Tokyo Keiki UFL-30 User manual

Doc No. KF08-001J
Ultrasonic Flowmeter
UFL-30
Installation & Operation Manual

(1)
Safety Precautions
The following safety precautions contain important information pertaining to the safe use of
the Ultrasonic Flowmeter. Read this text carefully and make sure to fully understand its
contents before installing and operating this equipment. Follow directions given herein at all
times when operation. TOKYO KEIKI INC. is not at all liable for an injury and/or a damage
resulting from misuse of this equipment by the user that is contrary to these cautionary
notes.
For quick reference, store this manual in a designated location with easy access (preferably
near the equipment).
In this manual and on the equipment, the following safety symbols are used to ensure the
equipment is used safety and to protect operators and property from possible hazards or
damage. Read the explanations below carefully and familiarize yourself with the symbols
before reading the manual.
Safety symbols
DANGER Indicates that incorrect usage can result directly in death or
serious injury to the operator.
WARNING Indicates that incorrect usage may result in loss of life or
serious injury to the operator.
CAUTION Indicates that incorrect usage may result in injury to the
operator or damage to the equipment.
Indicates referring to information for usage of the function or
features. (Put on the equipment)
NOTE Indicates attention to information for usage of the function or
features.
Indicates Protective conductor terminal
Indicates Earth terminal (Functional earth terminal)
Indicates near by power supply voltage line.
Indicates Alternating current, "AC".
Indicates Direct current, "DC".

(2)
Name of each part
Front Cover
Window
Pocket
Packing
Cable Glands Inner Panel
Switch Panel
Fuse Power Switch
Panel Cover
Protective Earth cable
Protective Earth cable
Enclosure
LCD
Operation Key
RS232C connector
Internal View
Front View
Bracket
Front
cover
screw
Bracket
Bottom View
Front
cover
screw
Bracket
Functional
Earth
terminal
Cable
Glands

(3)
Labels and attached place
Functional
Earth
Label
Caution Label
Regulation Label
Warning Label
lating Label for Fuse
Rating Label for power supply
Production Label
Caution Label for Electric shock
Caution Label

(4)
Labels attached inside of the equipment are as follows.
[Warning Label]
Indicates that incorrect usage may result in death or serious injury to the operator.
[Caution Label]
Indicates that incorrect usage may result in loss of life or serious injury to the operator.
[Rating Label]
Power supply rating
[ For AC power supply type ] [ For DC power supply type (Option) ]
Fuse rating
Regulation
Earth
[ For protective earth ] [ For functional earth ]

(5)
view of service space
[Wiring Diagram for AC power supply type] [Wiring diagram for DC power supply type]
[Caution Label] [Protective Earth Label]
Caution Label
Wiring Diagram label
Protective Earth Label

(6)
Usage Precautions
This instrument is used to measure flow quantities by means of ultrasound. For safe usage
and optimum performance of the flowmeter, always operate the instrument according to the
usage precautions below.
WARNING
Do not open the inner panel while feeding power.
Do not modify and disassemble the unit.
These actions may result in electrical shock or equipment damage.
CAUTION
1. Failure to comply with one or more of the following conditions may result in poor
measurement performance or incorrect measurement values.
・Use an appropriate power supply rated for the voltage range designated in the
specifications.
・Fill pipes entirely with water.
・Be sure bubbles or particles that might interfere with ultrasonic waves are absent
during measurement.
・Position the transducer in accordance with the required straight pipe length.
・Do not subject the transducer to vibration or mechanical shock.
・Place the flowmeter unit, transducer and cable in a location without noise
interference.
・Use the equipment within the predetermined ambient temperature and humidity
range.
・Do not remove cable glands that attached with main unit. In case of removal it,
main unit can not satisfy performance of protection class.
2. If the signal level is below the minimum detection requirement of the instrument, the
LCD display of the main unit will display the R (no wave reception) alarm.
The D (disturbance) alarm is triggered when an abnormal measurement value is
detected.
Note that in both cases the flowmeter may display the flow value preceding the alarm.
3. Be sure to use the instructions in the Manual when changing settings on the main
flowmeter unit (maximum flow, integration units, etc.). Incorrect settings will result in
poor performance or incorrect measurement values (output signals).
4. If this manual is lost, contact the nearest dealership.

