Tek-Trol Tek-Clamp 1200A User manual

Technology Solutions
TEK-CLAMP 1200A
Instruction Manual
Ultrasonic Clamp-On Flow Meter
Document Number: IM-1200A
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NOTICE
Read this manual before working with the product. For personal and system safety, and for optimum
product performance, make sure you thoroughly understand the contents before installing, using, or
maintaining this product.
For technical assistance, contact
© COPYRIGHT Tek-Trol LLC 2021
No part of this publication may be copied or distributed, transmitted, transcribed, stored in a
retrieval system, or translated into any human or computer language, in any form or by any means,
electronic, mechanical, manual, or otherwise, or disclosed to third parties without the express
written permission. The information contained in this manual is subject to change without notice.
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Table of Contents
1Safety Instructions ....................................................................................................3
1.1 Intended Use ...............................................................................................................3
1.2 Safety Instructions from the Manufacturer ...................................................................3
Disclaimer..........................................................................................................................3
Product Liability and Warranty .........................................................................................4
Information Concerning the Documentation....................................................................4
1.3 Safety Precautions .......................................................................................................4
1.4 Packaging, Transportation and Storage.........................................................................5
Packaging...........................................................................................................................5
Transportation...................................................................................................................5
Storage ..............................................................................................................................5
Nameplate.........................................................................................................................6
2Product Description ..................................................................................................6
2.1 Introduction ................................................................................................................6
2.2 Measuring Principle .....................................................................................................6
2.3 Specifications...............................................................................................................8
2.4 Dimensional Drawing of Tek-Sonic 1200A-100F1...........................................................9
Dimensional Drawing of Tek-Sonic 1200A-100F1 S2 & M2 Sensor ................................10
2.5 Dimensional Drawing of Tek-Sonic 1200A-100EXP....................................................... 10
2.6 Model Chart............................................................................................................... 11
3Installation.............................................................................................................. 12
3.1 Selection of Installation Place..................................................................................... 12
3.2 Installation of the Wall Mount Enclosure.................................................................... 12
3.3 Installation of the Transducer..................................................................................... 13
Sensors ............................................................................................................................13
3.3.1.1 Selection Of Sensor Position ...............................................................................................13
3.3.1.2 Sensor Installation...............................................................................................................14
3.3.1.3 Spacing Between the Sensors .............................................................................................15
Length of the straight pipe..............................................................................................16
Transducer Installation Method......................................................................................18
3.3.3.1 Installation Space ................................................................................................................20
3.3.3.2 Installation Method.............................................................................................................21
3.4 Instrument Well Construction Requirements .............................................................. 23
3.5 Quick Pipe Parameter Setting..................................................................................... 23
4Electrical Connections ............................................................................................. 24
4.1 Basic Requirement ..................................................................................................... 24
4.2 Power Supply and Signal Wiring Diagram of 1200A-100F1 Enclosure ........................... 24
Keypad.............................................................................................................................25
Menu Windows ...............................................................................................................25
Menu Window List ..........................................................................................................26
4.3 Power Supply and Signal Wiring Diagram of 1200A-100M ........................................... 27
4.4 Power Supply and Signal Wiring Diagram of 1200A-100EXP......................................... 29
4.5 Transducer Wiring Diagram........................................................................................ 29
4.6 Installation Check-Up................................................................................................. 30
Signal Strength (S) ...........................................................................................................30
Signal Quality (Q).............................................................................................................30
Total Transit Time and Delta Time ..................................................................................30
