ELECTROMAGNETIC FLOW METER

AFLOWT MF VERSION PROFI

OPERATION MANUAL

9001:2008

Saint-Petersburg, Russia

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* * *

VZLJOT JSC quality management system is certified to ISO 9001:2008

* * *

Vzljot JSC

Postal address: Masterskaya Str., 9, 190121, Saint-Petersburg, RUSSIA

Tel.: +7 (812) 714-81-62 Fax: +7 (812) 714-71-38

E-mail: im@vzljot.ru URL: http://www.aflowt.com

VZLJOT JSC provides free consultation services and personnel training

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TABLE OF CONTENTS Page

INTRODUCTION ..................................................................................................... 4

1. DESCRIPTION AND OPERATION ..................................................................... 5

1.1. Application ................................................................................................... 5

1.2. Specifications ............................................................................................... 6

1.3. Contents of the delivery package................................................................. 7

1.4. Design and operation ................................................................................... 8 1.4.1. Measuring principle ......................................................................................... 8 1.4.2. Arrangement ................................................................................................... 9 1.4.3. Design ........................................................................................................... 12 1.4.4. Design versions ............................................................................................. 13 1.4.5. Operating modes ........................................................................................... 13 1.4.6. External Connections and Displaying of the Results ..................................... 15

1.5. Marking and sealing ................................................................................... 20

2. OPERATION ..................................................................................................... 21

2.1. Operating restrictions ................................................................................. 21

2.2. Selecting standard sizea) .......................................................................... 22

2.3. Preparing for operation .............................................................................. 24

2.4. Operation procedure .................................................................................. 25

2.5. Troubleshooting ......................................................................................... 26

3. MAINTENANCE ................................................................................................ 27

3.1. Maintenance check .................................................................................... 27

3.2. Calibration .................................................................................................. 27

4. PACKING, STORAGE AND TRANSPORTATION ............................................ 28

APPENDIX А. View of components................................................................... 29

APPENDIX B. Wiring diagrams ........................................................................ 37

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INTRODUCTION This document covers “AFLOWT FM” Electromagnetic Flowmeter

of PROFI model (PROFI-112, 122, -212, -222, -212А, -222А, -211B, -221B, -312, -322, -312А, -322А, -311B, -321B versions) hereinafter re-ferred to as the flowmeter, and contains information about its operation and design.

Due to continuous improvement of product, actual flowmeter’s specifications may differ from the data specified in this manual. Howev-er, this will not affect the metrological characteristics and functionality.

LIST OF ABBREVIATIONS MB BED DN LCD PC PCF EMF MF

- Measuring block - Block of the external display - Nominal diameter - Liquid-crystal display - Personal computer - Flow sensor (Primary flow converter) - Electromotive force - Magnetic flowmeter

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1. DESCRIPTION AND OPERATION

1.1. Application 1.1.1. "AFLOWT MF" electromagnetic flowmeter is designed for measuring

average volumetric flow rate and volume of various electrically conduc-tive liquids in wide temperature and viscosity ranges and for various operating conditions.

"AFLOWT MF" flowmeters can be used in a wide range of applica-tions in power industry, oil, gas and mining industries, municipal engi-neering as well as in iron and nonferrous, chemical, oil refining, cellu-lose and paper, food and other industries. The flowmeters can be used as part of heat meters, metering systems, automatic process control systems etc.

1.1.2. Depending on design type and firmware, "AFLOWT FM" flowmeter of PROFI model performs the following functions:

- Measuring of average volumetric flow rate in either forward or reverse flow directions

- Totalizing of volume for forward and reverse flows independently or calculation of their algebraic sum with regard to flow direction

- Batching of preset liquid volume or batching in the start-stop mode along with determining of the amount of batched liquid, batching time and flow rate

- Displaying of data on the flowmeter’s LCD - Outputting of measurement results to current, pulse or logical output - Logging of measurement data and configuration settings in the internal

nonvolatile memory - Transferring of measurement, diagnostic, configuration, log data etc. to

a PC via RS-232 or RS-485 serial interfaces - Automatic monitoring and displaying of alarm conditions and faults - Protecting of logged data and configuration settings from unauthorized

access.

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1.2. Specifications 1.2.1. General Specifications are listed in Table 1.

