X-9900 Revision 03
Model 9900 Series Oval Gear Meter with Smart Meter Manager Installation and Operation Manual
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Brodie Meter Co., LLC 19267 Highway 301 North (30461) PO Box 450 Statesboro, GA 30459-0450
Phone: (912) 489-0200 Fax: (912) 489-0294 www.brodiemeter.com
Manufacturers of BiRotors, Oval Gear Meters, and Control Valves
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Essential Instructions Brodie Meter Co., LLC designs, manufactures and tests its products to meet many national and international standards. Because these instruments are sophisticated technical products, you must properly install, use and maintain them to ensure they continue to operate within their normal specifications. The following instructions must be adhered to and integrated into your safety program when installing, using and maintaining Brodie Meter Co., LLC products. • Read all instructions prior to installing, operating, and servicing the product. If this instruction manual is not the correct manual, telephone 1-912-489-0200 and the requested manual will be provided. Save this instruction manual for future reference. • If you do not understand any of the instructions, contact your Brodie representative for clarification. • Follow all warnings, cautions, and instructions marked on and supplied with the product. • Inform and educate your personnel in the proper installation, operation, and maintenance of the product. • Install your equipment as specified in the installation instructions of the appropriate instruction manual and per applicable local and national codes. Connect all products to the proper electrical and pressure sources. • To ensure proper performance, use qualified personnel to install, operate, update, program, and maintain the product. • When replacement parts are required, ensure that qualified people use replacement parts specified by the manufacturer. Unauthorized parts and procedures can affect the product’s performance and place the safe operation of your process at risk. Look-alike substitutions may result in fire, electrical hazards, or improper operation. • Ensure that all equipment doors are closed and protective covers are in place, except when maintenance is being performed by qualified persons, to prevent electrical shock and personal injury.
Warning This instrument contains electronic components that are susceptible to damage by static electricity. Proper handling procedures must be observed during the removal, installation, or other handling of internal circuit boards or devices. Handling Procedure: 1. Power to unit must be removed. 2. Personnel must be grounded, via wrist strap or other safe, suitable means before any printed circuit card or other internal device is installed, removed, or adjusted. i 3. Printed circuit cards must be transported in a conductive bag or other conductive container. Boards must not be removed from protective enclosure until immediately before installation. Removed boards must immediately be placed in protective container for transport, storage, or return to factory. Comments This instrument is not unique in its ESD (electrostatic discharge) sensitive components. Most modern electronic designs contain components that utilize metal oxide technology (NMOS, CMOS, etc.). Experience has proven that even small amounts of static electricity can damage or destroy these devices. Damaged components, even though they appear to function properly, exhibit early failure.
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Notice Brodie Meter Co., LLC (“Brodie”) shall not be liable for technical or editorial errors in this manual or omissions from this manual. Brodie makes no warranties, expressed or implied, including the implied warranties of merchantability and fitness for a particular purpose with respect to this manual and, in no event, shall Brodie be liable for any special or consequential damages including, but not limited to, loss of production, loss of profits, etc. Product names used herein are for manufacturer or supplier identification only and may be trademarks/ registered trademarks of these companies. The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, expressed or implied, regarding the products or services described herein or their use or applicability. We reserve the right to modify or improve the designs or specifications of such products at any time. Brodie does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any Brodie product remains solely with the purchaser and end-user.
Brodie Meter Co., LLC Statesboro, Georgia, USA All rights reserved. No part of this work may be reproduced or copied in any form or by any means - graphic, electronic or mechanical - without first receiving the written permission of Brodie Meter Co., LLC., Statesboro, Georgia, U.S.A.
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Warranty 1. LIMITED WARRANTY: Subject to the limitations contained in Section 2 herein and except as otherwise expressly provided herein, Brodie Meter Co., LLC (“Brodie”) warrants that the firmware will execute the programming instructions provided by Brodie, and that the Goods-manufactured or Services provided by Brodie will be free from defects in materials or workmanship under normal use and care until the expiration of the applicable warranty period. Goods are warranted for twelve (12) months from the date of initial installation or eighteen (18) months from the date of shipment by Brodie, whichever period expires first. Consumables and Services are warranted for a period of 90 days from the date of shipment or completion of the Services. Products purchased by Brodie from a third party for resale to Buyer (“Resale Products”) shall carry only the warranty extended by the original manufacturer. Buyer agrees that Brodie has no liability for Resale Products beyond making a reasonable commercial effort to arrange for procurement and shipping of the Resale Products. If Buyer discovers any warranty defects and notifies Brodie thereof in writing during the applicable warranty period, Brodie shall, at its option, promptly correct any errors that are found by Brodie in the firmware or Services, or repair or replace F.O.B. point of manufacture that portion of the Goods or firmware found by Brodie to be defective, or refund the purchase price of the defective portion of the Goods/Services. All replacements or repairs necessitated by inadequate maintenance, normal wear and usage, unsuitable power sources, unsuitable environmental conditions, accident, misuse, improper installation, modification, repair, storage or handling, or any other cause not the fault of Brodie are not covered by this limited warranty, and shall be at Buyer’s expense. Brodie shall not be obligated to pay any costs or charges incurred by Buyer or any other party except as may be agreed upon in writing in advance by an authorized Brodie representative. All costs of dismantling, reinstallation and freight and the time and expenses of Brodie’s personnel for site travel and diagnosis under this warranty clause shall be borne by Buyer unless accepted in writing by Brodie. Goods repaired and parts replaced during the warranty period shall be in warranty for the remainder of the original warranty period or ninety (90) days, whichever is longer. This limited warranty is the only warranty made by Brodie and can be amended only in writing signed by an authorized representative of Brodie. Except as otherwise expressly provided in the Agreement, THERE ARE NO REPRESENTATIONS OR WARRANTIES OF ANY KIND, EXPRESSED OR IMPLIED, AS TO MERCHANTABILITY, FITNESS FOR PARTICULAR PURPOSE, OR ANY OTHER MATTER WITH RESPECT TO ANY OF THE GOODS OR SERVICES. It is understood that - corrosion or erosion of materials is not covered by our guarantee. 2. Limitation Of Remedy And Liability: Brodie Shall Not Be Liable For Damages Caused By Delay In Performance. The Sole And Exclusive Remedy For Breach Of Warranty Hereunder Shall Be Limited To Repair, Correction, Replacement OriiiRefund Of Purchase Price Under The Limited Warranty Clause In Section 1 Herein. In No Event, Regardless Of The Form Of The Claim Or Cause Of Action (Whether Based In Contract, Infringement, Negligence, Strict Liability, Other Tort Or Otherwise), Shall Brodie’s Liability To Buyer And/Or Its Customers Exceed The Price To Buyer Of The Specific Goods Manufactured Or Services Provided By Brodie Giving Rise To The Claim Or Cause Of Action. Buyer Agrees That In No Event Shall Brodie’s Liability To Buyer And/Or Its Customers Extend To Include Incidental, Consequential Or Punitive Damages. The Term “Consequential Damages” Shall Include, But Not Be Limited To, Loss Of Anticipated Profits, Loss Of Use, Loss Of Revenue And Cost Of Capital.
