maximum service temperature is 500 °F (260 °C). • The electronics must be remote mounted when service temperatures exceed 500 °F (260 °C). • ProBar models with a sensor size of 15 or 16 require remote mounted electronics. After installing the sensor, refer to Section 8: ProBar Remote Mounting for electronics installation instructions. • ProBar models with a sensor size of 45 or 46 are shipped with a packing guide cover instead of a compression nut. SAFETY MESSAGES Instructions and procedures in this section may require special precautions to ensure the safety of the personnel performing the operations. Please refer to the following safety messages before performing any operation in this section. Explosions could result in death or serious injury: • Do not remove the transmitter cover in explosive atmospheres when the circuit is alive. • Before connecting a HART-based communicator in an explosive atmosphere, make sure the instruments in the loop are installed in accordance with intrinsically safe or non-incendive field wiring practices. • Verify that the operating atmosphere of the transmitter is consistent with the appropriate hazardous locations certifications. • Both transmitter covers must be fully engaged to meet explosion-proof requirements. Failure to follow these installation guidelines could result in death or serious injury: • Make sure only qualified personnel perform the installation. 3-1 ProBar Flowmeter FIGURE 3-1. ProBar Regular Components. Figure 3-1 identifies the components of the ProBar Regular. The flowmeter is shown in this position for hardware clarity; see the actual installation instructions for proper positioning of the flowmeter. Compression Nut Integral 3-Valve Manifold Head ProBar Electronics Packing Follower Weld Coupling with Shaped Support Ring Support Plug Adapter Body WeldLock Ring Packing Rings (3) Pipe Supplied by Customer Weld Fitting (opposite-side support) Flow Sensor (316L) 8900-8900V18A PROBAR REGULAR COMPONENTS STEP 1: DETERMINE THE PROPER PROBAR ORIENTATION Orientation of the ProBar depends upon two factors: the orientation of the pipe that will receive the flowmeter, and the service that uses the pipe. The following sections provide illustrations of the possible pipe orientations and services. After determining the flowmeter orientation, proceed with Step 2 on page 3-5. Liquid Service in a Horizontal Pipe Install the flowmeter within 40 degrees of the vertical axis to prevent air from becoming entrapped within the probe. Do not position the ProBar within 50 degrees of the horizontal axis unless full bleeding of air from the probe is possible. Figure 3-2 illustrates the recommended location for the ProBar when used with liquid service. FIGURE 3-2. Liquid Service in a Horizontal Pipe. 50° 80° (Recommended Zone) 3-2 8900-8900V15A 50° Hardware Installation for ProBar Regular (Threaded, Pak-Lok) Gas Service in a Horizontal Pipe Install the flowmeter in the upper half of the pipe, but not within 30 degrees of the horizontal axis, as shown in Figure 3-3 below. This orientation prevents condensate from becoming entrapped in the sensor probe. FIGURE 3-3. Gas Service in a Horizontal Pipe. 30° Steam Service in a Horizontal Pipe 30° 8900-8900V16A 120° (Recommended Zone) Install the flowmeter within 40 degrees of the vertical axis to prevent air from becoming entrapped within the sensor probe. Do not position the ProBar within 50 degrees of the horizontal axis unless full bleeding of air from the probe is possible. Figure 3-4 illustrates the recommended location for the ProBar when used with steam service. FIGURE 3-4. Steam Service in a Horizontal Pipe. 50° 80° (Recommended Zone) 8900-8900V15A 50° 3-3 ProBar Flowmeter Install the flowmeter anywhere around the circumference of the pipe, as shown in Figure 3-5. The ProBar electronics run in the opposite direction of the process piping. 8900-8900V19A Flow FIGURE 3-5. Liquid or Gas Service in a Vertical Pipe. Opposite-Side Support 360° Steam Service in a Vertical Pipe FIGURE 3-6. Steam Service in a Vertical Pipe. Install the flowmeter anywhere around the circumference of the pipe, as shown in Figure 3-6. The ProBar electronics must be remote mounted. See Section 8: ProBar Remote Mounting for instructions. ProBar Remote Head Instrument Valve SHIPPING NOTE 3-4 All ProBar Regular models are shipped with the ProBar sensor pre-assembled and the Pak-Lok nut, follower, and lock ring in place. The factory-supplied weld fitting with support ring is required to install the ProBar. To prevent injury, remove pressure and drain pipe before installing or removing the sensor. 8900-8900_04A Liquid or Gas Service in a Vertical Pipe Hardware Installation for ProBar Regular (Threaded, Pak-Lok) STEP 2: DRILL THE HOLE IN THE PIPE Follow the steps below to drill the hole in the pipe. 1. Depressurize and drain the pipe. 2. Select the location for the hole you are about to drill. Select a location anywhere around the circumference of the pipe for vertical pipes. For horizontal pipes, the hole location depends upon the service for which the ProBar is to be used: • Liquid service: drill the hole along the bottom of the pipe • Gas service: drill the hole along the top of the pipe • Steam service: drill the hole along the bottom of the pipe 3. Determine the diameter of the hole to be drilled. Use the chart in Figure 3-7. 4. After the hole is drilled, deburr the hole on the inside of the pipe. Drill a Hole for Opposite-Side Support A second hole must be drilled for the opposite-side support weld coupling if opposite-side support is supplied. This hole must be the same diameter as the first hole; place it directly opposite the first hole so that the sensor can pass completely through the pipe. Use the following steps to find the location for the second hole: 1. Wrap a piece of soft wire or string around the pipe to measure the pipe’s circumference. 2. Remove the wire or string and measure half of the circumference length. 3. Re-wrap the half-length around the pipe from the center of the first hole. 4. Mark the center of what will become the second hole, as shown in Figure 3-7. Note: Drill the hole 180 degrees from the first hole for opposite-side support models. Drill Sensor 15/16 25/26 35/36 45/46 Drill the appropriate diameter hole through the pipe wall. Diameter (in.) 7 /16 /8 1-5/16 2-1/8 7 8900-8900_15A FIGURE 3-7. Sensor Size/Hole Diameter Chart. 5. Deburr the drilled hole on the inside of the pipe. 3-5 ProBar Flowmeter STEP 3: TACK WELD THE FITTINGS TO THE PIPE Follow these steps to tack weld the fittings to the pipe: 1. Insert the ProBar assembly into the factory-supplied weld fitting (with integral support ring), then into the hole. 2. Align the head and electronics so they are parallel with the ground. 3. Tack weld the fitting(s) to the pipe and remove the ProBar. See Figure 3-8 below. FIGURE 3-8. Tack Weld the Fittings to the Pipe. 8900-8900V20A The support ring shall be in-line or parallel to plane of pipe as shown. NOTE The larger radius in Figure 3-8 must be parallel to the centerline of the pipe. To protect the weld fitting threads from weld splatter, wrap the factory-supplied heavy aluminum foil around the threads before welding, or use a thread protector cap, as shown in Figure 3-9. Be sure to allow the mounting to cool or serious burns may occur. FIGURE 3-9. Protect Threads from Weld Splatter: A (Liquid or Steam Service) and B (Gas Service). A B 8900-8900_16A Protect Threads from Weld Splatter 3-6 Hardware Installation for ProBar Regular (Threaded, Pak-Lok) STEP 4: INSERT THE PROBAR INTO THE PIPE After the mounting hardware has cooled, install the adapter body and support plug (for opposite-side support models), as shown in Figure 3-10. Use a sealant compound rated for use at the process temperature on the threads. NOTE The adapter body must be threaded into the weld fitting before the Pak-Lok nut is threaded onto the adapter body. A B Adapter Body Support Plug Weld Fitting (opposite-side support models) Weld Fitting 8900-8900_01A FIGURE 3-10. Adapter Body and Support Plug Installation: A (Liquid or Steam Service) and B (Gas Service). Weld Fitting (opposite-side support models) Weld Fitting Adapter Body Support Plug 1. Mark the tip of the ProBar sensor with a marker. 2. Insert the flowmeter into the adapter body until the sensor tip contacts the pipe wall (or support plug). 3. Remove the flowmeter. 4. Verify that the sensor tip touched the pipe wall. If the tip did not touch the wall, adjust the adapter body until sensor tip touches the wall, and re-install the ProBar. 5. Install the first packing ring on the ProBar between the lock ring and the packing follower; take care not to damage the split packing rings. 6. Push the packing ring into the adapter body and against the weld-lock ring. Repeat this process for the two remaining rings, alternating the location of the packing ring split by 180 degrees. Figure 3-11 illustrates the ProBar insertion process described here. A B Weld Fitting Weld Lock Ring Packing Follower Packing Rings (3) Compression Nut ProBar Electronics Packing Follower Weld Lock Ring Weld Fitting ProBar Electronics 8900-8900V22A FIGURE 3-11. Packing Ring Installation: A (Liquid or Steam Service) and B (Gas Service). 3-7 ProBar Flowmeter NOTE If the ProBar appears to be too long, go back to step 3. Verify that the adapter body was installed into the weld fitting before the ProBar was installed. 7. With the flow arrow on the ProBar head pointed in the direction of the pipe flow, thread the Pak-Lok nut onto the adapter fitting until it is hand tight only. 8. Use a wrench to tighten the Pak-Lok nut in ¼ turn increments until it has been tightened one full turn. The Pak-Lok nut should be tightened only enough to prevent leakage. Do not overtighten the Pak-Lok nut; damage to the sensor will result. NOTE Use a maximum of 1¼ turns when installing the sensor. This is critical when installing ProBar models with a sensor size of 15 or 16. 3-8 Section 4 Hardware Installation for ProBar Flanged PROBAR MODELS: PBF+15S/16S PBF+25S/26S PBF+25H/26H PBF+25M/26M PBF+35S/36S PBF+45S/46S PBF+45H/46H PBF+45M/46M This section provides hardware installation instructions for the ProBar Flanged for service in either a horizontal or vertical pipe. Installation procedures are similar for all services. Service-specific instructions are provided where necessary; otherwise, all instructions in this section apply to all services. SAFETY MESSAGES Instructions and procedures in this section may require special precautions to ensure the safety of the personnel performing the operations. Please refer to the following safety messages before performing any operation in this section. If remote mounting of the electronics is required, use this section for hardware installation. Then, see Section 8: ProBar Remote Mounting for electronics installation. • The direct mount maximum service temperature is 500 °F (260 °C). • The electronics must be remote mounted when service temperatures exceed 500 °F (260 °C). Explosions could result in death or serious injury: • Do not remove the transmitter cover in explosive atmospheres when the circuit is alive. • Before connecting a HART-based communicator in an explosive atmosphere, make sure the instruments in the loop are installed in accordance with intrinsically safe or non-incendive field wiring practices. • Verify that the operating atmosphere of the transmitter is consistent with the appropriate hazardous locations certifications. • Both transmitter covers must be fully engaged to meet explosion-proof requirements. Failure to follow these installation guidelines could result in death or serious injury: • Make sure only qualified personnel perform the installation. 4-1 ProBar Flowmeter FIGURE 4-1. ProBar Flanged Components. Integral 3-Valve Manifold Head Figure 4-1 identifies the components of the ProBar Flanged. Sensor (316) Sensor Flange Support Plug Weld-Neck Flange ProBar Electronics Weld Fitting Weld Coupling Stud and Nut Set Pipe Supplied by Customer 8900-8900V03A PROBAR FLANGED COMPONENTS STEP 1: DETERMINE THE PROPER ORIENTATION OF THE PROBAR The orientation of the flowmeter depends upon two factors: the orientation of the pipe that will receive the flowmeter, and the service that uses the pipe. The following sections provide illustrations of the possible pipe orientations and services. After determining the flowmeter orientation, proceed with step 2 on page 4-4. Liquid Service in a Horizontal Pipe Install the flowmeter within 40 degrees of the vertical axis to prevent air from becoming entrapped within the sensor probe. Do not position the ProBar within 50 degrees of the horizontal axis unless full bleeding of air from the probe is possible. Figure 4-2 illustrates the recommended location for the ProBar when used with liquid service. FIGURE 4-2. Liquid Service in a Horizontal Pipe. 50° 80° (Recommended Zone) 4-2 8900-8900V04A 50° Hardware Installation for ProBar Flanged Gas Service in a Horizontal Pipe Install the flowmeter in the upper half of the pipe, but not within 30 degrees of the horizontal axis, as shown in Figure 4-3. This will prevent condensate from becoming entrapped in the sensor probe. FIGURE 4-3. Gas Service in a Horizontal Pipe. 30° Steam Service in a Horizontal Pipe 8900-8900V05A 120° (Recommended Zone) 30° Install the flowmeter within 40 degrees of the vertical axis to prevent air from becoming entrapped within the sensor probe. Do not position the ProBar within 50 degrees of the horizontal axis unless full bleeding of air from the probe is possible. Figure 4-4 illustrates the recommended location for the ProBar when used with steam service. FIGURE 4-4. Steam Service in a Horizontal Pipe. 50° 8900-8900V04A 50° 80° (Recommended Zone) Liquid Service in a Vertical Pipe Install the flowmeter anywhere around the circumference of the pipe, as shown in Figure 4-5 below. 8900-8900V10A FIGURE 4-5. Liquid Service in a Vertical Pipe. 4-3 ProBar Flowmeter Gas Service in a Vertical Pipe Install the flowmeter anywhere around the circumference of the pipe, as shown in Figure 4-5 below. The ProBar electronics run in the opposite direction of the process piping. 8900-8900V11A FIGURE 4-6. Gas Service in a Vertical Pipe. Steam Service in a Vertical Pipe Install the ProBar anywhere around the circumference of the pipe, as shown in Figure 4-7. The ProBar electronics must be remote mounted. See Section 8: ProBar Remote Mounting for instructions. 8900-8900_05A FIGURE 4-7. Steam Service in a Vertical Pipe. SHIPPING NOTE All ProBar Flanged models are shipped with the weld fitting and weld-neck flange pre-welded for ease of installation. To prevent injury, remove pressure and drain the pipe before installing or removing the sensor. STEP 2: DRILL THE HOLE IN THE PIPE Follow the steps below to drill the hole in the pipe. 1. Depressurize and drain the pipe. 2. Select the location for the hole you are about to drill. Select a location anywhere around the circumference of the pipe for vertical pipes. For horizontal pipes, the hole location depends upon the service for which the ProBar is to be used: • Liquid service: drill the hole along the bottom of the pipe • Gas service: drill the hole along the top of the pipe • Steam service: drill the hole along the bottom of the pipe 3. Use the chart in Figure 4-8 to determine the diameter of the hole to be drilled. 4. After the hole is drilled, deburr the hole on the inside of the pipe. 4-4 Hardware Installation for ProBar Flanged Drill a Hole for Opposite-Side Support A second hole must be drilled for the opposite-side support weld coupling if opposite-side support is supplied. This hole must be the same diameter as the first hole; place it directly opposite the first hole so that the sensor can pass completely through the pipe. Use the following steps to find the location for the second hole: 1. Wrap a piece of soft wire or string around the pipe to measure the pipe’s circumference. 2. Remove the wire or string and measure half of the circumference length. 3. Re-wrap the half-length around the pipe from the center of the first hole. 4. Mark the center of what will become the second hole, as shown in Figure 4-8. FIGURE 4-8. Sensor Size/Hole Diameter Chart. Note: Drill the hole 180 degrees from the first hole for opposite-side support models. Drill 15/16 25/26 35/36 45/46 Diameter (in.) 7 /16 /8 1-5/16 2-1/8 7 Drill the appropriate diameter hole through the pipe wall. 8900-8900_15A Sensor 5. Deburr the drilled hole on the inside of the pipe. STEP 3: WELD THE WELDNECK FLANGE STEP 4: ASSEMBLE THE PROBAR AND MOUNTING HARDWARE Weld the weld-neck flange and weldolet assembly to the pipe. See Appendix B: Standard ODF Dimensions for the proper ODF. 1. Assemble the ProBar to the mounting hardware with the gasket and bolts. 2. Hand-tighten the bolts just enough to hold the position of the ProBar sensor centered in the mounting hardware. 3. Install the studs and nuts. 4. Tighten the studs and nuts in a cross pattern. 5. Attach the ProBar to the mounting hardware as described below. (The high point of the contoured weld fitting will define the alignment of the ProBar to the pipe. For horizontal pipes, the ProBar head axis will be parallel to the pipe axis. For vertical pipes, the ProBar head will be perpendicular to the pipe axis.) 4-5 ProBar Flowmeter STEP 5: CHECK THE FIT-UP OF THE PROBAR TO THE PIPE 1. Check the fit of the ProBar to the pipe by inserting a rule, stick, or stiff wire through the hole. 2. Note the distance from the opposite inside wall to the outside wall at the hole. 3. Measure the distance on the ProBar assembly from the weld fitting high point to the ProBar sensor tip. The length should be slightly less than the measured length of the pipe. Large discrepancies may cause installation problems or errors in measurement. See Figures 4-9 and 4-10. High Point ODF High Point to Sensor Tip Inside Wall to Top of Pipe ODF Inside Wall to Top of Pipe High Point to Sensor Tip 8900-8900V13A FIGURE 4-9. ProBar Fit-Up Check for Liquid or Steam Service. High Point 4-6 8900-8900V07A FIGURE 4-10. ProBar Fit-Up Check for Gas Service. Hardware Installation for ProBar Flanged Check the Fit-Up of the ProBar with OppositeSide Support 1. Check the fit of the ProBar assembly to the pipe by inserting a rule, stick, or stiff wire through both mounting holes. 2. Note the distance across the outside wall (pipe outside diameter). 3. Transfer this length to the ProBar assembly from the high point of weld fitting to the ProBar sensor. The marked distance to the first ProBar sensing port A (near the tip) should be the same as the distance from the high point of the weld fitting to the closest sensing port B. Small discrepancies can be compensated for with the fit-up of the mounting hardware. Large discrepancies may cause installation problems or errors in measurement. See Figures 4-11 and 4-12. FIGURE 4-11. ProBar with Opposite-Side Support FitUp Check for Liquid or Steam Service. Port B The same within 1/8-in. Pipe Outside Diameter ODF 8900-8900V12A Port A FIGURE 4-12. ProBar with Opposite-Side Support FitUp Check for Gas Service. ODF Port B The same within 1/8-in. Port A 8900-8900V06A Pipe Outside Diameter 4-7 ProBar Flowmeter STEP 6: TACK WELD THE MOUNTING HARDWARE Follow these steps to tack weld the mounting hardware. 1. Insert the ProBar assembly through the pipe hole. 2. Align the flow arrow on the ProBar head to point in the direction of the flow. 3. Check that the contoured weld fitting is aligned properly on the pipe wall. The ProBar tip should just touch or be just above the inside opposite pipe wall. 4. Confirm that the ProBar is perpendicular to the pipe. 5. Tack weld the fitting to the pipe with the proper weld gap. Tack Weld the OppositeSide Support Fitting If opposite-side support is supplied, follow the instructions below. 1. Insert the ProBar assembly through the pipe wall, making sure that the tip of the sensor passes through the opposite wall. 2. Align the flow arrow on the ProBar head to point in the direction of the flow. 3. Check that the contoured weld fitting is aligned properly on the pipe wall. 4. Check the alignment of the assembly to the pipe. 5. Tack weld the fitting to the pipe with the proper weld gap, as shown in Figure 4-13. 6. Assemble the support coupling to the support plug until it is hand tight. 7. Slide the assembly over the sensor tip protruding from the pipe wall. The sensor tip should engage the plug bore. 8. Align the contour of the fitting to the pipe and tack weld the fitting to the pipe with the proper weld gap. FIGURE 4-13. Tack Weld the Opposite-Side Support Fitting: A (Liquid or Steam Service) and B (Gas Service). 1 /16-in. Weld Gap A B Flow Flow 1 /16-in. Weld Gap 1 Flow Flow 1 /16-in. Weld Gap STEP 7: FINISH WELDING 4-8 Disassemble the ProBar and mounting hardware. Remove the gasket. Complete welding the weld fitting and support coupling (if required). 8900-8900V08A /16-in. Weld Gap Hardware Installation for ProBar Flanged STEP 8: ASSEMBLE THE PROBAR AND MOUNTING FLANGE Opposite-Side Support 1. Allow the mounting hardware to cool to avoid serious burns. 1. Reassemble the ProBar and mounting flange using gasket, bolts, and nuts. 2. Tighten the nuts in a cross pattern to allow even compression of the gasket. If opposite-side support is supplied, apply an appropriate thread-sealant compound to the support plug threads. Assemble the plug and support coupling. Be sure to tighten the plug until it bottoms on the ProBar tip. NOTE Threaded connections may have to be retightened after the system comes up to operating temperature. A B Flow Flow Flow Flow 8900-8900v09a FIGURE 4-14. Opposite-Side Support Plug and Coupling Assembly: A (Liquid or Steam Service) and B (Gas Service). 4-9 ProBar Flowmeter 4-10 Section 5 PROBAR MODELS: PHF+15S PHF+25S PHF+25M PHF+35S PHF+45S PHF+45H PHF+45M Hardware Installation for ProBar Flanged Flo-Tap This section provides hardware installation instructions for the ProBar Flo-Tap used in either a horizontal or vertical pipe. Installation procedures are similar for all services. Service-specific instructions are provided where necessary; otherwise, all instructions in this section apply to all services. If remote mounting of the electronics is required, use this section for the hardware installation. Then, see Section 8: ProBar Remote Mounting for electronics installation. • The direct mount maximum service temperature is 500 °F (260 °C). • The electronics must be remote mounted when service temperatures exceed 500 °F (260 °C). SAFETY MESSAGES Instructions and procedures in this section may require special precautions to ensure the safety of the personnel performing the operations. Please refer to the following safety messages before performing any operation in this section. Explosions could result in death or serious injury: • Do not remove the transmitter cover in explosive atmospheres when the circuit is alive. • Before connecting a HART-based communicator in an explosive atmosphere, make sure the instruments in the loop are installed in accordance with intrinsically safe or non-incendive field wiring practices. • Verify that the operating atmosphere of the transmitter is consistent with the appropriate hazardous locations certifications. • Both transmitter covers must be fully engaged to meet explosion-proof requirements. Failure to follow these installation guidelines could result in death or serious injury: • Make sure only qualified personnel perform the installation. 5-1 ProBar Flowmeter PROBAR FLO-TAP COMPONENTS Figure 5-1 identifies the components of the ProBar Flo-Tap. FIGURE 5-1. ProBar Flo-Tap Components. Gear Drive Handle Gear Drive Rod Protective Cover Weld-Neck Mounting Flange Rods ProBar Electronics Packing Gland Cage Nipple Sensor Isolation Valve 8900-8900V23A Integral 3-Valve Manifold Head STEP 1: DETERMINE THE PROPER ORIENTATION OF THE PROBAR The orientation of the ProBar depends upon two factors: the orientation of the pipe that will receive the flowmeter, and the service that uses the pipe. The following sections provide illustrations of the possible pipe orientations and services. After determining the ProBar’s orientation, proceed with step 2 on page 5-4. Liquid or Steam Service in a Horizontal Pipe Install the ProBar within 40 degrees of the vertical axis to prevent air from becoming entrapped within the sensor probe. Do not position the ProBar within 50 degrees of the horizontal axis unless full bleeding of air from the probe is possible. Figure 5-2 illustrates the recommended location for the ProBar when used with liquid or steam service. FIGURE 5-2. Liquid or Steam Service in a Horizontal Pipe. 50° 80° (Recommended Zone) 5-2 8900-8900V24A 50° Hardware Installation for ProBar Flanged Flo-Tap Gas Service in a Horizontal Pipe Install the ProBar Flo-Tap in the upper half of the pipe, but not within 30 degrees of the horizontal axis. This orientation will prevent condensate from becoming entrapped in the sensor probe. Figure 5-3 illustrates the recommended location of the ProBar when used with gas service. FIGURE 5-3. Gas Service in a Horizontal Pipe. 30° Liquid or Gas Service in a Vertical Pipe 8900-8900V27A 120° (Recommended Zone) 30° Install the ProBar anywhere around the circumference of the pipe, as shown in Figure 5-4. 8900-8900V28A FIGURE 5-4. Liquid or Gas Service in a Vertical Pipe. Flow NOTE Verify that the pipe pressure and temperature are within the rated limits of the Flo-Tap ProBar as shown on the ProBar tag or by the flow calculation provided by the factory. 5-3 ProBar Flowmeter Steam Service in a Vertical Pipe Install the ProBar anywhere around the circumference of the pipe, as shown in Figure 5-5. • ProBar electronics must be remote mounted when used with steam service in a vertical pipe installations. See Section 8: ProBar Remote Mounting for instructions. All hardware required for installation under pressure is furnished with the Flo-Tap. The required hardware is shown in Figure 5-6. NOTE During insertion and retraction, the flow rate must be reduced below the limits shown on the ProBar tag. FIGURE 5-6. Pressure Installation Hardware. Locking Mechanism Clean-Out Notch Bleeder Valve Flanged Nipple Oil Hole Collar Feed Tube Ratchet Handle 8900-8900_17A STEP 2: OBTAIN THE REQUIRED WELDING EQUIPMENT AND HARDWARE 8900-8900V29A FIGURE 5-5. Steam Service in a Vertical Pipe. The additional welding equipment, pressure drilling machine and the special tooling required is as follows. 1. Welding equipment. 