(7)
Introduction
Thank you for your selecting our Ultrasonic Flowmeter.
This Manual includes detailed explanations regarding safety cautions, structure, set up,
operation, troubleshooting, and maintenance of the Ultrasonic Flowmeter.
Read this manual carefully before operation to ensure an adequate understanding of the
equipment.
Proper use of the Operation Manual
The following points must be observed:
CAUTION
1. Carefully read the Manual. The contents of this Manual are very important and should
be read completely.
2. Store the Manual in a safe location. The Manual is essential for appropriate operation
of the equipment. Store the manual in a safe and accessible location. The storage
location and person in charge should be determined after careful consideration.
3. Ensure that the Manual is supplied to the operator of the equipment. The
representative or dealer of this equipment must provide this Manual to the user who
will actually operate the equipment.
4. The Manual must be replaced if lost or damaged. If the Manual is lost, contact the
representative. A new manual is available for purchase.
5. Ensure that the warning label is properly attached. If the warning label is illegible or
has come off, contact the manufacturer to purchase a new label.
Precautions regarding the Manual
This Manual was written in accordance with the standard specifications of the original
instrument.
In case of discrepancies between written specifications and approved drawings, the
drawings should be given precedence.
Restrictions and precautions necessary to maintain the equipment
The following items must be observed in order to maintain the equipment.
CAUTION
1. Do not drop or bump the unit and the transducer.
2. Do not use the unit in environmental conditions (ambient temperature, ambient
humidity) other than those prescribed in this manual.
3. Do not use the unit with a power supply other than the one prescribed in this manual.
4. Do not use damaged or worn-out cables (power cables, coaxial cables, signal
cables).
5. The device contains high-voltage circuit boards. Never, under any circumstances,
touch terminals or the inside of the device when the power is on.
6. The device is operated via the opened panel (display, keyboard) of the main
flowmeter unit. Do not manipulate electrical circuits (printed circuit boards, electrical
parts, etc.) inside the panel.
7. Under no circumstances attempt to modify or disassemble the instrument. Contact
the manufacturer in the event of a malfunction.
8. Do not use the unit and/or accessories in restricted hazardous areas.
Disposal
In EU area, do not dispose this equipment as household waste, please contact with the
nearest representatives. (WEEE directive 2002/96/EG)

(8)
Safety Precaution ............................................................................................... (1)
Safety Symbols ................................................................................................... (1)
Name of each parts ............................................................................................ (2)
Labels and attached place ................................................................................. (3)
Usage Precaution ...............................................…............................................ (6)
Introduction ......................................................................................................... (7)
Proper use of the Manual ...................................................................................... (7)
Precautions regarding to the Manual .................................................................. (7)
Restrictions and precautions necessary to maintain the equipment ................... (7)
Disposal .............................................................................................................. (7)
INDEX
I. Installation
Here you can see how to install flowmeter system.
I-1. Configuration ................................…............................................... I-3
I-2. Installation and Wiring ................................…........................…... I-8
I-2-1 Setup Procedure ........................................................................... I-8
I-2-2 Selection of transducer setup position .......................................... I-10
I-2-3 Placement of the main unit ............................................................ I-12
I-2-4 Wiring ............................................................................................ I-12
I-2-5 Multi-Path Connection to main unit .................................................. I-19
I-2-6 Functional ground connection ........................................................ I-24
I-2-7 Installation of disconnection device for power line .......................... I-24
I-2-8 Insulation for DC power source ....................................................... I-24
I-2-9 Transducer Installation procedure ................................................... I-25
I-2-10 Transducer cable treatment for main unit ..................................... I-36
I-2-11 Cable connection treatment with chemical binder.......................... I-39
I-2-12 Installation Outfit ............................................................................ I-41
I-2-13 Input parameters by Commissioning software.................................. I-42
II. Operation
Here you can see how to operate main unit.
II-1. Function ......................................................................................... II-5
II-2. Operation ....................................................................................... II-19
II-2-1 Main operating unit layout................................................................. II-19
II-2-2 Startup and shutdown procedure...................................................... II-20
II-2-3 LCD and operating keys.................................................................... II-20
II-2-4 Display layout and description .......................................................... II-21
II-2-4-1 Measurement display ................................................................... II-21
II-2-4-2 Menu screen ............................................................................. II-22
II-2-5 Menu Overview in LCD .................................................................... II-23
II-2-6 How to operate .............................................................................. II-24
II-2-7 Output operating during aberrations in measurement ...................... II-47
II-2-8 Error Message................................................................................... II-49

