Endress+Hauser Proline Prosonic Flow 91W Technical specifications

KA00049D/06/EN/14.12
71162949
Brief Operating Instructions
Proline Prosonic Flow 91W
Ultrasonic flow measuring system
6
These Brief Operating Instructions are not intended to replace the
Operating Instructions provided in the scope of supply.
Detailed information is provided in the Operating Instructions and
the additional documentation on the CD-ROM supplied.
The complete device documentation consists of:
•These Brief Operating Instructions
• Depending on the device version:
–Operating Instructions and the Description of Device Functions
–Approvals and safety certificates
–Special safety instructions in accordance with the approvals for
the device (e.g. explosion protection, pressure equipment
directive etc.)
–Additional device-specific information

Proline Prosonic Flow 91W
2Endress+Hauser
Table of contents
1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Installation, commissioning and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Operational safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Safety conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Installation conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Preparatory steps prior to installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Determining the necessary installation distances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4 Mounting the transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.5 Connecting the power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.6 Mechanical preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.7 Installing Prosonic Flow W sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.8 Post-installation check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3 Hardware and software settings . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4 Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.1 Sensor/transmitter connecting cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.2 Connecting the transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.3 Protective ground connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.4 Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.5 Post-connection check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.1 Switching on the measuring device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.3 Navigating within the function matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.4 Group Sensor Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Proline Prosonic Flow 91W Safety instructions
Endress+Hauser 3
1Safety instructions
1.1 Designated use
• The measuring device described in these Operating Instructions is to be used only for
measuring the flow rate of liquids in closed pipes, e.g.:
–Ultrapure water with low conductivity
–water, wastewater etc.
•As well as measuring the volume flow, the sound velocity of the fluid is also always measured.
Different fluids can be distinguished or the fluid quality can be monitored.
•Any use other than that described here compromises the safety of persons and the entire
measuring system and is, therefore, not permitted.
•The manufacturer is not liable for damage caused by improper or non-designated use.
1.2 Installation, commissioning and operation
•The measuring device must only be installed, connected, commissioned and maintained by
qualified and authorized specialists (e.g. electrical technicians) in full compliance with the
instructions in these Brief Operating Instructions, the applicable norms, legal regulations and
certificates (depending on the application).
•The specialists must have read and understood these Brief Operating Instructions and must
follow the instructions they contain. If you are unclear on anything in these Brief Operating
Instructions, you must read the Operating Instructions (on the CD-ROM). The Operating
Instructions provide detailed information on the measuring device.
•The measuring device may only be modified if such work is expressly permitted in the
Operating Instructions (on the CD-ROM).
•Repairs may only be performed if a genuine spare parts kit is available and this repair work is
expressly permitted.
•If performing welding work on the piping, the welding unit may not be grounded by means
of the measuring device.
1.3 Operational safety
•The measuring device is designed to meet state-of-the-art safety requirements, has been
tested, and left the factory in a condition in which it is safe to operate. Relevant regulations
and standards have been observed.
•The manufacturer reserves the right to modify technical data without prior notice. Your
Endress+Hauser distributor will supply you with current information and updates to these
Operating Instructions.
•The information on the warning notices, nameplates and connection diagrams affixed to the
device must be observed. These contain important data on the permitted operating conditions,
the range of application of the device and information on the materials used.
•If the device is not used at atmospheric temperatures, compliance with the relevant marginal
conditions as specified in the device documentation supplied (on CD-ROM) is mandatory.
•Observe the technical data on the nameplate.

