ACS contsys Flowcont UN User manual

03.14
Operating Instructions
Main features
Flow sensor for conductive and non-conductive liquids
No moving parts, compact design
Process temperature up to 80 ° C, process pressure up to
10 bar
High chemical resistance due to seal-free sensor design
Large display with keypad
Integrated empty pipe detection
Easy to clean, hygienic version available (EHEDG-approved
and FDA compliant), CIP
Maintenance free ow sensor, saving maintenance costs
Adjustable ranges, reduces variants
Can be used for conducting and non-conducting liquids,
reduces variants and storage costs
Straight measuring tube reduces pressure loss, thus
saving on energy costs
Seal-free sensor increases process reliability and
availability
Flexible measuring system for all industries
Flowcont UN
Flow meter
Ultrasonic ow meter Flowcont UN
Non-contact ow measurement

ACS-CONTROL-SYSTEM GmbH l Lauterbachstr. 57 l D-84307 Eggenfelden l www.acs-controlsystem.de l [email protected]
2
You have purchased a high-grade and modern measuring device of ACS-CONTROL-SYSTEM GmbH.
We want to give thanks for your purchase and for your condence to us.
The actual technical manual includes instructions for installation, electrical connection and inauguration,
as well as the technical data of the device.
Modications, that answer the purpose of the technical progress, are reserved by
ACS-CONTROL-SYSTEM GmbH without prior notice.
If a question occurs, that can‘t be answered by the listed informations, please call on our technicians
team in Eggenfelden Tel: [phone] or [email protected]
All rights reserved

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Index
Principle of operation4
Safety notes 4
Applications 4
Commissioning5
Installation notes 5
Mounting 6
Electrical connection 8
Operation 11
Commissioning procedure 11
Display and menu 11
Overview of default settings 18
General instructions 18
Dimensional drawing 19
Technical data 22
Return 29
Disposal 29

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Principle of operation
Swimming against the stream requires greater physical strength than swimming with the stream. This
is the simple fact on which ultrasonic ow measurement according to the phase difference process is
based. Two sensors positioned opposite one another send and receive ultrasonic signals in alternation.
When static media are used, both sensors receive the sent ultrasonic signal in phase, meaning without
phase difference. If owing media are used, there is a phase shift. The phase shift is different when
measured in the direction of current than when measured against the direction of current. The phase
difference is directly proportional to the speed of the ow. The ow volume is determined from the
speed of the ow and the known diameter of the pipeline.
Safety notes
• Read the instruction manual before commissioning.
• Connection, mounting, and setting only to be done by trained specialists.
• The Flowcont UN is not a safety module according to the EU Machinery Directive.
• Observe the national safety and work safety regulations.
• Repairs may only be carried out by the manufacturer. Changing or altering the device is not
permitted.
• Wiring work and opening and closing of electrical connections are only to be carried out in a de-
energized state.
• Incorrect handling or improper use can lead to malfunctions in your application.
• Flowcont UN can be used by the Pressure Equipment Directive (PED) of group 2 only for „non-
hazardous liquids.“
Applications
The Flowcont UN ow meter is particularly suited for measuring highly dynamic processes in pipelines.
The device measures liquids. It can be used in the following applications, to name but a few:
• Chemical supply for controlling, logistics and monitoring
• Filling processes in the food industry
• Production machines for controlling and monitoring formulae
• Valve control for dosing liquid volumes
• DI water supply
• Dynamic processes
The following featured comprise its performance characteristics:
• no moving parts, and thus no wear
• high reproducibility
• ease of cleaning
• tamper-proof
• compact design
• integrated empty pipe detection
• chemical resistance
• integrated display with membrane keyboard