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Table of Contents 1.0 Oval Flowmeter Series 9900 .........................................................................................3 1.1 Description ................................................................................................................................................... 3 1.2 Design Features - Oval Flowmeter ............................................................................................................. 3 1.3 Principle of Operation - Oval Flowmeter ................................................................................................... 3 1.4 Specifications - Oval Flowmeter................................................................................................................. 4 1.5 Specifications - Smart Meter Manager ..................................................................................................... 10
2.0 Installation ................................................................................................................... 11 2.1 Receipt of Equipment ................................................................................................................................ 11 2.2 Recommended Storage Practice .............................................................................................................. 11 2.3 Return Shipment ........................................................................................................................................ 11 2.4 Installation - Mechanical ........................................................................................................................... 11 2.5 Electrostatic Discharge Protection .......................................................................................................... 11 2.6 Installation - Electrical ............................................................................................................................... 12
3.0 Operation ..................................................................................................................... 16 3.1 Pre-Start Check .......................................................................................................................................... 16 3.2 Start-up and Operation of Flowmeter ...................................................................................................... 16 3.3 Operation of the HART Communicator with Smart Meter Manager ...................................................... 16
4.0 Maintenance ................................................................................................................ 25 4.1 General ........................................................................................................................................................ 25 4.2 Disassembly and Assembly ...................................................................................................................... 25 4.3 Removal of Smart Meter Manager ............................................................................................................ 27 4.4 Pickoff Removal/Installation Instructions ............................................................................................... 27 4.5 Monitoring the Integrity of the SMM Electronics-Alarms....................................................................... 27
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Brodie Smart Meter Manager Technology • 2-wire, loop-powered device for ease of wiring and installation • 4-20 mA analog output with Bell-202 modulated HART communication channel • User selectable 0% and 100% analog output ranges with optional smoothing • Flexible (mix & match) units of measure for flowrates, totals, temperatures, densities, etc. • User configurable, scalable pulse output for various engineering units • Comprehensive alarms for both process flow and internal diagnostic checks
1.0 Oval Flowmeter Series 9900 1.1 Description The Brodie 9900 Series Oval Flowmeter/ Transmitter with Smart Meter Manager (SMM) is a very high accuracy, positive displacement meter which utilizes microprocessor based electronics to provide multivariable flow computation and output for volumetric and mass measurement requirements. It is designed for use in the chemical, industrial, food and beverage, pharmaceutical and hydrocarbon process industries.
Flowmeters are supplied with the SMM mounted with the explosion proof UMB enclosure. • Capabilities include: • Automatic Temperature Compensation • Analog and Pulse Output to remote instrumentation • Diagnostic and System Alarms • 2-Wire Mass or Volume Input • Model 275 Hand-held Interface
One of the most significant features of these meters is their ability to handle both low and high viscosity products with a low pressure drop across the meter. They are supplied in a compact, 3-piece design which uses both front and rear flanges instead of the closed-end body configuration found in traditional oval flowmeters. Available sizes are 1/2" through 3". “Smart Meter Manager inside” best defines the Brodie 9900 Oval Flowmeter/Transmitter. Past products have only delivered simple square wave pulse outputs that represented raw unfactored meter pulses (K-Factors).
1.2 Design Features - Oval Flowmeter • 2-Wire loop powered flowmeter/transmitter • 316 Stainless steel measuring unit • Automatic temperature compensation • Pocketless measuring chamber • Low pressure drop • 2-Wire Mass or volume output • 4-20 mA analog output with HART communication • User configurable, scalable pulse output • Comprehensive alarms for both process flow and internal diagnostic checks • Easy access programming • 10-Point meter factor linearization • Class I, Division 1, Groups C & D; Class II, Division 1, Groups E, F & G; Type 4 Weatherproof • Intrinsically safe
K-Factors require additional processing by a secondary piece of electronics to convert to engineering units or factored 4-20 mA analog output. The need for secondary electronics, additional wiring and power supplies can be eliminated by using the SMM. The Smart Meter Manager (SMM) is a multivariable flow computer 3 that fits inside the standard Brodie UMB (Universal Mounting Box). Because the SMM only requires 4-20 mA loop power it hooks up as a simple 2-wire transmitter. The SMM expands the capability of the Oval to include factored 2wire, 4-20 mA output, and with ATC (Automatic Temperature Compensation) the once simple KFactor now represents both corrected volume and mass flow. This can be in the form of a 4-20 mA output, gross total and/or inventory total. In addition, transistor contacts provide scaled pulse outputs in both net and gross values. An additional contact provides an alarm output. This expanded capability is enhanced by HART’S communications and the ability to use the standard 275 HART Communicator.
