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FLOMIC FL 3005

1. 31 Ip BE Ie Koi circa secs e a a aA N EA 31 82 2 Gurrent OUIDUE sic ik sec ke anarien aX X acad ee p E ASen n De EE RAN u ek EEEE EE EEEE TA EEE qun 32 8 3 Commi nicatiom Interface cioe c ein oce em tha ete cae tee ihr e ple pa ER E a EE EEE aeons 32 8 3 1 Optical interface sees eene eite nnns nnne sans sets setas ee rns seres eats serena tasses 32 8 3 2 HS 232 Inl rfaGe i eii ad iere EE rae e eae an e EI NEUE RP EEE A Pa Bn Ade ee dg eR ON Rud aman EE 33 853 2 EZ ITI UI Igi o PEDE EN Lm 33 8 4 Communication modes esses eene nennen nnne res aae oaa akaa entes tents entente resin tenen nnne tenens 34 8 4 1 Optical probe personal notebook compuler esses einen nnne 34 8 4 2 RS 232 personal notebook computer esses esent nnne nnne nnn 34 8 42 RS 232 4 GSM module ecce et older ete esta ei a n RED ba aed 35 Rois dedi irem 35 8 6 Battery lifetime and replacement cceeececeseceeeeseceeeeeneeeeeseneeeesgeeenesaaaeeenseeseeesgeneensseeeeseseeeesseeeeeeesneneenesaees 36 9 WARRANTY AND POST WARRANTY SERVICES aeeieeeeesieeeeeeeeen nennen a nnnnnnn ansia tn annii snas sss nn nnana nnn nnn 37 971 Watrarnty ServICBS errors e S eee erre rites E ee ea ee Ee ha info citer P edes 37 9 2 POSt Walranty SGIVICCS oi 37 1
2. sssss eene nnns 21 6 1 6 Determination of mechanical parameters of the meter sensor ssseeeeennnes 22 6 1621 Measuring fay angle 5 ertet eer nent Sa adie ee ee tot eere aaan 22 6 1 6 2 Distance between the outer end faces of welded on pieces sssessesssss 23 6 1 6 3 Inner diameter of meter PiPiNg eee eeeeseeeeeeescessseeseseeceeeeeaeessaeecsaeeeseeeeenessaeeesseeesaeeeaees 23 6 1 7 Flow meter sensor assembly scccceceecnecenenseneneenenenenaeenenenseseneesenessaaseneranseeseueneensaranenerenssenenenees 24 6 1 8 External signal connections 1 eiie eite ena ien nieder ea pn aote a UTR nha e adn pe uoa dokn enn unen san d 24 7 SETTING FLOW METER IN OPERATION eeeeeeeeeeeeeeenennnn nennen na nnnntn nnns hann nnns nnns asas atn nsns sana asses Rn ss sean anna 25 EVs Theoretical CalOFAtlOM nm 25 7 2 Description of calibration procedure eccccesecceeeeseceeeeeneeeeeseneeeesseeenessaeeeseseeseeesgeaeensseeeeeeseesesteseeeeseeeneeneneees 25 7 2 1 THCOC AIC progra M M EENE ERN aa 26 7 2 2 Caliber RL pIOQgFatm usate eaan E t EH ege O A EE ARER RERE 27 7 2 9 Check on zero Settihg seiersen EnEn rE iR EOE EEEn E En EAEE SENA ARE REDRE A APEERE i 30 8 METER ORERATION a eet 30 8 1 Reading measured data from display sssssseeeeeeeeeeeeeen mener nere nnne nns 30 8 2 Elgctrical 0 tpUtS L
3. 12 PRODUCT ACCEPTANCE The product acceptance procedure consists of visual inspection of the delivered product and check on its completeness in reference to the delivery note As specified in to the product order the delivery kit shall include the complete FL 3005 meter system product assembly and measuring fixtures and tooling optional equipment Product Application Installation and Service Manual product compliance certificate and the respective delivery note 13 WARRANTY TERM AND CONDITIONS Unless agreed otherwise with the customer the warranty term for the FL 3005 ultrasonic meter is 12 months counted from the date of sale Any meter failures within the warranty period due to defective materials parts or non standard workmanship will be repaired free of charge The warranty period shall be extended by the time the meter was inoperative due to a warranty repair Manufacturer s warranty shall not be applicable to product failures due to incorrect assembly and or installation operation wilful damage theft alienation or events classified as force majeure ELIS PLZE a s Lu n 15 P O BOX 126 304 26 Plze Czech Republic tel 420 377 517 711 fax 420 377 517 722 Es 90 398K a Product application installation and service manual FLOMIC FL 3005 battery powered ultrasonic flow meter Page 38 of 40 ELIS PLZEN a s for direct installation in piping 14 ORDERING PROCEDURE To order a FL 3005 ultrasonic flow
4. Et 15 Product application installation and service manual T FLOMIC FL 3005 battery powered ultrasonic flow meter Page 1 of 40 ELIS PLZEN a s for direct installation in piping Battery powered ultrasonic flow meter for direct installation in piping FLOMIC FL 3005 ELIS PLZEN a s Lu n 15 P O BOX 126 304 26 Plze Czech Republic tel 420 377 517 711 fax 420 377 517 722 Es 90 398K a Product application installation and service manual FLOMIC FL 3005 battery powered ultrasonic flow meter Page 2 of 40 ELIS PLZE a s for direct installation in piping Contents UI dBegue m 3 Miu leugsHiiie lcem 3 3 TECHNICAL DESCRIPTION m nannan annann 4 3 1 Terminology and symbols used in this manual essen eene nennen nnns 4 3 2 rige t To gro io PR 5 3 3 qe n 9 3 3 1 QAI TIT gne 9 3 3 2 Electronic unit UP 8 00 sss aak nenne nnne nennen nnns 9 4 TECHNICAL PARAMETERS 1 c1 ccce Leone nore nter e tnnc na rane E cri na Dre cu aUa cce a Dc E cana enc Ora seo ce Ense curan arcu RUE re EIecas 9 4 1 Flow velocity determiratiORm e ei eere tot niu eee Ere Re XE RU e ARI uR secngasstevenesuussunadgeestavasedsnpeaseraniucet
5. 15 P O BOX 126 304 26 Plze Czech Republic tel 420 377 517 711 fax 420 377 517 722 Es 90 398K a Product application installation and service manual FLOMIC FL 3005 battery powered ultrasonic flow meter Page 22 of 40 ELIS PLZEN a s for direct installation in piping 6 1 6 Determination of mechanical parameters of the meter sensor To achieve the specified measurement precision of the FLOMIC FL 3005 flow meter the mechanical parameters dimensions of the meter piping need be determined with the tolerances of 1 o Example For DN 500 meter piping with the measurement ray angle a 45 and the distance between the outer end faces of the welded on pieces L 850mm the mechanical parameters need be determined with the dimensional errors not exceeding AL E 0 85mm 1 000 i Ei 0 5mm 1 000 Angle a needs be determined with the precision of Aa 0 1 irrespective of the meter piping size DN 6 1 6 1 Measuring ray angle A Remove all corrosion products traces of paint and other contamination from the piping surface where the strap piece is to be laid B Place the strap piece on the piping so that its longitudinal axis is parallel to the side surface line on the piping Use rubber bandages to hold the strap piece firmly in position on the piping surface see Fig 27 C Attach a protractor onto the protractor adaptor mounted at one of the rectification pin ends D The angle measurements t
6. User manual id number to be Es 90 368 K referred to as the background material for determination of the ordering number ELIS PLZE a s Lu n 15 P O BOX 126 304 26 Pize Czech Republic tel 420 377 517 711 fax 420 377 517 722 Es 90 398K a Product application installation and service manual FLOMIC FL 3005 battery powered ultrasonic flow meter Page 40 of 40 ELIS PLZEN a s for direct installation in piping Manufacturer s address ELIS PLZEN a s Lu n 15 P O BOX 126 304 26 Pizen Czech Republic Tel 420 377 517 711 Fax 420 377 517 722 E mail sales elis cz http www elis cz Issue No 2 ELIS PLZE a s Lu n 15 P O BOX 126 304 26 Pize Czech Republic tel 420 377 517 711 fax 420 377 517 722 Es 90 398K a
7. 21 ELIS PLZE a s Lu n 15 P O BOX 126 304 26 Plze Czech Republic tel 420 377 517 711 fax 420 377 517 722 Es 90 398K a Product application installation and service manual FLOMIC FL 3005 battery powered ultrasonic flow meter Page 18 of 40 ELIS PLZEN a s for direct installation in piping Indirect method Prepare a template of installation points using a sheet of paper of minimum dimensions 1 1 Do x 1 8 Do Do A Draw a centre line py and mark on it points X and X at the distance of for a 45 it is D o for a 60 tea the distance of D x 0 5774 B At points X and X draw parallel lines perpendicular to central line py one on each side and mark on them points M and Me at the distance of D x 0 7854 Identify points M and M by crosses of lines of minimum length 100mm see Fig 22 min1 1xDo min1 8xDo Fig 22 Paper template C Lay the paper template on the piping so that the central line p coincides with the top surface line marked on the meter piping Then using a centre punch transfer all key installation points including the ends of the cross lines onto the piping D Using a drawing awl mark the crosses defining points M and M on the piping surface as with the direct method above 6 1 4 Fitting welded on pieces into meter piping A Using oxy acetylene torch cut circular holes in the meter piping of diameter 60mm