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Commissioning
Installation notes
An arrow on the measuring channel of the Flowcont UN indicates the ow measurement direction.
The measuring device must be installed such that the ow passes through the measuring tube in the
direction of the arrow.
TOP -> Outlet
Bottom -> Inlet
Optimal FLowcont UN mounting orientation
To detect gases as quickly as possible, the pipeline between the storage container and the FFU
should be as short as possible. An error-free measurement can only be ensured when the pipeline is
completely full and when no liquid is being released as gas. In the case of dosing applications, it may
be useful to position the FFU as close to the dosing valve as possible, because tubing tends to expand
in diameter depending on system pressure. This can lead to deviations.
To avoid cavitations, depending on the measured liquid it can be helpful to have sufcient
backpressure on the outlet Flowcont UN
If any solid particles are present, this can lead to measurement errors.
When pumps are used, the ow sensor must be mounted in the ow direction behind the pump (on
the delivery side) in order to ensure that adequate pressure will be available. The maximum pressure
rating of the FFU must be observed. In order to ensure correct volume ow measurement using the
FFU, in inlet and output paths should be straight and free of obstacles. The minimum inlet and output
paths are dependant on the nominal size:
DN10 DN15 DN20 DN25
Inlet zone 10 cm 30 cm 50 cm 80 cm
Outlet zone 0 cm 5 cm 10 cm 20 cm
Always make sure that the maximum torque of the nuts for the hydraulic connections is not overstep.
Please use the supplied seals. If you seal with teon tape that can result in to excessive tightening
torques. We commend a maximum torque depending on the diameter of:
DN10 DN15 DN20 DN25
Torque G 2 Nm 3 Nm 4 Nm 6 Nm
Caused by the material characteristics of PSU the Flowcont UN has a limited resistance
against UV rays Remind this when mounting Flowmax outdoor

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Mounting
The measuring device is mounted in the pipeline using a process connection. In order to ensure
optimal gas venting, we recommend mounting the Flowcont UN vertically in the pipe. The device
should not be mounted behind an output valve, or it might run idle. To prevent outgassing and bubble
formation in the media during the ow measurement, the Flowcont UN should always be mounted on
the pressure side of the system pump.
If the device cannot be mounted vertically, the pipe in which the measuring device is located should
always be full. Preventing the formation of gas bubbles in the Flowcont UN measuring channel will aid
optimal measurements.
For applications with a „Clean Design“ when complete drain of the measuring tube is needed, we
recommend to mount the ow meter in vertical position. When ow meter is mounted horizontal
caused by the internal geometry of the device there might be a rest of liquid inside.
Attention: The process connections from the FFU are offset by 5 mm (see dimensional drawing on
page 17-19).
Mounted Flowcont UN must alway be mechanically stress free. Strong tension in the pipe system can
lead to damage to the devise. Shocks or mechanical loads can affect the measurement accuracy of
the measuring device. If the FFU must be additionally secured due to the presence of vibrations or
mechanical
motion, two mounting clamps can be mounted to the inlet and outlet of the measuring device.
Flowcont UN with mounting clamps

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Application with hot uids
In applications where the Flowcont UN is subject to high heat (t < 60 °C), we recommend mounting
the measuring device and electronic housing beneath the measurement area. This allows the heat to
radiate upwards and reduces its effects on the device electronics.

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Electrical connection
The Flowcont UN is connected via a ready-made cable socket with M12x1 plug, with 5 pins or 8
pins. Plug in the cable socket without power onto the sensor and screw it tight. Connect the cable in
accordance with its function. After application of the supply voltage, the sensor carries out a self-test
– in an installed state, the sensor is ready for operation after the self-test has been concluded (ca. 4
s) – the display shows the current measured value.
Connection diagram 5-pin variant
Pin Wire colour Function Description
1brown L+ Supply voltage
18 V DC … 30 V DC
2white Digital output Q1
Functions:
1. Pulse
2. Empty pipe detection
3. Dosing output
4. Threshold monitoring
5. Negative ow
Digital output Q1
Can be freely set in the
range of 0.1 to 3000 ml/
pulse
in stages of 0.1 ml/pulse,
npn or pnp transistor,
max. load 18 ... 30 V /
100mA.
Programmable output of 0 V
or 24 V when measuring
tube is empty.
Programmable output of 0 V
or 24 V when dosing
volume is reached.
Programmable output of 0 V
or 24 V when a preset
threshold is exceeded or not
reached.
Programmable output of 0 V
or 24 V during negative
ow.
3blue GND Supply ground: 0 V
4black Communication Communication interface