Table 1 Parameter Value

1. Nominal diameter of the pipe-line, DN, mm 10 15 20 25 32 40 50 65 80 100 150 200 300

2. Measured average volumetric flow rate of liquid, m3/h: - maximum, Qmax 2.5 6.3 10.0 16.0 25.0 40.0 63.0 100 160 250 630 1000 2500 - minimum, Qmin1/40* 0.062 0.157 0.25 0.4 0.625 1.0 1.575 2.5 4.0 6.25 15.75 25 62.5 - minimum, Qmin1/80* 0.031 0.078 0.125 0.2 0.312 0.5 0.787 1.25 2.0 3.125 7.87 12.5 31.25 - minimum, Qmin1/150* 0.016 0.042 0.066 0.106 0.166 0.266 0.42 0.666 1.066 1.666 4.2 6.66 16.66 3. Flowmeter's sensitivity to flow velocity, no less than, m/s 0.02

4. Maximum pressure in the pipe-line, MPa 2.5

5. Minimum specific conductivity of medium, S/m 5·10

-4

6. Temperature of medium, °С −10 to +150 (fluoroplastic lining) −10 to +70 (polyurethane lining)

7. Flowmeter power supply stabilized DC voltage (18-25) V or AC voltage (154-264) V frequency (501) Hz

(via Secondary Power Source) 8. Power consumption, W no more than 2.4 (PROFI-1 model)

no more than 2.9 (PROFI-2 model) no more than 4.0 (PROFI-3 model)

9. Mean time to failure, h 75 000 10. Mean life time, years 12

NOTE. * - Qmin1/40, Qmin1/80, Qmin1/150 – measured minimal average volumetric flow rate for the flowmeters with measuring range factor of 1:40, 1:80 and 1:150, respectively.

1.2.2. Limits of permissible relative error for measurement, indication, logging, storage and transferring the results of average volumetric flow rate and volume measurement for various liquids and for any flow direction do not fall outside the following ranges:

- ±1.0% − for flowmeters with flow rate range from Qmax to 0.025Q max

(Qmin1/40), and from Qmax to 0.0125Qmax (Qmin1/80) - ±2.0% − for flowmeters with flow rate range from Qmax to 0.0067Q max

(Qmin1/150). Limits of permissible relative error for recording the time of opera-

tion are no more than ±0.1%. 1.2.3. The flowmeter shall be classified according to the requirements stated

in GOST R 52931 as specified hereinafter: - Environmental resistance shall correspond to class B4 (ambient air

temperature range is 5-50°C; relative humidity cannot exceed 80% at t ≤ 35°C, without moisture condensation)

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- Mechanical resistance shall correspond to class N2 - Atmospheric pressure resistance shall correspond to class Р2.

Protection provided by the enclosure is IP65 as per National Standard (GOST) 14254.

1.2.4. View, overall dimensions and weight are given in Appendix A.

1.3. Contents of the delivery package Items of the delivery package are specified in Table 2.

Table 2 Name Qty Notes

Flowmeter 1 Notes 1 Block of External Display 1 Optional Secondary DC 24 V power source 1 Optional Installation kit 1 Notes 2, 3 RS-232 adaptor with cables 1 Optional Operating documentation: 1 - Equipment Certificate 1

CD disk

- Operation manual 1 - Installation manual NOTES:

1. Flowmeter's nominal diameter and design type (see 1.4.4) are specified in the purchase order.

2. Socket connectors for power and signal cables are included in the standard supply. A cable for display backlight is optional.

3. Set of fittings is provided for on-site installation at customer’s option (specified in the purchase order or "AFLOWT KPA" fitting assembly). The fittings provided are rated at pressure of 1.6MPa or 2.5MPa (op-tional).

4. Items of the delivery package are specified in the purchase order. Operating documentation and order sheets for this product and

other "VZLJOT" JSC products are available on: www.aflowt.com. In addition, here you can find "Multipurpose viewer" software pack-

age with "AFLOWT MF Monitor" program included, which is used to process data on a PC via RS-232 or RS-485 interfaces.

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1.4. Design and operation 1.4.1. Measuring principle

MF operation principle is based on measuring electromotive force (EMF) induced in electrically conductive liquid when it flows in magnet-ic field. The magnetic field is furnished in the flow sensor's inner chan-nel by a special electromagnetic system (see Fig.1).

Fig.1. Flowmeter design

The Primary Flow Converter (PCF) is designed as a hollow magne-to transparent cylinder with solenoid coils located outside. The inside of the cylinder is covered with an electrically insulating material. The in-duced signal is picked up by two electrodes, which are in conductive contact with the liquid under control.

Inductive electromotive force (EMF) E is proportional to the mean flow velocity v, distance between the electrodes d (which is equal to the sensor's inner diameter), and magnetic field strength B:

E = kВdv, (1) where k is linear factor. В and d are constants for MF of a given standard size. The value

of electromotive force is independent of liquid temperature and viscosi-ty, and also it is independent of conductivity provided that the value of conductivity is no less than specified in the flowmeter’s specifications.

