LEVIFLOW INTEGRATED FLOWMETER LFIF USER MANUAL

Transcription

1 LEVIFLOW INTEGRATED FLOWMETER LFIF USER MANUAL LEVIFLOW Integrated Flowmeter: LFIF-06 (10 l/min) This manual contains information necessary for the safe and proper use of the LEVIFLOW LFS flowmeter series. Included are specifications for the standard configuration, components, and instructions regarding its use, installation, operation, adjustment, inspection and maintenance. For special configuration of the LEVIFLOW flowmeters refer to accompanying information. If the flowmeters have to be configured for other parameter settings then the LEVIFLOW Configuration Software (see relevant manual Levitronix Doc.# PL ) is necessary. Please familiarize yourself with the contents of this manual to ensure the safe and effective use of this product. After reading, please store the manual where the personnel responsible for operating can readily refer to it at any time. PL , RevA, DCO# RD First Release: 14-Jun-17 Last Update: 14-Jun-17

2 Table of Contents 1 SAFETY PRECAUTIONS SPECIFICATIONS Component Overview General Specifications Basic Dimensions of Main Components Dimensions of Flowmeter Dimensions of Cables Overview of Parameter Configuration INSTALLATION Electrical Installation Overview and Preparation Instructions for Electrical Installation Configuration of Flowmeter Data Mechanical and Hydraulic Installation Instructions OPERATION General Timing Specifications Startup Time Thermal Stability Time Zero Adjustment Activation Time Automatic Zero Adjustment Duration Operation System Operation with PLC Interface Operation with RS LED Messages Operation with LEVIFLOW Configuration Software INSPECTION AND MAINTENANCE TROUBLESHOOTING Common Troubles Troubleshooting with LEVIFLOW Configuration Software TECHNICAL SUPPORT APPENDIX Regulatory Status CE Marking Symbols and Signal Words PL , RevA, DCO# RD 2

3 1 Safety Precautions CAUTION Do not under any circumstances open the flowmeter housing. Levitronix does not assume responsibility for any damage, which occurs under such circumstances.! WARNING Hazardous voltage may be present. In case of the usage of an inadequate AC/DC power supply, mains voltages may be present (even if the system is designed for 24VDC). Do not under any circumstances open the powered converter. The usage of galvanic separated 3 rd party tested (like CE and/or UL) AC/DC supply is highly recommended. Toxic chemicals may be present.! WARNING When using the flowmeter to measure chemicals skin contact and toxic gases may be hazardous to your health. Wear safety gloves and other appropriate safety equipment. PL , RevA, DCO# RD 3

