Nivus NFP User manual

Instruction Manual
NFP
®
NFP - Rev. 02 as of 24.11.2009 page 1
Instruction Manual for Measurement System NFP
(Original Instruction Manual – German)
valid as of Software Revision No. 1.52
NIVUS GmbH
Im Täle 2
D – 75031 Eppingen
Tel. 0 72 62 / 91 91 - 0
Fax 0 72 62 / 91 91 - 999
E-mail: [email protected]
Internet: www.nivus.com

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Branch offices
page 2
NIVUS AG
Hauptstrasse 49
CH - 8750 Glarus
Tel.: [phone]
Fax: [phone]
E-Mail: [e-mail]
Internet: www.nivus.de
NIVUS Austria
Mühlbergstraße 33B
A-3382 Loosdorf
Tel.: [phone]
Fax: [phone]
E-Mail: [email protected]
Internet: www.nivus.de
NIVUS France
14, rue de la Paix
F - 67770 Sessenheim
Tel.: [phone]
Fax: [phone]
E-Mail: [email protected]
Internet: www.nivus.com
NIVUS U.K.
Wedgewood Rugby Road
Weston under Wetherley
Royal Leamington Spa
CV33 9BW, Warwickshire
Tel.: [phone]
E-mail: [email protected]
Internet: www.nivus.com
NIVUS U.K.
1 Arisaig Close
Eaglescliffe
Stockton on Tees
Cleveland, TS16 9EY
Phone: [phone]
E-mail: [email protected]
Internet: www.nivus.com
NIVUS Sp. z o.o.
ul. Hutnicza 3 / B-18
PL - 81-212 Gdynia
Tel.: [phone]
Fax: [phone]
E-Mail: [email protected]
Internet: www.nivus.pl
NIVUS Middle East (FZE)
Building Q 1-1 ap. 055
P.O. Box: 9217
Sharjah Airport International
Free Zone
Tel.: [phone]
Fax: [phone]
E-Mail: [e-mail]
Internet: www.nivus.com
NIVUS Korea Co. Ltd.
#411 EZEN Techno Zone,
1L EB Yangchon Industrial Complex,
Gimpo-Si
Gyeonggi-Do 415-843,
Tel. [phone]
Fax. [phone]
E-Mail: [email protected]
Internet: www.nivus.com

Instruction Manual
NFP
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NFP - Rev. 02 as of 24.11.2009 page 3
Translation
If the device is sold to a country in the European Economic Area (EEA)
this instruction handbook must be translated into the language of the
country in which the device is to be used.
Should the translated text be unclear, the original instruction handbook
(German) must be consulted or the manufacturer contacted for clarifica-
tion.
Copyright
No part of this publication may be reproduced, transmitted, sold or dis-
closed without prior permission. Damages will be claimed for violations.
All rights reserved.
Names
The use of general descriptive names, trade names, trademarks and the
like in this handbook does not entitle the reader to assume they may be
used freely by everyone. They are often protected registered trademarks
even if not marked as such.