Considering the formula for inductive EMF, flow rate Q is calculat-ed as follows:

E4kB

d=v

4d

=Q2 ππ

(2)

Volume V of the liquid passed through the flow sensor during the time interval Т is calculated by the formula:

. (3)

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1.4.2. Arrangement The flowmeter consists of the primary flow converter (PCF) and

secondary converter which is a microprocessor-based measuring block (MB).

The measuring block can contain either one or two modules: dis-play and processing modules.

MB processing module: - Provides power supply for solenoids - Receives and processes the induced EMF signals and determines av-

erage volumetric flow rate - Converts an average volumetric flow rate value into the sequence of

output pulses - Determines flow direction and generates a flow direction signal in the

form of logic signal - Receives external control signal - Provides data exchange with external devices via serial interface (if an

optional RS-485 module is present) - Totalizes volume and time of operation - Performs equipment diagnostics - Stores configuration settings and collected data.

Data logs are stored without power supply for minimum 1 year. MB display module (if present):

- Displays data on the LCD - Generates output current signal - Provides data exchange with external devices via RS-232 or RS-485

serial interface. To display data at a remote location, you may use the Block of the

External Display (BED) containing display and processing modules. BED display module:

- Displays data on the LCD - Generates output current signal - Provides data exchange with external devices via RS-232 or RS-485

serial interface. BED processing module:

- Exchanges data with the flowmeter’s measuring module via internal RS-485 interface (maximal cable length is 1200m)

- Generates the sequence of output pulses corresponding to measured average volumetric flow rate

- Issues flow direction signal in the form of logic signal - Receives external control signal.

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Flowmeter's functions depend on design type and are specified in the purchase order (see fig.2, 3, 4).

Fig.2. Block diagram for PROFI-1 flowmeter

Fig.3. Block diagram for PROFI-2 flowmeter

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Fig.4. Block diagram for PROFI-3 flowmeter

The following modifications are factory made on customer’s re-quest:

- Either measuring block or the flowmeter may be equipped with the dis-play module or the BED

- Either the display module of Measuring Block or the BED is equipped with current output

- Either the processing module of the MB or the BED is equipped with control input

- The Measuring Block processing module of the flowmeter without the display module and without the BED is equipped with additional RS-485 module for communication with external devices.

The serial interface type (RS-232 or RS-485) for the display mod-ule MB or BED are also specified in the purchase order.

The flowmeter is powered from stabilized 18...25V DC voltage with pulse level of no more than 1.0%. Optional secondary AC 154-264V (501) Hz power source allows powering the flowmeter with AC volt-age.

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1.4.3. Design The design of the flowmeter's flow pipe depends on the pipe con-

nection type and may be as follows: - Wafer connection type (DN10-DN150): PCF is fixed by studs between

the flanges welded to the pipeline ends where the flowmeter is cut in - Flanged type (DN25-DN300): the PCF flanges are fixed to the mating

flanges of the pipeline by bolts. Depending on application, the inner surface of the flow pipe is cov-

ered by various materials: fluoroplastic, polyurethane etc. For the wafer connection type, protection rings are installed to pro-

tect fluoroplastic lining from damages during mounting and operation. The protection rings used with the flanges of design type 3 as per Na-tional Standard GOST12820 provide alignment of PCF inner channel with mating flanges.

The Measuring Block (without the display module) contains the processing module board and is designed in a metal case. MB with the display module has the case made of plastic and comprises two boards: the processing module board placed inside the case, and the display module board placed in the cover of the front panel. The mod-ules are connected by the signal flexible flat cable and display back-light cable (if necessary).

PCF case and hollow stand fixing MB are made of metal. It is pos-sible to turn the MB about the stand axis by 90, 180 or 270 (factory-installed on customer's request).

If necessary (to conveniently read MB display), MB front panel may be set on the unit at an angle of 90 or 180 (it is not required to dis-connect signal flat cable). To do this, unscrew four fixing screws and place the panel in the desired position.

The power supply cable and signal cables are entered into the case through two cable throughs of standard Pg7 size.

One of the screws fixing MB to the stand is used as a grounding terminal. This screw is fixing the electric wires connecting the flowmeter case with the pipeline mating flanges.

BED has just the same design as MB equipped with the display. The rear panel has fixing holes for the brackets, which are used to mount the BED on DIN rail.

Optional ADN15-24 power supply is shown in Fig.А.10 of Appen-dix A.