(9)
III. Other
Here you can see concerned with Maintenance, Specification or Measuring Principle.
III-1. Maintenance and Inspection ....................................................... III-3
III-1-1 Transducer and main unit maintenance and inspection ................ III-3
III-1-2 Parts like reference ........................................................................ III-3
III-2. General Specifications ................................................................ III-5
III-2-1 Overall Specification ....................................................................... III-5
III-2-2 Main unit specification .................................................................... III-6
III-2-3 Transducer ........................................................................................ III-12
III-2-4 Accessories .................................................................................... III-13
III-2-5 Dimensions ................................................................................... III-14
III-2-6 Analog output profile ...................................................................... III-17
III-2-7 Digital output profiles (Origianl Protocol) .......................................... III-21
III-2-8 Digital output profiles (MODBUS Protocol) ....................................... III-30
III-3. Principle of the ultrasonic flowmeter .............................................. III-37
III-3-1 Measurement Principle .................................................................. III-37
III-3-2 Transmission and reflection methods ............................................ III-40
III-4. Appendix ....................................................................................... III-41
III-4-1 Flow volume and average flow velocity............................................. III-41
III-4-2 Pipe conditions and required straight length...................................... III-42
III-4-3 Sound velocity & kinematics viscosity reference list ......................... III-43
III-5. FAQ ............................................................................................. III-45
III-5-1. Measured method ......................................................................... III-45
III-5-2. Measured fluids .......................................….................................. III-47
III-5-3. Pipes ................................................................................................ III-48
III-5-4. Installation location........................................................................... III-49
III-5-5. Other................................................................................................. III-52
III-6. Trouble shooting .......................................................................... III-53
III-6-1. Main flowmeter unit and components............................................... III-53
III-6-2. Measurement........................................................................................ III-54

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(blank)

I. Installation

Chapter I Index
I-1. Configuration
Configuration ......................................................................................... I-3
Basic Configuration (for large pipe 1 or 2path) ............................….…… I-4
Basic Configuration (for large pipe 4path) ...........................….…………. I-5
Basic Configuration (for small pipe 1 or 2path) ....................….…………. I-6
Basic Configuration (for small pipe 4path) ...........................….…………. I-7
I-2. Installation and Wiring
I-2-1 Setup Procedure ............................................................................. I-8
I-2-2 Selection of transducer setup position .............................................. I-10
I-2-3 Placement of the main unit ............................................................. I-12
I-2-4 Wiring .............................................................................................. I-12
- transducer cable
- I/O (Analog output, Relay output) cable
- power cable
I-2-5 Multi-Path Connection to main unit..................................................... I-19
I-2-6 Functional ground connection ......................................................... I-24
I-2-7 Installation of disconnection device for power line .......................... I-24
I-2-8 Insulation for DC power source ....................................................... I-24
I-2-9 Transducer Installation procedure ................................................... I-25
I-2-10 Transducer cable treatment for main unit ..................................... I-36
I-2-11 Cable connection treatment with chemical binder............................ I-39
I-2-12 Installation Outfit .............................................................................. I-41
I-2-13 Input parameters by Commissioning software.................................. I-42

I-3
I-1. Configuration
This Ultrasonic Flowmeter consists of the following primary components. Fig. 1-1 to 1-4 shows the
interrelationship among the different parts.
No
Name
Q'ty
Details
Chap.
Page
1.
Main Unit
1pc
Ultrasonic Flowmeter Main Unit
III-2-5
III-14
2.
Transducers
2pcs
(1pair)
Ultrasonic transmitter-receiver sensors
(to be used in combination with cables)
III-2-5
III-15,16
3.
Mounting fixture
1set
Metal fixtures used to attach transducers
to a pipe
III-2-5
III-15,16
4.
Coaxial cables
1pair
Used to connect the transducers to the
main flowmeter unit
---
---
5.
Multi-Path
Junction Box
1pc
Junction Box for 4 path measuring
(Option)
---
---
NOTE
Q'ty of item 2,3,4 depends on its specification.

