AFLOWT LV Series User manual

ULTRASONIC LEVEL GAUGE

AFLOWT LV

VERSION

LV-2xx

INSTALLATION MANUAL

9001:2008

Saint-Petersburg, Russia

TABLE OF CONTENTS Page

INTRODUCTION.....................................................................................................3

1. SAFETY INSTRUCTIONS...................................................................................4

2. PREPARATION FOR MOUNTING......................................................................5

3. MOUNTING CONSIDERATIONS........................................................................6

4. MOUNTING THE LEVEL GAUGE.......................................................................7

4.1. Types of acoustic systems.....................................................................7

4.2. Mounting acoustic systems....................................................................7

4.3. Mounting modules..................................................................................8

4.4. Wiring the Level gauge..........................................................................8

5. START-UP PROCEDURES..............................................................................10

5.1. Initial configuration...............................................................................10

5.2. Configuring the Level gauge installed on the object under control.......11

5.3. Special-purpose configuration .............................................................13

6. DISMOUNTING.................................................................................................15

APPENDIX A. Acoustic systems.................................................................16

APPENDIX B. Methods for mounting acoustic systems..............................25

APPENDIX C. Wiring diagrams..................................................................31

APPENDIX D. Report on mounting and start-up procedures......................35

APPENDIX E. Adjustment profiles..............................................................37

APPENDIX F. Velocity of ultrasound for pure gases ..................................38

The present manual covers the procedures for on-site mounting

and dismounting of "AFLOWT LV" ultrasonic Level gauges of LV-2xx

versions. In the course of work, also refer to "ULTRASONIC LEVEL

GAUGE AFLOWT LV. LV-2xx version. Operation manual, Part I and

Part II" document.

LIST OF ABBREVIATIONS

- Acoustic system

BMD

- Digital measuring block

- Communication block

PEP

- Piezoelectric converter

SPS

- Secondary power source

RTD

- Resistance temperature detector (temperature sensor)

- Ultrasonic Level gauge.

NOTE. Words in the text marked in bold, for example, Setting,

correspond to the items displayed on the Device's screen.

CAUTION!

1. It is highly recommended to study Operation Manual before you start

work with the Level gauge.

2. You must not do the following, unless otherwise agreed by the

manufacturer:

- Perform any modifications to the recommended measurement and

mount procedures (Appendices B, C)

- Perform any modifications to PEP (Piezoelectric Converter) design

- Use cables of the types not specified in the present operational

documentation for making connections between BMD (Digital

Measuring Block) and PEP, and between RTDs (Resistance

temperature detectors) and BMD

- Install self-manufactured and modified acoustic systems (AS) excluding

fastening components.

1. SAFETY INSTRUCTIONS

1.1. The Level gauge should be mounted (dismounted) by the qualified

technical staff:

- Certified for performing work of this type on the site where the Level

gauge is installed and authorized by the manufacturer

- Authorized to work with electrical installations up to 1000 V

- Familiar with all the instructions outlined for the Level gauge and

auxiliary equipment used for mounting and dismounting.

1.2 When working with the Level gauge, the dangerous factors are as

follows:

- AC voltage with RMS of up to 264 V, frequency 50 Hz (when the device

is powered from mains 220 V 50 Hz via Secondary Power Source)

- Other site-specific factors.

Prior to performing work, make sure that no dangerous AC/DC

voltage which may cause injury or death is applied to the tank (pipeline)

to be worked on. Use the appropriate measuring device for this

purpose.

In the course of mounting, start-up, commissioning and

dismounting works, it is strictly forbidden:

- To make connections to the Device, switch over modes and replace

electronic components, if the Level gauge is powered up

- To use electronic devices and electric tools unless their cases are

connected to the protective earthing trunk line. Also, you must not use

the defective devices and tools.

1.5. Prior to connection of the device to mains, it is necessary to connect

BMD grounding terminal and terminal of SPS (if applicable) to the

earthing trunk line.

2. PREPARATION FOR MOUNTING

2.1. To mount the Level gauge on site, the following areas should be

available:

- Free channel (tank, pipeline) section for mounting an acoustic system

(AS)

- Free space used to place structures providing protection of AS from

precipitation, wind, and solar/heat radiation

- Free area suitable for positioning BMD, SPS and CB (Communication

Block).