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Instruction Manual
NFP
page 4 NFP - Rev. 02 as of 24.11.2009
1 Contents
1.1 Table of Contents
1Contents...............................................................................4
1.1 Table of Contents.............................................................................4
2Ex-Approval Transmitter.....................................................6
3Overview and use in accordance with the requirements.7
3.1 Overview..........................................................................................7
3.2 Use in accordance with the requirements .......................................7
3.3 Specifications...................................................................................8
4General Notes on Safety and Danger.................................9
4.1 Danger Notes...................................................................................9
4.1.1 General Danger Signs .....................................................................9
4.1.2 Special Danger Notes......................................................................9
4.2 Device Identification.......................................................................10
4.3 Installation of Spare Parts and Parts subject to wear and tear .....11
4.4 Turn-off Procedure.........................................................................11
4.5 User’s Responsibilities...................................................................11
5Functional Principle ..........................................................12
5.1 General ..........................................................................................12
5.2 Device Versions.............................................................................15
6Storing, Delivery and Transport.......................................16
6.1 Receipt...........................................................................................16
6.1.1 Delivery..........................................................................................16
6.2 Storing............................................................................................16
6.3 Transport........................................................................................16
6.4 Return ............................................................................................16
7Installation..........................................................................17
7.1 General ..........................................................................................17
7.2 Transmitter Installation and Connection........................................18
7.2.1 General ..........................................................................................18
7.2.2 Enclosure Dimensions...................................................................19
7.2.3 Transmitter Connection .................................................................19
7.2.4 Sensor Connection ........................................................................22
7.3 NFP Power Supply.........................................................................23
7.4 Overvoltage Protection Precautions..............................................24
8Initial start-up.....................................................................26
8.1 General ..........................................................................................26
8.2 Operator Panel...............................................................................27
8.3 Display ...........................................................................................28
8.4 Operation Basics............................................................................29
9Parameter Setting..............................................................30
9.1 Basics ............................................................................................30
9.2 Parameter storage.........................................................................32
9.2.1 >PaDa< Installation........................................................................32

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9.2.2 >PaDa< Operation.........................................................................33
9.3 Operation Mode (RUN)..................................................................34
9.4 Display Menu (EXTRA)..................................................................36
9.5 Parameter Menu (PAR) .................................................................38
9.5.1 Parameter Menu „Measurement Place “ .......................................39
9.5.2 Parameter Menu „Flow Velocity“ ...................................................41
9.5.3 Parameter Menu „Digital Input“......................................................41
9.5.4 Parameter Menu "Analog Output" .................................................42
9.5.5 Parameter Menu „Relays“..............................................................44
9.5.6 Parameter Menu „Settings“............................................................46
9.6 Signal Input/Output Menu (I/O)......................................................48
9.7 Calibration and Calculation Menu (CAL) .......................................51
10 Parameter Tree...................................................................53
10.1 Parameter Menu RUN ...................................................................53
10.2 Parameter Menu PAR....................................................................54
10.3 Parameter Menu I/O ......................................................................56
10.4 Parameter Menu CAL....................................................................56
10.5 Parameter Menu EXTRA...............................................................57
11 Troubleshooting ................................................................58
12 Lists of Resistiveness.......................................................60
12.1 Table of Resistiveness...................................................................61
12.2 Resistiveness Legend....................................................................62
13 Maintenance and Cleaning ...............................................63
14 Emergency.........................................................................64
15 Dismantling/Disposal........................................................64
16 Table of Pictures................................................................64
17 Index...................................................................................65
18 Declaration of Conformity.................................................67

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Instruction Manual
NFP
page 6 NFP - Rev. 02 as of 24.11.2009
2 Ex-Approval Transmitter

Instruction Manual
NFP
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NFP - Rev. 02 as of 24.11.2009 page 7
3 Overview and use in accordance with the requirements
3.1 Overview
1 Clear view door
2 Graphic display
3 Keypad
4 Cable Glands
5 Terminal Clamp Housing
6 USB-B Interface
Fig. 2-1 Overview
3.2 Use in accordance with the requirements
The measurement device type NIVUS Full Pipe (NFP) including the active pipe
sensor is intended to be used for continuous flow measurement of slight to
heavy polluted media in permanent full pipes.
Here the allowed maximum values, as specified in chapter 2.3 Specifications
must be strictly kept. All cases which vary from these conditions and are not
passed by NIVUS GmbH in writing are left at owner’s risk.
The device is exclusively intended to be used for purposes as described
above.
Modifying or using the devices for other purposes without the written consent
of the manufacturer will not be considered as use in accordance with the re-
quirements. Damages resulting from this are left at user’s risk.
The device is designed for a lifetime of approx. 10 years. After that period an
inspection in addition with a general overhaul has to be made.
The transmitter always has to be installed outside of Ex-zones!

