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Mounting and Operating Instructions EB 9520 EN
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1. 2 gis ne Pressure gauge connection G V2 LH with coupling sleeve G V for pressura gauge NG 100 and O ring 26 12x2 as well as for G 4 for 2 ressure gauge NG 63 with pi G Ya a i eddie Fig 12 Dimensional drawing 18 EB 9520 EN EB 9520 EN 19 SAMSON AG MESS UND REGELTECHNIK Weism llerstraBe 3 60314 Frankfurt Germany Phone 49 69 4009 0 Fax 49 69 4009 1507 Internet http www samson de EB 9520 EN S Z 2011 03
2. Differential Pressure and Flow Meter Media 05 Fig 1 Media 05 indicating unit with differential pressure cell with valve block and pressure gauge right Mounting and Operating Instructions EB 9520 EN C Edition November 2010 Contents Contents 1 Design and principle of operation 2 2 222er 5 2 WSGNONa ae see eae eee ne tenes Bene ted wee 6 2 1 Arrangement of instruments for liquid level measurement 6 2 2 Arrangement of instruments for flow rate measurement 6 2 3 Media 05 indicating unit aa 6 2 4 Differential pressure lines 2222 oo oo oo 8 2 5 Orifice plate assembly 22222 2 oo oo 8 3 JACCOSSODIBS x0 40e OK GSK a ee d rennt 9 Sl VOWEIDIOGK s och RG ene DERE ERG ERG EEE TOES 7 5 9 3 2 Shut off and equalizing valves o a a oo oo 10 3 3 Equalizing tanks o 444 ac na aa aaa 10 3 4 Accessories for connection 22222 22m 2 nme 10 A IOS 6 2 99 en 3 90 ae ee a Re are e 10 4 1 Flow rate measurement 2 222 Co oo 10 4 2 Liquid level measurement Coon 11 3 Operdiom s s sp A ad ee ee ee ee ar Break EE EE YE 4 11 5 1 Zero adjustment u 5 ace ai Be aK are 11 5 2 Drang s xu 9 x ee 89 5 9 RM EUR SE NES S 12 5 3 Adjusting and modifying the measuring range 2 2 22 lll 12 6 Version with limit switches cens 14 6 1 Electrical connection 2 14 6 2 Adjusting the alarm contacts 2 22 22 2 Cm nme 14 6 3 Retrofitting r
3. ction of the lever 1 8 The movement of the lever in the high pres sure chamber is transmitted to the pointer mechanism 2 2 located in the indicating unit by a flexible disc 1 9 The scale is linear for the differential pressure and squared for the flow rate Version with limit switches The gear segment 2 1 carries the tags 3 1 and actuates the alarm contacts by moving the tags into the adjustable proximity switches 3 2 When the tag enters the pick up field of the associated proximity switch the switch be comes highly resistive contact open When the tag leaves the field the proximity switch becomes low resistive contact closed Design and principle of operation The switching function is activated when the tag moves either into or out of the proximity switch depending on the contact setting SSI b 7 mr NN NN a 4 r P2727 Differential pressure cell Indicating unit 1 1 dp cell 2 1 Gear segment 2 High pressure chamber 2 2 Pointer mechanism 3 Low pressure chamber 2 3 Scale 4 Range Springs Limit switch optional 5 Measuring diaphragm 3 1 Metal tags 7 3 2 Proximity switches 8 for alarm contacts 2 Al and A2 Diaphragm plates Diaphragm shaft Lever Flexible disk u u ee l er rn Fig 2 Version with two alarm contacts EB9520EN 5 Installation 2 Installation 2 1 Arrangement of instruments for liquid level measurement The center schematic top
4. do not exceed the sizing data specified in the order When mounted on vessels in which hazardous area conditions of Zone O are to be expected the Media 05 Differential Pressure and Flow Meter without limit switches may be used to measure flammable gases and liquids provided that the operator observes the relevant regulations on the measurement of flammable gases and liquids of Zone O This means measuring instruments suitable for connection to Zone O may be installed provided that 1 The pipes connecting the instruments have been sized and installed according to the German Technical Regulations for Flammable Liquids TRbF 50 or 2 Flame arresters or endurance burning flame arresters have been installed in the two measuring lines Whether you have to install flame arresters or endurance burning flame ar resters depends on the conditions on site It is however preferable to install endurance burning flame arresters You are required to contact the appropri ate regulatory authority to agree on the necessary measures Nolte that it is the operator s responsibility to meet the requirements specified in 1 and 2 and that SAMSON AG does not assume any responsibility if the operator fails to do so Proper shipping and appropriate storage are assumed Note Devices with the CE mark meet the requirements specified in the Directive 94 9 EC and the Directive 89 336 EEC The Declaration of Conformity is available on request EB 9520 EN 3 Tech