I- 4
(Note) This is sample system. Analog orTotalized devices are not included in the standard system.
Fig 1-1；Ultrasonic Flowmeter basic system (1path or 2path)
Main Unit
Coaxial Cable
Max. 300m
Mounting Fixture
Transducer
for Large Pipe
AC100 to 230V±10% or DC24V±20%（Option）
Pulse Output
4-20mA Analog Output
（Max. Resistance 1k ohm）Analog Devices
Functional earth
Totalizer
or
Relay Receiver
Contact Relay Output
Power Supply
Note: [ For AC power source ] A switch or circuit-breaker shall be included in the building installation. It shall be in close proximity to the equipment and within easy reach of the OPERATOR. It shall be marked as the disconnecting device for the equipment. [ For DC power source ] The DC power source must be separated from mains by means of reinforced insulation.

I- 5
Main Unit
Coaxial Cable
Max. 300m
Transducer
for Large Pipe (4 path)
Multi-Path
Junction Box
AC100 to 230V±10%
or DC24V±20% （Option）
Pulse Output
4-20mA Analog Output
（Max. Resistance 1k ohm）Analog Devices
Functional earth
Totalizer
or
Relay Receiver
Contact Relay Output
Power Supply
Mounting Fixture
(Note)
This is sample system.
Analog orTotalized devices are not included in the standard system.
Fig 1-2 ;Ultrasonic Flowmeter basic system (4path)
Note: [ For AC power source ] A switch or circuit-breaker shall be included in the building installation. It shall be in close proximity to the equipment and within easy reach of the OPERATOR. It shall be marked as the disconnecting device for the equipment. [ For DC power source ] The DC power source must be separated from mains by means of reinforced insulation.

I- 6
Fig 1-3；Ultrasonic Flowmeter basic system (1path or 2path)
(Note)
This is sample system.
Analog orTotalized devices are not included in the standard system.
AC100 to230V±10%
or DC24V ±
20% （Option）
Pulse Output
4-20mA Analog Output
（Max. Resistance 1k ohm ）Analog Devices
Fanctional earth
Totalizer
or
Relay Receiver
Contact Relay Output
Power Supply
Main Unit
Coaxial Cable
Max. 300m
Transducer
for Small Pipe
Mounting Fixture
Note: [ For AC power source ] A switch or circuit-breaker shall be included in the building installation. It shall be in close proximity to the equipment and within easy reach of the OPERATOR. It shall be marked as the disconnecting device for the equipment. [ For DC power source ] The DC power source must be separated from mains by means of reinforced insulation.

I- 7
Fig 1-4 ；Ultrasonic Flowmeter basic system (4Path)
Mounting Fixture
AC100 to 230V±10%
or DC24V ±20%（Option）
Pulse Output
4-20mA Analog Output
（Max. Resistance 1k ohm ）Analog Devices
Functional earth
Totalizer
or
Relay Receiver
Contact Relay Output
Power Supply
(Note)
This is sample system.
Analog or Totalized devices are not included in the standard system.
Coaxial Cable
Max. 300m
Multi-Path
Junction Box
Main Unit
Transducer
for Small Pipe (4 Path)
Note: [ For AC power source ] A switch or circuit-breaker shall be included in the building installation. It shall be in close proximity to the equipment and within easy reach of the OPERATOR. It shall be marked as the disconnecting device for the equipment. [ For DC power source ] The DC power source must be separated from mains by means of reinforced insulation.

