truflo ULTRAFLO 5000 User manual

Flowmeter Ultrasonic Flow
Metering / Dosing Device
Operating Manual
Read the user's manual carefully before starting to use the unit or software.
Producer reserves the right to implement changes without prior notice.
PVDF-PE Plastic Ultrasonic Flow Meter
ULTRAFLO 5000
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Table of Contents
Table of Figures
General safety instructions
1. Planning information
 1.1 Areas of application
 1.2 Measuring principle
 1.3 Operational safety
2. Assambly and installation
 2
.1 Installation instructions
 2.2 Assembly of the flowmeter
 2
.3 Electrical wiring
3. Commissioning
 3
.1 Operation
 3.2 Functionalities of flowmeter and default settings
 3
.3 Overview of default settings
 3.4 General Information
4. Exchange of measuring device
5. Technical specifications
 5.1 Dimensions and weight
 5
.2 Technical specifications
01
02
02
02
03
03
03
04
07
09
09
13
23
23
23
25
25
26
Fig. 1: Presentation of the principle of ultrasonic flow measuring
Fig. 2: Installation position of Flowmeter
Fig. 3: Mounting examples for Flowmeter
Fig. 4: Mounting possibilities
Fig. 5: Fixing Flowmeter
Fig. 6: Flowmeter mounted on a DIN rail
Fig. 7: Pin code: Connection plug / socket for 5-pin version
Fig. 8: Pin code: Connection plug / socket for 8-pin version
Fig. 9: Operating with the key pad
Fig. 10: Menu organization for 5-pin version
Fig. 11: Menu organization for 8-pin version
Fig. 12: Function of the creeping suppression illustrated with 0.6 l/min
Fig. 13: Connecting output Q1 to relay
Fig. 14: Connecting output Q2 to counter
02
03
05
05
06
06
07
08
10
11
12
15
20
21
PVDF-PE Plastic Ultrasonic Flow Meter
ULTRAFLO 5000
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General Safety Instructions
Personnel for Installation, Commissioning and Operation
Technological Progress
Intended Use :
Please always observe the following safety instructions!
Please pay attention to the safety instructions with the following pictograms and signal words in
these operating instructions:
The flow meter Flowmeter may only be used for measuring the flow of pure, homogeneous
liquids.
The Flowmeter is not intended for use in medical applications.
The volume flow meter Flowmeter is built operationally safe in accordance with the latest state
of the art technologized developments and industry standard EN 61010 regulations
(corresponds to VDE 0411 "Safety specifications for electrical measurement, control and
laboratory devices").
The manufacturer is not liable for any injury, damage or harm due to inappropriate or
unintended use or modifications of the flow meter. Conversions and/or changes to the flow
meter may only be made, if they are expressly performed in accordance with the operating
instructions in this operating manual.
Assembly, electrical installation, commissioning and maintenance of the flow
meter must be carried out by qualified, trained personnel. The qualified
personnel must have read and understood the operating instructions in this
operating manual and must follow the operating instructions in this manual.
The installer has to ensure that the flow meter is correctly connected
according to the electrical connection diagrams in this operating manual.
Serious injury or death from electric shock may occur if wiring, installation,
disassembly or remove of wires is performed while electrical power is
energized
The manufacturer reserves the right to revise, alter, or modify the flow meter to the most current
technology without special prior notice. Further information about the latest updates and potential
additions to these operating instructions are available from the manufacturer.
IMPORTANT! indicates situations or cases which, if not avoided, could result in
damage or failure of the Flowmeter 44i equipment.
WARNING! Iindicates general hazardous situations or cases which, if not avoided,
could result in serious injury or death.
Is used to lead users to helpful information not related to personal injury.
NOTICE
WARNING!