2. Pressure (hot-tap) drilling machine: Mueller D-5, T.D. Williamson T-101, 360 or equivalent. Maximum working pressure = 1440 psig @ 100 °F, or 700 psig @ 700 °F. 3. A flanged machine adapter nipple that fits the isolation valve, such as those available from Mueller or T.D. Williamson. NOTE A blind flange, bored and tapped with the proper thread, can be used instead of the flanged nipple. 4. Drill bit: 7/16-in, 7/8-in, 15/16-in. 5. Drill holder: 7/16-in, 7/8-in, 15/16-in. Items 2 through 5 are available from a drilling machine manufacturer, such as Mueller Co., in Decatur, IL. or T.D. Williamson, in Tulsa, OK. This equipment can usually be purchased locally, or the local utility company may be able to provide pressure drilling, or “hot-tapping” services. 5-4 Hardware Installation for ProBar Flanged Flo-Tap STEP 3: PREPARE THE WELDNECK FLANGE ASSEMBLY 1. Grind off any paint or other coatings from the pipe in the area where the weld fitting is to be positioned. 1. Orient the flange to the pipe so that the pipe centerline is between the holes of the flange, and in line with the pipe axis, as shown in Figures 5-7 and 5-8. 2. Position the weld-neck assembly on the pipe. 3. Tack weld the weld-neck in place with the proper weld gap. FIGURE 5-7. Weld Fitting/Weld-Neck Flange Assembly for Liquid or Steam Service. Flow 1 /16-in. Weld Gap ODF Field Weld Field Weld Weld-Neck Flange Alignment is Critical 8900-8900_38A Flow FIGURE 5-8. Weld Fitting/Weld-Neck Flange Assembly for Gas Service. Flow Weld-Neck Flange Alignment is Critical Field Weld 1 /16-in. Weld Gap Flow 8900-8900_38A ODF Field Weld 5-5 ProBar Flowmeter STEP 4: WELD THE WELDNECK FLANGE Weld the weld fitting/weld-neck flange assembly to the pipe. See Appendix B: Standard ODF Dimensions for the proper ODF dimensions. STEP 5: ATTACH THE UNIT ISOLATION VALVE Fasten the unit isolation valve to the weld-neck flange with the gasket, bolts and nuts. The valve stem must be positioned to provide clearance for the Flo-Tap insert/retract mechanism, as shown in Figure 5-9. Tighten the bolts in a cross pattern to compress the gasket evenly. STEP 6: ATTACH THE ADAPTER Fasten the special adapter flanged nipple to the unit isolation valve, as shown in Figure 5-9. Adapter Fully Open Flow Flow STEP 7: ATTACH THE PRESSURE DRILLING MACHINE 8900-8900_07A FIGURE 5-9. Valve Stem and Adapter Positioning. Install the drill bit and adapter nipple into the pressure drilling machine. Use the chart in Figure 5-10 to determine the drill bit size according to the size of the sensor. Attach the machine to the special flanged nipple, as shown in Figure 5-10. FIGURE 5-10. Pressure Drilling Diagram. Drill Sensor 15 25 35 45 Diameter (in.) 7 Pressure Drilling Machine /16 /8 1-5/16 2-1/8 7 Unit Isolation Valve is Fully Closed After Withdrawing Drill 8900-8900_08A Unit Isolation Valve is Fully Open When Inserting Drill 5-6 Hardware Installation for ProBar Flanged Flo-Tap STEP 8: DRILL THE HOLE Drill the hole through the pipe wall in accordance with the instructions supplied with the drilling machine. The hole is completely drilled when resistance to the hand cranking reduces, or when the air or hydraulic drilling motor speeds up. After the hole is drilled, retract the drill fully beyond the unit isolation valve. STEP 9: REMOVE THE DRILLING MACHINE 1. Withdraw the drill past the valve. 2. Close the unit isolation valve. 3. Bleed and remove the drilling machine and special flanged nipple. 4. Check the unit isolation valve and welds for leakage. FIGURE 5-11. Flo-Tap Assembly on the Closed Unit Isolation Valve. Install the complete Flo-Tap assembly onto the unit isolation valve as shown in Figure 5-11 below. NOTE When installing the Flo-Tap assembly, take care not to scratch or dent any portion of the sealing surfaces. Flo-Tap Assembly Closed Unit Isolation Valve 8900-8900_09A STEP 10: INSTALL THE FLOTAP ASSEMBLY 1. Align the flow arrow on the ProBar head with the pipe axis. 2. Point the arrow in the direction of the flow. 3. Use the gasket and flange bolts supplied to fasten the Flo-Tap assembly to the isolation valve. 4. Tighten the nuts in a cross pattern to compress the gasket evenly. 5. Ensure that the vent valves on the ProBar are closed before proceeding with the next step. STEP 11: OPEN THE ISOLATION VALVE STEP 12: TIGHTEN THE BOLTS 1. Slowly open the isolation valve. 2. Check the entire installation for leakage. 3. Tighten connections as required or reapply thread sealant to repair any leakage. Alternately tighten the packing gland bolts as required to eliminate leakage. Do not overtighten. 5-7 ProBar Flowmeter STEP 13: INSERT THE SENSOR Standard Drive (IHR) Insert the sensor with one of the two drive options available on the ProBar Flo-Tap; standard drive (IHR) or gear drive (IHD). Follow the instructions for the drive option used by your ProBar, then proceed with step 12 on page 5-9. 1. Position the retract drive nuts near the orange stripe on the threaded rods before initiating insertion. 2. Insert the sensor by rotating the insert drive nuts counterclockwise as viewed from the top. The nuts must be tightened alternately, about two turns at a time, to prevent binding caused by unequal loading. 3. Continue this procedure until the sensor firmly contacts the opposite pipe wall. NOTE Do not over-insert the sensor as damage to the sensor or pipe may occur. 4. After the sensor is fully inserted, with the tip solidly against the pipe wall, set the insertion stop nuts in place. 5. Tighten the nuts on either side of the packing gland against the gland. 6. Tighten the second nut against the first as a lock nut, as shown in Figure 5-12. FIGURE 5-12. Setting the Stop Nut and Lock Nut. Lock Nut Packing Gland Stop Nut 8900-8900_10A Stop Nut NOTE Refer to the tag attached to the ProBar for insertion stop nut location instructions. The orange paint stripe on the rods alert the installer that the sensor is approaching full insertion. 5-8 Hardware Installation for ProBar Flanged Flo-Tap Gear Drive (IHD) 1. Insert the ProBar sensor by rotating the crank clockwise. If a power drill with an adapter is used, do not exceed 200 rpm. 2. Continue rotating the crank until the sensor firmly contacts the opposite side of the pipe. 3. Secure the drive by inserting the drive lock pin, as shown in Figure 5-13. NOTE For operating and maintenance procedures for the gear drive option, see DS-1635. FIGURE 5-13. Insert the Drive Lock Pin. 8900-8900_11A Drive Lock Pin NOTE Refer to the tag attached to the ProBar for insertion stop nut location instructions. The orange paint stripe on the rods alert the installer that the sensor is approaching full insertion. Remove the drill and complete the insertion manually until the sensor firmly contacts the pipe wall. STEP 14: CHECK FOR LEAKAGE Inspect the packing gland for leakage. Tighten any bolts as required to stop leakage. 5-9 ProBar Flowmeter STEP 15: RETRACT THE SENSOR Standard Drive (IHR) Retract the sensor with one of two drive options available on the ProBar FloTap; standard drive (IHR) or gear drive (IHD). Follow the instructions for the drive option used by your ProBar, then proceed with step 16 on page 5-10. 1. Retract the Flo-Tap by rotating the retract drive nuts clockwise as viewed from the top. The nuts must be turned alternately, about two turns at a time, to prevent binding caused by unequal loading. 2. Continue this procedure until the rod end nuts are against the packing body mechanism. FIGURE 5-14. ProBar Flo-Tap at Full Retraction and Insertion. Fully Inserted 8900-8900V25A, 8900V26A Fully Retracted Personal hazard! To prevent injury, remove pressure and drain pipe or cage nipple assembly before installing or removing sensor. Gear Drive (IHD) 1. Remove the drive lock pin. 2. Retract the sensor by rotating the crank counterclockwise. If a power drill with adapter is used, do not exceed 200 rpm. 3. Retract until the rod end nuts are against the packing body mechanism. STEP 16: CLOSE THE ISOLATION VALVE After the sensor is fully retracted, the Flo-Tap unit isolation valve may be closed to isolate the probe from the pipe. STEP 17: REMOVE THE FLO-TAP ASSEMBLY The Flo-Tap may be removed entirely if desired by unbolting the cage nipple from the unit isolation valve. If the ProBar is to be removed entirely from the isolation valve, the cage nipple must be depressurized. Open the equalizer valve on the ProBar head, then open the vent valve on either the high or low side of the ProBar. 5-10 Section 6 PROBAR MODELS: PHT+15S PHT+25S PHT+35S Hardware Installation for ProBar Threaded Flo-Tap This section provides hardware installation instructions for the ProBar Flo-Tap used in either a horizontal or vertical pipe. Installation procedures are similar for all services. Service-specific instructions are provided where necessary; otherwise, all instructions in this section apply to all services. If remote mounting of the electronics is required, use this section for the hardware installation. Then, see Section 8: ProBar Remote Mounting for electronics installation. • The direct mount maximum service temperature is 500 °F (260 °C). • The electronics must be remote mounted when service temperatures exceed 500 °F (260 °C). SAFETY MESSAGES Instructions and procedures in this section may require special precautions to ensure the safety of the personnel performing the operations. Please refer to the following safety messages before performing any operation in this section. Explosions could result in death or serious injury: • Do not remove the transmitter cover in explosive atmospheres when the circuit is alive. • Before connecting a HART-based communicator in an explosive atmosphere, make sure the instruments in the loop are installed in accordance with intrinsically safe or non-incendive field wiring practices. • Verify that the operating atmosphere of the transmitter is consistent with the appropriate hazardous locations certifications. • Both transmitter covers must be fully engaged to meet explosion-proof requirements. Failure to follow these installation guidelines could result in death or serious injury: • Make sure only qualified personnel perform the installation. 6-1 ProBar Flowmeter PROBAR FLO-TAP COMPONENTS Figure 6-1 identifies the components of the ProBar Flo-Tap. FIGURE 6-1. ProBar Flo-Tap Components. Gear Drive Handle Gear Drive Rod Protective Cover Weld-Neck Mounting Flange Rods ProBar Electronics Packing Gland Cage Nipple Isolation Valve Sensor Dieterich-PHTI01 Integral 3-Valve Manifold Head STEP 1: DETERMINE THE PROPER ORIENTATION OF THE PROBAR The orientation of the ProBar depends upon two factors: the orientation of the pipe that will receive the flowmeter, and the service that uses the pipe. The following sections provide illustrations of the possible pipe orientations and services. After determining the ProBar’s orientation, proceed with step 2 on page 6-4. Liquid or Steam Service in a Horizontal Pipe Install the ProBar within 40 degrees of the vertical axis to prevent air from becoming entrapped within the sensor probe. Do not position the ProBar within 50 degrees of the horizontal axis unless full bleeding of air from the probe is possible. Figure 6-2 illustrates the recommended location for the ProBar when used with liquid or steam service. FIGURE 6-2. Liquid or Steam Service in a Horizontal Pipe. 50° 80° (Recommended Zone) 6-2 Dieterich-PHTI02 50° Hardware Installation for ProBar Threaded Flo-Tap Gas Service in a Horizontal Pipe Install the ProBar Flo-Tap in the upper half of the pipe, but not within 30 degrees of the horizontal axis. This orientation will prevent condensate from becoming entrapped in the sensor probe. Figure 6-3 illustrates the recommended location of the ProBar when used with gas service. FIGURE 6-3. Gas Service in a Horizontal Pipe. 30° Liquid or Gas Service in a Vertical Pipe Dieterich-PHTI03 120° (Recommended Zone) 30° Install the ProBar anywhere around the circumference of the pipe, as shown in Figure 6-4. Dieterich-PHTI04 FIGURE 6-4. Liquid or Gas Service in a Vertical Pipe. Flow NOTE Verify that the pipe pressure and temperature are within the rated limits of the Flo-Tap ProBar as shown on the ProBar tag or by the flow calculation provided by the factory. 6-3 ProBar Flowmeter Steam Service in a Vertical Pipe Install the ProBar anywhere around the circumference of the pipe, as shown in Figure 6-5. • ProBar electronics must be remote mounted when used with steam service in a vertical pipe installations. See Section 8: ProBar Remote Mounting for instructions. All hardware required for installation under pressure is furnished with the Flo-Tap. The required hardware is shown in Figure 6-6. NOTE During insertion and retraction, the flow rate must be reduced below the limits shown on the ProBar tag. FIGURE 6-6. Pressure Installation Hardware. Locking Mechanism Clean-Out Notch Bleeder Valve Oil Hole Collar Feed Tube Ratchet Handle Dieterich-I06 STEP 2: OBTAIN THE REQUIRED WELDING EQUIPMENT AND HARDWARE Dieterich-PHTI05 FIGURE 6-5. Steam Service in a Vertical Pipe. The additional welding equipment, pressure drilling machine and the special tooling required is as follows. 1. Welding equipment. 2. Pressure (hot-tap) drilling machine: Mueller D-5, T.D. Williamson T-101, 360 or equivalent. Maximum working pressure = 1440 psig @ 100 °F, or 700 psig @ 700 °F. 3. A threaded machine adapter nipple that fits the isolation valve, such as those available from Mueller or T.D. Williamson. 4. Drill bit: 7/16-in, 7/8-in, 15/16-in. 5. Drill holder: 7/16-in, 7/8-in, 15/16-in. Items 2 through 5 are available from a drilling machine manufacturer, such as Mueller Co., in Decatur, IL. or T.D. Williamson, in Tulsa, OK. This equipment can usually be purchased locally, or the local utility company may be able to provide pressure drilling, or “hot-tapping” services. 6-4 Hardware Installation for ProBar Threaded Flo-Tap STEP 3: PREPARE THE WELDNECK FLANGE ASSEMBLY 1. Grind off any paint or other coatings from the pipe in the area where the weld fitting is to be positioned. 2. Position the weld fitting and the tack weld in place using the proper weld gap. 3. Complete the welding of the weld fitting. Install the close nipple using the proper thread sealant compound. 4. Tack weld the weld-neck in place with the proper weld gap. CAUTION The close nipple threaded connection must be leak-tight; it can not be serviced after hot-tapping. FIGURE 6-7. Weld Fitting Assembly for Liquid or Steam Service. Flow /16-in. Weld Gap ODF Weld-Neck Flange Alignment is Critical FIGURE 6-8. Weld Fitting/Weld-Neck Flange Assembly for Gas Service. Field Weld Dieterich-I07 Field Weld 1 Field Weld Field Weld 1 /16-in. Weld Gap Flow Weld-Neck Flange Alignment is Critical STEP 4: ATTACH THE UNIT ISOLATION VALVE Dieterich-I08 ODF Install the unit isolation valve to the close nipple using proper thread sealant. The valve stem must be positioned to provide clearance for the Flo-Tap insert/retract mechanism, as shown in Figure 6-9. Verify the isolating valve is in the fully open position. 6-5 ProBar Flowmeter STEP 5: ATTACH THE ADAPTER Fasten the special adapter flanged nipple to the unit isolation valve, as shown in Figure 6-9. FIGURE 6-9. Valve Stem and Adapter Positioning. Dieterich-I09 Adapter Fully Open Flow STEP 6: ATTACH THE PRESSURE DRILLING MACHINE Install the drill bit and adapter nipple into the pressure drilling machine. Use the chart in Figure 6-10 to determine the drill bit size according to the size of the sensor. Attach the machine to the special flanged nipple, as shown in Figure 6-10. FIGURE 6-10. Pressure Drilling Diagram. Drill 15 25 35 45 Diameter (in.) 7 /16 7 /8 1-5/16 2-1/8 Unit Isolation Valve is Fully Open When Inserting Drill STEP 7: DRILL THE HOLE Pressure Drilling Machine Unit Isolation Valve is Fully Closed After Withdrawing Drill Dieterich-I010 Sensor Drill the hole through the pipe wall in accordance with the instructions supplied with the drilling machine. The hole is completely drilled when resistance to the hand cranking reduces, or when the air or hydraulic drilling motor speeds up. After the hole is drilled, retract the drill fully beyond the unit isolation valve. STEP 8: REMOVE THE DRILLING MACHINE 1. Withdraw the drill past the valve. 2. Close the unit isolation valve. 3. Bleed and remove the drilling machine and special flanged nipple. 4. Check the unit isolation valve and welds for leakage. 6-6 Hardware Installation for ProBar Threaded Flo-Tap STEP 9: INSTALL THE FLO-TAP ASSEMBLY FIGURE 6-11. Flo-Tap Assembly on the Closed Unit Isolation Valve. Install the complete Flo-Tap assembly onto the unit isolation valve as shown in Figure 6-11 below. NOTE When installing the Flo-Tap assembly, take care not to scratch or dent any portion of the sealing surfaces. Flo-Tap Assembly Dieterich-I011 Closed Unit Isolation Valve 1. Install the complete Flo-Tap assembly (fully retracted) on the unit isolation valve by threading the close nipple into the valve using the proper thread sealant compound. The flow arrow on the head must point in the direction of the flow 2. Point the arrow in the direction of the flow. 3. Use the gasket and flange bolts supplied to fasten the Flo-Tap assembly to the isolation valve. 4. Tighten the nuts in a cross pattern to compress the gasket evenly. 5. Ensure that the vent valves on the ProBar are closed before proceeding with the next step. STEP 10: OPEN THE ISOLATION VALVE STEP 11: TIGHTEN THE BOLTS 1. Slowly open the isolation valve. 2. Check the entire installation for leakage. 3. Tighten connections as required or reapply thread sealant to repair any leakage. Alternately tighten the packing gland bolts as required to eliminate leakage. Do not overtighten. 6-7 ProBar Flowmeter STEP 12: INSERT THE SENSOR Standard Drive (IHR) Insert the sensor with one of the two drive options available on the ProBar Flo-Tap; standard drive (IHR) or gear drive (IHD). Follow the instructions for the drive option used by your ProBar, then proceed with step 12 on page 6-9. 1. Position the retract drive nuts near the orange stripe on the threaded rods before initiating insertion. 2. Insert the sensor by rotating the insert drive nuts clockwise as viewed from the top. The nuts must be tightened alternately, about two turns at a time, to prevent binding caused by unequal loading. 3. Continue this procedure until the sensor firmly contacts the opposite pipe wall. NOTE Do not over-insert the sensor as damage to the sensor or pipe may occur. 4. After the sensor is fully inserted, with the tip solidly against the pipe wall, set the insertion stop nuts in place. 5. Tighten the nuts on either side of the packing gland against the gland. 6. Tighten the second nut against the first as a lock nut, as shown in Figure 6-12. FIGURE 6-12. Setting the Stop Nut and Lock Nut. Lock Nut Packing Gland Stop Nut Dieterich-I012 Stop Nut NOTE Refer to the tag attached to the ProBar for insertion stop nut location instructions. The orange paint stripe on the rods alert the installer that the sensor is approaching full insertion. Gear Drive (IHD) 1. Insert the ProBar sensor by rotating the crank clockwise. If a power drill with an adapter is used, do not exceed 200 rpm. 2. Continue rotating the crank until the sensor firmly contacts the opposite side of the pipe. 3. Secure the drive by inserting the drive lock pin. NOTE For operating and maintenance procedures for the gear drive option, see DS-1635. 6-8 Hardware Installation for ProBar Threaded Flo-Tap NOTE Refer to the tag attached to the ProBar for insertion stop nut location instructions. The orange paint stripe on the rods alert the installer that the sensor is approaching full insertion. Remove the drill and complete the insertion manually until the sensor firmly contacts the pipe wall. STEP 13: CHECK FOR LEAKAGE Inspect the packing gland for leakage. Tighten any bolts as required to stop leakage. STEP 14: RETRACT THE SENSOR Retract the sensor with one of two drive options available on the ProBar FloTap; standard drive (IHR) or gear drive (IHD). Follow the instructions for the drive option used by your ProBar, then proceed with step 16 on page 6-10. Standard Drive (IHR) 1. Retract the Flo-Tap by rotating the retract drive nuts clockwise as viewed from the top. The nuts must be turned alternately, about two turns at a time, to prevent binding caused by unequal loading. 2. Continue this procedure until the rod end nuts are against the packing body mechanism. Fully Retracted Fully Inserted Dieterich-IPHTIO13 FIGURE 6-13. ProBar Flo-Tap at Full Retraction and Insertion. Personal hazard! To prevent injury, remove pressure and drain pipe or cage nipple assembly before installing or removing sensor. 6-9 ProBar Flowmeter Gear Drive (IHD) 1. Remove the drive lock pin. 2. Retract the sensor by rotating the crank counterclockwise. If a power drill with adapter is used, do not exceed 200 rpm. 3. Retract until the rod end nuts are against the packing body mechanism. STEP 16: CLOSE THE ISOLATION VALVE After the sensor is fully retracted, the Flo-Tap unit isolation valve may be closed to isolate the probe from the pipe. STEP 17: REMOVE THE FLO-TAP ASSEMBLY The Flo-Tap may be removed entirely if desired by unbolting the cage nipple from the unit isolation valve. If the ProBar is to be removed entirely from the isolation valve, the cage nipple must be depressurized. Open the equalizer valve on the ProBar head, then open the vent valve on either the high or low side of the ProBar. 6-10 Section 7 PROBAR MODELS: PNT+10S PNW+10S PNF+10S PNF+10H PNF+10M Hardware Installation for ProBar In-Line This section provides hardware installation instructions for the In-Line Threaded, Welded, and Flanged ProBar models used in either a horizontal or vertical pipe. If remote mounting of the electronics is required, use this section for hardware installation. Then, see Section 8: ProBar Remote Mounting for electronics installation. • The direct mount maximum service temperature is 500 °F (260 °C). • The electronics must be remote mounted when service temperatures exceed 500 °F (260 °C). SAFETY MESSAGES Instructions and procedures in this section may require special precautions to ensure the safety of the personnel performing the operations. Please refer to the following safety messages before performing any operation in this section. Explosions could result in death or serious injury: • Do not remove the transmitter cover in explosive atmospheres when the circuit is alive. • Before connecting a HART-based communicator in an explosive atmosphere, make sure the instruments in the loop are installed in accordance with intrinsically safe or non-incendive field wiring practices. • Verify that the operating atmosphere of the transmitter is consistent with the appropriate hazardous locations certifications. • Both transmitter covers must be fully engaged to meet explosion-proof requirements. Failure to follow these installation guidelines could result in death or serious injury: • Make sure only qualified personnel perform the installation. 7-1 ProBar Flowmeter PROBAR IN-LINE CONFIGURATIONS The ProBar In-Line series comes pre-assembled and requires only installation into a service pipe. General installation instructions are as follows. 1. Determine the appropriate ProBar orientation according to two factors: the type of service used and the pipe orientation. Orientation guidelines are provided in the following pages. 2. Make sure the line is depressurized. 3. Remove the section of pipe. 4. Prep the pipe ends as required. • For flanged models, ensure that the pipe mounting lange is the same size or rating. • For threaded models, ensure that the pipe union or coupling is the same size pipe thread as the flowmeter. 5. Orient the ProBar flow arrow so that it points in the same direction as the flow in the pipe. 6. Ensure that the ID of the ProBar and the ID of the pipe are concentric. 7. Complete assembly to the appropriate connections. 7-2 Hardware Installation for ProBar In-Line LIQUID SERVICE IN A HORIZONTAL PIPE Install the ProBar within 40 degrees of the vertical axis to prevent air from becoming entrapped within the sensor probe. Do not position the ProBar within 50 degrees of the horizontal axis unless full bleeding of air from the probe is possible. Figure 7-1 illustrates the recommended location for the ProBar when used with liquid service. FIGURE 7-1. Liquid Service in a Horizontal Pipe. 50° 50° 8900-8900V34A In-Line Threaded 80° (Recommended Zone) 50° 50° 8900-8900V38A In-Line Welded 80° (Recommended Zone) 50° 50° 80° (Recommended Zone) 8900-8900V30A In-Line Flanged 7-3 ProBar Flowmeter GAS SERVICE IN A HORIZONTAL PIPE Install the ProBar in the upper half of the pipe, but not within 30 degrees of the horizontal axis, as shown in Figure 7-2. This orientation will prevent condensate from becoming entrapped in the sensor probe. FIGURE 7-2. Gas Service in a Horizontal Pipe. 120° (Recommended Zone) 30° 30° 8900-8900V36A In-Line Threaded 120° (Recommended Zone) 30° 30° 8900-8900V40A In-Line Welded 120° (Recommended Zone) 30° 7-4 30° 8900-8900V32A In-Line Flanged Hardware Installation for ProBar In-Line STEAM SERVICE IN A HORIZONTAL PIPE Install the ProBar within 40 degrees of the vertical axis to prevent air from becoming entrapped within the sensor probe. Do not position the ProBar within 50 degrees of the horizontal axis unless full bleeding of air from the probe is possible. Figure 7-3 illustrates the recommended location for the ProBar when used with steam service. FIGURE 7-3. Steam Service in a Horizontal Pipe 50° 50° 8900-8900V34A In-Line Threaded 80° (Recommended Zone) 50° 50° 8900-8900V38A In-Line Welded 80° (Recommended Zone) 50° 50° 80° (Recommended Zone) 8900-8900V30A In-Line Flanged 7-5 ProBar Flowmeter LIQUID SERVICE IN A VERTICAL PIPE The ProBar can be installed anywhere around the circumference of the pipe, as shown in Figure 7-4. For liquid service, ensure that the side vent valves are on the upper or top of the ProBar electronics flange. FIGURE 7-4. Liquid Service in a Vertical Pipe 8900-8900V35A In-Line Threaded 8900-8900V39A In-Line Welded 8900-8900V31A In-Line Flanged 7-6 Hardware Installation for ProBar In-Line GAS SERVICE IN A VERTICAL PIPE The ProBar can be installed anywhere around the circumference of the pipe, as shown in Figure 7-5. For gas service, ensure that the side vent valves are on the lower or bottom of the ProBar electronics flange. FIGURE 7-5. Gas Service in a Vertical Pipe 8900-8900V37A In-Line Threaded 8900-8900V41A In-Line Welded 8900-8900V33A In-Line Flanged 7-7 ProBar Flowmeter STEAM SERVICE IN A VERTICAL PIPE The ProBar can be installed anywhere around the circumference of the pipe, as shown in Figure 7-6. For steam service, ensure that the side vent valves are on the upper or top of the ProBar electronics flange. • ProBar electronics must be remote mounted when used with steam service in a vertical pipe. See Section 8: ProBar Remote Mounting for instructions. FIGURE 7-6. Steam Service in a Vertical Pipe. 8900-8900_13A In-Line Threaded 8900-8900_19A In-Line Welded 8900-8900_12A In-Line Flanged 7-8 Section 8 ProBar Remote Mounting NOTE This section is for remote mounting the ProBar electronics after having installed the ProBar sensor probe. If you have not installed the sensor probe assembly, please return to the appropriate section and complete the necessary steps. NOTE Do not rotate the electronics housing on the electronics more than 180° relative to the dP cell. SAFETY MESSAGES Instructions and procedures in this section may require special precautions to ensure the safety of the personnel performing the operations. Please refer to the following safety messages before performing any operation in this section. Explosions could result in death or serious injury: • Do not remove the transmitter cover in explosive atmospheres when the circuit is alive. • Before connecting a HART-based communicator in an explosive atmosphere, make sure the instruments in the loop are installed in accordance with intrinsically safe or non-incendive field wiring practices. • Verify that the operating atmosphere of the transmitter is consistent with the appropriate hazardous locations certifications. • Both transmitter covers must be fully engaged to meet explosion-proof requirements. Failure to follow these installation guidelines could result in death or serious injury: • Make sure only qualified personnel perform the installation. 