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1.4.4. Design versions Flowmeter design versions differ in type of the Measuring Block

(data output functionality), type of connection to the pipeline (with re-gard to the flow channel), electrodes (considering the type of medium under control), and materials used for lining of the inner surface of the flow channel.

The design versions are identified as follows: PROFI - 1 – MB without display module, in metal case; PROFI - 2 – MB with display module, in plastic case; PROFI - 3 – MB without display module, in metal case; BED in plastic case; PROFI - 1 – connection type – "wafer" (available sizes: DN10-DN150);

PCF with fluoroplastic lining – with protection rings; PROFI - 2 – connection type – flanged (available sizes: DN25-DN300);

PCF with fluoroplastic lining – with protection rings; PROFI - 2 – fluoroplastic lining; electrodes made of stainless steel; PROFI - 1B – wear proof design (for abrasive liquids);

polyurethane liner, stainless steel electrodes, without protection rings; PROFI - 2A – corrosion resistant design (for aggressive liquids);

fluoroplastic liner, electrodes – from tantalum, titanium or other material (on request), without protection rings.

Functionality: PROFI - 1 – without display;

two general-purpose outputs; RS-485 serial interface, optional; control input, optional;

PROFI - 2 – two-line character display; two general-purpose outputs; RS-232 or RS-485 serial interface, optional; current output, optional; control input, optional;

PROFI - 3 – two-line character display on the BED; two general-purpose outputs (MB); two general-purpose outputs (BED); RS-232 or RS-485 (BED) serial interface, optional; current output (BED), optional; control input (MB), optional; control input (BED), optional.

1.4.5. Operating modes

1.4.5.1. The flowmeter operates in three modes: - "Adjustment": adjustment and calibration - "Service": start-up procedures - "Operation": user mode.

Flowmeter's operating modes are set by placing (removing) jump-ers on J5 and J6 terminals, which are located on the board of the MB processing module (see Fig.A.7 in Appendix A). Combinations of jump-ers with regard to operating modes are specified in Table 3 ("+" means

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that the terminal contacts are closed by a jumper, and "-" means that the terminal contacts are opened).

Table 3 Name

of the mode MB terminal pair Mode description J5 J6

Adjustment + – Adjustment and calibration Service – + Start-up procedures

Operation – – Operation BED is switched to "Service" mode when J5 terminal pair of the

BED processing module is closed (see Fig.A.9 in Appendix A), and to "Operation" mode when J5 terminal is opened.

1.4.5.2. In different operating modes the user can modify different device’s set-tings. The settings are reconfigured programmatically via RS-232 or RS-485 serial interface.

In the "Operation" mode, only the settings which have no effect on the flowmeter’s operation can be changed:

- Batch value in the batching mode - Communication settings via serial interface - Display settings.

In the "Service" mode, in addition to the above the operator can configure the following flowmeter’s operational settings:

- Flow cutoffs - Settings for general-purpose and current outputs and control input - Constant for the signal filter and settings for the Automatic flowrate

quick setup module. These setting determine flowmeter's time of re-sponse to the changes in flowrate. Table 4 illustrates how the response time depends on the filter constant for standard settings of the Auto-matic flowrate quick setup module.

Table 4

Filter Constant Response Time, s

Automatic Flowrate Quick Setup On Off

0 7 82 1 6 41 2 5 20 3 5 11 4 5 5 5 3 3 6 2 2 7 1 1

In the "Adjustment" mode, all settings may be changed. Adjustment during manufacture and after-calibration adjustment are made in this mode.

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Configuring the settings in the "Service" and "Operation" modes does not affect flowmeter’s metrological characteristics and may be performed on-site, if necessary. In the "Service" and "Operation" modes, adjustment and calibration settings are inaccessible.

1.4.6. External Connections and Displaying of Results 1.4.6.1. Displaying results

A two-line character LCD shows measurement results, some con-figuration settings and error messages. One or two parameters can be displayed simultaneously.

Measurement units and number of displayed digits are given in Table 5.

Table 5

Displayed Name of the parameter Units

Number of digits Notes integer part fractional

part

Q Average volumetric flow rate

l/min m3/h

Up to 7 Up to 7

Up to 5 Up to 6

Note 1

V Total Volume (cumulative)

l m3

Up to 11 Up to 8

- 3

Note 1 Note 2

V+ Totalized volume of forward flow

l m3

Up to 11 Up to 8

- 3

Note 2

V- Totalized volume of reverse flow

l m3

Up to 11 Up to 8

- 3

Note 1

T Time of totalizer operation hours hour:min

Up to 6 Up to 5 (h)

2 2 (min)

Batch value: Ve - set value l Up to 7 3 Vb - measured value l Up to 7 3

NOTES 1. Reverse flow flowrate and volume along with the negative values of to-

tal volume are indicated by negative sign. 2. Totalized volume is the algebraic (considering the sign of the flow) sum

of flow volumes totalized for both forward (positive) and reverse (nega-tive) flows. For unidirectional flowmeters, “Totalized volume” value equals “Totalized volume of forward flow” value.