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5grey Analog output QA
Functions:
1. Flow
2. Temperature
4 ... 20 mA; 0 ... 20 mA
For example: 0 l/min => 4
mA
36 l/min => 20 mA
Alarm => 3,5 mA
(dependent on set measuring
area)
Connection diagram 8-pin variant
Pin Wire colour Function Description
1brown L+ Supply voltage
18 V DC … 30 V DC
2white Digital output Q1
Functions:
1. Pulse
2. Empty pipe detection
3. Dosing output
4. Threshold monitoring
5. Negative ow
Digital output Q1
Can be freely set in the range of
0.1 to 3000 ml/
pulse in stages of 0.1 ml/pulse,
npn or pnp
transistor,
max. load 18 ... 30 V / 100 mA.
Programmable output of 0 V or
24 V when
measuring tube is empty.
Programmable output of 0 V or
24 V when a preset
threshold is exceeded or not
reached.
Programmable output of 0 V or
24 V during
negative ow.
3blue GND Supply ground: 0 V

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4black Digital output Q2
Functions:
1. Empty pipe detection
2. Pulse
3. Threshold monitoring
4. Negative ow 5.Negativ
Fluss
Digital output Q2
Can be freely set in the range of
0.1 to 3000 ml/
pulse in stages of 0.1 ml/pulse,
npn or pnp transistor,
max. load 18 ... 30 V / 100 mA.
Programmable output of 0 V or
24 V when
measuring tube is empty.
Programmable output of 0 V or
24 V when a preset
threshold is exceeded or not
reached.
Programmable output of 0 V or
24 V during
negative ow.
5grey Analog output QA
Functions:
1. Flow
2. Temperature
4 ... 20 mA; 0 ... 20 mA
For example: 0 l/min => 4 mA
36 l/min => 20 mA
Alarm => 3,5 mA
(dependent on set measuring
area)
6pink Communication Communication interface
7purple Digital input IN1
1. Dosing input
2. Offsett compensation
3. Reset counter
4. Creeping ow
Digital input IN1
Starts the dosage by a rising
edge of 24V.
The Offset is set by a rising
edge of 24V.
Reset of the counter by a rising
edge of 24V.
Creeping suppression is
deactivated as long as
there are 24V at the input
8orange No function

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Operation
WARNING: If the Flowcont UN ow sensor is being used for a media other than water, the “Basic
Trim” function must be carried out via the device display during commissioning when the device
is lled with uid. The medium should not be owing during the adjustment, since this affects the
operation of the function.
Commissioning procedure
If the Flowcont UN is being used as a ow meter for water or liquids similar to water, it generally does
not require an on-site adjustment because the factory setting parameters listed below ensure optimal
function.
The following parameters can be adjusted and set in accordance with individual circumstances.
For 5-pin variant:
Digital output 1 (Q1), function and behavior
Analog output (QA)
Flow range for current output
Pulse value
Creeping suppression
The following parameters can be adjusted and set in accordance with individual circumstances.
For 8-pin variant:
- Digital output 1 (Q1), function and behavior
- Digital output 2 (Q2), function and behavior
- Analog output (QA)
- Flow range for current output
- Pulse value
- Creeping suppression
- Digital input (IN1).
Display and menu
The FLowcont UN is available with a display for displaying current measured values as well as for
setting application- specic parameters. The four pushbuttons on the membrane keyboard can be
used to navigate through the menu and carry out settings. Pressing the “Set” button will return you to
the main menu.
The main menu contains a number of submenus for selection. The arrow buttons are used to navigate
through the menu. To select a menu item, press the “Set” button again. To input limit values, such
as the value for “Analog output - Max. range”, you should select the desired settings using the arrow
button. The input value will be saved when the “Set” button is pressed. To return to the menu,
press the “Esc” button. You will need to enter a password to make any changes to the parameters
via the display menu. This ensures that only authorized personnel can make changes to the device
parameters.
The menu password on delivery is 00338.
The user level is valid for 5 minutes after the last press on any button.