Safety instructions Proline Prosonic Flow 91W
4Endress+Hauser
• The device must be wired as specified in the wiring and connection diagrams.
Interconnections must be permitted.
•All parts of the device must be included in the potential equalization of the system.
•Cables, certified cable glands and certified dummy plugs must be suitable to withstand the
prevailing operating conditions, (ambient temperature range, process conditions). 
Housing apertures that are not used must be sealed with certified dummy plugs.
• When hot fluids pass through the measuring tube, the surface temperature of the housing
increases. In the case of the sensor, in particular, users should expect temperatures that can
be close to the fluid temperature. If the temperature of the fluid is high, implement sufficient
measures to prevent burning or scalding.
•Hazardous areas
Measuring devices for use in hazardous areas are labeled accordingly on the nameplate.
Relevant national regulations must be observed when operating the device in hazardous areas.
The Ex documentation on the CD-ROM is an integral part of the entire device documentation.
The installation regulations, connection data and safety instructions provided in the 
Ex documentation must be observed. The symbol on the front page provides information on
the approval and certification body (0Europe, 2USA,
1Canada). The nameplate also
bears the documentation number of this Ex documentation (XA***D/../..).
• Endress+Hauser will be happy to assist in clarifying any questions on approvals, their
application and implementation.
1.4 Safety conventions
#Warning!
“Warning” indicates an action or procedure which, if not performed correctly, can result in
injury or a safety hazard. Comply strictly with the instructions and proceed with care.
"Caution!
“Caution” indicates an action or procedure which, if not performed correctly, can result in
incorrect operation or destruction of the device. Comply strictly with the instructions.
!Note!
"Note" indicates an action or procedure which, if not performed correctly, can have an indirect
effect on operation or trigger an unexpected response on the part of the device.

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2 Installation
2.1 Installation conditions
2.1.1 Dimensions
For the dimensions of the measuring device, see the associated Technical Information on the
CD-ROM.
Mounting location
Correct flow measurement is possible only if the pipe is full. Entrained air or gas forming in the
pipe can result in an increase in measuring errors. For this reason avoid the following mounting
locations in the pipe:
•Highest point of a pipeline. Risk of air accumulating.
•Directly upstream of a free pipe outlet in a vertical pipeline.
A0001103
Fig. 1: Mounting location
Down pipes
Notwithstanding the above, the installation proposal below permits installation in an open down
pipe. Pipe restrictions or the use of an orifice plate with a smaller cross-section than the nominal
diameter prevent the pipe from running empty while measurement is in progress.
Orientation
Vertical
Recommended orientation with upward direction of flow (View A). With this orientation,
entrained solids will sink and gases will rise away from the sensor when the fluid is stagnant.
The piping can be completely drained and protected against solids buildup.

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Horizontal
In the recommended installation range in a horizontal installation position (View B), gas and air
collections at the pipe cover and problematic deposits at the bottom of the pipe have a smaller
influence on measurement.
A0001105
Fig. 2: Orientation
A Recommended orientation with upward direction of flow
B Recommended installation range with horizontal orientation
C Recommended installation range max. 120°
A
B
CC

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Inlet and outlet runs
If possible, install the sensor well clear of fittings such as valves, T-pieces, elbows, etc. If several
flow obstructions are installed, the longest inlet or outlet run must be considered. Compliance
with the following inlet and outlet runs is recommended in order to ensure measuring accuracy.
A0013079
Fig. 3: Ein- und Auslaufstrecken (Draufsicht)
1 Valve (2/3 open)
2 Pump
3 Two pipe bends in different directions
2.2 Preparatory steps prior to installation
Depending on the conditions specific to the measuring point (e.g. Clamp On, number of
traverses, fluid etc.), a number of preparatory steps have to be taken before actually installing the
sensors:
1. Using the conditions specific to the measuring point, determine which installation
distances are necessary for installation.
2. Determine the values for the requisite installation distances.
A number of methods are available for determining the values:
–Local operation of the device
–FieldCare (operating program) procedure explained in the Operating Instructions on
the CD-ROM
–Applicator (software) procedure explained in the Operating Instructions on the
CD-ROM
3. Mechanical preparation of the "Clamp On" holders for the sensors:
– Premount the strapping bands (DN 50 to 200 / 2 to 8") or 
(DN 250 to 4000 / 10 to 160")
1
2
3
³15xDN ³3xDN
³20xDN
³15xDN
³20xDN

Installation Proline Prosonic Flow 91W
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2.3 Determining the necessary installation distances
The installation distances that are necessary for installation depend on:
•Insertion version: Clamp On with strapping band, installation in pipe
•Number of traverses or single-path/dual-path version
2.4 Mounting the transmitter
The transmitter can be mounted in the following ways:
• Wall mounting
•Pipe mounting (with separate mounting kit)
"Caution!
• The ambient temperature range (–25 to +60 °C / –13 to +140 °F) may not be exceeded at
the mounting location. Avoid direct sunlight.
•If a warm pipe is used for the installation, ensure that the housing temperature does not
exceed the max. permitted value of +60 °C (+140 °F).
a0005819
Fig. 4: Mounting the transmitter
A = Direct wall mounting, B = Pipe mounting
DN 50 to 4000 (2 to 160")
Clamp On (Strapping band)
1 traverse 2 traverses
SENSOR DISTANCE SENSOR DISTANCE
WIRE LENGTH POSITION SENSOR
190 (7.48)
Esc E
- +
A
Esc E
- +
B
80
(3.15)
172.5 (6.79)
&185 ( 3.34)
&
mm (inch)

