Endress+Hauser prowirl 77 User manual

prowirl 77
Vortex Flow Measuring
System
(PROFIBUS-PA)
Operating Manual
Hauser+Endress
The Power of Know How
BA 037D/06/en/03.00
No. 50090715
CV 5.0
valid as of software version
PW77 PA V1.00.XX


Prowirl 77 PROFIBUS-PA
2 Endress+Hauser

Contents
1 Safety Instructions . . . . . . . . 5
1.1 Correct usage . . . . . . . . . . . 5
1.2 Dangers and Notes . . . . . . . . . 5
1.3 Operational safety . . . . . . . . . . 5
1.4 Personnel for Installation, Start-up and
Operation . . . . . . . . . . . . . 6
1.5 Repairs, Dangerous Chemicals . . . . . 6
1.6 Technical Improvements . . . . . . . 6
2 System Description . . . . . . . 7
2.1 Prowirl 77 Measuring System . . . . . 7
3 Mounting and Installation . . . . 9
3.1 General Information . . . . . . . . . 9
3.2 Installation . . . . . . . . . . . . . 10
3.3 Mounting the Flowmeter . . . . . . . 13
3.4 Rotating the electronics housing . . . . 14
4 Electrical Connection . . . . . 15
4.1 Connecting the Transmitter . . . . . . 15
4.2 Wiring Diagram . . . . . . . . . . . 15
5 Communication . . . . . . . . 17
5.1 PROFIBUS-PA interface . . . . . . . 17
5.2 Configuration of Device Address . . . . 18
5.3 System integration . . . . . . . . . . 19
5.4 Cyclic Data Transfer (Data_Exchange) . . 20
5.5 Acyclic Data Transfer . . . . . . . . 23
5.6 Prowirl 77 Slot / Index list . . . . . . . 24
5.7 Operation . . . . . . . . . . . . . 27
6 Device Functions . . . . . . . 29
6.1 Commuwin II operating matrix . . . . . 29
6.2 Functions descriptions . . . . . . . . 33
7 Trouble-shooting . . . . . . . 45
8 Dimensions and Weights . . . . 49
8.1 Dimensions Prowirl 77 W . . . . . . . 49
8.2 Dimensions Prowirl 77 F . . . . . . . 50
8.3 Dimensions Prowirl 77 H . . . . . . . 52
8.4 Dimensions Flow Conditioner (DIN) . . . 53
8.5 Dimensions Flow Conditioner (ANSI) . . 54
9 Technical Data . . . . . . . . 55
9.1 Measuring Ranges (Sensor) . . . . . . 60
10 Index . . . . . . . . . . . . 61
Prowirl 77 PROFIBUS-PA
Endress+Hauser 3

Registered Trademarks
PROFIBUS®
Registered trademark of PROFIBUS Trade Organization PTO, Karlsruhe, Germany
HART®
Registered trademark of the HART Communication Foundation, Austin, USA
KALREZ®, VITON®
Registered trademarks of E.I. Du Pont de Nemours & Co., Wilmington, USA
GYLON®
Registered trademark of Garlock Sealing Technologies, Palmyra, NY, USA
INCONEL®
Registered trademark of Inco Alloys International, Inc., Huntington, USA
Prowirl 77 PROFIBUS-PA
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1 Safety Instructions
1.1 Correct usage
•Prowirl 77 is only to be used for measuring the volumentric flowrate of saturated
steam, superheated steam, gases and liquids. If the process pressure and
temperature are constant, then Prowirl 77 can also indicate the flowrate in units of
mass, energy or corrected volume.
•The manufacturer assumes no liability for damage caused by incorrect use of the
instrument.
•Instruments which are ordered with hazardous area approvals are supplied with a
separate “Ex documentation”, which is an integral part of this Operating Manual.
The instructions and connected loads provided in this supplement must be closely
observed! An appropriate pictogram is shown on the front page of the
Ex documentation according to the approval given and the test centre.
1.2 Dangers and Notes
All instruments are designed to meet state-of-the-art safety requirements, have been
tested, and have left the works in an operationally perfectly safe condition.