1.3 Principle of Operation - Oval Flowmeter The Oval Flowmeter accurately measures liquid flow by using a slight pressure differential to rotate a pair of oval gears located within the measuring chamber. Each complete rotation of the gears (rotors) displaces a fixed amount of liquid from the inlet to the outlet of the meter in a 3
continuous flow pattern. When in the position as shown in Figure 1.1, Diagram 1, all of the driving torque resulting from differential pressure is applied to Gear A. Gear B has zero driving torque since equal areas of gear surface on opposite sides of the axis of rotation are exposed to higher inlet pressure. As the gears begin to rotate (Diagram 2), the torque applied to Gear A decreases but Gear B now has driving torque due to increased area exposed to the high pressure. At the position shown in Diagram 3, all of the driving torque is exerted on Gear B and Gear A has decreased to zero. This alternate driving action provides a smooth rotation of almost constant torque without dead spots.
• Shafts Standard: 316 stainless steel Optional: Chrome Plated • Rotor Bearings Standard: Carbon Optional: Waukesha or Ceramic Carbon for corrosive/abrasive products • O-rings Standard: Viton® Optional: Teflon®, EPR, Silicon Capacities Refer to Tables 1.1A (Mass) and 1.1B (Volumetric) Performance Accuracy: ±0.25% on viscosities of 5 centipoise and above ±0.5% on viscosities from 0.2 to 5 centipoise Repeatability: ±0.05% or better Accuracy vs. Pressure Drop: Refer to Table 1.p2
Because the amount of slippage between the oval gears and measuring chamber wall is minimal, the meter is essentially unaffected by the viscosity and lubricity of liquids being metered.
1.4 Specifications - Oval Flowmeter
Warning Do not operate this instrument in excess of the specifications below. Failure to heed this warning can result in serious personal injury and/or damage to the equipment. Viscosity • Basic viscosity classifications include: • Standard viscosity class from 0.2 to 500 centipoise • High viscosity class above 500 centipoise Materials of Construction • Body: Stainless steel CF8M with polyurethane paint • Rotors: 316 stainless steel
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4444444 Figure 1.1 Principle of Operation
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Table 1.1 Capacities and Operating Range, Mass Line Size Model Units (Inches) Number (U.S. gal) 1/2
9952
1
9953
1
9955
1 1/2
9956
2
9957
3
9958
lb/min kg/min lb/min kg/min lb/min kg/min lb/min kg/min lb/min kg/min lb/min kg/min
Water SpGr =1 10.8-55.0 4.9 - 25.0 22.5 - 110 10.2 - 49.9 33.4 - 258 15.1-117 75.0 - 517 34.0 - 234 150 - 1,101 68.1 - 499 292 - 2,210 132 - 1,002
Hot Water 140 to 230°F (60° to 110°C) SpGr = 0.98 15.0-36.7 6.8 - 16.6 29.2 - 73.4 13.2 - 33.3 41.7 - 183 18.9-83.2 91.7 - 367 41.6 - 166 183 - 734 83.2 - 333 367 - 1,467 166 - 666
LPG 0.2 cP SpGr = 0.05
Gasoline 0.3 to 1.7 cP SpGr = 0.78
Kerosene 0.7 to 1.8 SpGr = 0.82
Light Oil 2 to 4 cP SpGr = 0.90
Heavy Oil 5 to 300 cP Sp Gr = 0.95
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15.0-66.7 6.8 - 30.3 29.2 - 132 13.2 - 59.8 41.7 - 308 18.9-140 91.7 - 584 41.6 - 265 100 - 1,284 45.4 - 582 292 - 2,568 132 - 1,165
10.8 - 66.7 4.9 - 30.3 22.5 - 132 10.2 - 59.8 33.4 - 308 15.1-140 75.0 - 584 34.0 - 265 150 - 1,284 68.1 - 582 292 - 2,568 132 - 1,165
5.8-75.0 2.6 - 34.0 11.7 - 147 5.3 - 66.6 16.7 - 367 7.6-166 33.4 -734 15.1 - 333 75.0 - 1,467 34.0 - 666 150 - 2,935 68.1 - 1,331
3.3 - 75.0 1.5 - 34.0 5.8 - 147 2.6 - 66.6 8.3 - 367 3.8-166 25.0 - 734 11.3 - 333 50.0 - 1,467 22.7 - 666 91.7 - 2,935 41.6 - 1,331
21.7 66.7 9.8 - 30.3 44.2 - 132 20.0-59.8 66.7 - 308 30.3-140 133 - 584 60.5 - 265 300 - 1,284 136 - 582 550 - 2,568 250 - 1,165
Table 1.2 Capacities and Operating Range, Volumetric Line Size Model Units (Inches) Number (U.S. gal) 1/2
9952
1
9953
1
9955
1 1/2
9956
2
9957
3
9958
gpm L/min gpm L/min gpm L/min gpm L/min gpm L/min gpm L/min
Water 1.3 - 6.6 4.9-25.0 2.7-13.2 10.2-50.0 4.0-31.0 15.1-117 9.0-62.0 34.1 -235 18.0-132 68.1 - 500 35.0 - 265 132 - 1,003
Hot Water 140 to 230°F (60° to 110°C) 1.8 - 4.4 6.8-16.7 3.5-8.8 13.2-33.3 5.0-22.0 18.9-83.3 11.0-44.0 41.6-167 22.0-88.0 83.3 - 333 44.0 - 176 167 - 666
LPG 0.2 cP
Gasoline 0.3 to 1.7 cP
Kerosene 0.7 to 1.8
Light Oil 2 to 4 cP
Heavy Oil 5 to 300 cP
2.6 - 8.0 9.8-30.3 5.3-15.8 20.1-59.8 8.0-37.0 30.3-140 16.0-70.0 60.6-265 36.0-154 136 - 583 66.0 - 308 250 - 1,166
1.8 - 8.0 6.8-30.3 3.5-15.8 13.2-59.8 5.0-37.0 18.9-140 11.0-70.0 41.6-265 12.0-154 45.4 - 583 35.0 - 308 132 - 1,166
1.3 - 8.0 4.9-30.3 2.7-15.8 10.2-59.8 4.0-37.0 15.1-140 9.0-70.0 34.1 -265 18.0-154 68.1 - 583 35.0 - 308 132 - 1,166
0.7 - 9 2.6-34.1 1.4-17.6 5.3-66.6 2.0-44.0 7.6-167 4.0-88.0 15.1 -333 9.0-176 34.1 - 666 18.0 - 352 68.1 - 1,332
0.4 - 9.0 1.5-34.1 0.7-17.6 2.6-66.6 1.0-44.0 3.8-167 3.0-88.0 11.4-333 6.0-176 22.7 - 666 11.0 - 352 41.6 - 1,332
Figure 1.2 Accuracy vs. Pressure Drop
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Ratings: Maximum Working Temperature (Limited to electronics): Process Operating Temperature Class A: -40°F to 230°F (-40°C to 110°C) Class C: 230°F to 400°F (110°C to 204°C) Ambient Operating Temperature -20°F to 150°F (-29°C to 65°C) Storage Temperature -58°F to 175°F (-50°C to 79°C) Class I, Division 1, Groups C & D; Class II, Division 1, Groups E, F & G; Type 4 Weatherproof
Output Signals: 4-20 mA Analog Output Update Rate: 4 times per sec. Range: 3.8 to 22.0 mA Contact Output Open collector: assignable to alarm output, reverse flow indicator or manual value Maximum off-state voltage: 30 Vdc Maximum on-state voltage: 1.2 Vdc Maximum on-state current: 40 mA Standard Pulse Outputs Type: Open collector, two channels (Two singlephase) Frequency Range: Zero to 500 Hz Maximum off-state voltage: 30 Vdc Maximum on-state voltage: 1.2 Vdc Maximum on-state current: 40 mA
SAMA Vibration Specification PMC 31.1, Table 2, Condition 3 For process pipe mounted instrumentation Humidity 0-95% R.H. non-condensing
Ambient Temperature Limit -20°F to 150°F (-29°C to 65°C). For conditions outside of range consult factory.