8. and centres at points M and M2 Prevent the cut out section from falling inside the piping and save them they will be needed to determine the inner diameter of the meter piping In the cases of pipe with the wall thickness t in excess of 5mm for a 459 ort greater than 15mm for a 603 the holes of diameter 60mm need be modified so that the welded on pieces can be inserted into the piping as shown in Fig 23 Make sure that both the inner and our edges of the holes are smooth and clean B Ground the edges of the cut out sections without damaging the surface parts Then use a slide rule to determine the thickness of the pipe wall ELIS PLZE a s Lu n 15 P O BOX 126 304 26 Plze Czech Republic tel 420 377 517 711 fax 420 377 517 722 Es 90 398K a Product application installation and service manual FLOMIC FL 3005 battery powered ultrasonic flow meter Page 19 of 40 for direct installation in piping ELIS PLZEN a s C Slide the welding flanges onto the welded on pieces and adjust their positions with respect to the setting marks The insertion depth shall be such that the bottom part of the welded on piece is flush with the internal surface of the meter piping See Fig 23 Mark on the welded on piece the correct depth of insertion of the same into the flange WELDED ON PIECE CERDO NE POSITION MARK N WELDING FLANGE gt E 2 HOLES IN THICK WALL PIPIN
9. meter use the correct ordering code number identified in reference to the following table Position within ordering code No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 ORDERING NUMBER imc Se IEEE SS Sac TECHNICAL PARAMETERS Sensor dimension DN mm AJN ojajoja ojojojo ojojojo AJOJN oja ojojo ojojo ojojo l O C1 oo o ojio ojojo e c m T No eoo Ojo Q4 1 600 1 1 800 1 6 Piping material carbon steel stainless steel 2 Probe protection class IP 68 2 Current output no 2 Data communication system no communication CO1 c5 n9 Cable length m Assembly fixtures tooling ELIS PLZE a s Lu n 15 P O BOX 126 304 26 Pize Czech Republic tel 420 377 517 711 fax 420 377 517 722 Es 90 398K a Product application installation and service manual FLOMIC FL 3005 battery powered ultrasonic flow meter Page 39 of 40 ELIS PLZEN a s for direct installation in piping Position within ordering code No 15 16 17 18 19 20 21 22 ORDERING NUMBER fs E ESSERE a S TRE HER ERR COMMERCIAL CONDITIONS Quantity 1 piece 999 pieces 9 9g 1 000 pieces more 0 0 0 User manual language English 2 Packaging no packaging Delivery collected personally shipping agent at supplier s costs shipping agent at customer s costs special OJN Warranty term mos S a 18 18 months 3 3
10. on Calibration to have the following empty table displayed see Fig 33 File Inner diameter mm Omas m3 h Insensivity near zero mm s Pulse number limp fi 0 fi 0 E fi oo Calculated distance of probes mm Inner units 00000728 Calculate to inner unis AQ const and V table generation A V mm s errs 4 Q I h ecrojorojorjoro AD correction o OK Read table from EEPROM Write table to EEPROM Fig 33 Using the following procedure copy into this table the data created by the TheoCalc program Click on File and Open to access the screen in Fig 34 Select the file created by TheoCalc and click on Open to transfer it to the previous table shown in Fig 33 Otev t 20x Oblast hled n lt j Dokumenty amp jo c N zev souboru 12345 bpt Soubory typu bpt Stomo Z Fig 34 ELIS PLZE a s Lu n 15 P O BOX 126 304 26 Plze Czech Republic tel 420 377 517 711 fax 420 377 517 722 Es 90 398K a Product application installation and service manual FLOMIC FL 3005 battery powered ultrasonic flow meter Page 29 of 40 ELIS PLZEN a s for direct installation in piping In the filled out table see Fig 35 select and double click on the field Insensivity near zero and enter the required insensitivity typically 20 values less than 10 are not recommended Then fill out the field Pulse number taking into account the given mul
11. see Fig 39 FLOMIC Optical probe Supporting pins Obr 39 Working position of the optical probe 8 3 2 RS 232 interface The cable of the RS 232 communication line is connected to terminals 1 through to 4 on the terminal strip X10 of the meter control unit see Fig 29 The RS 232 line makes possible data reading and storage reading of error messages and setting of the data archiving parameters in the same extent as described in Section 8 3 1 To use this communication facility the personal computer connected to the meter control unit must have the ArchTerm program installed The RS 232 interface is also compatible with a GSM module The meter system configuration including the RS 232 interface as supplied from the manufacturing factory cannot be customer modified to M bus communication 8 3 3 M Bus interface The M bus communication interface is connected to terminals 1 and 2 on the terminal strip X10 of the meter control unit see Fig 29 The fixed communication cable facilitates reading of the measured data on instantaneous flow rate and total fluid volume passed through the meter sensor The M bus interface configuration cannot be changed at the customer s plant to the RS 232 format ELIS PLZE a s Lu n 15 P O BOX 126 304 26 Pize Czech Republic tel 420 377 517 711 fax 420 377 517 722 Es 90 398K a Product application installation and service manual FLOMIC FL 3005 battery powered ultr
12. the condition of zero flow rate cannot be ensured the zero setting procedure is not performed 8 METER OPERATION 8 1 Reading measured data from display The 8 character display unit shows the values of flow rate in m hour or the total fluid volume in m passed through the meter sensor The figures on display must be multiplied by appropriate coefficients see the table below The displayed value of instantaneous flow rate has certain time delay it is calculated as the average value of the last six measurements taken over the last six seconds Such floating average values are displayed and brought to the meter outputs The delay due to the average value calculation may become noticeable in the cases of rapid flow rate increase and decrease Should an error in the meter function be detected the corresponding error massage is displayed Because ofthe power saving mode of the battery supply the push button switching ELIS PLZEN a s Lu n 15 P O BOX 126 304 26 Plze Czech Republic tel 420 377 517 711 fax 420 377 517 722 Es 90 398K a Product application installation and service manual FLOMIC FL 3005 battery powered ultrasonic flow meter Page 31 of 40 ELIS PLZEN a s for direct installation in piping commands changing the display modes from flow rate to total fluid volume and back can be given no faster than once a second It is therefore recommended that to ensure correct switching function the control push
13. 0 TESTING ssassn riase aeaa araara aaaea raaraa aa aaa ES aE cu araa Eare suse eaacesdvueceardetocdeevtGacuessebundesesuan 37 11 eccllcm 37 12 PRODUCT ACCEPTANCE oare ces cccecis cectecncenccecenstens Ap aeaa E A EER rE aea E ADEA cqtteeescctuensesetecaeenateeeensenteeeseneereedea 37 13 WARRANTY TERM AND CONDITIONG 00 ccccccceseeeeeseeeeeseeeeeeeeneeeeeseeaeeeseneaeeeseneaeesenneeeeseeeeeeesseaaeeseeaaeeeseneaeeeeens 37 14 ORDERING PROCEDURE 38 ELIS PLZE a s Lu n 15 P O BOX 126 304 26 Plze Czech Republic tel 420 377 517 711 fax 420 377 517 722 Es 90 398K a Product application installation and service manual FLOMIC FL 3005 battery powered ultrasonic flow meter Page 3 of 40 ELIS PLZEN a s for direct installation in piping 1 APPLICATION The FLOMIC battery powered ultrasonic flow meter of the type series FL 3005 for direct installation into piping is intended for measurements of instantaneous flow rate and of the total volume of water passed through fully flooded piping The flow meter includes hardware and software for communication with plant control systems The FLOMIC FL 3005 meter can be installed into existing steel piping with minimum modifications and relatively low investment costs The advantages of this solution are p
14. 126 304 26 Plze Czech Republic tel 420 377 517 711 fax 420 377 517 722 Es 90 398K a Product application installation and service manual FLOMIC FL 3005 battery powered ultrasonic flow meter Page 24 of 40 ELIS PLZEN a s for direct installation in piping 6 1 7 Flow meter sensor assembly The preceding assembly and measurement operations have yielded the following basic sensor parameters necessary to perform the so called theoretical meter calibration measuring ray angle a distance L between the outer end faces of the welded on pieces inner piping diameter D Upon finishing the measurements the sensor assembly can be completed Insert the ultrasonic probes including sealing into the welded on pieces and tighten the holding nuts using the torque of 150 Nm Connect coaxial cables from the probes to terminal strip X1 of the associated electronic control unit see Fig 29 The meter is now ready for theoretical calibration 6 1 8 External signal connections Remove the lid held in position by two M4 screws at the bottom of the front panel of the UP 8 00 electronic unit box to gain access to the terminal strip for sensor probe cables and output signals COMUNICATION COMUNICATION INTERFACE RS 232 INTERFACE M BUS DEP CEEE EB Pulse output power supply Rs Rs Rx Tx o a a 5 wn o z o a ES x v LS PROBE 1 PROBE 2 Pulse output Current output power supply U 10 24V ESI
