KROHNE OPTISWIRL 4200 User manual

Vortex flowmeter
Electronic revision: ER 1.0.5_
OPTISWIRL 4200
OPTISWIRL 4200OPTISWIRL 4200
OPTISWIRL 4200 Quick Start
Quick StartQuick Start
Quick Start
© KROHNE 03/2016 - 4003931402 - QS OPTISWIRL 4200 R02 en

CONTENTS
2
www.krohne.com 03/2016 - 4003931402 - QS OPTISWIRL 4200 R02 en
OPTISWIRL 4200
1 Safety instructions 3
2 Installation 4
2.1 Intended use ..................................................................................................................... 4
2.2 Scope of delivery............................................................................................................... 6
2.3 Storage ............................................................................................................................. 6
2.4 Transport .......................................................................................................................... 7
2.5 Installation conditions ...................................................................................................... 8
2.5.1 Prohibited installation when measuring liquids .................................................................... 9
2.5.2 Prohibited installation when measuring steam and gases.................................................. 10
2.5.3 Pipelines with control valve .................................................................................................. 10
2.5.4 Preferred mounting position ................................................................................................ 11
2.6 Minimum inlet sections.................................................................................................. 12
2.7 Minimum outlet sections................................................................................................ 13
2.8 Flow straightener ........................................................................................................... 13
2.9 Installation...................................................................................................................... 14
2.9.1 General installation notes..................................................................................................... 14
2.9.2 Installing devices in sandwich design .................................................................................. 15
2.9.3 Installing devices in flange design ....................................................................................... 16
2.9.4 Mounting the field housing, remote version ........................................................................ 17
2.10 Heat insulation.............................................................................................................. 18
2.11 Turning the connection housing................................................................................... 19
2.12 Turning the display .......................................................................................................20
3 Electrical connections 21
3.1 Safety instructions.......................................................................................................... 21
3.2 Connecting the signal converter .................................................................................... 22
3.3 Electrical connections .................................................................................................... 23
3.3.1 Power supply......................................................................................................................... 23
3.3.2 Current output ...................................................................................................................... 23
3.3.3 Current input......................................................................................................................... 24
3.3.4 Binary output......................................................................................................................... 24
3.3.5 Limit switch output ............................................................................................................... 25
3.3.6 Pulse output / Frequency output ..........................................................................................27
3.3.7 Status output......................................................................................................................... 28
3.4 Connection of remote version ........................................................................................ 28
3.5 Grounding connections................................................................................................... 30
3.6 Ingress protection .......................................................................................................... 31

SAFETY INSTRUCTIONS 1
3
OPTISWIRL 4200
www.krohne.com03/2016 - 4003931402 - QS OPTISWIRL 4200 R02 en
Warnings and symbols used
HANDLING
• This symbol designates all instructions for actions to be carried out by the operator in the
specified sequence.
iRESULT
RESULTRESULT
RESULT
This symbol refers to all important consequences of the previous actions.
Safety instructions for the operator
DANGER!
This information refers to the immediate danger when working with electricity.
DANGER!
These warnings must be observed without fail. Even partial disregard of this warning can lead to
serious health problems and even death. There is also the risk of seriously damaging the device
or parts of the operator's plant.
WARNING!
Disregarding this safety warning, even if only in part, poses the risk of serious health problems.
There is also the risk of damaging the device or parts of the operator's plant.
CAUTION!
Disregarding these instructions can result in damage to the device or to parts of the operator's
plant.
INFORMATION!
These instructions contain important information for the handling of the device.
CAUTION!
Installation, assembly, start-up and maintenance may only be performed by appropriately
trained personnel. The regional occupational health and safety directives must always be
observed.
LEGAL NOTICE!
The responsibility as to the suitability and intended use of this device rests solely with the user.
The supplier assumes no responsibility in the event of improper use by the customer. Improper
installation and operation may lead to loss of warranty. In addition, the "Terms and Conditions of
Sale" apply which form the basis of the purchase contract.
INFORMATION!
• Further information can be found on the supplied CD-ROM in the manual, on the data sheet,
in special manuals, certificates and on the manufacturer's website.
• If you need to return the device to the manufacturer or supplier, please fill out the form
contained on the CD-ROM and send it with the device. Unfortunately, the manufacturer
cannot repair or inspect the device without the completed form.