8-1 ProBar Flowmeter This section provides remote mounting installation instructions for the ProBar electronics for liquid, gas or steam service in either horizontal or vertical pipes. Figures 8-1 through 8-3 illustrate how the ProBar sensor should be aligned for a specific service and pipe orientation prior to remote mounting. ProBar Head ProBar Head Instrument Valve Instrument Valve FIGURE 8-2. Gas Service: A (Horizontal Pipe) and B (Vertical Pipe). A B Instrument Valve ProBar Head ProBar Head Instrument Valve FIGURE 8-3. Steam Service: A (Horizontal Pipe) and B (Vertical Pipe). A B ProBar Head ProBar Head Instrument Valve Instrument Valve ProBar Valves and Fittings 8900-8900_32A, 8900_03A B 8900-8900_33A, 8900_03A A 8900-8900_32A, 8900_03A FIGURE 8-1. Liquid Service: A (Horizontal Pipe) and B (Vertical Pipe). Throughout the remote mounting process: • Use only valves and fittings rated for the service pipeline design pressure and temperature as specified in Section 16: Specifications and Reference Data. • Use a pipe thread sealant compound that is rated for use at the service temperature and pressure for all valves and fittings. • Verify that all connections are tight and that all instrument valves are fully closed. • Verify that the sensor probe is properly oriented for the intended type of service: liquid, gas or steam (see Figures 8-1, 8-2, and 8-3). 8-2 ProBar Remote Mounting Impulse Piping A remote mounted electronics is connected to the sensor by means of impulse piping. Temperatures in excess of 250 °F at the electronics will damage electronics components; impulse piping allows service flow temperatures to decrease to a point where the electronics is no longer vulnerable. Each service uses a different impulse piping arrangement to maintain a single phase of fluid in the piping and ProBar electronics. For example, liquid applications must maintain a liquid state and allow any air or gas formation to travel up and away from the ProBar electronics, and gas applications must maintain a gaseous state and allow the formation of liquids to drain down and away from the ProBar electronics. The piping used to connect the sensor probe and electronics must be rated for continuous operation at the pipeline-designed pressure and temperature. A minimum of one-half inch (½-in., 12mm) O.D. stainless steel tubing with a wall thickness of at least 0.035" is recommended. Threaded pipe fittings are not recommended because they create voids where air can become entrapped and have more possibilities for leakage. The following restrictions and recommendations apply to impulse piping location. 1. Impulse piping that runs horizontally must slope at least one inch per foot (83mm/m). • It must slope downwards (toward the ProBar electronics) for liquid and steam applications. • It must slope up (away from the ProBar electronics) for gas applications. 2. For applications where the pipeline temperature is below 250 °F (121 °C), the impulse piping should be as short as possible to minimize flow temperature changes. Insulation may be required. 3. For applications where pipeline temperature is above 250 °F (121 °C), the impulse piping should have a minimum length of one foot (0.3048 m) for every 100 °F (38 °C) over 250 °F (121 °C), which is the maximum operating ProBar electronics temperature. Impulse piping must be uninsulated to reduce fluid temperature. All threaded connections should be checked after the system comes up to temperature, because connections may be loosened by the expansion and contraction caused by temperature changes. 4. Outdoor installations for liquid, saturated gas, or steam service may require insulation and heat tracing to prevent freezing. 5. For installations where the ProBar electronics are more than six feet (1.8m) from the sensor probe, the high and low impulse piping must be run together to maintain equal temperature. They must be supported to prevent sagging and vibration. 6. Run impulse piping in protected areas or against walls or ceilings. If the impulse piping is run across the floor, ensure that it is protected with coverings or kick plates. Do not locate the impulse piping near high temperature piping or equipment. 7. Use an appropriate pipe sealing compound rated for the service temperature on all threaded connections. When making threaded connections between stainless steel fittings, Loctite PST Sealant is recommended. 8-3 ProBar Flowmeter EQUIPMENT REQUIRED TO REMOTE MOUNT THE PROBAR ELECTRONICS Proper installation of the ProBar electronics requires the following tools and equipment. Tools Required Tools required include the following: 1. Open end or combination wrenches (spanners) to fit the pipe fittings and bolts: 9/16-in., 5/8-in., 7/8-in. 2. Adjustable wrench: 15-in. (1½-in. jaw). 3. Nut driver: 3/8-in. for vent/drain valves (or 3/8-in. wrench). 4. Phillip’s screwdriver: #1. 5. Standard screwdrivers: ¼-in., and 1/8-in. wide. 6. Pipe wrench: 14-in. 7. Wire cutters/strippers. Supplies Required Supplies required include the following: 1. ½-in. Tubing (recommended) or ½-in. pipe to hook up the ProBar electronics to the sensor probe. The length required depends upon the distance between the electronics and the sensor. 2. Fittings including, but not limited to: a. Two tube or pipe tees (for steam or high temperature liquid) b. Six tube/pipe fittings (for tube) 3. Pipe compound or teflon tape (where local piping codes allow). INSTRUMENT MANIFOLDS An instrument manifold is recommended for all installations. A manifold allows an operator to equalize the pressures prior to the zero calibration of the ProBar electronics as well as to isolate the electronics from the rest of the system without disconnecting the impulse piping. Although a 3-valve manifold can be used, a 5-valve manifold is recommended. Figure 8-4 identifies the valves on a 5-valve and a 3-valve manifold. 5-valve manifolds provide a positive method of indicating a partially closed or faulty equalizer valve. A closed for faulty equalizer valve will block the DP signal and create errors that may not be detectable otherwise. Figure 8-4 shows the DP manifold assembly and identifies the valves on both types of manifolds, and Table 8-1 provides a description of the valves. The labels for each valve will be used to identify the proper valve in the procedures to follow. NOTE Some recently-designed instrument manifolds have a single valve actuator, but cannot perform all of the functions available on standard 5-valve units. Check with the manufacturer to verify the functions that a particular manifold can perform. In place of a manifold, individual valves may be arranged so as to provide the necessary isolation and equalization functions. NOTE The ProBar should be shipped with the instrument manifold already bolted to the electronics. 8-4 ProBar Remote Mounting To PH To PL To PH To PL MV MH MH ME ML MEH ML MEL DVL DVH 5-Valve Manifold TABLE 8-1. Description of Impulse Piping Valves and Components. Name 3-Valve Manifold Description 8900-8900_34A, 8900_35A FIGURE 8-4. Valve Identification for 5-Valve and 3-Valve Manifolds. Purpose Impulse Piping Valves PH PL Primary Sensor—High Pressure Primary Sensor—Low Pressure Isolates the flowmeter sensor from the impulse piping system DVH DVL Drain/Vent valve—High Pressure Drain/Vent valve—Low Pressure Drains (for gas service) or vents (for liquid or steam service) the DP electronics chambers BH BL Blowdown—High Pressure Blowdown—Low Pressure Allows pipeline pressure to blow and clear sediment from impulse piping VH VL Vent Valve—High Pressure Vent Valve—Low Pressure Allows venting of collected gases from impulse piping in liquid applications DH DL Drain Valve—High Pressure Drain Valve—Low Pressure Allows draining of collect condensate from impulse piping in gas applications Components 1 2 3 4 ProBar Electronics ProBar Manifold Vent Chamber Condensate Chamber Reads Differential Pressure Isolates and equalizes ProBar electronics Collects gases in liquid applications Collects condensate in gas applications Numbers 1–4 in the components section of Table 8-1 are used in Figures 8-5 through 8-10. 8-5 ProBar Flowmeter LOCATION FOR THE PROBAR ELECTRONICS The location for the ProBar electronics depends upon the service to be used. Liquid Service up to 250 °F (121 °C) (See page 8-10 for liquid service above 250 °F.) The electronics may be installed in one of two ways, depending on the space limitations of the installation site. Refer to Figures 8-5 and 8-6 to help you determine which installation variation to use. Recommended Location The recommended installation mounts the ProBar electronics below the primary sensor to ensure that air will not be introduced into the impulse piping or the electronics. Figure 8-5 illustrates the recommended electronics location for use in either a horizontal or vertical pipe. 8900-8900_21A FIGURE 8-5. Recommended Electronics Installation for Liquid Service up to 250 °F (121 °C). 8-6 ProBar Remote Mounting Alternate Location When it is impossible to mount the ProBar electronics below the pipeline, mount the ProBar electronics above the pipeline using the arrangement shown in Figure 8-6. The alternate installation requires periodic maintenance to assure that air is vented from the chambers. The alternate location can be used with horizontal pipes only, as shown in Figure 8-6. 8900-8900_22A FIGURE 8-6. Alternate Electronics Installation for Liquid Service up to 250 °F (121 °C). 8-7 ProBar Flowmeter Gas Service The electronics may be installed in one of two ways, depending on the space limitations of the installation site. Refer to Figures 8-7 and 8-8 to help you determine which installation variation to use. Recommended Location The recommended installation mounts the ProBar sensor through the top half of the pipe (for horizontal process piping), and the ProBar electronics above the process piping to prevent condensable liquids from collecting in the impulse piping and DP cell. Figure 8-7 illustrates the recommended electronics location for use in either a horizontal or vertical pipe. 8900-8900_23A FIGURE 8-7. Recommended Electronics Installation for Gas Service. 8-8 ProBar Remote Mounting Alternate Location When it is impractical or impossible to mount the ProBar electronics above the process piping, the electronics can be mounted below the process piping as shown in Figure 8-8. This alternate installation requires periodic maintenance to assure that condensate from saturated gas applications is drained from the chambers. Figure 8-8 illustrates the alternate location for use in either a horizontal or vertical pipe. 8900-8900_29A FIGURE 8-8. Alternate Electronics Installation for Gas Service. 8-9 ProBar Flowmeter Steam or Liquid Service above 250 °F (121 °C) For steam service (at any temperature) or liquid service at temperatures above 250 °F (121 °C), the ProBar electronics must be installed below the process piping. NOTE Steam (or hot water) must not enter the electronics. Fill the system of impulse piping and ProBar electronics with cool water before pressurizing the system. Horizontal Pipes For horizontal steam process piping, the ProBar flow sensor is mounted through the bottom half of the piping, as shown in Figure 8-9. Route impulse piping down to the ProBar electronics. Fill the system with cool water through the two tee fittings. 8900-8900_24A FIGURE 8-9. Electronics Installation for Steam or Liquid Service above 250 °F (121 °C) in a Horizontal Pipe. 8-10 ProBar Remote Mounting Vertical Pipes Steam service in a vertical pipe uses a ProBar flow sensor constructed specifically for vertical pipelines; it must be mounted through the side of the pipe, as shown in Figure 8-10. Two ½–14 NPT cross fittings are used to fill the system with water. Insulate the impulse piping from the pipe to and including the PH and PL instrument valves. Do not insulate the NPT cross fittings. FIGURE 8-10. Electronics Installation for Steam or Liquid Service above 250 °F (121 °C) in a Vertical Pipe. Fill 8900-8900_25A Fill 8-11 ProBar Flowmeter 8-12 Section 9 SAFETY MESSAGES ProBar Electronics Functions Procedures and instructions in this section may require special precautions to ensure the safety of the personnel performing the operations. Information that raises potential safety issues is indicated by a warning symbol ( ). Refer to the following safety messages before performing an operation preceded by this symbol. Explosions could result in death or serious injury: • Do not remove the transmitter cover in explosive atmospheres when the circuit is alive. • Before connecting a HART-based communicator in an explosive atmosphere, make sure the instruments in the loop are installed in accordance with intrinsically safe or non-incendive field wiring practices. • Verify that the operating atmosphere of the transmitter is consistent with the appropriate hazardous locations certifications. • Both transmitter covers must be fully engaged to meet explosion-proof requirements. • The unused conduit opening on the electronics housing must be plugged and sealed to meet explosion-proof requirements. Failure to follow these installation guidelines could result in death or serious injury: • Make sure only qualified personnel perform the installation. For intrinsically safe installations, wiring connections must be made in accordance with ANSI/ISA-RP12.6, and Rosemount drawings 03031-1019 or 03031-1024. For ALL installations, wiring connections must be made in accordance with local or national installation codes such as the NEC NFPA 70. This section contains information on commissioning and operating ProBar flowmeters. Tasks that should be performed on the bench prior to installation (setting flowmeter jumpers) and software functions are explained in this section. For your convenience, HART communicator fast key sequences are listed for each software function. If you are unfamiliar with the communicator or how to follow fast key sequences, please refer to Appendix A: HART Communicator for communicator operations. 9-1 ProBar Flowmeter COMMISSIONING THE FLOWMETER ON THE BENCH Commissioning consists of testing the flowmeter, testing the loop, and verifying flowmeter configuration data. You may commission ProBar flowmeters either before or after installation. Commissioning the flowmeter on the bench before installation ensures that all flowmeter components are in good working order and acquaints you with the operation of the device. To avoid exposing the flowmeter electronics to the plant environment after installation, set the failure mode and flowmeter security jumpers during the commissioning stage on the bench. FAILURE MODE ALARM As part of normal operation, the ProBar continuously monitors its own operation. This automatic diagnostic routine is a timed series of checks repeated continuously. If the diagnostic routine detects a failure, the flowmeter drives its output either below or above specific values depending on the position of the failure mode jumper. • For 4–20 mA flowmeters factory-configured for standard operation, the flowmeter drives its output either below 3.75 mA or above 21.75 mA. • For 4–20 mA flowmeters factory-configured for NAMUR-compliant operation, the flowmeter drives its output either below 3.6 mA or above 22.5 mA. The failure mode alarm jumper is located on the front of the electronics board inside of the electronics housing cover. The position of this jumper determines whether the output is driven high or low when a failure is detected (see Figure 9-1 on page 9-4). If the alarm jumper is not installed the flowmeter will operate normally, and the default alarm condition will be high. NOTE The failure mode alarm jumper pins occupy one row of a ten-pin socket that also is used to attach the optional LCD meter. In order to function appropriately, the jumper must be positioned correctly, as shown in Figure 9-1 on page 9-4. Failure Mode Alarm vs. Saturation Output Values TABLE 9-1. Analog Output: Standard Alarm Values vs. Saturation Values. TABLE 9-2. Analog Output: NAMUR-Compliant Alarm Values vs. Saturation Values. 9-2 The failure mode alarm output levels differ from the output values that occur when applied pressure is outside the range points. When pressure is outside the range points, the analog output continues to track the input pressure until reaching the saturation value listed below; the output does not exceed the listed saturation value regardless of the applied pressure. For example, with standard alarm and saturation levels and pressures outside the 4–20 range points, the output saturates at 3.9 mA or 20.8 mA. When the flowmeter diagnostics detect a failure, the analog output is set to a specific alarm value that differs from the saturation value to allow for proper troubleshooting. Level 4–20 mA Saturation Value 4–20 mA Alarm Value Low 3.9 mA ≤ 3.75 mA High 20.8 mA ≥ 21.75 mA Level 4–20 mA Saturation Value 4–20 mA Alarm Value Low 3.8 mA ≤ 3.6 mA High 20.5 mA ≥ 22.5 mA ProBar Electronics Functions NOTE You can alter the actual flowmeter mA output values from the values listed above by performing an analog output trim (see page 9-20). NOTE When a flowmeter is in an alarm condition, the hand-held HART communicator indicates the analog output the flowmeter would drive if the alarm condition did not exist. Alarm and Saturation Values for Flowmeters Set to Burst Mode Saturation and alarm conditions operate differently when a flowmeter is set to burst mode operation: Alarm Condition (Hi or Lo): 1. Analog output switches to alarm level (see Table 9-1). 2. Primary variable (flow pressure) is burst with a status bit set. 3. Percent of range follows primary variable (flow pressure). 4. Secondary variable (DP pressure) and Tertiary variable (temperature) are burst with a status bit set. (Note that during alarm conditions, the burst primary variable, secondary variable, or percent of range, or temperature may not be valid depending on the error type – refer to the HART protocol for details.) Saturation: 1. Analog output switches to saturation level (see Table 9-1). 2. Primary variable (flow pressure) is burst normally. 3. Secondary variable (D.P. pressure) and tertiary variable (temperature) are burst normally. Alarm Level Verification Flowmeters with electronics board revision 5.3 or later (shrouded design) have increased functionality that allows verification testing of alarm current levels. If you repair or replace the flowmeter electronics board, sensor module or LCD meter, verify the flowmeter alarm level before you return the flowmeter to service. This feature is also useful in testing the reaction of your control system to a flowmeter in an alarm state. To verify the flowmeter alarm levels, perform a loop test (see Loop Test on page 9-14). 9-3 ProBar Flowmeter FLOWMETER SECURITY You can prevent changes to the flowmeter configuration data with the write protection jumper. Position the jumper on the flowmeter circuit board in the “ON” position to prevent accidental or deliberate change of configuration data. Figure 9-1 shows the jumper positions for 4–20 mA flowmeters. For flowmeters with an optional LCD meter, see “LCD Meter” in Installation Options. If the flowmeter write protection jumper is in the “ON” position, the flowmeter will not accept any “writes” to its memory. Configuration changes (such as digital trim and reranging) cannot take place when the flowmeter security is on. To reposition the jumper, perform the following procedure. 1. If the flowmeter is installed, secure the loop, and remove power. 2. Remove the housing cover opposite the field terminal side. Do not remove the flowmeter covers in explosive atmospheres when the circuit is alive. 3. Reposition the jumper. See Figure 9-1 for the ON and OFF jumper positions. Previous circuit boards carried a two-pin or three-pin jumper assembly on the connector side of the board (see Figure 9-1). To activate security using a two-pin version, install the jumper. To activate security with the three-pin assembly, move the jumper to the ON pin position. 4. Reattach the flowmeter cover. Flowmeter covers must be fully engaged to meet explosion-proof requirements. NOTE If the security jumper is not installed, the flowmeter will continue to operate in the security OFF configuration. FIGURE 9-1. 4–20 mA Flowmeter Electronics Boards. Previous Electronics Board Improved Electronics Board Security and Alarm Jumpers OFF ON HI LO Alarm Security 9-4 ProBar Electronics Functions COMMISSIONING THE PROBAR WITH A HART-BASED COMMUNICATOR Before placing the ProBar into operation, you should commission the instrument using a HART-based communicator. To commission on the bench, connect the flowmeter and the communicator as shown in Figure 9-2. Make sure the instruments in the loop are installed in accordance with intrinsically safe or nonincendive field wiring practices before connecting a communicator in an explosive atmosphere. Connect the communicator leads at any termination point in the signal loop. It is most convenient to connect them to the terminals labeled “COMM” on the terminal block. Connecting across the “TEST” terminals will prevent successful communication. For 4–20 mA flowmeters, you will need a power supply capable of providing 10.5 to 55 V dc at the flowmeter, and a meter to measure output current. To enable communication, a resistance of at least 250 ohms must be present between the communicator loop connection and the power supply. Do not use inductive-based transient protectors with the ProBar. Setting the Loop to Manual Whenever you are preparing to send or request data that would disrupt the loop or change the output of the flowmeter, you must set your process application loop to manual. The HART Communicator Model 275 will prompt you to set the loop to manual when necessary. Keep in mind that acknowledging this prompt does not set the loop to manual. The prompt is only a reminder; you have to set the loop to manual yourself, as a separate operation. Wiring Diagrams (Bench Hook-up) Connect the bench equipment as shown in Figure 9-2 and turn on the HART-based communicator by pressing the ON/OFF key. The communicator will search for a HART-compatible device and will indicate when the connection is made. If the communicator fails to connect, it will indicate that no device was found. If this occurs, refer to Section 15: Troubleshooting. FIGURE 9-2. Bench Hook-up (4–20 mA Flowmeters). RL≥ 250 ς 24 V dc Supply 3051-3031G02B Current Meter 9-5 ProBar Flowmeter FIGURE 9-3. Field Hook-up (4–20 mA Flowmeters). The following diagrams illustrate wiring loops for a field hook-up with a HART-based communicator. CAUTION Do not use inductive-based transient protectors. RL≥ 250 ς Current Meter Power Supply Signal point may be grounded at any point or left ungrounded. 9-6 3051-3031H02B Wiring Diagrams (Field Hook-up) ProBar Electronics Functions REVIEW CONFIGURATION DATA HART Comm. 1, 5 NOTE Information and procedures in this section that make use of HART Communicator fast key sequences assume that the flowmeter and communicator are connected, powered, and operating correctly. If you are not familiar with the HART Communicator or fast-key sequences, refer to Appendix A: HART Communicator. Before you place the flowmeter into operation, it is recommended that you review the flowmeter configuration data that was set at the factory. You should review the following configuration data: Flowmeter Model, Type, Tag, Range, Date, Descriptor, Message, Minimum and Maximum Sensor Limits, Minimum Span, Units, 4 and 20 mA points, Output (linear or square root), Damping, Alarm Setting (high, low), Security Setting (on, off), Local Keys (enabled, disabled), Integral Meter, Sensor Fill, Isolator Material, Flange (type, material), O-Ring Material, Drain/Vent, Remote Seal (type, fill fluid, isolator material, number), Flowmeter S/N, Address, and Sensor S/N. CHECK OUTPUT Before performing other flowmeter on-line operations, review the digital output parameters to ensure that the flowmeter is operating properly and is configured to the appropriate process variables. Process Variables The process variables for the ProBar provide the flowmeter output, and are continuously updated. The process variable menu displays the following process variables: HART Comm. 1, 2 • Flow Pressure • Percent of Range • Analog Output • DP Pressure • Sensor Temperature The flow pressure reading in both Engineering Units and Percent of Range will continue to track with pressures outside of the defined range from the lower to the upper range limit of the sensor module.(1) Sensor Temperature HART Comm. 1, 1, 5 The ProBar contains a temperature sensor just above its pressure sensor in the sensor module. When reading this temperature, keep in mind that this is not a process temperature reading. (1) Previous versions of the software will track with pressure up to 105% of span, and remain there as pressure increases. 