4 2 Specifications 2.1 Component Overview 3c 3b 1 2 3a Figure 1: Standard LEVIFLOW LFIF components and accessories Pos. Article Name Part # Feature/Description Note 1 LFIF Integrated Flowmeter Calibration parameters are stored in flowmeter. 2a LFE-E Extension Cable 5m PVC Waterproof lock-release mounting connector type for flowmeter connection. Open wires at cable end for connecting to other equipment. 2b LFE-E Extension Cable 5m PVC 2b LFE-E Extension Cable 5m PVC 3 YN-485I-TR, USB to RS485 Adaptor-TR Isolated Waterproof lock-release mounting connector type for flowmeter connection. Integrated pull-up resistor at digital output for flow switch applications. Waterproof lock-release mounting connector type for flowmeter connection. Open wires at cable end, integrated conversion for analog output from current to voltage. Structure/Design USB connector (3a) with termination resistor and cable with connector pair (3b and 3c) for external RS485 wire connection. Magnetically isolated. Cable length is 2m. Purpose Communication over fieldbus of converter with PC Table 1: Order information for standard flow sensor models 2.2 General Specifications Characteristics Specification Characteristics Specification Flow Range [l/min] Accuracy of 20 C Water Kinematic Viscosity Sound Speed Fluid Temperature 0 10 l/min For > 1.7 l/min: ± 2% For < 1.7 l/min: ± 34 ml/min mm 2 /s ( cst) m/s (water) o C ( o F ) Ambient must be < 40 C at 80 C fluid temp. Ambient Temperat o C ( o F) Max. Fluid Pressure Power Supply Inrush current Pressure Drop Wet Parts / Fittings 0.5 MPa = 5 bar 24 VDC ±10%, 38 ma Peak < 690 ma during < 1 ms 380 mbar at 10 l/min and 20 C water PFA / Tube 3/8 (OD=9.52, ID=6.38 mm) Weight Housing Materials IP Classification Electrical Connector ~ 80 g for flowmeter and ~ 180 g for 5m extension cable PPS for housing body, FKM for sealing gaskets PEEK for screws, PET for label IP-65 (indoor) Circular type, lock-release mounting (housing material: PPS) Cables Separate extension cable with connector (see Figure 3) Interfaces (see also Table 5) Configuration Parameters (Lev. Config. SW) RS485 with Modbus protocol Analog Output with 0-20 ma (4-20mA configurable) Digital Output: Measurement Error, Flow Alarm, Volume Counter Pulse, Pulsed Flow Output (0-1000Hz) Viscosity Low Cutoff Damping Time (filter) Linearization (up to 10 points) Alarm Outputs (low and high) Volume Counter Table 2: Specifications of flowmeter LFIF-06 (All data based on water at 20 o C with zeroing and ambient at 25 C.) PL , RevA, DCO# RD 4

5 2.3 Basic Dimensions of Main Components Dimensions of Flowmeter Figure 2: Dimensions of LFIF-06 Flowmeter Dimensions of Cables Figure 3: Dimensions of extension cable LFE-E.1/2/3-50 Note: Maximum bending load is 15N. PL , RevA, DCO# RD 5

6 2.4 Overview of Parameter Configuration Table 3 shows the standard ( Default ) and possible parameter configurations of the flowmeter. This user manual is dealing with the standard configuration. For setting up other configurations the LEVIFLOW Configuration Software is needed. Consult the Configuration-SW User Manual (Levitronix Doc.# PL ) for more detailed description. Note: The LFIF-06 flowmeter needs configuration software version V1.34 or higher. Block Parameter Option/Range Default Note Basic Analog output settings Digital output settings Flow alarm Volume counter settings Measurement Error Settings Sensor size LFIF-xx xx = 06 xx = 06 (accord. Sensor size) Full scale L/min (accord. Sensor size) xx indicates the measurement ID of the tube. Default Values: LFIF-06 = 10 L/min Damping time 0 25 s 2 s Low-pass filter with Low cutoff % 2 % Kinematic Viscosity cst 1 cst Analog output setting Digital output 4 20 ma or 0 20 ma Flow alarm High Flow alarm Low Vol. counter Pulse Measurement Error Flow as Frequency Digital Output Off 0 20 ma Measurement Error 1 f3 db 2 T Flow cut to 0 below this percentage of full-scale If cutoff 0% is chosen, negative flow becomes visible Kinematic Visc. = Dynamic Visc. / Density Not implemented for LFIF-06 flowmeter. With the LFE-E.3 cable the current can be converted into 0 10 V voltage. - Upper flow limit detection - Lower flow limit detection - Pulse per volume - Error signal (empty sensor etc.) - Flow as Frequency output (100% of full-scale = 1 khz) - Set digital output off Hysteresis (Flow alarm) 0 20 % 0 % Can be used to get tolerance to noise. Alarm high % 105 % Alarm setting In percentage of full-scale. Contact type N.O. = normally open N.C. = normally closed N.O. = norm. open For digital output. Alarm low % -5 % Alarm setting In percentage of full-scale. Contact type Volume counter enable (activation box) N.O. = normally open N.C. = normally closed activated, not activated N.O. = norm. open not activated Volume counter base unit 1 ml, 1 L, 1 m3 1 L Multiplier factor 0.01, 0.1, 10, 100, Volume counter pulse length 0.5, 50, 100ms 0.5 ms Instant Measurement Error Ignore Time Flow Level on Measurement Error 0-99 s 10s 0%, -25, 125% Hold 0 % Table 3: Overview of parameters For digital output. These are settings for volume detection (integration of flow). Has to be active for the option Vol. Counter Pulse on digital output. During this time instant measurement errors are ignored. If an instant measurement error stays active for longer time than this time, measurement error arises. Signal level of analog output and flow, when measurement error arises PL , RevA, DCO# RD 6

