KRAL OMS Series User manual

Operating instructions
KRAL flowmeters.
Series OMS
High-viscosity liquids
OIO 31en-GB
Edition 2018-08
Original instructions
www.kral.at

Table of contents
1 About this document ..................................................... 3
1.1 General information .......................................................3
1.2 Target groups ................................................................3
1.3 Symbols.........................................................................3
1.3.1 Danger levels ....................................................3
1.3.2 Danger signs.....................................................4
1.3.3 Symbols in this document .................................4
1.4 Associated documents ..................................................4
2 Safety .............................................................................. 5
2.1 Proper use .....................................................................5
2.2 Foreseeable misuse ......................................................5
2.3 Obligations of the operator-owner .................................5
2.4 Dangers during transportation .......................................6
2.5 Dangers during storage .................................................6
2.6 Dangers during installation ............................................6
2.7 Dangers during removal ................................................6
2.8 Dangers during connection work ...................................6
2.9 Dangers during operation ..............................................6
2.10 Dangers during servicing...............................................7
2.11 Dangers during disposal................................................7
3 Identification................................................................... 8
3.1 Type code......................................................................8
3.2 Rating plate ...................................................................8
4 Technical data ................................................................ 9
4.1 Operating limits..............................................................9
4.2 Pressure pulsation.........................................................9
4.3 Maximum values............................................................9
4.4 Pick up...........................................................................9
4.5 Pin assignment / Connection diagram.........................10
4.6 Dimensions and weights..............................................10
4.6.1 Pipe thread (BSPP thread) .............................10
5 Function description.................................................... 11
5.1 Structure ......................................................................11
5.2 Functional principle......................................................11
5.3 Signal generation.........................................................11
5.4 Recognition of flow direction........................................12
5.5 Temperature compensation (optional).........................12
6 Transportation, storage............................................... 12
6.1 Dangers during storage ...............................................12
6.2 Unpacking and checking the state of delivery .............12
6.3 Transporting flowmeters ..............................................12
6.4 Storing the flowmeter...................................................12
7 Installation, removal .................................................... 13
7.1 Dangers during installation ..........................................13
7.2 Dangers during removal ..............................................13
7.3 Installing the flowmeter................................................13
7.3.1 Protecting the flowmeter against soiling .........13
7.3.2 Installation types .............................................14
7.3.3 Installation recommendation ...........................15
7.3.4 Installing the flowmeter ...................................16
7.4 Installing the trace heating (optional)...........................16
7.5 Removing the flowmeter..............................................17
8 Connection ................................................................... 18
8.1 Dangers during connection work .................................18
8.2 Connecting the flowmeter to the pipe system ..............18
8.3 Connecting the pick up ................................................19
9 Operation........................................................................20
9.1 Dangers during operation ............................................20
9.2 Commissioning ............................................................20
9.2.1 Cleaning the pipe system ................................20
9.2.2 Checking the function ......................................20
9.2.3 Commissioning the flowmeter .........................20
9.3 Decommissioning.........................................................21
9.3.1 Switching off the flowmeter..............................21
9.4 Recommissioning.........................................................21
9.4.1 Recommissioning the flowmeter......................21
10 Maintenance...................................................................22
10.1 Required maintenance.................................................22
10.2 Recalibration of the flowmeter .....................................22
11 Disposal..........................................................................22
11.1 Dangers during disposal ..............................................22
11.2 Dismantling and disposing of the flowmeter ................22
12 Troubleshooting ............................................................24
12.1 Possible faults..............................................................24
12.2 Troubleshooting ...........................................................24
13 Appendix ........................................................................26
13.1 Tightening torque for screws with metric screw threads
and head contact surfaces...........................................26
13.2 Tightening torques for screw plugs with thread meas-
ured in inches and elastomer seal ...............................26
13.3 Contents of the Declaration of Conformity ...................26
2OIO 31en-GB Edition 2018-08 Operating instructions