01
PVDF-PE Plastic Ultrasonic Flow Meter
ULTRAFLO 5000
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1. Planning Information
1.1 Areas of application
1.2 Measuring principle
The flow measurement device in the Flowmeter designed to measure dynamic flow in pipes and
tubes. This flow meter is suitable for liquids only. The Flowmeter is used in
It usually takes more energy to swim against the flow than with the flow. The ultrasonic flow
measurement is based on the phase-difference approach:
Two ultrasonic-sensors located opposite from each other alternatively transmitting and receiving
ultrasonic signals. If there is no liquid flow both sensors receive the transmitted ultrasonic signals in
the same phase, i.e. without phase difference. If liquid is flowing there is a phase shift. It differs
when measured in direction of the flow than when measured against the direction of the flow. This
phase difference is directly proportional to the flow rate.
Flowmeter has the following features and benefits:
Chemicals supply for controlling, logistics, monitoring
Cooling systems, logistics, monitoring
Process equipment for control and monitoring of formulas
Valve control for continuous release of liquid volumes
Supply with de-ionized water
Very dynamic liquid processes with dosing times of below 1 second
No movable parts, therefore no wear
High repeatability
Easy to clean
Safe operation
Compact design
Integrated detection of empty conduits
Integrated dosing function with pre-set and adjustable amounts
Chemical resistant
Constant pipe cross-section over the entire measurement channel
Fig. 1: Presentation of the principle of ultrasonic flow measuring
L: length of measuring pipe
K: factor
D: diameter of measuring pipe
v: flow velocity
c: sound velocity of the fluid
: phase with the flow
: phase against the flow
+
-
wL
c + v
=
+
- +
wL
c - v
=
-
D
L
v
c
c+v
vreceiver /
sender
sender /
receiver c
vc-v
v
02
PVDF-PE Plastic Ultrasonic Flow Meter
ULTRAFLO 5000
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1.3 Operational Safety
2.1 Installation instructions
Comprehensive self-tests ensure highest possible safety.
Faults (process or system errors) are output on a digital output or displayed on the display menu.
The protection class is IP 67.
Flowmeter meets the general EMC immunity requirements according to CE, EN 61000-6-3, EN
61000-4-2, EN 61000-4-3, EN 61000-4-4, EN 61000-4-5, EN 61000-4-6.
Flowmeter meets the safety requirements concerning the Protective Extra Low Voltage directive
according to EN 50178, SELV, PELV.
For fastest possible bubble detection it is important to keep the pipe distance from tank to
Flowmeter as short as possible. Accurate measurement can only be assured, if the pipe is
completely filled and the liquid does not outgas.
The housing of Flowmeter is labeled with an arrow symbolizing the direction of the flow. The
flowmeter must be installed in direction of the flow.
2. Assembly and Installation
The nameplate of the Flowmeter has an arrow, symbolizing the flow direction of measurement.
The flow meter has to be installed in a way so that the flow-through is in the same direction as
the arrow symbol.
NOTICE
Fig. 2: Installation position of flowmeter
03
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ULTRAFLO 5000
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Notwithstanding it may be advantageous for dosing applications to install the Flowmeter as close
as possible to the dosing valve, since soft pipes increases the cross-section depending on the
system pressure. This may lead to repeatable differences.
When using pumps, Flowmeter must be installed in flow direction on the pressure side, on order to
ensure sufficient pressure. The maximum pressure rating of Flowmeter has to be considered.
For correct volume flow measurements straight and unobstructed inflow and outflow distances have
to be observed. Starting from the connection thread these straight and unobstructed flow zones
must be:
Particles present in the flow stream may result in measuring errors.
Insure that no cavitations dissolve from the measured liquid. Depending on the measured
liquid it can be helpful to have enough back pressure on the outlet of Flowmeter to avoid
cavitations. Insure all mechanical connections are tight.
NOTICENOTICE
Do not exceed the maximum pressure allowance for of the Flowmeter (see section
5.2 Technical specifications). Exceed the maximum pressure can lead to destruction
of the Flowmeter.
WARNING!
2.2 Assembly of the flow meter
The flow meter is mounted into a pipe system by using the mechanical connection.