7 3 Installation 3.1 Electrical Installation Overview and Preparation 4: High LED 3: Flow LED 5: Low LED 2: Zero Button 1: Cable Connector 6: Arrow Label for Flow Direction 8: Type Label 7: Label with Serial Number Figure 4: Integrated flowmeter LFIF-06 Interface Item Description 1 Cable Connector Supply and electrical interface (see Table 5 for specifications). 2 Zero Button 3 Flow LED For offset elimination with zeroing. To be pressed for more than 3 seconds to start zeroing. Zeroing process duration is about 20 seconds. Indicates status of flow measurement is blinking with frequency proportional to flow (~20 Hz at 100% of full scale). At zero flow it is constantly on. 4 High LED Indicates high flow alarm (see Table 3). 5 Low LED Indicates low flow alarm (see Table 3). 6 Arrow Label Indicates flow direction. 7 Label with Serial Number Unique serial number for traceability. 8 Type Label Contains article number and part name. Table 4: Standard specifications of interface items on flowmeter Pin # Cable Wire Color 6 Brown 5 Red 4 Yellow 3 Orange 2 Green 1 Blue Wire Size Description Standard Designation AWG mm 2 DC24V- Power Supply AWG mm 2 DC24V+ Specification and Description. Supply Voltage: 24 VDC ±10% DC24V- to be connected to earth. AWG mm 2 RS485- Field Bus Modbus protocol for communication with PC. AWG mm 2 RS485+ AWG mm 2 Analog Out+ Flow Value Current: 0 20 ma (load resistance < 500 Ohm), Reference is DC24V- Note: Cable LFE-E.3 contains integrated resistor for conversion 0 10V output. AWG mm Digital Out+ Error Open collector with nominal load DC 30V/10mA, Reference is DC24V- 1 Note: Cable LFE-E.2 contains integrated pull-up resistor for electrical definition of default signal. Note: see Table 3 for origin of errors. Table 5: Standard interface specification of flow sensor connector and cable LFE-E.1/2 Note 1: Cable LFE-E.2 contains integrated pull-up resistor for electrical definition of default signal. PL , RevA, DCO# RD 7

8 LFIF-06 Cable Wires Colors/Designation LFE-E.1 Example of User Interface Circuit LFIF-06 Cable Wires Colors/Designation LFE-E.3 Example of User Interface Circuit Open Collector Max. 30V / 10mA Blue: Digital Output R > 3 kohm Relais 24V Open Collector Max. 30V / 10mA Blue: Digital Output R > 3 kohm Relais 24V 4-20mA / 0-20mA Green: Analog Output 0-20mA Green: Analog Output 0-10V R < 500 Ohm R > 100 kohm R = 510 Ohm +5V R = 510 Ohm +5V Orange: RS485+ Yellow: RS485- R = 120 Ohm Tool Control Orange: RS485+ Yellow: RS485- R = 120 Ohm Tool Control R = 510 Ohm RS485/USB Cable with Termination Personal Computer (Service) Current-voltage resistor 20mA to 10V conversion 500Ohm/0.5W integrated in cable LFE-E.3. R = 510 Ohm RS485/USB Cable with Termination Personal Computer (Service) GND Brown: Ground GND GND Brown: Ground GND Red: 24 VDC AC/DC Supply 24 VDC Red: 24 VDC AC/DC Supply 24 VDC Figure 5: Typical interface connection chart with LFE-E.1 (current output) and LFE-E.3 (voltage output) LFIF-06 Cable Wires Colors/Designation LFE-E.2 Example of User Interface Circuit Open Collector Max. 30V / 10mA Blue: Digital Output R > 8.3 kohm Safety Switch Relais 24V 4-20mA / 0-20mA Green: Analog Output Orange: RS485+ Yellow: RS485- R = 510 Ohm R = 120 Ohm +5V Tool Control Pull-Up resistance 4.7 kohm is integrated in cable LFE-E.2. R = 510 Ohm RS485/USB Cable with Termination Personal Computer (Service) GND Brown: Ground GND Red: 24 VDC AC/DC Supply 24 VDC Figure 6: Typical interface connection chart with LFE-E.2 (flow switch applications) Instructions for Electrical Installation! WARNING Hazardous voltage may be present. Always isolate the electrical power supply before making or changing connections to the unit. Flammable gases.! WARNING Do not place the integrated flowmeter next to flammable gases. PL , RevA, DCO# RD 8

