ABB SwirlMaster FSS430 Training manual

Commissioning and Safety Instruction CI/FSS/FSV430/450-EN Rev. D
SwirlMaster FSS430, FSS450 VortexMaster FSV430, FSV450
Vortex & Swirl Flowmeter
Measurement made easy

2 CI/FSS/FSV430/450-EN Rev. D | SwirlMaster FSS430, FSS450 VortexMaster FSV430, FSV450
Short product description
V
ortex & Swirl Flowmeter for flow measurement of liquid and
gaseous measuring media.
Devices firmware version: 01.00.00
Further information
A
dditional documentation on SwirlMaster FSS430, FSS450
V
ortexMaster FSV430, FSV450 is available for download free
of charge at www.abb.com/flow.
A
lternatively simply scan these codes:
FSV430 FSV450 FSS430 FSS450
Manufacturer
A
BB Automation Products GmbH
Process Automation
Dransfelder Str. 2
37079 Göttingen
Germany
Tel: [phone]
Fax: [phone]
Customer service center
Tel.: [phone]
Fax: [phone]-29031
[email protected]
A
BB Inc.
Process Automation
125 E. County Line Road
Warminster, PA 18974
USA
Tel.: [phone]
Fax: [phone]
A
BB Engineering (Shanghai) Ltd.
Process Automation
No. 4528, Kangxin Highway,
Pudong New District
Shanghai, 201319, P.R. China
Tel.: [phone]
Fax: [phone]
[email protected]

SwirlMaster FSS430, FSS450 VortexMaster FSV430, FSV450 | CI/FSS/FSV430/450-EN Rev. D 3
Contents
1Safety............................................................................... 4
1.1General information and instructions .................... 4
1.2Warnings ............................................................. 4
1.3Intended use........................................................ 4
1.4Improper use ....................................................... 4
2Use in potentially explosive atmospheres ..................... 5
2.1Obligations of the owner ...................................... 5
2.1.1ATEX, IECEx, NEPSI ............................................ 5
2.1.2FM, CSA.............................................................. 5
2.2Zone 2, 22 - type of protection "non-sparking"..... 5
2.2.1Ex-marking .......................................................... 5
2.2.2Electrical data ...................................................... 6
2.2.3Temperature data ................................................ 6
2.3Zone 0, 1, 20, 21 - type of protection "intrinsically
safe".................................................................... 7
2.3.1Ex-marking .......................................................... 7
2.3.2Electrical and temperature data............................ 8
2.3.3Limit value tables ................................................. 9
2.4Zone 1, 21 - type of protection "flameproof
(enclosure)"........................................................ 12
2.4.1Ex-marking ........................................................ 12
2.4.2Electrical and temperature data.......................... 12
2.5Temperature resistance for the connecting cables
.......................................................................... 13
3Product identification.................................................... 14
3.1Name plate........................................................ 14
4Transport and storage .................................................. 15
4.1Inspection.......................................................... 15
4.2Transport........................................................... 15
4.3Storing the device.............................................. 15
4.3.1Ambient conditions ............................................ 15
4.4Returning devices .............................................. 15
5Installation ..................................................................... 16
5.1Installation conditions......................................... 16
5.1.1General information............................................ 16
5.1.2Inlet and outlet sections ..................................... 16
5.1.3Installation at high measuring medium temperatures
.......................................................................... 17
5.1.4Installation for external pressure and temperature
measurement .................................................... 18
5.1.5Installation of final controlling equipment ............ 18
5.1.6Sensor insulation ............................................... 18
5.1.7Use of trace heating........................................... 18
5.2Installing the sensor ........................................... 19
5.2.1Centering the wafer type design......................... 19
5.2.2Adjusting the transmitter position ....................... 20
5.3Electrical connections ........................................ 21
5.3.1Cable entries ..................................................... 21
5.3.2Earthing............................................................. 22
5.3.3Electrical connection.......................................... 22
5.4Connection examples ........................................ 23
5.4.1Electrical data for inputs and outputs ................. 24
5.4.2Connection to remote mount design .................. 26
5.4.3Cutting the signal cable to length and terminating it
.......................................................................... 26
5.4.4Connecting the signal cable ............................... 26
6Commissioning.............................................................. 27
6.1Safety instructions.............................................. 27
6.2Checks prior to commissioning .......................... 27
6.2.1Configuration of the outputs............................... 28
6.3Checking and configuring the basic settings....... 29
6.3.1Parameterization via the "Easy Setup" menu
function ............................................................. 29
6.4Operating mode................................................. 32
6.5Special operating modes ................................... 37
6.5.1Measuring the energy of steam .......................... 37
6.5.2Measuring the energy of liquids.......................... 37
7Operation....................................................................... 38
7.1Safety instructions.............................................. 38
7.2Parameterization of the device ........................... 38
7.2.1Menu navigation ................................................ 38
7.3Menu levels........................................................ 39
7.3.1Process display.................................................. 40
7.3.2Switching to the information level (operator menu)40
7.3.3Error messages on the LCD display ................... 41
7.3.4Parameter overview ........................................... 42
8Appendix ....................................................................... 48
8.1Declarations of conformity.................................. 48

4 CI/FSS/FSV430/450-EN Rev. D | SwirlMaster FSS430, FSS450 VortexMaster FSV430, FSV450
1Safety
1.1 General information and instructions
These instructions are an important part of the product and
must be retained for future reference.
