Mecon Re 250 User manual

Operating Instructions

RE 250 Variable Area Flowmeter

age 2 / 32 www.mecon.de BA / RE 250 / EN / V17-11

Imprint

authorization of MECON GmbH.

Subject to change without notice.

MECON GmbH - Röntgenstraße 105 - 50169 Kerpen - Germany

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Contents

1 Safety instructions _________________________________________________________ 4

1.1 Intended use _____________________________________________________________ 4

1.2 Certifications ______________________________________________________________ 5

1.3 Safety instructions from the manufacturer _______________________________________ 5

2 Start-up _________________________________________________________________ 6

3.1 Standard device ___________________________________________________________ 6

3.2 Device with electrical output (MEM) ____________________________________________ 7

3.3 Device with limit switches ____________________________________________________ 7

3 Installation ode of operation _______________________________________________ 8

2.1 Notes on installation ________________________________________________________ 8

2.2 Installation _______________________________________________________________ 8

2.3 Operating principle ________________________________________________________ 10

2.4 Classification according the ressure Equipment Directive 2014/68/EU ________________ 10

4 Service ________________________________________________________________ 11

4.1 Storage _________________________________________________________________ 11

4.2 Maintenance and cleaning __________________________________________________ 11

4.3 Replacing float ___________________________________________________________ 12

4.4 Replacing float damping ____________________________________________________ 12

4.5 Returning the device to the manufacturer ______________________________________ 13

5 Device description _______________________________________________________ 14

5.1 Scope of delivery _________________________________________________________ 14

5.2 Device versions ___________________________________________________________ 14

5.3 Name plate ______________________________________________________________ 16

6 Description code _________________________________________________________ 17

7 Technical Data ___________________________________________________________ 21

7.1 ressure limits vs. temperature stainless steel ___________________________________ 23

7.2 Dimensions and weights ____________________________________________________ 24

8 Electrical connections _____________________________________________________ 28

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Safety Instructions

1 Safety Instructions

1.1 Intended use

The series RE 250 of flowmeters with a standard length of 250 mm (9.84 inch) and a completely

metal design is suitable for measuring different liquids and gases in closed piping.

The robust design enables the operation in rough conditions. Different types of flanges, liners and

float materials meet the requirements of the pharmaceutical and chemical industries.

The devices are particularly suitable for the easure ent of:

• Water

• Fluids

• Corrosion protection agents

• Lubricants

• Saturated and superheated steam

• Food and beverages

• Industrial gases

Warning!

The operator of these measuring devices is solely responsible for the

suitability, intended use and corrosion resistance of the selected mate

rials. It must be particularly ensured that the materials selected for the

wetted parts of the flowmeter are suitable for the process media to be

measured.

The manufacturer is not liable for any damage resulting from improper or

unintended use of these devices.

No external loads may act upon the meter. The flowmeters are primarily designed for static

applications.

Caution!

Hot surfaces resulting from hot process media.

Danger of burns resulting from surface temperatures above 70 °C.

● Take appropriate protective measures, for example contact protection.

● The design of the contact protection must meet the maximum permissible

ambient temperature of the meter..

Caution!

For devices used in hazardous areas, additional safety notes

apply; please refer to the Ex documentation!

The flowmeter may only be operated within the pressure and voltage limits specified on the name

plate.

Before taking the flowmeter out of operations, check that the unit is free of hazardous media and

de-pressurized.

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Safety Instructions

1.2 Certifications

CE arking

The anufacturer certifies for the device RE 250 eets all statutory require ents of the

following EC directives by applying the CE arking:

• ressure equipment directive 2014/68/EU

• Low voltage directive 2014/35/EU *

• EMC-directive 2014/30/EU

• NAMUR recommandation NE21 *

• ATEX directive 94/9/EC **

(*Devices with electrical installations)

(**Devices for use in hazardous areas)

1.3 Safety instructions fro the anufacturer

Disclai er

The manufacturer will not be liable for any damage resulting from the use of its product, including,

but not limited to direct, indirect, incidental, punitive and consequential damages.

Any product purchased from the manufacturer is warranted in accordance with the relevant product

documentation and our Terms and Conditions of Sale.

The manufacturer reserves the right to revise the content of its documents, including this disclaimer,

without prior notification, and will not be liable in any way for possible consequences of such changes.