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Menu

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Set Offset
In the sub menu “Offset” it is possible to set the actual offset of the ow meter. This function should
just be used when FFU is completely lled with liquid and there is no ow.
A small offset change e.g. caused by variable temperatures is automatically done by the ow meter. It
is also possible to set the offset via the congurable digital inputs.
Language
The language of the display can be changed. Available languages are English and German.
Filter
The function „Filter“ determines the average determination of the analog output signal. Possible
congurations : Soft, Medium, Strong, Off
The analog output signal reacts faster to signal changes when average determination is soft. Whereas
the output signal reacts slower when average determination is strong.
Units
The Flowcont UN is able to show actual ow or the volume in different unities. Following unities can be
selected:
ml/s + l , Gal/min +Gal , l/min + l , l/min + m³.
Example: ml/s + l
The rst letters correspond the unity of the ow value. The letters after the + correspond the unity of
the volume value.
Reset Counter
The volume counter of FFU can be reseted. Note, accidentally erased counter values are permanent
lost. After doing a reset the counting starts again at value „0“.
Basic Trim
This function makes sure that the ow meter is conforming to the media specic characteristics.
Through execute this function FFU runs a self conguration which optimises all important parameters.
This process may last app. 1 minute. To make sure the basic trim is correctly done the ow meter has
to be lled with liquid without a ow. When there is an error detected while doing the basic trim the
display shows “Error”. After successful nishing the function basic trim the display shows “Done”.

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Creeping ow
The creeping suppression serves the purpose of excluding ows from the measurement that can
evolve through convection in a narrow frame around zero, even with a closed valve. At the factory,
the creeping suppression is set at a reasonable standard value in relation to the cross-section of the
ow meter. There are higher tolerances below the standard default settings. The creeping suppression
works with a hysteresis of ±25 %.
Function of the creeping ow illustrated with 0.6 l/min
Example: Creeping ow = 0,6 l/min
If the ow rate is lower than 0.45 l/min the pulse output/analog putput becomes inactive. If the ow
rate exceeds 0.75 l/min a pulse is output again and added to the quantity counter. Similarly, a value is
transmitted to the analog output again.
Setting range: 0,0 ... 20 l/min, in 0,006 l/min steps
Default settings: 0,3 l/min for DN10
0,9 l/min for DN15
3,5 l/min for DN20
5,0 l/min for DN25
Diagnostic
The sub menu „Diagnostic“ shows the actual software/hardware version and many helpful values for
analysis. Knowing about the actual values or the state bits makes it easy to review the measurement
by the manufacturer.
Analog output QA
The analog output is available as current output 4 ... 20 mA or 0 ... 20 mA. Type depending on
purchase order. As a standard it comes with current output 4 ... 20 mA. It can be switched off with
by using the display menu. The current outputs ows from 0 to 22 mA as measure for the ow or the
state of the measuring pipe.
The values here signify for 4 ... 20mA conguration:
- 20 mA the upper limit of the relevant measuring area
- 4 mA the lower limit of the relevant measuring area
- 3.8 mA undershoot the lower limit
- 22 mA overshoot the upper limit
- 3.5 mA empty pipe
Upper and lower limit parameters can be set freely within the type-specic measuring areas of the
device. By default zero ow is set at 4 mA and the respective maximum ow is set at 20 mA.
Setting range: 0 ... 20 mA, 4 ... 20 mA, off
Output value: Flow, temperature
When current output is used make sure the load is not higher than 500 Ohm A higher load
may cause the device can not provide the maximum current of 22 mA