Installation, commissioning, and maintenance of the product
may only be performed by trained specialist personnel who
have been authorized by the plant operator accordingly. The
specialist personnel must have read and understood the
manual and must comply with its instructions.
For additional information or if specific problems occur that are
not discussed in these instructions, contact the manufacturer.
The content of these instructions is neither part of nor an
amendment to any previous or existing agreement, promise or
legal relationship.
Modifications and repairs to the product may only be
performed if expressly permitted by these instructions.
Information and symbols on the product must be observed.
These may not be removed and must be fully legible at all
times.
The operating company must strictly observe the applicable
national regulations relating to the installation, function testing,
repair and maintenance of electrical products.
1.2 Warnings
The warnings in these instructions are structured as follows:
DANGER
The signal word "DANGER" indicates an imminent danger.
Failure to observe this information will result in death or
severe injury.
WARNING
The signal word "WARNING" indicates an imminent danger.
Failure to observe this information may result in death or
severe injury.
CAUTION
The signal word "CAUTION" indicates an imminent danger.
Failure to observe this information may result in minor or
moderate injury.
NOTE
The signal word "NOTE" indicates useful or important
information about the product.
The signal word "NOTE" is not a signal word indicating a
danger to personnel. The signal word "NOTE" can also refer
to material damage.
1.3 Intended use
This device is intended for the following uses:
— For conveying liquid and gaseous media (including
unstable liquids and gases)
— For measuring the volume flow (directly by calculating the
pressure / temperature effect)
— For measuring the mass flow (indirectly via volume flow,
pressure / temperature and density)
— For measuring the energy flow (indirectly via volume flow,
pressure / temperature and density)
— For measuring the temperature of the medium
The device has been designed for use exclusively within the
technical limit values indicated on the identification plate and
in the data sheets.
When using media for measurement the following points must
be observed:
— Measuring media may only be used if, based on the state
of the art or the operating experience of the user, it can be
assured that the chemical and physical properties
necessary for safe operation of the materials of transmitter
components coming into contact with these will not be
adversely affected during the operating period.
— Media containing chloride in particular can cause
corrosion damage to stainless steels which, although not
visible externally, can damage wetted parts beyond repair
and lead to the measuring medium escaping. It is the
operator's responsibility to check the suitability of these
materials for the respective application.
— Measuring media with unknown properties or abrasive
measuring media may only be used if the operator can
perform regular and suitable tests to ensure the safe
condition of the meter.
1.4 Improper use
The following are considered to be instances of improper use
of the device:
— For operating as a flexible adapter in piping, e.g. for
compensating pipe offsets, pipe vibrations, pipe
expansions, etc.
— For use as a climbing aid, e.g. for mounting purposes
— For use as a support for external loads, e.g. as a support
for piping, etc.
— Material application, e.g. by painting over the name plate
or welding/soldering on parts
— Material removal, e.g. by spot drilling the housing

SwirlMaster FSS430, FSS450 VortexMaster FSV430, FSV450 | CI/FSS/FSV430/450-EN Rev. D 5
2Use in potentially explosive
atmospheres
DANGER
Danger of explosion if the device is operated with the
transmitter housing or terminal box open!