15. 17 722 Es 90 398K a Product application installation and service manual FLOMIC FL 3005 battery powered ultrasonic flow meter Page 37 of 40 ELIS PLZEN a s for direct installation in piping 9 WARRANTY AND POST WARRANTY SERVICES 9 1 Warranty services Warranty services include product repairs performed free of charge within the warranty period either by the manufacturer or a duly authorised partner service centre Product repair is performed free of charge in the cases where the product defect has been identified as caused by defective material component part or non standard workmanship within the specified warranty period Should a product be found irreparable due to the above reasons it will be replaced free of charge Warranty services shall be provided either directly by the manufacturer ELIS PLZEN a s or a duly authorised service centre or product distributor provided these have been duly trained to perform such activities and can prove their capabilities by a certificate in writing Warranty services are not applicable to products with broken factory or metrological seals products with defects caused by incorrect product assembly installation products with defects caused by non standard product application or use the cases of alienated or stolen products product defects caused due to force majeure circumstances or elementary disaster Requirements for warranty services shall be communicated to the manufa
16. 61811176248 0 953871 423589945 0 544546558255982 0 324483003567652 0 17175508687373 0 0503342889531 955 Fig 31 Table data entry instruction enter data into blue fields double click the mouse to move between fields The following data need be entered Inner diameter inner diameter of the meter piping Qmax maximum flow rate Surface roughness inner piping surface roughness recommended value 0 2 Distance weld on p distance between face parts of welded on pieces Probe length Angle of probes angle formed by probes and longitudinal piping axis Cable length length of coaxial cables connecting probes and el unit Recalculate multiplier shown on the electronic unit rating plate Upon entering all required data depress key Generate AO and table V Q to perform calculations and fill out the bottom table Then click on File Write and store the data file The file name should consist of the first five digits of the production series number without slash and the production year and the btp suffix ELIS PLZEN a s Lu n 15 P O BOX 126 304 26 Plze Czech Republic tel 420 377 517 711 fax 420 377 517 722 Es 90 398K a t 15 Product application installation and service manual Z FLOMIC FL 3005 battery powered ultrasonic flow meter Page 27 of 40 ELIS PLZEN a s for direct installation in piping 7 2 2 CaliberFL program Using coaxial ca
17. G TO BE MODIFIED TO ACCOMMODATE WELDED ON PIECE C MARK ON WELDED ON PIECE Ee e ee MARKS ON FLANGE Fig 23 Assembly of welded on pieces D Assemble the rectification pin of the following component parts milling adaptor I connecting parts selected to fit the piping size and protractor adaptor The parts must be properly tightened to form a stable whole The rectification pin assembly parts and their fitting are shown in the following picture ELIS PLZE a s Lu n 15 P O BOX 126 304 26 Plze Czech Republic tel 420 377 517 711 fax 420 377 517 722 Es 90 398K a ELIS PLZEN a s S VUE Fig 24 Rectification pin assembly parts Insert the assembled rectification pin into the holes in the meter piping is the direction indicated by the arrow in Fig 24 E From both sides of the meter piping slide the welding flanges and welded on pieces on the rectification pin The flange marks must be positioned against the cross marks drawn on the meter piping The welded on pieces shall be set to the desired position with respect to the assembly marks Check the ease of movement of the rectification pin in the welded on pieces F Check the correct setting of one of the flanges with respect to the respective cross mark and fix its position by four point welds Repeat the procedure with the other flange G Check the play of the rectification pin in the welded on piece
18. OX 126 304 26 Plze Czech Republic tel 420 377 517 711 fax 420 377 517 722 Es 90 398K a Product application installation and service manual FLOMIC FL 3005 battery powered ultrasonic flow meter Page 4 of 40 ELIS PLZEN a s for direct installation in piping v is ultrasonic ray velocity in the direction of fluid flow m s vo is ultrasonic ray velocity against the direction of fluid flow m s t is passage time of ultrasonic ray sent in the fluid flow direction s t is passage time of ultrasonic ray sent against the fluid flow direction s C is ultrasonic signal propagation velocity in the measured medium m s is distance between the face parts of ultrasonic probes m v isinstantaneous value of the average velocity of the flowing medium m s a is angle formed by the measuring ray and the longitudinal axis of the piping deg After some modifications of equations 1 to 4 the average velocity of the fluid flowing through the piping can be expressed as follows l t2 t1 m n For the flow rate it holds q v s k v 6 where S is square section of the meter piping m k v iscorrection coefficient related to the velocity profile of the fluid flowing through the meter piping From equations 5 and 6 it follows that the flow rate of the measured medium is independent of either sound propagation velocity in the measured medium or the medium pressure or temperature The flow rate only depe
19. ace line pv The top surface line is defined as the section line common to a perpendicular plane including the longitudinal axis of the piping and the outer piping surface Measuring ray ray Measuring ray is ultrasonic signal wave propagating between the face parts of ultrasonic probes along a line identical with the longitudinal axes of the probes ELIS PLZE a s Lu n 15 P O BOX 126 304 26 Plze Czech Republic tel 420 377 517 711 fax 420 377 517 722 Es 90 398K a Product application installation and service manual FLOMIC FL 3005 battery powered ultrasonic flow meter Page 5 of 40 ELIS PLZEN a s for direct installation in piping Side surface line Pb The side surface line is defined as the section line common to a horizontal plane including the longitudinal axis of the piping and the outer piping surface Outer diameter OD of the meter piping D Inner diameter ID of the meter piping Di Angle formed by the measuring ray and the longitudinal axis of the meter a piping Ultrasonic probe probe Welded on piece used as a holder for the ultrasonic probe welded on piece Welding flange flange Rectification alignment pin Distance between the face parts of ultrasonic probes I Distance between the outer end faces of the welded on pieces L Probe sealing thickness p Piping wall thickness t Length of the ultrasonic probe body m 3 2 Meter description The FLOMIC FL 3005 ultrasonic flow meter
20. articularly evident in the cases of large piping diameter where a flow meter sensor installation between flanges is far more expensive than a system using direct sensor mounting 2 FUNCTION PRINCIPLE The FLOMIC FL 3005 meter uses a single channel transit time impulse measuring method where the flow rate as the basic measured parameter is determined from the flight time of the ultrasonic signal between the sensor probes The two ultrasonic probes installed into the fluid piping under specified angle operate in turns as a sender and receiver see Fig 1 a RECEIVER SENDER d JLTRA SOUND BEAM tg 4 p 221 na ULTRA SOUND I BEAM DIRECTION ES hil RECEIVER P d F Fig 1 Principle of flow rate measurement It holds that in the configuration shown in Fig 1 ultrasonic ray propagates faster in the direction of the flowing fluid that against it Electronic converter evaluates the differences between the transit passage times of ultrasonic waves sent in and against the fluid flow direction determines the average flow velocity of the fluid and taking into account the parameters of the meter piping calculates the value of instantaneous flow rate The above principle of flow rate measurement using ultrasonic ray can be described by the following equations V C V COoSa 1 V2 C V cosa 2 1 ti 3 v 1 t2 4 v2 ELIS PLZE a s Lu n 15 P O B