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Dosing
By using the dosing function via the user display manually dosing is congurable. The volume
„Dosing Batch“ and the „Dosing Time“ are freely adjustable. When the „Dosing Time“ is set to zero the
timer control is inactive. A dosage can be started and stopped with the menu function keys „Start“ and
„Stop“ or can be started by the digital input.
Setting range “Dosing Batch”: 0 – 3500 Liters
Setting range “Dosing Time” 0 –30000 Seconds
Default setting “Dosing Batch”: 0 Liters
Default setting “Dosing Time”: 3 Seconds
Pulse value
This determines for what ow volumes an output pulse will be emitted.
Choose conguration such as to neither exceed the maximum ouptput frequency of the FFU (10 kHz)
nor the maximum input frequency of the control.
Example: 2.0 ml/pulse
This means: a pulse is emitted every 2.0 ml.
Setting range: 0.1 ... 3000.0 ml/pulse, in 0.1 ml/pulse steps
Default setting: 1.0 ml/pulse
Digital output Q1
Digital output Q1 may be used as pulse output, empty pipe detection, limit control or negative ow
(ow direction). By using display it is possible to switch between npn and pnp logic.
Setting area: off, pulse output, empty pipe, lower limit, upper limit, negative ow
Digital output Q2
Digital outputs Q2 may be used as pulse output, empty pipe detection, for switching dosing valve,
limit control or ow direction control. The npn or pnp logic can be chosen.
Example 2: FFU pnp-out connected to a counter
Connecting output 2 to external counter
Setting area: off, pulse output, empty pipe, lower limit, upper limit, negative ow
Media
The Flowcont Un dispose of a medium matrix with up to 8 interpolation values. Different medias can
be managed in the sub menu “Media”. Matrix values can be saved and if needed be loaded for different
medias.

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Digital input IN1
The Flowcont UN has a digital input that is programmable to following functions: dosing input, set
offset, creeping suppression inactive and reset counter. In order to start a dosing process, wiring to
24V DC is required. The condition is the conguration of the dosing parameters with the user display.
Dosing input is debounced so that re-start is not possible during a running dosing process. After
changing congurations a restart of the device is needed to activate the function.
Example Dosing
Dosing can basically be realized in two ways:
1. The Flowcont UN as dosing device (dosing control Flowcont UN)
The Flowcont UN does the entire dosing control. The dosing quantity (e.g. 400 ml) is pre-set in the
FFU using the user menu of the display. Dosing starts, as soon as line digital input is wired to 24
V, e.g. via a pushbutton. FFU will now open the dosing valve via the output congured for it. When
the pre-set dosing quantity is reached, the dosing valve is closed via the above output. The dosing
procedure can also be started and stopped by using the dosing user menu. The 2nd output can be
used independently for signaling of empty pipe detection, limit control or ow direction.
The following settings are necessary:
Adjustment of dosage in the menu
Dosing → Dosing quantity → 400 ml
Setting the max. dosing time that should be allowed for safety reasons.
Digital Input I1 → Dosing
Digital Output Q1/Q2 → Function → Dosing
2) Flowcont UN as ow meter (dosing control via dosing equipment)
The dosing equipment is responsible for the entire dosing control. Therefore, the dosing quantity is
xed in the dosing equipment control during commissioning by pre-selecting the meter pulses. Dosing
starts, when the relevant pushbutton of the dosing equipment is pushed. The control will now open
the dosing valve. From now on FFU will send a voltage pulse to the control for each volume unit that
has own through (e.g. per 1ml). When the pre-selected pulse quantity is reached, the control closes
the dosing valve. In this case, output Q1/Q2 is used to send out pulses.
The following settings are necessary:
Adjustment of puls output in the menu
Digital Output Q1/Q2 ==> Function ==> Pulse Output
Options Output ==> Pulse Value ==> e.g. 1 ml per pulse.

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Overview of default settings
Function Default settings
Digital output 1 (Q1) Pulse output
Digital output 2 (Q2) Empty pipe output
Digital input 1 (IN1 No function assigned
Current output (QA) 4 mA … 20 mA
Pulse value 1 ml/pulse
Creeping suppression 0.3 l/min at NW10
0.9 l/min at NW15
3.5 l/min at NW20
5.0 l/min at NW25
General instructions
The following checks should be carried out before the measuring device is switched on for the rst
time:
- Check the electrical connections and the cable conguration
- Check the measuring device mounting position. Is the direction of the arrow on the housing/type
plate the same as the actual ow direction in the pipeline?
- Is the sample line completely lled with liquid?
- Is there a corresponding counterpressure?
The Flowcont UN is ready for operation.

ACS-CONTROL-SYSTEM GmbH l Lauterbachstr. 57 l D-84307 Eggenfelden l www.acs-controlsystem.de l [email protected] 19
Dimensional drawing

ACS-CONTROL-SYSTEM GmbH l Lauterbachstr. 57 l D-84307 Eggenfelden l www.acs-controlsystem.de l [email protected]
20