Transit Time Ratio ...........................................................................................................30
5Operation ............................................................................................................... 31
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5.1 Menu Window Details................................................................................................ 32
5.2 Work parameter solidification of the Flow meter and option indication ...................... 36
5.3 Zero-Point Setup and Zero-Point Solidification............................................................ 36
5.4 Factory Use of the Scaling Factor Solidification ........................................................... 37
5.5 Analog Calculating Function Application ..................................................................... 37
5.6 Analogue Input Interface as Digital Input Interface: Method and Introduction............. 37
5.7 Introduction of Serial Peripheral Extension Interface .................................................. 37
5.8 Realize Medium Identifying Function.......................................................................... 37
5.9 Restoring the Flow meter to Factory Default............................................................... 37
6Totalizer reset......................................................................................................... 38
7BTU settings............................................................................................................ 38
8Maintenance........................................................................................................... 38
8.1 Maintenance Service.................................................................................................. 38
8.2 Software Upgrade Service .......................................................................................... 39
8.3 Important Notice for Product Return .......................................................................... 39
9Troubleshooting...................................................................................................... 39
9.1 Error Messages After Switching On............................................................................. 41
9.2 Further Errors and Countermeasures.......................................................................... 41
9.3 Further Errors and Countermeasures.......................................................................... 42
10 Appendix ................................................................................................................ 43
10.1 Tables: Pipe Size ........................................................................................................ 43
Copper - Standard Pipe Size Charts: ...........................................................................43
PVC - Standard Pipe Size Charts:.................................................................................44
Steel - Standard Pipe Size Charts: ...............................................................................45
Cast Iron Pipe - Standard Pipe Size Charts:.................................................................49
Ductile Iron Pipe - Standard Pipe Size Charts: ............................................................49
10.2 Tables: Sound Speed .................................................................................................. 50
Solids: Sound Speed Data ...........................................................................................50
Water: Sound Speed ...................................................................................................51
Liquids: Sound Speed..................................................................................................52
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1Safety Instructions
1.1 Intended Use
Tek-Clamp 1200A is an Ultrasonic Clamp-on Flow meter are used only for measuring the
flow of liquids in closed pipes, e.g.: clean water, wastewater etc.
The manufacturer is not liable for damage caused by improper or non-designated use.
1.2 Safety Instructions from the Manufacturer
This meter was calibrated at the factory before shipment. To ensure correct use of the
meter, please read this manual thoroughly.
•The device must only be used within the approved temperature range:
a) Environmental humidity max. <80 % RH
b) Environmental temperature 0 ... 158 °F
•Do not expose the device to extreme temperatures, direct sunlight, extreme
humidity, condensation, or moisture.
•With wet hands never use the instrument.
•Before taking a measurement, the device should be stabilised to the ambient
temperature (important when carrying the device from cold to warm rooms and
vice versa).
•Avoid strong electrical shocks.
•Do not use the meter around corrosive or explosive gases.
•The case should only be opened by qualified Tek-Trol LLC personnel.
•Repairs and maintenance work may only be carried out by qualified Tek-Trol LLC
personnel.
•Never place the front side of the device on a workbench or work surface to avoid
damage to the operating elements.
•You must not make any technical changes to the device.
•Keep the flow meter clean and dry.
•The appliance should only be cleaned with a damp cloth. Use only pH-neutral
cleaner, no abrasives, or solvents.
•Non-observance of the safety notes can cause damage to the device and injuries
to the user.
We do not assume liability for printing errors or any other mistakes in this manual. We
expressly point to our general guaranteed terms which can be found in our general
terms of business. If you have any questions, please contact Tek-Trol LLC. The contact
details can be found at the end of this manual.
Disclaimer
The manufacturer will not be held accountable for any damage that happens by using
its product, including, but not limited to direct, indirect, or incidental and
consequential damages.
Any product purchased from the manufacturer is warranted in accordance with the
relevant product documentation and our Terms and Conditions of Sale.
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The manufacturer has the right to modify the content of this document, including the
disclaimer, at any time for any reason without prior notice, and will not be answerable
in any way for the possible consequence of such changes.
Product Liability and Warranty
The operator shall bear authority for the suitability of the device for the specific
application. The manufacturer accepts no liability for the consequences of misuse by
the operator. Wrong installation or operation of the devices (systems) will cause the
warranty to be void. The respective Terms and Conditions of Sale, which forms the
basis for the sales contract shall also apply.