Product liability and warranty

MECON GmbH assumes no guarantee for repair work carried out by the customer without prior

notification and consultation. Any instruments or parts rejected by a customer must be returned to

us, if no other arrangement has been made.

General infor ation

This manual is intended for the correct installation as well as operation and maintenance of the

devices. Read the instructions carefully before installing the device and placing it into operation.

Specially designed or customized models and specialized applications are not included in this

manual.

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Start up

2 Start-up

2.1 Standard device

When starting up the device, the following points must be observed:

● Ensure that the actual operation conditions (pressure, temperature) do not exceed the limits

which are given on the nameplate of the device

● Avoid float impacts!

Therefore it is recommended to start up with a closed shut-off valve to be opened slowly. The use

of solenoid valves is not recommended.

● When measuring liquids, the pipes must be vented slowly to prevent shock pressure due to gas

bubbles.

● When measuring gases, the pressure must be increased slowly in order to prevent high shock

pressure.

● During start-up of new systems, residual materials may be carried in the medium and could

adhere to the float. In such cases it is recommended to clean the instrument after a relatively

short period of operation.

● When operating the flowmeter at low flowrates, the device has to start-up with a high flowrate to

allow the float to level out. This will ensure measurements within the specified accuracy class.

Special issues for easuring gas flow:

● Valves have to be installed downstream of the device if p

abs

>1.013 bar and upstream of the

device if p

abs

=1.013 bar (free outflow).

● Install a throttle just downstream of the device to prevent compression oscillations during

measurement.

● Ensure that the operating pressure for the flowmeter corresponds to the calibration reference

pressure to avoid erroneous measurements.

Float da ping

A float damping is recommended

● in general for measuring gases

● where piping vibrations can not be avoided

It is also strongly recommended in the case of:

● applications where air bubbles in the medium cannot be avoided

● possibility of shock pressure in the piping, e.g. due to rapid throttling or process shut-off

● turbulence, pulsations, etc. which could lead to vibrations of the flowmeter

● rapid pressure build-up in the piping

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Start up

2.2 Device with current output (MEM)

The magneto-electrical measuring transducer (MEM) is factory-set when it is delivered to the

customer.

After applying the supply voltage to the device, initially the current output will be about 3.5 mA

to 4 mA for a few seconds. After that a current corresponding to the pointer deflection will flow.



Important!

Due to the influence of the float magnet, the MEM transmitter will only

output the correct current if the pointer position is caused by the float.

Turning the pointer manually will cause incorrect values, but it is suitable

for testing the unit.

2.3 Device with li it switches

The limit switches can be set over the entire measuring range by varying the position of the limit

pointers.



Important!

Unless otherwise specified by the customer, the factory set value for the

switching point on versions with one limit switch is about 0% of URV

and for devices with two limit switches it is about 20% / 80% of URV.

To set the limit switches at the desired position the following steps have to be observed:

● Unloosen the two small fixing screws (2) before moving the pointer (1).

● Move the pointer to the desired position.

● Tighten the screws to fix the pointer.

Fig. 2 Adjustment of the switching point (limit switch)

1 Limit pointer

2 Fixing screw

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Installation

3 Installation and ode of operation

3.1 Notes on installation



Information !

All instruments are carefully checked for functional capability before

shipment. Upon receipt of the device please carry out a visual inspection

of the outer packing for damage or improper handling.

Please contact the delivery carrier if you discover any defects. In such

cases a description of the defect, the type and the serial number of the

device are needed.



Information !

Unpack the equipment with care to prevent damage.



Information !

All instruments are carefully checked for order conformity.

Please check the delivery for completeness using the packing list. Please

examine the flowmeter nameplate to verify that the device was built

according to your order. Particularly check devices with electrical

components for the correct supply voltage.

3.2 Installation

Below the essential points concerning installation are described and have to be observed:

● Remove the transport securing device from the fitting.

● rior to the installation verify that the float slides smoothly in the fitting without canting or

deadlocking. The pointer must follow the float movement smoothly.

● Verify that all accessories such as spring stop, gas/fluid damping are still correctly fixed in the

fitting.

● In the zero position (no flow) the pointer must be at the marked reference point (first line on

the scale). When moving the float manually to the end position, the pointer must be above the

final value of the scale.

● The flowmeter must be installed vertically – flow direction from bottom to top. For installation

recommendations refer to guideline VDI/VDE 3513 art 3.