The devices were developed according to EN 61010 “Protection Measures for
Electrical Equipment for Measurement, Control, Regulation and Laboratory Proce-
dures”. A hazardous situation may occur if the flowmeter is not used for the purpose it
was designed for or is used incorrectly. Please carefully note the information
provided in this Operating Manual indicated by the pictograms:
Warning!
A “warning” indicates actions or procedures which, if not performed correctly, may
lead to personal injury or a safety hazard.
Please strictly observe the instructions supplied and proceed carefully.
Caution!
A “caution” indicates actions or procedures which, if not performed correctly, may
lead to faulty operation or destruction of the instrument. Please strictly observe the
respective instructions.
Note!
A “note” indicates actions or procedures which, if not performed correctly, may indi-
rectly affect operation or lead to an unexpected instrument response.
1.3 Operational safety
•The Prowirl 77 measuring system fulfills the general safety regulations according to
EN 61010 and the interference immunity regulations (EMC) according to European
standard EN 50081 Part 1 and 2 / EN 50082 Part 1 and 2 as well as NAMUR recom-
mendations.
•Housing ingress protection IP 67 according to EN 60529.
•A comprehensive self-monitoring feature of the measuring system ensures high
operational safety.
•After loss of power supply (which is provided by the field bus), the configuration
data of the measuring system remain in the EEPROM (without batteries).
The totalizer remains on the value last shown.
Warning!
Caution!
Note!
Prowirl 77 PROFIBUS-PA 1 Safety Instructions
Endress+Hauser 5

1.4 Personnel for Installation, Start-up and Operation
•Mounting, electrical installation, start-up and maintenance of the instrument may
only be carried out by trained personnel authorised by the operator of the facility.
Personnel must absolutely and without fail read and understand this Operating
Manual before carrying out its instructions.
•The instrument may only be operated by personnel who are authorised and trained
by the operator of the facility. All instructions in this manual are to be observed
without fail.
•In case of corrosive fluids, the compatibility of the material of all wetted parts such
as measuring pipe, bluff body, sensor and gaskets is to be verified. This also ap-
plies to fluids used to clean the Prowirl 77 flowmeter. Endress+Hauser will be
pleased to provide you with any help required.
•The installer has to make sure that the measuring system is correctly wired up
according to the wiring diagrams. The complete bus system is to be grounded.
Please observe all provisions valid for your country pertaining to opening and repair
of electrical devices.
1.5 Repairs, Dangerous Chemicals
The following procedures must be carried out before a Prowirl 77 is sent to
Endress+Hauser for repair:
•A note must be enclosed with the instrument, containing a description of the fault,
the application and the chemical and physical properties of the fluid being
measured.
•Remove all residue which may be present. Pay special attention to the gasket
grooves and crevices where fluid may be present. This is especially important if the
fluid is dangerous to health, e.g. corrosive, poisonous, carcinogenic, radioactive,
etc.
•No instrument should be returned to us without all dangerous material being
removed first.
Incomplete cleaning of the instrument may result in waste disposal requirements or
cause harm to personnel (burns, etc.). Any costs arising from this will be charged to
the operator of the instrument.
1.6 Technical Improvements
The manufacturer reserves the right to modify technical data without prior notice.
Your local E+H Sales Office will supply you with all current information and any
updates to this Operating Manual.
There is no longer any contact protection once the housing cover is removed
Warning!
1 Safety Instructions Prowirl 77 PROFIBUS-PA
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2 System Description
The Prowirl 77 vortex flowmeter measures the volumetric flow of steam, gases and liq-
uids for fluid temperatures in the range of –200...+400 °C and at nominal pressures of
up to PN 160 / ANSI class 600.
Prowirl 77 measures the volumetric flow at operating conditions. If the process
pressure and temperature are constant, Prowirl 77 can be programmed to supply the
flowrate in mass, energy or corrected volume units.
2.1 Prowirl 77 Measuring System
A measuring system consists of:
•Prowirl 77 transmitter
•Prowirl 77 W, Prowirl 77 F or Prowirl 77 H body
The Prowirl 77 transmitter is available in different versions. The transmitter versions
differ in the type of electrical output signals and digital communication capabilities.
