SUTO S 460 Manual

English
Instruction and operation manual
S 460
Ultrasonic Flow meter

Dear Customer,
Thank you for choosing our product.
Before starting up the device please read this manual in full and
carefully observe instructions stated in this manual. The manufacturer
cannot be held liable for any damage that occurs as a result of non-
observance or non-compliance with this manual.
Should the device be tampered with in any manner other than a
procedure that is described and specified in the manual, the warranty is
cancelled and the manufacturer is e empt from liability.
The device is destined e clusively for the described application.
SUTO offers no guarantee for the suitability for any other purpose.
SUTO is also not liable for consequential damage resulting from the
delivery, capability or use of this device.
2 S 460

Table of Contents
1 Safety instructions......................................................................4
2 Applications................................................................................6
3 Features....................................................................................6
4 Technical Data............................................................................7
4.1 General......................................................................................7
4.2 Electrical Data.............................................................................7
4.3 Output-Signals............................................................................7
4.4 Accuracy ...................................................................................7
5 Determination of installation point.................................................8
6 Installation...............................................................................10
6.1 Configuration.............................................................................10
6.1.1 Usage of keypad ..................................................................10
6.1.2 Configuring the transducer parameters ...................................11
6.1.3 Description for the parameter settings ....................................11
6.2 Installation procedure ................................................................12
6.2.1 Installing the transducers.......................................................12
6.2.2 Removing a transducer..........................................................14
6.2.3 Installing the housing (Optional).............................................14
6.3 Electrical connection .................................................................14
6.4 Final check................................................................................15
7 Troubleshooting........................................................................16
7.1 Power-on errors and countermeasures..........................................16
7.2 Error codes and countermeasures.................................................16
7.3 Other problems and solutions......................................................18
8 Signal outputs..........................................................................19
8.1 Analog / Pulse output ................................................................19
8.2 Interface ..................................................................................19
9 Calibration................................................................................19
10 Maintenance...........................................................................20
11 Disposal or waste....................................................................20
12 Warranty................................................................................20
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1 Safety instructions
1 Safety instructions
Please check if this instruction manual accords to the
product type
Please observe all notes and instructions indicated in this
manual. This manual contains essential information that must
be observed before and during installation, operation and
maintenance. Therefore this manual must be read carefully by the
technician as well as by the responsible user or qualified personnel.
This instruction manual must be available at the operation site of the
product at any time. In case of any obscurities or questions regarding
this manual or the product, please contact the manufacturer.
WARNING!
Voltage used for supply!
Any contact with energized parts of the product, may
lead to a electrical shock which can lead to serious
injuries or even death!
•Consider all regulations for electrical installations.
•The system must be disconnected from any power supply during
maintenance work.
•Any electrical work on the system is only allowed by authorized
qualified personal.
WARNING!
Permitted operating parameters!
Observe the permitted operating parameters, any
operation exceeding this parameters can lead to
malfunctions and may lead to damage on the
instrument or the system
•Do not e ceed the permitted operating parameters.
•Make sure the product is operated in its permitted limitations.
Store and operate the product at the permitted temperature and
pressure.
•The product must be maintained and calibrated frequently, at least
annually.
4 S 460