5. e lines located below the shut off valves or the valve block and fill the instru ment with water As an alternative method wait approximately 20 minutes after start up steam switched on with closed shut off and equalizing valves or closed valve block until condensate in the dif ferential pressure lines rises above the valve up to the orifice plate 1 Open the high pressure plus line 2 Close the equalizing valve i e the by pass of the valve block Open the low pressure minus line 4 Wait a moment before unscrewing both vent plugs of the dp cell one after the other until condensate escapes free of bubbles Retighten vent plugs In the same manner vent the equalizing tanks Lightly tap on the housing of the in dicating unit or the equalizing tanks to promote the escape of air 5 Check zero as described in section 5 1 and put the instrument back into service Note In case of reverse installation measuring in strument located above the point of measure ment the differential pressure lines could be come partially drained if the plant is relieved of pressure When starting up again the measuring arrangement must be vented so that it can refill with condensate For liquid measurement 1 Open the high pressure plus line by gradually turning 2 Close the equalizing valve or the bypass of the valve block 3 Open the low pressure minus line Scale screws Fig 7 Zero correction by turni
6. eplacing the contact unit 2 2 mm onen 16 7 JDunensions an MM ss s doo onem he RO oo HABE eRe RE eS 18 WARNING Devices intended to measure gaseous oxygen are labeled vel Da Oxygen Keep free of oil and grease The manufacturer has cleaned and assembled all devices for oxygen service under special con ditions When replacing parts that come into contact with gaseous oxygen e g range springs wear appropriate gloves When returning devices for oxygen service for repair the sender as sumes full responsibility that the devices are handled to meet all requirements stipulated by Ger man specification BVG 7 or similar regulations until they are handed over to the manufacturer Otherwise SAMSON AG does not accept any responsibility 2 EB 9520 EN Safety instructions General safety instructions The device must be installed started up and serviced by fully trained and qualified personnel only observing the accepted industry codes and prac tices Make sure employees or third persons are not exposed to any danger All safety instructions and warnings in these mounting and operating instruc tions particularly those concerning installation start up and maintenance must be observed Any hazards that could be caused at the instrument by the medium and the operating pressure in the instrument are to be prevented by appropriate measures Make sure that the instrument is only used where temperatures and operating pressure
7. erential pressure lines on orifice plate assembly Inlet 20t0 50 xd Outlet 5 x d Fig 4 Orifice plate assembly 8 EB9520 EN For steam For liquids 3 Accessories We recommend that you install both a shut off valve and additionally an equaliz ing valve in the differential pressure lines They are used to shut off the two differential pressure lines and to provide a short circuit at the indicating unit for checking zero 3 1 Valve block A valve block Fig 5 with three combined valves is available accessories The valve block is directly flanged to the bottom side of the dp cell Liquid level measurement Rc inm ne M EEE FE T Media 05 Pressure gauge connection dp line connection Fig 5 SAMSON valve block Accessories On measuring the flow rate of liquids and gases the SAMSON valve block can also be mounted upside down to allow the connec tions to be assigned properly i e to and to However the pressure gauge connection can no longer be used due to the reversed mounting and it must be sealed us ing an O ring and screw cap G 1 LH see dimensional diagram in section 7 Flow rate measurement From the measuring point to the indicating unit l Shut off valves 2 Equalizing valve Fig 6 Shut off and equalizing valves separate or combined as a block EB9520EN 9 Start up 3 2 Shut off and equalizing valves As an alternative to the SAMSON valve bl