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2.5 Connecting the power supply
#Warning!
Risk of electric shock. Components carry dangerous voltages.
•Never mount or wire the measuring device while it is connected to the power supply.
• Before connecting the power supply, check the safety equipment.
• Route the power supply cable so that it is seated securely.
• Seal the cable entries and covers tight.
• When wiring Ex-certified measuring devices, all the safety instructions, wiring diagrams,
technical information etc. of the related Ex documentation must be observed 
Ex documentation on the CD-ROM.
"Caution!
Risk of damaging the electronic components!
Connect the power supply in accordance with the connection data on the nameplate.
2.6 Mechanical preparation
The way in which the sensors are secured differs on account of the pipe nominal diameter and
the sensor type. Depending on the type of sensor, users also have the option of securing the
sensors with strapping bands or screws such that they can be later removed, or permanently
fixing the sensors in place with welded bolts or welded retainers.
Overview of possible ways to secure the various sensors:
2.6.1 Mounting the sensor holder with U-shaped screws (small nominal diameters)
For mounting on a pipe with a nominal diameter of DN 32 (1¼")
Sensors: Prosonic Flow (DN 15 to 65 / ½ to 2½")
1. Disconnect the sensor from the sensor holder.
2. Position the sensor holder on the pipe.
3. Put the U-shaped screws through the sensor holder and slightly lubricate the thread.
4. Screw nuts onto the U-shaped screws.
5. Set the holder to the exact position and tighten the nuts evenly.
Prosonic Flow Measuring range Pipe nominal diameter Secured by
91W DN 15 to 65 
(½ to 2½")
DN 32 (1¼") Sensor holder with U-shaped screws 
(small nominal diameters)

ä9
DN 32 (1¼") Sensor holder with strapping bands 
(small nominal diameters)

ä10
91W DN 50 to 4000 
(2 to 160")
DN 200 (8")
Strapping bands (medium nominal diameters) ä10
Welded bolts ä8
DN 200 (8")
Strapping bands (large nominal diameters) ä13
Welded bolts ä8

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#Warning!
Risk of damaging plastic or glass pipes if the nuts of the U-shaped screws are tightened too
much! The use of a metal half-shell is recommended (on the opposite side of the sensor)
when working with plastic or glass pipes.
6. The visible pipe surface "A" must be smooth to ensure good acustic contact.
A0011524
Fig. 5: Mounting the Prosonic Flow-sensor holder (DN 15 to 65 / ½ to 2½") with U-shaped screws
2.6.2 Mounting the sensor holder with strapping bands (small nominal diameters)
For mounting on a pipe with a nominal diameter of DN 32 (1¼")
For sensor (DN 15 to 65 / ½ to 2½")
1. Disconnect the sensor from the sensor holder.
2. Position the sensor holder on the pipe.
3. Wrap the strapping bands around the sensor holder and pipe without twisting them.
4. Guide the strapping bands through the strapping band locks (strapping screw is 
pushed up).
5. Tighten the strapping bands as tight as possible by hand.
6. Set the sensor holder to the correct position.
7. Push down the strapping screw and tighten the strapping bands so that they cannot slip.
8. Where necessary, shorten the strapping bands and trim the cut edges.
#Warning!
Risk of injury. To avoid sharp edges, trim the cut edges after shortening the strapping
bands.
9. The visible pipe surface "A" must be smooth to ensure good accustic contact.
A

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A0011525
Fig. 6: Positioning the sensor holder and mounting the strapping bands
A0011526
Fig. 7: Tightening the strapping screws of the strapping bands