21. asonic flow meter Page 34 of 40 ELIS PLZEN a s for direct installation in piping 8 4 Communication modes 8 4 1 Optical probe personal notebook computer The optical probe cable is provided with a connector either RS 232 or USB depending on the customer requirements see Fig 40 In the case of the USB interface a special controller needs be installed into the computer ELIS PLZE o s Fig 40 Communication via optical probe 8 4 2 RS 232 personal notebook computer At one end of the connection box sealed with a plastic compound is a fixed 5m long cable to be connected to terminals 1 2 3 and 4 on terminal strip X10 of the meter control unit This cable can be cut shorter as need be The other end of the connection box is provided with a connector to accommodate another cable to connect the co operating personal computer On the computer side this cable is terminated with an RS 232 connector see Fig 41 CONNECTION BOX im ei e a I Q lr Dm d A PEER inn UNIT ee ee eee CONNECTION BN brown BOX Fig 41 Communication via RS 232 interface ELIS PLZE a s Lu n 15 P O BOX 126 304 26 Plze Czech Republic tel 420 377 517 711 fax 420 377 517 722 Es 90 398K a Product application installation and service manual FLOMIC FL 3005 battery powered ultrasonic flow meter Page 35 of 40 ELIS PLZEN a s for direct installation in p
22. asonic probes fitted into it 3 3 2 Electronic unit UP 8 00 The flow meter control and signal processing unit is accommodated in a plastic box attached to a steel plate designed to be hung on a vertical support plate or wall On the front panel of the box there are flow meter name and type designation production series number the manufacturers logo and trade name back lighted display unit membrane push button and optical probe window At the bottom of the box under a removable lid there are terminals for connecting cables The bottom wall further includes four PG 7 grommets for cables of circular cross section and diameters 3 to 6 5mm and earthing bolt M4 Both the front panel and terminal lid are provided with seals CAUTION Prior to starting the meter operation make sure that all grommets containing cables are properl tightened and the unused grommets blinded CAUTION When installed in the open air the box containing electronic unit must be protected against direct sunshine However the box must not be placed inside a sealed unventilated cabinet Dimensional sketch of the electronic unit box FLOMIC C LJ E1 E2 E3 E4 E5 m Is x10 x10 o OFFICIAL SEALS INSTALLATION SEALS 4 TECHNICAL PARAMETERS 4 1 Flow velocity determination The basic parameter to be ascertained prior to installation of a flow meter is the range of operational flow rate range exp
23. ble or optical probe connect your PC to the electronic control unit and start the CaliberFL program With the table shown in Fig 32 displayed check the agreement between the port number displayed in the table and the number of the port to which communication channel is connected Should it be necessary to change the port number stop and re initialise the CaliberFL program Please note that unless communication is in operative condition the menu items are not accessible to rewrite data in a particular field double click on such field if Qmax is changed the program must be reset do not let the program run without the communication channel connected operative should communication appear not to work properly close and re initialise the program H gt CaliberFL Iof Xx Calibration Setting Close Version and product number puva 74v 21 27 05 Flow speed mm s CaliberFL Flomic FL calibration software Flow m3h Average flow speed Clear average speed Average counter 2484 Symetry setting FFFFFFCC Zero adjustment Com2 1 Fig 32 ELIS PLZEN a s Lu n 15 P O BOX 126 304 26 Plze Czech Republic tel 420 377 517 711 fax 420 377 517 722 Es 90 398K a Product application installation and service manual FLOMIC FL 3005 battery powered ultrasonic flow meter Page 28 of 40 ELIS PLZEN a s for direct installation in piping Click
24. button be held depressed for at least one second and the period between two successive switching commands be longer than one second The position of the decimal point on the display see Fig 37 depends on the measured total fluid volume and the applicable multipliers see the table below OOOO Decimal point for values up to 5 digits Decimal point Decimal point for 6 digit values for 7 digit values Decimal point for 8 digit values Fig 37 Decimal point positions on the display CAUTION The display readings and values read from the archive files must be multiplied by one of the coefficients shown in Table 4 below The applicable coefficient is given on the front panel under the respective units of measurement m m h see the dimensional drawing in Section 3 3 2 above Piping size DN 200 to 450 500 to 2 000 3 Coefficient mn x 10 x 100 8 2 Electrical outputs 8 2 1 Impulse output The passive impulse output is a standard feature of all meter versions It is an optically isolated output connected to terminals 11 and 12 of the output terminal strip X10 see Fig 29 Section 6 1 8 with maximum loading capacity of 10 mA The impulse width preset at the manufacturing plant is 2 ms It can be reset at any time to 40 ms using jumper J5 see Fig 38 Impulse output setting by means of jumper J5 Jumper J5 1 2 2 3 Impulse width 2ms 40 ms Impulse level L OV L OV Ex
25. ches Hand held angle grinder grinding wheel 125mm Hand held electric drill max chucking diameter 12mm 6 1 2 Flow meter installation criteria 6 1 2 1 Measuring spot selection When selecting the piping section where the flow meter sensor is to be installed see also Chapter 5 make sure that the surface quality of the piping in particular any irregularities of shape deformations the position and surface finish of welding joints whether longitudinal helical or others is such that it allows for accurate determination of the angle formed by the measuring ray and the longitudinal axis of the piping ELIS PLZE a s Lu n 15 P O BOX 126 304 26 Plze Czech Republic tel 420 377 517 711 fax 420 377 517 722 Es 90 398K a t 15 Product application installation and service manual Z FLOMIC FL 3005 battery powered ultrasonic flow meter Page 15 of 40 ELIS PLZEN a s for direct installation in piping 6 1 2 2 Necessary room for flow sensor installation The flow sensor installation in the existing piping using the fixtures and tooling specified in this manual requires free room of at least 900mm to the sides of the welded on pieces and in the direction of the measuring ray see Fig 20 WELDED ON PIECE Fig 20 Required free room in the vicinity of welded on pieces In the ideal case the ultrasonic ray axis should lie in the horizontal plane Shou
26. ct application installation and service manual FLOMIC FL 3005 battery powered ultrasonic flow meter Page 16 of 40 ELIS PLZEN a s for direct installation in piping Direct diameter measurement using diameter gauge Take three diameter measurements equally spaced 120 apart along the piping circumference at eac h of the two intended positions of the welded on pieces Calculate the outer piping diameter as the average value of the average diameter values measured at the positions of the welded on pieces Dl D2 D3 D4 D5 D6 Da 02 77 3 3 D Da Dy x 2 Where D1 to D6 are the measured OD values on the meter piping 6 1 3 2 Marking of top surface line Use water level to identify the top surface line on the meter piping see Fig 20 The two points of the surface top line a1 a2 are the points of contact between the piping and water level after the water level has been set in the horizontal position The distance between points a and a is recommended to be selected equal to the piping diameter b Do Use a steel ruler to draw the top surface line p Fig 20 Top surface line marking on meter piping 6 1 3 3 Laying out of installation points To identify and mark the key sensor installation points on the meter piping select and use one of the following two methods The indirect method is less time consuming and therefore preferred in most practical situations Direct method Measurements are take
27. cturer in writing by e mail fax or registered letter Should the manufacturer not acknowledge the warranty claim this fact will be made known to the customer in writing whereby the product repair costs will be invoiced to the customer 9 2 Post warranty services Post warranty services include any and all product repairs where the subject defects originated after expiry of the agreed warranty term Such services whether performed at the manufacturer s premises or anywhere else as directed by the customer will be invoiced by the manufacturer to the customer In the cases of commercial invoicing meters each repair action shall be followed by metrological verification of specified meter parameters by an authorised metrological centre Requirements for post warranty services shall be communicated to the manufacturer in writing by e mail fax or registered letter 10 TESTING While in production each flow meter system component is subject to quality control procedures in observance of internal quality assurance directives of the manufacturer Finished products are subject to checks on completeness and final quality tests including a 15 hour burn in operational test 11 PACKAGING Unless agreed otherwise with the customer the company products are packaged in compliance with the standard requirements regarding domestic and international transport The packaging procedures are performed in observance of the manufacturer s internal directives
