Flexim FLUXUS G801 User manual

FLUXUS G801
UMFLUXUS_G801V1-0EN
Operating instruction

FLEXIM GmbH
Boxberger Straße 4
12681 Berlin
Germany
Tel.: [phone]
Fax: [phone]
E-mail: [email protected]
www.flexim.com
FLUXUS is a registered trademark of FLEXIM GmbH.
Operating instruction for
FLUXUS G801
UMFLUXUS_G801V1-0EN, 2020-06-26
Article number: 21644
Copyright (©) FLEXIM GmbH 2020
Subject to change without prior notice.

FLUXUS G801 Table of contents
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UMFLUXUS_G801V1-0EN, 2020-06-26
Table of contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2.1 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2.3 Not intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2.4 Safety instructions for the user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2.5 Safety instructions for the operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2.6 Safety instructions for electrical work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2.7 Safety instructions for transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.8 Recommended procedure in hazardous situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
3 General principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
3.1 Measurement principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
3.2 Measurement arrangements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
3.3 Acoustic penetration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
3.4 Undisturbed flow profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
3.5 Influence of noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
3.6 Selection of the measuring point taking into account the flow profile
and the influence of noise 19
4 Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
4.1 Measuring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
4.2 Handling concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
4.3 Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4.4 Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
5 Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
5.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
5.2 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
6 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
6.1 Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
6.2 Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
7 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
7.1 Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
7.2 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
7.3 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
7.4 Serial interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
8 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
8.1 Start-up settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
8.2 Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
8.3 Program branches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
8.4 HotCodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
8.5 Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
8.6 Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
8.7 Date and time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
8.8 Instrument information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
8.9 Interruption of the power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

Table of contents FLUXUS G801
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9 Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
9.1 Parameter input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
9.2 Measurement settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
9.3 Start of the measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
9.4 Display of measured values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
9.5 Execution of special functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
9.6 Determination of the flow direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
9.7 Stop of the measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
10.1 Problems with the measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
10.2 Measuring point selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
10.3 Maximum acoustic contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
10.4 Application-specific problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
10.5 Significant deviations of the measured values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
10.6 Problems with the totalizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
11 Maintenance and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
11.1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
11.2 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
11.3 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
11.4 Examination of the O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
11.5 Examination of the thread on the flameproof enclosure housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
11.6 Examination of housing and sight glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
12 Dismounting and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
12.1 Dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
12.2 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
13 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
13.1 Installation of a binary output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
13.2 Configuration of a frequency output as pulse output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
13.3 Activation of a binary output as pulse output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
14 Data logger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
14.1 Activation/deactivation of the data logger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
14.2 Setting of the storage rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
14.3 Configuration of the data logger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
14.4 Measurement with activated data logger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
14.5 Deletion of measured values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
14.6 Information regarding the data logger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
15 Data transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
15.1 FluxDiagReader/FluxDiag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
15.2 Terminal program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
15.3 Transmission parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
15.4 Data format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
15.5 Data structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

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16 Advanced functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
16.1 Totalizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
16.2 Upper limit of the flow velocity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
16.3 Cut-off flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
16.4 Profile correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
16.5 Uncorrected flow velocity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
16.6 FastFood mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
16.7 Calculation channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
16.8 Diagnosis with the help of the snap function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
16.9 Modification of the limit for the inner pipe diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
16.10 Transducer temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
16.11 Activation of a binary output as alarm output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
16.12 Behavior of the alarm outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
17 SuperUser mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
17.1 Activation/deactivation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
17.2 Transducer parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
17.3 Definition of the flow parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
17.4 Limit of the signal amplification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148
17.5 Upper limit of the sound speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149
17.6 Detection of long measurement failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149
17.7 Number of decimal places of the totalizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
17.8 Manual reset of the totalizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
17.9 Display of the totalizer sum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
17.10 Display of the last valid measured value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
17.11 Displays during the measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
18 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
18.1 Dialogs and menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
18.2 Measurement settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
18.3 Setting of the standard conditions for gas measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
18.4 Libraries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
18.5 Contrast settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
18.6 Program code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
Annex
A Menu structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
B Units of measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171
C Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .174