This Operating Manual describes the “PROFIBUS-PA”version.
The Prowirl 77 transmitter is available in two other versions:
•Version: “PFM”
•Version: “4...20 mA”(optional with HART)
Operation of those versions is not included in this Operating Manual. Separate
Operating Manuals for those instruments are available on request.
Prowirl 77 W
(wafer)
DN 15...150
Prowirl 77 F
(flanged)
DN 15...300
(larger sizes
upon request)
Transmitter
Prowirl 77
ba037y10
Prowirl 77 H
(high pressure)
DN 15...150
Sensor
Fig. 1
Prowirl 77 measuring system
Prowirl 77 PROFIBUS-PA 2 System Description
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The various Prowirl 77 transmitters can be freely combined with all meter body
versions. This guarantees flexibility when matching a complete meter to specific
industrial process conditions.
2 System Description Prowirl 77 PROFIBUS-PA
8 Endress+Hauser

3 Mounting and Installation
3.1 General Information
Protection IP 67 (EN 60529)
The instruments fulfil all the requirements for IP 67. The following points must always
be observed in order to ensure protection to IP 67 after istallation in the field or after
servicing:
•Housing gaskets must be clean and
undamaged when inserted in the
gasket groove. The gaskets may need
to be dried, cleaned or replaced.
•All housing screws and the housing
cover must be firmly tightened.
•The cables used for connecting
must have an outer diameter in the
specified range.
•The cable gland must be firmly
tightened (see Fig. 2).
•The cable must loop down before
entering the cable gland to ensure that
no moisture can enter it
(see Fig. 2).
•Any unused cable glands are to be
replaced with a plug.
•The protective bushing should not be
removed from the cable gland.
Temperature ranges
•The maximum approved ambient and process temperatures must be observed
(see page 56).
•Observe also the instructions on piping insulation and mounting position
(see page 11).
ba037y11
Fig. 2
Protection IP 67
Prowirl 77 PROFIBUS-PA 3 Mounting and Installation
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3.2 Installation
A vortex flowmeter requires a fully developed flow profile as a prerequisite for
measuring volume accurately. The following points must therefore be noted when
mounting the Prowirl 77 in the pipeline.
Pipe inner diameter
When ordering, ensure that the nominal diameter and pipe schedule (DIN/ANSI/JIS)
are correct, since calibration of the flowmeter and therefore the achieveable accuracy
of the measuring point are dependent on these specifications.
Inlet and outlet sections
To ensure an undisturbed flow profile,
the vortex flowmeter should be mounted
upstream of any flow disturbances such
as pipe elbows, reducers or valves,
otherwise the longest possible section of
piping should be between the distur-
bance and the flowmeter. The figures on
the left show the minimum section of
straight piping
downstream of the distur-
bance as multiples of the nominal diame-
ter of the pipe in DN. If two or more flow
disturbances are located upstream, then
the longest inlet section recommended
should be used.
There must also be a straight outlet
section of sufficient length downstream
from the flowmeter to ensure that the vor-
tices are properly developed.
Flow conditioner
With limited space and large pipes, it
is not always possible to use the inlet
sections given above. In such cases the
specially developed perforated plate flow
conditioner (see page 53 ff.) can be fitted
as shown on the left. The flow conditioner
is held between two piping flanges and
centred with the flange bolts. It reduces
the length of the inlet section downstream
from flow disturbances to 10 x DN while
maintaining high accuracy measurement.
Inlet Outlet
Reducer
Expander
90°elbow or T-piece
2x90°elbows, 3-dimensional
2x90°elbows
Control valve / on-off valve
with flow conditioner
ba037y06
Fig. 3
Inlet and outlet piping
requirements
3 Mounting and Installation Prowirl 77 PROFIBUS-PA
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Installation site
The Prowirl 77 can be mounted in any
position in the piping. An arrow on the
meter body shows the direction of flow.
For measuring liquids in vertical pipes,
the meter should be installed in upward
flow direction (Position A) to ensure a full
pipe.