● The installation in the piping must be tension-free – therefore the piping must be positioned

parallel and aligned with each other.

● Avoid a corrosive atmosphere –provide ventilation where necessary.

● Ensure a sufficient distance of at least 200 mm to magnet-influencing parts such as solenoid

valves or ferromagnetic components e.g. steel brackets.

● Observe a lateral distance of at least 300 mm between two devices mounted next to one

another. The distance can be reduced by mounting the devices staggered by the length of one

device. To eliminate doubt the influence can be tested by moving the instrument up and down

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Installation

ca. 200 mm at a selected distance while observing whether the position of the pointer on the

display changes.

● Specify the installation zone regarding a reliable reading of the displayed values and adequate

spacing for servicing.

● An inlet run upstream and an outlet run downstream the device is not necessary in case of a

linear media flow profile. In cases of highly asymmetrical flow profiles, however, additional

measures (e.g. inlet tracks, flow rectifiers) with a length of at least 250 mm could be

appropriate to ensure the measuring accuracy.

● Avoid the installation of unilaterally constricting fittings upstream of the device.

● Ensure that the piping is installed securely to avoid vibration or oscillation of the devices.

● The nominal width of the flowmeter and the connected piping must be identically.

● Use connectors connecting bolts suitable for the particular device version (dimension, pressure

rating).

● Ensure that the clearance between the flanges of the piping corresponds to the device

dimension in addition to two gaskets.

● Before connecting the device, blow or flush out the pipes leading to the device.

● The surface roughness of the flange sealing areas must be appropriate for the used gaskets.

● The gaskets and bolts of the prescribed dimensions must be appropriate for the operating

pressure, the temperature and the media.

● Do not use carbon steel ounting brackets for the device!

Additionally for devices with PTFE liner:

● Use gaskets which conform to the inner and outer dimensions of the raised face of the

flowmeter.

● Tighten the screws crosswise to ensure the tightness of the process connections. For tightening

torques please refer to Tab. “2.2 Tightening torques”.

● If the instrument is absolutely calibrated for a pressure exceeding 1.013 bar any valve is

usually installed at the rear of the flowmeter, at 1.013 bar absolute (free emanation) in front

of the instrument.

Special issues for easuring gas flow:

● Valves have to be installed downstream of the device if p

abs

>1.013 bar and upstream of the

device if p

abs

=1.013 bar (free outflow).

● Install a throttle just downstream of the device to prevent compression oscillations during

measurement.

● Ensure that the operating pressure for the flowmeter corresponds to the calibration reference

pressure to avoid erroneous measurements.

Tightening torques

The flange bolts for devices with TFE liner may be tightened with the following torques (acc.

guideline VDI/VDE 3513):

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Installation

Process connection ax. torque

EN1092-1 ANSI B16.5 N ft



lbf

15 ½” 14 10

25 1” 14 10

40 1 ½” 25 18

50 2” 25 18

80 3” 35 25

100 4” 42 30

Tab 2.2 Tightening torques for devices with TFE liner

Magnetic filters

To prevent a malfunction of the flowmeter caused by ferromagnetic substances contained in the

medium (such as weld beads) a magnetic filter should be mounted in flow direction upstream of

the instrument.

This kind of filter is also recommended if such particles cannot be avoided in standard operation.

3.3 Operating principle

Like other devices of this series the variable area flowmeter RE 250 operates according to the

principle of flotation:

The measuring unit consists of a metal tube with a measuring ring in which a float can move up

and down. The media is flowing upwards through the tube and raises the conical float. Here the

annular gap enlarges until the equilibrium between the buoyancy force F

, the drag force F

and

the weight of the float F

is reached. The adjusted height of the float is directly proportional to

the flowrate. The movement of the float is transmitted via a magnet inside the float to a

corresponding magnet inside the display unit outside of the measuring pipe.