Table of contents FLUXUS G801
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1 Introduction
FLUXUS G801
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1 Introduction
This operating instruction has been written for users operating the ultrasonic flowmeter FLUXUS. It contains important
information about the measuring equipment, how to handle it correctly, and how to avoid damages. Read the safety
instructions carefully. Make sure you have read and understood this operating instruction before using the measuring
equipment.
Any work on the measuring equipment has to be carried out by authorized and qualified personnel in order to detect and
avoid possible risks and dangers.
Presentation of warnings
This operating instruction contains warnings marked as follows:
Storage of the operating instruction
The operating instruction must permanently be available at the place where the measuring equipment is used. It must
always be available to the user.
User comments
All reasonable effort has been made to ensure the correctness of the content of this operating instruction. If you, however,
find some erroneous information or miss information, please inform us.
We will be grateful for any suggestions and comments regarding the concept and your experience working with the
measuring equipment. If you have any suggestions about improving the documentation and particularly this operating
instruction, please let us know so that we can consider your comments for future reprints.
Copyright
The contents of this operating instruction are subject to changes without prior notice. All rights reserved. No part of this
operating instruction may be reproduced in any form without FLEXIM's written permission.
Danger!
Type and source of danger
danger with high level of risk, which, if not avoided, can lead to death or serious injuries
→ measures of prevention
Warning!
Type and source of danger
danger with medium level of risk, which, if not avoided, can lead to serious or moderate injuries
→ measures of prevention
Caution!
Type and source of danger
danger with low level of risk, which, if not avoided, can lead to moderate or minor injuries
→ measures of prevention
Important!
This text contains important information which should be observed to avoid material damage.
Notice!
This text contains important information about the handling of the measuring equipment.

2 Safety instructions
2.1 General safety instructions FLUXUS G801
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2 Safety instructions
2.1 General safety instructions
Prior to any work, read the operating instruction carefully and in full.
Failure to comply with the instructions, in particular with the safety instructions, poses a risk to health and can lead to
material damages. For further information, contact FLEXIM.
During installation and operation of the measuring equipment, observe the ambient and installation conditions specified in
the documentation.
Explanation of symbols on the transmitter:
The measuring equipment has to be checked for proper condition and operational safety before each use. If troubles or
damages have occurred during installation or operation of the measuring equipment, please inform FLEXIM.
It is not allowed to make unauthorized modifications or alterations to the measuring equipment.
If the measuring point is within an explosive atmosphere, the danger zone and present explosive atmosphere have to be
determined. The transmitter, transducers and accessories have to be appropriate and approved for the conditions within
the corresponding zone.
The personnel has to be suitably trained and experienced for the work.
Observe the "Safety instructions for the use in explosive atmospheres" (see document SIFLUXUS). Observe the instructions
for hazardous substances and the respective safety data sheets. Observe the regulations for the disposal of electrical
equipment.
2.2 Intended use
The measuring equipment is intended for the measurement of fluid properties in closed pipes. By means of connected
transducers, the transit times of the ultrasonic signals in the fluid and the pipe are measured and evaluated.
The transmitter uses these values to calculate the sought quantities, e.g., volumetric flow rate and mass flow rate.
Through comparison with the values stored in the transmitter further physical quantities can be determined. The physical
quantities are provided via configurable outputs and the display.
• All instructions of this operating instruction have to be observed to ensure intended use.
• Any use beyond or other than the intended use is not covered by warranty and can present a danger. Any damage
arising from not intended use shall be solely the liability of the operator or user.
• The measurement is carried out without direct contact to the fluid in the pipe. The flow profile is not influenced.
• The transducers are fixed to the pipe using the supplied transducer mounting fixture.
• If an extension cable is required to connect the transducers to the transmitter, a junction box can be used (optional).
Observe the safety instructions in the operating instruction. For the technical data of the junction box, see technical
specification.
• Observe the operating conditions, e.g., environment, voltage ranges. For the technical data of the transmitter,
transducers and accessories, see technical specification.
symbol explanation
direct current
connection to ground
ground conductor terminal
warning of voltage
observe the operating instruction
Attention!
i