Before opening the transmitter housing or the terminal box,
note the following points:
— Check that a valid fire permit is available.
— Make sure that there is no explosion hazard.
— Before opening the device, switch off the power supply
and wait for t > 2 minutes.
2.1 Obligations of the owner
2.1.1 ATEX, IECEx, NEPSI
The installation, commissioning, maintenance and repair of
devices in areas with explosion hazard must only be carried
out by appropriately trained personnel.
When operating the meter in the presence of combustible
dusts, IEC 61241 ff must be complied with.
The safety instructions for electrical apparatus in potentially
explosive areas must be complied with, in accordance with
Directive 94/9/EC (ATEX) and IEC60079-14 (Installation of
electrical equipment in potentially explosive areas).
To ensure safe operation, the requirements of EU Directive
ATEX 118a (minimum requirements concerning the protection
of workers) must be met.
2.1.2 FM, CSA
The installation, commissioning, maintenance and repair of
devices in areas with explosion hazard must only be carried
out by appropriately trained personnel.
The operator must strictly observe the applicable national
regulations with regard to installation, function tests, repairs,
and maintenance of electrical devices. (e.g. NEC, CEC).
2.2 Zone 2, 22 - type of protection "non-sparking"
2.2.1 Ex-marking
ATEX
Order code B1
Type examination certificate FM13ATEX0056X
II 3G Ex nA IIC T4 to T6 Gc
II 3 D Ex tc IIIC T85 °C DC
For electrical parameters, see certificate FM13ATEX0056X
IECEx
Order code N1
Certificate of conformity IECEx FME 13.0004X
Ex nA IIC T4 to T6 Gc
Ex tc IIIC T85 °C DC
For electrical parameters, see certification IECEx FME 13.0004X
FM approval for USA and Canada
Order code F3
CL I, ZONE 2 AEx/Ex nA IIC T6, T5, T4
CL I/DIV 2/GP ABCD
NI CL 1/DIV 2/GP ABCD, DIP CL II,III/DIV 2/GP EFG
Housing: TYPE 4X
NEPSI
Order code S2
Ex nA IIC T4 to T6 Gc
DIP A22 Ta 85 °C
For electrical parameters, see certificate GYJ14.1088X
Power supply
Ex nA UB= 12 ... 42 V DC
Switch output
The switch output is designed as an optoelectronic coupler or
a NAMUR contact (in accordance with DIN 19234).
— When the NAMUR contact is closed, the internal
resistance is approx. 1000 Ω.
— When the contact is open, the internal resistance is
> 10 kΩ.
The switch output can be changed over to "optoelectronic
coupler" if required.
— NAMUR with switching amplifier
— Switch output
Ex nA: UB= 16 ... 30 V, IB= 2 ... 30 mA

6 CI/FSS/FSV430/450-EN Rev. D | SwirlMaster FSS430, FSS450 VortexMaster FSV430, FSV450
2.2.2 Electrical data
Fig. 1: Power supply in Zone 2, explosion protection, non-sparking
The minimum voltage USof 12 V is based on a load of 0 Ω.
USSupply voltage
RBMaximum permissible load in the power supply circuit,
e.g. indicator, recorder or power resistor.
Power supply / current output / HART output
Terminals PWR/COMM + / PWR/COMM -
UM45 V
Zone 2: Ex nA IIC T4 to T6 Gc
Tamb = -40 ... 85 °C*
Zone 22 Ex tc IIIC T85 °C Dc
Tamb = -40 ... 75 °C
CL I, ZONE 2 AEx/Ex nA IIC T6, T5, T4
CL I/DIV 2/GP ABCD TYPE 4X
NI CL 1/DIV 2/GP ABCD, DIP CL II,III/DIV 2/GP EFG
Housing: TYPE 4X
Digital output
Terminals DIGITAL OUTPUT 1+ / DIGITAL OUTPUT 4-
UM45 V
Zone 2: Ex nA IIC T4 to T6 Gc
Zone 22 Ex tc IIIC T85 °C Dc
Tamb = -40 ... 75 °C 1)
CL I, ZONE 2 AEx/Ex nA IIC T6, T5, T4
CL I/DIV 2/GP ABCD TYPE 4X
NI CL 1/DIV 2/GP ABCD, DIP CL II,III/DIV 2/GP EFG
1) See temperature ranges in the chapter titled „Temperature data“ on page 6.