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Instruction Manual
NFP
page 8 NFP - Rev. 02 as of 24.11.2009
Approval
II(2)G [EEx ib] IIB
Sensor connections ignition protection type intrinsically safe EEx ia IIB
Clamps 50...54 for connection of certified sensors only
Type POA/... according to TÜV 03 ATEX 2262
Max. values per circuit:
U0= 10,5 V
I0= 640 mA
rectangular characteristic
Max outer inductivities allowed: 0,12 mH
Max. outer capacities allowed: 4,8 µF
The intrinsically safe circuits are isolated galvanically safe from the remaining
circuits up to a peak voltage value of 375 V.
3.3 Specifications
Power supply
100 to 240 V AC, +10 % / -15 %, 47 to 63 Hz
or 24 V DC ±15 %, 5 % residual fluctuation
Power consumption
max. 18 VA, type 7 VA
Wall mount enclosure
- Material: Polycarbonate
- Weight: approx. 1620 g
- Protection: IP 65
Ex-Approval (optional)
II(2)G [EEx ib] IIB
Operating temperature
-20 °C to +60 °C (-4 °F to +140 °F)
Ex: -20 °C to +40 °C (-4 °F to +104 °F)
Storage temperature
-30 °C to +70 °C (-22 °F to +158 °F)
Max. humidity
90 %, non-condensing
Display
Back-lit graphic display, 128 x 64 pixel
Operation
6 keys, menu driven in German, English and French
Inputs
- 1 x digital input
- 1 active tube sensors connectable
Outputs
- 1/3 x 0/4–20 mA, load 500 Ohm, 12 bit resolution,
accuracy better than 0.1 % (after calibration)
- 2 switchable relays, loadable up to 230 V AC / 2 A (cos. ϕ 0.9 )

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4 General Notes on Safety and Danger
4.1 Danger Notes
4.1.1 General Danger Signs
Cautions
are framed and labelled with a warning triangle.
Notes
are framed and labelled with a “hand“.
Danger by electric voltage
is framed and labelled with the Symbol on the left.
Warnings
are framed and labelled with a “STOP“-sign.
For connection, initial start-up and operation of the NFP the following information
and higher legal regulations (e.g. in Germany VDE), such as Ex-regulations as
well as safety requirements and regulations in order to avoid accidents, must be
observed.
All operations which go beyond steps to install, to connect or to program the de-
vice shall be carried out by NIVUS staff or authorised persons or companies only
due to reasons of safety and guarantee.
4.1.2 Special Danger Notes
Please note that due to the operation in the waste water field, transmitter,
sensors and cables may be loaded with dangerous disease germs. Respec-
tive precautionary measures must be taken to avoid damage to one’s health.

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Instruction Manual
NFP
page 10 NFP - Rev. 02 as of 24.11.2009
4.2 Device Identification
The instructions in this manual are valid only for the type of device indicated on
the title page.
The nameplate is fixed on the bottom of the device and contains the following:
- Name and address of manufacturer
- CE label
- Type and serial number
- Year of manufacture
- Ex-label (on Ex-version devices only) as mentioned in chapter 2.2.
It is important for enquiries and replacement part orders to specify article num-
ber as well as serial number of the respective transmitter or sensor. This en-
sures correct and quick processing.
Art. Nr. NFP-xx W0 xx E x
Ser. Nr. JJKW NFP yyyyy
NR. 0044
IBExU07ATEXxxxx
II (2)G [EEx ib] IIB
Elektrische Werte siehe Be-
scheinigung/Betriebsanleitung
18-36V DC
18W
Fig. 3-1 NFP nameplate
This instruction manual is a part of the device and must be available for the
user at any time.
The safety instructions contained within have to be observed.
For installation and operation of the entire system additionally please refer to
technical instructions of correlation sensors and “Installation Instruction for
Pipe and Wedge Sensors” besides this instruction manual.
It is strictly prohibited to disable the safety features or to modify their function.