Set batch value Ve and measured batch value Vb are displayed simultaneously and in the batching mode only. Flowrate value Q is dis-played alternately.

The set of displayed parameters, measurement units, display peri-od and flow cutoff value may be set at the factory on customer request or on site when putting the flowmeter into operation.

Display period is the time for one or two parameters to be dis-played in the automatic indication switching mode. This parameter can be configured from 1 to 100s (5s is a factory set value).

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It is possible to switch indication by applying the corresponding command to the control input. To do this, select Menu navigation item for the control input.

In case of alarm pipeline conditions or flowmeter’s fault, the display indicates an error message (see Fig. 5) in two lines: the upper line dis-plays error type numbers and the lower line indicates the error type.

Fig.5. Displaying error messages

The х sign below a number means that the error of the indicated type occurs, while sign - means no error. Error messages are inter-preted in section 2.5 of this document. The error message and meas-ured values will be alternately displayed in a specified period.

1.4.6.2. Control inputs The flowmeter can be equipped with up to 2 control inputs: one in-

put connected to MB and the other – to BED. Functions of the inputs are configurable and can be set programmatically:

- Start of batching – to start batching upon control signal - "Start-stop" mode – to start and stop batching upon control signal - Volume reset – setting the totalizer to zero - Menu navigation – to switch over indication upon control signal.

To configure each control input when the flowmeter is equipped with BED it is necessary to connect a PC to the MB and BED interface inputs separately. Control input circuit diagram and control signal char-acteristics are given in Appendix B.

1.4.6.3. Universal outputs The flowmeter may have up to four galvanically isolated outputs:

N1 and N2 on MB and N1 and N2 on BED. These outputs are versatile both with regard to operating mode (frequency, pulse or logical) and function.

Operating mode, function and parameters of the outputs are con-figured at the factory (if ordered) or on site during commissioning.

To configure each control input when the flowmeter is equipped with BED it is necessary to connect a PC to the MB and BED interface inputs separately.

Circuit diagrams of output stages and description of their operation modes are specified in Appendix B.

When working in the pulse and frequency modes, the outputs can be used to output measurement results in the form of square pulse se-quence with period-to-pulse duration ratio of 2 and standardized pulse weight. The maximum pulse repetition rate is 2000Hz.

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Output scaling constant Kр (pulse/l) that defines the pulse weight may be set within the range from 0.0001 to 200 000 (with minimal in-crement of 0.0001).

To determine Kp having regard to the maximal flow rate in the pipe-line where the flowmeter is installed and frequency characteristics of the input receiving the pulse signal, the following formula may be used:

( )pmax

3

maxp Q

10×1.8=

Q3.6F

≤p/lКτ

, (4)

Qmax – maximum operational flow rate in the pipeline, m3/h F – maximum flowmeter’s pulse repetition rate permissible for a receiving

input, Hz

p = 2Tp – minimum flowmeter’s pulse duration permissible for a receiving

input, ms Тp – pulse repetition period for the pulses on the flowmeter's output, ms.

The default mode for N1 output is the frequency mode, and the de-fault Kр values are specified in Table 6 which correspond to a frequen-cy of 1500Hz at Qmax flow rate.

Table 6

DN, mm 10 15 20 25 32 40 50 65 80 100 150 200 300 Кp, p/l 1600 700 400 250 160 100 65 40 25 15 7 4 1.7

In the frequency mode, frequency is proportional to average volumetric flow rate measured over previous 80ms.

For the frequency mode, Kр, Maximal frequency and Alarm fre-quency parameters are configured.

Maximum frequency is the frequency of output signal correspond-ing to the maximum flow rate in the pipeline. Exceeding maximum fre-quency of output signal is identified by the flowmeter as an alarm con-dition, i.e. the value of Кp set for this output is incorrect.

Emergency frequency is the pulse repetition rate of a pulse se-quence (no more than 2000Hz) generated on the output if the meas-ured flow rate exceeds Qmax for a given DN. The value set for the Alarm frequency must be no less than the Maximum frequency value for this output. To disable the Alarm frequency function, set the Alarm fre-quency parameter to 0.