8. h for moving the unit frame upward or downward If you want to increase the measuring range turn the screwdriver counterclock wise If you want to decrease the measuring range turn the screwdriver clockwise Retighten the mounting screw 3 4 Correct zero according to section 5 1 Pressurize the dp cell again until the pointer indicates the full scale value 6 Check the upper measuring range value reading the pressure gauge Should it not correspond with the desired measuring range repeat the adjustment procedure until zero and upper range value are properly adjusted 7 Reattach the cover plate 2 and fasten the screws 1 Operation Groove for screwdriver Caw Cover plate Mounting screw Unit frame Scale screws WARNING For devices in oxygen service make absolutely sure that the test medi um is free of oil and grease Use oil free air or other gases e g N Gaseous oxygen as the process medium Max temperature 60 C max oxygen pressure 30 bar When the device is used for oxygen service make sure that the dp cell and any SAMSON accessories only come into contact with gaseous oxygen Supply pressure reducing station with oil filter and test pressure gauge Fig 8 Test arrangement and modifying the measuring range EB9520EN 13 Version with limit switches 6 Version with limit switches One or two proximity switches can be in stalled as alarm contacts AT and A2 as fol low
9. ll the way The instrument is in operation again For applications with installed valve block proceed as described above 5 2 Draining When gases are measured the condensate must be drained from the draining tanks from time to time Close the valves in the differential pressure lines valve block prior to opening the drain plugs 5 3 Adjusting and modifying the measuring range The measuring range of the differential pres sure and flow meter is determined by the in stalled range springs The instrument is cali brated at the factory to the range specified in the order Subsequently it can only be modi fied infinitely variably up to approx 60 of the max measuring span for technical data refer to page 4 For best results adjust on the test bench Fig 8 12 EB 9520 EN Checking the measuring range 1 Adjust zero in the depressurized dp cell as described in section 5 1 2 Make sure that the low pressure minus line is open and apply pressure to the high pressure plus chamber until the pointer indicates 100 Read the pressure gauge and check if the adjusted pressure value corresponds to the current upper range value 3 Depressurize again Correcting and modifying the measuring range 1 Undo the screws 1 and remove the cover plate 2 2 Undo the mounting screw 3 so that the unit frame 4 can be moved easily 3 Place the tip of an appropriate screw driver into the 7 mm notc
10. ng the scale Operation 4 Unscrew one vent plug of the dp cell until the air has escaped and retighten 5 Check zero as described in section 5 1 and put the instrument back into service 4 2 Liquid level measurement See Fig 5 for start up Proceed as described in steps 1 2 3 and 5 for the flow rate measurement Note During measurement make sure that the equalizing valve is closed and that the shut off valves are open NOTICE For cryogenic applications an open equaliz ing valve during measurement causes the me dium to circulate and as a result the valve block to freeze up 5 Operation 5 1 Zero adjustment If the differential pressure lines are fitted with shut off and equalizing valves zero can be checked even when the plant is in operation 1 Close the shut off valve on the high pres sure side Open the equalizing valve Close the shut off valve on the low pres sure side so that a balance of pressure is achieved in the dp cell The pointer must indicate zero EB9520EN 11 Operation If it does not read zero unfasten the scale screws and turn the dial plate adjustable by m In case of larger deviations remove the pointer using an appropriate tool Align the dial plate in the middle position Then reat tach the pointer in zero position on the axis For start up 1 Open the low pressure line 2 Close the equalizing valve 3 Slowly but gradually open the high pres sure line a