9 1. Remove the DC power from the flowmeter. 2. Remove the cable from the flowmeter connector. 3. Attach the necessary cable wires according to the pin specifications in Table For usage of a fuse at the power input (24 VDC) a 200 ma slow-blow type is recommended. Consider inrush current specification (see Table 2), when choosing the fuse type and the AC/DC power supply. 5. Attach the cable to the flowmeter connector. 6. Before powering on check again all wiring connections. Confirm that the terminals are securely fastened and that there is no possibility of short circuit Configuration of Flowmeter Data The flowmeter comes configured with the sensor specific data already stored in it. A calibration sheet including the calibration data (the K-Factor and the 5 Calibration Values) is also part of the package. In case this data should have to be changed to the users specific needs LEVIFLOW Configuration Software can be used. Consult the configuration Configuration-SW User Manual (Levitronix Doc.# PL ) for handling with the LEVIFLOW configuration software. Note: The LFIF-06 flowmeter needs configuration software version V1.34 or higher. 3.2 Mechanical and Hydraulic Installation Instructions 1. In order to mechanically fix the sensor body 4 threads (see Figure 2) can be used. 2. Assure that at the mounting location the allowed ambient temperature is not exceeded (see Table 2) 3. The flow circuit should be completely filled with fluid. The converter DSP (Digital Signal Processor) contains special algorithms, which increase the robustness of the measurement against bubbles. However, assure that excessive bubbles are avoided in the circuit. 4. Ideal mounting position for the flow sensor is upward flow direction to avoid the stagnation of bubbles and particles in the measuring tube. 5. Make sure that the arrow mark on the flowmeter shows into the direction of the flow in the hydraulic circuit. 6. Avoid excessive vibrations such as in the neighborhood of displacement pumps. Insufficient contact of the transducer (within the sensor) onto the pipe wall caused by vibration may result in inaccurate measurement. 7. The flowmeter measures flow velocity. In order to obtain fully developed flow pattern for accurate velocity measurement, straight run of 60 mm upstream and of 40 mm downstream is recommended. If non-uniform turbulent flow or swirl flow is expected, install longer upstream straight run and/or a flow-rectifier. 8. To install on pipe that has open end, the sensor should be mounted in lower position of the pipe line. 9. The flowmeter should be mounted where pressure in the pipe is above the atmospheric pressure. 10. Devices like valves are recommended to be installed downstream of the sensor in order to prevent formation of bubbles in the liquid. An upstream valve may form bubbles reducing the intensity of the ultrasound signal and interfering with measurement. 11. A bypass pipe run (including bypass valve and shutoff valve) is recommended for easy zero adjustment and maintenance. 12. Please confirm that the maximum pressure is below the in Table 2 specified pressure of the sensor. 13. After setup a Zeroing is recommended. Assure that the sensor is completely filled with the according fluid and is free of bubbles. Stable liquid properties should be assured by flushing the circuit with the final liquid until temperature and viscosity becomes stable. After this zero flow shall be realized. Then push the ZERO button on the flowmeter for about 3 seconds. During adjustment the High and LOW LEDs are blinking. 14. In the following cases a re-zero is recommended: a. 30 minutes after power-on of a cool converter and sensor b. Change of fluid properties (temperature, viscosity, density) c. Change of chemistry d. Change of the hydraulic circuit PL , RevA, DCO# RD 9