1 Safety instructions
General safety instructions
•It is not allowed to use the product in e plosive areas.
•Please observe the national regulations before/during installation
and operation.
Remarks
•It is not allowed to disassemble the product.
•Always use spanner to mount the product properly.
ATTENTION!
Measurement values can be affected by malfunction!
The product must be installed properly and
frequently maintained, otherwise it may lead to
wrong measurement values, which can lead to
wrong results
•Do not e ceed the ma imum operation temperature of the
transducer.
•Avoid condensation on the transducer element as this will affect
the accuracy enormously.
Storage and transportation
•Make sure that the transportation temperature of the device is
between -30 °C... 70 °C.
•For transportation it is recommended to use the packaging which
comes with the device.
•Please make sure that the storage temperature of the device is
between -10 °C... 50 °C.
•Avoid direct UV and solar radiation during storage.
•For the storage the humidity has to be <90%, no condensation.
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2 Applications
2 Applications
The S 460 is an ultrasonic flow meter which is designed to measure the
flow and consumption of liquids within the permissible operating
conditions. S 460 uses clamp-on transducers that can be mounted
outside the pipe and brings you flow measurement with benefits
including reduced installation costs, uninterrupted production, and no
contact with internal liquid.
The liquids that S 460 can measure include the following:
•Chemical addition
•Cooling and heating water
•Drinking water
•Broad range of refined hydrocarbons
•Potable water
•De-ionized and de-mineralized water
•Sanitary liquid
•Purified water
The default units are: Velocity in m/s, Volume flow in m3/h and Total
Consumption in m3. Other units are available by configurations through
the optional display or the service kit.
The S 460 flow meter is mainly used in industrial environment. It is not
developed to be used in e plosive areas. To use it in e plosive areas
please contact the manufacturer.
3 Features
•Uses the proven clamp-on transit-time correlation technique.
•Easy to install for permanent and temporary installations.
•High accuracy.
•Configurable physical units.
•A wide range of pipe sizes from DN32 to DN6000.
•Plug and play for the display and data logger products from the
same manufacturer.
•Data analysis via the S4M software.
6 S 460

4 Technical Data
4 Technical Data
4 1 General
Physical units Standard flow unit: m3/h
Available flow units: m3/min, l/min, l/s, cfm
Standard velocity unit: m/s
Principle of measurement Clamp-on transit-time correlation technique
Sensor Transducer
Measuring medium Different kinds of Liquid
Operating temperature Transducer: -30 °C... 90 °C
Controller: -20 °C... 60 °C
Housing material Aluminum
Protection class IP65
Dimensions 190 mm 155 mm 85 mm
Tube diameter Depending on the transducers:
TS-2: DN32 ... DN100
TM-1: DN100 ... DN700
TL-1: DN300 ... DN6000
Weight 2.55 kg
4 2 Electrical Data
Power supply 230 VAC or 24 VDC
4 3 Output-Signals
Analogue output 4... 20 mA
Pulse output 1 pulse per consumption unit
Pulse width selectable (6 ... 1000 ms)
Interface Modbus RTU
4 4 Accuracy
Accuracy 2% (0.03 … 2.00 m/s)
1% (2.00 … 7.00 m/s)
Repeatability 0.20%
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5 Determination of installation point
5 Determination of installation point
To maintain the accuracy stated in the technical data, the ultrasonic
transducers must be clamped on a straight pipe with unhindered flow
characteristics. The pipe can be in vertical or horizontal position.
Unhindered flow characteristics are achieved if the section in front of
the transducer (upstream) and behind the transducer (downstream) are
sufficiently long, absolutely straight and free of obstructions such as
edges, seams, curves, and so on.
The following table shows e amples of optimum installation locations.
8 S 460