Information Concerning the Documentation
To prevent any injury to the operator or damage to the device it is essential to read
the information in this document and the applicable national standard safety
instructions. This operating manual contain all the information that is required in
various stages, such as product identification, incoming acceptance and storage,
mounting, connection, operation, and commissioning, troubleshooting, maintenance,
and disposal.
1.3 Safety Precautions
You must read these instructions carefully prior to installing and commissioning the
device. These instructions are an important part of the product and must be kept for
future reference. Only by observing these instructions, optimum protection of both
personnel and the environment, as well as safe and fault-free operation of the device
can be ensured.
For additional information that are not discussed in this manual, contact the
manufacturer
Warnings and Symbols Used
The following safety symbol marks are used in this operation manual and on the
instrument.
WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury
CAUTION
Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury. It may also be used to alert against unsafe practices.
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NOTE
Indicates that operating the hardware or software in this manner may damage it or
lead to system failure.
1.4 Packaging, Transportation and Storage
Packaging
The original package consists of
1. Tek-Clamp 1200A-100 Ultrasonic Clamp-on Flow meter
2. Documentation
NOTE
Unpack and check the contents for damages or signs of rough handling. Report
damage to the manufacturer immediately. Check the contents against the packing
list provided.
Transportation
•Avoid impact shocks to the device and prevent it from getting wet during
transportation.
•Verify local safety regulations, directives, and company procedures with respect
to hoisting, rigging, and transportation of heavy equipment.
•Transport the product to the installation site using the original manufacturer’s
packing whenever possible.
Storage
The Tek-Clamp 1200A-100 is designed for installation and usage purpose in typical
commercial/industrial environments. The following considerations must be observed
in selecting a location for the meter:
•The ambient operating temperature range is -22°F (-30°C) to 176°F (80°C)
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•Do not expose the meter to corrosive liquids or fumes
•Avoid installation locations that are close to strong sources of electrical
interference
•Avoid installing the electronics enclosure in direct sunlight
•Avoid installation locations where the transducers will be exposed to vibrations
in the piping system
•Always run transducer cables in a dedicated conduit separate from signal and
power cables
•Allow sufficient space for daily inspection, wiring, etc.
•Avoid installing the meter at a place subjected to, or at risk of, flooding
Nameplate
The nameplate lists the order number and other important information, such as
design details and technical data
Note
Check the device nameplate to ensure that the device is delivered according to
your order. Check for the correct supply voltage printed on the nameplate.
2Product Description
This section covers the reference and specification data, as well as ordering
information.
2.1 Introduction
Tek-Clamp 1200A Ultrasonic Clamp-on Flow meter is designed to measure the velocity
of liquid in a full/closed pipe. It operates according to the difference in the Transit Time
of Flight measured and determines the flow velocity by measuring the travel time of a
pulse from one transducer to the next. Electroacoustic transducers receive and emit
brief ultrasonic waves through the liquid of the pipe. Transducers are vertically placed
at both sides of the measured pipe and fastened by means of a clamp. The Tek-Clamp
1200A can be used for metallic, plastic and rubber tubes.
2.2 Measuring Principle
When the ultrasonic waves are transmitted through the flowing liquid, there will be a
difference between the upstream and downstream transit time (travel time or time of
flight), which is proportional to flow velocity. Ultrasonic waves travelling in the same
direction as that of the flow takes lesser time to reach the second transducer than that
of the waves which travels in the opposite direction of the flow.