1 About this document
1.1 General information
1 About this document
1.1 General information
These instructions form part of the product and must be kept for future reference. Furthermore please
observe the associated documents.
1.2 Target groups
The instructions are intended for the following persons:
oPersons who work with the product
oOperator-owners who are responsible for the use of the product
Information on the required qualification of the personnel is provided separately at the beginning of the
individual chapters in these instructions. The following table provides an overview.
Target group Activity Qualification
Transport per-
sonnel
Transportation,
unloading
Transport personnel are qualified personnel who carry out the trans-
portation of products properly due to their training, knowledge and
experience and on the basis of the relevant provisions. Transport
personnel recognize and avoid possible dangers and damage to
property that are connected with this activity.
Mobile crane
operators,
crane operat-
ors, forklift oper-
ators
Unloading, pos-
itioning
Mobile crane operators, crane operators and forklift operators are
qualified personnel who carry out work with cranes and forklifts
properly due to their training, knowledge and experience and on the
basis of the relevant provisions. Mobile crane operators, crane op-
erators and forklift operators recognize and avoid possible dangers
and damage to property that are connected with this activity.
Fitter Mounting, con-
nection
Fitters are qualified personnel who carry out the mounting work
properly due to their training, knowledge and experience and on the
basis of the relevant provisions. Fitters recognize and avoid pos-
sible dangers and damage to property that are connected with this
activity.
Electrician Electrical con-
nection
Electricians are qualified personnel who carry out work on electrical
equipment and installations properly due to their training, know-
ledge and experience and on the basis of the relevant provisions.
Electricians recognize and avoid possible dangers and damage to
property that are connected with this activity.
Trained person-
nel
Delegated task Trained personnel were instructed by the operator-owner in the task
delegated to them and the possible dangers arising through im-
proper behaviour.
Tab.1: Target groups
1.3 Symbols
1.3.1 Danger levels
Signal word Danger level Consequences of non-observance
DANGER Immediate threat of danger Serious personal injury, death
WARNING Possible threat of danger Serious personal injury, invalidity
CAUTION Potentially dangerous situation Slight personal injury
ATTENTION Potentially dangerous situation Material damage
Operating instructions OIO 31en-GB Edition 2018-08 3

1 About this document
1.4 Associated documents
1.3.2 Danger signs
Meaning Source and possible consequences of non-observance
Electrical voltage Electrical voltage causes serious physical injury or death.
Raised load Falling objects can result in serious physical injury or death.
kg
Heavy load Heavy loads can result in serious back problems.
Risk of slipping Discharging pumped liquid and oils on the foundation or
tread surfaces can cause falls with serious physical injury
or death.
Flammable substances Discharging pumped liquid and oils can be easily inflam-
mable and can result in serious burns.
Hot surface Hot surfaces can cause burns.
1.3.3 Symbols in this document
Meaning
Warning personal injury
Safety instruction
Request for action
1.
2.
3.
Multi-step instructions for actions

Action result

Cross-reference
1.4 Associated documents
oCalibration certificate (optional)
oDeclaration of conformity according to EU Directive 2006/42/EC
oManufacturer's declaration according to EU Directive 2014/68/EU
oCorresponding operating instructions for accessories
4OIO 31en-GB Edition 2018-08 Operating instructions