Flowmeter should be mounted vertically into the pipe for the best measuring performance. Do
not install the flow meter after a dosing valve where the flow meter can run empty. Placing
the flow meter after a dosing valve and allowing it to run empty will cause a measuring
deviation at the next measurement. To avoid bubbles in the liquid, Flowmeter should be
installed on the pressure side of the pump.
Nominal Diameter
Inflow distance
Outflow distance
DN 5
0cm
0cm
DN 7
0cm
0cm
DN 10
5cm
0cm
DN 15
40cm
20cm
04
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If it is not possible to mount the flow meter vertically, then mount the instrument in a
location where the pipe will be filled at all times. The best measuring result is achieved if
bubbles do not pass through Flowmeter.
For applications with a "clean design" for which it is necessary to completely drain the pipe system,
we recommend mounting the flow meter in the vertical position. Residual liquid may remain inside
the device if flow meter is mounted horizontally.
Vibrations or mechanical forces may decrease measuring accuracy. So if there is due to vibration
or mechanical movements is necessary to fix Flowmeter additionally, the instrument can be either
mounted on a DIN rail, or be fixed on the lateral slot.
Fig. 3: Mounting examples for Flowmeter
Fig. 4: Mounting possibilities
05
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ULTRAFLO 5000
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Fig. 5: Fixing Flowmeter
Fig. 6: Flowmeter mounted on a DIN rail
Flowmeter must be installed without mechanical tensions on the existing pipe system. The
flow meter may be damaged if there is tension on the existing pipe system.
Non-compliance of the installation instructions may result in tearing of the
housing, liquid may leak out.
06
PVDF-PE Plastic Ultrasonic Flow Meter
ULTRAFLO 5000
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2.3 Electrical Wiring
Connector cable pin configuration defined by manufacturer
The outlets may be re-programmed for specific applications
Fig. 7: Pin code: Connection plug / Socket
Serious injury or death from electric shock may occur if wiring, installation,
disassembly or remove of wires is performed while electrical power is energized.
Always shut off or disconnect electrical power at service panel and lock switch or
breaker and tag to prevent energizing electrical power during work or while
Flowmeter is not assembled and installed.
Wiring installation, disassembly and removal must be performed by qualified
persons experienced and knowledgeable about electrical work.
WARNING!
4
1
3
52
4 3
152
1 L+ Power supply: 18...30 VDC
Pin Function Description
2 Pulse output O1 alternative:
1. Empty-pipe output
2. Dosing output
3. Upper or Lower Limit output
4. Negative flow
Digital Output Q1
Freely adjustable ranging from 0.1 to 3000 ml/pulse in 0.1
ml/pulse steps, npn-Transistor, max. load 30V/100mA.
Max. Voltage must be less than the supply voltage.
Configurable output of 0V or 24V when pipe is empty.
Configurable output of 0V or 24V
Configurable output of 0V or 24V when reaching upper or
lower limit
Configurable output of 0V or 24V when liquid flows in
negative direction
3 GND Ground : 0 V
4 Communication Communication interface
5 Analog output QA 4….20mA ; 0….20mA
Example: 0L/min => 4mA
60L/min => 20mA
Empty pipe Alert => 3.5mA
(4-20mA depending on the configured limits)
07
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ULTRAFLO 5000
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Connector cable pin configuration defined by manufacturer
The outlets may be re-programmed for specific applications.
plug / socketFig. 8: Pin code: Connection
Digital output Q2
Configurable npn- or pnp-Transistor, max. Load 30V/
100mA. Max. Voltage must be less than the supply voltage.
Configurable output of 0V or 24V when pipe is empty.
Configurable output of 0V or 24V
Freely adjustable ranging from 0.1 to 3000 ml/pulse in 0.1
ml/pulse steps.
Configurable output of 0V or 24V when flow reaches upper
or lower limit.
Configurable output of 0V or 24V when liquid flows in
negative direction.