28. ding of the real time data instantaneous flow rate and total fluid volume the stored data setting of the data archiving parameters and reading of error messages The meter software makes possible storage of data on instantaneous flow rate the total fluid volume measured in specified time intervals and the maximum and minimum values of instantaneous flow rate over a specified period including the times when such extreme values occurred Recorded also are any error messages including the times of occurrence To use this facility the user must have available the ArchTerm PC program and an optical probe including a connecting cable 1 5m long provided with the RS 232 connector On request the optical probe can be supplied with the USB connector ELIS PLZE a s Lu n 15 P O BOX 126 304 26 Pize Czech Republic tel 420 377 517 711 fax 420 377 517 722 Es 90 398K a Product application installation and service manual FLOMIC FL 3005 battery powered ultrasonic flow meter Page 33 of 40 ELIS PLZEN a s for direct installation in piping The optical probe shall be applied to the respective reading window below the LC display on the front panel of the electronic control unit The correct probe position is defined by two positioning pins The probe is then held in place on the front panel by means of a permanent magnet CAUTION For the correct data transmission turn the probe so that cable grommet is on the bottom side
29. e electronic unit from the right side The locking pin is held in position by company seals see the dimensional drawing in Section 3 3 2 During the battery replacement operation the measurements will be interrupted but all current data including those on the total fluid volume will be retained in the meter memory Replace batteries one at a time starting with B2 followed by B3 and B4 WARNING Incorrect battery polarity may cause damage to the electronic unit circuits CABEL LEADING FROM ELECTRONIC BOARD SAFETY PIN TO FRONT PANEL REMOVAL DIRECTION H Alcalic H battery 9V B3 SF Alcalic H battery 9V B4 Fig 43 Battery replacement Check the correct placement and fit of batteries in their respective holders The meter should resume operation with the measured values shown on the display and no errors indicated Should error E5 be indicated recheck the correct fitting of all batteries and their voltage Also check the flat cable connection between the PC board and the front panel of the electronic unit Depress the push button at the front panel and make sure that the mode switching function works Then push the front panel back and secure its position by locking pin Make sure that the electronic unit box is properly closed and sealed as required by the IP65 specifications Replace the seals on the locking pin ELIS PLZE a s Lu n 15 P O BOX 126 304 26 Pize Czech Republic tel 420 377 517 711 fax 420 377 5
30. ected in the given piping The flow rate is defined by the following formula 3 v m s 353 dee hod D mm where D is ID of the meter piping q is measured flow rate v is flow velocity The fluid flow rate in the meter piping must be within the range of 3 to 6 m s ELIS PLZE a s Lu n 15 P O BOX 126 304 26 Plze Czech Republic tel 420 377 517 711 fax 420 377 517 722 Es 90 398K a t 15 Product application installation and service manual Z FLOMIC FL 3005 battery powered ultrasonic flow meter Page 10 of 40 ELIS PLZE a s for direct installation in piping 4 2 Technical specifications Piping ID DN 200 to 2 000 for DN 200 to DN 800 45 for DN gt 800 to DN 2 000 60 Measurement accuracy 2 of the measured flow rate within the range of 5 to 100 q qs maximum flow rate at the flow velocity of 6 m s Rated nominal pressure of measured fluid max 40 PN Temperature of measured fluid Measuring ray angle o 0 to 150 C 5 to 55 C max relative humidity 8096 Ambient temperature Ambient humidity Storage temperature 10 to 70 C at relative humidity not exceeding 70 Protection class electronic unit UP 8 00 IP 65 ultrasonic probe US 2 1 IP 54 Ultrasonic probes model US 2 1 2 pieces manufacturer ELIS PLZEN a s Probe installation direct fitting into the meter piping see the product manual Connecting cable to probe US 2 1 max length 20m Difference in pr
31. eesdiceeasszese 9 4 2 Technical Speciticatloris c ie dices Site er ier ee tete eid ee ee EBERT eee 10 5 GENERAL RULES FOR FLOW METER APPLICATION eeeeseeeeeeeeeeennn nnne nnnn nnn nnnn nana nn tn nasa nnn nans sn nnnm na 11 6 FLOW METER INSTALLATION eeeeeeeeeeenne nennen nnn nnnnn nn nnnn nans inna asas nnns asas anas sss sm sanas anms sss s snas sss s nn anas anna nna 13 6 1 Meter assembly and installation principles 0 00 0 ee eeeeeeeeeeeeeeeeneeeteneeeeeeeeeeeeseaeeeeseaeeeeeenaeeesesaeeeeseeesenenaeeeeeaes 13 6 1 1 Recommended assembly fixtures and tooling eessssseeeseeeeenn nennen nnns 14 6 1 2 Flow meter installation criteria eese seen nnne nnne nnn rennes 14 6 1 2 1 Measuring Spot Selection rir rre retento ente ettet ee n nann 14 6 1 2 2 Necessary room for flow sensor installation ssssessseseeeeeenen 15 6 1 3 Preparatory and measuring operations on meter piping sees 15 6 1 3 1 Determination of OD of meter piping ssesssesseseeeeenneeneenen nennen 15 6 1 3 2 Marking of top surface lNO sssini isisisi enne nnne 16 6 1 3 3 Laying out of installation points ssessesssessseeseeeeneeeneeeneeneene nere 16 6 1 4 Fitting welded on pieces into meter piping eessssssssseeeee eene nnne nnne nnne nnns 18 6 1 5 Facing of seating surfaces on welded on pieces
32. equipment and data PC and calibration programs TheoCalc 1 0 and CaliberFL 2 3 Communication cable or optical reading probe Meter piping data maximum flow rate Inner diameter distance between the face parts of the welded on pieces probe length angle formed by probes and longitudinal piping axis length of the probe cables multiplier 10 or 100 shown on the front panel under the display unit The theoretical calibration consists of three steps ELIS PLZE a s Lu n 15 P O BOX 126 304 26 Plze Czech Republic tel 420 377 517 711 fax 420 377 517 722 Es 90 398K a Product application installation and service manual FLOMIC FL 3005 battery powered ultrasonic flow meter Page 26 of 40 ELIS PLZEN a s for direct installation in piping 7 2 1 TheoCalc program Start the TheoCalc program and fill out the table in Fig 31 At this stage the PC need not be connected to the meter control unit TheoCalc Generation of values for direct assembly File Inner diameter mm Omax m3 h 1200 140 Flomic FL software Surface roughness 0 2 mm TheoCalc Distance weld on p 11450 mm Angle of probes 60 Cable length 25 m Recalculate fi 00 x Generate AU and tane vA Calculated probe distance fi 170 mm AD e t 4333130435 V mm s corrections 22 info only Q I h qm pm uo pmo om 2040 77170565095 4000 1 3
33. g the procedure described in Section 8 6 Should battery replacement not help send the meter back to the manufacturer for repair ELIS PLZE a s Lu n 15 P O BOX 126 304 26 Plze Czech Republic tel 420 377 517 711 fax 420 377 517 722 Es 90 398K a Product application installation and service manual FLOMIC FL 3005 battery powered ultrasonic flow meter Page 36 of 40 ELIS PLZEN a s for direct installation in piping 8 6 Battery lifetime and replacement The power for the electronic control unit is supplied by two battery sources Batteries B3 and B4 alkali batteries MN1604 9V 550 mAh Battery B2 Li battery SAFT LITHIUM 3 6V 16 5 Ah type designation LS 33600 The guaranteed battery lifetime is 4 years After expiry of the specified lifetime all batteries should be replaced at the same time In case of need or on the customer s request smaller battery SAFT LITHIUM 3 6V 3 6 Ah type designation LSH 14 light containing less than 1g of lithium can be used instead of battery B2 above The manufacturer supplies this battery with a plastic cover fitting into the holder of the original larger battery The lifetime of the LSH 14 battery is 1 year counted from the day of dispatch It can be at any time replaced by the original battery of capacity 16 5 Ah To access the battery compartment pull out the locking pin in the direction indicated by arrow in Fig 43 and then lift off the front panel of th