I- 8
I-2 Installation and Wiring
Installation and wiring should be worked carefully.
DANGER
Be sure to stop power supply to the main unit for installation and wiring work to prevent electrical shock .
WARNING
Make sure that wiring are made correctly as incorrect connections may result in damage to the main unit
and connected accessories.
Do not install or use the equipment in a atmosphere where any flammable or explosive gas is present.
CAUTION
After installation and wiring work, tighten the front cover screws and cable glands of the main unit exactly to
protect against water and dust.
Torque: Front cover screw Approx. 2.5 N･mCable gland Approx. 1.5 N･m
I-2-1. Setup Procedure
(1) Procedure
The basic steps in setting up the flowmeter system are outlined below.
Please note some limitations placed on operation from LCD.
No.
Step
Procedure
Reference
Chapter
From
PC
From
LCD
1
Selection of transducer position
I-2-2
-------
-------
2
Installation Main Unit
Placement & Wiring connection
I-2-3 to 8
-------
-------
3
Transducer Parameter Input
(1) Unit System Selection
I-2-13 (8)
Yes
N/A
(2) Q'ty of measuring path
I-2-13 (8)
(3) Pipe information input
I-2-13 (9)
(4) Transducer type
I-2-13 (9)
(5) Cable length
I-2-13 (9)
(6) Fluid parameter input
I-2-13 (9)
4
Transducer distance confirmation
I-2-13 (11)
Yes
N/A
5
Output Setup
(1) Flow rate unit settings
I-2-13 (12)
II-2-6 (2) a
Yes
Yes
(2) Totalized output settings
I-2-13 (12)
II-2-6 (4)
Yes
Yes
(3) Analog output settings
I-2-13 (13)
II-2-6 (3)
Yes
Yes
(4) Alarm setting
I-2-13 (14)
II-2-6 (3)
Yes
Yes
(5) Contact output settings
I-2-13 (15)
II-2-6 (5)
Yes
Yes
(6) Digital output settings
I-2-13 (16)
II-2-6 (6)
Yes
N/A
(7) Upload parameters
I-2-13 (17)
Yes
N/A
6
Transducer Installation
Temporary installation by using couplant.
Transducer distance parameter required.
I-2-9
-------
-------
7
Cable Treatment
I-2-10 & 11
-------
-------
8
Wiring Connection to Main Unit
I-2-4 to 7
-------
-------
9
AGA settings
Pipe should be fulfilled with fluid.
I-2-13 (18)
Yes
Yes
10
Transducer Installation (Final)
Permanent Installation by Adhesive.
I-2-9
-------
-------
11
Finalizing Setup through PC
configuration software or LCD
(1) AGA settings
(Pipe should be fulfilled with fluid.)
I-2-13 (19)
Yes
Yes

I- 9
(2) Required tool for installation
Following tools are required for installation site work.
No.
Item Name
Q’ty
Purpose
(1)
Monkey wrench (approx. 300mm)
2 pcs
For tightener handling
(2)
Second-cut file (approx. 300mm)
2pcs
For pipe or cable treatment
(3)
Hammer
1 pc
For wire or tightener location adjustment
(4)
Disc sander
1 pc
For pipe polish (Pipe treatment)
(5)
Cold chisel (200mm~300mm)
1pc
For sputter remover
(6)
Knife (or Cutter)
1pc
For cable treatment
(7)
Punch (or Marker)
1pc
For making on mounting point of transducer
(8)
Screw driver + (Phillips type)#1 & #2
1pc
For Inner panel handling & wiring
(9)
Screw driver – (Slotted type)3.5mm
1pc
For wiring terminal lever operation
(10)
Nippers (125～150mm)
1pc
For cable treatment
(11)
Long-nose pliers (125～150mm)
1pc
(12)
Crimp tool (AMP 22～16)
1pc
For cable end treatment of PE cable
(13)
Soldering gun
1pc
For cable binding treatment (If any)
(14)
Wrench
1set
For tightener handling
(15)
Tape measure (3～10m)
1pc
For Transducer distance verification
(16)
Miscellaneous
Electrical tape
For cable treatment
Marker
Gauge Paper
For confirm vertical line for transducer position
Thinner
For paint remover or degreasing
Couplant
For temporary installation of transducer
Paint
For repaint for pipe