2 INSTALLATION
4
OPTISWIRL 4200
www.krohne.com 03/2016 - 4003931402 - QS OPTISWIRL 4200 R02 en
2.1 Intended use
The vortex flowmeters are used for flow measurement of gases, vapours and liquids.
The devices are particularly suitable for the measurement of:
•Clean liquids with low viscosity (< 10 cP)
•Hydrocarbons with low viscosity (< 10 cP)
•Water
•Chemicals with low corrosiveness
•Saturated steam
•Superheated steam, including CIP and SIP applications in the food industry
•The flow sensors are made from stainless steel 316 L (1.4404) or Hastelloy
®
C22.
•In your project planning, please observe the data given in the corrosion tables.
•The pressure-bearing parts have been designed and rated for stationary operation taking into
account the maximum pressure and temperature.
•Observe the data indicated on the nameplate for PS, TS and PT (PED 97/23/EC).
•External forces and moments, caused e.g. by pipe stresses, have not been taken into account.
Primarily, volumetric flow and temperature are measured, with pressure measurement as an
option. From these parameters the measuring device calculates the mass flow or standard
volumetric flow using pre-programmed density data and then exports the measured values via
various communication interfaces.
CAUTION!
Responsibility for the use of the measuring devices with regard to suitability, intended use and
corrosion resistance of the used materials against the measured fluid lies solely with the
operator.
INFORMATION!
This device is a Group 1, Class A device as specified within CISPR11:2009. It is intended for use in
industrial environment. There may be potential difficulties in ensuring electromagnetic
compatibility in other environments, due to conducted as well as radiated disturbances.
INFORMATION!
The manufacturer is not liable for any damage resulting from improper use or use for other than
the intended purpose.

INSTALLATION 2
5
OPTISWIRL 4200
www.krohne.com03/2016 - 4003931402 - QS OPTISWIRL 4200 R02 en
The devices are rated for the following flow velocities:
Liquids:
DN15...DN300 V
min
: 0.25 m/s 0.8 ft/s 1
V
max
: 10 m/s 32 ft/s 2
Gases and
steam: DN15 V
min
: 3 m/s 10 ft/s 1
V
max
: 45 m/s 147 ft/s 2
DN15C V
min
: 3 m/s 10 ft/s 1
V
max
: 55 m/s 180 ft/s 2
DN25 V
min
: 2 m/s 6.6 ft/s 1
V
max
: 70 m/s 229 ft/s 2
DN25C V
min
: 2 m/s 6.6 ft/s 1
V
max
: 80 m/s 262 ft/s 2
DN40...
DN300 V
min
: 2 m/s 6.6 ft/s 1
V
max
: 80 m/s 262 ft/s 2
1 Use the larger value, according to the amount.
2 Use the smaller value, according to the amount.
INFORMATION!
DN15C and DN25C have a robust flow sensor (signal pick-up) for harsh measuring conditions
and higher maximum velocity compared to the standard version.

2 INSTALLATION
6
OPTISWIRL 4200
www.krohne.com 03/2016 - 4003931402 - QS OPTISWIRL 4200 R02 en
2.2 Scope of delivery
2.3 Storage
•Store the device in a dry, dust-free location.
•Avoid extended direct exposure to the sun.
•Store the device in the original packaging.
•The permissible storage temperature for standard devices is -40...+85°C / -40...+185°F.
INFORMATION!
Inspect the packaging carefully for damages or signs of rough handling. Report damage to the
carrier and to the local office of the manufacturer.
INFORMATION!
Do a check of the packing list to make sure that you have all the elements given in the order.
INFORMATION!
Look at the device nameplate to ensure that the device is delivered according to your order.
Check for the correct supply voltage printed on the nameplate.
Figure 2-1: Scope of delivery
1 Measuring device in ordered version
2 Product documentation
3 Certificates, calibration report and parameter data sheet
4 CD with complete documentation
5 Bar magnet
6 Centering rings (only for sandwich devices)
7 Handle to pull off the display
8 Key for opening the front and rear cover

INSTALLATION 2
7
OPTISWIRL 4200
www.krohne.com03/2016 - 4003931402 - QS OPTISWIRL 4200 R02 en
2.4 Transport
•Use lifting straps wrapped around both process connections for transport.
•Do not lift measuring devices by the signal converter housing for transport.
•Never lift the measuring device by the pressure sensor.
•Do not use lifting chains as they may damage the housing.
Figure 2-2: Transport instructions
CAUTION!
Non-secured devices can pose risk of injury. The centre of mass of the device is often higher
than the point at which the lifting straps are attached.
Prevent the measuring device from sliding or rotating accidentally.