10 4 Operation 4.1 General Timing Specifications Startup Time After power-on a startup sequence proceeded. During this sequence flow measurement is not performed. Start-up time is about 3 seconds Thermal Stability Time To guarantee specified accuracy thermal stability of sensor has to be reached. Therefore it is recommended to wait 30 minutes after power-on Zero Adjustment Activation Time There are two possibilities to activate zero adjustment: 1. Activating by LEVIFLOW configuration software: Zero adjustment starts immediately after pressing corresponding button. 2. Activating by Zero button on the flowmeter (see Figure 4) has to be pressed during more than 3 seconds to initiate zero adjustment Automatic Zero Adjustment Duration The duration to perform an automatic zero adjustment is about 20 seconds. 4.2 Operation System Operation with PLC Interface Figure 5 shows the standard configuration of the digital and analogue output. For other configurations the LEVIFLOW configuration software has to be used (according manual is Levitronix Doc.# PL ). Note: The LFIF-06 flowmeter needs configuration software version V1.34 or higher Operation with RS485 Operation with communication over an RS485 bus is possible. The according MODBUS protocol can be requested at Levitronix LED Messages # Event/Situation LED Flow High Low Status Description 1a Power-on - successful On 3 times blinking of all LEDs and then Flow constantly on. 1b Power on - error On On 1c After power-on zero error On On On 1d After power-on firmware rewriting mode 2a Zero adjustment - successful On Off Off Off 2b Zero adjustment - failed On On On Zeroing failed. 3a Flow measurement - normal Blinking 3b Flow measurement high alarm Blinking On High flow alarm error. 3b Flow measurement low alarm Blinking On Low flow alarm error. 3 times blinking of all LEDs and then Flow and High constantly on. Origin of error can be bubbles etc. 3 times blinking of all LEDs ant the all constantly on. Zero adjustment failed when the power was turned on last time. 3 times blinking and then all LEDs off. Firmware rewriting mode. Contact Levitronix for more information. Successful zeroing start is indicated by High on and then High and Low are on during the 20 seconds zeroing process. Is blinking with frequency proportional to percentage of full scale. At zero flow constantly on. 4 At parameter writing - error On On On Parameter writing failed (EEPROM write error etc.). 4 Firmware Download On Blinking Firmware download on-going. Table 6: LED messages/designation of flowmeter PL , RevA, DCO# RD 10

11 4.2.2 Operation with LEVIFLOW Configuration Software For debugging, data collection and configuration of the flowmeter system the LEVIFLOW Configuration Software is available at Levitronix. Contact Levitronix for a sample of the configuration software and the according manual (Levitronix Doc.# PL ). An approved USB to RS485 adaptor with the according connection cable can be ordered according to the information in Table 1. Note: The LFIF-06 flowmeter needs configuration software version V1.34 or higher. Flow Out Flow In LEVIFLOW Integrated Flowsensor LFIF-06 Sensor Cable (Opten Wire) Analog and Digital Outputs - 1x Analog Output - 1x Digital Output Screw type connector for open-wires connection included in converter cable package. Fieldbus RS485 Power Supply 24 VDC LEVIFLOW Configuration Software System Configuration Service, Firmware Update Monitoring USB to RS485 Converter with Cable Figure 7: System operation with LEVIFLOW configuration software 5 Inspection and Maintenance The LEVIFLOW ultrasonic flowmeters do not require special maintenance since there are no moving parts that can be subjected to wear and tear. However, the following periodical checks are recommended to ensure smooth and reliable operation: 1. Check for excessive mechanical stress onto the flow sensor body for example caused by bended piping. 2. Inspect for loosen connections caused by excessive pipe vibrations. 3. Inspect the sensor visually for any deposits, excessive bubbles or foreign materials in the measuring tube. PL , RevA, DCO# RD 11