To set the function for the output, select Flow rate in absolute value, Forward flow rate or Reverse flow rate option.

Flow rate in absolute value – a pulse sequence with pulse repeti-tion rate proportional to the measured flow rate is generated on the output regardless of flow direction. Forward flow rate – the pulse se-quence is only generated for forward flow. Reverse flow – the pulse sequence is only generated for reverse flow.

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In the pulse mode, a burst of pulses is generated on the output within a second, in which the number of pulses (considering pulse weight Кp) corresponds to the flow volume measured over a previous second. Maximum pulse repetition rate in the burst (square pulse sequence with period-to-pulse duration ratio of 2) is 500Hz.

To set the function for the output in pulse mode, select Volume in absolute value, Forward volume or Reverse volume option. Batcher pulse option means that a pulse is generated on the output at the end of batching.

In the logic mode, one signal level corresponds to ”event” (or its state), and the other level corresponds to “no event” (or another state).

For the logical mode, Active level i.e. High or Low signal level is set programmatically when the event is present. Electrical parameters of corresponding signal levels are specified in Appendix B.

To set the function for the logical output, the following options may be selected:

- Flow direction – signal level on the output is changed without lag on changing flow direction

- Error Q>Qmax – Signal level on the output is changed if the actual value of flow rate exceeds Qmax for a given DN

- Any Error – Signal level on the output is changed in case of any alarm situation detected by the flowmeter

- Batcher relay – signal level on the output is changed at the end of batching

- Flow direction for heat metering – signal level on the output is changed only if the period of changing flow direction exceeds the pre-set lag. Тlag may be set from 0 to 60min

- Power Supply flag – High signal level is generated in the presence of power, in case of power supply failure there is no signal on the output.

CAUTION! If the current output is configured for operation, gen-eral-purpose output N2 is used to control the current output and cannot be used for its intended purpose.

1.4.6.4. Current output The flowmeter's current output can operate in one of three ranges:

0-5mA, 0-20mA or 4-20mA. The standard curve of a current output is calculated as follows:

outmax

minoutltutlt I-I

I-I)Q-(Q+Q=Q , (5)

Q – measured flow rate, m3/h Qut – specified low setpoint for the current output corresponding to Imin, m3/h Qlt – specified high setpoint for the current output corresponding to Imax,

m3/h

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Iout – value of output current signal corresponding to the measured flow rate, mA

Imax – maximum operating range for the current output (5 or 20), mA Imin – minimum operating range for the current output (0 or 4), mA.

The current output is configured by setting the operating range, setpoints and function. Flow rate in absolute value – current propor-tional to the measured flow rate is generated on the output regardless of flow direction. Direct flow rate – current is generated for direct flow. Reverse flow rate – current is generated for reverse flow only.

Parameters of the current output and circuit diagram are given in Appendix B.

CAUTION! To enable the MU current output, set the active mode for the general-purpose N2 output stage by placing jumpers on J4 and J2 terminals of the processor module. In this case, general-purpose output N2 cannot be used.

1.4.6.5. Serial interface The serial interface is used to transfer measurement and configu-

ration data and modify configuration parameters, if accessible. If MB is equipped with the display module or BED is available, the

flowmeter is equipped with RS-232 or RS-485 serial interface modules. If the display module is not installed, MB may be equipped with an ad-ditional RS-485 module.

The RS-232 and RS-485 interfaces support ModBus protocol (RTU ModBus and ASCII ModBus).

In case there is no built-in RS-232 interface, the flowmeter can be configured with use of the optional external RS-232 adaptor supplied optionally and connected to the MB or/ and DU processing module. RS-232 adaptor connection is described in the Installation manual.

The built-in RS-232 interface module may be used for connection to a PC via:

- Cable (maximum cable length is 15m) - Phone line (telephone modem) - Wireless channel (wireless modem).

Communication distance via phone and wireless communications channel is determined by characteristics of the channel.

The RS-485 interface module provides cable communication be-tween several stations (one may be a PC) with maximum cable length of 1200m.

The data transfer rates via RS-232 and RS-485 interfaces (from 1200 to 19200baud) as well as communication properties are set from a PC.

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1.5. Marking and sealing 1.5.1. MB and BED front panels of the MF bear:

- Name and identification - Manufacturer’s trademark - Sign of the Type Approval Certificate - Design version - MF standard size; - Power supply voltage.

Serial numbers are on the nameplates located on MB and BED cases. Power cable glands on the MB and BED cases are marked as "24VDC".