11. nical data Media 05 Differential Pressure Meter M vibarloTs20 Oto Oto Oto Oto Oto Oto Oto Oto Oto u s 99 100 160 250 400 600 1000 1600 2500 3600 Measuring spanmbar 4010 600 100 to 160 to 250 to 400 to 600 to pond B rin max 60 100 160 250 400 600 1000 1600 2500 3600 Nominal pressure PN 50 overloadable on one side up to 50 bar Scale 250 scale length approx 162 mm division of scale 0 to 100 Indicator linear or squared for any linear measured quantities for measured quantities acc to equation curve or table Performance Characteristic linear to differential pressure scale linear to tank contents Conforming error lt 2 5 including hysteresis Sensitivity lt 0 5 lt 0 25 Effect of static pressure lt 0 03 1 bar Limit switches 2 inductive alarm contacts Al and A2 acc to EN 60947 5 6 Control circuit Values corresponding to connected isolating switch amplifier e g KFA6 SR2 Ex2 W Proximity switch SJ2 SN when used for hazardous areas corresponding to PTB 00 ATEX 2049 X Switching accuracy lt 2 96 Range of inversion approx 0 6 Perm ambient temperature 40 to 80 C With oxygen 40 to 60 C Perm storage temperature 40 to 100 C Use with gaseous oxygen as the operating medium Max temperature 60 C Max oxygen pressure 30 bar Degree of pro
12. nt is chosen The use of screw joints ensures tight sealing of the lines Lines which would normally be routed hori zontally must be installed with a continuous slope of min 1 20 sloping downward from the orifice plate or the point that enables venting The smallest bending radius must not be below 50 mm Purge the differentia pressure lines thor oughly prior to connecting them to the instru ment 2 5 Orifice plate assembly The process medium flows in the direction in dicated by the arrow An undisturbed straight length of pipe is required at the inlet and outlet sides of the orifice plate assembly Type 90 Orifice With the orifice tubes supplied by SAMSON these pipe lengths are ensured by the welded on calibrated pipes With orifice flanges the straight length of pipe which must precede the orifice plate is specified in the or der confirmation The orifice plate assembly and the seals must not be eccentrically displaced to the pipeline Do not install control valves e g manually op erated valves or temperature regulators that continuously vary the operating state of the process medium upstream of the orifice plate assembly as the operating state is expected to correspond to the calculated state as much as possible Regulators however which do not vary the operating state e g pressure regulators prove to be advantageous upstream of the measuring instrument Type 91 Orifice Tube Attachment of diff
13. ock you can also install the two shut off valves as well as the bypass valve equalizing valve according to Fig 6 3 3 Equalizing tanks Equalizing tanks for maintaining a constant liquid column are required when measuring steam When measuring liquids these tanks are only needed if the indicating unit is lo cated above the point of measurement When measuring gas equalizing tanks func tioning as separation chambers are required for draining the condensate if the indicating unit is located below the point of measure ment 3 4 Accessories for connection The instruments are supplied without screw joints versions for oxygen are protected from contamination by four NBR blanking plugs Required screw joints drain or vent plugs as well as screw joints with orifice plates to dampen the vibrations caused by the mea sured medium especially gas must be or dered separately Note The screw joints as well as SAMSON valve blocks including order numbers are listed in the Data Sheet T 9555 EN 10 EB 9520 EN WARNING Oxygen service When the device is used for oxygen service make sure that the dp cell and any SAMSON accessories e g valve block only come into contact with gaseous oxygen 4 Start up See Fig 6 for start up 4 1 Flow rate measurement For steam measurement The steam should never have direct contact with the measuring diaphragm of the instru ment For this reason unscrew the differential pressur
14. racteristic The bottom edge of the tag causes the contact to be made Maximum contacts Always adjust the switching points according to the increasing characteristic The top edge of the contact causes the contact to be made Adjustment with pressure specifications Connect the device to a switching am plifier as described in section 6 1 Apply a pressure to the high pressure connection of the dp cell which corre sponds to the desired switching point NOTICE The low pressure connection of the dp cell must be open for this pur pose Loosen the clamping screw of the proximity switch bracket according to Fig 10 and manually move the contact into the desired switching position note that the middle of the bracket indicates the position Adjustment range A2 Max contact 100 Ne 0 A 0 Clamping screw M3 SW 5 5 100 Adjustment range Al Min contact Fig 10 Alarm contacts 2 0 100 Adjustment range Al Min contact Version with limit switches Minimum contact From the left move the proximity switch onto the left side of the tag until contact is made Maximum contact From the right move the proximity switch onto the right side of the tag until contact is made Slightly tighten the clamping screw Check the switching point and repeat adjustment if necessary Adjustment without pressure specifications e g on site Connect the instrument to a switching amplifier as desc