2.2. The Level gauge should be transported packed in the manufacturer’s

box.

After the Level gauge has been moved to the mounting location

from a cold environment into a warm one (with ambient temperature

above zero), it shall be left to stand in the manufacturer’s box for at

least 3 hours to make sure that no condensation remains inside.

When unpacking the Level gauge, check that the delivery package

contains all items specified in the Equipment Certificate.

3. MOUNTING CONSIDERATIONS

3.1. Site requirements for mounting AS should be as follows:

- Tank (channel, pipeline) operation conditions exclude foreign items on

the surface of media interface within the area of measurements

- Liquid turbulence and pulsations are absent or minimal

- Foams on the surface of media interface are minimal

- There are no structural components on the way of acoustic beam from

PEP to the media interface

- Foreign items inside the AS sound guide are excluded

- Icing over PEP emitting surface and reference reflector surface as well

as built-up of ice caused by fumes inside the sound guide are

prevented.

3.2. AS can be mounted on a horizontal section of tank (channel, pipeline).

Mounting location is selected considering the minimal distance from

media interface to the AS base plane that must be no less than:

- 1400 mm –for acoustic systems of AS-40x-xx0 and AS-50x-xx0

versions

- 800 mm –for acoustic systems of AS-11x-xx3, AS-6xx-xx0, and AS-

7xx-xx0 versions.

3.3. AS must be mounted in vertical plane. Deflection of the sound guide axis

from the vertical axis must not exceed 3 degrees of arc.

It is recommended to mount acoustic systems of suspended type

AS-50x-xx0, and AS-7xx-xx0 in the areas where rocking by wind and

draft is excluded.

3.4. The on-site structure where AS is installed must be rigid enough to

prevent sound guide axis shift from the vertical and shift of the base

plane from the vertical.

Flanges on the ends of the acoustic system are fixed to the mount

adaptor via a rubber gasket included in the set of AS fittings.

3.5. When mounting (dismounting) and operating the Level gauge, protection

of PEP emitting surface from impacts must be provided.

3.6. The following conditions should be observed at the site of BMD

installation:

- Operation conditions are in accordance with the requirements of the

Operation Manual

- Free access to BMD and convenience in operation is provided

3.7. BMD must not be installed in areas where it can be exposed to water jets

or near sources of heat and electromagnetic radiation.

3.8. When mounting the two-channel Level gauge, the components originally

assigned to a particular measuring channel must be used: serial

numbers of the components specified in the Equipment Certificate and

marking of connection cables must relate to the measuring channel of a

particular number. The connection cables must not be changed in

length.

3.9. The following components may be sealed on completion of on-site

mounting procedure:

- Two fixing screws located on the front panel of BMD

- Cover of Communication Block case

- Cover of RTD (if applicable).

4. MOUNTING THE LEVEL GAUGE

4.1. Types of acoustic systems

4.1.1. Simplistically designed AS-1xx-xx3 systems come without reference

reflectors and sound guides. AS-11x-xx3 systems is equipped with disc

mount ones (Fig.A.1). Mount disc both have holes for fixing an acoustic

system to the object under control.

4.1.2. A sound guide as part of AS-40x-xx0 (having reference reflectors)

systems is designed as a pipe run with a mount flange installed on the

upper end. There are holes in the flange used to fix the assembly to the

object under control (Fig.A.2). PEP is installed in the mount flange

center with the emitting surface facing inside the sound guide.

Reference reflector, a hollow fluoroplastic cylinder on a metal rod,

is fixed to the lower end of the sound guide by holders. Being installed

at the known distance from the PEP emitting surface, the reference

reflector provides reflection of ultrasonic waves from the reference

distance.

4.1.3. AS-50x-xx0 (with reference reflector) acoustic systems come with a

mount disc installed. The disc is without fixing holes, however, a ring

bolt mounted on it provides suspension of AS by snap hooks and a

cable (Fig.A.3).

Flexible suspension provides that the Level gauge is capable of

working in thin-walled tanks that are prone to distort in shape under the

effect of temperature.