1.5.2. After flowmeter calibration J5 (MB) terminal is sealed to disable the possibility of changing calibration settings.

1.5.3. J6 (MB) and J5 (BED) terminals enabling configuration of service set-tings shall be sealed after putting the flowmeter into operation.

In addition, to protect the device from unauthorized access during transportation, storage or operation, you may hang seals on two fixing screws on the cover of the MB metal case or seal a recess of one fixing screw of the MB plastic case. One fixing screw on the cover of the BED may be sealed in a recess.

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2. OPERATION

2.1. Operating restrictions 2.1.1. Environmental restrictions with regard to the factors affecting the per-

formance and characteristics of the controlled medium shall comply with the requirements specified in the operating documentation.

2.1.2. The MF may be mounted into the pipeline installed horizontally, verti-cally or obliquely. Special filters or dirt traps are not needed.

2.1.3. For precision and reliable operation, when choosing PCF mounting lo-cation, the following conditions must be met:

- No air accumulation in the mounting location - Liquid pressure in the pipeline must not be of values that may facilitate

gas release - Straight pipe runs of appropriate length and DN equal to DN of the PCF

must be provided upstream and downstream the flow sensor (PCF). These runs must not include devices or components that may disturb flow structure

- When the Device is operated, PCF inner channel must be fully filled with liquid

- Intensity of external magnetic field (commercial frequency) should not exceed 40A/m.

CAUTION! DO NOT touch the electrodes in the PCF inner channel at any time when working with the flow meter.

Mounting considerations, mounting and dismounting instructions, description of AFLOWT KPA fitting assembly are given in the Installa-tion Manual.

CAUTION! If PCF is covered with fluoroplastic and the protection rings are removed, DO NOT remove the tightening stud (bolt) and clamping plates from the flow sensor for more than 10 minutes.

2.1.4. Type and composition of controlled medium (presence and concentra-tion of suspensions, impurity substances, etc.), operating mode and pipeline conditions must not lead to sedimentation affecting perfor-mance and metrological characteristics of the flowmeter.

To provide proper operation of the flowmeter in pipelines equipped with carbon filters, it is necessary to keep the filters in good condition.

2.1.5. Grounding system is necessary according to the requirements of RF Electrical Code, Chapter 1.7 depending on power supply voltage and environment conditions.

2.1.6. Lightning protection system for the site where the flowmeter is located (in compliance with "Guidelines on lightning protection of buildings, constructions and industrial pipelines" SO153-34.21.122-2003 ap-proved by administrative order of RF Ministry of Energy N280 dated

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30.06.2003) protects the device against failures caused by lightning strokes.

2.1.7. Requirements for mounting location and operating conditions specified in this operating documentation are based on the most typical factors affecting Device's performance.

The external factors that cannot be foreseen, evaluated or tested by the manufacturer during designing may exist or appear on site.

In this case, it is necessary to eliminate these factors or place the flowmeter in other location where they are not present or do not affect the MF operation.

2.2. Selecting standard size 2.2.1. Flowmeter’s standard size is selected on the basis of flow rate range in

the pipeline where PCF is installed. If several sizes are suitable, the standard size is selected from the specified limit of pressure losses.

2.2.2. If the selected DN is less than DN of the pipeline where PCF is ex-pected to be installed, you may use pipe reducers (confusor and diffu-sor).

2.2.3. To evaluate hydraulic losses in the confusor-FS-diffusor system shown in Fig. 6 use the following method.

2.2.3.1. The initial values for evaluation of the hydraulic losses: - Liquid volumetric flow rate in the pipeline - Q (m3/h); - DN of the inlet pipeline - D1 (mm); - DN of the PCF - D2 (mm); - DN of the outlet pipeline - D3 (mm); - Confusor taper angle - 1 (deg.); - Diffusor taper angle - 3 (deg.); - Length of the straight pipe run - / (mm).

1 – confusor; 2 – full bore spherical valve; 3 – PCF; 4 – diffusor.

Fig.6. Pipeline at PCF mounting location

2.2.3.2. According to superposition principle, total pressure losses in the confusor-PCF-diffusor system hh are the sum of pressure losses in the confusor hh1, losses in the straight pipe run (having length l) hh2, and losses in diffusor hh3.

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Hydraulic losses in the confusor are determined according to Graph 7a (V2 is the flow velocity in the straight pipe run). The Graph of hydraulic losses as a function of flow velocity is calculated for confusor taper angle 1= 20. To determine flow velocity by volumetric flow rate Q use Graph 8 or the formula:

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3

10×)mm(DN××9.0

)h/m(Q=)s/m(v

π (6)

To determine hydraulic losses in the straight pipe run, Graph 7b is used. The Graph of the hydraulic losses as a function of flow velocity corresponds to straight pipe run length-to-diameter ratio 15; 20; 25 and 30.