Digital output Q2 Functions:
1. Empty pipe output
2. Dosing output
3. Pulse output
4. Upper or Lower Limit output
5. Negative flow
1 L+ Power supply: 18...30 VDC
Pin Function Description
2 Pulse output O1 alternative:
1. Empty-pipe output
2. Dosing output
3. Upper or Lower Limit output
4. Negative flow
Digital Output Q1
Freely adjustable ranging from 0.1 to 3000 ml/pulse in 0.1
ml/pulse steps, npn-Transistor, max. load 30V/100mA.
Max. Voltage must be less than the supply voltage.
Configurable output of 0V or 24V when pipe is empty.
Configurable output of 0V or 24V
Configurable output of 0V or 24V when reaching upper or
lower limit
Configurable output of 0V or 24V when liquid flows in
negative direction
3 GND Ground : 0 V
4
5 Analog Output QA 4….20mA ; 0….20mA
Example: 0L/min => 4mA
60L/min => 20mA
Empty pipe Alert => 3.5mA
(4-20mA depending on the configured limits)
6 Communication Communication Interface
7
8 Shielding EMC safety
Digital input I1
1. Dosing output
2. Set offset
3. Reset counter
4. Creeping flow off
Digital input I1
Starts the dosage by a rising edge of 24V.
The Offset is set by a rising edge of 24V.
Reset of the counter by a rising edge of 24V.
Creeping suppression is deactivated as long as there are
24V at the input.
65
1
4
87 3
2
65
1
4
87 3
2
08
PVDF-PE Plastic Ultrasonic Flow Meter
ULTRAFLO 5000
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3.1 Operation
If Flowmeter is used as a volume flow meter for water or water-like liquids it will not require on-site
calibration. Parameters for water are calibrated at the factory. The Flowmeter 44i may also be
ordered with customized settings, but customized settings must be requested when Flowmeter is
ordered.
The following parameters may be changed to settings suitable for the individual
conditions: for 5-pin version
Digital output Q1, function and behavior
Analog output QA, function and behavior
Flow range, for which shall apply 4...20 mA
Pulse value
Creeping suppression
Optimization of measurement curve with up to 8 interpolation values (medium matrix)
The following parameters may be changed to settings suitable for the individual
conditions: for 8-pin version
Digital output Q1, function and behavior
Digital output Q2, function and behavior
Digital input I1, function and behavior
Analog output QA, function and behavior
Flow range, for which shall apply 4...20 mA
Pulse value
Creeping suppression
Optimization of measurement curve with up to 8 interpolation values (medium matrix)
3. Commissioning
Attention : Only operate the flow meter Flowmeter44i within the operating limits
stipulated on the product label and the operating manual / data sheet. Use of the
Flowmeter 44i outside these conditions will lead to overloads which cause permanent
damage.
NOTE : If Flowmeter is used for a fluid other than water the "basic trim" has to be carried
out during commissioning. Therefor the device has absolutely be filled with medium.
The basic trim can be done on the device display (alternatively Programmtool). During the
adjustment the medium may not flow as it affects the function
NOTICE
NOTE : If necessary, e.g. if viscosity and/or speed of sound deviate significantly from
water, the pre-set parameters can be adjusted via Programmtool. It is always necessary to
adjust the manufacturer pre-set parameters when using the Flowmeter as a dosing device
according to section 3.2 (Dosing 1. Flowmeter as a dosing device). Adjusting the
manufacturer pre-set parameters requires Programmtool.
NOTICE
09
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ULTRAFLO 5000
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Display and user menu
Flowmeter is equipped with a display to visualize actual measurement values and to change
parameters of the flow meter. Menu navigation and parameter changes are controlled by the four
keys on the keypad.
Press the "Set" key to display the main menu. Different menu options can be selected by using the
two arrow keys.
To enter e.g. analog limits "Analog output - Upper limit" use the arrow keys to change values and
press "Set" to confirm. To switch back to the last menu level press the "Esc" key. As soon as the
operator tries to change values the user will be prompted to enter a password. Password protection
is used to ensure changes to values or configurations are done by authorized personnel. The
default password for Flowmeter is 41414. The password can be changed with Programmtool. The
user level will remain active for 5 minutes after the last press on any button.