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4.3 Installation of Spare Parts and Parts subject to wear and tear
We herewith particularly emphasize that replacement parts or accessories,
which are not supplied by us, are not certified by us, too. Hence, the installation
and/or the use of such products may possibly be detrimental to the device’s abil-
ity to work.
Damages caused by using non-original parts and non-original accessories are
left at user’s risk.
4.4 Turn-off Procedure
For maintenance, cleaning and repairs (authorised staff personnel only) the
device shall be disconnected from mains and shall be prevented from being
turned on again unintentionally.
4.5 User’s Responsibilities
In the EEA (European Economic Area) national implementation of the frame-
work directive 89/391/EEC and corresponding individual directives, in particu-
lar the directive 89/655/EEC concerning the minimum safety and health re-
quirements for the use of work equipment by workers at work, as amended,
are to be observed and adhered to.
In Germany the Industrial Safety Ordinance of October 2002 must be ob-
served.
The customer must (where necessary) obtain any local operating permits re-
quired and observe the provisions contained therein.
In addition to this, he must observe local laws and regulations on
- personnel safety (accident prevention regulations)
- safety of work materials and tools (safety equipment and maintenance)
- disposal of products (laws on wastes)
- disposal of materials (laws on wastes)
- cleaning (cleansing agents and disposal)
- environmental protection
Connections:
Before operating the device the user has to ensure, that the local regulations
(e.g. for operation in channels) on installation and initial start-up are taken into
account, if this is both carried out by the user.

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Instruction Manual
NFP
page 12 NFP - Rev. 02 as of 24.11.2009
5 Functional Principle
5.1 General
The NFP is a permanent measurement system for flow measurement of slightly
to heavily polluted media with various consistencies in constantly full filled pipes.
The method of flow velocity investigation is based on the ultrasound reflection
principle. Hence, it is indispensable for the system to work that there are parti-
cles in the water, which are able to reflect the ultrasonic signal sent by the
sensor (dirt particles, gas bubbles or similar).
The piezo crystal, which has a slope towards the flow direction, operates as a
flow velocity sensor. Here an ultrasonic burst with a defined angle is sent into
the medium. All the particles in the measurement path (air, dirt) reflect a small
amount of the ultrasonic signal. Depending on shape and size of the particle a
particular signal results. Hence, the multitude of the reflected signals results in a
reflection pattern (see Fig. 4-1). This signal pattern will be loaded into the active
pipe sensor’s built-in digital signal processor (DSP).
1 Pipe wall
2 Pipe sensor
E1 – E7 Reflecting particles
1, 2, 3, 4, n Measurement window
Fig. 4-1 Situation at first signal detection
After a certain period a second ultrasonic burst is sent into the medium (see
Fig. 4-2). The newly generated reflection signal is saved in the DSP too.
In various sections there are different flow velocities, where in case of full filled
pipes and sufficient calming sections the maximum velocity is in the centre of the
pipe. Depending on medium viscosity, flow velocity and wall roughness this ve-
locity decreases approaching the pipe wall (flow velocity profile, see Fig. 4-4).

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The reflecting particles have moved away from the first measurement point by
varying distances due to the flow velocity profile prevailing in the pipe. Hence, a
distorted reflection pattern results (see Fig. 4-3). At the same time slightly differ-
ent reflections will emerge additionally resulting from the fact that some particles
have been turning around and thus have another shape of reflection; some par-
ticles are no longer within the measurement range and others have now moved
into the measurement range.
1 Pipe wall
2 Pipe sensor
E1 – E7 Reflecting particles
1, 2, 3, 4, n Measurement window
Fig. 4-2 Situation at second signal detection
The DSP checks both the received reflection patterns for similarities using the
cross correlation method. All existing signal differences are rejected so that two
similar but temporarily offset signal patterns are left for velocity evaluation.
Depending on the inner pipe diameter set an overlay consisting of up to 16
measurement windows of different lengths will be added. Then, in each meas-
urement window the lag ∆t of the signal pattern is investigated (see Fig. 4-3).
Fig. 4-3 Echo signal images and evaluation
Based on the beam angle, the interval between both transmitted signals and the
lag of the signal pattern therefore in each single measurement window the flow
velocity can be determined.