Fig. 1 Operating principle of the RE 250

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Service

3.4 Classification

Classification in accordance with the ressure Equipment Directive 2014/68/EU:

Process connection Ad issible edia Category

EN1092-1 ANSI B16.5

DN 15 ½ ” Gases and fluids of fluid group 1 Art. 3.3

DN 20 ¾ ” Gases and fluids of fluid group 1 Art. 3.3

DN 25 1 ” Gases and fluids of fluid group 1 Art. 3.3

DN 32 1 ¼ ” Gases and fluids of fluid group 1 III

DN 40 1 ½ ” Gases and fluids of fluid group 1 III

DN 50 2 ” Gases and fluids of fluid group 1 III

DN 65 2 ½ ” Gases and fluids of fluid group 1 III

DN 80 3” Gases and fluids of fluid group 1 III

DN 100 4” Gases and fluids of fluid group 1 III

DN 125 5” Gases and fluids of fluid group 1 III

DN 150 6” Gases and fluids of fluid group 1 III

4 Service

4.1 Storage

● Store the device in a dry and dust-free place.

● Keep away from direct sun and heat.

● Avoid external loads to the device.

● The storage temperature range for standard devices with electrical components is

-40 … +70 °C / -40 … +158 °F.

4.2 Maintenance and cleaning

The devices are built for low maintenance operations but periodically the flowmeters should be

inspected for signs of corrosion, mechanical wear as well as damage to the fitting and the display

unit.

We advise to carry out inspections at least once a year.

For a

detailed inspection and cleaning the device must be removed from the piping.

Caution!

Appropriate safety precautions have to be taken when removing the device.

Always use new gaskets when reinstalling the device in the piping.

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Service

4.3 Replacing float

Devices with measuring ring

For devices with standard measuring ranges

starting from 5 - 50 l/h (gases: 0.15 – 1.5 m³/h)

the replacement of the float can be provided by the

customer:

● Remove the device from the piping.

● Fix the device ideally in a horizontal position,

ensuring that the fitting will not be damaged.

● revent the float



from torsion by fixing the

upper guide bracket



using a suitable tool.

● Remove the self-locking nut



which fixes the

lower guide bracket



and take the guide

bracket out of the fitting.

● Take the float upwards out of the measuring

unit.

● Insert the new float into the fitting from the top.

At the same time carefully guide the bottom

end of the float through the measuring ring.

● Slip the lower guide bracket through the thread at the bottom end of the float and fix it with

the self-locking nut.

● Install the device back into the piping.

Important!

Avoid damaging both float and measuring ring.

Important!

After float replacement a recalibration of the flowmeter is highly

recommended, otherwise the measurement accuracy cannot be ensured.

Devices with cone

● Replacing floats for devices with cone (standard measuring ranges up to 5 - 50 l/h (gases:

0.15 – 1.5 m³/h) cannot be done by the customer. The device has to be returned to the

manufacturer. For details please refer to chapter “6.4 Returning the device to the

manufacturer”.

Fig. Replacing floats

1 Float

2 Upper guide bracket

3 Self-locking nut

4 Lower guide bracket

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Device Description

4.4 Replacing float da ping

Devices with measuring ring

For devices with standard measuring ranges starting from

5 - 50 l/h (gases: 0.15 – 1.5 m³/h) the float damping can

be replaced by the customer:

● Remove the device from the piping.

● Fix the device, ensuring that the fitting will not be

damaged.

● The damping cylinder  is fixed by retaining clamps .

Bend up these two clamps carefully using a suitable tool.

● Move the damping cylinder slightly to the bottom end of

the fitting, make a quarter turn and take the cylinder out

of the fitting.

● Insert the new damping cylinder into the fitting from the

top, slide it over the damping part of the float and

arrange it into the retaining clamps.

● Fix the cylinder by bending the retaining clamps

together.

● Install the device back into the piping.

4.5 Returning the device to the anufacturer

This device has been carefully manufactured and tested. Should you nevertheless need to return

a device to MECON GmbH please observe the following points:

Caution!

According to the actual waste disposal directives, the owner/customer is

responsible for the waste management of hazardous and toxic waste.

For reasons of environmental protection and safeguarding the health and

safety of our personnel all devices sent to MECON GmbH to be

repaired must be free of toxic and hazardous substances. This also

applies to cavities of the devices. If necessary the customer is

kindly requested to neutralize or rinse the devices before returning

them to MECON.

The customer has to confirm this by filling in an appropriate form which is

available for download on the MECON website:

www.mecon.de/en/Declaration/Decontamination.pdf

Fig. 3 Replacing float damping

1 Float with damping

2 Upper guide bracket

3 Self-locking nut

4 Lower guide bracket

5 Retaining clamp

6 Damping cylinder

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Device Description

5 Device Description

5.1 Scope of delivery

Fig. 5 Scope of delivery



Information!