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2.6.3 Premounting the strapping bands (medium nominal diameters)
When mounting on a pipe with a nominal diameter of DN 200 (8")
For sensor (DN 50 to 4000 / 2 to 160")
First strapping band
1. Fit the mounting bolt over the strapping band.
2. Wrap the strapping band around the pipe without twisting it.
3. Guide the end of the strapping band through the strapping band lock (strapping screw is
pushed up).
4. Tighten the strapping band as tight as possible by hand.
5. Set the strapping band to the desired position.
6. Push down the strapping screw and tighten the strapping band so that it cannot slip.
Second strapping band
7. Proceed as for the first strapping band (steps 1 to 7). Only slightly tighten the second
strapping band for final mounting. It must be possible to move the strapping band for final
alignment.
Both strapping bands
8. Where necessary, shorten the strapping bands and trim the cut edges.
#Warning!
Risk of injury. To avoid sharp edges, trim the cut edges after shortening the strapping
bands.
A0001109
Fig. 8: Premounting strapping bands for pipe diameters DN 200 (8")
1) Mounting bolt 2) Strapping band 3) Strapping screw
1
2
3

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2.6.4 Premounting the strapping bands (large nominal diameters)
When mounting on a pipe with a nominal diameter in the range of DN 600 (24")
For sensor (DN 50 to 4000 / 2 to 160")
1. Measure the pipe circumference.
2. Shorten the strapping bands to one length (pipe circumference +32 cm (12.6 in)) and trim
the cut edges.
#Warning!
Risk of injury. To avoid sharp edges, trim the cut edges after shortening the strapping bands.
First strapping band
3. Fit the mounting bolt over the strapping band.
4. Wrap the strapping band around the pipe without twisting it.
5. Guide the end of the strapping band through the strapping band lock (strapping screw is
ushed up).
6. Tighten the strapping band as tight as possible by hand.
7. Set the strapping band to the desired position.
8. Push down the strapping screw and tighten the strapping band so that it cannot slip.
Second strapping band
9. Proceed as for the first strapping band (steps 3 to 8). Only slightly tighten the second strapping
band for final mounting. It must be possible to move the strapping band for final alignment.
A0015461
Fig. 9: Premounting strapping bands for pipe diameters DN > 600 (24")
1) Mounting bolt with guide* 2) Strapping band* 3) Strapping screw
* Distance between mounting bolt and strapping band lock min 500 mm (20 in)
3.
³500 mm (20 in)

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2.7 Installing Prosonic Flow W sensor
2.7.1 Installing Prosonic Flow W (DN 15 to 65 / ½ to 2½")
Prerequisites
•The installation distance (sensor distance) is known ä8.
•The sensor holder is already mounted ä9.
Material
The following material is needed for mounting:
• Sensor incl. adapter cable
• Connecting cable for connecting to the transmitter
•Coupling fluid for an acoustic connection between the sensor and pipe
Procedure
1. Set the distance between the sensors as per the value determined for the sensor distance. 
Press the sensor down slightly to move it.
A0011529
Fig. 10: Setting the distance between the sensors as per the value for the sensor distance
a) Sensor distance b) Contact surface of the sensor
2. Coat the contact surfaces of the sensors with an even layer of coupling fluid 
(approx. 0.5 to 1 mm / 0.02 to 0.04 inch) thick.
3. Fit the sensor housing on the sensor holder.
a
b

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A0011527
Fig. 11: Fitting the sensor housing
4. Fix the sensor housing with the bracket.
!Hinweis!
–If necessary, the holder and sensor housing can be secured with a screw/nut or 
a lead-seal (not part of the scope of supply).
–The bracket can only be released using an auxiliary tool.
A0011528
Fig. 12: Fixing the sensor housing
5. Connect the connecting cable to the adapter cable.
This completes the mounting process. The sensors can now be connected to the transmitter via
the connecting cables ä23.