NOTE : Always the first parameter of the menu appears in the display.This need not be the
adjusted enabled parameter. The enabled parameter appears inverted and possibly visible
by scrolling.
NOTICE
Fig. 9: Operating with the key pad
The Password should only be shared with personnel authorized to make
changes to setting.
NOTE : Functions marked with asterisk (*) are only available for the Flowmeter 8-pin version.
Flowmeter without user display supports the same functions as the display-version. The
display and programming unit Programmtool is needed to change configurations of
Flowmeter without user display.
NOTICE
10
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Fig. 10: Menu organization for 5-pin version
11
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Fig. 11: Menu organization for 8-pin version
12
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3.2 Functionalities of flow meter and default settings
In the sub menu "Set Offset" it is possible to set the actual offset of the flow meter. Use this function
only when Flowmeter is completely filled with liquid, and there is no flow. If the offset is set while
flow is present or when the pipe is empty it will cause an offset drift what results in a faulty
measurement. Example of operation see appendix.
A small offset change, e.g. caused by variable temperatures, is automatically done by the flow
meter. It is also possible to set the offset via the configurable digital inputs.
The analog output signal reacts faster to signal changes when average determination is set to
"soft". Whereas the analog output signal reacts slower when average determination is set to
"strong".
The language of the display can be changed. Available languages are English and German.
Set Offset
Language
The function "Filter" averages the analog output signal. Possible settings: Soft, Medium, Strong, Off
Filter
Filter
off
soft
medium
strong
100%
16ms
0,3s
1s
4,2s
13
PVDF-PE Plastic Ultrasonic Flow Meter
ULTRAFLO 5000
Response time analog output
Zeit [s]
Wert [%]
100
80
60
40
20
00 1 2 3 4
Off
Soft
Medium
Strong
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Units
Reset Counter
Flowmeter is able to show actual flow or the volume in different units. Following units can be
selected:
ml/s + l , Gal/min +Gal , l/min + l , l/min + m³.
The first letters correspond to the unit of the flow value. The letters after the + correspond to the
unit of the volume value.
The creeping suppression excludes flow measurements that result from convection in a narrow
band around zero, even with a closed valve. At the factory, the creeping suppression is set at a
standard value in relation to the cross-section of the flow meter. Changes to a smaller value of the
parameter may cause an offset drift what results in a faulty measurement.
There are higher tolerances below the standard default settings, see also section 5.2 measurement
errors!
The volume counter of Flowmeter can be reset. Example of operation see appendix
Basic Trim
Creeping suppression
NOTE : The "Basic Trim" function insures that the flow meter is conforming to the media
specific characteristics. To execute this function, Flowmeter runs a self-diagnostic function
which optimizes all important parameters. This process lasts approximately 1 minute.
NOTICE
Important! : Once reset, counter values cannot be restored. After a reset the counter
works normally.
Important! : To make sure the basic trim is correctly done, the flow meter has to be filled
with liquid without a flow.
When there is an error detected while performing the basic trim function, the display shows
"Error". After successfully finishing the basic trim function, the display will show "Done"
Setting range : 0.0...20 l/min, in 0.006 l/min steps
Default settings : 0.024 l/min for DN 5
 0.09 l/min for DN 7
 0.3 l/min for DN10
 0.9 l/min for DN15
14
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The creeping suppression works with a hysteresis of - 25%.
Example : Creeping suppression = 0.6 l/min
If the flow rate is lower than 0.45 l/min the pulse output/analog output becomes inactive. If the flow
rate exceeds 0.6 l/min a pulse is output again and added to the totalizer. Similarly, a value is
transmitted to the analog output again.
The analog output is available as current output 4-20mA or 0-20mA. This is selected with the
purchase order. As a standard it comes with current output 4-20mA. It can also be switched off by
using the device menu or Programmtool.