The formula for calculating velocity is:
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V = 𝑴𝑫
𝐬𝐢𝐧 𝟐𝜽 × ∆𝑻 𝑻𝒖𝒑 × 𝑻𝒅𝒐𝒘𝒏
Where,
𝜃 is the include angle to the flow direction
M is the number of times that the ultrasonic beam travels
D is the pipe diameter
Tup is the time for the beam to travel from upstream transducer to the downstream
Tdown is the time for the beam to travel from downstream transducer to the upstream
∆T = Tup -Tdown
Fig 1: Tek-Clamp 1200A-100H Handheld Ultrasonic Flow Meter
The Tek-Clamp 1200A-100H has been developed to measure the flow velocity of liquids
in pipes. The non-contact transducers/sensors are placed on the pipes and thus not
subject to wear and tear. The Tek-Clamp 1200A-100H works with two signal
transducers (sensors) that serve as ultrasonic transmitters and ultrasonic receivers. The
sensors are installed on the outer wall of the pipe at a defined distance, one below the
other. The sensors can be installed in Z shape (Z method). In this case, the ultrasound
will pass through the pipe once. The ultrasound will pass through the pipe four times if
the sensors are installed in W shape (W method). When using the Z method, the
sensors are placed opposite to each other. The sound passes through the pipe or liquid
diagonally. The selection of the right method depends on the characteristics of the
liquid.
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2.3 Specifications
Parameters
Specifications
Accuracy
±1% of Reading
Velocity
±0.03 to ±100 ft/s (±0.01 to ±30m/s)
Repeatability
0.2%
Measurement Period
0.5 Seconds
Measurement Principle
Transit-time measurement principle
Display
LCD with backlight. 2 x 20 letters
Media
All liquids with solids of <5 % and a flow of >0.19pm
Flow Units
Cubic
m³
Liter
l
Gallon
gal
Imperial
Gallon (UK)
igl
Million USA
Gallons
mgl
Cubic foot
cf
Barrel (USA)
bal
Imperial
Barrel (UK)
ib
Oil Barrel
ob
The time can be per day [/d], per hour [/h], per minute [/m] and per second
[/s]
Output
100F1
Modbus RS485, 4-20 mA, Pulse
100M
Modbus RS485, 4-20 mA, Pulse
100EXP
Modbus RS485, 4-20 mA, Pulse
Input
Two three wire system PT100 platinum resistor input loop.
For BTV process monitoring
Other Functions
Automatically stores the memory of the positive, negative,
net totalizer flow rate and heat quantity of the last 512 days,
128 months, 10years
Power
100F1
85 to 264VAC or 8 to 36VDC
100M
8 to 36VDC
100EXP
8 to 36VDC
Power Consumption
Less than 1.5W
Environment Temperature
-22 °F to 176 °F (-30 °C to 80 °C)
Environment Humidity
85% RH
Protection Class
IP65 (Tek-Clamp 1200A-100F1)
IP65; Class I Div II (Tek-Clamp 1200A-100EXP)
Main Unit
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2.4 Dimensional Drawing of Tek-Sonic 1200A-100F1
Fig 2: Tek-Sonic 1200A-100F1
Clamp-On
S2-type: for pipe size ½” to 4”
M2-type: for pipe size 2” to 28”
1200A-L2: 12” to 200”
1200A-IM: 3” to 7”
1200A-IL: 3” to 12”
Protection Class
IP68, can work in water with depths less than 10’ (3m)
Types
Virtually all commonly used clean liquids. Liquids with small
quantity of tiny particles may also be applicable. Particle size
should be less than 75um, particle concentration less than
20,000ppm. Liquids should contain no or very minor air bubbles.
Process Temperature
-40 °F to 320 °F (-40 °C to 160 °C)
Pipe Material
All metals, most plastics, fiberglass, etc.
Pipe Size
½” to 200”
Pipe Straight Run
More than 10D for upstream, more than 5D for downstream,
where D is pipe diameter.