2 Safety instructions
FLUXUS G801 2.3 Not intended use
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2.3 Not intended use
Not intended use in terms of a misuse means:
• any work on the measuring equipment without observing all instructions in this operating instruction
• use of transmitter, transducer and accessory combinations not intended by FLEXIM
• installation of the transmitter, transducers and accessories in explosive atmospheres they are not approved for
• any work on the measuring equipment (e.g., installation, dismounting, connection, start-up, operation, service and
maintenance) carried out by unauthorized and untrained personnel
• storage, installation and operation of the measuring equipment outside the specified ambient conditions (see technical
specification)
2.4 Safety instructions for the user
Any work on the transmitter has to be carried out by authorized and qualified personnel. Observe the safety instructions in
the operating instruction. For the technical data of the transmitter, transducers and accessories, see technical
specification.
• Observe the safety and accident prevention regulations applicable on the site of operation.
• Only use the supplied mounting fixtures and transducers as well as the intended accessories.
• Always wear the required personal protective equipment.
2.5 Safety instructions for the operator
• The operator shall qualify the personnel to perform their assigned tasks. The operator shall provide the required personal
protective equipment and oblige the personnel to wear it. It is recommended to risk assess the workplace.
• Besides the safety instructions in this operating instruction, the health, safety and environment regulations applicable for
the range of application of the transmitter, transducers and accessories have to be observed.
• With the exceptions stated in chapter 11, the measuring equipment is maintenance-free. Any components and spare
parts may only be replaced by FLEXIM. The operator shall carry out periodic checks for changes or damages that can
present a danger. For further information, contact FLEXIM.
• Observe the specifications for the installation and connection of the transmitter, transducers and accessories.
2.6 Safety instructions for electrical work
• Prior to any work on the transmitter (e.g., installation, dismounting, connection, service and maintenance), the
transmitter has to be disconnected from the power supply.
• Electrical work may only be carried out if there is enough space.
• Open the transmitter in safe ambient conditions only (e.g., air humidity < 90 %, no conductive pollution, no explosive
atmosphere).
• The degree of protection of the transmitter is only ensured if all cables are tightly fitted using cable glands and the
housing is firmly screwed.
• The condition and tight fit of the electrical connections have to be checked at regular intervals.
• When connecting the transmitter to the power supply, an appropriate equipment switch according to IEC 60947-1 and
IEC 60947-3 has to be installed as disconnecting device. The equipment switch has to disconnect all live wires. The
ground conductor connection must not be interrupted. The equipment switch has to be easily accessible and clearly
marked as a disconnecting device for the transmitter. It should be located near the transmitter. If the transmitter is used
in an explosive atmosphere, the equipment switch has to be installed outside the explosive atmosphere. If this is not
possible, it has to be installed in the least hazardous area.
• The connection may only be made to networks up to overvoltage category II. When connecting the inputs and outputs as
well as the power supply, observe the installation instructions, in particular the terminal assignment.
• The module must not be removed from the housing. The transmitter does not contain any components to be maintained
by the user. For repair and service work, please contact FLEXIM.
• Observe the safety and accident prevention regulations for electrical systems and equipment.

2 Safety instructions
2.7 Safety instructions for transport FLUXUS G801
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2.7 Safety instructions for transport
• If you detect a transport damage when unpacking the delivery, please contact the supplier or FLEXIM immediately.
• The transmitter is a sensitive electronic measuring instrument. Avoid shocks or impacts.
• Handle the transducer cable with care. Avoid excessive bending or buckling. Observe the ambient conditions.
• Select a solid surface to put the transmitter, transducers and accessories on.
• The transmitter, transducers and accessories have to be properly packed for transport:
– Use, if possible, the original packaging by FLEXIM or an equivalent cardboard box.
– Position the transmitter, transducers and accessories in the middle of the cardboard box.
– Fill any voids with appropriate packaging material (e.g., paper, foam, bubble wrap).
– Protect the cardboard box against humidity.
2.8 Recommended procedure in hazardous situations
Fire fighting measures
• If possible, disconnect the transmitter from the power supply.
• Prior to extinguishing, protect any electrical parts that are not affected by the fire (e.g., using a cover).
• Select a suitable extinguishing agent. Avoid, if possible, conductive extinguishing agents.
• Observe the applicable minimum distances. The minimum distances differ depending on the used extinguishing agent.
Fig. 2.1: Transmitter
Caution!
Warning of injuries due to falling objects
Unsecured and falling objects can lead to severe injuries.
→ Secure all components against falling during transport.
→ Wear the required personal protective equipment.
→ Observe the applicable rules.
module