34. hree measurements at each of the welded on piece positions shall be performed in the plane defined by the longitudinal piping axis and the respective side surface line Between the measurements knock slightly on the strap piece or move it to the side and back to ensure its correct seating E The value of a shall then be determined as the arithmetic average of all measurements taken T a1 a2 a3 a4 a5 a6 6 where a1 to 3 are measured angles formed by the rectification pin and the surface of the meter piping at one of the welded on pieces and a4 to o6 are angles formed by the rectification pin and the surface of the meter piping at the other welded on piece PROTRACTOR HOLDER RECTIFICATION PIN PROTRACTOR STRAP PIECE METER PIPING FIXING RUBBER ROPES Fig 27 Determination of the measuring ray angle ELIS PLZE a s Lu n 15 P O BOX 126 304 26 Plze Czech Republic tel 420 377 517 711 fax 420 377 517 722 Es 90 398K a Product application installation and service manual FLOMIC FL 3005 battery powered ultrasonic flow meter Page 23 of 40 ELIS PLZEN a s for direct installation in piping 6 1 6 2 Distance between the outer end faces of welded on pieces Depending on the given arrangement and space available the inner diameter of the meter piping free room in the vicinity of the welded on pieces etc the di
35. ieces To ensure a perfect alignment of the ultrasonic probes the seating surfaces on the welded on pieces need be end faced To do that fit a milling tool onto the milling adaptor fitted onto the rectification pin and secure its position by a nut see Fig 25 Fig 25 Facing of the seating surfaces on the welded on pieces Grease slightly with vaseline those parts of the rectification pin that will rotate in the welded on pieces Using a hand held drilling machine with controlled speed rotate the rectification pin in the clockwise direction and face the seating surface on the welded on piece Then remove the rectification pin assembly insert it into the welded on pieces in the opposite direction and face mill the other seating surface Should there be insufficient room on the other side of the piping do not remove the rectification pin but replace the protractor adaptor by milling adaptor Il with a milling tool attached secure the threads against turning using Loctite or similar bonding agent and face the otherwise inaccessible seating surface by pulling the rectification pin out and rotating it in the counter clockwise direction see Fig 26 After the milling operation remove the milling tool and nut and leave the rectification pin inserted in the welded on pieces on the meter piping S MILLING TOOL Fig 26 Facing of the seating surface on the inaccessible welded on piece ELIS PLZE a s Lu n
36. iping 8 4 2 RS 232 GSM module The meter control unit can be connected to a GSM module by means of an RS 232 communication line see Fig 42 One end of the connecting cable is provided with a connector matching its counterpart on the GSM module the other end should be connected to terminals 1 2 3 and 4 of the X10 terminal strip on the meter control unit The cable is supplied 5 metres long and can be shortened as need be FLOMIC GSM MODUL EPEC Ji ugrom a GSM UNIT CONECTOR 2 2 lx 1 f t ENSIA PC CONTROL SYSTEM SERVER Fig 42 Flow meter data communication via a GSM port 8 5 Error identification Meter errors E1 through to E5 are indicated by symbol v at the bottom of the meter display unit Types of error indicated E1 The passage of ultrasonic waves in the sensor is blocked e g by air bubbles or mechanical particles E2 Too great difference between the transit times of ultrasonic waves travelling in and against the fluid flow direction e g due to an air bubble caught at one of the probes which may be a transient condition during filling the piping with fluid or due to excessive contamination of the face part of a probe E3 A D converter error e g due to strong electromagnetic interference E4 Flow rate greater than Q E5 Flat battery Should the display go completely blank check the battery voltage it should be higher than 3V Replace defective or flat battery usin
37. is an electronic device for measuring water flow rate in a fully flooded piping It consists of the battery powered UP 8 00 electronic control unit and flow meter sensor including two US 2 1 ultrasonic probes In the standard configuration the FL 3005 meter is suitable for application in piping of nominal sizes DN 200 to DN 2 000 with angle 45 for piping sizes up to DN 800 and with angl e 60 for larger sizes see the schematic drawing below DN 200 DN 800 DN 800 DN 1201 The meter software makes possible determination and display of the instantaneous flow rate values and those of the total fluid volume passed through the meter sensor since the last resetting of the respective counter The flow meter is provided with a passive optically isolated impulse output The standard impulse length is 2ms On customer s request the setting can be changed to 40ms The electronic control unit further includes the RS 232 communication interface ELIS PLZE a s Lu n 15 P O BOX 126 304 26 Plze Czech Republic tel 420 377 517 711 fax 420 377 517 722 Es 90 398K a Product application installation and service manual FLOMIC FL 3005 battery powered ultrasonic flow meter Page 6 of 40 ELIS PLZEN a s for direct installation in piping The flow meter configuration can be extended to include optional features such as passive current output data archiving memory M Bus communicati
38. ith fluid control function the straight piping section should be at least 40DN long see Fig 14 20DN _ 10 40 DN SS FLOW DIRECTION FLOW DIRECTION Fig 14 Straight piping sections to eliminate the effect of disturbances on the sensor input side ELIS PLZE a s Lu n 15 P O BOX 126 304 26 Plze Czech Republic tel 420 377 517 711 fax 420 377 517 722 Es 90 398K a Product application installation and service manual FLOMIC FL 3005 battery powered ultrasonic flow meter Page 12 of 40 ELIS PLZEN a s for direct installation in piping In the cases of a disturbance after the sensor the required minimum length of straight piping section is 3DN see Fig 15 FLOW DIRECTION FLOW DIRECTION Fig 15 Straight piping sections to eliminate the effect of disturbances on the sensor output side If complete flooding of the whole piping system cannot be guaranteed at all times the flow sensor should be located at bottom pockets in the piping where this requirement is met under all circumstances and operational conditions see Fig 16 d FLOW DIRECTION Fig 16 Sensor placement in bottom pockets ensuring complete flooding at all times Where the meter sensor is to be placed in a vertical piping section the flow direction shall be upwards see Fig 17 FLOW DIRECTION Fig 17 Sensor fitted in
39. ld the spatial limitations necessitate selection of another angle of the ultrasonic ray the method of marking the key installation points on the piping needs be modified accordingly The manufacturer s specifications require that the angle formed by the ultrasonic ray and the horizontal plane should not exceed 30 The preparatory steps for the sensor installation determination of the mechanical parameters of the measuring spot and the installation process itself as described below have been designed for application at the customer s plant and operating conditions 6 1 3 Preparatory and measuring operations on meter piping The surface of the meter piping must be clean and smooth any adhering dirt rough irregularities of shape corrosion products and traces of paint must be removed 6 1 3 1 Determination of OD of meter piping Each of the two methods described below can be used Diameter calculation from piping circumference This method is suitable for piping of larger sizes Measure the piping circumference using a flat steel measuring tape O The outer diameter of the meter piping can then be calculated as follows D T where O is piping circumference being the average value of two circumference measurements taken at the locations where the welded on pieces are to be attached ELIS PLZE a s Lu n 15 P O BOX 126 304 26 Plze Czech Republic tel 420 377 517 711 fax 420 377 517 722 Es 90 398K a Produ
40. mal insulation layers on piping if applicable Proper earthing is required for the electronic unit To do that use earthing conductor of cross section 4mm or larger and connect the earthing bolt on the electronic unit box with the meter piping at the measuring location see Fig 19 ELIS PLZE a s Lu n 15 P O BOX 126 304 26 Plze Czech Republic tel 420 377 517 711 fax 420 377 517 722 Es 90 398K a Product application installation and service manual FLOMIC FL 3005 battery powered ultrasonic flow meter Page 14 of 40 ELIS PLZEN a s for direct installation in piping 6 1 1 Recommended assembly fixtures and tooling Apart from special measurement and assembly fixtures listed in Section 3 2 above you will need the following Emery cloth No 60 Water level min length 400mm Flexible steel ruler length 1 000mm Steel measuring rule length 3m Steel measuring tape flat min length 10m Slide rule Marking awl Hammer Centre punch Steel angle 40 x 40mm length 0 6D Sheet of paper dimensions 1 1D x 1 8D Drawing tools setsquare drawing pen etc White chalk Black spirit marker o 1mm Rubber rope bandages Thread cap for welded on piece G 1 Half round file Steel pin 7mm length 200mm Side spanner size 19mm 2 pieces Calculator with trigonometric and other mathematical functions Electric welding equipment 250A including accessories Oxy acetylene equipment and cutting tor