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Maximum Working Pressure at 100°F (38 C) Stainless Steel, 150 lb. ANSI Fig.: 275 psi (1895 kPa) Stainless Steel, 300 lb. ANSI Fig.: 720 psi (4960 kPa)
Loop Current Linearity Less than 0.1 % from min. to max. current Temperature Influence on Loop Current Less than 0.007% per °C
Mechanical Connections Standard: 1 /2" to 3", 150 lb. ANSI flange Optional: 1/2" to 3", 300 lb. ANSI flange, DIN,Triclover
Loop Voltage Influence on Loop Current Less than 0.002%Ndc Load Resistance Influence on Loop Current +0.1 % full scale
Electrical Classification UL/cUL - Intrinsically Safe Class I, Groups A, B, C, and D Class II, Groups E, F, and G Class III UL/cUL - Hazardous Locations Class I, Groups C and D Class II, Groups E, F, and G NEMA 4X Power Supply and Maximum Load Resistance Power Supply, refer to Figure 1.3.
Dimensions Refer to Figure 1.3. For certified dimension prints, contact factory. Typical Applications Refer to Figures 1.7and 1.8
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Input Power - Derived from Analog Output 2-wire 4-20 mA loop transmitter Input Signals: RTDTemperature Input Supports 100 ohm, platinum or copper RTD input for temperature, 3 or 4 wire
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Figure 1.3 Power Supply/Maximum Load Resistance.
Figure 1.4 Pressure Loss and Flow Range for High Viscosity Liquids.
7 Figure 1.5 Relationship between Viscosity and Coefficient of Maximum Flow Rate.
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Figure 1.6 9900 Series Dimensions
Mounting Dimensions Brodie 9900 Series Oval Flowmeter with UMB.
Figure 1.7 typical Application: 9900 Series Oval Flowmeter with Integral Smart Meter Manager
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8888888
Brodie Series 9900 Oval Flowmeter with Smart Meter Manager
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Figure 1.8 Typical Application: 9900 Series Oval Flowmeter with Smart Meter Manger.
Local Operator interface available with complete Model 20 only.
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1.5 Specifications - Smart Meter Manager
Maximum off-state voltage: 30 V dc Maximum on-state voltage: 1.2 Vdc Maximum on-state current: 40 mA
Warning
Standard Pulse Outputs
Do not operate this instrument in excess of the specifications below. Failure to heed this warning can result in serious personal injury and/or damage to the equipment.
Type: Open collector, two channels (two singlephase) Frequency Range: Zero to 500 Hz Maximum off-state voltage: 30 Vdc Maximum on-state voltage: 1.2 Vdc Maximum on-state current: 40 mA
Power Supply and Maximum Load Resistance 21.0 to 33.0 Vdc Power Supply, refer to Figure 1.3. Input Power - Derived from Analog Output 2-wire 4-20 mA loop transmitter
Ambient Temperature Limit -20°F to 150°F (-29°C to 65°C) For conditions outside of range consult factory.
Input Power - Derived from Analog Input 2-wire 4-20 mA loop transmitter.
Loop Current Linearity Less than 0.1 % from min. to max. current
Input Signals: Pulse Inputs Power Pulse or Reluctance Frequency Range: Zero to 1 KHz Threshold: 35 m Vpp Start-up Accuracy: -1 meter pulse
Temperature Influence on Loop Current Less than 0.007% per °C Loop Voltage Influence on Loop Current Less than 0.002%Ndc Load Resistance Influence on Loop Current +0.1 % full scale
Logic Driven Pulse Frequency Range: Zero to 1 KHz Input Voltage: 3 to 30 Vdc Start-up Accuracy: -1 meter pulse
Dimensions See Figure 1.6. For certified dimension prints, contact factory.
Wiegand/Amorphous Frequency Range: Zero to 250 Hz Threshold: 200m Vpp Start-up Accuracy: -1 meter pulse Dry Contact Closure Frequency Range: Zero to 50 Hz Recommended Contact Type: Gold or Silver Wetting Voltage (supplied by SMM): 3.3 Vdc Start-up Accuracy: -1 meter pulse
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RTDTemperature Input Supports 100 ohm, platinum or copper RTD input 10101010101010 for temperature, 3 or 4 wire Output Signals: 4-20 mA Analog Output Update Rate: 4 times per sec. Range: 3.8 to 22.0 mA Contact Output Open collector: assignable to alarm output, reverse flow indicator or manual value
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2.0 Installation 2.1 Receipt of Equipment When the equipment is received, the outside of the packing case should be checked for any damage incurred during shipment. If the packing case is damaged, the local carrier should be notified at once concerning his liability.