15. revent the tags from moving into and out of the proximity switches Moreover make sure that the lines are not damaged when tightening the case cover later on 7 Insert the printed circuit board 1 into the positioning notch from the left and tighten it using a Philips screw 6 Replace the blanking plug of the indicating unit with a cable gland 8 M12x1 5 Protect the cable gland against water en tering until the signal line has been estab lished Establish the electrical connection as de scribed in section 6 1 Positioning notch Fig 11 Retrofitting the alarm contacts Retrofitting replacing the contact unit 10 Reposition the dial from the top and se 11 cure it to the unit frame using the scale screws 2 Fig 8 assuring the right zero position according to section 5 1 Attach the case cover and screw tight preventing the connecting lines of the proximity switches from being damaged Printed circuit board Contact module Unit frame Connecting line A1 Connecting line A2 Slotted head screws Philips screw Cable gland o OocRERGON NO EB9520EN 17 Dimensions in mm 7 Dimensions in mm Hole pattern for wall panel mounting enter of the indicator unit Two holes 8 5 mm for attachment to rear of measuring chamber M8 screws Valve block when mounted upside Two holes 8 5 mm for attachment to valve block M8 screws Pipe mounting m dde lige fle CH
16. ribed in section 6 1 Fig 10 2 AN N Max contact A2 AN OD NZ Min contact Al EB 9520 EN 15 Retrofitting replacing the contact unit Adiust the tag by carefully moving the pointer manually NOTICE Do not move the pointer past the currently in dicated position on the dial You may move the pointer below the indicated position When the tank is full with 100 reading the above action can always be performed how ever when the tank is empty and the dial indi cates O this is not possible 16 EB 9520 EN 6 3 Retrofitting replacing the contact unit The contacts can only be retrofitted or re placed as complete units Contact module Order no 1 Min contact Al 1400 7570 2 Min contacts Aland A2 1400 7571 1 Min contact Al and 1400 7720 1 Max contact A2 1 Unscrew the case cover 2 Undo the screws 1 Fig 8 and remove the cover plate 2 Fig 8 3 Undo the two scale screws 5 Fig 8 lift the dial forward toward the pointer and then remove it upward 4 Slide the contact unit 2 onto the unit frame plate from the right so that the metal tags reach into the proximity switches without touching the contacts 5 Secure the contact unit 2 to the unit frame using two slotted head screws 5 6 Establish the connecting line 4 1 for the alarm contact Al below the unit frame and the connecting line 4 2 for the alarm contact A2 above the unit frame Ensure that the lines do not p
17. row illustrated on the following page shows the additional height z that is included in the measurement Therefore z should be kept as small as possi ble You can select the compensation height K see schematic on the top right of the following page as large as required by the installation conditions on site 2 2 Arrangement of instruments for flow rate measurement The decision whether you have to attach the instrument above or below the point of mea surement or whether you must install equaliz ing tanks or not depends on the type of pro cess fluid and the conditions on site The installation schematics illustrated at the bottom of the following page show standard and reverse installation Standard installation is always to be preferred Choose reverse in stallation only if there is no alternative which often occurs especially when measuring steam For further details on reverse installation we recommend that you refer to VDE VDI 3512 Part 1 6 EB9520 EN 2 3 Media 05 indicating unit Make sure that the high pressure plus line is connected to the high pressure connection and the low pressure minus line to the low pressure connection of the instrument Note You need screw joints to connect the differential pressure lines In addition the un used instrument connections must be fitted with plugs or vent plugs depending on how the instruments are arranged see also sec tion 3 4 Carefully clean the connec