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Instruction Manual
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page 14 NFP - Rev. 02 as of 24.11.2009
Stringing together the single flow mathematically velocities results in the flow
profile of the acoustic path which is directly indicated on the display.
Fig. 4-4 Investigated flow profile
If there are appropriate banking distances on the measurement place available,
based on the known pipe geometry and the velocity distribution a 3-dimensional
flow distribution can be rendered.
From this flow velocity distribution and the mathematical weighting of the indi-
vidual gates regarding the Reynolds number it is possible to calculate the aver-
age flow velocity. From this velocity multiplied by the circular pipe area we can
obtain the flow rate.
This rate can either be a free programmable analog signal or an impulse signal
as well.

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5.2 Device Versions
The NFP transmitter as well as the accompanying flow velocity are available in
different versions.
The transmitters primarily vary in terms of maximum pipe diameter, power sup-
ply, Ex-protection as well as the number of analog outputs.
The current type of device is indicated by the article number, which can be found
on a weatherproof label on the bottom of the enclosure. From this article key the
type of device can be specified.
NFP- Type
05 Nominal diameter 100 - 500 mm
08 Nominal diameter 550 - 800 mm
Construction
W0 Wall mount enclosure IP65
Power Supply
AC 115-230 V AC, 50-60 Hz
DC 18-36 V DC
Approvals
0none
EATEX approval
Extensions (Hardware)
11 analog output
33 analog outputs
NFP-
Fig. 4-5 Type key for NFP measurement transmitter

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Instruction Manual
NFP
page 16 NFP - Rev. 02 as of 24.11.2009
6 Storing, Delivery and Transport
6.1 Receipt
Please check your delivery according to the delivery note for completeness and
intactness immediately after receipt. Any damage in transit must be instantly re-
ported to the carrier. An immediate, written report must be sent to NIVUS GmbH
Eppingen as well.
Please report any delivery incompleteness in writing to your representative or di-
rectly to NIVUS Eppingen within two weeks.
Mistakes cannot be rectified later!
6.1.1 Delivery
The standard delivery of the NFP transmitter contains:
- the instruction manual with the certificate of conformity. Here, all necessary
steps to correctly install and to operate the measurement system are listed.
- a NFP transmitter
- a 2.5 mm special screw driver to use the caged spring terminals in the con-
nection compartment of the transmitter
Additional accessories such as sensors, welding nozzle, tapping saddle, ball
stop valve, pipe sensor retaining element etc. depending on order. Please check
by using delivery note.
6.2 Storing
The following storing conditions shall be strictly adhered to:
Transmitter:
max. temperature: + 70 °C (158 °F)
min. temperature: - 30 °C (-22 °F)
max. humidity: 90 %, non-condensing
The devices must be protected from corrosive or organic solvent vapours, radio-
active radiation as well as strong electromagnetic radiation.
6.3 Transport
The device is conceived for harsh industrial conditions. Despite this do not ex-
pose them to heavy shocks or vibrations.
Transportation must be carried out in the original packaging.
6.4 Return
The device must be returned at customer cost to NIVUS Eppingen in the
original packaging.
Otherwise the return cannot be accepted!