12 6 Troubleshooting 6.1 Common Troubles # Phenomenon Possible Cause Countermeasure 1 Zero flow is indicated even if there is flow in the hydraulic circuit Wrong parameter and mechanical setup of sensor or zero adjustment performed under flow conditions. - Check if the parameters have been set to the optimal values - Check if the flow direction is correct - Redo zeroing at 0 lpm 2 Zero flow is indicated at flow level below cut-off value. Standard cut-off value as shown in Table 3 is not adequate for application. - Adapt lower cut-off value with LEVIFLOW Configuration Software 3 The flow indication does not match the real flow Wrong parameter settings, excessive bubbles or solids in the measurement path. - Check if the parameters in the converter are set correctly - Inspect the flow path for stagnating solids - Inspect the measurement path for excessive bubbles 4 Above full scale flow is indicated or the flow signal is unstable Wrong parameter settings, excessive bubbles or solids in the measurement path. - Check if the parameters in the converter are set correctly - Inspect the flow path for stagnating solids - Inspect the measurement path for excessive bubbles Table 7: Potential troubles and the possible countermeasures 6.2 Troubleshooting with LEVIFLOW Configuration Software More detailed error analysis can be done with the LEVIFLOW Configuration Software. Contact Levitronix for a sample of the configuration software and the according manual (Levitronix Doc.# PL ). Note: The LFIF-06 flowmeter needs configuration software version V1.34 or higher. 7 Technical Support For troubleshooting, support and detailed technical information contact Levitronix Technical Service Department: Levitronix Technical Service Department Technoparkstr. 1 CH-8005 Zurich Switzerland Phone for US: Phone for outside US: TechSupport@levitronix.com PL , RevA, DCO# RD 12

13 8 Appendix 8.1 Regulatory Status CE Marking The LEVIFLOW LFIF-06 flowmeter, in its various configurations is in conformity with the below mentioned European Directives. The flowmeter is thought to be used in hydraulic circuits of the production equipment of Semiconductor and Chemical industry. EMC Directive 2014/30/EC: The following particular harmonized standards of the EMC Directive are tested and confirmed. EN EN Generic Emission standard for industrial environments Generic Immunity standard for industrial environments Pressure Equipment Directive 97/23/EC: The pressure equipment directive is used as guide line according to Category I Modul A (internal quality control). For maximum pressure validation the following standard is followed: EN ISO ISO12100 Plastic piping system for industrial applications Safety for machinery principles for risk assessments: used for system risk analysis. 8.2 Symbols and Signal Words Symbol / Signal Word Description Type Source DANGER WARNING CAUTION Indication of an imminently hazardous situation that, if not avoided, will result in death or severe injury. Limited to the most extreme situation Indication of a potentially hazardous situation which, if not avoided, could result in death or severe injury. Indication of potentially hazardous situations which, if not avoided, could result in moderate or minor injury. Also alert against unsafe practice. Without safety alert indication of hazardous situation which, if not avoided, could result in property damage. Signal word SEMI S Signal word SEMI S Signal word SEMI S1-0701! Safety alert for Warning and Caution Safety alert SEMI S1-0701! Safety alert for Danger Safety alert SEMI S Caution (refer to accompanying documents) (is used on article labels for reference to manual) Refer to manual ISO 3864 Toxic material, poison Hazard identification IEC Danger: electricity, electrical hazard Hazard identification IEC 61310, ISO 3864 General warning Hazard identification ISO 3864 Wear safety gloves Hazard avoidance Mandatory action IEC Table 8: Safety symbols and signal words PL , RevA, DCO# RD 13