5 Determination of installation point
Principles to select an optimum location:
•Install the transducers on a long straight pipe. The longer the
better and make sure that the pipe is completely full of liquid.
•Make sure that the temperature on the location does not e ceed
the permitted temperature range for the transducers. Generally,
the closer to the room temperature the better.
•Take the pipe fouling into consideration. Select a straight and
relatively new pipe. If the condition is not satisfying, consider the
fouling thickness as part of the liner for a more accurate result.
Remarks
Some pipes have a kind of plastic liner. Between the outer pipe and the
liner there may be a certain thickness difference that will prevent the
ultrasonic waves from direct travelling. Such conditions will make the
measurement impossible. Try to avoid this kind of pipes whenever
possible. If that is impossible, plug-in transducers are necessary that
are installed permanently on the pipe by drilling holes on the pipe while
liquid is running inside.
ATTENTION!
Wrong measurement may occur if the transducers
are not installed correctly
•The flow meter is for indoor use only! At an outdoor installation,
the device must be protected from solar radiation and rain.
•It is strongly recommended not to install S 460 permanently in
wet environment.
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6 Installation
6 Installation
Make sure that all components listed below are included in your
package.
Qty Description Part no
1 Ultrasonic flow meter
controller
D554 0074
1 Ultrasonic transducer
pair
S694 4604, S694 4607, or S694 4608
depending on the pipe size.
2 5 m connection cable to
transducers
A553 0127
1 Metal strap A554 0077
1 Coupling agent A554 0078
1 Instruction manual N/A
6 1 Configuration
Before installing transducers, configure the transducer parameters using
the keypad in front of the meter controller.
Note: The S 460 keypad does not support all settings but most of them.
Instead the software S4C-Display does. You can download S4C-Display
from our Website at www.suto-itec.com.
6 1 1 Usage of keypad
The S 460 has a keypad available for you to configure and view
parameter values.
Key “MENU” – Pressed followed by
2-digit numbers to enter the
corresponding menu window.
Key “ /+” – To scroll up the menu▲
window. It also works as the “+”
key when entering numbers.
Key “ /+” – To scroll down the▼
menu window. It also works as the
“+” key when entering numbers.
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6 Installation
Key “ ” – To scroll left or go◀
backspace.
Key “ENT” – To confirm changes.
6 1 2 Configuring the transducer parameters
The S 460 keypad provides about 100 different menus for configuring
the transducers parameters.
Configure parameters using the following steps:
1. Press “Menu” and enter a menu
number as needed.
2. In the menu window, enter a
desired value or select an
option by pressing the UP and
DOWN keys.
3. Press “ENT” to confirm the
change.
For more information about required
parameters and the corresponding
menu numbers, see the following
table.
6 1 3 Description for the parameter settings
The following table lists parameters that you must configure before
starting measurement.
Parameter Description Menu
No
Pipe outer diameter Enter a value in mm. 11
Pipe wall thickness Enter a value in mm. 12
Pipe inner diameter Enter a value in mm. 13
Pipe material Select a material from the selection list. 14
Fluid type Select the proper fluid from the selection
list.
For non-standard fluids, the sound speed
and viscosity of the fluid are also needed.
20
Transducer type Select the type based on the pipe size: 23
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6 Installation
TS-2: DN32 … DN100
TM-1: DN100 … DN700
TL-1: DN300 … DN6000
Installation method Select V-method or Z-method.
For description of these two methods, see
section 6.2.1 .
24
US transmitter space Enter the distance between the two
transducers in mm.
25
Flow unit Enter the desired flow unit, e.g. m3/h. 31
Consumption unit Enter the desired consumption unit, e.g.
m3.
32
6 2 Installation procedure
This section describes procedures for installing and removing
transducers.
6 2 1 Installing the transducers
Ultrasonic measurement is realized by measuring the travelling time
difference of ultrasonic signals. That is why the alignment and the
spacing of the transducers are critical factors for the measurement
accuracy and the system performance.
Follow the steps for a proper installation:
1. Locate an optimum position where the straight pipe length is
sufficient and the pipe is in a good condition. For e ample, a
relatively new pipe with no rust and easy to operate.
2. Clean any dust and rust on the pipe surface.
3. Choose one of the two installation methods based on the pipe
diameters.
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6 Installation
V-Method:
The transducers are
mounted on the same side
of the pipe and the sound
crosses the pipe twice.
It is commonly used when
the pipe inner diameter
ranging from 15 mm to
200 mm.
Z-Method:
The transducers are
mounted on opposite sides
of the pipe and the sound
crosses the pipe once.
It is commonly used when
the pipe inner diameter is
above 200 mm.
If the Z-Method is used,
make sure that the
transducers are mounted
on a pipe within a valid
angle range, as shown in
the left picture.
4. Grease the underside of the transducers with the coupling agent.
5. Use the metal strap to attach a transducer on the pipe and leave
no gap between the pipe surface and the transducer.
ATTENTION!
The strap is under tension Please open it carefully!
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6 Installation
6. Install the other transducer on the pipe as described in steps 4
and 5. Make sure that the distance between the two transducers is
as close as possible to the “US transmitter space” value configured
through the menu number 25.
6 2 2 Removing a transducer
Remove a transducer as described below.
1. Hold the transducer.
2. Release the metal strap.
3. Remove the coupling agent from the underside of the transducer.
6 2 3 Installing the housing (Optional)
The housing can be mounted at a wall. To do so, follow the steps below:
1. Release the wall mounting brackets on the backside of the
housing.
2. Mount the housing near the transducer so that the cables are not
under the tension.
6 3 Electrical connection
The S 460 is shipped with e -work electrical connection.
To make any changes, please refer to the following wiring diagram.
Wiring diagram
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6 Installation
6 4 Final check
After you complete installation and configuration, perform an
installation check to ensure that the signal strength and signal quality of
the transducers are in a valid range.
Use the following menu numbers to perform the check.
Parameters Menu No Valid range
Signal strength 90 60.0 ... 99.9
Signal quality 90 60.0 ... 90.0
Transit time ratio 91 97 ... 103
If an error appears in the window, please contact the manufacturer and
provide the error code.
If the signal strength is not in the valid range, do the following:
•Relocate the transducers to a better position.
•Try to apply more coupler or clean the surface.
•Adjust position of the transducers vertically and horizontally while
checking the varying signal strength and stop at the position of
the highest signal strength. Please remember to change the
setting for the distance between the two transducers through the
menu number 25.
•Check the transducers spacing to make sure the transducers
spacing is the same as the setting on the menu number of 25.
If the signal quality is not in the valid range, do the following:
•Avoid interferences from other instruments and devices such as a
powerful working converter nearby. Try to relocate the flow meter
to a new place where there is littler interference.
•Avoid bad sonic coupling for the transducers with the pipe. Try to
apply more couplers or clean the surface.
•Relocate the transducers to a better position.
If the transmit time ratio is not in the valid range, check the following
to ensure:
•The pipe parameters are correctly entered.
•The actual spacing of the transducers is correctly placed and the
same as displayed in the menu number 25.
•The transducers are installed properly in the right directions.
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6 Installation
•The mounting location is good and the pipe is not changed in
shape or there is not too much fouling inside the pipes.
7 Troubleshooting
This chapter provides common errors and their countermeasures.
7 1 Power-on errors and countermeasures
The ultrasonic flow meter provides an automatic online diagnosis for the
hardware problems. When any message in the following table appears,
countermeasures should be taken.
Error message Causes Actions
ROM Testing
error
Software problem. 1. Power off and on again.
2. Contact the manufacturer.
Segment Test
error
Stored data
error
The parameters
entered by the user
lose integration.
Press “ENT” and reset all the
configuration.
Timer slow error Problem with the
timer-keeper or the
crystal oscillator.
1. Power off and on again
2. Contact the manufacturer
Timer fast error
Date time error Number errors with
the calender
Initialize the calender by menu
number 60
Reboot
repetitively
Hardware problems Contact the manufacturer
7 2 Error codes and countermeasures
The ultrasonic flow meter shows error codes in the lower right corner of
the screen with a single letter like I, R, on the menu window M00, M01,
M02, M03, M90 and M08. When any abnormal error code shows,
countermeasures should be taken.
Erro
r
code
Message
displayed on M08
Causes Actions
R System normal No error. NA
I Detect no signal 1. No signal detected. 1. Relocate
16 S 460