2.2 Recommended Storage Practice
Equipment returned to the factory without proper documentation will be returned to sender at their expense. Ship the container to: Brodie Meter Co., LLC Product Service Department 19267 Hwy. 301 North Statesboro, GA 30461 Telephone: 1 912 489 0200 Fax: 1 912 489 0294
2.4 Installation - Mechanical
If intermediate or Iong-term storage is required for equipment, as supplied by Brodie Meter, it is recommended that the equipment be stored in accordance with the following:
Warning Do not operate this instrument in excess of the specifications listed in Section 1. Failure to heed this warning can result in serious personal injury and/or damage to the equipment.
a. Within the original shipping container. b. Stored in a sheltered area, preferably a warm, dry heated warehouse. c. Ambient temperature of 70°F (21 °C) nominal, 110°F (43°C) maximum, 45°F (7°C) minimum. d. Relative humidity 45% nominal, 60% maximum, 25% minimum. Upon removal from storage, a visual inspection should be conducted to verify the condition of equipment is “as received”.
1. Align the piping. 2. Remove the protective covering from the meter inlet and outlet. 3. Install the meter with the arrows on the meter body pointing in the direction of flow.
Caution
2.3 Return Shipment To be able to process return goods quickly and efficiently, it is IMPORTANT that you provide essential information. Do not return any assembly or part without an “R.M.R.”(Retumed Materials Report), or a letter which describes the 11 problem, correction action, if any, to be taken, and the work that is to be performed at the factory. R.M.R. forms can be obtained from Brodie Sales Offices or the Service Department, Brodie Instrument, P.O. Box 450, Highway 301 N., Statesboro, Georgia, 30459. Place a copy of either of the above inside the shipping container and attach it physically to the material being returned. A copy of your packing list should be placed inside an envelope and attached to the outside of the shipping container, or placed inside the container.
The rotor shafts must be horizontal. If the shafts are vertical (on end) the meter will be damaged.
4. For flanged meters, use the standard gaskets used in the system. First tighten the flange bolts hand-tight. Then tighten the bolts with a wrench in a diagonal pattern to keep the flanges parallel.
2.5 Electrostatic Discharge Protection Some of the equipment covered by this manual has electronic components that are sensitive to static electricity. Charges too low to be measured can damage, or lead to premature failure. Such equipment is noted by the ESD (Electrostatic Discharge) symbol.
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Transmitter electrical installation consists of connecting power, output and accessory wiring to the Smart Meter Manager is in the universal mounting box on top of the oval gear meter.
Caution Observe and follow ESD protection procedures when in contact with printed circuit boards or devices.
A. Analog Output or Power Wiring
1. Disconnect line power and output cable from the transmitter. 2. Ground yourself, such as with a wrist grounding strap, using a 1 megohm resistor for personal protection. 3. Before using tools with a nonconductive handle, touch both the handle and metallic part to be sure complete electrostatic discharge of the tool. 4. Place the board on a grounded, conductive work surface or make certain that it and everything that may contact it is brought to ground potential. 5. Store boards in conductive, antistatic containers. Do not store boards in nonconductive, plastic bags.
2.6 Installation - Electrical
Caution CE Compliance: Shielded cable must be used in installation: • Loop power (4 to 20 mA) cable must provide 100% shield coverage. Units were tested with Belden 9844 cable which is recommended • Optically isolated or Dry Contact pulse inputs may be run in the same cable as the Loop.The customer's pulse driver circuits should conform to CE-MARK requirements. Note that the low level pulse inputs (Wiegand, Amorphous, Reluctance, etc.) are intended to be driven by sensor contained within the meter housing. • Optically isolated outputs (pulses, alarms, etc.) may be run in the same cable as the Loop and 12121212121212 pulse inputs.The customer's receiver circuits should conform to CE-MARK requirements. Conduit or Cable Glands must provide RFI shielding over 360°. Units must be properly earthed in accordance with local codes using the lugs provided.
The analog output can be programmed to represent one of four variables: • gross volumetric flow, • net (temperature compensated) volumetric flow • mass flow, or • process temperature Your SMM is programmed as noted on the order acknowledgment and packing slip. SMM variables can be reprogrammed in the field. Programming instructions are in Section 3. The analog output can be left at the default values if it is not used. For applications in which the SMM is powered by the 4 to 20 mA output loop, connect the wiring to the SMM as shown in Figure 2.1. For applications in which the analog output is not used and/or for multidrop applications connect a 24 Volt power supply to the SMM as shown in Figure 2.2. Use shielded cable of sufficient size to handle the power required by the system. A minimum wire size of 20 gage is recommended. Analog output systems must adhere to the following: 1. For intrinsically safe Division 1 applications, the safety barrier, cable, and power supply must be suitable for the SMM electrical characteristics shown in Figures 2-3 through 2-5. 2. For Division 2 applications, a barrier is not required.The NEC (National Electrical Code) 12 conduit for wire protection. requires 3. Use shielded cable. Connect the shield to chassis ground at the transmitter end. Do not connect the shield at the receiver end, but trim and tape it. Insulation of the shield at the receiving end is especially important for intrinsically safe installations. 4. The power supply voltage limits the maximum loop resistance as shown in Figure 1.2. 5. The NEC requires conduit seals within 18 inches of the electrical housing.
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Caution Because this unit uses an intrinsically safe sensor circuit, an earth ground must be supplied to meet the hazardous area certification.
B. Pulse (Frequency) Outputs The SMM has two pulse outputs. The outputs are optically-isolated transistors that can be connected in a common collector or commonemitter fashion. A typical wiring diagram for a single-phase, open-collector pulse output is shown in Figure 2.6.
bundle the RTD cable with power wiring. A 4-wire RTD is the most accurate because it nulls out the effects of lead-wire resistance from disturbing the process temperature reading. If the 4th wire is not available, then a jumper wire must be installed between Pins 1 and 2. If this is done, you must configure a variable within the SMM to request that a site-measured leadwire resistance (Roffset) be subtracted from the RTD ohms reading prior to calculation of the observed process temperature. D. Alarm Outputs An open collector alarm can be programmed to represent a number of variables. Programming instructions are in Section 3.
