Truflo ULTRAFLO 5000 User manual

Flowmeter Ultrasonic Flow

Metering / Dosing Device

Operating Manual

Read the user's manual carefully before starting to use the unit or software.

Producer reserves the right to implement changes without prior notice.

PVDF-PE Plastic Ultrasonic Flow Meter

ULTRAFLO 5000

Distributed By Aetna Plastics

www.aetnaplastics.com

Aetna Plastics - Phone 800.634.3074 - Fax 216.524.2280 - Email [email protected]

Table of Contents

Table of Figures

General safety instructions

1. Planning information

 1.1 Areas of application

 1.2 Measuring principle

 1.3 Operational safety

2. Assambly and installation

 2

.1 Installation instructions

 2.2 Assembly of the flowmeter

 2

.3 Electrical wiring

3. Commissioning

 3

.1 Operation

 3.2 Functionalities of flowmeter and default settings

 3

.3 Overview of default settings

 3.4 General Information

4. Exchange of measuring device

5. Technical specifications

 5.1 Dimensions and weight

 5

.2 Technical specifications

Fig. 1: Presentation of the principle of ultrasonic flow measuring

Fig. 2: Installation position of Flowmeter

Fig. 3: Mounting examples for Flowmeter

Fig. 4: Mounting possibilities

Fig. 5: Fixing Flowmeter

Fig. 6: Flowmeter mounted on a DIN rail

Fig. 7: Pin code: Connection plug / socket for 5-pin version

Fig. 8: Pin code: Connection plug / socket for 8-pin version

Fig. 9: Operating with the key pad

Fig. 10: Menu organization for 5-pin version

Fig. 11: Menu organization for 8-pin version

Fig. 12: Function of the creeping suppression illustrated with 0.6 l/min

Fig. 13: Connecting output Q1 to relay

Fig. 14: Connecting output Q2 to counter

PVDF-PE Plastic Ultrasonic Flow Meter

ULTRAFLO 5000

Distributed By Aetna Plastics

www.aetnaplastics.com

Aetna Plastics - Phone 800.634.3074 - Fax 216.524.2280 - Email [email protected]

General Safety Instructions

Personnel for Installation, Commissioning and Operation

Technological Progress

Intended Use :

Please always observe the following safety instructions!

Please pay attention to the safety instructions with the following pictograms and signal words in

these operating instructions:

The flow meter Flowmeter may only be used for measuring the flow of pure, homogeneous

liquids.

The Flowmeter is not intended for use in medical applications.

The volume flow meter Flowmeter is built operationally safe in accordance with the latest state

of the art technologized developments and industry standard EN 61010 regulations

(corresponds to VDE 0411 "Safety specifications for electrical measurement, control and

laboratory devices").

The manufacturer is not liable for any injury, damage or harm due to inappropriate or

unintended use or modifications of the flow meter. Conversions and/or changes to the flow

meter may only be made, if they are expressly performed in accordance with the operating

instructions in this operating manual.

Assembly, electrical installation, commissioning and maintenance of the flow

meter must be carried out by qualified, trained personnel. The qualified

personnel must have read and understood the operating instructions in this

operating manual and must follow the operating instructions in this manual.

The installer has to ensure that the flow meter is correctly connected

according to the electrical connection diagrams in this operating manual.

Serious injury or death from electric shock may occur if wiring, installation,

disassembly or remove of wires is performed while electrical power is

energized

The manufacturer reserves the right to revise, alter, or modify the flow meter to the most current

technology without special prior notice. Further information about the latest updates and potential

additions to these operating instructions are available from the manufacturer.

IMPORTANT! indicates situations or cases which, if not avoided, could result in

damage or failure of the Flowmeter 44i equipment.

WARNING! Iindicates general hazardous situations or cases which, if not avoided,

could result in serious injury or death.

Is used to lead users to helpful information not related to personal injury.

NOTICE

WARNING!

PVDF-PE Plastic Ultrasonic Flow Meter

ULTRAFLO 5000

Distributed By Aetna Plastics

www.aetnaplastics.com

Aetna Plastics - Phone 800.634.3074 - Fax 216.524.2280 - Email [email protected]

1. Planning Information

1.1 Areas of application

1.2 Measuring principle

The flow measurement device in the Flowmeter designed to measure dynamic flow in pipes and

tubes. This flow meter is suitable for liquids only. The Flowmeter is used in

It usually takes more energy to swim against the flow than with the flow. The ultrasonic flow

measurement is based on the phase-difference approach:

Two ultrasonic-sensors located opposite from each other alternatively transmitting and receiving

ultrasonic signals. If there is no liquid flow both sensors receive the transmitted ultrasonic signals in

the same phase, i.e. without phase difference. If liquid is flowing there is a phase shift. It differs

when measured in direction of the flow than when measured against the direction of the flow. This

phase difference is directly proportional to the flow rate.