3 General principles
FLUXUS G801 3.1 Measurement principle
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3 General principles
In the ultrasonic flow measurement, the flow velocity of the fluid in a pipe is determined. Further physical quantities are
derived from the flow velocity and from additional physical quantities, if necessary.
3.1 Measurement principle
The flow velocity of the fluid is measured using the transit time difference correlation principle.
3.1.1 Terms
Flow profile
Distribution of flow velocities over the cross-sectional pipe area. For an optimal measurement, the flow profile has to be
fully developed and axisymmetrical. The shape of the flow profile depends on whether the flow is laminar or turbulent and
is influenced by the conditions at the inlet of the measuring point.
Reynolds number Re
Coefficient describing the turbulence behavior of a fluid in the pipe. The Reynolds number Re is calculated from the flow
velocity, the kinematic viscosity of the fluid and the inner pipe diameter.
If the Reynolds number exceeds a critical value (usually approx. 2300, if the fluid flows in a pipe), a transition from a
laminar flow to a turbulent flow takes place.
Laminar flow
A flow without any turbulence. There is no mixing between the parallel flowing layers of the fluid.
Turbulent flow
A flow with turbulences (swirling of the fluid). In technical applications, the flow in the pipe is mostly turbulent.
Transition range
The flow is partly laminar and partly turbulent.
Sound speed c
Speed of the propagating sound. The sound speed depends on the mechanical properties of the fluid or the pipe material.
In pipe materials and other solid materials, a distinction is made between the longitudinal and transversal sound speed.
Flow velocity v
Average value of all flow velocities of the fluid over the cross-sectional pipe area.
Acoustic calibration factor ka
ka =
The acoustic calibration factor ka is a transducer parameter which results from the sound speed c within the transducer
and the angle of incidence. According to Snell's law of refraction, the angle of propagation in the adjoining fluid or pipe
material is:
ka = = =
Fluid mechanics calibration factor kRe
With the fluid mechanics calibration factor kRe, the measured value of the flow velocity in the area of the sound beam is
converted into the value of the flow velocity across the whole cross-sectional pipe area. In case of a fully developed flow
profile, the fluid mechanics calibration factor only depends on the Reynolds number and the roughness of the inner pipe
wall. The fluid mechanics calibration factor is recalculated by the transmitter for each new measurement.
Operating volumetric flow rate
The volume of the fluid that passes through the pipe per unit time. The operating volumetric flow rate is calculated from the
product of the flow velocity v and the cross-sectional pipe area A.
c
sin
------------
c
sin
------------ c
sin
------------ c
sin
-----------
V
·
V
·

3 General principles
3.1 Measurement principle FLUXUS G801
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Standard volumetric flow rate N (or S)
Volumetric flow rate of a gas under specified standards conditions. During the measurement of a gas, the temperature and
the pressure have a strong influence on the measured operating volumetric flow rate. The measured operating volumetric
flow rate can be converted into the standard volumetric flow rate N by the transmitter:
N =
where
The values for standard pressure pN and standard temperature TN can be entered. The compressibility coefficient of the
gas K is stored in the data set of the fluid or can be entered by the user. The operating temperature T and the operating
pressure p can be fed into the transmitter via the inputs or entered as constant values.
Mass flow rate
= · ρ
The mass of the fluid that passes through the pipe per unit time. The mass flow rate is calculated from the product of the
volumetric flow rate and the density ρ.
3.1.2 Measurement of the flow velocity
The signals are emitted and received by two transducers alternatively in and against the flow direction. If the fluid is
flowing, the signals propagating in the fluid are displaced with the flow.
Caused by this displacement, the sound path of the signal is reduced in flow direction and increased in the opposite
direction.
This causes a change in the transit times. The transit time of the signal in flow direction is shorter than the transit time
against the flow direction. The transit time difference is proportional to the average flow velocity.
The average flow velocity of the fluid is calculated as follows:
v = kRe · ka ·
where
N– standard volumetric flow rate
– operating volumetric flow rate
pN– standard pressure (absolute value)
p – operating pressure (absolute value)
TN– standard temperature in K
T – operating temperature in K
K – compressibility coefficient of the gas: ratio of the compressibility factors of the gas at operating conditions
and at standard conditions (Z/ZN)
v – average flow velocity of the fluid
kRe – fluid mechanics calibration factor
ka– acoustic calibration factor
Δt – transit time difference
tγ– transit time in the fluid
V
·V ·
V
·
V
·V ·p
pN
----- TN
T
----- 1
K
---
V
·
V
·
m
·
m
·V
·
V
·
t
2 t