2 Safety
2.1 Proper use
2 Safety
2.1 Proper use
oUse the flowmeter solely for measuring the flow of liquids that do not contain any gas components
or solid particles.
oIf coarse soiling, solid particles in the liquid or abrasive fine particles occur during operation, the
flowmeter has to be protected additionally by a correspondingly dimensioned operating filter in the
pipe system.
oUse the flowmeter only within the operating limits specified on the rating plate and in the chapter
"Technical data". Deviating operating data can result in damage to the flowmeter. In the case of op-
erating data that do not agree with the specifications on the rating plate, please contact the manu-
facturer.
oStrong changes in the flow rate (for example rapid shutdown, pulsations, etc.) cause marked pres-
sure differences in the flowmeter and can damage the measuring unit. The pressure loss of the
flowmeter must not exceed the values shown in the chapter "Technical data".
2.2 Foreseeable misuse
oAny use that extends beyond the proper use or any other use is misuse.
oThe product is not suitable for pumping liquids outside the operational limits.
oAny bypassing or deactivation of safety equipment during operation is prohibited.
2.3 Obligations of the operator-owner
The operator-owner is the person who operates the product commercially or permits a third party to
use it and who bears the legal responsibility for the product, the protection of the personnel and third
parties during its operation.
The product is used in industrial applications. The operator-owner is therefore subject to the statutory
obligations concerning occupational health and safety.
In addition to the safety instructions in these instructions, the regulations on safety, accident prevention
and environmental protection respectively valid for the range of application of the product are to be ob-
served.
This results in the following obligations for the operator-owner:
oObserve the rules and regulations such as national standards, international standards and provi-
sions applicable at the site of use.
oObserve the obligations arising from occupational safety and from safety, accident protection and
environmental protection.
oDraw up a hazard assessment for the utilization of the product at the site of use.
oDraw up the operating guidelines for the operation of the product on the basis of the hazard assess-
ment.
oKeep the operating guidelines up-to-date during the entire operating life of the product, by ensuring
that the current version of the applicable rules and regulations are integrated.
oEnsure the qualification, instruction, information on dangers as well as regular training of the per-
sonnel.
oSpecify clear responsibilities for all work on the product, for example for the installation, operation,
maintenance, troubleshooting.
oKeep the operating instructions available at the site of use - also for future use.
oEnsure that the operating instructions as well as the associated documents are read, understood
and observed by the personnel.
oObserve the safety regulations for handling dangerous pumped liquids and comply with the safety
data sheets. Pumped liquids can, for example, be hot, poisonous, combustible and caustic.
oMake personal protective equipment available and instruct their use.
oEquip systems with an increased potential of danger with protective equipment and/or alarm equip-
ment. The failure of a component may not result in injury and/or damage to property.
oMaintain and check protective equipment and alarm equipment regularly.
oEnsure the technically flawless state of the product during its entire operating life.
Operating instructions OIO 31en-GB Edition 2018-08 5

2 Safety
2.4 Dangers during transportation
2.4 Dangers during transportation
The following safety instructions must be observed:
oHave all work only carried out by authorized transport personnel.
oUse intact and correctly dimensioned hoisting equipment.
oEnsure that the means of transport is in a flawless state.
oEnsure that the centre of gravity of the load is taken into consideration.
oDo not stand under raised loads.
2.5 Dangers during storage
The following safety instructions must be observed:
oObserve the storage conditions.
2.6 Dangers during installation
The following safety instructions must be observed strictly:
oHave all work only carried out by authorized qualified personnel.
oDo not take apart the flowmeter.
2.7 Dangers during removal
The following safety instructions must be observed strictly:
oHave all work only carried out by authorized qualified personnel.
oEnsure that the collection tank for emitted liquids is sufficiently large.
oCollect any discharging pumped liquid safely and dispose of it in an environmentally compatible
manner in accordance with the applicable local regulations.
2.8 Dangers during connection work
The following safety instructions must be observed strictly:
oHave all the work on the flowmeter and pipe system only carried out by authorized qualified per-
sonnel.
oEnsure that solid particles cannot get into the flowmeter and pipe system.
oEnsure that mechanical connections are mounted free of stress.
oObserve the tightening torques.
oHave all the work on the electrical equipment only carried out by electricians.
oBefore beginning work on the flowmeter ensure that the electrical power supply is deenergized
and is secured against being switched back on.
oIf the insulation of the electrical cables or wires is damaged, disconnect the power supply immedi-
ately.
oThe connecting line of the pick up/temperature sensor connection is to be shielded and laid separ-
ately from the supply lines.
2.9 Dangers during operation
The following safety instructions must be observed strictly:
oHave all work only carried out by authorized qualified personnel.
oEnsure that the flowmeter is only operated within the operating limits.
oEnsure that during cooling down or heating up the flowmeter is only subjected to slow temperat-
ure changes.
oEnsure that existing safety equipment is not bypassed or activated during operation.
6OIO 31en-GB Edition 2018-08 Operating instructions

2 Safety
2.10 Dangers during servicing
2.10 Dangers during servicing
The following safety instructions must be observed strictly:
oHave all work only carried out by authorized qualified personnel.
oTo ensure the measuring precision, the measuring unit may only be replaced by the manufac-
turer.
oBefore beginning work, let the flowmeter cool down slowly to the ambient temperature. Avoid
rapid temperature changes.
oPumped liquids can be hot, poisonous, combustible and caustic.
oObserve the tightening torques Ä Appendix,Page26.
oObserve the operating instructions and data sheets of the sensors.
2.11 Dangers during disposal
The following safety instructions must be observed strictly:
oCollect any discharging pumped liquid safely and dispose of it in an environmentally compatible
manner in accordance with the applicable local regulations.
oEnsure that the collection tank for emitted liquids is sufficiently large.
oNeutralize residues.
Operating instructions OIO 31en-GB Edition 2018-08 7