Please check the delivery for completeness using the packing list.

5.2 Device versions

Display unit ade of alu iniu

Fig. 6 Standard device with display unit made of aluminium

The measurement range is indicated directly on the scale. The equipment can be supplied with

auxiliary electrical components and touch-sensitive switches for process monitoring and control.

1 Flowmeter RE 250

2 Operating Instructions

3 Certificates (optional)

4 Software (optional)

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Device Description

Display unit ade of stainless steel

Fig. 7 Standard device with display unit made of stainless steel

For applications with requirements for higher protection category or corrosion resistance the

devices are available with a display unit made of stainless steel.

Heating shield

Fig. 8 Device with heating sheath

For installations where temperature drops are unacceptable the devices are available with an

external heating shield.

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Device Description

5.3 Na eplate

Important!

Please refer to the device nameplate to ensure that the device is built

according to your order.

Check particularly for the correct supply voltage.

Fig. 9 Nameplate of the RE 250

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Description Code

6 Description code

Individual part for versions CF-S (stainless steel) and EF-H (Hastelloy

)

The description code consists of the following elements:

Flow tube

A DN 15

B DN 25

C DN 40

D DN 50

E DN 80

F DN 100

Version

1 CF-S wetted parts: stainless steel

2 EF-H wetted parts: Hastelloy

Process connections

Flanges

EN1092-1 ANSI B16.5

Flow tube EN Flow tube ANSI

No inal size

Axx DN 15 ½ ”

   

Bxx DN 20 ¾ ”

   

Cxx DN 25 1 ”

  

Dxx DN 32 1 ¼ ”

      

Exx DN 40 1 ½ ”

       

Fxx DN 50 2 ”

       

Gxx DN 65 2 ½ ”

       

Hxx DN 80 3”

      

Jxx DN 100 4”

     

Kxx DN 125 5”

   

Lxx DN 150 6”

   

 = available  = reduced scale raised face

Pressure rating

xBx N 16 (EN 1092-1) DN 65 - DN 150

xDx N 40 (EN 1092-1) DN 15 - DN 150

xEx N 63 (EN 1092-1) DN 50 - DN 150

xFx N 100 (EN 1092-1) DN 15 - DN 150

xGx N 160 (EN 1092-1) DN 15 - DN 150 (DN 20 and DN 32 not available)

xHx 150 lbs (ASME B16.5) ½ ” – 6 ”

xJx 300 lbs (ASME B16.5) ½ ” – 6 ”

xKx 600 lbs (ASME B16.5) ½ ” – 6 ”

Flange for

xxA B1 (EN 1092-1) N 16 / N 40

xxB B2 (EN 1092-1) N 63 / DN 100

xxC Form D (EN 1092-1) DN 15 - DN 150

xxD Form C (EN 1092-1) DN 15 - DN 150

xxG Form RF (ASME B16.5) ½ ” – 6 ”

xxH Form FF (ASME B16.5) ½ ” – 6 ”

xxJ Form RTJ (ASME B16.5) 1 ” – 6 ”

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Description Code

Process connections (continued)

Threaded connection

Txx Female thread Flow tube EN

xTx DIN ISO 228 1500lbs 1500lbs 1500lbs 900lbs

xNx N T ANSI B 1.20.1 N100 N100 N100 N63

DIN ISO 228

ANSI B1.20.1

A B C D

xx7 G ¼ N T ¼” 

xx8 G ⅜ N T ⅜” 

xx1 G ½ N T ½”   

xx2 G ¾ N T ¾”   

xx3 G 1 N T 1”    

xx4 G 1 ¼ N T 1 ¼”  

xx5 G 1 ½ N T 1 ½”  

xx6 G 2 N T 2” 

Heating sheath

0 Without

1 With flange connection DN 15 DIN 2501 N 40 in stainless steel

2 With flange connection DN 25 DIN 2501 N 40 in stainless steel

3 With flange connection ½ “ ANSI B16.5 150 RF in stainless steel

4 With flange connection 1 “ ANSI B16.5 150 RF in stainless steel

Maxi u range values / Measuring ranges

Fluids Gases Ratio

Pressure drop

[ bar]

[l/h]

[USgp ]

[ ³/h]

[scf ]

1 5 0,022

0,15

0,088