18. s Contact made with Contact and function Min Al as main contact Bottom Min Al as main contact Bottom Min A2 as initial contact Top Min Al as main contact Bottom Max A2 as main contact Top The maximum contact can also be used as a second minimum contact i e as an initial contact In this case however there must bea minimum difference of 15 between the switching point of the initial contact and that of the main contact AT 6 1 Electrical connection This procedure involves connecting the alarm contacts Al and A2 of the indicating unit to a Switching amplifier acc to EN 60947 5 6 Fig 9 Terminal assignment 14 EB 9520 EN switching amplifier or an alarm system ac cording to Fig 9 The listed maximum specifications in the table below apply for the connection of proximity switches to certified intrinsically safe circuits in the type of protection EEx ia IIC T6 PTB OO ATEX 2049 X TA 100 C 6 2 Adjusting the alarm contacts The minimum contacts Aland A2 as well as the contacts in the combination with minimum contact Al and maximum contact A2 can be shifted in the range of O to 100 of the ad justed measuring span Minimum and maxi mum contacts have different designs Contact is made when the tag moves approx imately 6 mm into the proximity switch Minimum contacts Always adjust the switching points according to the decreasing cha
19. tection IP 54 acc to EN 60529 Without SAMSON valve block Approx 2 6 kg plates functional parts lever Weight With SAMSON valve block Approx 4 6 kg Materials Version Standard version Housing Brass CW617N or CrNi steel Measuring diaphragm and seals ECO 2l Range springs diaphragm CrNi steel Indicating unit Polycarbonate 1 Based on the upper measuring range value 2 Other on request NOTE All pressures specified as gauge pressures All errors and deviations in of the adjusted measuring span 4 EB9520 EN 1 Design and principle of operation The Media 05 Differential Pressure and Flow Meter serves to measure and indicate the dif ferential pressure or variables derived from the differential pressure of gases or liquids For example it is used for measuring the liq uid level in pressure vessels the differential pressure between flow and return flow the pressure drops across valves and filters as well as the flow rate according to the differen tial pressure method The device consists of a differential pressure cell with a measuring diaphragm and range springs and an indicating unit including a pointer mechanism and a scale The differential pressure Ap pi p2 pro duced by the orifice plate creates a force act ing on the measuring diaphragm 1 5 pro portionally to the differential pressure This force is balanced by the range springs 1 4 and results in a defle
20. tions prior to con necting the differential pressure lines to the in strument Do not purge the instrument with compressed air or pressurized water At the place of installation attach the instru ment to the pipe wall or mounting plate free of vibrations For attachment to vertical or horizontal pipes use a mounting part with a clamp For wall mounting use a mounting part without a clamp For panel mounting a mounting bracket is re quired see dimensional drawing in sec tion 7 Installation Liquid level measurement Measuring range Shown with SAMSON valve block Measured height Additional height Compensation height Measurement in cryogenic Measurement on pressure Measurement on open vessels with plants liquefied gases vessels with condensing or low lying meter non condensing cushion Flow rate measurement Measuring liquids Measuring steam Measuring gases Orifice plate assembly Equalizina tank qualizing tan Installation Separation chamber Standard Reverse Standard Standard Reverse 1 SAMSON valve blocks can be installed upside down with the dp cell on top to match connections to and to Refer to section 3 1 for more details Fig 3 Arrangement of devices EB 9520EN 7 Installation 2 4 Differential pressure lines Select differential pressure lines with an exter nal diameter of 12 mm and install them ac cording to Fig 3 Make sure the correct ar rangeme
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