3 Identification
3.1 Type code
3 Identification
3.1 Type code
OMS-020.XBXXAX.0001
1
2
3
4
5
68
7 9
Fig.1: Type code
1Series
2Size
3Sensor equipment (pick up)
4Function of the sensor equipment
5Material of bearing
6Material of seal
7Mechanical connection
8Electrical connection
9Version index
Item Designation Description
1Series OMS Stainless steel
2Size Corresponds to the diameter of the large measur-
ing screw in [mm]
3Sensor equipment (pick up) X Special design
4Function of the sensor equipment B With recognition of flow direction
D With recognition of flow direction, with temperat-
ure compensation
X Special design
5Material of bearing X Special design
6 Material of seal X Special design
7 Mechanical connection A Thread connection BSPP
B Flange connection DIN
C Thread connection NPT
D Flange connection ANSI
E Flange connection JIS
F Flange connection SAE
X Special design
8Electrical connection X Special design
9Version index For internal administration
Tab.2: Type code
3.2 Rating plate
R
1 2 3
4567
Fig.2: Rating plate
1Serial number
2Construction year
3K-factor
4Preferred flow direction
5Max. temperature
6Series
7Max. pressure
8OIO 31en-GB Edition 2018-08 Operating instructions

4 Technical data
4.1 Operating limits
4 Technical data
4.1 Operating limits
The values specified on the rating plate apply, as well as the values on the calibration certificate if the
optional calibration of the flowmeter was ordered.
The permissible operating limits of individual values influence each other so that every application is
checked individually by the manufacturer when selecting the flowmeter.
If no operating data are provided by the orderer, standardized substitute operating data are used.
4.2 Pressure pulsation
p
[bar]
10 3020 40 t [ms]
30
10
20
0
p
[bar]
Fig.3: Pressure pulses
Strong pressure pulsations in the system can reduce the service life of the flowmeter.
4.3 Maximum values
The following table shows the respective maximum values that, however, may not occur simultan-
eously. In addition, the operating limits of the corresponding completion, of the sealing material and of
the pick up are to be observed.
Unit OMS-020
Flow rate
Qrated [l/min] 10
Qmin [l/min] 0.04
Max. pressure [bar] 400
Temperature
min - max [°C] -20 ... +80
Viscosity
min - max [mm2/s] 102 – 106
K-factor [P/l] 66000
Tab.3: Maximum values
4.4 Pick up
Unit OMS-020
Supply voltage UB[VDC] 10 – 29
Closed current [mA] < 20
Frequency range [Hz] 44 – 11000 (with K-factor 66000 P/l)
Electrical connection M12 socket connector, 5-pole, A-coding
Output Push-pull, driver stages
Short-circuit-proof Yes
Output current limiting [mA] 30 (per output)
Output low level [V] < 0.5 (@ 1mA),
1 (@10mA)
Output high level [V] Uhigh > 22.5 (@Ub = 24V, 1mA)
Uhigh > 22.0 (@Ub = 24V, 10mA)
Degree of protection IP 67
Tab.4: Pick up
Operating instructions OIO 31en-GB Edition 2018-08 9

4 Technical data
4.5 Pin assignment / Connection diagram
4.5 Pin assignment / Connection diagram
1
2 3
4
5
1
2/4
3
5
Fig.4: Pin assignment / Connection diagram
1+UB
2fB (signal OUT (push-pull))
3GND (0 V)
4fA (signal OUT (push-pull))
5Not connected
4.6 Dimensions and weights
4.6.1 Pipe thread (BSPP thread)
T T L2
L1
D
G
G
Fig.5: Dimensional drawing pipe thread
GPipe thread
DOuter diameter
L1 Total length
L2 Length of the flowmeter without
connections
TMax. screw-in depth
Unit OMS-020
G [inch] 3/4
Pressure stage [bar] 400
D [mm] 84
L1 [mm] 156
L2 [mm] 94
T [mm] 21
Weight [kg] 6.0
Tab.5: Dimensions and weights - pipe thread connection
10 OIO 31en-GB Edition 2018-08 Operating instructions