Analog input
Terminals ANALOG INPUT + / ANALOG INPUT -
UM45 V
Zone 2: Ex nA IIC T4 to T6 Gc
Zone 22 Ex tc IIIC T85 °C Dc
Tamb = -40 ... 85 °C
CL I, ZONE 2 AEx/Ex nA IIC T6, T5, T4
CL I/DIV 2/GP ABCD TYPE 4X
NI CL 1/DIV 2/GP ABCD, DIP CL II,III/DIV 2/GP EFG
Special Requirements
The devices must be installed in a protected environment in
accordance with the specific conditions on the test certificate.
Pollution degree 3 (see IEC 60664-1) must not be exceeded
for the macro environment of the device.
The devices are in accordance with the IP rating IP66 / IP67. If
the device is installed correctly, this requirement is met
by the housing as standard.
When connected to the power supply / not connected to the
power supply, the electrical circuits must not exceed
overvoltage category III / II.
2.2.3 Temperature data
Operating temperature ranges:
— The ambient temperature range Tamb. is -40 ... 85 °C (-40
... 185 °F).
— This is dependent on the temperature class and
measuring medium temperature, as listed in the following
tables.
— The measuring medium temperature Tmedium
is -200 ... 400 °C (-328 ... 752 °F).
Without LCD indicator
Temperature class Tamb. max. Tmedium max.
T4 ≤ 85 °C 90 °C
≤ 82 °C 180 °C
≤ 81 °C 280 °C
≤ 79 °C 400 °C
T4 ≤ 70 °C 90 °C
≤ 67 °C 180 °C
≤ 66 °C 280 °C
≤ 64 °C 400 °C
T5 ≤ 56 °C 90 °C
≤ 53 °C 180 °C
≤ 52 °C 280 °C
≤ 50 °C 400 °C
T6 ≤ 44 °C 90 °C
≤ 41 °C 180 °C
≤ 40 °C 280 °C
≤ 38 °C 400 °C
G11784
10
0
0,2
0,4
0,6
0,8
0,9
1,0
1,2
1,4
1,6
1,8
12
Ex nA / NI
U [V]
S
R[k] B Ω
30 40 42 50
20
Ex A /iIS

SwirlMaster FSS430, FSS450 VortexMaster FSV430, FSV450 | CI/FSS/FSV430/450-EN Rev. D 7
With LCD indicator, order code L1
Temperature class Tamb. max. Tmedium max.
T4 ≤ 85 °C 90 °C
≤ 82 °C 180 °C
≤ 81 °C 280 °C
≤ 79 °C 400 °C
T4 ≤ 70 °C 90 °C
≤ 67 °C 180 °C
≤ 66 °C 280 °C
≤ 64 °C 400 °C
T5 ≤ 40 °C 90 °C
≤ 37 °C 180 °C
≤ 36 °C 280 °C
≤ 34 °C 400 °C
T6 ≤ 40 °C 90 °C
≤ 37 °C 180 °C
≤ 36 °C 280 °C
≤ 34 °C 400 °C
With LCD indicator, order code L2 (operation through the
front glass)
Temperature class Tamb. max. Tmedium max.
T4 ≤ 60 °C 90 °C
≤ 57 °C 180 °C
≤ 56 °C 280 °C
≤ 54 °C 400 °C
T4 ≤ 60 °C 90 °C
≤ 57 °C 180 °C
≤ 56 °C 280 °C
≤ 54 °C 400 °C
T5 ≤ 56 °C 90 °C
≤ 53 °C 180 °C
≤ 52 °C 280 °C
≤ 50 °C 400 °C
T6 ≤ 44 °C 90 °C
≤ 41 °C 180 °C
≤ 40 °C 280 °C
≤ 38 °C 400 °C
2.3 Zone 0, 1, 20, 21 - type of protection "intrinsically
safe"
2.3.1 Ex-marking
ATEX
Order code A4
Type examination certificate FM13ATEX0055X
II 1 G Ex ia IIC T4 to T6 Ga
II 1 D Ex ia IIIC T85 °C
For electrical parameters, see certificate FM13ATEX0055X
IECEx
Order code N2
Certificate of conformity IECEx FME 13.0004X
Ex ia IIC T4 to T6 Ga
Ex ia IIIC T85 °C
For electrical parameters, see certificate IECEx FME 13.0004X
FM approval for USA and Canada
Order code F4
IS/S. Intrinseque(Entity) CL I,
Zone 0 AEx/Ex ia IIC T6, T5, T4
Cl I/Div 1/ABCD IS-CL II, III/DIV 1/EFG TYPE 4X
IS Control Drawing: 3KXF065215U0109
NEPSI
Order code S6
Ex ia IIC T4 to T6 Ga
Ex iaD 20 T85 °C
For electrical parameters, see certificate GYJ14.1088X
Power supply
Ex ia: Ui= 30 V DC
Switch output
The switch output is designed as an optoelectronic coupler or
a NAMUR contact (in accordance with DIN 19234).