2 INSTALLATION
8
OPTISWIRL 4200
www.krohne.com 03/2016 - 4003931402 - QS OPTISWIRL 4200 R02 en
2.5 Installation conditions
The meter MUST be protected from strong sunlight.
A sunshade is available from the manufacturer as an option.
INFORMATION!
For accurate volumetric flow measurement the measuring device needs a completely filled pipe
and a fully developed flow profile.
CAUTION!
Any vibration will distort the measuring result. That is why any vibrations in the pipeline must be
prevented through suitable measures.
CAUTION!
Procedures to carry out before installing the device:
• Nominal diameter of connection pipe flange = nominal flange diameter of pipe!
• Use flanges with smooth holes, e.g. welding neck flanges.
• Align carefully the holes of the connecting flange and the flowmeter flange.
• Check the compatibility of the gasket material with the process product.
• Make sure that the gaskets are arranged concentrically. The flange gaskets must not project
into the pipe cross-section.
• The flanges have to be concentric.
• There must not be any pipe bends, valves, flaps or other internals in the immediate inlet run.
• Devices in sandwich version may only be installed using centering rings.
• Never install the device directly behind piston compressors or rotary piston meters.
• Do not lay signal cables directly next to cables for the power supply.
INFORMATION!
If there is a risk of water hammers in steam networks, appropriate condensate separators must
be installed. Suitable measures must be taken to avoid water cavitation if it is a possible risk.
Sunshades
Figure 2-3: Installation recommendations
1 Horizontal mounting
2 Vertical mounting

INSTALLATION 2
9
OPTISWIRL 4200
www.krohne.com03/2016 - 4003931402 - QS OPTISWIRL 4200 R02 en
2.5.1 Prohibited installation when measuring liquids
Figure 2-4: Upper pipe bend
CAUTION!
Prohibited: Installing the device in an upper pipe bend 1, because there is a risk of gas bubbles
2forming. Gas bubbles can lead to pressure surges and inaccurate measurement.
Figure 2-5: Downstream pipe and outlet
CAUTION!
Installing the device in a downstream pipe 3or upstream pipe of an outlet 4. There is the risk of
partially filled pipes leading to inaccurate measurements.

2 INSTALLATION
10
OPTISWIRL 4200
www.krohne.com 03/2016 - 4003931402 - QS OPTISWIRL 4200 R02 en
2.5.2 Prohibited installation when measuring steam and gases
2.5.3 Pipelines with control valve
1 Lower pipe bends
2 Condensate
DANGER!
Prohibited: Installing the device in a lower pipe bend 1, because there is a risk of condensate
forming 2.
Condensate can lead to cavitation and inaccurate measurement. Under certain circumstances
the device can be destroyed and the measured product can leak.
INFORMATION!
To ensure smooth and correct measurement, the manufacturer recommends not installing the
measuring device downstream from a control valve. This would run the risk of vortex formation,
which would distort the measuring result.
Figure 2-6: Pipeline with control valve
1 Recommended: installing the device before the control valve at a distance of ≥5 DN
2 Not recommended: Installing the flowmeter directly downstream of control valves, due to vortex formation.

INSTALLATION 2
11
OPTISWIRL 4200
www.krohne.com03/2016 - 4003931402 - QS OPTISWIRL 4200 R02 en
2.5.4 Preferred mounting position
Preferred mounting position
Figure 2-7: Mountig position
1 Above a horizontal pipe
2 Underneath a horizontal pipe (not permitted with lines at risk of condensate forming)
3 On a vertical pipe
4 Horizontal pipeline with signal converter-orientation 90°to the side
INFORMATION!
Depending on the installation position, you may have to rotate the display and/or the connection
housing.