4.1.4. A sound guide coming with AS-6xx-xx0 (with RTDs) acoustic systems

has a mount flange with fixing holes (Fig.A.4). PEP and RTD are both

installed on the flange. RTD's sensor is located inside the sound guide.

These sound guides come without reference reflectors.

4.1.5. A sound guide included in AS-7xx-xx0 (with RTDs) acoustic systems

has a mount flange without fixing holes, but it is equipped with a ring

bolt (Fig.A.5). These sound guides come without reference reflectors.

4.1.6. To seamlessly mount an AS on any tank regardless of the design, the

Level gauge can be supplied complete with optional mount adaptors of

corresponding type. Types of mount adaptors and adaptor pipes are

shown in Fig.A.6-A.9.

4.1.7. Selection of materials for the sound guide, mount adaptor, and seal

gaskets is determined by AS design.

4.2. Mounting acoustic systems

4.2.1. Depending on the design of an object under control and type of AS in

use, various types of mounting are available (Appendix B).

4.2.2. Various sets of fittings may be provided to mount BMD and AS on

various objects under control. Contents of the set of fittings and number

of particular items depend on the type of AS and mounting method.

4.2.3. Acoustic systems without sound guides are generally mounted on

existing tanks or open channel structures. AS-1xx-xx3 system is

installed on a mount disc (Fig.B.1).

4.2.4. AS-40x-xx0 and AS-6xx-xx0 systems are mounted as shown in figures

B.2-B.4. Several mounting methods are available:

- Mounting AS on a frame installed on the object under control (Fig.B.2).

AS mount flange is fixed to the frame by bolts. Deflection of the

base plane of the mount flange from the horizontal plane is checked

with a builder's level in two mutually perpendicular directions. This will

ensure that the sound guide axis is positioned vertically.

- Mounting AS with use of mount adaptor (Fig.B.3, B.4).

A mount adaptor (Fig.A.6) is welded to the tank (pipe) wall or to a

frame constructed as desired and installed on the object under control,

after which the AS mount flange is fixed to the mount adaptor flange by

bolts.

- In the case when submerging of AS is possible, one (for AS-6xx-xx0

version) or two (for AS-40x-xx0 version) adaptor pipes are installed

(Fig.A.8). The adaptor pipes are fixed by bolts between the mount

adaptor flange and AS mount flange. Position of the sound guide axis is

checked with a builder's level.

To vent volatile gases in case these are present above the tank

(pipeline) and/or to optimize AS heat exchange, you may use perforated

adaptor pipes (Fig.A.9).

4.2.5. Acoustic systems of AS-50x-xx0 and AS-7xx-xx0 design versions are

installed with use of the "Flexible mount" method (Fig.B.5, B.6). Several

mounting techniques are available:

- AS is suspended from a structural component of the object under

control on a snap hook or a cable via a ring bolt (Fig.B.5).

- Mount adaptor is welded to a tank (pipeline) wall. A flange with a ring

bolt installed is fixed to the mount adaptor flange by bolts (Fig.A.7), and

the acoustic system is suspended on snap hooks or on a cable via the

ring bolt (Fig.B.6).

4.2.6. It is recommended to seal a recess on the mount flange at the PEP

cable output to prevent moisture accumulation.

4.3. Mounting the modules

BMD, Power Source and Communication block (CB) are installed

and fixed on the vertical plane considering their overall and mount

dimensions (see Fig.A.1, A.3, A.5, A.6, Appendix A of Part I of the

Operation manual). The modules are mounted on a pre-installed DIN

rail (mount rail 35/7.5). The Communication Block can be installed at a

certain distance from AS considering that the length of connection

cables terminated in PEP and RTD is 5 m.

It is not necessary that the room where the system is installed be

lighted considering that BMD has its own backlight.

4.4. Wiring the Level gauge

4.4.1. AS is connected to BMD considering that the components are assigned

to particular channels as outlined in section 3.8.

4.4.2. Communication and network cables are fixed on the wall wherever

possible. The network cable is laid separately at a distance of 0.3 m as

a minimum from other cables. It is recommended not to coil the

excessive cables.

CAUTION! YOU MUST NOT change the length of BMD-CB and

CB-PEP cables.