— When the NAMUR contact is closed, the internal
resistance is approx. 1000 Ω.
— When the contact is open, the internal resistance is
> 10 kΩ.
The switch output can be changed over to "optoelectronic
coupler" if required.
— NAMUR with switching amplifier
— Switch output:
Ex ia: Ui= 30 V DC

8 CI/FSS/FSV430/450-EN Rev. D | SwirlMaster FSS430, FSS450 VortexMaster FSV430, FSV450
2.3.2 Electrical and temperature data
Fig. 2: Power supply in Zone 2, explosion protection, intrinsic
safety
The minimum voltage USof 12 V is based on a load of 0 Ω.
USSupply voltage
RBMaximum permissible load in the power supply circuit,
e.g. indicator, recorder or power resistor.
Power supply / current output / HART output
Terminals PWR/COMM + / PWR/COMM -
Zone 0: Ex ia IIC T4 to T6 Ga
Tamb = -40 ... 85 °C 1)
Umax 30 V
Imax See the chapter titled „Limit value tables“ on page
9
Pi
Ci— 13 nF for indicator option L1
— 17 nF for all other options
Li10 μH
Zone 20: Ex ia IIIC T85 °C
Tamb = -40 ... 85 °C 1)
IS/S. Intrinseque (Entity) CL I,
Zone 0 AEx/Ex ia IIC T6, T5, T4
Cl I/Div 1/ABCD IS-CL II, III/DIV 1/EFG TYPE 4X
IS Control Drawing: 3KXF065215U0109
1) See temperature ranges in the chapter titled „Limit value tables“ on page 9.
Digital output
Terminals DIGITAL OUTPUT 1+ / DIGITAL OUTPUT 4-
Zone 0: Ex ia IIC T4 to T6 Ga
Umax 30 V
Imax 30 mA
Ci7 nF
Li0 mH
Zone 20: Ex ia IIIC T85 °C
Tamb = -40 ... 85 °C 1)
IS/S. Intrinseque (Entity) CL I,
Zone 0 AEx/Ex ia IIC T6, T5, T4
Cl I/Div 1/ABCD IS-CL II, III/DIV 1/EFG TYPE 4X
IS Control Drawing: 3KXF065215U0109
Analog input
Terminals ANALOG INPUT + / ANALOG INPUT -
Zone 0: Ex ia IIC T4 to T6 Ga
Umax See the chapter titled „Limit value tables“ on page
9
Imax
Ci7 nF
Li0 mH
Zone 20: Ex ia IIIC T85 °C
Tamb = -40 ... 85 °C 1)
IS/S. Intrinseque (Entity) CL I,
Zone 0 AEx/Ex ia IIC T6, T5, T4
Cl I/Div 1/ABCD IS-CL II, III/DIV 1/EFG TYPE 4X
IS Control Drawing: 3KXF065215U0109
1) See temperature ranges in the chapter titled „Limit value tables“ on page 9.
Special Requirements
The devices must be installed in a protected environment in
accordance with the specific conditions on the test certificate.
Pollution degree 3 (see IEC 60664-1) must not be exceeded
for the macro environment of the device.
The devices are in accordance with the IP rating IP66 / IP67. If
the device is installed correctly, this requirement is met
by the housing as standard.
When connected to the power supply / not connected to the
power supply, the electrical circuits must not exceed
overvoltage category III / II.
For input limits or analog input limits, see the chapter titled
„Limit value tables“ on page 9.