C. RTD Inputs For applications requiring a process fluid temperature input, install the RTD (Resistance Temperature Detector) in accordance with the manufacturer’s literature. Connect the RTD output cable to the SMM as shown in Figure 2.7. Because this is a low-power signal it is sensitive to EMI and RFI. Therefore, use shielded cable of size specified by the manufacturer. Do not
For a typical open collector alarm, connect the digital output wiring as shown in Figure 2-6.
Figure 2.1 SMM Transmitter Analog Output/Power Wiring (4-20 mA signal)
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Figure 2.3 UMB Wiring Diagram
Figure 2.4 UMB Entiity Concept
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Figure 2.6 Single Phase, Open Collection Pulse Output Typical Wiring Diagram
Figure 2.7 RTD (Resistance Temperature Detector) Wiring Diagram
Figure 2.8 Typical Digital Wiring Diagram 15
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3.0 Operation
For applications in which an RTD is used, proper values must also be programmed into the RTD values. The density and RTD variables are accessible with the HART Communicator
3.1 Pre-Start Check The SMM is in the meter’s universal mounting box on top of the meter of Flowmeter Variables can be programmed into the SMM using the HART 275 Communicator see Figures 3.1 and 3.2 for HART 275 menus. All of the SMM variables can be programmed with a HART Communicator or with a computer equipped with Fisher Rosemount AMS software. Instructions for programming the SMM with a HART Communicator are in Section 3. Your SMM has been factory programmed as noted on the order acknowledgment and packing slip. These are the values requested on the order, if not, default values are set. Table 3 1 shows the variables that will be factory configured to specification along with their default values. SMM variables can be reprogrammed in the field.
3.3 Operation of the HART Communicator with Smart Meter Manager a.Start up the meter as described in Section 3 2. b.Programming performed prior to shipment (parameters)The SMM transmitter with or without alarms and pulse output is preprogrammed prior to shipment for the following parameters based on the order information, meter configuration and application. If parameters are not specified in the customer purchase order, the defaults inherent to the electronics will be as shown in Table 3.1.
Verity that the SMM variables are properly programmed before putting the system in operation.
3.2 Start-up and Operation of Flowmeter The 9900 Oval flowmeter can be placed in operation with accurate volumetric output if proper values are programmed into the: 1) K factor, 2) K factor units, and 3) analog outputs. The K factor is on the meter calibration data. It is also stamped on the meter nameplate and is factory programmed into the SMM. The units and analog outputs were factory programmed to the customer’s values or set to default values. The programmed values are listed on the order acknowledgment and packing list. The default values are listed in Table 3.1. If the analog output 16161616161616 is not going to be used, leave the analog output at its default setting. If the values are correct, place the meter in operation. If some of the values must be changed, they are accessible with the HART Communicator. For accurate mass output, the proper value must also be programmed into the density parameter. 16
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Table 3.1 Default Values for Variable Configuration
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Figure 3.1 Smart Meter Manager Device Description Tree (Detailed Set-up)
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Figure 3.2 Smart Meter Manager Device Description Tree (Detailed Set-up)
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* See Detailed Menu Listing, Figure 3.2 19
Figure 3.3 Smart Meter Manager LOl Main Menu
Figure 3.4 Smart Meter Manager LOl Basic Menu Listing
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c.Manual Programming or Reprogramming of the SMM electronics. If electronic parameters were not preprogrammed prior to shipment or new settings are required, programming of the SMM transmitter with or without alarms and pulse output may also be done locally via a Fisher-Rosemount Model 275 hand held Communicator. Refer to Figures 3.1 and 3.2 for Device Description Basic Setup and Detailed Description SetupTrees.
Figure 3.6 Typical HART Communicator Interface
The HART Communicator is the hand held interface that provides a common communication link to all HART compatible, microprocessor based devices. A keypad, liquid crystal display (LCD) and software menu structure make up the HART Communicator user interface. The Fisher Rosemount Model 275 is easy to use. Just press a few buttons to become familiar with the Action Keys and menu structure.
Fisher Rosemount Model 275 Communicator Functions Action Keys and Hot Key Six Action Keys promote easy navigation through the menu structure.You may customize the Hot Key to quickly access a menu of your most frequently performed on line tasks. The Hot Key Menu is a user definable menu containing one permanent option, Range Values. Range Values provides quick access to rearrange capability. Up to 19 frequently performed tasks can also be added to this menu. These tasks are stored even when the communicator is off, and are always readily available by simply pressing the Hot Key.
Figure 3.5 HART Communicator
Figure 3.7 HART Communicator Action/Hot Keys
Typical Connection Fisher Rosemount Model 275 Communicator Interface
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The HART Communicator interfaces with any HART instrument from any wiring termination point in a 4-20 mA loop, provided a minimum load resistance of 250 ohms is present between the HART Communicator and power supply. (An optional rugged 250 ohm resistor that attaches to the lead set is available from Fisher Rosemount. The resistor must be installed in series, not in parallel.
LCD The LCD is an eight line by twenty one character display that provides a window to all the functions of a HART compatible device. When connected to a HART compatible device, the top line of each menu displays the model name of the device and its tag. The bottom line of each menu is reserved for a dynamic label for each function key, F1 through F4. 21
b.Recalibration of Analog Transmitter Output (spanning high and low)
Figure 3.8 HART LCD
At any time after factory calibration, shipment, installation, or service, the SMM transmitter can be recalibrated by overwriting any of the previous calibration data, assuming that the user can provide a series of accurate rates of flow through the meter. If preferred, the meter with transmitter maybe returned for recalibration at the Brodie Meter Service Department for a fee. c. Basic Transmitter Setup Parameters Refer to Figures 3.1 and 3.2. These are meter identification parameters set prior to shipment of the meter.