9-7 ProBar Flowmeter BASIC SETUP The PV Unit command sets the process variable units to allow you to monitor your process using the appropriate units of measure. Select from the following engineering units: Set Process Variable Units HART Comm. 1, 3 Set Output HART Comm. 1, 3, 5 • inH20 • inH20 at 4 °C(1) • inHg • ftH20 • mmH20 • mmH20 at 4 °C(1) • mmHg • psi • bar • mbar • g/cm2 • kg/cm2 • Pa • kPa • torr • atm Activate the flowmeter square root output option to make the analog output proportional to flow. To avoid the extremely high gain that results as the input approaches zero, the ProBar automatically switches to a linear output in order to ensure a more stable output near zero. The transition from linear to square root output is smooth, with no step change or discontinuity in output (see Figure 9-4). The transition from linear to square root is not adjustable. It occurs at 0.8% of ranged pressure input. In earlier software, the transition point occurred at 4% of ranged pressure input, or 20% of full scale flow output. From 0 percent to 0.6 percent of the ranged pressure input, the slope of the curve is unity (y = x). This allows accurate calibration near zero. Greater slopes would cause large changes in output for small changes at input. From 0.6 percent to 0.8 percent, the slope of the curve equals 42 (y = 42x) to achieve continuous transition from linear to square root at the transition point. (1) Not available with previous ProBar flowmeters. 9-8 ProBar Electronics Functions FIGURE 9-4. Square Root Output Transition Point. Full Scale Output (mA dc) Full Scale Flow (%) Full Scale Full Scale Output Flow (%) (mA dc) Square Root Curve Transition Point Linear Section of Curve 3051-0148A Square Root Curve Transition Point 0.8% Slope = 42 Linear Section of Curve Linear Transition Detail Full Scale Pressure (%) Slope = Full Scale Pressure (%) 9-9 ProBar Flowmeter Rerange The Range Values command sets the 4 and 20 mA points (lower and upper range values). Setting the range values to the limits of expected readings maximizes flowmeter performance; the flowmeter is most accurate when operated within the expected pressure ranges for your application. In practice, you may reset the flowmeter range values as often as necessary to reflect changing process conditions. NOTE Regardless of the range points, the ProBar will measure and report all readings within the digital limits of the sensor. For example, if the 4 and 20 mA points are set to 0 and 10 inH20, and the flowmeter detects a pressure of 25 inH20, it digitally outputs the 25 in H20 reading and a 250% percent of span reading. However, there may be up to ±5.0% error associated with output outside of the range points. You may use one of three methods to rerange the flowmeter. Each method is unique; examine all three closely before deciding which method to use. When reranging a calibrated ProBar, the new DP must be calculated at the factory during calibration. The ProBar is a flowmeter calibrated at reference conditions and has been ranged according to the conditions given at the time of order placement. If the density, pressure, temperature, fluid, or pipe ID has changed, please consult publication number DS-4012 ProBar Flow Handbook for equations prior to reranging the flowmeter. The ProBar information specific to the flowmeter can be found on the flow calibration report (as shown below) or on the ProBar flowmeter tag. The calculation used to rerange the ProBar output is as follows: New DP Range newQmax 2 = -------------------------- 3 Old DP Range oldQmax For instance, if the ProBar is currently setup as follows: ProBar Information Model: ProBar Flanged Serial#: 222222.2 Max Flow @ 20 mA: 1600 GPM Max DP @ 20 mA: 153 inH2O And then you want to rerange 20 mA to 2000 gpm, the calculation is as follows: New DP Range 2000 = ------------ 1600 2 3 153 inH2O = 239 inH2O The ProBar can now be reranged to the following new settings: 4 mA = 0 in H2O 20 mA = 239 inH20 9-10 ProBar Electronics Functions Rerange with a Communicator Only HART Comm. 1, 2, 3, 1, 1 Reranging using only the communicator is the easiest and most popular way to rerange the flowmeter. This method changes the values of the analog 4 and 20 mA points independently without a pressure input. NOTE Changing the lower or upper range point results in similar changes to the span. To rerange using only the communicator enter the fast-key sequence above, select 1 Keypad input, and follow the on-line instructions. Or enter the values directly from the HOME screen. NOTE If the flowmeter security jumper is in the “ON” position, you will not be able to make adjustments to the zero and span. Refer to Figure 9-1 on page 9-4 for the appropriate placement of the flowmeter security jumper. Rerange with a Pressure Input Source and a Communicator HART Comm. 1, 2, 3, 1, 2 Reranging using the communicator and a pressure source or process pressure is a way of reranging the flowmeter when specific 4 and 20 mA points are not known. This method changes the values of the analog 4 and 20 mA points. NOTE When you set the 4 mA point the span is maintained; when you set the 20 mA point the span changes. If you set the lower range point to a value that causes the upper range point to exceed the sensor limit, the upper range point is automatically set to the sensor limit, and the span is adjusted accordingly. To rerange using the communicator and a pressure source or process pressure enter the fast-key sequence above, select 2 Apply values, and follow the on-line instructions. NOTE If the flowmeter security jumper is in the “ON” position, you will not be able to make adjustments to the zero and span. Refer to Figure 9-1 on page 9-4 for the appropriate placement of the flowmeter security jumper. 9-11 ProBar Flowmeter Rerange with a Pressure Input Source and the Local Zero and Span Buttons Reranging using the local zero and span adjustments (see Figure 9-5 on page 9-13), and a pressure source is a way of reranging the flowmeter when specific 4 and 20 mA points are not known and a communicator is not available. NOTE When you set the 4 mA point the span is maintained; when you set the 20 mA point the span changes. If you set the lower range point to a value that causes the upper range point to exceed the sensor limit, the upper range point is automatically set to the sensor limit, and the span is adjusted accordingly. To rerange the flowmeter using the span and zero buttons, perform the following procedure. 1. Loosen the screw holding the certifications label on top of the flowmeter housing, and rotate the label to expose the zero and span buttons (see Figure 9-5 on page 9-13). 2. Using a pressure source with an accuracy three to ten times the desired calibrated accuracy, apply a pressure equivalent to the lower range value to the high side of the flowmeter. 3. To set the 4 mA point, press and hold the zero button for at least two seconds, then verify that the output is 4 mA. If a meter is installed, it will display ZERO PASS. NOTE The zero and span adjustments on previous versions of the flowmeter are screws instead of buttons. To activate the zero or span adjustment loosen the screw until it pops up. 4. Apply a pressure equivalent to the upper range value to the high side of the flowmeter. 5. To set the 20 mA point, press and hold the span button for at least two seconds, then verify that the output is 20 mA. If a meter is installed, it will display SPAN PASS. NOTE If the flowmeter security jumper is in the “ON” position, or if the local zero and span adjustments are disabled through the software, you will not be able to make adjustments to the zero and span using the local buttons. Refer to Figure 9-1 on page 9-4 for the proper placement of the flowmeter security jumper. Or refer to Local Span and Zero Control on page 9-14 for instructions on how to enable the span and zero buttons. 9-12 ProBar Electronics Functions FIGURE 9-5. Local Zero and Span Adjustments. 3051-3031D02A Span and Zero Adjustment Buttons After you rerange the flowmeter using the span and zero adjustments, it is possible to disable the adjustments to prevent further reranging. Refer to “Local Span and Zero Control” below for more information. Damping HART Comm. 1, 3, 6 The PV damp command changes the response time of the flowmeter to smooth variations in output readings caused by rapid changes in input. Determine the appropriate damping setting based on the necessary response time, signal stability, and other requirements of the of loop dynamics of your system. The default damping value is 1.6 seconds, and can be reset to any value between 0 and 25.6 seconds. LCD Meter Options HART Comm. 1, 4, 3, 4 The Meter Options command allows you to customize the LCD meter for use in your application. You can configure the meter to display the following information: • Engineering Units • Percent of Range • User-Configurable LCD Scale • Alternating between any two of the above 9-13 ProBar Flowmeter DETAILED SETUP Local Span and Zero Control HART Comm. 1, 4, 4, 1, 7 The Local keys command allows software control over the use of the local span and zero adjustments. To enable or disable the span and zero adjustment buttons on your flowmeter, perform the fast key sequence at left. NOTE Disabling the local keys does not disable all flowmeter configuration changes. With the local keys disabled, you can still make changes to the flowmeter configuration using a HART Communicator. DIAGNOSTICS AND SERVICE The diagnostics and service functions listed here are primarily for use after you install the flowmeter in the field. The transmitter test feature is designed to verify that the flowmeter is operating properly, and can be performed either on the bench or in the field. The loop test feature is designed to verify proper loop wiring and flowmeter output, and should only be performed after you install the flowmeter. Transmitter Test The transmitter test command initiates a more extensive diagnostics routine than that performed continuously by the flowmeter. The flowmeter test routine can quickly identify potential electronics problems. If the transmitter test detects a problem, messages to indicate the source of the problem are displayed on the communicator screen. HART Comm. 1, 2, 1, 1 Loop Test HART Comm. 1, 2, 2 The Loop Test command verifies the output of the flowmeter, the integrity of the loop, and the operations of any recorders or similar devices installed in the loop. To initiate a loop test, perform the following procedure: 1. Connect a reference meter to the flowmeter. To do so, either connect the meter to the test terminals on the flowmeter terminal block, or shunt the power to the flowmeter through the meter at some point in the loop. 2. From the HOME screen, Select 1 Device Setup, 2 Diagnostics and Service, 2 Loop Test, to prepare to perform a loop test. 3. Select “OK” after you set the control loop to manual (see Setting the Loop to Manual on page 9-5). The communicator displays the loop test menu. 4. Select a discrete milliamp level for the flowmeter to output. At the “Choose analog output” prompt, select 1 4mA, 2 20mA, or select 3 other to manually input a value. If you are performing a loop test to verify the output of a flowmeter, enter a value between 4 and 20 mA. If you are performing a loop test to verify the flowmeter alarm levels, enter the milliamp value at which the flowmeter should enter an alarm state (see Tables 9-1 and 9-2 on page 9-2). 5. Check the electrical current meter installed in the test loop to verify that it reads the value you commanded the flowmeter to output. If the readings match, the flowmeter and the loop are configured and functioning properly. If the readings do not match, there may be a fault in the wiring, the flowmeter may require an output trim, or the electrical current meter may be malfunctioning. After completing the test procedure, the display returns to the loop test screen and allows you to choose another output value or to exit loop testing. 9-14 ProBar Electronics Functions CALIBRATION Calibrating a smart flowmeter is different from calibrating an analog flowmeter. The one-step calibration process of an analog flowmeter is done in three steps with a smart flowmeter: • Rerange – sets the 4 and 20 mA points at the desired pressures; • Sensor Trim – Adjusts the position of the factory characterization curve to optimize the flowmeter performance over a specified pressure range or to adjust for mounting effects; • Analog Output Trim – Adjusts the analog output to match the plant standard or the control loop. To understand the calibration of a ProBar smart flowmeter, it is necessary to understand that smart flowmeters operate differently than analog flowmeters. A smart flowmeter uses a microprocessor that contains information about the sensor’s specific characteristics in response to pressure and temperature inputs; each sensor varies slightly. A smart flowmeter compensates for these sensor variations. The process of generating the sensor performance profile is called factory characterization, and it enables a smart flowmeter to maintain higher performance specifications than analog flowmeters. It is also important to understand the difference between the trim and the rerange functions of smart flowmeters. Reranging sets the flowmeter analog output to the selected upper and lower range points, and can be done with or without an applied pressure. Reranging does not change the factory characterization curve stored in the microprocessor. In contrast, sensor trimming requires an accurate pressure input, and adds additional compensation that adjusts the position of the factory characterization curve. NOTE Sensor trimming adjusts the position of the factory characterization curve. It is possible to degrade the performance of the flowmeter if the sensor trim is done improperly or with equipment that does not meet the accuracy requirements. If you have questions about the calibration process or the trim procedure, contact your local Dieterich Standard representative or contact Dieterich Standard Inc. at 1 (303) 530-9600. Bench Calibration Tasks 1. Set output configuration parameters: a) Set the transmitter range points. b) Set the Output Units. c) Set the Output Type. d) Set the Damping Value. 2. Optional: Perform a Full Sensor Trim -- Accurate pressure source required. 3. Optional: Perform an Analog Output Trim -- Accurate multimeter required. Field Calibration Tasks 1) Reconfigure parameters if necessary. 2) Zero Trim the transmitter to compensate for mounting position effects or static pressure effects. 9-15 ProBar Flowmeter Calibration Overview Complete calibration of the ProBar flowmeter involves the following tasks: Configure the Analog Output Parameters • Set Process Variable Units (page 9-8) • Set Output Type (page 9-10) • Rerange (page 9-10) • Set Damping (page 9-13) Calibrate the Sensor • Full Trim, ProBar UC or ProBar field revision 3 or later (page 9-19) NOTE Do not perform a full trim for ProBar flowmeters with a device-type ProBar and a field revision earlier than field revision 3. • Zero Trim (page 9-19) Calibrate the 4–20 mA Output • 4–20 mA Output Trim (page 9-20) or • 4–20 mA Output Trim Using Other Scale (page 9-20) Figure 9-6 illustrates the ProBar flowmeter data flow. This data flow can be summarized in four major steps: 1. A change in pressure is measured by a change in the sensor output (Sensor Signal). 2. The sensor signal is converted to a digital format that can be understood by the microprocessor (Analog-to-Digital Signal Conversion). 3. Corrections are performed in the microprocessor to obtain a digital representation of the process input (Digital PV). 4. The Digital PV is converted to an analog value (Digital-to-Analog Signal Conversion). Figure 9-6 also identifies the approximate flowmeter location for each calibration task. Note that the data flows from left to right, and a parameter change affects all values to the right of the changed parameter. Not all calibration procedures should be performed for each ProBar flowmeter. In addition, some procedures are appropriate for bench calibration, but should not be performed during field calibration. Figure 9-6 identifies the recommended calibration procedures for each type of ProBar flowmeter for both bench and field calibration. 9-16 ProBar Electronics Functions (Flowmeter Ranged 0 to 100 inH2O) Flowmeter Electronics Module Analog-to-Digital Signal Conversion Sensor 100 inH2O Input Pressure Input Device NOTES 1) Value on PV line should equal the input pressure 2) Value on AO line should equal the output device reading Deciding Which Trim Procedure to Use Microprocessor Digital PV Digital-to-Analog Signal Conversion 20.00 mA Analog Output Sensor Signal HART Communications FIGURE 9-6. Flowmeter Data Flow with Calibration Options. Output Device ProBar: FT-4001 Process Variables 1 Flow Press 2 % rnge 100.00 3 AO 20.00 mA 4 Press 0.00 inH2O 5 Snsr Temp 23.0 °C To decide which trim procedure to use, you must first determine whether the analog-to-digital section or the digital-to-analog section of the flowmeter electronics is in need of calibration. To do so, refer to Figure 9-6 and perform the following procedure: 1. Connect a pressure source, a HART communicator, and a digital readout device to the flowmeter. 2. Establish communication between the flowmeter and the communicator. 3. Apply pressure equal to the upper range point pressure (100 in H20, for example). 4. Compare the applied pressure to the Secondary Variable (Press) line on the Communicator Process Variables Menu. If the Press reading on the communicator does not match the applied pressure, and you are confident that your test equipment is accurate, perform a sensor trim. 5. Compare the Analog Output (AO) line on the communicator on-line menu to the digital readout device. If the AO reading on the communicator does not match the digital readout device, and you are confident that your test equipment is accurate, perform an output trim. 9-17 ProBar Flowmeter You can trim the sensor using either the full trim or the zero trim function. The trim functions vary in complexity, and their use is application-dependent. Both trim functions alter the interpretation of the input signal. Sensor Trim A zero trim is a single-point adjustment. It is useful for compensating for mounting position effects, and is most effective when performed with the flowmeter installed in its final mounting position. Since this correction maintains the slope of the characterization curve, it should not be used in place of a full trim over the full sensor range. When performing a zero trim, ensure that the equalizing valve is open and all wet legs are filled to the correct levels. A full trim is a two-point sensor calibration where two end-point pressures are applied, and all output is linearized between them. You should always adjust the low trim value first to establish the correct offset. Adjustment of the high trim value provides a slope correction to the characterization curve based on the low trim value. The factoryestablished characterization curve is not changed by this procedure. The trim values allow you to optimize performance over your specified measuring range at the calibration temperature. Zero Trim HART Comm. 1, 2, 3, 3, 1 To calibrate the sensor with a HART Communicator using the zero trim function, perform the following procedure. 1. Vent the flowmeter and attach a communicator to the measurement loop. 2. From the communicator main menu select 1 Device setup, 2 Diagnostics and service, 3 Calibration, 3 Sensor trim, 1 Zero trim to prepare to adjust the zero trim. NOTE The flowmeter must be within 3% of true zero (zero based) in order to calibrate using the zero trim function. 3. Follow the commands provided by the communicator to complete the adjustment of the zero trim. 9-18 ProBar Electronics Functions Full Trim HART Comm. 1, 2, 3, 3 Model 268 F4, F4, F3, F2, F1 NOTE Do not perform a full trim for ProBar flowmeters with a device-type ProBar and a field revision earlier than field revision 3. To calibrate the sensor with a HART communicator using the full trim function, perform the following procedure. 1. Assemble and power the entire calibration system including a flowmeter, HART communicator, power supply, pressure input source, and readout device (see Figure 9-7). NOTE Use a pressure input source that is at least three times more accurate than the flowmeter, and allow the input pressure to stabilize for 10 seconds before entering any values. 2. From the communicator main menu select 1 Device setup, 2 Diagnostics and service, 3 Calibration, 3 Sensor trim, 2 Lower sensor trim to prepare to adjust the lower trim point. NOTE Select pressure input values so that the low and high values are equal to or outside the 4 and 20 mA points. Do not attempt to obtain reverse output by reversing the high and low points. The flowmeter allows approximately a 5% URL deviation from the characterized curve established at the factory. 3. Follow the commands provided by the communicator to complete the adjustment of the lower value. 4. Repeat the procedure for the upper value, replacing 2 Lower sensor trim with 3 Upper sensor trim in Step 2. FIGURE 9-7. Digital Trim Connection. Drawing (4–20 mA Flowmeters). Dead Weight Tester Calibration Standard for Sensor Trim Only 250 Ω Minimum Loop Resistance 24 V dc Power Supply ProBar NOTE 4–20 mA wiring shown. 3051-3051A01A HART-based Communicator Precision Meter 9-19 ProBar Flowmeter Analog Output Trim The Analog Output Trim commands allow you to adjust the current output at the 4 and 20 mA points to match the plant standards. This command adjusts the digital to analog signal conversion (see Figure 9-6 on page 9-17). Digital to Analog Trim To perform a digital-to-analog trim with a HART communicator, perform the following procedure. HART Comm. 1, 2, 3, 2, 1 1. From the HOME screen, select 1 Device setup, 2 Diag/Service, 3 Calibration, 4 D/A trim. Select “OK” after you set the control loop to manual (see Setting the Loop to Manual on page 9-5). 2. Connect an accurate reference ammeter to the flowmeter at the “Connect reference meter” prompt. To do so, connect the positive lead to the positive terminal and the negative lead to the test terminal in the flowmeter terminal compartment, or shunt the flowmeter power through the reference meter at some point. 3. Select “OK” after connecting the reference meter. 4. Select “OK” at the “Setting fld dev output to 4 mA” prompt. The flowmeter outputs 4.00 mA. 5. Record the actual value from the reference meter, and enter it at the “Enter meter value” prompt. The communicator prompts you to verify whether or not the output value equals the value on the reference meter. 6. Select 1 Yes if the reference meter value equals the flowmeter output value, or 2 No if it does not. If you select 1 Yes, proceed to Step 7. If you select 2 No, repeat Step 5. 7. Select “OK” at the “Setting fld dev output to 20 mA” prompt, and repeat Steps 5 and 6 until the reference meter value equals the flowmeter output value. 8. Select “OK” after you return the control loop to automatic control. Digital to Analog Trim Using Other Scale HART Comm. 1, 2, 3, 2, 2 The Scaled D/A Trim command matches the 4 and 20 mA points to a userselectable reference scale other than 4 and 20 mA (1 to 5 volts if measuring across a 250 ohm load, or 0 to 100 percent if measuring from a DCS, for example). To perform a scaled D/A trim, connect an accurate reference meter to the flowmeter and trim the output signal to scale as outlined in the Output Trim procedure. NOTE Use a precision resistor for optimum accuracy. If you add a resistor to the loop, ensure that the power supply is sufficient to power the flowmeter to a 20 mA output with the additional loop resistance. 9-20 ProBar Electronics Functions ADVANCED FUNCTIONS Saving, Recalling, and Cloning Configuration Data HART Comm. left arrow, 1, 2 Use the cloning feature of the Model 275 HART Communicator if you need to configure several ProBar flowmeters similarly. The cloning process involves configuring a flowmeter, saving the configuration data, then sending a copy of the data to a separate flowmeter. There are a number of possible procedures to use when saving, recalling, and cloning configuration data. For complete instructions refer to the HART Communicator manual, p/n 00275-8026-0001. One common method is as follows: 1. Completely configure the first flowmeter. 2. Save the configuration data: a. Select F2 Save from the communicator Home/On-line screen. b. Ensure that the location to which the data will be saved is set to Module. If it is not, select 1 Location to set the save location to module. c. Select 2 Name to name the configuration data. The default is the flowmeter tag number. d. Ensure that the data type is set to standard. If it is not, select 3 Data Type to set the data type to standard. e. Select F2 Save. 3. Connect and power the receiving flowmeter and communicator. 4. Select the back arrow from the Home/On-line screen. The HART Communicator menu appears. 5. Select 1 Off-line, 2 Saved Configuration, 1 Module Contents to reach the Module Contents menu. 6. Use the down arrow to scroll through the list of configurations in the memory module, and use the right arrow to select the configuration you wish to retrieve. 7. Select 1 Edit. 8. Select 1 Mark All. 9. Select F2 Save. 10. Use the down arrow to scroll through the list of configurations in the memory module, and use the right arrow to select the configuration again. 11. Select 3 Send to download the configuration to the flowmeter. When finished, the communicator informs you of the status. To on figure another flowmeter, repeat Steps 3 through 10. NOTE The flowmeter receiving the cloned data must have the same or a newer version of software than the original flowmeter. 