Diagnostic
Analog output QA
The sub menu "Diagnostic" shows the software/hardware version and other helpful values for
analysis. Actual values and the instrument´s present status are important to analyze the
measurement or failure by the manufacturer service
NOTICE
Fig. 12: Function of the creeping suppression illustrated with 0.6 l/min
15
PVDF-PE Plastic Ultrasonic Flow Meter
ULTRAFLO 5000
1.2
1.05
0.9
0.75
0.6
0.45
0.3
0.15
0
-25%
1. Creeping Suppression switch on
2. Creeping Suppression switch off
Flow [l/min]
Pulse/Analog output active inactive active inactive active
1
22
1
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The current output ranges from 0 to 22.6mA measuring the flow rate or the condition of the flow
measurement.
Upper and lower limit parameters can be set within the type-specific measurement of the device. By
default, zero flow is set at 4 mA and the maximum flow is set at 20 mA.
The analog output is available as current output 4-20mA or 0-20mA. This is selected with the
purchase order. As a standard it comes with current output 4-20mA. It can also be switched off by
using the device menu or Programmtool.
Characteristic curves analog output
The values here signify for 4-20mA configuration:
20 mA the upper limit of the relevant measurement
4 mA the lower limit of the relevant measurement
3.5 mA empty pipe
When current output is used, the load must not be higher than 500Ohm. A higher load
prevents the device from providing the maximum current of 22.6mA.
Set point ranges : 0-20mA, 4-20mA, off
Output value : Flow, Temperature
For the following graphic "min Range" is used for 0% and "max Range" is used for 100%.
0 - 20mA
24
22
20
18
16
14
12
10
8
6
4
2
0
Current output 0...20mA
-20-100102030405060708090100 110
Value [%]
120
Current [mA]
16
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Smaller 0%
0% (min Range)
Value
Between 0% and 100%
100% (max Range)
Bigger 100%
0
0
Current [mA]
Linear interpolation from 0 to 20 mA
20
20
Bigger max Value 20
For the following graphic "min Range" is used for 0% and "max Range" is used for 100%
0 - 20mA
Empty pipe
Smaller -1.2%
Value
Between -1.2% and 0%
0% (min Range)
Between 0% and 100%
3.5
3.8
Current [mA]
Linear interpolation from 3.8 to 4mA
4
Linear interpolation from 4 to 20mA
100% (max Range)
Between 100% and 103%
20
Linear interpolation from 20 to 20.5mA
Bigger 103% 22.6
Current [mA]
24
22
20
18
16
14
12
10
8
6
4
2
0
-20-100102030405060708090100 110 120
Current output 0...20mA
17
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Pulse value
This section determines the output settings for pulsed outputs.
Choose configuration such as to neither exceed the maximum output frequency of the Flowmeter
(10kHz) nor the maximum input frequency of the control. If the maximum frequency is exceeded the
Flowmeter will not output pulses correctly.
Example
This Means
2.0 ml/Pulse
a pulse is emitted every 2.0 ml.
Setting Range
Default Setting
0.1...3000.0 ml/Pulse, in 0.1 ml/Pulse steps
1.0 ml/Pulse
1
100
1000
100
1
1
0.1
10
1
100
10000
10
1
0.01
0.0001
0.1
0.5
0.005
0.00005
0.05
500
5
Flow
ml/s
Pulse value
ml/Pulse
Frequency
Hz
Period
s
Duration of the Pulse
s ms
0.05
50
0.5 10 0.05 20 1 1000
In the last case every 20 seconds, a pulse of 1 second duration is put out.
The Flowmeter can be configured for manually dosing by choosing the dosing function via the user
display. The Volume "Dosing Batch" and the "Dosing Time" are freely adjustable. When the
"Dosing Time" is set to zero, the timer control is inactive. A dosage can be started and stopped with
the menu function keys "Start" and "Stop".
Dosing
Important! : If Dosing Time =0 the time switch-off is inactive.
Setting range "Dosing Batch" : 0 - 3500 Liters
Setting range "Dosing Time" : 0 -30000 Seconds
Default setting "Dosing Batch": 0 Liters
Default setting "Dosing Time" : 3 Seconds
18
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