Function Keys
Flowmeter Identification: Model Number, Serial Number, Tag Name
Use the four function keys, marked F1 through F4 located below the LCD to perform software functions as indicated by the dynamic labels. Different labels appear over the four function keys as you move among the various menus.
Flowmeter Configuration: Low Flow Cutoff, K factor, K factor Units of Measure, Flow Rate Units of Measure
On line Root Menu
Transmitter Analog Output: Analog Output HiRange (URV), Analog Output LoRange (LRV)
When connected to a HART compatible device, simply press the ON Key to display the On line Menu. This menu contains the most critical information about the connected device and your measurement including:
d. Optional Programmable Alarm and Pulse Output Parameters and Features Alarm Contact Output: HiLimit, LoLimit
• Model Number
One output is available for alarm signal(s). Contact output polarity is configurable as Normally Open (N.O.) or Normally Closed (N.C.). The alarm may be set at the minimum and maximum flow rate or at any other preferred high and low limits. The units of measure for the alarm limits 22 is the same units of measure as the process variable itself.
• User defined Tag Name • Flow Rate Units of Measure • Analog Output LoRange • Analog Output HiRange a. Simulation Mode The HART Communicator provides a mode that allows you to simulate an on line 22222222222222 connection to a specific HART compatible device.The simulation mode is a training tool that enables you to become familiar with a device before configuring it in a critical environment. Access to the simulation mode is through the utility menu. For more details and instructions on use of the Fisher Rosemount Model 275 Communicator please contact the Brodie Meter, LLC Service Department. 22
Computations: Totalization Totalizers are available in both Resettable and Inventory types. Resettable totalization is used for batching while inventory totalization measures the total volume over time. Units of measure are set independently for each of these options.
Pulse Output: Pulse Out Scaler, Pulse Out Width The SMM has a pulse output channel that indicates flow rate as a variable frequency and therefore can pass information to many types of external equipment such as batch controllers, automation systems or provers. The output pulse width default is 1 millisec but may be user configured since certain external receiving equipment cannot keep up with high incoming frequency. Low Flow Cutoff Warning for Pulse Output and Totalization The low flow cutoff parameter can be programmed to signal when the flow level is below which the process is intended. Below this level, the totalizer will assume that the flow rate is actually zero and that no data should be accumulated by the totalizers.
the defined’destination’ digital contact closure. Therefore the alarms may be managed according to local operating practices and the need to notify upstream control/safety systems.
An alarm may be posted at a designated destination only when the alarm situation is occurring or posted until the alarm is acknowledged by the operator. The decision to’latch or unlatch the alarm is controlled by setting the alarm type parameter. By utilizing this optional parameter, the operator can see that there is an alarm as it is occurring (unlatched) or even after the fact, in the case when the operator did not directly observe the unit alarm (latched).
Pulse Output Overrun Alarm If a larger than acceptable output pulse width is configured, totalizer pulses may be delayed or queued. No loss of pulses will occur. The totalizer output pulses will continue to be sent until the queue is empty. Under these circumstances, an alarm message will be sent to the control station. However, the alarm can be disabled if not required. Optional Alarm Configurations Enable, Destination, Alarm Type (Latching) Three additional parameters may be programmed for process and diagnostic alarms to control functionality-enable, destination, and alarm type (latching). Enable allows alarms to be enabled 23 and disabled depending on use of the alarm. For example, if output pulses are being used it may be normal practice to delay (e.g. queue up) output pulses because of a slow receiving end device that requires a wide pulse width. The enable’parameter allows the user to disable the pulse output overrun alarm and not send an alarm when in fact pulse outputs are delayed by choice. Some critical diagnostic alarms, such as database initialization, can not be disabled or turned off. When an alarm occurs, it can be posted through 23
The following are two examples of typical programming via a FisherRosemount Model 275 hand held communicator.
Note: Two Warnings will Typically appear. • Warning Pressing OK will change device output. Put loop in manual.
EXAMPLE 1: Programming Flow-Rate Units.
• Warning Return control loop to automatic control. Theses warnings confirm changes to the programming and alert the user to make changes in other related fields.
From the Root Menu, select Device Setup.
EXAMPLE 2: Programming Low Flow Cutoff. From the Device Setup Menu, select Detailed Setup.
From the Root Menu, select Device Setup.
From the Detailed Setup Menu, select Measurements.
From the Device Setup Menu, select Basic Setup.
From the Measurements Menu, select Flow.
From the Basic Setup Menu, selcet Meter Config.
From the Flow Menu, slect FlowRate Units of Measure 24242424242424 (FlowRate UOM).
In Flow, scroll through list optional units. Highlight the FlowRate UOM desired. Press ENTER (F4) to enter the new info, and press SEND (F2) to send the info to the transmitter.
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24 From the Meter Config. Menu, slect Cutoff.
Enter the Cuttoff value in Hz. Press ENTER (F4) to enter the new info, and press SEND (F2) to send the info to the transmitter.
Basic Meter Inspection Symptom: The fluid will not pass through the meter Possible Cause: Rotors jammed with scales or other foreign matter causing the rotors not to rotate.
4.0 Maintenance 4.1 General The 9900 Oval requires no routine maintenance, cleaning or lubricating. However, establish a schedule for periodic checking and cleaning of the strainer. The following items are manufacturer’s recommendations that apply to all flowmeters. Users must give careful consideration to the consequences that may result should the user fail to follow these recommendations.
A. Disassembly 1. Close off all valves and isolate the meter from line pressure and back pressure. 2. If used at elevated temperatures, reduce the temperature of the meter (including internals) to ambient.
Warning
a. No attempt should be made by the user to alter any physical dimension of the f lowmeter or component part.
Power to the generator must be turned off. Failure to heed this warning can result in serious personal injury and/or damage to the equipment.
b. Do not use excessive force in any assembly or disassembly procedure. All components are machined to exact tolerances. c. When an unserviceable flowmeter is returned to the factory for rework, it must be understood that in extreme cases, it may be economically impractical to repair the flowmeter.