9-21 ProBar Flowmeter Burst Mode HART Comm. 1, 4, 3, 3, 3 When configured for burst mode, the ProBar provides faster digital communication from the flowmeter to the control system by eliminating the time required for the control system to request information from the flowmeter. Burst mode is compatible with use of the analog signal. Because HART protocol features simultaneous digital and analog data transmission, the analog value can drive other equipment in the loop while the control system is receiving the digital information. Burst mode applies only to the transmission of dynamic data (pressure and temperature in engineering units, pressure in percent of range, and/or analog output), and does not affect the way other flowmeter data is accessed. Access to information other than dynamic flowmeter data is obtained through the normal poll/response method of HART communication. A HART-based communicator or the control system may request any of the information that is normally available while the flowmeter is in burst mode. Between each message sent by the flowmeter, a short pause allows the HART-based communicator or a control system to initiate a request. The flowmeter will receive the request, process the response message, and then continue “bursting” the data approximately three times per second. Multidrop Communication Multidropping transmitters refers to the connection of several transmitters to a single communications transmission line. Communication between the host and the flowmeters takes place digitally with the analog output of the flowmeters deactivated. With the HART smart communications protocol, up to 15 transmitters can be connected on a single twisted pair of wires or over leased phone lines. This feature can greatly reduce wiring costs. The application of a multidrop installation requires consideration of the update rate necessary from each transmitter, the combination of transmitter models, and the length of the transmission line. Multidrop installations are not recommended where intrinsic safety is a requirement. Communication with the transmitters can be accomplished with commercially available Bell 202 modems and a host implementing the HART protocol. Each transmitter is identified by a unique address (1– 15) and responds to the commands defined in the HART protocol. HARTbased communicators can test, configure, and format a multidropped flowmeter the same way as a transmitter in a standard point-to-point installation. Figure 9-8 on page 9-23 shows a typical multidrop network. This figure is not intended as an installation diagram. Contact Dieterich Standard product support with specific requirements for multidrop applications. 9-22 ProBar Electronics Functions FIGURE 9-8. Typical Multidrop Network. Bell 202 Modem 3051-0087A, 3051A07B RS-232-C Power Supply NOTE The ProBar is set to address 0 at the factory, allowing it to operate in the standard point-to-point manner with a 4–20 mA output signal. To activate multidrop communication, the flowmeter address must be changed to a number from 1 to 15. This change deactivates the 4–20 mA analog output, sending it to 4 mA. It also disables the failure mode alarm signal, which is controlled by the upscale/downscale jumper position. Failure signals in multidropped flowmeters are communicated through HART messages. Changing a Flowmeter Address HART Comm. 1, 4, 3, 3, 1 Polling a Multidropped Loop HART Comm. To change the address of a multidropped flowmeter, follow these fast key sequences. To activate multidrop communication, the flowmeter address must be changed to a number from 1 to 15, and each flowmeter in a multidropped loop must have a unique address. Polling a multidropped loop determines the model, address, and number of flowmeters on the given loop. Left Arrow, 4, 1 (note) NOTE The HART Communicator Model 275 requires you to use the Utility Menu to perform an auto poll. This menu is available from the Main Menu of the HART Communicator. Press the left arrow to move from the On-line Menu to the Main Menu. Press 4 from the Main Menu to access the Utility Menu. 9-23 ProBar Flowmeter 9-24 Section 10 Field Wiring and Electrical Considerations This section provides electrical considerations and ProBar field wiring instructions. SAFETY MESSAGES Procedures and instructions in this section may require special precautions to ensure the safety of the personnel performing the operations. Information that raises potential safety issues is indicated by a warning symbol ( ). Refer to the following safety messages before performing an operation preceded by this symbol. Explosions could result in death or serious injury: • Do not remove the transmitter cover in explosive atmospheres when the circuit is alive. • Before connecting a HART-based communicator in an explosive atmosphere, make sure the instruments in the loop are installed in accordance with intrinsically safe or non-incendive field wiring practices. • Verify that the operating atmosphere of the transmitter is consistent with the appropriate hazardous locations certifications. • Both transmitter covers must be fully engaged to meet explosion-proof requirements. • The unused conduit opening on the electronics housing must be plugged and sealed to meet explosion-proof requirements. Failure to follow these installation guidelines could result in death or serious injury: • Make sure only qualified personnel perform the installation. For intrinsically safe installations, wiring connections must be made in accordance with ANSI/ISA-RP12.6, and Rosemount drawings 03031-1019 or 03031-1024. For ALL installations, wiring connections must be made in accordance with local or national installation codes such as the NEC NFPA 70. 10-1 ProBar Flowmeter The following diagram illustrates wiring loops for a field hook-up with a HART-based communicator. Refer to Appendix A: HART Communicator for an overview of HART communication operations. FIGURE 10-1. Field Hook-up (4–20 mA Flowmeters). CAUTION Do not use inductive-based transient protectors. RL≥ 250 ς Current Meter Power Supply Signal point may be grounded at any point or left ungrounded. ELECTRICAL CONSIDERATIONS The signal terminals are located in a compartment of the electronics housing separate from the ProBar electronics. Connections for the HARTbased communicator are located below the signal terminals. The Model 272 Field Calibrator can be connected at the signal terminals to provide power to the electronics temporarily for calibration or diagnostic purposes. Otherwise, the calibrator may be attached to the test connections on the terminal block of the electronics for indication purposes. Figure 10-2 illustrates power supply load limitations for the ProBar. Operating Region 3051-0103A Load (Ohms) FIGURE 10-2. Power Supply Load Limitations. Voltage (V dc) Communication requires a minimum loop resistance of 250 ohms. (1) For CSA approval, power supply must not exceed 42.4 V. POWER SUPPLY (4–20MA ELECTRONICS) The dc power supply should provide power with less than 2 percent ripple. The total resistance load is the sum of the resistance of the signal leads and the load resistance of the controller, indicator, and related pieces. Note that the resistance of intrinsic safety barriers, if used, must be included. NOTE A minimum loop resistance of 250 ohms is required to communicate with a HART-based communicator. With 250 ohms of loop resistance, the ProBar will require a minimum of 15.5 volts to output 20 mA. If a single power supply is used to power more than one ProBar, the power supply used, and circuitry common to the ProBars, should not have more than 20 ohms of impedance at 1200Hz. 10-2 3051-3031H02B WIRING DIAGRAMS (FIELD HOOK-UP) Field Wiring and Electrical Considerations WIRING To make connections, remove the housing cover on the side marked FIELD TERMINALS. Do not remove the instrument covers in explosive atmospheres when the circuit is alive. All power to the ProBar is supplied over the signal wiring. Connect the lead that originates at the positive side of the power supply to the terminal marked “+” and the lead that originates at the negative side of the power supply to the terminal marked “–.” Avoid contact with the leads and terminals. Inductive-based transient protectors, including the Model 470, can adversely affect the output of the ProBar. Do not use the Model 470 for transient protection with the ProBar. If transient protection is desired, install the Transient Protection Terminal Block. Consult the factory for instructions. HAZARDOUS LOCATIONS The ProBar has an explosion-proof housing and circuitry suitable for intrinsically safe and non-incendive operation. Individual ProBar models are clearly marked with a tag indicating the certifications they carry. See Section 16: Specifications and Reference Data for specific approval categories. 10-3 ProBar Flowmeter NOTE Signal wiring does not require shielding; however, twisted pairs provide the best results. In order to ensure communication, wiring should be 24AWG or larger and shorter than 5,000 feet (1500 meters) in length. Do not connect the powered signal wiring to the test terminals. Power may damage the test diode in the test connection. Plug and seal unused conduit connections on the electronics housing to avoid moisture accumulation in the terminal side of the housing. Excess moisture accumulation may damage the ProBar electronics. If the connections are not sealed, the ProBar electronics should be remote mounted with the electrical housing positioned downward for drainage. Wiring should be installed with a drip loop, and the bottom of the drip loop should be lower then the conduit connections and the housing. Grounding the Signal Wiring Do not run signal wiring in conduit or open trays with power wiring, or near heavy electrical equipment. Signal wiring may be grounded at any one point on the signal loop, or it may be left ungrounded. The negative terminal of the power supply is a recommended grounding point. Grounding the ProBar Case The ProBar should always be grounded in accordance with national and local electrical codes. The most effective ProBar case grounding method is a direct connection to an earth ground with minimal impedance. Methods for grounding the ProBar case include: • Internal Ground Connection: Inside the FIELD TERMINALS side of the electronics housing is the Internal Ground Connection screw, which is identified by a ground symbol: . NOTE Grounding the electronics case via threaded conduit connection may not provide sufficient ground. Environmental Considerations Mount the ProBar to minimize ambient temperature changes. Section 16: Specifications and Reference Data lists the ProBar temperature operating limits. Mount the ProBar electronics to avoid vibration and mechanical shock, and to avoid external contact with corrosive materials. Access Requirements When choosing an installation location and position, consider the need for access to the ProBar. Process Flange Orientation Orient the process flanges on a remote mounted ProBar so that process connections can be made. For safety reasons, orient the drain/vent valves so that process fluid is directed away from technicians when the valves are used. In addition, consider the possible need for a testing or calibration input. Housing Rotation The electronics housing may be rotated up to 180 degrees (left or right) to improve field access to the two compartments or to better view the optional LCD meter. To rotate the housing, release the housing rotation set screw and turn the housing not more than 180 degrees. NOTE Do not rotate the housing greater than 180 degrees. Rotating the housing greater than 180 degrees will damage the sensor module and void the warranty. 10-4 Field Wiring and Electrical Considerations Terminal Side of the Electronics Housing Wiring connections are made through the conduit openings on the top side of the housing. The field terminal side is marked on the electronics housing. Mount the ProBar so that the terminal side is accessible. A 0.75’’ clearance is required for cover removal. Use a conduit plug on the unused side of the conduit opening. Circuit Side of the Electronics Housing The circuit compartment should not routinely need to be opened when the unit is in service; however, provide 0.75-in. clearance if possible to allow access. A 3-in. clearance is required for cover removal if a meter is installed. Exterior of the Electronics Housing The integral span and zero push-buttons are located under the certifications plate on the top of the ProBar. The plate will be blank if no certifications are ordered. Cover Installations Always install the electronics housing covers metal-to-metal to ensure a proper seal. 10-5 ProBar Flowmeter 10-6 Section 11 Direct Mount ProBar Commissioning Commissioning is the process of testing the ProBar to ensure that it operates accurately and safely. This section provides instructions for commissioning direct mounted ProBar models in horizontal or vertical pipes. NOTE The commissioning process differs between direct mounted and remote mounted ProBar flowmeters. See Section 12: Remote Mount ProBar Commissioning for instructions. SAFETY MESSAGES Instructions and procedures in this section may require special precautions to ensure the safety of the personnel performing the operations. Please refer to the following safety messages before performing any operation in this section. Explosions could result in death or serious injury: • Do not remove the transmitter cover in explosive atmospheres when the circuit is alive. • Before connecting a HART-based communicator in an explosive atmosphere, make sure the instruments in the loop are installed in accordance with intrinsically safe or non-incendive field wiring practices. • Verify that the operating atmosphere of the transmitter is consistent with the appropriate hazardous locations certifications. • Both transmitter covers must be fully engaged to meet explosion-proof requirements. Failure to follow these installation guidelines could result in death or serious injury: • Make sure only qualified personnel perform the installation. If the line is pressurized, serious injury or death could occur by opening valves. 11-1 ProBar Flowmeter COMMISSIONING DIRECT MOUNTED PROBARS The commissioning process differs according to the service used. The following sections provide commissioning instructions for each type of service. Liquid Service This section provides instructions for commissioning direct mounted ProBar models used for liquid service in horizontal or vertical pipes. Figure 11-1 identifies the valves used during the commissioning process. FIGURE 11-1. Valve Identification for Direct Mounted ProBars in Liquid Service. ML ME MH DVH 8900-8900V01A DVL Use the following procedure to commission the ProBar. 1. Open the high and low manifold valves MH and ML. 2. Open the equalizer valve ME. 3. Open the drain/vent valves on the electronics; bleed until no air is apparent in the liquid. 4. Close both drain/vent valves DVL and DVH. 5. Close the high and low manifold valves MH and ML. 6. Check the ProBar zero by noting the electronics output—this is called a wet zero. If the signal reads outside of the range 3.98 mA to 4.02 mA, air is probably still in the system; repeat step 2, and trim zero if necessary. 7. Open the high and low manifold valves ML and MH. 8. Close equalizer valve ME. The system is now operational. 11-2 Direct Mount ProBar Commissioning Gas Service This section provides instructions for commissioning direct mounted ProBar models used for gas service in horizontal or vertical pipes. Figure 11-2 identifies the valves used during the commissioning process. FIGURE 11-2. Valve Identification for Direct Mounted ProBars in Gas Service. ML ME MH DVL 8900-8900V01A DVH Use the following procedure to commission the ProBar. 1. Ensure that the pipe is pressurized. 2. Open the drain valves DVL and DVH on the electronics to ensure that no liquid is present. 3. Open equalization valve ME. 4. Open both high and low side main valves MH and ML. 5. Close drain valves DVL and DVH. 6. Check the electronics for the 4 mA signal. Trim zero if necessary. 7. Close the equalizer valve ME. The system is now operational. 11-3 ProBar Flowmeter Steam Service This section provides instructions for commissioning direct mounted ProBar models used for steam service in horizontal pipes. Steam service in vertical lines must be remote mounted. Refer to Section 12: Remote Mount ProBar Commissioning. Figure 11-3 identifies the valves used during the commissioning process. FIGURE 11-3. Valve Identification for Direct Mounted ProBars in Steam Service. ML ME Hose Connection MH DHL DVL 8900-8900V02A Hose Connect Valve Use the following procedure to commission the ProBar. 1. Ensure that the steam line is depressurized with no steam. 2. Check the electronics for a dry zero of 4 mA with no water loss. 3. Attach a water supply to the hose connection. The water supply should have a maximum psi of 100. 4. Open the high and low main valves MH and ML and equalizer valve ME. 5. Close low side vent DVL on the electronics. 6. Open the hose connect valve for a minimum of 30 seconds. Water will flow through both the high and low chambers and into the pipe. 7. Close the high MH for 30 seconds to force water to the ML side. 8. Re-open the MH valve. 9. Open low side vent DVL on the electronics until no air is observed. 10. Close the vent. 11. Close the hose connect valve. 12. Close both MH and ML. 13. Check the ProBar zero by noting the electronics output. If the signal reads outside of the range 3.98 mA to 4.02 mA, air is probably still in the system; repeat this procedure from step 2, and trim sensor if necessary. 14. Open MH and ML. 15. Close equalizer valve ME. The system is now operational. 11-4 Section 12 Remote Mount ProBar Commissioning Commissioning is the process of testing the ProBar to ensure that it operates accurately and safely. This section provides instructions for commissioning remote mounted ProBar models in horizontal or vertical pipes. NOTE The commissioning process differs between direct mounted and remote mounted ProBar flowmeters. See Section 11: Direct Mount ProBar Commissioning for instructions. SAFETY MESSAGES Instructions and procedures in this section may require special precautions to ensure the safety of the personnel performing the operations. Please refer to the following safety messages before performing any operation in this section. Explosions could result in death or serious injury: • Do not remove the transmitter cover in explosive atmospheres when the circuit is alive. • Before connecting a HART-based communicator in an explosive atmosphere, make sure the instruments in the loop are installed in accordance with intrinsically safe or non-incendive field wiring practices. • Verify that the operating atmosphere of the transmitter is consistent with the appropriate hazardous locations certifications. • Both transmitter covers must be fully engaged to meet explosion-proof requirements. Failure to follow these installation guidelines could result in death or serious injury: • Make sure only qualified personnel perform the installation. If the process fluid is caustic or otherwise hazardous, the procedure outlined here must be modified as required to prevent death or serious injury to personnel. If the line is pressurized, serious injury or death could occur by opening valves. 12-1 ProBar Flowmeter COMMISSIONING REMOTE MOUNTED FLOWMETERS This section contains four procedures to follow in preparation for commissioning a remote mounted ProBar: 1. Identify the location and purpose of manifold valves. 2. Zero the electronics. 3. Check for system leaks. 4. Perform a zero calibration. Before beginning the ProBar commissioning process, you should become familiar with the location and purpose of the various valves involved. Figure 12-1 identifies the location of valves for both 5-valve and 3-valve manifolds, and Table 12-1 identifies the purpose of those valves. FIGURE 12-1. Valve Identification: A (5-Valve Manifold) and B (3-Valve Manifold). To PH To PL To PH To PL MV MH MH ME ML MEH MEL DVL DVH 5-Valve Manifold TABLE 12-1. Description of Impulse Piping Valves and Components 12-2 Name ML 3-Valve Manifold Description 8900-8900_34A, 8900_35A ProBar Valve Identification Purpose Impulse Piping Valves PH PL Primary Sensor—High Pressure Primary Sensor—Low Pressure Isolates the flowmeter sensor from the impulse piping system DVH DVL Drain/Vent valve—High Pressure Drain/Vent valve—Low Pressure Drains (gases) or vents (liquids) the DP electronics chambers BH BL Blowdown—High Pressure Blowdown—Low Pressure Allows pipeline pressure to blow and clear sediment from impulse piping VH VL Vent Valve—High Pressure Vent Valve—Low Pressure Allows venting of collected gases from impulse piping in liquid applications DH DL Drain Valve—High Pressure Drain Valve—Low Pressure Allows draining of collect condensate from impulse piping in gas applications Remote Mount ProBar Commissioning Zero the Electronics Before the ProBar electronics are exposed to line pressure, check the “zero” calibration (or, “dry” zero) by using the following procedure. 1. Open first the equalizer valve(s) MEL and MEH or ME. 2. Close valves MH and ML. 3. Read the ProBar output. It should read within the range 3.98 mA to 4.02 mA. If the output is outside of this range, trim zero as described in Section 9: ProBar Electronics Functions. Check for System Leaks Check the system for leaks after installation is complete. A leak in a differential pressure instrument system can produce a difference in pressure that is larger than the signal itself. Before the system is filled and/or commissioned, it is a simple matter to use compressed air or another inert, compressed gas to check for leaks. The gas pressure must be below the maximum allowed, but at least equal to the normal operating pressure in order to reveal potential leaks. A typical pressure used is 100 psig (690 kPa). Before pressurizing the system, check for leaks by doing the following: 1. Open equalizer valve(s) MEH, MEL or ME to prevent overpressuring the DP. 2. Close valves PH, PL (unless the piping system is also being pressure-checked), MV, DVH, DVL. • If present, also close valves BH and BL or DH and DL. 3. Open valves MH and ML. 4. Install all appropriate tapped plugs. 5. Install a current meter to read the signal, if necessary. Apply pressure at a convenient point on either the high or low side of the system. Use a suitable leak detection solution and apply to all of the impulse piping, valves, manifold, and connections. A leak is indicated by a continuous stream of bubbles. 5-Valve Manifolds If a 5-valve manifold is installed, the equalizer valves can be tested by performing the following after system leaks are repaired and the system is stable: 1. Close equalizer valves MEH and MEL. 2. Open vent valve MV. There should be no leakage from the manifold vent. 3. Close vent valve MV. 4. Open equalizer valves MEH and MEL. 5. Bleed off the air and remove the source fitting. 6. Return the system to the original configuration. Use extreme care when bleeding high temperature fluids. Bleed piping may need to be installed. 12-3 ProBar Flowmeter “Calibrate Out” Temperature Effects Do not begin this procedure until the system leak check has been completed and all leaks have been fixed. The ProBar’s proportional output-to-flow ratio makes a true “zero” calibration critical for producing accurate measurements. The “zero” calibration procedure is affected by static pressure and ambient temperature, but these effects can be removed by calibrating them “out.” The effect of static pressure is calibrated out by exposing the ProBar electronics to the line pressure and performing a “zero” or wet calibration, as described below. In order to calibrate out the effect of ambient temperature, two aspects should be taken into consideration: 1. The electronics should be located in a place where the ambient temperature does not change rapidly or vary by more than 10 to 15 °F (26 to 29 °C). 2. When commissioning the electronics, the flowing fluid (condensate/ water for steam service) could bring the sensor to a temperature significantly different than the temperature during normal operations. In this situation, perform another “zero” calibration at least 60 minutes after the ProBar has been commissioned. The sensor temperature can be monitored using a HART-based communicator, as described in the Wet Calibration section below. Although the above effects are relatively small, they significantly affect the accuracy of the ProBar when used with low flows. Periodic “zero” calibration and/or commissioning is recommended to maintain the accuracy of ProBar. The frequency of this type of maintenance should be established for each individual application. Zero or Wet Calibration Follow this procedure to obtain a true zero at static or “pipe” pressure: 1. Open equalizer valves: • For 5-valve manifolds, open valves MEH and MEL • For 3-valve manifolds, open valves ME and high side MH 2. Close low side valve ML to prevent generating differential pressure. 12-4 Remote Mount ProBar Commissioning COMMISSIONING Complete the following tasks before beginning the commissioning procedure: 1. Power the ProBar, if required. 2. Connect an appropriate readout instrument so the differential pressure signal can be monitored. 3. Identify the manifold equalizer valves by their ME prefix. • 5-valve manifolds have two equalizer valves, MEH and MEL. • 3-valve manifolds have one equalizer valve, ME. 4. Close all valves before commissioning the system. See Figures 8-4 through 8-10 for valve identification while following the procedures given below. Liquid Service below 250 °F (121 °C) Refer to Figures 8-5 and 8-6 for electronics location and valve identification for liquid service at temperatures of 250 °F (121 °C) or less. See page 12-7 to commission a remote mounted ProBar for liquid service above 250 °F (121 °C). 1. Ensure that primary instrument valves PH and PL are closed. 2. Open valves ME, ML, and MH. • For 5-valve manifolds, open valves MEH and MEL. 3. Slowly open valve PL and then PH, which are the primary instrument valves. 4. Open drain/vent valves DVL and DVH to bleed air out of system. Bleed until no air is apparent in the liquid. 5. Close valves DVL and DVH. NOTE For the alternate electronics location shown in Figure 8-6, open vent valves VH and VL and bleed until no air is apparent in the liquid. 6. Slowly open vent valve MV to bleed out any entrapped air in manifold. Bleed until no air is apparent in the liquid. 7. Close vent valve MV. 8. Gently tap the electronics body, valve manifold, and impulse piping with a small wrench to dislodge any remaining entrapped air. 9. Repeat steps 2, 2A, and 3. 10. Close valve PH. 11. Check the ProBar zero by noting the electronics output — this is called a wet zero. The electronics should indicate a zero DP (Differential Pressure) signal. If the signal reads outside the range 3.98 mA to 4.02 mA, air is probably still in the system; repeat the procedure from step 2. Trim zero if necessary. 12. Close equalizer valve(s). • For 3-valve manifolds, close valve ME. • For 5-valve manifolds, close valves MEH and MEL. 13. Slowly open valve PH. The system is now operational. For 5-valve manifolds only: 14. Open valve MV. If valve MV is leaking, valves MEH and/or MEL are not fully closed or require repair. This must be done before taking any readings. 12-5 ProBar Flowmeter Gas Service Follow this procedure for commissioning a remote mounted ProBar for gas service. Refer to Figures 8-7 and 8-8 for electronics location and valve identification. 1. For an impulse piping arrangement as shown in Figure 8-7 (vertical pipe) only, open primary instrument valves PH and PL. 2. Open drain valves DH and DL slowly to allow the condensate to drain. 