7 Trou leshooting
Erro
r
code
Message
displayed on M08
Causes Actions
2. Transducers installed
improperly.
3. Too much fouling.
4. The pipe liners are
too thick.
5. The transducer cords
are not properly
connected.
measuring location.
2. Clean the spot.
3. Check the cords.
J Hardware error Hardware problem. Contact the
manufacturer.
H Poor Sig detected 1. Poor signal detected.
2. The transducers
installed improperly.
3. Too much fouling.
4. The pipe liners are
too thick.
5. Problem with
transducer.
1. Relocate
measuring location.
2. Clean the spot.
3. Check the cords.
4. Check the
coupler.
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7 Trou leshooting
Error
code
Message
displayed on M08
Causes Actions
Q Frequ. Output over The actual frequency
for the frequency
output is out of the
range set by the user.
Check the value
entered at M66,
M67, M68 and M69
and try to enter a
larger value in M69.
F System RAM error
Date time error
CPU or IRQ error
ROM parity error
1. Temporary
problems with RAM,
RCT.
2. Permanent
problems with
hardware.
1. Power on again.
2. Contact the
manufacturer.
G Adjust gain The instrument is in
the progress of
adjusting the gain for
the signal and the
number indicates the
progressive steps.
NA
K Empty pipe No liquid inside the
pipe or setting error.
Relocate where the
pipe is full of liquid.
Or enter 0 on M29 if
there is liquid inside.
7 3 Other problems and solutions
The following table lists other common problems and their solutions.
Problem Action
The display shows 0.0000 for the
flow rate while the flow inside the
pipe is not zero.
Use the “Reset Zero” function on
menu M43 to solve the problem.
The display shows a much higher
or lower flow rate than the actual
one.
1. Check if the problem results
from an offset value wrongly
entered by the user through the
M44 menu “Setup a flow bias”, and
enter “0” in M44 to fi the problem.
2. Check if the transducer is
correctly installed.
18 S 460