For horizontal pipelines positions B, C
and D are possible. With hot piping
(e.g. steam), position C or D must be
selected in order to respect the maximum
permissible ambient temperature at the
electronics. For ambient temperatures see
Technical Data, page 56.
Pressure and temperature
measurement points
Pressure and temperature measurement
points are to be mounted
downstream of
the Prowirl 77 so that they affect vortex
formation as little as possible.
Pipeline insulation
wafer/flanged version
Pipeline insulation is often used to
prevent energy loss in hot processes.
Caution!
When insulating, ensure that sufficient
pipe stand surface area is exposed. The
exposed area serves as a radiator and
protects the electronics from overheating.
ba037y07
A
B
C
D
Fig. 4
Orientation
ba037y08
Fig. 5
Mounting pressure and
temperature sensors
ba037y26
Applies to both the wafer and
flanged versions
max.
5 mm
Fig. 6
Pipeline insulation
wafer/flanged version
Caution!
Prowirl 77 PROFIBUS-PA 3 Mounting and Installation
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Piping insulation
high pressure version
The pipe stand must be free from
insulation in order to guarantee tempera-
ture radiation and therefore to keep the
electronics from overheating.
Minimum spacing
When servicing or connecting the
“Flowjack”simulator, it is necessary to
remove the transmitter housing from the
housing support.
When installing in the piping, observe the
following cable lengths and minimum
space:
•Minimum space in all directions
100 mm
•Cable length required L + 150 mm
Caution!
Removing the transmitter from the pipe stand is to be carried out by E+H service
personnel only!
Caution!
ba037y42
Hatched area must
be free of insulation
material
Maximum insulation height is
the screw seat
Fig. 7
Piping insulation
high pressure version
ba037y09
min. 100 mm
Fig. 8
Minimum spacing for mounting
and removing the transmitter
housing
3 Mounting and Installation Prowirl 77 PROFIBUS-PA
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3.3 Mounting the Flowmeter
Caution!
Note the following points before installing the flowmeter:
•Remove all packaging used for transport and protective coverings from the
flowmeter before installing the flowmeter in the pipeline.
•Ensure that the inner diameters of the gaskets are identical or larger than those of
the meter body and process piping. Gaskets which protrude into the flow affect
vortex formation behind the bluff body and lead to inaccurate measurement.
Therefore, the gaskets delivered by E+H come with a slightly bigger inner diameter
than the measuring pipe.
•Ensure that the direction of the arrow on the meter body agrees with the direction of
flow in the pipeline.
•Face-to-face lengths:
–Prowirl W (wafer version): 65 mm
–Prowirl F (flanged version) →see page 50
–Prowirl H (high pressure version) →see page 52
Mounting Prowirl W
Mounting the wafer is carried out using a mounting set consisting of:
•bolts
•centering rings
•nuts
•washers
•gaskets
Caution!
ba037y33
bolt
washer nut
centering ring
gasket
Fig. 9
Mounting the Prowirl W wafer
version
Prowirl 77 PROFIBUS-PA 3 Mounting and Installation
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3.4 Rotating the electronics housing
The electronics housing of Prowirl 77 can be rotated in 90°steps on the pipe stand.
This is carried out as follows:
➀Remove the securing screw at the pipe stand (minimum one turn).
➁Pull out the electronics housing to the mechanical stop and then
rotate it to the position required (in 90°steps). Push the housing back
into the housing support.
➂Fasten the securing screw.
ba037y28
➁
➁
➁
➀
➂
Fig. 10
Rotating the electronics housing
3 Mounting and Installation Prowirl 77 PROFIBUS-PA
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4 Electrical Connection
4.1 Connecting the Transmitter
Caution!
•All relevant national installation regulations must be observed.
•When installing an Ex version transmitter, please read the separate
Ex documentation supplied.
Procedure
1. Unscrew the front cover.
2. Loosen the two Phillips screws on the upper cover plate and let it swing down.
3. Feed the power and signal cables through the cable gland.
4. Wire up according to the wiring diagram shown on this page.
5. Replace the cover plate and secure.
6. Screw the front cover securely again to the transmitter housing.
4.2 Wiring Diagram
Connect cable according to wiring diagram.