-----------

3 General principles
FLUXUS G801 3.1 Measurement principle
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Fig. 3.1: Sound path of the signal in the flow direction
c – sound speed
1 – transducer (emitter)
2 – transducer (receiver)
3 – pipe wall
Fig. 3.2: Sound path of the signal against the flow direction
c – sound speed
1 – transducer (emitter)
2 – transducer (receiver)
3 – pipe wall
Fig. 3.3: Transit time difference Δt
1 – signal in the flow direction
2 – signal against the flow direction
cβ
β
α
γcγ
3
21
cαcα
reduction of the
sound path
flow direction of the fluid sound path
with flow
sound path
without flow
cβ
flow direction of the fluid sound path
with flow
sound path
without flow
β
α
γ
cγ
increase of the
sound path 3
12
cαcα
1 2
Δt

3 General principles
3.2 Measurement arrangements FLUXUS G801
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3.2 Measurement arrangements
3.2.1 Terms
Sound path
The distance covered by the ultrasonic signal after crossing the pipe once. The number of the sound paths is:
• odd if the measurement is carried out in diagonal arrangement
• even if the measurement is carried out in reflection arrangement
Beam
The path covered by the ultrasonic signal between the transducers, i.e., the transducer emitting the ultrasonic signal and
the transducer receiving it. One beam consists of 1 or several sound paths.
Transducer distance
The transducer distance is measured between the inner edges of the transducers.
diagonal arrangement reflection arrangement
The transducers are mounted on opposite sides of the pipe. The transducers are mounted on the same side of the pipe.
Fig. 3.4: Diagonal arrangement with
2 beams and 3 sound paths
Fig. 3.5: Reflection arrangement with
1 beam and 4 sound paths
reflection arrangement
diagonal arrangement
(positive transducer distance)
diagonal arrangement
(negative transducer distance)
a – transducer distance
a
a
a

3 General principles
FLUXUS G801 3.2 Measurement arrangements
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Sound beam plane
Plane containing 1 or several sound paths or beams
3.2.2 Examples
Fig. 3.6: 2 beams in 1 plane Fig. 3.7: 2 sound paths in 1 plane
diagonal arrangement with 1 beam reflection arrangement with 1 beam
1 transducer pair
1 sound path
1 beam
1 plane
1 transducer pair
2 sound paths
1 beam
1 plane
diagonal arrangement with 2 beams reflection arrangement with 2 beams and 2 planes
2 transducer pairs
2 sound paths
2 beams
1 plane
2 transducer pairs
4 sound paths
2 beams
2 planes
X arrangement
displaced X arrangement

3 General principles
3.3 Acoustic penetration FLUXUS G801
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3.3 Acoustic penetration
The pipe has to be acoustically penetrable at the measuring point. The acoustic penetration is given when pipe and fluid
do not attenuate the sound signal so strongly that it is completely absorbed before reaching the second transducer.
The attenuation caused by the pipe and the fluid depends on:
• kinematic viscosity of the fluid
• proportion of liquids and solids in the fluid
• deposits on the inner pipe wall
• pipe material
The following requirements have to be met at the measuring point:
• no solid deposits in the pipe
• no accumulation of liquid (condensate), e.g., before orifice plates or at pipe sections located lower
Observe the following notes on the selection of the measuring point:
Horizontal pipe
Select a measuring point where the transducers can be mounted laterally on the pipe, allowing the sound waves to
propagate horizontally in the pipe. By doing this, the solid or liquid deposits on the bottom of the pipe or gas bubbles in the
pipe's upper part are prevented from influencing the propagation of the signal.
3.4 Undisturbed flow profile
Some flow elements (e.g., elbows, valves, pumps, reducers) distort the flow profile in their vicinity. The axisymmetrical
flow profile in the pipe needed for correct measurement is no longer given. A careful selection of the measuring point helps
to reduce the impact of disturbances.
It is most important that the measuring point is chosen at a sufficient distance from any disturbances. Only then it can be
assumed that the flow profile in the pipe is fully developed. However, measuring results can be obtained even if the
recommended distance to disturbances cannot be met for practical reasons (no ideal inflow, see section 16.4).
The recommended straight inlet and outlet pipe lengths for different types of flow disturbances are shown in the following
table.
Fig. 3.8: Recommended transducer mounting position Fig. 3.9: Disadvantageous transducer mounting position
Tab. 3.1: Recommended distance from disturbances
D – nominal pipe diameter at the measuring point
l – recommended distance between disturbance and transducer position
disturbance: 90° elbow
inlet: l ≥ 10 D outlet: l ≥ 5 D
l l