2 INSTALLATION
12
OPTISWIRL 4200
www.krohne.com 03/2016 - 4003931402 - QS OPTISWIRL 4200 R02 en
2.6 Minimum inlet sections
Figure 2-8: Inlet sections
1 General inlet section without disturbing flow ≥15 DN
2 Behind a control valve ≥50 DN
3 After a pipe diameter reduction ≥20 DN
4 After a single bend 90°≥20 DN
5 After a double bend 2x90°≥30 DN
6 After a double three-dimensional bend 2x90°≥40 DN
7 Outlet section: >5 DN
INFORMATION!
The nominal diameter of the flange is significant for the determination of the minimum inlet and
outlet sections for the nominal diameter reduced versions of vortex flowmeter versions F1R and
F2R.

INSTALLATION 2
13
OPTISWIRL 4200
www.krohne.com03/2016 - 4003931402 - QS OPTISWIRL 4200 R02 en
2.7 Minimum outlet sections
2.8 Flow straightener
If, due to the type of installation, the required inlet sections are not available, the manufacturer
recommends using flow straighteners. Flow straighteners are installed between two flanges
upstream of the device and shorten the required inlet section.
Figure 2-9: Minimum outlet sections
1 Upstream of pipe expanders, pipe bends, control valves, etc. ≥5 DN
2 Upstream of measuring points ≥5 DN
INFORMATION!
The interior of the pipe at the metering points must be free of burrs and other flow impediments.
The measuring device has an internal temperature sensor. The distance from external
temperature measuring points must be ≥5 DN. Use flow sensors that are as short as possible to
avoid disturbances of the flow profile.
Figure 2-10: Flow straightener
1 Straight inlet section upstream of straightener ≥2 DN
2 Flow straightener
3 Straight pipe run between flow straightener and device ≥8 DN
4 Minimum straight outlet section ≥5 DN

2 INSTALLATION
14
OPTISWIRL 4200
www.krohne.com 03/2016 - 4003931402 - QS OPTISWIRL 4200 R02 en
2.9 Installation
2.9.1 General installation notes
The following procedures have to be carried out before installing the device:
• Ensure that the gaskets have the same diameter as the pipelines.
• Note the correct flow direction for the device. This is indicated by an arrow on the neck of the
flow sensor.
• On measuring points with varying thermal loads, the devices have to be mounted with stress
bolts (DIN 2510).
• Stress bolts or bolts and nuts are not included in the scope of delivery.
• Ensure that the measuring flange is concentrically fitted.
• Note the exact installation length of the measuring device when preparing the measuring
point.
CAUTION!
Installation, assembly, start-up and maintenance may only be performed by appropriately
trained personnel. The regional occupational health and safety directives must always be
observed.
Figure 2-11: Preparing the metering point
1 Installation length of measuring device + thickness of gaskets.
CAUTION!
The internal diameter of the pipelines, the flow sensor and the gaskets must match. The gaskets
may not protrude into the flow.
Figure 2-12: Inner diameter
1 Inner diameter of connection pipe
2 Inner diameter of flange and gasket
3 Inner diameter of flow sensor

INSTALLATION 2
15
OPTISWIRL 4200
www.krohne.com03/2016 - 4003931402 - QS OPTISWIRL 4200 R02 en
2.9.2 Installing devices in sandwich design
• Push the first bolt 3through the hole 4of both flanges.
• Screw on the nuts and washers to both ends of the bolt 3but do not tighten them.
• Install the second bolt through the holes 4.
• Place the flow sensor 1between the two flanges.
• Insert the gaskets 5between flow sensor 1and flanges and align them.
• Check that the flange is concentric.
• Install the remaining bolts, washers and nuts. Do not yet tighten the nuts.
• Turn the centring ring 2in a counter-clockwise direction and align the device.
• Check that the gaskets 5are concentric; they must not protrude into the pipe cross-section.
• Now tighten all nuts bit by bit alternately across the diagonal.
Figure 2-13: Installation using centering ring
1 Flow sensor
2 Centering ring
3 Bolts with fixing nuts
4 Drill hole
5 Sealing