Warning If the meter has been used for corrosives, toxins, or other hazardous liquids, follow the procedures outlined in Subpart 1, Sections 1910.132 through 1910.140 of the Occupational Safety and Health Standards, Federal Register No. 202 Pt. II 1, or subsequent changes thereto.
d. No attempt should be made by the user to replace the rotor bearings. Rotors and bearings are manufactured as a subassembly and are available as replacement or spare parts.
4.2 Disassembly and Assembly It is not normally necessary to remove the flowmeter from the line for disassembly.
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Warning Read the entire procedure for disassembly before making any attempt to disassemble the meter. Serious personal injury and/or damage to the meter could result if not properly handled.
3. Reduce the pressure inside the meter to zero by completely draining the part of the process line which is isolated with the meter. It is recommended that product be removed through the strainer, drain plug, of device other than the meter itself for this operation. If pressure must be reduced through the flowmeter, be very careful and slowly loosen the front cover fitting bolts until the meter begins to drain and pressure is reduced to zero. 4.Drain the flowmeter completely
Although it depends on individual operating conditions, periodic disassembly and inspection should be performed at least once a year. 25
Caution
Caution
Never use gripping tools on internal components of the measuring unit, for this can damage the unit.
Extreme caution should be taken as the crescent shaped pockets of the measuring chamber may still contain fluid. See WARNING above for reference source for handling hazardous liquids.
e. Wash clean the measuring chamber, rotors, and front cover assembly thoroughly with cleaning oil or other appropriate cleaning method.
Caution
B. Assembly As with most measurement instruments, the measuring internal components of the Oval flowmeter are critical for proper operation. The use of gripping tools on any internal component is discouraged, as damage to the measuring element could result. Care should be taken in handling all parts and subassemblies to avoid dropping or other potential hazards.
The assembly procedure is the reverse of the removal procedure. It is recommended that new O-rings be installed following each meter disassembly. 1.Orient the meter in such a way as to have the meter’s measuring chamber facing up and out. 2. Installation is correct if the side of the rotor with the embedded signal generating magnets faces you. With left to right flow, install the rotors such that the single match mark (on the first rotor) is above with the two match marks (on the second rotor) below it.
The meter’s measuring chamber can only be accessed from the front cover. It is not always necessary to remove the meter from the process line. If the flowmeter is to remain in the line, it is recommended that the flange connections (if equipped) be loosened and the meter rotated to the vertical position to accommodate servicing from the top by positioning the UMB in an upright position.
3. Check for proper rotor mesh and rotation by turning the rotors one or more complete revolutions. If the mesh is not properly aligned, disengage one rotor and rotate one tooth in either direction. Reengage and check for proper alignment. Continue this procedure until a proper alignment mesh is achieved which allows free rotation of the rotors.
a. Take off the four front cover fitting bolts while supporting the UMB and separate the front cover from the body
Caution
b. With the front cover and UMB removed, the measuring chamber is exposed and accessible for inspection and cleaning.
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c. Inspect rotors for jamming with foreign material, excessive wear on rotor or rotor 26262626262626 thrust bearing surfaces, shaft wear, and other noticeable measuring chamber damage or wear. d. DO NOT remove oval rotors from their shafts unless necessary, as rotor placement is critical to the timing of the rotors. If removal or replacement is required, note the timing marks on the face of each rotor and mark clearly.
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Incorrect rotor installation will result in poor or erratic signal generation. Ensure that the rotors are installed correctly as described above. 4. Place the O-ring into the groove in the meter body. Lightly lubricating the O-ring will assist in the assembly. 5. Carefully place the front cover with the UMB attached on the meter body. 6. Insert the screws and alternately draw the cover flush onto the meter body.
4.3 Removal of Smart Meter Manager
Warning The mating surfaces of the UMB housing constitute flame path areas. Do not mar or scratch these surfaces.
A. UMB Remove the 4 hex head socket screws that secure the UMB cover. Remove the cover. Remove the terminal blocks from the Smart Meter Manager. Remove the 2 screws that secure the SMM and pull it from the UMB.
4.4 Pickoff Removal/Installation Instructions A. Pickoff Removal 1. Disconnect the main power to the UMB, if supplied, and any conduit connections to the UMB housing. 2. Loosen the three set screws in the UMB housing and lift off the UMB. B. Pickoff Installation 1. Place the pickoff in the UMB housing, utilizing the locator pin. 2. Place the UMB on the meter flange making usre the location pin on the housing engages one of the slots in the meter flange. The location pin and slot prevents the pickoff from being improperly located.
Automatic diagnostics can trigger alarms indicating poor communications, memory integrity, or sensor problems. The user can define whether these malfunctions are serious and instruct how the 4-20 mA analog signal should be sent to a receiving device such as a DCS or PLC system. Some of the possible alarms that may occur are as follows: A. Power Failure Alarm The power failure alarm will occur when the current loop is broken and then restored. In this case, the transmitter will raise the power fail alarm to notify the user that there was a gap in data collection. The 4 20 mA loop provides all internal power for the SMM electronics. However, if power is lost, the setup parameters are internally stored in nonvolatile memory (lithium battery) and maintained in the event that external power is disconnected. B. Database initialization Alarm Occurs when the transmitter powers up and finds that the internal parameter database was not saved properly and must return parameters to default values. C. High Internal Temperature Alarm Occurs when the electronics unit exceeds designed functional limits (700C). D. Diagnostic Alarm Can occur due to internal test failures when checking RAM, AD conversion, database checksum error, etc.
3. Tighten the three set screws in the UMB 27 housing to prevent shifting and/or separation of the UMB from the meter.
4.5 Monitoring the Integrity of the SMM Electronics-Alarms As part of its normal operations, the SMM continuously monitors its own internal health. 27
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Brodie Meter Co., LLC 19267 Highway 301 North (30461) PO Box 450 Statesboro, GA 30459-0450
Phone: (912) 489-0200 Fax: (912) 489-0294 www.brodiemeter.com
The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. Brodie Meter Co., LLC reserves the right to modify or improve the designs or specifications of such products at any time without notice.