Flowmeter has the following features and benefits:

Chemicals supply for controlling, logistics, monitoring

Cooling systems, logistics, monitoring

Process equipment for control and monitoring of formulas

Valve control for continuous release of liquid volumes

Supply with de-ionized water

Very dynamic liquid processes with dosing times of below 1 second

No movable parts, therefore no wear

High repeatability

Easy to clean

Safe operation

Compact design

Integrated detection of empty conduits

Integrated dosing function with pre-set and adjustable amounts

Chemical resistant

Constant pipe cross-section over the entire measurement channel

Fig. 1: Presentation of the principle of ultrasonic flow measuring

L: length of measuring pipe

K: factor

D: diameter of measuring pipe

v: flow velocity

c: sound velocity of the fluid

: phase with the flow

: phase against the flow

c + v

- +

c - v

c+v

vreceiver /

sender

sender /

receiver c

vc-v

PVDF-PE Plastic Ultrasonic Flow Meter

ULTRAFLO 5000

Distributed By Aetna Plastics

www.aetnaplastics.com

Aetna Plastics - Phone 800.634.3074 - Fax 216.524.2280 - Email [email protected]

1.3 Operational Safety

2.1 Installation instructions

Comprehensive self-tests ensure highest possible safety.

Faults (process or system errors) are output on a digital output or displayed on the display menu.

The protection class is IP 67.

Flowmeter meets the general EMC immunity requirements according to CE, EN 61000-6-3, EN

61000-4-2, EN 61000-4-3, EN 61000-4-4, EN 61000-4-5, EN 61000-4-6.

Flowmeter meets the safety requirements concerning the Protective Extra Low Voltage directive

according to EN 50178, SELV, PELV.

For fastest possible bubble detection it is important to keep the pipe distance from tank to

Flowmeter as short as possible. Accurate measurement can only be assured, if the pipe is

completely filled and the liquid does not outgas.

The housing of Flowmeter is labeled with an arrow symbolizing the direction of the flow. The

flowmeter must be installed in direction of the flow.

2. Assembly and Installation

The nameplate of the Flowmeter has an arrow, symbolizing the flow direction of measurement.

The flow meter has to be installed in a way so that the flow-through is in the same direction as

the arrow symbol.

NOTICE

Fig. 2: Installation position of flowmeter

PVDF-PE Plastic Ultrasonic Flow Meter

ULTRAFLO 5000

Distributed By Aetna Plastics

www.aetnaplastics.com

Aetna Plastics - Phone 800.634.3074 - Fax 216.524.2280 - Email [email protected]

Notwithstanding it may be advantageous for dosing applications to install the Flowmeter as close

as possible to the dosing valve, since soft pipes increases the cross-section depending on the

system pressure. This may lead to repeatable differences.

When using pumps, Flowmeter must be installed in flow direction on the pressure side, on order to

ensure sufficient pressure. The maximum pressure rating of Flowmeter has to be considered.

For correct volume flow measurements straight and unobstructed inflow and outflow distances have

to be observed. Starting from the connection thread these straight and unobstructed flow zones

must be:

Particles present in the flow stream may result in measuring errors.

Insure that no cavitations dissolve from the measured liquid. Depending on the measured

liquid it can be helpful to have enough back pressure on the outlet of Flowmeter to avoid

cavitations. Insure all mechanical connections are tight.

NOTICENOTICE

Do not exceed the maximum pressure allowance for of the Flowmeter (see section

5.2 Technical specifications). Exceed the maximum pressure can lead to destruction

of the Flowmeter.

WARNING!

2.2 Assembly of the flow meter

The flow meter is mounted into a pipe system by using the mechanical connection.

Flowmeter should be mounted vertically into the pipe for the best measuring performance. Do

not install the flow meter after a dosing valve where the flow meter can run empty. Placing

the flow meter after a dosing valve and allowing it to run empty will cause a measuring

deviation at the next measurement. To avoid bubbles in the liquid, Flowmeter should be

installed on the pressure side of the pump.

Nominal Diameter

Inflow distance

Outflow distance

DN 5

0cm

DN 7

0cm

DN 10

5cm

0cm

DN 15

40cm

20cm

PVDF-PE Plastic Ultrasonic Flow Meter

ULTRAFLO 5000

Distributed By Aetna Plastics

www.aetnaplastics.com

Aetna Plastics - Phone 800.634.3074 - Fax 216.524.2280 - Email [email protected]

If it is not possible to mount the flow meter vertically, then mount the instrument in a

location where the pipe will be filled at all times. The best measuring result is achieved if

bubbles do not pass through Flowmeter.

For applications with a "clean design" for which it is necessary to completely drain the pipe system,

we recommend mounting the flow meter in the vertical position. Residual liquid may remain inside

the device if flow meter is mounted horizontally.

Vibrations or mechanical forces may decrease measuring accuracy. So if there is due to vibration

or mechanical movements is necessary to fix Flowmeter additionally, the instrument can be either

mounted on a DIN rail, or be fixed on the lateral slot.