•Connect cable cores to clamp 1 and 2. An exchange of the polarity has no
influence on operation.
•Connect cable shielding to the internal grounding.
•The external ground terminal must be connected to the potential equalization grid.
The grounding design of the plant is to be observed.
The bus cable should always be screened at both ends.
Caution!
12
3
+-
PROFIBUS-DP
Segment coupler
ba037y16
PROFIBUS-PA
Cable screen
Potential equalization
31.25 kbit/s
PA+ PA–
Fig.11
Connection of PROFIBUS-PA
devices to a PROFIBUS-DP
network
Prowirl 77 PROFIBUS-PA 4 Electrical Connection
Endress+Hauser 15

4 Electrical Connection Prowirl 77 PROFIBUS-PA
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5 Communication
5.1 PROFIBUS-PA interface
Note!
Additional specification details about PROFIBUS-PA Profile 2.0 fieldbus can be found
in Operating Manual BA 198F/00/en “Field Communication PROFIBUS-DP/-PA:
Guidelines for planning and commissioning”.
General
Prowirl 77 (PROFIBUS-PA version) has a PROFIBUS-PA interface according to the
fieldbus standard PROFIBUS-DP, EN 50170 Volume 2.
This enables it to exchange data with process control systems which comply to
this standard. Integrating into a control system must be in accordance with the
specifications for PROFIBUS-PA profiles.
Transmission partner
Prowirl 77 always acts as a slave in a control system and, depending on the type of
application, can therefore exchange data with one or several masters.
The master can be a process control system, a PLC or a PC with a PROFIBUS-DP
plug-in communication board.
Note!
In project management, note that the Prowirl 77 current consumption is 12 mA.
Caution!
In order to protect the PROFIBUS-PA segment from the effects of any serious faults
occurring in the instrument (e.g. short circuiting), the IEC 61158-2 interface is fitted
with a safety fuse. When the fuse is activated, the instrument is permanently sepa-
rated from the bus. The electronics must then be replaced.
Segment coupler
PLC
31.25 kbit/s
31.25 kbit/s
Safe area
Ex area
PROFIBUS PA
Process control system
Commuwin II
IEC 1158 IEC 1158
RS 485
ba037y37
Fig. 12
Principle of PROFIBUS-PA
Note!
Note!
Caution!
Prowirl 77 PROFIBUS-PA 5 Communication
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5.2 Configuration of Device Address
The address of a PROFIBUS-PA device must always be set. Without a correctly set
address, the device will not be recognized by the control system. Valid device
address numbers range from 0...126. In a PROFIBUS-PA network, the address must
only be assigned once. All devices are delivered from the factory with the default
address 126. This address can be used for testing the device and for connecting the
device to a running PROFIBUS-PA network. After that the address must be changed
in order to connect with further devices. The configuration of the device address for a
Prowirl 77 can be done either with the help of an operating program (DP master
Class II, e.g. Commuwin II) or locally by using DIP switches which can be reached by
unscrewing the front cover.
Configuration of address mode
DIP switch No. 8: OFF = Addressing via the bus system
ON = Addressing via DIP switches No. 1...7 at the device
(see Fig. 13)
Configuration of application (fluid)
DIP switch No. 10: OFF = Application is configured via bus system
ON = Application is configured via DIP switch No. 9
(No. 9: OFF = liquid or No. 9: ON = gas/steam)
2
15678910
34
2
116 32 64
48
Device address
(here: 0+2+4+8+16+32+64 = 126)
Address mode (see above)
Application (see below)
Application mode (see below)
Procedure
1. Remove the housing cover.
2. Set the DIP switches with a pointed object.
3. Replace and secure the housing cover.
ba037e38
Note!
The Prowirl 77 factory
setting is as indicated
below.
ON
OFF
Fig. 13
Configuration of device address
using the DIP switches
Note!
5 Communication Prowirl 77 PROFIBUS-PA
18 Endress+Hauser

5.3 System integration
The GSD files are necessary for the configuration of a PROFIBUS-DP network. The
GSD file (simple text file) describes e.g. the data transmission rate supported by the
device or the kind and format of digital information which the PLC receives from the
device.