3 General principles
FLUXUS G801 3.4 Undisturbed flow profile
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disturbance: 2 × 90° elbow on different planes
inlet: l ≥ 40 D outlet: l ≥ 5 D
disturbance: valve
inlet: l ≥ 40 D outlet: l ≥ 5 D
disturbance: reducer
inlet: l ≥ 10 D outlet: l ≥ 5 D
disturbance: compressor
inlet: l ≥ 20 D
Tab. 3.1: Recommended distance from disturbances
D – nominal pipe diameter at the measuring point
l – recommended distance between disturbance and transducer position
l l
l l
l l
l

3 General principles
3.5 Influence of noise FLUXUS G801
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3.5 Influence of noise
Ultrasonic waves do not only propagate in the fluid but also in the pipe wall. They are reflected at flanges.
The reflected pipe wall signals can disturb the measurement, especially if:
• the measuring point is close to the reflection point
• the pipe wall signals and measuring signals are received by the transducer at the same time
Measuring points to be avoided
• measuring point directly at the reflection point (l < 3 D)
• measuring point at a distance of (lS± 2) D from the reflection point
– pipe wall signal and measuring signal are received by the transducer at the same time
– Is = · · D
Fig. 3.10: Propagation of ultrasonic waves
1 – ultrasonic waves in the fluid (measuring signal)
2 – ultrasonic waves in the pipe wall (pipe wall signal)
l, ls– distance to reflection point
D – outer pipe diameter
cγ– sound speed of the fluid
cβ– sound speed of the pipe
n – number of sound paths
Fig. 3.11: Measuring points to be avoided
2
1
n
2
--- c
c
-----
l < 3 D (ls - 2) D (ls + 2) D
disadvantageous measuring range
lS

3 General principles
FLUXUS G801 3.6 Selection of the measuring point taking into account the flow profile and the influence of noise
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UMFLUXUS_G801V1-0EN, 2020-06-26
3.6 Selection of the measuring point taking into account the flow profile
and the influence of noise
• Select an area on the pipe where the flow profile is fully developed.
• Select the measuring point within this area so that the influence of noise can be neglected.
Sometimes, both demands cannot be reconciled at the same time. In these cases, the measuring point has to be selected
in such way that the influence of noise is min. and the measuring point is as far from the disturbances of the flow profile as
possible.
Example
fluid: natural gas, cγ= 400 m/s
pipe material: stainless steel, cβ = 3000 m/s
length of pipe segment 1: 20 D
length of pipe segment 2: 20 D
number of sound paths: 2
ls = 7.5 D
• area with developed flow profile:
disturbance: 90° elbow
recommended area for the measuring point: l ≥ 10 D (complete pipe segment 2)
• area with low influence of noise:
reflection point: flange
recommended area for the measuring point: l ≥ 3 D and outside of lS = (7.5 ± 2) D on pipe segment 2
Fig. 3.12: Area for the measuring point with a favorable flow profile and low influence of noise
Considering flow profile and influence of noise, the measuring point can be selected in the area 3...(7.5 - 2) D on the
right side of pipe segment 2 (with max. distance from the elbow).
In the example, a distance of 36 D from the elbow was selected.
20 D 20 D
36 D
(7.5 - 2) D
3 D
disadvantageous measuring range
10 D

3 General principles
3.6 Selection of the measuring point taking into account the flow profile and the influence of noise FLUXUS G801
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Example
fluid: natural gas, cγ= 400 m/s
pipe material: stainless steel, cβ= 3000 m/s
length of pipe segment 1: 20 D
length of pipe segment 2: 5 D
number of sound paths: 2
ls = 7.5 D
• area with developed flow profile:
disturbance: 90° elbow
recommended area for the measuring point: l ≥ 10 D (complete pipe segment 2)
• area with low influence of noise:
reflection point: flange
recommended area for the measuring point: l ≥ 3 D and outside of lS = (7.5 ± 2) D on pipe segment 1
Fig. 3.13: Area for the measuring point with low influence of noise and not fully developed flow profile
In the example, there is no area where both demands are met at the same time. The measuring point has to be selected
as far as possible from the elbow, at a point where the influence of noise can be neglected: 3...(7.5 - 2) D on the right
side of pipe segment 1. In the example, a distance of 16 D from the elbow was selected.
20 D 5 D
16 D
(7.5 - 2) D
3 D
disadvantageous measuring range
10 D