Installation Proline Prosonic Flow 91W
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2.7.2 Installing Prosonic Flow W (DN 50 to 400 0 / 2" to 160")
Installation for measurement via one traverse (DN 600 to 2000 /24" to 80")
Prerequisites
•The installation distances (sensor distance and wire length) are known ä8.
•The strapping bands are already mounted ä10.
Material
The following material is needed for mounting:
• Two strapping bands incl. mounting bolts and centering plates where necessary 
(already mounted ä10)
• Two measuring wires, each with a cable lug and a fixer to position the strapping bands
• Two sensor holders
• Coupling fluid for an acoustic connection between the sensor and pipe
•Two sensors incl. connecting cables.
Procedure
1. Prepare the two measuring wires:
–Arrange the cable lugs and fixer such that the distance they are apart corresponds to the
wire length (SL).
–Screw the fixer onto the measuring wire.
A0001112
Fig. 13: Fixer (a) and cable lugs (b) at a distance that corresponds to the wire length (SL)
2. With the first measuring wire:
–Fit the fixer over the mounting bolt of the strapping band that is already securely
mounted.
– Run the measuring wire clockwise around the pipe.
–Fit the cable lug over the mounting bolt of the strapping band that can still be moved.
3. With the second measuring wire:
–Fit the cable lug over the mounting bolt of the strapping band that is already securely
mounted.
– Run the measuring wire counterclockwise around the pipe.
–Fit the fixer over the mounting bolt of the strapping band that can still be moved.
1234567891011
SL

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4. Take the still movable strapping band, incl. the mounting bolt, and move it until both
measuring wires are evenly tensioned and tighten the strapping band so that it cannot slip.
A0001113
Fig. 14: Positioning the strapping bands (steps 2 to 4)
5. Loosen the screws of the fixers on the measuring wires and remove the measuring wires
from the mounting bolt.
6. Fit the sensor holders over the individual mounting bolts and tighten securely with the
retaining nut.
A0001114
Fig. 15: Mounting the sensor holders
7. Coat the contact surfaces of the sensors with an even layer of coupling fluid approx. 1 mm
(0.04 inch) thick, going from the groove through the center to the opposite edge.

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A0011373
Fig. 16: Coating the contact surfaces of the sensor with coupling fluid
8. Insert the sensor into the sensor holder.
9. Fit the sensor cover on the sensor holder and turn until:
–The sensor cover engages with a click
– The arrows (Å/ Æ "close") are pointing towards one another.
10. Screw the connecting cable into the individual sensor.
A0001115
Fig. 17: Mounting the sensor and connecting the connecting cable
This completes the mounting process. The sensors can now be connected to the transmitter via
the connecting cables ä9.

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Installation for measurement via two traverses (DN 50 to 600 /2" to 24")
Prerequisites
•The installation distance (position sensor) is known ä8.
•The strapping bands are already mounted ä10.
Material
The following material is needed for mounting:
•Two strapping bands incl. mounting bolts and centering plates where necessary 
(already mounted ä10)
• A mounting rail to position the strapping bands
• Two mounting rail retainers
• Two sensor holders
• Coupling fluid for an acoustic connection between the sensor and pipe
• Two sensors incl. connecting cables.
Mounting rail and POSITION SENSOR installation distance
The mounting rail has two rows with bores. The bores in one of the rows are indicated by letters
and the bores in the other row are indicated by numerical values. The value determined for the
POSITION SENSOR installation distance is made up of a letter and a numerical value.
The bores that are identified by the specific letter and numerical value are used to position the
strapping bands.
Procedure
1. Position the strapping bands with the aid of the mounting rail.
–Slide the mounting rail with the bore identified by the letter from POSITION SENSOR
over the mounting bolt of the strapping band that is permanently fixed in place.
–Position the movable strapping band and slide the mounting rail with the bore identified
by the numerical value from POSITION SENSOR over the mounting bolt.
A0001116
Fig. 18: Determining the distance in accordance with the mounting rail (e.g. POSITION SENSOR G22)
G
22

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2. Tighten the strapping band so that it cannot slip.
3. Remove the mounting rail from the mounting bolt.
4. Fit the sensor holders over the individual mounting bolts and tighten securely with the
retaining nut.
A0001117
Fig. 19: Mounting the sensor
5. Coat the contact surfaces of the sensors with an even layer of coupling fluid approx. 1 mm
(0.04") thick, going from the groove through the center to the opposite edge.
A0011373
Fig. 20: Coating the contact surfaces of the sensor with coupling fluid
6. Insert the sensor into the sensor holder.
7. Fit the sensor cover on the sensor holder and turn until:
–The sensor cover engages with a click
– The arrows (Å/ Æ "close") are pointing towards one another.
8. Screw the connecting cable into the individual sensor.