Each device receives an identification number from the PROFIBUS user organization
(PROFIBUS Nutzerorganisation PNO) which defines the GSD file name.
For Endress+Hauser, this ID number always starts with “15XX”.
Name of
device
ID-No. GSD-file Type-file Bitmaps
Prowirl 77 1510
(hex)
EH__1510.gsd EH_1510x.200 EH1510_d.bmp
EH1510_n.bmp
EH1510_s.bmp
The GSD files of all Endress+Hauser devices can be obtained as follows:
•INTERNET: –Endress+Hauser →
http://www.endress.com (Product Avenue →
Downloadstreet →Field Communication St.)
–PNO →
http://www.profibus.com (GSD library)
•As floppy disc from Endress+Hauser: Order number 943157-0000
Contents of Download file in INTERNET and floppy disc:
•All Endress+Hauser-GSD files
•Endress+Hauser type files
•Endress+Hauser bitmap files
•Useful information about the devices
Using the GSD and type files:
The GSD files have to be copied in a specific subdirectory of the PROFIBUS-DP
configuration software of your PLC.
Example 1:
Configuration software Siemens STEP7 for PLC Siemens S7-300/400.
There is a subdirectory \siemens\step7\s7data\gsd.
Additional to the GSD files there are bitmap files. With these the measuring devices
are graphically presented. The bitmap files must be copied in subdirectory
\siemens\step7\s7data\nsbmp.
Example 2:
If you are using a Siemens S5 PLC and your PROFIBUS-PA network is configured with
configuration software COM ET200, you need type files (x.200 files).
Example 3:
On the floppy disc in directory GSD there is a subdirectory which contains GSD files
with a standard identifier (0x94). These GSD files must be used e.g. for a PLC5 from
Allen-Bradley.
For another configuration software, please ask your PLC supplier for the correct
subdirectory.
Prowirl 77 PROFIBUS-PA 5 Communication
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5.4 Cyclic Data Transfer (Data_Exchange)
With PROFIBUS-PA, the cyclic transmission of analog values to the process control
system uses data blocks with a length of 5 bytes. The measured value is portrayed in
the first 4 bytes in the form of floating comma numbers according to the IEEE stand-
ard (see page 22). The 5th byte contains standardized status information which
belongs to the instrument (see page 22).
PLC →Prowirl 77 (Output data)
Index
output
data
Data item Access Data format/remarks Factory
setting
(unit)
0 control write With every transition of this byte from 0 to
another number, a binary control can be
performed with the cyclic service. A transition
from any bit pattern to 0 has no effect.
0→1: reset totalizer
0→2... 255: reserved
–
Prowirl 77 →PLC (Input data)
Index
output
data
Data item Access Data format/remarks Factory
setting
(unit)
0, 1, 2, 3 flow
(volume/time)
read 32-Bit floating point number (IEEE-754)
see page 22
dm3/s
4 status flow read see status codes page 22 –
5, 6, 7, 8 totalizer
(volume)
read 32-Bit floating point number (IEEE-754) dm3
9 status totalizer read see status codes page 22 –
If not all outputs of Prowirl 77 are required, single data blocks can be eliminated from
the cyclic telegram using the device configuration from the PLC software. Only data
blocks which are needed in the system should be activated, thereby improving the
throughput of a PROFIBUS-PA system.
In Prowirl 77, three data blocks can be activated for cyclic data exchange. The follow-
ing table shows the necessary configuration data in extended format (h means that
the number is a hexadecimal number).
Byte Data item Access GSD
block description
Configuration data
(depending on
PROFIBUS master)
0...4 flow + status read Flow Rate Block 42h, 84h, 08h, 05h
5...9 totalizer + status read Total Volume Block 42h, 84h, 08h, 05h
0 control write Total Volume Reset 20h
The identification code 94h can be used for PROFIBUS masters which do not support
the extended format. However, the extended format is preferable since it contains
additional information for interpreting the data.
5 Communication Prowirl 77 PROFIBUS-PA
20 Endress+Hauser