2 INSTALLATION
16
OPTISWIRL 4200
www.krohne.com 03/2016 - 4003931402 - QS OPTISWIRL 4200 R02 en
2.9.3 Installing devices in flange design
• Use bolts and fastening nuts 2to attach the measuring device to one side of the flange.
• While doing so, insert the gaskets 1between flow sensor and flange and align them.
• Check that the gasket is concentric and that it is not protruding into the pipe cross-section.
• Install the gasket, bolts and fastening nuts on the other side of the flange.
• Align the measuring device and the gaskets so they are concentric.
• Now tighten all nuts bit by bit alternately across the diagonal.
Figure 2-14: Installing devices in flange design
1 Sealing
2 Bolts with fastening nuts

INSTALLATION 2
17
OPTISWIRL 4200
www.krohne.com03/2016 - 4003931402 - QS OPTISWIRL 4200 R02 en
2.9.4 Mounting the field housing, remote version
Pipe mounting
1 Fix the signal converter to the pipe.
2 Fasten the signal converter using standard U-bolts and washers.
3 Tighten the nuts.
Wall mounting
1 Prepare the holes with the aid of the mounting plate.
2 Use the mounting material and tools in compliance with the applicable occupational health
and safety directives.
3 Fasten the housing securely to the wall.
INFORMATION!
Assembly materials and tools are not part of the delivery. Use the assembly materials and tools
in compliance with the applicable occupational health and safety directives.
Figure 2-15: Pipe mounting of the field housing
Figure 2-16: Wall mounting of the field housing
INFORMATION!
Signal converters with a wall mounting rack have to be mounted with screws (Ø8 mm / 0.3") or
with U-brackets (Ø8 mm / 0.3") in case of pole installation. In case of mounting directly to the
wall, a mounting system with a minimum load force of 0.1 kN (for example FISCHER type UX10)
suitable for the background has to be applied.

2 INSTALLATION
18
OPTISWIRL 4200
www.krohne.com 03/2016 - 4003931402 - QS OPTISWIRL 4200 R02 en
2.10 Heat insulation
CAUTION!
For applications with medium temperatures above +160
° C / +320 ° F an insulation of the pipeline
in accordance to the insulation guideline is suggested. Avoid higher electronic temperatures
than +80
° C / +176 ° F.
The area above the signal converter support must not be heat-insulated.
The heat insulation 3may only extend to the maximum height 1shown below.
Figure 2-17: Installation heat insulation
1 Max. height of the insulation up to the marking on the neck of the flow sensor
2 Max. thickness of the insulation up to the bend of the pressure pipe
3 Insulation
CAUTION!
The heat insulation 3may only extend as far as the bend of the pressure sensing line 2.

INSTALLATION 2
19
OPTISWIRL 4200
www.krohne.com03/2016 - 4003931402 - QS OPTISWIRL 4200 R02 en
2.11 Turning the connection housing
• Loosen the M4 Allen screw 1on the side of the connection housing.
• Rotate the connection housing to the desired position (0...<360°).
• Tighten the M4 Allen screw 1again.
DANGER!
All work on the device electronics may only be carried out by appropriately trained personnel.
The regional occupational health and safety directives must always be observed.
Figure 2-18: Turning the connection housing
1 M4 Allen screw on connection housing

2 INSTALLATION
20
OPTISWIRL 4200
www.krohne.com 03/2016 - 4003931402 - QS OPTISWIRL 4200 R02 en
2.12 Turning the display
Turn the display as follows:
• Disconnect the power supply from the measuring device.
• Unscrew the housing cover with the key 1.
• Please use the handle to pull out the display module.
• First put the handle on side "a" and then on side "b" of the display, and then pull out the
display 2carefully. Turn it into the favoured position 3.
• Disconnect the display from the handle first on side "a" and then on side "b".
• Press the display onto the spacer pins 4, until it clicks.
• Turn the cover with gasket 5back onto the housing and tighten it by hand.
DANGER!
All work on the device electronics may only be carried out by appropriately trained personnel.
The regional occupational health and safety directives must always be observed.
INFORMATION!
If the measuring device is installed in a vertical pipe, you will have to turn the display by 90
° ; if
installed below a pipe, turn 180
° .
INFORMATION!
The display can be turned in increments of 90
° to four positions.
Figure 2-19: Turning the display