To avoid mechanical damages, it is recommended to place all

cables in metal or plastic tubes, corrugated sleeves, and cable trays,

trunks, or conduits.

DO NOT lay BMD-PEP and BMD-RTD cables and signal cables for

external connections within proximity to power circuits, and, with

presence of high-level electromagnetic interference, DO NOT lay the

cables without putting them into properly grounded metal tubes or

sleeves. The metal tubes or sleeves shall only be grounded on one side

–on BMD side.

YOU MUST PREVENT tension of PEP and RTD cables connected

to CB. This may result in deflection of the sound guide from the vertical

axis.

4.4.4. Recommended cable types are given in Table.1.

Table 1

Circuit

Cable type

BMD –PEP *

UNITRONIC BUS IBS 3×2×0.22) –for AS-11х-хх3;

any cable 2×0.35 or 2×0.5 – for other types AS

BMD –RTD

any cable 4×0.2

Mains AC 220 V 50 Hz –SPS

any cable 3×0.5

SPS –BMD

any cable 2×0.5

* - Cable length is no more than 250 m

4.4.4. Prior to connection, cut isolation from the cable ends by 5 mm and

fabricate. The cables are directed via cable glands and attached to the

connectors according to the Wiring diagrams given in Appendix C. To

prevent ingress of moisture, the unused cable glands are covered by

plugs included in the set of fittings.

4.4.5. When mounting AS by the method shown in Fig. B.6, signal cables are

directed via cable glands on the mount flange and connected to CB.

4.4.6. The need for protective grounding is determined by power supply and

environment conditions under which the devise is operated.

The protective grounding and earthing device should correspond to

the rules on design of power electric installations.

Use a mechanically protected copper wire of no less than 2.5 mm2

cross-section or a copper wire without mechanical protection of no less

than 4 mm2cross section as a grounding wire connecting the Level

gauge with the grounding device.

Grounding terminal must not be connected to the lightning

protection system.

CAUTION! Prior to connecting the protective earthing trunk

line, you must make sure that the voltage is off.

4.4.7. The Level gauge has no standby mains switch, therefore, it is connected

to mains via an external switch.

5. START-UP PROCEDURES

5.1. Initial configuration

5.1.1. Prior to work, it is necessary to check that the Level gauge's operation

settings specified in the Equipment Certificate or Check Form

correspond to the ones in the Device's internal memory as well as to

check its configuration settings.

The following settings shown in Fig.1 are determined during the

configuration procedure, after which they are entered in the Device's

Start-up List (Appendix D):

- B –base level, m

- Hmax –maximal level of liquid in the tank under control

- C0 –velocity of ultrasound in gas medium inside the tank under control

at 0°C (applicable only for systems AS-11x-xx3, AS-61x-xx0, AS-62x-

xx0, AS-71x-xx0, AS-72x-xx0), m/s

- Volume/Level characteristic of the tank under control (required for

calculation of volume and/or filled volume).

When configuring the Device, the following settings are also

checked and recalculated:

- Dmin, Dmax –threshold values of the distance measuring range, m

- Cmin, Cmax –threshold values of the range of actual ultrasound velocities

within the sound guide, m/s;

- Cmc –ultrasound velocity value entered for the manual correction mode

(if necessary), m/s.

5.1.2. In the course of start-up, the base level Bcan be determined by two

methods:

- Measuring the distance between the base (reference) plane, from which

the distance readings are taken, and the bottom of the tank or a

conventional plane which is taken as the reference for level

measurements

- Calculating the sum of measured distance Dmcr and liquid level Hmcr in

the tank under control: B = Dmcr + Hmcr (1)

The distance is determined as a range from the base plane to the

media interface. You may use the Level gauge readings to determine

the distance.

For all acoustic systems, the base plane is a plane going through

the outer surface of the mount flange, mount bar, or mount disc.

Values of distance, level and the measurement base can be

measured by a measuring crossbar, measuring needle, or laser ranger.

The recommended accuracy for distance, level, and base level

measurements is ± 1 mm.

5.1.3. The threshold values for distance measuring range Dmin and Dmax are

calculated as follows:

Dmin = B –1.2⋅Hmax (2)

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