7 Trou leshooting
Problem Action
3. Zero calibrate the instrument by
using M42 menu “Zero calibration”
and make sure that the flow inside
the pipe is zero.
8 Signal outputs
8 1 Analog / Pulse output
The flow meter has an analog output range of 4... 20 mA. This output
can be scaled to match a desired measuring range.
The flow meter generates one pulse per a consumption unit. This pulse
output can be connected to an e ternal pulse counter to counter the
total consumption.
8 2 Interface
The data can be transmitted via RS-485 Modbus to a data collection
system or software.
9 Calibration
In certain installations the display will show a non-zero flow even if
there is absolutely no flow. In this case, a zero point calibration is
recommended. Make sure that there is zero flow in the pipe before
activating this function in the sensor menu.
The sensor is calibrated e work. The e act calibration date is printed
on the certificate which is supplied together with the sensor. The
accuracy of the sensor is regulated by the on site conditions,
parameters like oil, high humidity or other impurities can affect the
calibration and furthermore the accuracy. However we recommend to
calibrate the instrument at least once per year. The calibration is
e cluded from the instruments warranty.For this please contact the
manufacturer.
S 460 19

10 Maintenance
10 Maintenance
To clean the flow meter and its accessories it is recommended to use
moist cloth only.
ATTENTION!
Do not use isopropyl alcohol to clean the display!
11 Disposal or waste
Electronic devices are recyclable material and do not
belong in the household waste.
The device, the accessories and its packings must be
disposed according to your local statutory requirements.
The dispose can also be carried by the manufacturer of the
product. Please contact the manufacturer for details.
12 Warranty
SUTO provides a warranty for this product of 24 months covering the
material and workmanship under the stated operating conditions from
the date of delivery. Please report any findings immediately and within
the warranty time. If faults occurring during the warranty time SUTO
will repair or replace the defective unit, without charge for labour and
material costs but there is a charge for other service such as transport
and packing costs.
E cluded from this warranty is:
•Damage caused by:
◦Improper use and non-adherence to the instruction manual.
◦Use of unsuitable accessories.
◦E ternal influences (e.g. damage caused by vibration, damage
during transportation, e cess heat or moisture).
The warranty is cancelled when one of the following situations occurs:
•The user opens the measurement instrument without a direct
request written in this instruction manual.
•Repairs or modifications are undertaken by third parties or
unauthorised persons.
20 S 460