41. n and installation points marked directly on the meter piping Indirect method The installation points are transferred onto the piping by means of a template drawn on a sheet of paper ELIS PLZE a s Lu n 15 P O BOX 126 304 26 Plze Czech Republic tel 420 377 517 711 fax 420 377 517 722 Es 90 398K a Product application installation and service manual FLOMIC FL 3005 battery powered ultrasonic flow meter Page 17 of 40 ELIS PLZEN a s for direct installation in piping Direct method 7 Do Draw two parallel surface lines pp and py at the distance of FE i e Do x 0 7854 left and right of the top surface line see Fig 21 Fig 21 Laying out of key installation points On the top surface line p mark two points X and X at the distance of c Distance c is defined by the formula Do c from which it follows tga for a 45 c D and for 60 c D x 0 5774 From points X and X on the top surface line lead perpendicular lines along the piping surface towards the parallel lines p and pps The intersection points M and M3 are the points where the ultrasonic ray is to penetrate the surface of the meter piping The points M and M serve the purpose of accurate setting of the mounting positions of the welding flanges Identify the positions of points M and M by crosses of lines of at least 100mm each and mark the cross line ends by centre punch dots see Fig
42. nds on the difference between the passage times of the ultrasonic signals sent between the meter probes in and against the fluid flow direction and on the mechanical arrangement of the flow meter sensor i e its dimensions and physical properties of the construction materials used For a flow meter installed directly in the existing piping it is therefore necessary to identify precisely the dimensions and properties of the meter piping section Upon installation of ultrasonic probes in the piping all mechanical and physical data on the sensor assembly need be reduced to electronic form and stored in the UP 8 00 electronic control unit for the purposes of the so called theoretical meter calibration 3 TECHNICAL DESCRIPTION 3 1 Terminology and symbols used in this manual abbreviated term or symbol Meter piping piping Meter piping is a section of technological piping system complying with the requirements for flow meter installation Flow meter sensor sensor Meter piping section including ultrasonic probes Flow stabilising piping sections To ensure correct functioning of the flow meter the flow velocity profile in the meter piping must be stable This condition is met by locating the flow meter sensor at a spot where there are straight piping sections of sufficient length at the input and output sides of the meter sensor The required stabilisation length is given in multiples of the internal diameter ID of the meter piping Top surf
43. obe cable lengths Not exceeding 0 1m Electronic unit UP 8 00 overall dimensions 230 x 217 x 85mm weight 1 5kg power supply 1x Li battery 3 6V 16 5Ah 2x or 3x for DN1 400 to 2 000 alkali batteries 9V 0 5A Battery lifetime 4 years Fluid flow velocity range 3 to 6 m s Display unit 8 character LCD Outputs passive impulse output U 3 to 30V Imax 10mA communication interface RS 232 Optional features accessories passive current output 4 to 20mA Umax 24V data archiving memory archive data reading via GSM module optical interface function including optical probe and ArchTerm program communication interface M BUS ultrasonic probes with protection class IP 68 Qmax and impulse constants litres per impulse for particular piping sizes DN Qmax m h Imp l imp DN Qmax m h Imp l imp ELIS PLZE a s Lu n 15 P O BOX 126 304 26 Plze Czech Republic tel 420 377 517 711 fax 420 377 517 722 Es 90 398K a Product application installation and service manual FLOMIC FL 3005 battery powered ultrasonic flow meter Page 11 of 40 ELIS PLZEN a s for direct installation in piping 5 GENERAL RULES FOR FLOW METER APPLICATION When using an ultrasonic flow meter in a piping containing a particular fluid certain conditions need be met to ensure correct measurements The limiting o
44. on interface GSM module and optical interface for data reading On special request the ultrasonic probes can be supplied in the IP68 version The FLOMIC FL 3005 ultrasonic flow meter with ultrasonic probes to be fitted directly in the measured piping consists of the following component parts 1 pc Electronic control unit model UP 8 00 see Fig 2 2pcs Ultrasonic probe model US 2 1 see Fig 3 including coaxial cable the cable length should be specified in the product order 2pcs Welded on piece Fig 4 2pcs Welding flange Fig 5 2pcs Probe sealing Product application installation and service manual Es 90 398 K Theoretical calibration programs Es 90 470 D and Es 90 499 D User program handbooks Es 90 316 K and Es 90 318 k Figure 2 ELEKTRONIC CONTROL UNIT Figure 3 ULTRASONIC PROBE E Dy Ps Fiqure 5 Figure 4 WELDING ad WELDED ON PIECE FLANGE hon d ELIS PLZE a s Lu n 15 P O BOX 126 304 26 Plze Czech Republic tel 420 377 517 711 fax 420 377 517 722 Es 90 398K a Product application installation and service manual FLOMIC FL 3005 battery powered ultrasonic flow meter Page 7 of 40 ELIS PLZEN a s for direct installation in piping In the case of a meter installation by the customer the delivery kit may include various optional measuring and assembly fixtures such as 1 pc Communication cable 1 pc Protractor Fig 6 1 pc Protractor holder Fig 7 1 pc St
45. perational parameters of the fluid i e temperature pressure and flow velocity as well as the mechanical design and properties of the meter sensor flow stabilisation piping sections before and after sensor complete flooding of the sensor cavity at all times elimination of cavitation effects and fluid foaming must comply with the requirement for steady fluid flow with no gas bubbles or foam appearing in the piping Such conditions are different for various types of fluid and need be correctly identified for each specific measuring spot and or technological piping system CAUTION Ultrasonic flow meter of a specific DN must not be used in piping of lesser sizes smaller DN Selection of measuring spots in piping systems must be done in observance of certain basic rules Incorrect placement of meter may result in deteriorated measurement stability or precision To the extent possible avoid meter placement after valves or pumps in piping The recommended minimum lengths of straight piping sections before and after the meter are 5DN and 3DN respectively see Fig 13 FLOW DIRECTION Fig 13 Recommended fluid stabilisation piping section before and after the ultrasonic flow meter If there is a pump in the piping the recommended length of straight piping section between the pump and sensor is 20DN If there is at the sensor input side a fully open valve the recommended length of straight piping section is 10DN If it is a valve w
46. rap piece Fig 8 Fiqure 7 m PROTRACTOR Pad EN e P d HOLDER Figure 6 Figure 8 PROTRACTOR E d STRAP PIECE Set of parts associated with the rectification pin 1 pc Protractor adaptor Fig 9 1 pc Milling adaptor including milling tool and nut Fig 10 1 pc Milling adaptor II Fig 11 Set of connecting parts see Fig 12 in quantities given in the following table m o LC wm 3 LC mx 3 e So ooo L3 UI me 3 LL L9 UL me L3 Lm 7 LU mw 3 99 UL wm 0 3L 9m 7 UI mue 3 a 3 99 7 eo mmo 5 S a e m9 3 3 S ELIS PLZE a s Lu n 15 P O BOX 126 304 26 Plzeri Czech Republic tel 420 377 517 711 fax 420 377 517 722 Es 90 398K a ninl Product application installation and service manual FLOMIC FL 3005 battery powered ultrasonic flow meter Page 8 of 40 ELIS PLZEN a s for direct installation in piping S C9 ELIS PLZEN a s Lu n 15 P O BOX 126 304 26 Plze Czech Republic tel 420 377 517 711 fax 420 377 517 722 Es 90 398K a Product application installation and service manual FLOMIC FL 3005 battery powered ultrasonic flow meter Page 9 of 40 ELIS PLZEN a s for direct installation in piping 3 3 Meter design 3 3 1 Flow meter sensor The flow meter sensor assembly consists of the meter piping and ultr