G11784
10
0
0,2
0,4
0,6
0,8
0,9
1,0
1,2
1,4
1,6
1,8
12
Ex nA / NI
U [V]
S
R[k] B Ω
30 40 42 50
20
Ex A /iIS

SwirlMaster FSS430, FSS450 VortexMaster FSV430, FSV450 | CI/FSS/FSV430/450-EN Rev. D 9
Change from tw o to one column
2.3.3 Limit value tables
Operating temperature ranges:
— The ambient temperature range Tamb of the devices is -40 ... 85 °C.
— The measuring medium temperature range Tmedium is -200 ... 400 °C.
Devices without LCD indicator
Power supply, current / HART output, analog input
Temperature class Tamb max. Tmedium max. Umax I
max P imax
T4 ≤ 85 °C 90 °C 30 V 100 mA 0.75 W
≤ 82 °C 180 °C
≤ 81 °C 280 °C
≤ 79 °C 400 °C
T4 ≤ 70 °C 90 °C 30 V 160 mA 1.0 W
≤ 67 °C 180 °C
≤ 66 °C 280 °C
≤ 64 °C 400 °C
T5 ≤ 56 °C 90 °C 30 V 100 mA 1.4 W
≤ 53 °C 180 °C
≤ 52 °C 280 °C
≤ 50 °C 400 °C
T6 ≤ 44 °C 90 °C 30 V 50 mA 0.4 W
≤ 41 °C 180 °C
≤ 40 °C 280 °C
≤ 38 °C 400 °C
Digital output
Temperature class Tamb max. Tmedium max. Umax I
max P imax
T4 ≤ 85 °C 90 °C 30 V 30 mA 1.0 W
≤ 82 °C 180 °C
≤ 81 °C 280 °C
≤ 79 °C 400 °C
T4 ≤ 70 °C 90 °C 30 V 30 mA 1.0 W
≤ 67 °C 180 °C
≤ 66 °C 280 °C
≤ 64 °C 400 °C
T5 ≤ 56 °C 90 °C 30 V 30 mA 1.0 W
≤ 53 °C 180 °C
≤ 52 °C 280 °C
≤ 50 °C 400 °C
T6 ≤ 44 °C 90 °C 30 V 30 mA 1.0 W
≤ 41 °C 180 °C
≤ 40 °C 280 °C
≤ 38 °C 400 °C

10 CI/FSS/FSV430/450-EN Rev. D | SwirlMaster FSS430, FSS450 VortexMaster FSV430, FSV450
Devices with LCD indicator, order code L1
Power supply, current / HART output, analog input
Temperature class Tamb max. Tmedium max. Umax I
max P imax
T4 ≤ 85 °C 90 °C 30 V 100 mA 0.75 W
≤ 82 °C 180 °C
≤ 81 °C 280 °C
≤ 79 °C 400 °C
T4 ≤ 70 °C 90 °C 30 V 160 mA 1.0 W
≤ 67 °C 180 °C
≤ 66 °C 280 °C
≤ 64 °C 400 °C
T5 ≤ 40 °C 90 °C 30 V 100 mA 1.4 W
≤ 37 °C 180 °C
≤ 36 °C 280 °C
≤ 34 °C 400 °C
T6 ≤ 40 °C 90 °C 30 V 50 mA 0.4 W
≤ 37 °C 180 °C
≤ 36 °C 280 °C
≤ 34 °C 400 °C
Digital output
Temperature class Tamb max. Tmedium max. Umax I
max P imax
T4 ≤ 85 °C 90 °C 30 V 30 mA 1.0 W
≤ 82 °C 180 °C
≤ 81 °C 280 °C
≤ 79 °C 400 °C
T4 ≤ 70 °C 90 °C 30 V 30 mA 1.0 W
≤ 67 °C 180 °C
≤ 66 °C 280 °C
≤ 64 °C 400 °C
T5 ≤ 40 °C 90 °C 30 V 30 mA 1.0 W
≤ 37 °C 180 °C
≤ 36 °C 280 °C
≤ 34 °C 400 °C
T6 ≤ 40 °C 90 °C 30 V 30 mA 1.0 W
≤ 37 °C 180 °C
≤ 36 °C 280 °C
≤ 34 °C 400 °C