3. Close valves DH and DL. 4. Ensure that primary instrument valves PH and PL closed. 5. Open valves ME, ML and MH. • For 5-valve manifolds, open valves MEH and MEL. 6. Slowly open valve PL, the primary high pressure instrument valve. 7. Check electronics zero by noting the electronics reading. The electronics should indicate a “zero” DP signal. If the signal reads outside of the range 3.98 mA to 4.02 mA, condensate may be in the DP electronics or system; repeat the procedure from step 1 to remove any condensate. A signal outside the range 3.98 mA to 4.02 mA can also be caused by system leaks; check for leaks in system. 8. Close equalizer valve(s). • For 3-valve manifolds, close valve ME. • For 5-valve manifolds, close valves MEH and MEL. 9. Slowly open valve PH. The system is now operational. For 5-valve manifolds only: 10. Open valve MV. If valve MV is leaking, valves MEH and/or MEL are not fully closed or require repair. This must be done before taking any readings. 12-6 Remote Mount ProBar Commissioning Steam Service or Liquid Service above 250 °F (121 °C) Follow this procedure for commissioning a remote mounted ProBar for steam service or for liquid service at a temperature above 250 °F (121 °C). Refer to Figures 8-9 and 8-10 for electronics location and valve identification. 1. Ensure that primary instrument valves PH and PL closed; ME, ML and MH are closed; and DVL and DVH are closed. • For 5-valve manifolds, ensure that valves MEH and MEL are closed. 2. Fill tees with water on each side until water overflows. 3. Open valves MH, ML and equalizer valve ME. • For 5-valve manifolds, open equalizer valves MEH and MEL. 4. Open valves DVL and DVH. 5. Tap manifold until no air bubbles are visible. 6. Close both valves DVL and DVH. 7. Refill tees with water. 8. Gently tap electronics body, valve manifold, and impulse piping with a small wrench to dislodge any remaining entrapped air. 9. Check ProBar zero by noting the electronics output — this is called a wet zero. The electronics should indicate a “zero” DP signal. If the signal reads outside of the range 3.98 mA to 4.02 mA, air is probably still in the system; repeat this procedure from step 2. Trim zero if necessary. 10. Close equalizer valve ME. • For 5-valve manifolds, close equalizer valves MEH and MEL. 11. Replace plugs in tees. 12. Slowly open valves PH and PL. The system is now operational. For 5-valve manifolds only: 13. Open valve MV. If valve MV is leaking, valves MEH and/or MEL are not fully closed or require repair. This must be done before taking any readings. 12-7 ProBar Flowmeter 12-8 Section 13 Installation Options Options available with the ProBar can ease installation and enhance the security of control systems. These options include the integral zero and span adjustments, LCD meters, mounting brackets, custom configurations, the level flange, the traditional flange, optional bolt materials, and the transient protection terminal block. SAFETY MESSAGES Procedures and instructions in this section may require special precautions to ensure the safety of the personnel performing the operations. Information that raises potential safety issues is indicated by a warning symbol ( ). Refer to the following safety messages before performing an operation preceded by this symbol. Explosions could result in death or serious injury: • Do not remove the transmitter cover in explosive atmospheres when the circuit is alive. • Before connecting a HART-based communicator in an explosive atmosphere, make sure the instruments in the loop are installed in accordance with intrinsically safe or non-incendive field wiring practices. • Verify that the operating atmosphere of the transmitter is consistent with the appropriate hazardous locations certifications. • Both transmitter covers must be fully engaged to meet explosion-proof requirements. Electrical shock can result in death or serious injury. • Avoid contact with the leads and the terminals. INTEGRAL ZERO AND SPAN ADJUSTMENT OPTIONS The integral zero and span adjustments can be used for adjusting the analog output without the use of a communicator. Several options are available to customize the local zero and span adjustments. The J1 option only provides the external zero adjustment that enables the user to rezero the flowmeter locally. The J3 option excludes both the zero and span adjustments for security purposes. The push-button span and zero adjustments are hidden by the certifications label on top of the flowmeter. Loosen the label screw and rotate the label 180 degrees counterclockwise to expose the adjustments. 13-1 ProBar Flowmeter Disabling the Zero and Span Adjustments For security reasons, or to prevent accidental changes to the configuration data, there are three methods of controlling the local zero and span adjustments: Method 1: flowmeter Security Jumper Enabling the flowmeter security jumper on the circuit board prevents changes to flowmeter configuration information by both the HART Communicator and the local zero and span adjustments (see Flowmeter Security on page 9-4). Method 2: Communicator Software Lockout Sequence The communicator software lockout sequence disables only the span and zero adjustments; changes can still be made using the HART communicator (see page 9-14). Method 3: Remove the Zero and Span Buttons To remove the local zero and span buttons, use a small screwdriver to remove the blue plastic cover plate securing the buttons to the flowmeter housing. After you remove the cover plate, the button assemblies – including buttons, springs, and magnets – will slide out. If you intend to use the button at some time in the future, store the buttons separately to ensure that the magnets maintain their proper magnetic strength. LCD METER The LCD meter provides local indication of the output, and abbreviated diagnostic messages governing flowmeter operation. The meter is located on the electronics module side of the flowmeter, maintaining direct access to the signal terminals. An extended cover is required to accommodate the meter. The meter features a two-line display that accommodates five digits for reporting the process variable on the top line, and six characters for displaying engineering units on the bottom line(1). And in addition to units of pressure, the new LCD meter is capable of displaying flow and volume units. The meter uses both lines to display diagnostic messages. You can configure the meter to display the following information: • Engineering Units • Percent of Range • Alternating between any two of the above FIGURE 13-1. Exploded View of the ProBar with Optional LCD Meter. Interconnecting Pins Jumpers (top and bottom) LCD Meter 3051-3031A05A Extended Cover (1) Previous versions differ slightly. 13-2 Installation Options Installing the Meter For flowmeters ordered with the LCD meter, the meter is shipped installed. Installing the meter on an existing ProBar flowmeter requires a small instrument screwdriver and the meter kit. The kits vary depending on the version of flowmeter electronics. Examine the following numbers carefully to ensure you are installing the correct kit. For use with Shrouded Electronics Board Meter Kits Option M5: P/N 03031-0193-0101 Option M6: P/N 03031-0193-0111 For use with Non-Shrouded Electronics Board Meter Kits Option M5: P/N 03031-0193-0001 Option M6: P/N 03031-0193-0011 The meter kit includes: • one LCD meter assembly • one extended cover with cover O-ring installed • two nylon standoffs • two captive screws • one ten -pin interconnection header Use the following procedure and Figure 13-1 to install the LCD meter. If the meter is an upgrade from a previous version, upgrade the electronics board before attempting to install the meter. 1. If the flowmeter is installed in a loop, secure the loop and disconnect power. 2. Remove the flowmeter cover opposite the field terminal side. Do not remove the instrument covers in explosive environments when the circuit is alive. 3. Remove the failure mode and alarm jumpers from the electronics module, and insert them in their new positions above and below the meter readout on the meter assembly. NOTE On previous versions, remove only the alarm jumper. 4. Insert the interconnection header in the ten-pin(1) socket exposed by removal of the jumpers. 5. Remove the two captive screws from the electronics module. To do so, loosen the screws to release the module, then pull out the screws until they are stopped by the captive thread inside of the circuit board standoffs. Continue loosening the screws and remove them. 6. Rotate the electronics housing up to 180 degrees (left or right) to improve field access to the two compartments or to better view the optional LCD meter. To rotate the housing, release the housing rotation set screw and turn the housing not more than 180 degrees from the orientation shown in Figure 13-2. To rotate the housing greater than 180 degrees, follow Steps 1–6 of the disassembly procedure in Section 15: Troubleshooting. (1) Previous versions of the meter use a six-pin connector. See Safety Messages on page 13-1 for complete warning information. 13-3 ProBar Flowmeter NOTE Do not rotate the housing greater than 180 degrees without first following the disassembly procedure in Section 15: Troubleshooting. Rotating the housing greater than 180 degrees will damage the sensor module and void the Rosemount warranty. 7. Decide which direction to orient the meter. Insert the long meter screws into the two holes on the meter assembly that coincide with the holes on the electronics module. You can install the meter in 90-degree increments for easy viewing. Position one of the four connectors on the back of the meter assembly to accept the interconnection header. 8. Attach the meter assembly to the electronics module by threading the screws into the captive threads and attaching the meter assembly to the interconnection pins. Tighten the screws to secure the meter assembly and electronics board in place. 9. Attach the extended cover, and tighten. Flowmeter covers must be fully engaged to meet explosion proof requirements and to achieve the proper environmental seal. Note the following LCD temperature limits: Operating: –4 to 175 °F (–20 to 80 °C) Storage: –40 to 185 °F (–40 to 85 °C) NOTE Electronics board revision 5.3 or later (all shrouded designs) have increased functionality that allows verification testing of alarm current levels. If you repair or replace the flowmeter electronics board, sensor module or LCD meter, it is recommended that you verify the flowmeter alarm level before you return the flowmeter to service (see Alarm Level Verification on page 9-3). 3051-013BB FIGURE 13-2. ProBar Electronics with Optional LCD Meter. Diagnostic Messages 13-4 In addition to the output, the LCD meter displays abbreviated operation, error, and warning messages for troubleshooting the flowmeter. Messages appear according to their priority, with normal operating messages appearing last. To determine the cause of a message, use a Model 275 HART Communicator to further interrogate the flowmeter. A description of each LCD diagnostic message follows. See Safety Messages on page 13-1 for complete warning information. Installation Options Error Error messages appear on the LCD meter display to inform you of serious problems effecting the operation of the flowmeter. The meter displays an error message until the error condition is corrected, and the analog output is driven to the specified alarm level. No other flowmeter information is displayed during an alarm condition. FAIL(1) The flowmeter CPU board and the sensor module are incompatible. If you encounter this message, contact Dieterich Standard Inc. at 303-530-3600 if you need assistance. FAIL MODULE The sensor module is disconnected or is malfunctioning. Verify that the sensor module ribbon cable is connected to the back of the electronics board. If the ribbon cable is properly connected, there is a problem within the sensor module. Possible sources of problems include: • Pressure or temperature updates are not being received in the sensor module • A non-volatile memory fault that will effect flowmeter operation has been detected in the module by the memory verification routine Some non-volatile memory faults are user-repairable. Use a Model 275 HART Communicator to diagnose the error and determine if it is repairable. Any error message that ends in “FACTORY” is not repairable. In cases of non user-repairable errors, you must replace the sensor module. See on page 15-3, or contact Dieterich Standard Inc. at 303-530-3600 if you need assistance. (1) With previous versions of the ProBar, FAIL MODULE and FAIL ELECT were also grouped into the FAIL message. When dealing with a FAIL message on a previous version of the ProBar, review the information in the FAIL MODULE and FAIL ELECT sections as well. 13-5 ProBar Flowmeter FAIL ELECT The flowmeter electronics board is malfunctioning due to an internal fault. Some of the FAIL ELECT errors are user-repairable. Use a Model 275 HART Communicator to diagnose the error and determine if it is repairable. Any error message that ends in “FACTORY” is not repairable. In cases of non user-repairable errors, you must replace the electronics board. See REMOVE THE ELECTRONICS BOARD on page 15-4, or contact Rosemount Customer Central at 800-999-9307 if you need assistance. FAIL CONFIG A memory fault has been detected in a location that could effect flowmeter operation, and is user-accessible. To correct this problem, use a Model 275 HART Communicator to interrogate and reconfigure the appropriate portion of the flowmeter memory. Contact Dieterich Standard Inc. at 303-530-3600 if you need assistance. Warnings Warnings appear on the LCD meter display to alert you of userrepairable problems with the flowmeter, or current flowmeter operations. Warnings appear alternately with other flowmeter information until the warning condition is corrected or the flowmeter completes the operation that warrants the warning message. NOTE The warning messages on previous versions of the LCD meter may vary slightly from those listed here, but they represent the same warning. FPRES LIMIT The process variable read by the flowmeter is outside of sensor range limits. P/T LIMIT The secondary or tertierytemperature variable read by the electronics is outside of flowmeter range. CURR FIXED The flowmeter is in multidrop mode. The analog output is not tracking pressure changes. CURR SATURD The pressure read by the module is outside of the specified range, and the analog output has been driven to saturation levels (see page 9-3). LOOP TEST A loop test is in progress. During a loop test or 4–20 mA trim, the analog output is set to a fixed value. The meter display alternates between the current selected in milliamps and “LOOP TEST.” XMTR INFO A non-volatile memory fault has been detected in the flowmeter memory by the memory verification routine. The memory fault is in a location containing flowmeter information. To correct this problem, use a Model 275 HART Communicator to interrogate and reconfigure the appropriate portion of the flowmeter memory. This warning does not effect the flowmeter operation. Contact Dieterich Standard Inc. at 303-530-3600 if you need assistance. 13-6 Installation Options Operation Normal operation messages appear on the LCD meter to confirm actions or inform you of flowmeter status. Operation messages are displayed with other flowmeter information, and warrant no action to correct or alter the flowmeter settings. ZERO PASS The zero value, set with the local zero adjustment button, has been accepted by the flowmeter, and the output should change to 4 mA. ZERO FAIL The zero value, set with the local zero adjustment button, exceeds the maximum rangedown allowed for a particular range, or the pressure sensed by the flowmeter exceeds the sensor limits. SPAN PASS The span value, set with the local span adjustment button, has been accepted by the flowmeter, and the output should change to 20 mA. SPAN FAIL The span value, set with the local span adjustment button, exceeds the maximum rangedown allowed for a particular range, or the pressure sensed by the flowmeter exceeds the sensor limits. LOCAL DSBLD This message appears during reranging with the integral zero and span buttons and indicates that the flowmeter local zero and span adjustments have been disabled. The adjustments may have been disabled by the flowmeter security jumper on the flowmeter circuit board or through software commands from the Model 275. Refer to Flowmeter Security on page 9-4 for information on the position of the security jumper, and Disabling the Zero and Span Adjustments on page 13-2 for information on the software lockout. WRITE PROTCT This message appears if you attempt to change the flowmeter configuration data while the security jumper is in the “ON” position. See Flowmeter Security on page 9-4 for more information about the security jumper. 13-7 ProBar Flowmeter 13-8 Section 14 Maintenance for the Optional RTD PROBAR RTD MAINTENANCE This section covers maintenance procedures for the RTD option available with the ProBar electronics. SAFETY MESSAGES Instructions and procedures in this section may require special precautions to ensure the safety of the personnel performing the operations. Please refer to the following safety messages before performing any operation in this section. Explosions could result in death or serious injury: • Do not remove the transmitter cover in explosive atmospheres when the circuit is alive. • Before connecting a HART-based communicator in an explosive atmosphere, make sure the instruments in the loop are installed in accordance with intrinsically safe or non-incendive field wiring practices. • Verify that the operating atmosphere of the transmitter is consistent with the appropriate hazardous locations certifications. • Both transmitter covers must be fully engaged to meet explosion-proof requirements. Failure to follow these installation guidelines could result in death or serious injury: • Make sure only qualified personnel perform the installation. 14-1 ProBar Flowmeter Replacing a Direct Mount RTD If an RTD needs to be replaced on a direct mounted ProBar, proceed as follows. Refer to Figures 14-1 and 14-2. 1. Close instrument valves to ensure that the pressure is disconnected from the electronics. 2. Open the bleed valves on the electronics to remove all pressure. 3. Remove the cap. 4. Remove the RTD wiring only from the terminal. 5. Remove the hex nuts. 6. Remove the electronics. 7. Remove the ½–14 NPT plug. 8. Pull the RTD wire out of the nipple and remove the RTD. The RTD is in a thermowell, so no live line pressure will be present. 9. Install the new RTD and thread the wires through the nipple. 10. Reinstall the ½-in. NPT plug. 11. Use the same teflon gaskets to reinstall the electronics to the ProBar sensor head. 12. Use a torque wrench to tighten the stainless steel hex nuts in a cross pattern to 300 in-lbs (650 in-lbs for carbon steel hex nuts). 13. Reconnect the RTD wires to the terminal. This diagram is for a typical RTD transmitter wiring connection. 14. Refasten the electronics hex nut to the electronics and tighten. 15. Open the instrument valves. Replacing a Remote Mount RTD If an RTD needs to be replaced on a remote mounted ProBar, proceed as follows. Refer to Figures 14-1 and 14-2; this diagram is for a typical RTD transmitter wiring connection. 1. Close instrument valves to ensure that the pressure is disconnected from the electronics. 2. Open the bleed valves on the electronics to remove all pressure. 3. Remove the cap. 4. Remove the RTD wiring only from the terminal. 5. Remove the Terminal Housing from the ProBar head. 6. Pull the RTD wire out of the nipple and remove the RTD. The RTD is in a thermowell, so no live line pressure will be present. 7. Install the new RTD and thread the wires through the nipple. 8. Install the Terminal Housing onto the ProBar head. 9. Reconnect the RTD wires to the terminal. 10. Open the instrument valves. 14-2 Section 15 SAFETY MESSAGES Troubleshooting Procedures and instructions in this section may require special precautions to ensure the safety of the personnel performing the operations. Information that raises potential safety issues is indicated by a warning symbol ( ). Refer to the following safety messages before performing an operation preceded by this symbol. Explosions can result in death or serious injury. • Do not remove the instrument cover in explosive environments when the circuit is alive. • Both transmitter covers must be fully engaged to meet explosion-proof requirements. • Before connecting a communicator in an explosive atmosphere, make sure the instruments in the loop are installed in accordance with intrinsically safe or nonincendive field wiring practices. Electrical shock can result in death or serious injury. • Avoid contact with the leads and the terminals. Table 15-1 provides summarized troubleshooting suggestions for the most common ProBar operating problems. If you suspect a malfunction despite the absence of any diagnostic messages on the communicator display, follow the procedures described below to verify that the ProBar hardware and process connections are in good working order. Always approach the most likely and easiest-tocheck conditions first. 15-1 ProBar Flowmeter TABLE 15-1. Troubleshooting Chart Symptom Possible Cause Corrective Action Questionable accuracy or erroneous flow signal Improper installation • • • System leaks 15-2 Is the ProBar flow arrow pointed in the direction of the flow? Verify that the cross reservoirs are perfectly level with one another. Is there sufficient straight run upstream and downstream of the ProBar? Check for leaks in instrument piping. Repair and seal all leaks. Contamination/plugging Remove the ProBar and check for contamination. Closed valve Verify that both ProBar (PH & PL) or (MH & ML) valves are open. Verify that vent, equalizer, and line valves are properly positioned per the “start up procedure.” ProBar calibration Is the ProBar calibration too high or low for the flow rate? ProBar connections (remote mount only) Verify that the high side of the ProBar electronics is connected to the high side of the ProBar. Check the same for the low side. Entrapped air (liquid applications) Are there uneven water legs caused by air entrapment in the instrument connections? If so, bleed air. ProBar misalignment Misalignment of the ProBar beyond 3° will cause an erroneous signal. Opposite-side support ProBar If the ProBar is an opposite-side support model, is it installed through the pipe wall and into the support plug? Operating conditions Are the operating conditions in compliance with those given at the time the flowmeter was purchased? Check the flow calc and the fluid parameters for accuracy. Double-check pipe inside diameter for proper ProBar sizing. Note: For the multipoint flow calibrated ProBar, refer to the ProBar Flow Handbook for corrections. Spiking flow signal Two-phase flow The ProBar is a head measurement device and will not accurately measure a two-phase flow. Spiking flow signal (Stream Service) Improper insulation (Vertical pipes only) Excessive vibration Added insulation may be required to ensure that a phase change occurs at the cross reservoirs. Check the impulse piping for vibration. Vibration of sensor or leakage at Pak-Lok fitting Pak-Lok Compression nut(s) loose Tighten compression nut(s) until condition is corrected and then ½ turn more only. Milliamp reading is zero • • • • Check if power polarity is reversed Verify voltage across terminals (should be 10–55V dc) Check for bad diode in terminal block Replace electronics terminal block ProBar electronics not in communication • • • • Check power supply voltage at electronics (10.5V minimum) Check load resistance (250 ohms minimum) Check if unit is addressed properly Replace electronics board Milliamp reading is low or high • • • • Check pressure variable reading for saturation Check if output is in alarm condition Perform 4–20 mA output trim Replace electronics board No response to changes in applied flow • • • • • • Check test equipment Check impulse piping for blockage Check for disabled span adjustment Check electronics security jumper Verify calibration settings (4 and 20 mA points) Contact factory for replacement Low reading/high reading • • • • Check impulse piping for blockage Check test equipment Perform full sensor trim (if software revision is 35 or higher) Contact factory for replacement Erratic reading for pressure variable • • • • Check impulse piping for blockage Check damping Check for EMF interference Contact factory for replacement Troubleshooting BEFORE YOU DISASSEMBLE THE PROBAR ELECTRONICS IMPROVED HOUSING PREVIOUS HOUSING 4.0 in. (105 mm) 3.2 in. (80 mm) 3051-063AB FIGURE 15-1. Improved and Previous Styles of the ProBar Flowmeter Housing. Maintenance procedures differ for improved and previous style flowmeter housings. Verify the specific physical characteristics of your flowmeter before you begin any maintenance procedures. The width of the conduit entries is the most noticeable physical difference between the improved and the previous style housing (see Figure 15-1). Do not remove the cover in explosive atmospheres when the circuit is alive. REMOVE THE FLOWMETER FROM SERVICE NOTE Once you have determined a that flowmeter is inoperable, remove it from service. Be aware of the following: • Isolate and vent the process from the flowmeter before removing the flowmeter from service. • Remove all electrical leads and conduit. • Do not detach the process flange or the electronics without consulting the factory. See Safety Messages on page 15-1 for complete warning information. 15-3 ProBar Flowmeter REMOVE THE TERMINAL BLOCK Electrical connections are located on the terminal block in the compartment labelled “FIELD TERMINALS.” Loosen the two small screws located at the 9 o'clock and 4 o'clock positions, and pull the entire terminal block out to remove it. NOTE If removing the terminal block from the housing of a previous version of the flowmeter, you will have to manually disconnect the power leads from the rear of the terminal block before completely separating it from the housing. REMOVE THE ELECTRONICS BOARD The flowmeter electronics board is located in the compartment opposite the terminal side. To remove the electronics board perform the following procedure: 1. Remove the housing cover opposite the field terminal side. 2. Loosen the two captive screws that anchor the board to the housing. The electronics board is electrostatically sensitive; observe handling precautions for static-sensitive components. NOTE If you are disassembling a flowmeter with a LCD meter, loosen the two captive screws that are visible on the right and left sides of the meter display. The two screws anchor the LCD meter to the electronics board and the electronics board to the housing. 