47. s it shall be easily rotated and moved in the axial direction Apply fillet welds to fix the positions of the flanges on the piping H Using the assembly marks set the correct positions of the welded on pieces in the flanges and fix them by several point welds I Check the play of the rectification pin in the welded on pieces again Apply fillet welds to secure positions of the welded on pieces in the respective flanges Comment When performing the welding operations with the welded on pieces slid on the rectification pin make sure that the functional parts of the welded on pieces cannot be damaged by the flying sparks and protect them by suitable covers or nuts Should it be found that at any time during the welding operations the rectification pin has lost its desired play free rotation and displacement in the holes in the welded on pieces the reason for that condition must be established and the defect removed by slight knocking on the welded on pieces with the thread protected It is recommended to check the rectification pin play after each welding operation ELIS PLZE a s Lu n 15 P O BOX 126 304 26 Plze Czech Republic tel 420 377 517 711 fax 420 377 517 722 Es 90 398K a Product application installation and service manual FLOMIC FL 3005 battery powered ultrasonic flow meter Page 21 of 40 ELIS PLZEN a s for direct installation in piping 6 1 5 Facing of seating surfaces on welded on p
48. stance L between the outer end faces of the welded on pieces can be determined either by direct measurement using a suitable gauge or steel rule inserted by means of an auxiliary pin into the welded on pieces or indirectly by making marks on the rectification pin and measuring the distance between them after removal of the pin from the welded on pieces see Fig 28 The auxiliary pin used to insert a steel rule into the meter piping should be of a smaller diameter than the rectification pin Such pin is not included in the delivery kit WELDED ON PIECE Fig 28 Determination of distance L 6 1 6 3 Inner diameter of meter piping The meter piping is integral part of the piping system where flow measurements are to be performed The ID of meter piping can be determined by calculation as follows Di 2 D 2t where t is the pipe wall thickness The OD of the meter piping Do was determined earlier using the procedure outlined in Section 6 1 3 1 above The pipe wall thickness t should be determined by measurement on the cut out sections acquired when holes were cut in the pipe wall for fitting of the welded on pieces Each section shall be measured three times at spots 120 apart and the value t calculated as the averag e of the six measurements taken Regarding conditioning of the cut out sections prior to measurement see Section 6 1 4 B ELIS PLZE a s Lu n 15 P O BOX
49. ternal voltage 3 to 30 V 5 to 30 V Loading current range 0 003 to 10 mA 0 1 to 10 mA Loading resistor 1 kO to 1 MQ 1 KQ to 50 kQ The minimum loading resistance depends on the external voltage used u v 0 01 A Rmi Q ELIS PLZE a s Lu n 15 P O BOX 126 304 26 Pize Czech Republic tel 420 377 517 711 fax 420 377 517 722 Es 90 398K a Product application installation and service manual FLOMIC FL 3005 battery powered ultrasonic flow meter Page 32 of 40 ELIS PLZEN a s for direct installation in piping ssl Ko O Slo 00000 oooo OZ L Fig 38 Position of jumper J5 8 2 2 Current output The passive current output 4 to 20 mA is connected to terminals 13 and 14 of the output terminal strip X10 see Fig 29 Section 6 1 8 Upon reaching the upper limit of the output current 20 mA corresponding to Qmax the output current will grow no longer and error message E4 will appear on the display see Section 8 5 To use the current output connect an external DC power source of 10 to 24V to the output terminal board as shown in the schematic diagram in Section 6 1 8 The maximum permitted current loop resistance ohmic resistance of the line input resistance of the customer specific signal processing device is given by the following formula Usource V 7 RS Tol 0 02 8 3 Communication interface 8 3 1 Optical interface The optical interface facilitates rea
50. tiplier for example for desired impulse number 10 000 l min and multiplier 100 enter 100 The maximum Pulse number permitted is 110 Then click on software key Calculate to inner units whereby the key Write table to EEPROM will be enabled Use this key to start the programming procedure When this is completed close the table File Inner diameter mm max m3 h Insensivity near zero mm s Pulse number limp 1200 140 2o 100 Calculated distance of probes mm Inner units fi 170 00000728 V mm s errs Q l h presene fo po EEE pm pozsa Jo wm precor D x9 p o pmo fones o m D fi 40000 AD correction o OK Read table from EEPROM Write table to EEPROM Fig 35 2040 771 70565095 Now provided the meter piping is fully flooded the flow meter will start operation the E1 field signalling error on the display will go dark and provided the fluid in the piping is flowing the meter will display the actual flow rate ELIS PLZEN a s Lu n 15 P O BOX 126 304 26 Plze Czech Republic tel 420 377 517 711 fax 420 377 517 722 Es 90 398K a Product application installation and service manual FLOMIC FL 3005 battery powered ultrasonic flow meter Page 30 of 40 ELIS PLZEN a s for direct installation in piping 7 2 3 Check on zero setting If you can arrange for zero flo
51. to a vertical piping section ELIS PLZE a s Lu n 15 P O BOX 126 304 26 Plze Czech Republic tel 420 377 517 711 fax 420 377 517 722 Es 90 398K a Product application installation and service manual FLOMIC FL 3005 battery powered ultrasonic flow meter Page 13 of 40 ELIS PLZEN a s for direct installation in piping To ensure correct measurement at all times make sure that the sensor flow profile is always completely filled with the measured fluid Avoid sensor placement at top pockets or in vertical piping sections with the flow direction downwards in particular in the cases of piping sections discharging fluid to open tanks see Fig 18 FLOW DIRECTION FLOW DIRECTION Fig 18 Examples of incorrect sensor placement 6 FLOW METER INSTALLATION 6 1 Meter assembly and installation principles The flow meter assembly and installation must be done in strict observance of the rules and recommendations in this product manual To minimise electromagnetic interference make sure that the signal cables are laid at least 25cm away from the power cables feeding other electrical equipment Shielded conductors are recommended to use for all signal lines Any extension connections between signal conductors must be soldered and the soldered joints protected by suitable installation boxes against climatic and mechanical stresses All cables must be led outside the ther
52. vL s Current output ext power supply 4 20mA GROUNDING Fig 29 Input and output signal connections of the UP 8 00 electronic unit ELIS PLZE a s Lu n 15 P O BOX 126 304 26 Plze Czech Republic tel 420 377 517 711 fax 420 377 517 722 Es 90 398K a p ELS Product application installation and service manual Z FLOMIC FL 3005 battery powered ultrasonic flow meter Page 25 of 40 ELIS PLZEN a s for direct installation in piping To ensure correct functioning of the flow meter ultrasonic probes 1 and 2 must be connected as shown in Fig 30 probe 1 must be closer to the output end of the sensor and probe 2 on the input side The probe cables are marked accordingly FLUID FLOW P Fig 30 Probe marking 7 SETTING FLOW METER IN OPERATION 7 1 Theoretical calibration The relationship between flow rate q and flow velocity v is given by the general formula q f v Function f depends on the meter piping ID the inner surface roughness viscosity of the measured fluid and to some extent the delay of the probe excitation signal in the coaxial cable connecting the probe and the electronic control unit In practical situations the theoretical meter calibration is done using the TheoCalc and CaliberFL programs generating the q f v function for all flow rate values 7 2 Description of calibration procedure The necessary
53. w rate by closing the valves before and after the meter or by switching off the fluid pump check the flow rate zero setting Run the CaliberFL program again and display the table in Fig 36 H CaliberFL OF XI Calibration Setting Close Version and product number Buva 74v 221 27 05 Flow speed mm s CaliberFL Flomic FL calibration software Flow m3 Average flow speed Clear average speed Average counter pas Symetry setting FFFFFFCC Zero adjustment Elk Fig 36 Com2 Click on the key Clear average speed and reset the readings Average flow speed and Average counter the corresponding number of the measurements taken The reading Flow speed should be within the limits of 10 mm s and 10 mm s should any of these limit values be exceeded check the tightness of closed valves When the reading at Average counter reaches about 120 click on the key Zero adjustment to modify the reading at Symmetry setting About six seconds later repeat the procedure of the zero setting check Now the reading at Average flow speed should not be greater than 2mm The phenomenon called rocking can be observed with long piping where the steady state after the valve closure may take several minutes to attain In such a case wait till the reading at Flow speed drops below 4 mm s and then perform the zero setting check If

FLOMIC FL 3005

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