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7 Installation
7.1 General
For electric installation the local regulations in the respective countries (e.g. VDE
0100 in Germany) must be referred to.
The NFP power supply must be separately protected by a 6 A slow-blow fuse
and has to be isolated from other facility parts (separate turn-off, e.g. by using
an automatic cut-out with >B< characteristics).
Before feeding the rated voltage the transmitter and sensor installation must be
correctly completed. The installation should be carried out by qualified personnel
only. Further statutory standards, regulations and technical rulings have to be
taken into account.
All outer circuits, wires and lines connected to the device must have a minimum
isolation resistance of 250 V. If the voltage exceeds 42 V DC an isolation re-
sistance with 500 kOhm min. will be required.
The cross-sectional dimension of the power supply wires must be 0.75 mm2
(0.03 in2) and must be in accordance to IEC 227 or IEC 245. The device protec-
tion rating is IP 65.
The maximum allowed switching voltage on the relay contacts must not exceed
250 V. According to Ex protection it must be checked if the devices power sup-
plies must be integrated into the facility’s emergency shutdown conception.

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Instruction Manual
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page 18 NFP - Rev. 02 as of 24.11.2009
7.2 Transmitter Installation and Connection
7.2.1 General
The transmitters mounting place has to be selected according to certain criteria.
Please strictly avoid:
- direct sunlight (use weatherproof cover if necessary)
- heat emitting objects (max. ambient temperature: +40 °C (104 °F))
- objects with strong electromagnetic fields (e.g. frequency converters, electric
motors with high power consumption or similar)
- corrosive chemicals or gas
- mechanical shocks
- installation close to footpaths or travel ways
- vibrations
- radioactive radiation
The most simple way to install a wall mount enclosure is to fasten a DIN rail with
a length of 210 mm (8.3 in.) and then to snap-on the enclosure.
It is possible to install the enclosure by using 3 screws as well. Use a pan head
screw with a head diameter of 5.5 ... 8.0 mm (0.22 ... 0.32 in.) for this. This
screw must be screwed into the mounting plate protruding 4 mm (0.16 in.). Then
hang the enclosure on the screw and additionally fix it with 2 more screws from
the terminal clamp housing.
The clear view door of the measurement transmitter is provided with a protection
foil for protection during transport and from scratches during assembly. This pro-
tection foil has to be removed immediately after the assembly.
If the view door protection foil has been exposed to direct solar radiation for a
long period, it cannot be removed easily.
Cleaning of the front foil can be undertaken with spirit or if necessary with car
polish. If this is not successful, a new front door can be ordered from NIVUS
GmbH or your local representative.

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7.2.2 Enclosure Dimensions
Fig. 6-1 Wall Mount Enclosure
7.2.3 Transmitter Connection
General
The field enclosure has cable glands and dummy plugs. Some of them are
screwed in and some are enclosed as spare parts or additional parts.
The transmitter contains:
1 gland M20 x 1.5
2 glands M16 x 1.5
With the supplied glands the following outer cable cross-sections can be con-
nected reliably:
M16 x 1.5 3.5 mm – 10.5 mm
M20 x 1.5 6.0 mm – 14.0 mm
To be able to use cable diameters outside of the tolerance, glands must be used
which ensure IP 65 minimum protection.
Unused lead-ins have to be locked with an appropriate dummy plug before the
initial start-up.

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page 20 NFP - Rev. 02 as of 24.11.2009
Each time before opening the terminal clamp housing (see Fig. 2-1) please
ensure to disconnect the NFP from any voltage.
It is not allowed to remove the front panel.
Before the first connection it is necessary to have a slight pressure on the
screw of the clamping connection to ensure its safe opening and a correct
connection.
In terms of electric connection please note the device configuration (Fig. 4-5)
since unspecified inputs, outputs as well as power supply connections are not
connected.
On power supply and relay clamps one copper wire with a maximum cross-
section of 2.5 mm² (0.01 in.) can be connected per clamp. Connection is made
by using terminal clamps and a screwdriver with a 2.5 mm (0.01 in.) blade.
All other clamps are equipped with tension springs or plug connectors with
screw connections requiring the use of a special screw driver which is part of the
standard delivery. It is possible to connect one copper wire 1.5 mm² or one cop-
per strand with max. 1 mm² per clamp.
Fig. 6-2 Connection Enclosure
Water or dirt must not leak into the terminal housing. Please seal the housing
with the supplied lid and both screws respectively.