Transducers
Liquids
Pipe
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Dimensional Drawing of Tek-Sonic 1200A-100F1 S2 & M2 Sensor
S2 Sensor M2 Sensor
Fig 3: S2 or M2 Sensor
2.5 Dimensional Drawing of Tek-Sonic 1200A-100EXP
Fig 4: Tek-Sonic 1200A-100EXP
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Fig 5: Tek-Sonic 1200A-100EXP
2.6 Model Chart
Model Number
Description
Note: Controller, Sensors, and Options are all ordered individually
Controllers
1200A-100F1
Wall Mount Ultrasonic Flow Meter
1200A-100M
Low-Cost DIN Mount Flow Meter
1200A-100EXP
Explosion Proof Ultrasonic Flow Meter
1200A-100H
Handheld Ultrasonic Flow Meter (with carrying case)
Transducers
1200A-S2
½” to 4” Pipe (Wall and DIN Controller)
1200A-M2
2” to 28” Pipe (Wall and DIN Controller)
1200A-L2
12” to 200” Pipe (Wall or DIN Controller)
1200A-IM
Insertion Sensor 3” to 7” Pipe (Wall or DIN Controller)
1200A-IL
Insertion Sensor 3” to 12” Pipe (Wall or DIN Controller)
1200A-S2H
½” to 4” Pipe (Handheld)
1200A-M2H
2” to 28” Pipe (Handheld)
1200A-HSH
½” to 4” Pipe, Bracket Mounted Sensors (Handheld)
1200A-HMH
2” to 28” Pipe, Bracket Mounted Sensors (Handheld)
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Accessories
1200A-TM8812
Ultrasonic Thickness Gauge
1200A-SEYV75-2-5
Junction box and two 16’ Extension Cables
1200A-BIT
Drill Bit for Insertion Sensors
1200A-Gel
Coupling Gel
*Note: For pipe diameter greater than 1 inch with SS/Carbon steel please select M2
Transducers for better signal strength.
3Installation
This section covers instructions on installation and commissioning. Installation of the
device must be carried out by trained; qualified specialists authorized to perform such
works.
CAUTION
•When removing the instrument from hazardous processes, avoid direct
contact with the fluid and the meter
•All installation must comply with local installation requirements and local
electrical code
3.1 Selection of Installation Place
Careful attention should be given while selecting the place of installation for system
components as it will help the operators with the initial installation, reduce the start-
up problems and make further installations easier.
For example: Do not install the Tek-Clamp 1200A-100F1 flow meter where it will be
difficult for the personnel to perform periodic maintenance.
When selecting a site for mounting the system components, consider the criteria
under Section 1.4.3. Storage.
3.2 Installation of the Wall Mount Enclosure
•Find an easily accessible location where wire connections can be made, and flow
meter readings can be taken from floor level.
•Mount the enclosure on a vibration-free surface
•Avoid sites such as the plenum of a fan coil, heat exchanger, or other housings
containing motors
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•Avoid mounting the enclosure in close proximity to VFD’s, electric motors or other
strong sources of electrical interference
NOTE
Secure at least 4" (100mm) of space between the flow transmitter and nearby wall.
Also secure a space for opening the front cover for maintenance. Secure a cable
wiring space under the enclosure
3.3 Installation of the Transducer
Installation of Tek-Clamp 1200A-100 series is the easiest and convenient way in the
installation of all flow meters. Just choose a suitable measurement point, input the
pipe parameters of this pipe point to the flow meter, and then fix the transducers on
the pipe.
Sensors
3.3.1.1 Selection Of Sensor Position
The first step before installation should be finding a suitable position to place the
sensors. This is a requirement for accurate measurement results. Some basic
knowledge about the pipes / the plumbing system is necessary.
The ideal location would be an infinitely long, straight pipe, whereas there must be
no entrapped air (air bubbles) in the liquid. The pipes can either run vertically or
horizontally. A straight flow-calming section before and behind the measuring point
should be considered to avoid inaccuracies due to turbulence in the liquid. In
general, the section in front of the measuring point should be at least 10 x the pipe
diameter, and after the measuring point, it should be 5 x the pipe diameter.