Fig. 3: Mounting examples for Flowmeter

Fig. 4: Mounting possibilities

PVDF-PE Plastic Ultrasonic Flow Meter

ULTRAFLO 5000

Distributed By Aetna Plastics

www.aetnaplastics.com

Aetna Plastics - Phone 800.634.3074 - Fax 216.524.2280 - Email [email protected]

Fig. 5: Fixing Flowmeter

Fig. 6: Flowmeter mounted on a DIN rail

Flowmeter must be installed without mechanical tensions on the existing pipe system. The

flow meter may be damaged if there is tension on the existing pipe system.

Non-compliance of the installation instructions may result in tearing of the

housing, liquid may leak out.

PVDF-PE Plastic Ultrasonic Flow Meter

ULTRAFLO 5000

Distributed By Aetna Plastics

www.aetnaplastics.com

Aetna Plastics - Phone 800.634.3074 - Fax 216.524.2280 - Email [email protected]

2.3 Electrical Wiring

Connector cable pin configuration defined by manufacturer

The outlets may be re-programmed for specific applications

Fig. 7: Pin code: Connection plug / Socket

Serious injury or death from electric shock may occur if wiring, installation,

disassembly or remove of wires is performed while electrical power is energized.

Always shut off or disconnect electrical power at service panel and lock switch or

breaker and tag to prevent energizing electrical power during work or while

Flowmeter is not assembled and installed.

Wiring installation, disassembly and removal must be performed by qualified

persons experienced and knowledgeable about electrical work.

WARNING!

4 3

152

1 L+ Power supply: 18...30 VDC

Pin Function Description

2 Pulse output O1 alternative:

1. Empty-pipe output

2. Dosing output

3. Upper or Lower Limit output

4. Negative flow

Digital Output Q1

Freely adjustable ranging from 0.1 to 3000 ml/pulse in 0.1

ml/pulse steps, npn-Transistor, max. load 30V/100mA.

Max. Voltage must be less than the supply voltage.

Configurable output of 0V or 24V when pipe is empty.

Configurable output of 0V or 24V

Configurable output of 0V or 24V when reaching upper or

lower limit

Configurable output of 0V or 24V when liquid flows in

negative direction

3 GND Ground : 0 V

4 Communication Communication interface

5 Analog output QA 4….20mA ; 0….20mA

Example: 0L/min => 4mA

60L/min => 20mA

Empty pipe Alert => 3.5mA

(4-20mA depending on the configured limits)

PVDF-PE Plastic Ultrasonic Flow Meter

ULTRAFLO 5000

Distributed By Aetna Plastics

www.aetnaplastics.com

Aetna Plastics - Phone 800.634.3074 - Fax 216.524.2280 - Email [email protected]

Connector cable pin configuration defined by manufacturer

The outlets may be re-programmed for specific applications.

plug / socketFig. 8: Pin code: Connection

Digital output Q2

Configurable npn- or pnp-Transistor, max. Load 30V/

100mA. Max. Voltage must be less than the supply voltage.

Configurable output of 0V or 24V when pipe is empty.

Configurable output of 0V or 24V

Freely adjustable ranging from 0.1 to 3000 ml/pulse in 0.1

ml/pulse steps.

Configurable output of 0V or 24V when flow reaches upper

or lower limit.

Configurable output of 0V or 24V when liquid flows in

negative direction.

Digital output Q2 Functions:

1. Empty pipe output

2. Dosing output

3. Pulse output

4. Upper or Lower Limit output

5. Negative flow

1 L+ Power supply: 18...30 VDC

Pin Function Description

2 Pulse output O1 alternative:

1. Empty-pipe output

2. Dosing output

3. Upper or Lower Limit output

4. Negative flow

Digital Output Q1

Freely adjustable ranging from 0.1 to 3000 ml/pulse in 0.1

ml/pulse steps, npn-Transistor, max. load 30V/100mA.

Max. Voltage must be less than the supply voltage.

Configurable output of 0V or 24V when pipe is empty.

Configurable output of 0V or 24V

Configurable output of 0V or 24V when reaching upper or

lower limit

Configurable output of 0V or 24V when liquid flows in

negative direction

3 GND Ground : 0 V

5 Analog Output QA 4….20mA ; 0….20mA

Example: 0L/min => 4mA

60L/min => 20mA

Empty pipe Alert => 3.5mA

(4-20mA depending on the configured limits)

6 Communication Communication Interface

8 Shielding EMC safety

Digital input I1

1. Dosing output

2. Set offset

3. Reset counter

4. Creeping flow off

Digital input I1

Starts the dosage by a rising edge of 24V.

The Offset is set by a rising edge of 24V.

Reset of the counter by a rising edge of 24V.

Creeping suppression is deactivated as long as there are

24V at the input.

87 3

PVDF-PE Plastic Ultrasonic Flow Meter

ULTRAFLO 5000

Distributed By Aetna Plastics

www.aetnaplastics.com

Aetna Plastics - Phone 800.634.3074 - Fax 216.524.2280 - Email [email protected]

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