3. Slowly pull the electronics board out of the housing. With the two captive screws free of the flowmeter housing, only the sensor module ribbon cable holds the board to the housing. NOTE Previous versions of the electronics board utilize a snap-in power plug and receptacle. Carefully unsnap the power plug from the receptacle to free the board from the power cord. 4. Disconnect the sensor module ribbon cable to release the electronics board from the flowmeter. 15-4 See Safety Messages on page 15-1 for complete warning information. Troubleshooting REMOVE THE SENSOR MODULE FROM THE ELECTRONICS HOUSING (FOR SERVICE-TYPE PROBAR UC, UNCALIBRATED PROBAR ONLY) 1. Carefully tuck the cable connector completely inside the internal shroud. IMPORTANT Do not remove the housing until after the cable connector is completely inside the internal shroud. The shroud protects the cable from damage that can occur when the housing is rotated. 2. Loosen the housing rotation set screw with a 9/64-inch hex wrench; back off one full turn. IMPORTANT To prevent damage to the sensor module ribbon cable, disconnect it from the electronics board before you remove the sensor module from the electrical housing. 3. Unscrew the housing from the module. Make sure the shroud and sensor cable do not catch on the housing. IMPORTANT Make sure the sensor ribbon cable and internal shroud remain completely free of the housing as you rotate it. Damage can occur to the cable if the internal shroud and sensor cable become hung-up and rotate with the housing. ATTACH THE SENSOR MODULE TO THE ELECTRONICS HOUSING BLOCK 1. Inspect all cover and housing (non-process-wetted) o-rings and replace if necessary. Lightly grease them with silicone lubricant to ensure a good seal. 2. Carefully tuck the cable connector completely inside the internal shroud. To do so, turn the shroud and cable counterclockwise one rotation to tighten the cable. 3. Lower the electronics housing onto the module; guide the internal shroud and cable through the housing and into the external shroud. 4. Turn the housing clockwise to fasten it to the module. IMPORTANT To prevent damage to the cable connector, watch the cable and shroud as you attach the housing to the module. Make sure the cable connector does not slip out of the internal shroud and begin to rotate with the housing. Reinsert the cable connector into the shroud if it escapes before the housing is fully fastened. 5. Thread the housing completely onto the sensor module. To comply with explosion-proof requirements, the housing must be no more than one full turn from flush with the sensor module. 6. Tighten the housing rotation set screw using a 9/64-inch hex wrench. NOTE Electronics board revision 5.3.163 or later (all shrouded designs) have increased functionality that allows verification testing of alarm current levels. If you repair or replace the electronics board, sensor module or LCD meter, it is recommended that you verify the transmitter alarm level before you return the electronics to service. 15-5 ProBar Flowmeter ATTACH THE ELECTRONICS BOARD 1. Remove the cable connector from its position inside of the internal shroud, and attach it to the electronics board. 2. Insert the electronics board into the housing, making sure that the posts from the electronics housing properly engage the receptacles on the electronics board. NOTE If you are reassembling a previous version of the electronics board, or if you are placing a new version of the electronics board in a previous version of the housing, attach the snap-in power connection to the receptacle on the board with the black and red wires routed towards the center of the board and below the white reed switch holder. 3. Tighten the captive mounting screws. 4. Replace the electronics housing cover. The flowmeter covers must be engaged metal-to-metal to ensure proper seal and to meet explosion-proof requirements. NOTE Electronics board revision 5.3.163 or later (all shrouded designs) have increased functionality that allows verification testing of alarm current levels. If you repair or replace the flowmeter electronics board, sensor module or LCD meter, it is recommended that you verify the flowmeter alarm level before you return the flowmeter to service (see “Alarm Level Verification” on page 2-4). INSTALL THE TERMINAL BLOCK 1. Gently slide the terminal block into place, making sure the posts from the electronics housing properly engage the receptacles on the terminal block. 2. Tighten the captive screws, and replace the electronics housing cover. The flowmeter covers must be fully engaged to meet explosion-proof requirements. NOTE If you are reassembling a previous version of the terminal block, attach the black and red wires to the back side of the block before you insert it into the electronics housing. RETURNING PRODUCTS AND/OR MATERIALS To expedite the return process outside of the United States, call Rosemount Customer Central at 800-999-9307. Individuals who handle products exposed to a hazardous substance can avoid injury if they are informed of and understand the hazard. If the product being returned was exposed to a hazardous substance as defined by OSHA, a copy of the required Material Safety Data Sheet (MSDS) for each hazardous substance identified must be included with the returned goods. 15-6 See Safety Messages on page 15-1 for complete warning information. Section 16 Specifications and Reference Data ORDERING INFORMATION Ordering information is available in the ProBar Flowmeter Product Data Sheet, publication number 00813-0100-4761. FUNCTIONAL SPECIFICATIONS Service (1) Liquid, Gas or Steam service. Pipe Sizes (2) ½ to 72 in. (12 to 1800 mm). Ranges (3) Range 1:0-0.5” to 0-25” wc (0-0.12 to 0-7.22kPa). Range 2:0-2.5” to 0-250” wc (0-0.62 to 0-62.2kPa). Range 3:0-10” to 0-1000” wc (0-2.48 to 0-248kPa). Indication M5: Optional one-line, four character digital LCD meter. Output 4-20mADC, flow rate output. Digital HART protocol superimposed on 420mA signal, available to any host that conforms to the HART protocol. Power Supply External power supply required. Standard transmitter (4–20 mA) operates on 10.5-55VDC with no load. (1) Fluid density and Reynolds number corrections should be compensated per DSI Annubar Handbook Equation #2.1–2.5. (2) Consult the factory for line sizes greater than 72 in. Multipoint calibration is available for line sizes between ½ to 36 in. Consult the factory for calibration ranges in larger line sizes. (3) Consult the factory for calibration ranges for range 3. 16-1 ProBar Flowmeter Operating Region 3051-0103A Load (Ohms) 4–20mA Load Limitations Maximum loop resistance is determined by the voltage level of the external power supply, as described in the following flowmeter chart. Voltage (V dc) Communication requires a minimum loop resistance of 250 ohms. (1) For CSA approval, power supply must not exceed 42.4 V. Pressure Limits 0–1440 psig (100 barg) @ 100 °F (37.8 °C). Contact the factory for higher pressures. Temperature Limits Storage: –50 to 230 °F (–46 to 110 °C). With Integral Meter: –40 to 185 °F (–40 to 85 °C). Process: Integral Mount –40 to 500 °F (–40 to 260 °C). Remote Mount –40 to 850 °F (–40 to 454 °C). Ambient: –40 to 185 °F (–40 to 85 °C). With Integral Meter –4 to 175 °F (–20 to 80 °C). Damping Analog output response to a step input change is user selectable from 0 to 36 seconds for one time constant. This software damping is in addition to sensor module response time. Turn-on Time Performance within specification less than two seconds after power is applied. Humidity Limits 0–100% relative humidity. 16-2 Specifications and Reference Data PERFORMANCE SPECIFICATIONS Accuracy (Including Linearity, Hysteresis, Repeatability) Multipoint Calibration ±0.5% of volumetric flow rate (at reference conditions)(1). No Calibration ±1.1% of volumetric flow rate. ±3% of volumetric flow rate—elbow mount. Flow Turndown (2) Multipoint Calibration 10:1 turndown. No Multipoint Calibration 5:1 flow turndown. Stability ±0.25% of URL for 5 years. Time Response (Electronics Only) Dead time(Td): 45 milliseconds (nominal). Time Constant(Tc): 55 milliseconds. Update Rate: 20 times per sec. (minimum). Vibration Effect Less than 0.1% of URL per g when tested from 15 to 2000 Hz in any axis relative to pipe-mounted process conditions. Power Supply Effect Less than 0.005% of calibrated span per volt. RFI Effect 0.1% of span from 20 to 1000 MHz and for field strength up to 30 V/m. Ambient Temperature Effect Per 50°F (28°C) ±(0.0188% URL + 0.0938% span). Spans from 1:1 to 10:1. ±(0.038% URL + 0.188% span). Spans from 10:1 to 100:1. For Range 1: ±(0.18% URL + 0.375% span). Static Pressure Effect Zero error (can be calibrated out at line pressure). ±0.1% of URL/1,000 psi (6.9MPa) for line pressures from 0 to 2,000 psi (0 to 13.7MPa). ±0.2% of URL/1,000 psi (6.9MPa) for line pressure above 2,000 psi (13.7MPa). Range 1: +0.25% of URL/1,000 psi (6.9MPa). Mounting Position Effect Zero shifts up to 2.5” ws (0.62kPa), which can be calibrated out. No span effect. (1) Water Flow Calibration (Test condition: Water at 60 °F, 50 psig, in sch40, sch80 or schstd pipes) in totalizing test conditions. (2) Flow turndown is based on the upper range limit of the range selected and may vary depending on the customer application or ProBar operating limitations. 16-3 ProBar Flowmeter ProBar Operating Limitations Model Minimum Reynolds Number (Rerod) 10 15/16 25/26 35/36 45/46 2000 5000 10000 15000 25000 Where: dVρ Rerod = µ ρ = fluid density in lb/ft3 d = probe width in feet V = velocity of fluid in ft/sec µ = fluid viscosity in lbm/ft-sec See DSI Annubar Flow Handbook (DS-7300) for detailed information. 16-4 Specifications and Reference Data PHYSICAL SPECIFICATIONS Electrical Considerations ½–14 NPT, PG 13.5, and CM20 conduit. HART interface connections permanently fixed to terminal block. Process-Wetted Parts Sensor 316/316L SST. Integral manifolds 316 SST. Remote Manifolds 316SST or CS. Electronics Vent Valves and Process Flanges 316 SST. Process Isolating Diaphragms 316L SST. O-rings Glass-filled TFE. Integral Manifold O-Rings Teflon. Non-Wetted Parts Electronic Housing Low copper aluminum, NEMA 4x, IP65. Paint Polyurethane. Bolts (Integral Manifold & Electronics Process Flange) 316 SST. Sensor Module Fill Fluid Silicone oil. Cover O-Rings Buna-N. Remote Mounting Bracket All SST. Sensor Mounting (including nuts, bolts and gasket) CS (SS optional). 16-5 ProBar Flowmeter Flanged Pipe Section For special lay lengths, please indicate the required length “L” of the flange pipe section. The length must comply with the limits provided in Table 16-1. TABLE 16-1. Flanged Pipe Section Length Requirements. Line size in inches (mm) Minimum length in inches (mm) Maximum length in inches (mm) 2 (50) 3 (80) 4 (100) 6 (150) 8 (200) 6.5 (165) 7.5 (191) 8.0 (203) 8.5 (216) 10.0 (254) 11.0 (279) 13.5 (343) 15.0 (381 20.0 (508) 20.0 (508) FIGURE 16-1. Flanged Pipe Section. Integral ProBar Electronics ODE Three-Valve Integral Mount Electronics Mounting Line Size ½ NL Process Flange Connection NL L: ____________________________ Units: ___________ Flanged Pipe Sections are supplied in Schedule 40 pipe. 16-6 Specifications and Reference Data TABLE 16-2. Flanged Pipe Sections Lay Length for Listed Vendors. Nominal 2-in. (50 mm) 3-in. (80 mm) 4-in. (100 mm) 6-in. (150 mm) 8-in. (200 mm) Flg Rating Standard inch (mm) Foxboro Vortex inch (mm) Vortex E&H inch (mm) Yew Vortex inch (mm) Mag inch (mm) Class 150 9.26 (235.2) 7.75 (196.9) 7.87 (200) 6.69 (170) 7.87 (200) Class 300 9.76 (147.9) 7.75 (196.9) 7.87 (200) 6.69 (170) 7.87 (200) Class 600 10.52 (267.2) 8.50 (215.9) 10.91 (277) 6.69 (170) 7.87 (200) PN 16/40 8.04 (204.2) 7.68 (195) 7.87 (200) 6.69 (170) 7.87 (200) PN 100 9.62 (244.3) 8.07 (205) 10.00 (254) — 7.87 (200) Class 150 9.87 (250.7) 8.75 (222.3) 7.87 (200) 7.87 (200) 7.87 (200) Class 300 10.61 (269.5) 8.75 (222.3) 7.87 (200) 7.87 (200) 7.87 (200) Class 600 11.37 (288.8) 9.50 (241.3) 11.77 (299) 7.87 (200) 7.87 (200) PN 16/40 8.93 (226.8) 8.66 (220) 7.87 (200) 7.87 (200) 7.87 (200) PN 100 10.51 (266.9) 13.39 (340) 10.91 (277) — 7.87 (200) Class 150 10.24 (260.1) 9.50 (241.3) 9.84 (250) 8.66 (220) 9.84 (250) Class 300 11.0 (279.4) 9.50 (241.3) 9.84 (250) 8.66 (220) 9.84 (250) Class 600 12.74 (323.6) 10.50 (266.7) 14.53 (369) 9.45 (240) 9.84 (250) PN 16 8.34 (211.8) 9.45 (220) 9.84 (250) 8.66 (220) 9.84 (250) PN 40 9.36 (237.7) 9.45 (220) 9.84 (250) 8.66 (220) 9.84 (250) PN 100 11.32 (287.5) 10.24 (260) 13.15 (334) — 9.84 (250) Class 150 11.59 (294.4) 12.00 (304.8) 11.81 (300) 10.63 (270) 11.81 (300 Class 300 12.35 (313.7) 12.75 (323.9) 11.81 (300) 10.63 (270) 11.81 (300) Class 600 14.33 (364.0) 14.25 (362.0) 19.37 (492) 10.63 (270) 11.81 (300) PN 16 8.93 (226.8) 12.01 (305) 11.81 (300) 10.63 (270) 11.81 (300) PN 40 10.49 (266.5) 12.09 (307) 11.81 (300) 10.63 (270) 11.81 (300) PN 100 13.65 (346.7) 13.31 (338) 18.74 (476) — 11.81 (300) Class 150 13.58 (344.9) 15.00 (381) 11.81 (300) 12.20 (310) 13.78 (350) Class 300 14.34 (364.2) 15.75 (400.1) 11.81 (300) 12.20 (310) 13.78 (350) Class 600 16.58 (421.1) 17.50 (444.5) — 12.20 (310) 13.78 (350) PN 16 10.46 (265.7) 15 (381) 11.81 (300) 12.20 (310) 13.78 (350) PN 40 12.50 (317.5) 15.20 (386) — 12.20 (310) 13.78 (350) PN 100 15.82 (401.8) 16.42 (417) — — 13.78 (350) 16-7 ProBar Flowmeter Hazardous Locations Certifications Factory Mutual (FM) Approvals E5 — Explosion Proof for Class I, Division 1, Groups B, C, and D. DustIgnition Proof for Class II, Division 1, Groups E, F, and G. Dust-Ignition Proof for Class III, Division 1. NEMA 4X. Factory-sealed. I5 — Intrinsically safe for use in Class I, Division 1, Groups A, B, C, and D; Class II, Division 1, Groups E, F, and G; Class III, Division 1 when connected in accordance with Rosemount drawings 03031-1019 and 00275-0081 (when used with HART Communicator Model 275), or 00268-0031 (when used with Rosemount Model 268 Communicator). Temperature Code T4. Non-incendive for Class I, Division 2, Groups A, B, C, and D. NEMA 4X. Factory-sealed. K5 — Combination of E5 and I5. NEMA 4X. Factory-sealed. FM Approved Entity Parameters FM Approved for Class I, II, and III; Division 1 and 2; Groups for Model 8900V (1) VMax = 40 V dc IMax = 165 mA IMax = 225 mA IMax = 160 mA (Option Code T1) PMax = 1 W CI = 0.01 F (Output Code A) LI = 10 H LI = 1.05 mH (Output Code A with T1) A–G A–G C–G A–G A–G A–G A–G A–G (1) When connected in accordance with Rosemount drawings 3031-1019 and 00275-0081 (for use with the HART Communicator Model 275), or 00268-0031 (for use with the Rosemount Model 268 Communicator.) Canadian Standards Association (CSA) C6 — Explosion Proof for Class I, Division 1, Groups C, and D. DustIgnition Proof for Class II, Division 1, Groups E, F, and G. Dust-Ignition Proof for Class III, Division 1. Suitable for Class I, Division 2, Groups A, B, C, and D. CSA Enclosure-Type 4X. Factory-sealed. Intrinsically safe for use in Class I, Division 1, Groups A, B, C, and D when connected in accordance with Rosemount drawings 03031-1024. Temperature Code T3C. CSA Enclosure-Type 4X. Factory-sealed. Output Code M Output Code A CSA Approved Barriers for Model 8900V (2) ≤ 30 V, ≥ 330 V ≤ 28 V, ≥ 300 V ≤ 25 V, ≥ 200 V ≤ 22 V, ≥ 180 V ≤ 30 V, ≥ 150 V Supply ≤ 28V, ≥ 300 V Return ≤ 10 V, ≥ 47 V Supply ≤ 30 V, ≥ 150 V Return ≤ 10 V, ≥ 47 V CSA Approved for Class I, Division 1 and 2, Groups A–D C–D A–D C–D (2) When connected in accordance with Rosemount drawings 00275-0082 and 3031-1024. KEMA/CENELEC ED — Explosion Proof. EEx d IIC T5 (Tamb = 70 C); EEx d IIC T6 (Tamb = 40 C). Enclosure Type: IP65. ID — Intrinsically Safe. EEx ia IIC T5 (Tamb = -45 to +40 °C); EEx ia IIC T54 (Tamb = -45 to +70 °C). Enclosure Type: IP65. Ui = 30V dc. Ii = 200 mA. Pi = 0.9 W. Ci = 0.012 uF. Li = 0. 16-8 Appendix A INTRODUCTION HART Communicator This appendix provides basic communicator information on the HART Communicator Model 275 when used with a Model 8900V ProBar Volumentric Flowmeter. This brief appendix will familiarize you with the HART Communicator but is not meant to replace the HART Communicator product manual. For complete information on the HART Communicator, refer to the HART Communicator Product Manual p/n 00275-8026-0001. NOTE You must upgrade the software in your HART Communicator in order to take advantage of the additional features of the improved ProBar. If you initiate communication with an improved ProBar using a Communicator that has a previous version of the flowmeter Device Descriptors (DDs), the communicator will display the following message: NOTICE: Upgrade 275 software to access XMTR function. Continue with old description? If you select YES, the communicator will communicate properly with the flowmeter using the existing ProBar DDs. However, software features added since the revision of the DDs in the communicator will not be accessible. If you select NO, the communicator will default to a generic flowmeter functionality. Contact your nearest Rosemount Service Center or Sales Representative to upgrade your communicator SAFETY MESSAGES Procedures and instructions in this section may require special precautions to ensure the safety of the personnel performing the operations. Information that raises potential safety issues is indicated by a warning symbol ( ). Refer to the following safety messages before performing an operation preceded by this symbol. Explosions can result in death or serious injury. • Do not remove the flowmeter covers in explosive environments when the circuit is alive. • Both flowmeter covers must be fully engaged to meet explosion-proof requirements. • Before connecting a communicator in an explosive atmosphere, make sure the instruments in the loop are installed in accordance with intrinsically safe or nonincendive field wiring practices. A-1 ProBar Flowmeter FIGURE A-1. HART Communicator Menu Tree for the Improved ProBar*. 1 PROCESS VARIABLES 1 2 3 4 5 Flow Pressure Percent Range Analog Output DP Pressure Sensor Temperature 1 Self test 2 Status 1 TEST DEVICE 1 Keypad Input 2 Apply Values 1 RERANGE 2 DIAGNOSTICS AND SERVICE 2 Loop Test 1 Digital-to-Analog Trim 2 Scaled D/A Trim 2 TRIM ANALOG OUTPUT 3 CALIBRATION 3 SENSOR TRIM 4 RECALL FACTORY TRIM 1 Tag 2 Unit 1 Keypad Input 2 Apply Values 3 RANGE VALUES 3 BASIC SETUP 1 2 3 4 4 DEVICE INFO 5 Transfer Function 6 Damp 1 Meter Type 2 CUSTOM METER SETUP 7 METER OPTIONS 1 SENSORS Date Descriptor Message Write Protect 1 PRESSURE SNSR Zero Trim Lower Sensor Trim Upper Sensor Trim Sensor Trim Points 1 2 3 4 5 Select Dec. Pt. Pos. CM Upper Value CM Lower Value CM Units CM xfer function 1 PROCESS VARIABLES 2 SENSOR TRIM 3 RECALL FACTORY TRIM 4 Unit Online Menu 1 PROCESS VARIABLES DEVICE SETUP PV AO LRV URV 2 SIGNAL CONDITION 2 3 4 5 6 7 RANGE VALUES Unit Transfer Function Damp Snsr Temp Unit ALM/SAT LEVELS 4 DETAILED SETUP 3 OUTPUT CONDITION 1 Keypad Input 2 Apply Values 1 2 3 4 5 6 5 REVIEW 4 DEVICE INFORMATION 1 2 3 4 2 ANALOG OUTPUT 1 2 3 4 Loop Test Digital-to-Analog Trim Scaled D/A Trim AO Alarm Type 3 HART OUTPUT 1 2 3 4 Poll Address Number of Req. Pream. Burst Mode Burst Option 1 2 3 4 5 1 2 3 4 5 1 Meter Type 2 CUSTOM METER SETUP 3 Cust. Meter Value 1 FIELD DEVICE INFO * “ProBar” will appear in the upper left of the communicator screen when this menu tree is valid. Zero Trim Lower Sensor Trim Upper Sensor Trim Sensor Trim Points Flow Pressure % Range DP Pressure Snsr Temp 1 PROCESS VARIABLES 2 SENSOR INFO 3 Self Test 4 DIAPHRAGM SEALS INFO 1 2 3 5 4 High Alarm Low Alarm High Saturation Low Saturation AO Alarm Type Alarm/Sat Type 4 METER OPTIONS A-2 1 Flow Pressure 2 % Range 3 DP Pressure 1 Snsr Temp 2 Snsr Temp Unit 2 TEMP. SENSOR 1 2 3 4 5 1 2 3 4 1 2 3 4 5 6 7 8 Measurement Type Mod. Config. Type Isolator Material Fill Type Proc. Conn. Type Proc. Conn. Material O-Ring Material Drain Vent Material 1 2 3 4 # of Diaph. Seals Diaph. Seal Type Diaph. Seal Fill Fluid Diaph. Material 1 2 3 4 5 6 7 8 9 Flow Pressure % Range Analog Output DP Pressure Snsr Temp Select Dec. Pt. Pos. CM Upper Value CM Lower Value CM Units CM xfer function Tag Date Descriptor Message Model Write Protect Local Keys REVISIONS #S Final Assy # Device ID Distributor 1 Univ. Rev. 2 Fld. Dev. Rev. Appendix A TABLE A-1. HART Fast Key Sequences for the Improved ProBar. Function NOTE A check (✔) indicates the basic configuration parameters. At a minimum, these parameters should be verified as part of the configuration and startup procedures. HART Communicator Fast Key Sequences Alarm and Saturation Levels 1, 4, 2, 7 Analog Output Alarm Type 1, 4, 3, 2, 4 Burst Mode Control 1, 4, 3, 3, 3 Burst Operation 1, 4, 3, 3, 3 Clone Data See Saving, Recalling, and Cloning Configuration Data on page 2-22 Custom Meter Configuration 1, 3, 7, 2 Custom Meter Value 1, 4, 3, 4, 3 ✔ Damping 1, 3, 6 Date 1, 3, 4, 1 Descriptor 1, 3, 4, 2 Digital To Analog Trim (4–20 mA Output) 1, 2, 3, 2, 1 Disable Local Span/Zero Adjustment 1, 4, 4, 1, 7 DP Pressure 1, 1, 4 Field Device Info 1, 4, 4, 1 Flow Pressure 2 Full Trim 1, 2, 3, 3 Keypad Input – Rerange 1, 2, 3, 1, 1 Local Zero and Span Control 1, 4, 4,1, 7 Loop Test 1, 2, 2 Lower Sensor Trim 1, 2, 3, 3, 2 Message 1, 3, 4, 3 Meter Options 1, 4, 3, 4 Number Of Requested Preambles 1, 4, 3, 3, 2 Poll Address 1, 4, 3, 3, 1 Poll a Multidropped Flowmeter Left Arrow, 4, 1, 1 ✔ Range Values 1, 3, 3 Recall Factory Trim 1, 2, 3, 4 Rerange 1, 2, 3, 1 Scaled D/A Trim (4–20 mA Output) 1, 2, 3, 2, 2 Self Test (Flowmeter) 1, 2, 1, 1 Sensor Info 1, 4, 4, 2 Sensor Temperature 1, 1, 5 Sensor Trim Points 1, 2, 3, 3, 4 Status 1, 2, 1, 2 ✔ Tag ✔ Transfer Function (Setting Output Type) 1, 3, 1 Flowmeter Security (Write Protect) 1, 3, 4, 4 1, 3, 5 Trim Analog Output 1, 2, 3, 2 ✔ Units (Primary Variable) 1, 3, 2 Upper Sensor Trim 1, 2, 3, 3, 3 Zero Trim 1, 2, 3, 3, 1 A-3 ProBar Flowmeter FIGURE A-1. HART Communicator Menu Tree for the Previous ProBar*. 1 PROCESS VARIABLES 1 2 3 4 Pressure Percent Range Analog Output Sensor Temperature 1 Self test 2 Status 1 TEST DEVICE 1 Keypad Input 2 Apply Values 1 RERANGE 2 DIAGNOSTICS AND SERVICE 2 Loop Test 2 TRIM ANALOG OUTPUT 3 CALIBRATION 3 SENSOR TRIM 1 Digital-to-Analog Trim 2 Scaled D/A Trim 1 2 3 5 4 Zero Trim Lower Sensor Trim Upper Sensor Trim Sensor Trim Points 1 Tag 1 Keypad Input 2 Apply Values 2 Unit 3 RANGE VALUES 3 BASIC SETUP 1 2 3 4 5 4 DEVICE INFO 5 Transfer Function 6 Damp Date Descriptor Message Write Protect Meter Type 1 PROCESS VARIABLES 2 SENSOR SERVICE 1 SENSORS 1 PRESSURE SNSR 2 TEMP SENSOR Online Menu 1 2 3 4 5 DEVICE SETUP PV AO LRV URV 1 PROCESS VARIABLES 2 SIGNAL CONDITION 2 3 4 5 RANGE VALUES Unit Transfer Function Damp 4 DETAILED SETUP 3 OUTPUT CONDITION 1 PROCESS VARIABLES 2 ANALOG OUTPUT 3 Unit 1 Pressure 2 % Range 3 Snsr temp 1 SENSOR TRIM 2 Recall Factory Trim 1 2 3 4 Zero Trim Lower Sensor Trim Upper Sensor Trim Sensor Trim Points 1 Snsr Temp 2 Snsr Temp Units 1 Pressure 2 Percent Range 3 Snsr Temp 1 Keypad Input 2 Apply Values 1 2 3 4 Pressure Percent Range Analog Output Snsr Temp 1 Loop Test 2 Digital-to-Analog Trim 3 Scaled D/A Trim 3 Analog Output Alm 4 HART OUTPUT 5 REVIEW 4 DEVICE INFORMATION Poll Address Number of Req. Pream. Burst Mode Burst Option 1 FIELD DEVICE INFO 2 SENSOR INFO 3 METER TYPE 4 Self Test * “ProBar” will appear in the upper left of the communicator screen when this menu tree is valid. A-4 1 2 3 4 1 Measurement Type 2 Isolator Material 3 Fill Type 4 Flange Type 5 Flange Material 6 O-Ring Material 7 Drain Vent Material 8 # of Remote Seals 9 Remote Seal Type 10 Remote Seal Mat. 11 Remote Seal Fill 1 2 3 4 5 6 7 8 Tag Date Descriptor Message Model Write Protect Local Keys Revisions #s Appendix A TABLE A-2. HART Fast Key Sequences for the Previous ProBar. NOTE A check (✔) indicates the basic configuration parameters. At a minimum, these parameters should be verified as part of the configuration and startup procedures. Function HART Communicator Fast Key Sequences Analog Output Alarm 1, 4, 3, 3 Burst Mode Control 1, 4, 3, 4, 3 Burst Operation 1, 4, 3, 4, 4 Clone Data See Saving, Recalling, and Cloning Configuration Data on page 2-22 ✔ Damping 1, 3, 6 Date 1, 3, 4, 1 Descriptor 1, 3, 4, 2 Digital To Analog Trim (4–20 mA Output) 1, 2, 3, 2, 1 Disable Local Span/Zero Adjustment 1, 4, 4, 1, 7 Field Device Info 1, 4, 4, 1 Full Trim 1, 2, 3, 3 Keypad Input 1, 2, 3, 1, 1 Loop Test 1, 2, 2 Lower Sensor Trim 1, 2, 3, 3, 2 Message 1, 3, 4, 3 Meter Type 1, 4, 3, 5 Number Of Requested Preambles 1, 4, 3, 4, 2 Poll Address Left Arrow, 5, 1 ✔ Range Values 1, 3, 3 Rerange 1, 2, 3, 1 Scaled D/A Trim (4–20 mA Output) 1, 2, 3, 2, 2 Self Test (Flowmeter) 1, 2, 1, 1 Sensor Info 1, 4, 4, 2 Sensor Temperature 1, 1, 4 Sensor Trim Points 1, 2, 3, 3, 4 Status 1, 2, 1, 2 ✔ Tag ✔ Transfer Function (Setting Output Type) 1, 3, 1 Flowmeter Security (Write Protect) 1, 3, 4, 4 1, 3, 5 Trim Analog Output 1, 2, 3, 2 ✔ Units (Process Variable) 1, 3, 2 Upper Sensor Trim 1, 2, 3, 3, 3 Zero Trim 1, 2, 3, 3, 1 A-5 ProBar Flowmeter The HART Communicator Model 275 can interface with a flowmeter from the control room, the instrument site, or any wiring termination point in the loop through the rear connection panel as shown in Figure A-1. Do not make connections to the serial port or NiCad recharger jack in an explosive atmosphere. To communicate, connect the HART Communicator in parallel with the instrument or load resistor. The connections are non-polarized. Before connecting the HART Communicator in an explosive atmosphere, make sure the instruments in the loop are installed in accordance with intrinsically safe or nonincendive field wiring practices. CONNECTIONS AND HARDWARE NOTE The HART Communicator needs a minimum of 250 ohms resistance in the loop to function properly. The HART Communicator is not a measurement device and does not need to be calibrated; it is a communications device through which you can read and adjust the flowmeter configuration information. All variable outputs displayed by the communicator are functions of the flowmeter. FIGURE A-1. Rear Connection Panel with Optional NiCad Recharger Pack. Loop Connection Ports Optional NiCad Recharger Jack A-6 275-008AB Serial Port See Safety Messages on page A-1 for complete warning information. Appendix A FIGURE A-2. Bench Hook-up (4–20 mA Flowmeters). 