The following chart shows examples of good positions:
Pipe routings and sensor position
Upstream
Downstream
Lup x ø
Ldn x ø
10D
5D
10D
5D
10D
5D
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12D
5D
20D
5D
20D
5D
30D
5D
The following should be considered when looking for a good measuring position:
1. Install the sensors on a preferably long, straight pipe filled with the liquid and
does not contain any air bubbles.
2. Make sure that the liquid and thus the pipe is not too hot for the sensors. The
temperature should be as similar to the room temperature as possible.
3. Consider fouling of the pipes. If possible, choose a clean or new pipe for
measurement. You can also clean the pipe. If this is not possible, consider the
thickness of the fouling as part of the liner.
4. Some pipes have a synthetic liner. There can be a boundary layer between
the outer pipe and the liner. This boundary layer can divert or weaken the
ultrasonic waves, which will make a measurement very difficult. If possible,
these types of pipes should be avoided. If this is not possible, sensors can also
be built into the pipe
3.3.1.2 Sensor Installation
The Tek-Clamp 1200A-100H has piezoelectric sensors which can transmit and
receive ultrasonic waves. The ultrasonic waves pass through the pipe walls, and the
liquid allows conclusions about the flow velocity. As the transit time of the ultrasonic
pulses is very short, the sensors should be installed as precisely as possible to ensure
the highest system accuracy.
Take the following steps to install the sensors:
•Some pipes have a plastic liner. There can be a boundary layer between the
outer diameter of the pipe and the inner liner. This boundary layer can divert or
weaken the ultrasonic waves. In this case, an accurate measurement will be very
difficult. If possible, these types of pipes should be avoided.
•Find an ideal position in the piping system, i.e., a straight section with new and
clean pipes, if possible.
•The pipes must be clean. Grind or polish the locations where you would like to
place the sensors.
•If pollution cannot be removed, its thickness should be considered part of the
pipe's liner.
•There must not be an air gap between the sensors and the surface of the pipe.
Attach the sensors using sufficient contact gel.
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•Moreover, you should make sure there is no dust or sand between the pipe and
the sensor. To avoid air bubbles from causing measurement errors, place the
sensors on the pipe laterally.
3.3.1.3 Spacing Between the Sensors
The distance between the upstream and the downstream sensor can be seen in
window M25. The window states the inner distance between the two sensors, which
you should stick to as accurately as possible. The information in M25, however, must
only be considered a coarse adjustment. The fine adjustment is carried out by
arranging the spacing so that the time constant in M90 is exactly 100%.
To ensure accurate measurement values, the following data must be entered:
•The outer diameter of the pipe (M11)
•Material thickness of the pipe (M12)
•Material of the pipe (M14)
•The liner of the pipe (M16)
•Type of liquid (M20)
•Type of sensors connected (M23)
•The mounting method of sensors (M24)
•Check the spacing in window M25 and fix the sensors accordingly.
•During installation, ensure that the value of the time constant in M90 is 100 %,
that the signal strength is >700 and that the signal quality is >60.
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Length of the straight pipe
The length of upstream and downstream straight pipe of the ultrasonic transducer
should be long enough to ensure accurate measurements.
•For 90o bend
Fig 5: 90Obend pipe
•For Tee bend
Fig 6: Tee bend pipe
L≥10D
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•For Diffuser
Fig 7: Diffuser pipe
•For Reducer
Fig 8: Reducer pipe
•For Valve
Fig 9: Valve
L≥10D
L≥10D
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•For Pump
The figure below shows the installation point of transducers when a pump is used in
the pipeline.
Fig 10: Pump
The above figure shows the installation point of transducers when a compressor is
used in the pipeline.
Transducer Installation Method
Before installing, start by cleaning the installation area: remove any rust, paint, and
anti-rust layers. Then polish the area using a clean cloth with either alcohol or acetone.
Apply a sufficient amount of grease at the installation area and clamp the transducers
tightly on the pipe. The grease is used to eliminate any gaps between the transducer
and the pipe wall.
L≥20D
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