24 V dc Supply 3051-3051G02B RL≥ 250 ς Current Meter FIGURE A-3. Field Hook-up (4–20 mA Flowmeters). CAUTION Do not use inductive-based transient protectors. RL≥ 250 ς Power Supply 3051-3031H02B Current Meter Signal point may be grounded at any point or left ungrounded. A-7 ProBar Flowmeter COMMUNICATOR KEYS The keys of the HART Commuincator include action, function, alphanumeric, and shift keys FIGURE A-4. Model 275 HART Communicator. Function Keys Action Keys Alphanumeric Keys 275-011AB Shift Keys Action Keys As shown in Figure A-4, the action keys are the six blue, white, and black keys located above the alphanumeric keys. The function of each key is described as follows: ON/OFF Key Use this key to power the HART Communicator. When the communicator is turned on, it searches for a flowmeter on the 4–20 mA loop. If a device is not found, the communicator displays the message, “No Device Found. Press OK.” If a HART-compatible device is found, the communicator displays the Online Menu with device ID and tag. Directional Keys Use these keys to move the cursor up, down, left, or right. The right arrow key also selects menu options, and the left arrow key returns to the previous menu. A-8 Appendix A HOT Key Use this key to quickly access important, user-selectable options when connected to a HART-compatible device. Pressing the Hot Key turns the HART Communicator on and displays the Hot Key Menu. See Customizing the Hot Key Menu in the HART Communicator manual for more information. Function Keys F3 Alphanumeric and Shift Keys Use the four software-defined function keys, located below the LCD, to perform software functions. On any given menu, the label appearing above a function key indicates the function of that key for the current menu. As you move among menus, different function key labels appear over the four keys. For example, in menus providing access to on-line help, the HELP label may appear above the F1 key. In menus providing access to the Online Menu, the HOME label may appear above the F3 key. Simply press the key to activate the function. See your HART Communicator manual for details on specific function key definitions. The alphanumeric keys (Figure A-5) perform two functions: the fast selection of menu options and data entry. 275-0383A FIGURE A-5. HART Communicator Alphanumeric and Shift Keys. Data Entry Some menus require data entry. Use the alphanumeric and shift keys to enter all alphanumeric information into the HART Communicator. If you press an alphanumeric key alone from within an edit menu, the bold character in the center of the key appears. These large characters include the numbers zero through nine, the decimal point (.), and the dash symbol (—). To enter an alphabetic character, first press the shift key that corresponds to the position of the letter you want on the alphanumeric key. Then press the alphanumeric key. For example, to enter the letter R, first press the right shift key, then the “6” key (see Figure A-6). Do not press these keys simultaneously, but one after the other. 275-0532A, 0343A FIGURE A-6. Data Entry Key Sequence. A-9 ProBar Flowmeter Fast Key Sequences HART fast key sequences provide quick on-line access to flowmeter variables and functions. Instead of stepping your way through the menu structure using the action keys, you can press a HART fast key sequence to move from the Online Menu to the desired variable or function. Onscreen instructions guide you through the rest of the screens. Fast Key Sequence Conventions The fast key sequences for the Model 275 use the following conventions for their identification: 1 through 9–Refer to the keys located directly below the dedicated keypad. Left Arrow–Refers to the left arrow directional key. Fast Key Sequence Example HART fast key sequences are made up of the series of numbers corresponding to the individual options in each step of the menu structure. For example, from the Online Menu you can change the Date. Following the menu structure, press 1 to reach Device Setup, press 3 for Basic Setup, press 4 for Device Info, press 5 for Date. The corresponding HART fast key sequence is 1,3,4,5. HART fast keys are operational only from the Online Menu. If you use them consistently, you will need to return to the Online Menu by pressing HOME (F3) when it is available. If you do not start at the Online Menu, the HART fast key sequences will not function properly. Use Table A-1, an alphabetical listing of every on-line function, to find the corresponding HART fast key sequences. These codes are applicable only to ProBar flowmeters and the HART Communicator. A-10 Appendix A MENUS AND FUNCTIONS The HART Communicator is a menu driven system. Each screen provides a menu of options that can be selected as outlined above, or provides direction for input of data, warnings, messages, or other instructions. Main Menu When the HART Communicator is turned on, one of two menus will appear. If the HART Communicator is connected to an operating loop, the communicator will find the device and display the Online Menu (see below). If it is not connected to a loop, the communicator will indicate that no device was found. When you press OK (F4), it will display the Main menu. The Main menu provides the following options: • Offline–The Offline option provides access to offline configuration data and simulation functions. • Online–The Online option checks for a device and if it finds one, brings up the Online Menu. • Transfer–The Transfer option provides access to options for transferring data either from the HART Communicator (memory) to the flowmeter (device) or vice versa. Transfer is used to move off-line data from the HART Communicator to the flowmeter, or to retrieve data from a flowmeter for off-line revision. NOTE Online communication with the flowmeter automatically loads the current flowmeter data to the HART Communicator. Changes in on-line data are made active by pressing SEND (F2). The transfer function is used only for off-line data retrieval and sending. • Frequency Device–The Frequency Device option displays the frequency output and corresponding pressure output of currentto-pressure flowmeters. • Utility–The Utility option provides access to the contrast control for the HART Communicator LCD screen and to the autopoll setting used in multidrop applications. Once selecting a Main menu option, the HART Communicator provides the information you need to complete the operation. If further details are required, consult the HART Communicator manual. A-11 ProBar Flowmeter Online Menu The Online Menu can be selected from the Main menu as outlined above, or it may appear automatically if the HART Communicator is connected to an active loop and can detect an operating flowmeter. NOTE The Main menu can be accessed from the Online Menu. Press the left arrow action key to deactivate the on-line communication with the flowmeter and to activate the Main menu options. When configuration variables are reset in the on-line mode, the new settings are not activated until the data is sent to the flowmeter. Press SEND (F2) when it is activated to update the process variables of the flowmeter. On-line mode is used for direct evaluation of a particular meter, reconfiguration, changing parameters, maintenance, and other functions. A-12 Appendix A Diagnostic Messages The following pages contain a list of messages used by the HART Communicator (HC) and their corresponding descriptions. Variable parameters within the text of a message are indicated with <variable parameter>. Reference to the name of another message is identified by [another message]. Message Description 1k snsr EEPROM error-factory ON Replace the sensor module 1k snsr EEPROM error-user-no out ON Use the HART communicator to reset the following parameters: remote seal isolator, remote seal fill fluid, flange material, o-ring material, flowmeter type, remote seal type, flange type, meter type, number of remote seals. 1k snsr EEPROM error-user ON Perform a full trim to recalibrate the flowmeter. 4k micro EEPROM error-factory ON Replace the electronics board. 4k micro EEPROM error-user-no out ON Use the hart communicator to reset the message field. 4k micro EEPROM error-user ON Use the HART communicator to reset the following parameters: units, range values, damping, analog output, transfer function, tag, scaled meter values. Perform a d/a trim to ensure that the error is corrected. 4k snsr EEPROM error-factory ON Replace the sensor module. 4k snsr EEPROM error-user ON Use the HART communicator to reset the temperature units and the calibration type. Add item for ALL device types or only for this ONE device type. Asks the user whether the hot key item being added should be added for all device types or only for the type of device that is connected. Command Not Implemented The connected device does not support this function. Communication Error The communicator and the device are not communicating correctly. Check all connections between the communicator and the device and resend the information. Configuration memory not compatible with connected device The configuration stored in memory is incompatible with the device to which a transfer has been requested. CPU board not initialized ON The electronics board is not initialized. Replace the electronics board CPU EEPROM write failure ON Message sent to electronics board from HART signal failed. Replace the electronics board. Device Busy The connected device is busy performing another task. Device Disconnected The device failed to respond to a command. Check all connections between the communicator and the device and resend the command. Device write protected Device is in write-protect mode. Data can not be written. Device write protected. Do you still want to shut off? Device is in write-protect mode. Press YES to turn the HART communicator off and lose the unsent data. Display value of variable on hotkey menu? Asks whether the value of the variable should be displayed adjacent to its label on the hotkey menu if the item being added to the hotkey menu is a variable. Download data from configuration memory to device Press the SEND softkey to transfer information from the communicator memory to the device. A-13 ProBar Flowmeter A-14 Message Description Exceed field width Indicates that the field width for the current arithmetic variable exceeds the device-specified description edit format. Exceed precision Indicates that the precision for the current arithmetic variable exceeds the device-specified description edit format. Ignore next 50 occurrences of status? Select YES to ignore the next 50 occurrences of device status, or select no to display every occurrence. Illegal character An invalid character for the variable type was entered. Illegal date The day portion of the date is invalid. Illegal month The month portion of the date is invalid. Illegal year The year portion of the date is invalid. Incompatible CPU board and module ON Upgrade the electronics board or the sensor module to the current revision. Incomplete exponent The exponent of a scientific notation floating point variable is incomplete. Incomplete field The value entered is not complete for the variable type. Looking for a device Polling for multidropped devices at addresses 1–15. Local buttons operator error ON Illegal pressure applied during zero or span operation. Repeat the process after verifying the correct pressures. Mark as read only variable on hotkey menu? Asks whether the user should be allowed to edit the variable from the hotkey menu if the item being added to the hotkey menu is a variable. Module EEPROM write failure ON Message sent to the module from the HART signal failed. Replace the sensor module. No device configuration in configuration memory There is no configuration saved in memory available to reconfigure off-line or transfer to a device. No Device Found Poll of address zero fails to find a device, or poll of all addresses fails to find a device if auto-poll is enabled. No hotkey menu available for this device. There is no menu named “hotkey” defined in the device description for this device. No pressure updates ON No pressure updates being received from the sensor module. Verify that the sensor module ribbon cable is attached correctly. Or replace the sensor module. No offline devices available. There are no device descriptions available to be used to configure a device offline. No simulation devices available. There are no device descriptions available to simulate a device. No temperature updates ON No temperature updates being received from the sensor module. Verify that the sensor module ribbon cable is attached correctly. Or replace the sensor module. No UPLOAD_VARIABLES in ddl for this device There is no menu named “upload_variables” defined in the device description for this device. This menu is required for offline configuration. No Valid Items The selected menu or edit display contains no valid items. OFF KEY DISABLED Appears when the user attempts to turn the HC off before sending modified data or before completing a method. Online device disconnected with unsent data. RETRY or OK to lose data. There is unsent data for a previously connected device. Press RETRY to send data, or press OK to disconnect and lose unsent data. Out of memory for hotkey configuration. Delete unnecessary items. There is no more memory available to store additional hotkey items. Unnecessary items should be deleted to make space available. Overwrite existing configuration memory Requests permission to overwrite existing configuration either by a device-to-memory transfer or by an offline configuration. User answers using the softkeys. Appendix A Message Description Press OK... Press the OK softkey. This message usually appears after an error message from the application or as a result of HART communications. Restore device value? The edited value that was sent to a device was not properly implemented. Restoring the device value returns the variable to its original value. ROM checksum error ON Checksum of flowmeter software has detected a fault. Replace the electronics board. Save data from device to configuration memory Prompts user to press SAVE softkey to initiate a device-tomemory transfer. Saving data to configuration memory. Data is being transferred from a device to configuration memory. Sending data to device. Data is being transferred from configuration memory to a device. Sensor board not initialized ON The sensor module electronics board is not initialized. Replace the sensor module. There are write only variables which have not been edited. Please edit them. There are write-only variables which have not been set by the user. These variables should be set or invalid values may be sent to the device. There is unsent data. Send it before shutting off? Press YES to send unsent data and turn the HC off. Press NO to turn the HC off and lose the unsent data. Too few data bytes received Command returns fewer data bytes than expected as determined by the device description. Flowmeter Fault Device returns a command response indicating a fault with the connected device. Units for <variable label> has changed. Unit must be sent before editing, or invalid data will be sent. The engineering units for this variable have been edited. Send engineering units to the device before editing this variable. Unsent data to online device. SEND or LOSE data There is unsent data for a previously connected device which must be sent or thrown away before connecting to another device. Upgrade 275 software to access XMTR function. Continue with old description? The communicator does not contain the most recent ProBar Device Descriptors (DDs). Select YES to communicate using the existing DDs. Select NO to abort communication. Use up/down arrows to change contrast. Press DONE when done. Gives direction to change the contrast of the HC display. Value out of range The user-entered value is either not within the range for the given type and size of variable or not within the min/max specified by the device. <message> occurred reading/writing <variable label> Either a read/write command indicates too few data bytes received, flowmeter fault, invalid response code, invalid response command, invalid reply data field, or failed pre- or post-read method; or a response code of any class other than SUCCESS is returned reading a particular variable. <variable label> has an unknown value. Unit must be sent before editing, or invalid data will be sent. A variable related to this variable has been edited. Send related variable to the device before editing this variable. A-15 ProBar Flowmeter A-16 Appendix B Standard ODF Dimensions STANDARD ODF DIMENSIONS 15/16 Sensor ODF 35/36 Sensor ODF 1-in.–150# flg. 3.377-in. 2-in.–150# flg. 4.126-in. 1-in.–300# flg. 3.627-in. 2-in.–300# flg. 4.38-in. 1-in.–600# flg. 3.877-in. 2-in.–600# flg. 4.75-in. 25/26 Sensor ODF 45/46 Sensor ODF 1½-in.–150# flg. 3.375-in. 3-in.–150# flg. 4.63-in. 1½-in.–300# flg. 4.13-in. 3-in.–300# flg. 5.0-in. 1½-in.'–600# flg. 4.339-in. 3-in.–600# flg. 5.376-in. B-1 ProBar Flowmeter B-2 Appendix C Approval Drawings Index of intrinsically safe Factory Mutual barrier systems and entity parameters for Models 3051C/L/P/H/T and 3001C/S (Drawing Number 03031-1019, Rev J), pages C-2 through C-7. Index of intrinsically safe C.S.A. barrier systems for Models 3051C/L/P/ H/T and 3001C/S (Drawing Number 03031-1024, Rev G), pages C-8 through C-10. Index of intrinsically safe barrier systems and entity parameters for the Model 268 SMART FAMILY Interface (Drawing Number 00268-0031, Rev M), pages C-11 through C-17. C-1 ProBar Flowmeter C-2 Appendix C C-3 ProBar Flowmeter C-4 Appendix C C-5 ProBar Flowmeter C-6 Appendix C C-7 ProBar Flowmeter C-8 Appendix C C-9 ProBar Flowmeter C-10 Appendix C C-11 ProBar Flowmeter C-12 Appendix C C-13 ProBar Flowmeter C-14 Appendix C C-15 ProBar Flowmeter C-16 Appendix C C-17 ProBar Flowmeter C-18 Index Access Requirements 10-4 Accuracy 16-3 Alarm. See Failure Mode Alarm Ambient Temperature Effect 16-3 Approval Drawings C-1–C-16 List of C-1 Components Flanged Models 4-2 Flo-Tap Models 5-2, 6-2 Regular (Threaded, Pak-Lok) Models 3-2 Configuration Cloning 9-21 Review 9-7 Saving 9-21 Configurations Direct Mount 2-2 In-Line Models 7-2 Remote Mount 2-2 B D Bolt Installation 2-8 Burst Mode 9-22 D/A Trim. See Calibration Damping 9-13, 16-2 Direct Mount 2-2 Direct Mount ProBar Commissioning 11-1–11-4 Direct Mounted RTD Replacement 14-2 Disabling the Zero and Span Adjustments 13-2 Numerics 275. See HART Communicator 3-Valve Manifolds 8-5 5-Valve Manifolds 8-5 A C Calibration 9-17 Deciding Which Procedure to Use 9-17 Frequency, Determining 9-18 Output Trim 9-20 D/A Trim 9-20 Using other Scale 9-20 Overview 9-17 Sensor Trim 9-18 Full Trim 9-19 Zero Trim 9-18 Cloning a Configuration 9-21 Commissioning 11-1, 12-1 Direct Mounted ProBars 11-1–11-4 Gas Service 11-3 Liquid Service 11-2 Steam Service 11-4 On the Bench 9-1 Remote Mounted ProBars 12-1–12-8 Gas Service 12-6 Liquid Service below 250 °F (121 °C) 12-5 Steam Service or Liquid Service above 250 °F (121 °C) 12-7 With a HART-Based Communicator 9-5 E Electrical Considerations 10-1, 10-2, 16-5 Electronics Board Improved versus Previous 9-4 Installing 15-7 Removing 15-5 Electronics Housing Circuit Side 10-5 Exterior 10-5 Terminal Side 10-5 Electronics Remote Mounting Equipment 8-4 Environmental Considerations 2-5, 10-4 Equipment for Remote Mounting the Electronics 8-4 F Failure Mode Alarm Function of 9-3 Setting 9-3 Values for 9-2 NAMUR Compliant 9-2 versus Saturation Output Values 9-2 Verifying 9-3 see also Loop Test Field Hook-up Wiring Diagrams 10-2 Field Wiring and Electrical Considerations 10-1 Field Wiring Considerations 10-1 Flanged Pipe Section 16-6 Flanged Pipe Section Length Requirements 16-6 Flanged Pipe Sections Lay Length for Listed Vendors 16-7 Flo-Tap Gear Drive (IHD) 5-9, 5-10, 6-8, 6-10 Flo-Tap Installation Hardware 5-4, 6-4 Flo-Tap Isolation Valve 5-6, 5-7, 5-10, 6-5, 6-7, 6-10 Flo-Tap Standard Drive (IHR) 5-8, 5-10, 6-8, 6-9 Flo-Tap Welding Equipment 5-4, 6-4 Flow Turndown 16-3 Full Trim. See Calibration Functional Limitations 2-3 Functional Specifications 16-1 H HART Communicator Action Keys Directional Keys A-9 Hot Key A-9 ON/OFF Key A-9 Alphanumeric and Shift Keys A-10 I-1 ProBar Flowmeter Connecting to Transmitter A-8 Connections and Hardware A-7 Data Entry A-10 Diagnostic Messages A-14 Fast-Key Sequences A-3, A-6 Defined A-11 Function Keys Help Key A-10 Home Key A-10 Keypad A-9 Menu Tree A-2, A-5 Menus and Functions A-12 Head Code Number 2-5 Housing Rotation 10-4, 13-3 Humidity Limits 16-2 I Impulse Piping 8-3 Impulse Piping Valves and Components 8-5, 12-2 Installation Flanged Models 4-1–4-10 Flo-Tap Models 5-1–5-10, 6-1–6-10 In-Line Models 7-1–7-8 Regular (Threaded, Pak-Lok) Models 3-1–3-8 Installing the Electronics Board 15-7 Installing the LCD Meter 13-3 Installing the Terminal Block 15-5 Instrument Manifolds 8-4 Integral Mount. See Direct Mount Isolation Valve 5-6, 5-7, 5-10, 6-5, 6-7, 6-10 L LCD Meter 13-2 Custom Configuration for 9-13 Diagnostic Messages,Defined 13-4 Exploded View 13-2 Installing 13-3 Loop Test 9-14 Low Power Transmitters Selecting Output Range for 9-4 I-2 M Maintenance Disassembly Procedures 15-4 Return of Materials 15-9 Meter. See LCD Meter Mounting Bolts 2-8 Mounting Position Effect 16-3 Multidrop Communication 9-22 Changing a Transmitter Address 9-23 Polling a Loop 9-23 Multipoint Calibration 2-2, 16-3 N NAMUR-Compliant Operation 9-2 Non-flow Calibration 2-2, 16-3 Non-Wetted Parts 16-5 O Opposite-Side Support 3-5, 4-7, 4-8, 4-9 Orientation Flanged Models Gas Service in a Horizontal Pipe 4-3 Gas Service in a Vertical Pipe 4-4 Liquid Service in a Horizontal Pipe 4-2 Liquid Service in a Vertical Pipe 4-3 Steam Service in a Horizontal Pipe 4-3 Steam Service in a Vertical Pipe 4-4 Flo-Tap Models Gas Service in a Horizontal Pipe 5-3, 6-3 Gas Service in a Vertical Pipe 5-3, 6-3 Liquid or Steam Service in a Horizontal Pipe 5-2, 6-2 Liquid Service in a Vertical Pipe 5-3, 6-3 Steam Service in a Vertical Pipe 5-4, 6-4 In-Line Models Gas Service in a Horizontal Pipe 7-4 Gas Service in a Vertical Pipe 7-7 Liquid Service in a Horizontal Pipe 7-3 Liquid Service in a Vertical Pipe 7-6 Steam Service in a Horizontal Pipe 7-5 Steam Service in a Vertical Pipe 7-8 Regular (Threaded, Pak-Lok) Models Gas Service in a Horizontal Pipe 3-3 Gas Service in a Vertical Pipe 3-4 Liquid Service in a Horizontal Pipe 3-2 Liquid Service in a Vertical Pipe 3-4 Steam Service in a Horizontal Pipe 3-3 Steam Service in a Vertical Pipe 3-4 Output Linear versus Square Root 9-10 Reviewing 9-7 Setting 9-10 Output Trim. See Calibration P Performance Specifications 16-3 Permissible Misalignment 2-3 Physical Specifications 16-5 Power Supply 10-2, 16-1 Power Supply Effect 16-3 Pressure Drilling 5-7, 6-6 Pressure Drilling Diagram 5-6, 6-6 Pressure Installation Hardware 5-4, 6-4 Pressure Limits 16-2 ProBar Case Ground 10-4 ProBar Configurations 2-2 ProBar Flanged Components 4-2 ProBar Flo-Tap Components 5-2, 6-2 ProBar In-Line Configurations 7-2 ProBar Operating Limitations 16-4 ProBar Orientation Flanged Models Gas Service in a Horizontal Pipe 4-3 Liquid Service in a Horizontal Pipe 4-2 Liquid Service in a Vertical Pipe 4-3 Steam Service in a Horizontal Pipe 4-3 Steam Service in a Vertical Pipe 4-4 Flanged ModelsGas Service in a Vertical Pipe 4-4 Flo-Tap Models Gas Service in a Horizontal Pipe 5-3, 6-3 Gas Service in a Vertical Pipe 5-3, 6-3 Liquid or Steam Service in a Horizontal Pipe 5-2, 6-2 Liquid Service in a Vertical Pipe 5-3, 6-3 Steam Service in a Vertical Pipe 5-4, 6-4 In-Line Models Gas Service in a Horizontal Pipe 7-4 Gas Service in a Vertical Pipe 7-7 Liquid Service in a Horizontal Pipe 7-3 Liquid Service in a Vertical Pipe 7-6 Steam Service in a Horizontal Pipe 7-5 Steam Service in a Vertical Pipe 7-8 Regular (Threaded, Pak-Lok) Models Gas Service in a Horizontal Pipe 3-3 Gas Service in a Vertical Pipe 3-4 Liquid Service in a Horizontal Pipe 3-2 Liquid Service in a Vertical Pipe 3-4 Steam Service in a Horizontal Pipe 3-3 Steam Service in a Vertical Pipe 3-4 ProBar Regular Components 3-2 ProBar Valve Identification 12-2 ProBar Valves and Fittings 8-2 Process Connections 2-7 Process Flange Orientation 10-4 Process Variables 9-7 Setting Units for 9-8 Process-Wetted Parts 16-5 R Range Values. See Rerange Receiving and Inspection 2-1 Remote Mount 2-2 Remote Mount ProBar Commissioning 12-1–12-8 Remote Mounted ProBar Electronics Locations 8-6–8-11 Remote Mounted RTD Replacement 14-2 Remote Mounting Equipment 8-4 Remote Mounting Fittings 8-2 Remote Mounting ProBar Electronics 8-1–8-12 Remote Mounting Valves 8-2 Removing the Terminal Block 15-4 Replacing a Direct Mount RTD 14-2 Replacing a Remote Mount RTD 14-2 Rerange, Description of 9-10 Using Communicator 9-11 Using Communicator and Input Source 9-11 Using Zero and Span Buttons and Input Source 9-12 RFI Effect 16-3 RTD Maintenance 14-1 S Safety Messages 2-1, 3-1, 4-1, 5-1, 6-1, 7-1, 9-1, 10-1, 11-1, 12-1, 13-1, 14-1, 15-1, A-1 Saturation Output Values 9-2 Saving a Configuration 9-21 Sensor Size/Hole Diameter Chart 3-5, 4-5, 5-6, 6-6 Sensor Temperature 9-7 Sensor Trim. See Calibration Setting the Loop to Manual 9-5 Shipping Note 3-4, 4-4 Signal Wiring Ground 10-4 Span. See Zero and Span Specifications and Reference Data 16-1–8 Stability 16-3 Static Pressure Effect 16-3 Straight Run Requirements 2-3, 2-4 Structural Limitations 2-2 System Leak Check 12-3 T Temperature Effect Calibration 12-4 Terminal Block Installing 15-5 Removing 15-4 Time Response 16-3 Transmitter Housing Improved versus Previous 15-3 Rotating 13-3 Trim. See Calibration Turn-on Time 16-2 U Unit Isolation Valve 5-6, 5-7, 5-10, 6-5, 6-7, 6-10 V Valve Identification 12-2 Valves and Fittings 8-2 Vibration Effect 16-3 W Wet Calibration 12-4 Wiring 10-3 Wiring Diagrams In the Field 9-7 On the Bench 9-7 Wiring Diagrams for Field Hook-up 10-2 Z Zero and Span Adjustment Control 9-14 Disabling 13-2 Options 13-1 Zero or Wet Calibration 12-4 Zero the Electronics 12-3 Zero Trim. See Calibration I-3 ProBar Flowmeter I-4 Dieterich Standard Inc. Rosemount Inc. Fisher-Rosemount Limited Fisher-Rosemount 5601 North 71st Street Boulder, CO 80301 Tel (303) 530-9600 Fax (303) 530-7064 8200 Market Boulevard Chanhassen, MN 55317 USA Tel 1-800-999-9307 Telex 4310012 Fax (612) 949-7001 Heath Place Bognor Regis West Sussex PO22 9SH England Tel 44 (1243) 863 121 Fax 44 (1243) 867 5541 Singapore Pte Ltd. 1 Pandan Crescent Singapore 128461 Tel (65) 777-8211 Fax (65) 770-8007 Tlx RS 61117 FRSPL PR INT IN U. S. A. ED © 1998 Rosemount Inc. http://www.rosemount.com ¢00809-0100-47616¤ 00809-0100-4761 Rev. CA
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