To determine hydraulic losses in the diffusor, Graph 7c is used. The Graph of hydraulic losses as a function of flow velocity is calculat-ed for diffusor taper angle 3 = 20° and corresponds to diffusor’s maxi-mal-to-minimal diameter 2.0; 2.5; 3.5 and 4.0.

NOTE. Specialized software for accurate calculation of hydraulic losses in the confusor-PCF-diffusor system can be provided on re-quest.

a)

b)

c)

Fig.7. Graphs of hydraulic losses in confusor (a), straight pipe run (b) and

diffusor (c)

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Fig.8. Graph of flow rate vs flow velocity for various DNs

2.3. Preparing for operation 2.3.1. Safety instructions

2.3.1.1. The flowmeter should only be used by personnel familiar with all opera-tional documentation for the product.

2.3.1.2. When putting the product into operation and during operation, "Rules for Operating Electrical Systems By Consumers" and "Safety Rules For Operating of Electrical Systems" must be observed.

2.3.1.3. When working with the flowmeter, the dangerous factors are as follows: - AC voltage (RMS value up to 264V, frequency 50Hz) - Pipeline pressure (up to 2.5MPa) - Medium temperature (up to 150°С) - Other installation site-specific factors.

2.3.1.4. Do not use the flowmeter in the pipelines with pressure exceeding 2.5MPa.

2.3.1.5. On detecting external defects on the device or damages to mains ca-bling, you must remove power from the device and contact the author-ized technician for the information about the device's operability.

2.3.1.6. In the course of mounting, start-up or repair works you must not: - Make electrical connections to the flowmeter, switch over modes and

replace electronic components when the flowmeter is powered up - Remove the flowmeter from the pipeline until pressure in the pipeline

section worked on is fully released - Use defective electronic devices and electric tools or use them without

proper grounding (neutral earthing). 2.3.2. When putting the flowmeter into operation check the following:

- The flow is in the direction of the arrow on the flowmeter's body - Lengths of the inlet and outlet straight pipe runs correspond to flow di-

rection

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- The flowmeter and related equipment are connected in accordance with the selected wiring diagram

- The outputs correctly operate in the preset modes - Power supply voltage corresponds to the specifications.

2.3.3. At first power-up or after a long break in operation, the flowmeter is op-erational after:

- All hydraulic processes in the pipeline related to changes of flow rate (draining, filling, flow adjustment etc.) are fully terminated

- PCF is washed by medium for 30 minutes - The flowmeter is kept powered for 30 minutes.

2.3.4. Seal the flowmeter and bypass gate (if installed) before putting into op-eration.

2.4. Operation procedure 2.4.1. After putting into operation the flowmeter works in automatic mode.

Measurement results and flowmeter’s working status is read from the display (indication may be switched from automatic to command modes), general-purpose and current outputs or via RS-232 or RS-485 serial interfaces.

2.4.2. Batching may be set in two ways: batching a doze or start-stop batch-ing.

To batch a dose, you should enter the dose value to the flowmeter. Batching starts when the first signal comes from the control unit or when Start Batching command comes via the serial interface, and stops automatically when the specified dose is filled.

In the start-stop mode batching starts when the first signal comes to the control input or Start Batching command comes via the serial in-terface, and stops when the second signal comes to the control input or when Stop Batching command comes via the serial interface. To set the flowmeter for work in the start-stop mode, the dose value must be set to zero.

During the batching process, the set and measured dose values are displayed. Pulse and/ or logical signal applied to the actuator may be generated on general purpose outputs when batching is completed.

2.4.3. The flowmeter enables you to set cutoffs (thresholds) for flowrate measurement: Up Flow Cutoff, Down Flow Cutoff and Indicator Cutoff.

The Up Flow Cutoff and Down Flow Cutoff are the flowrate thresholds below which (on increasing or decreasing the flowrate value respectively) totalizing, pulse generating and outputting of current sig-nal are stopped. The flowrate value is displayed as zero.

Indicator Cutoff is the flowrate threshold below which the flowrate value is displayed as zero, however totalizing, pulse generating and outputting of current signal continue.

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Values for all cutoffs may be set from 0 to 0.255Qmax in the incre-ment of 0.001Qmax. The factory setting is 0.002Qmax.

For the reverse (bidirectional) flow, the cutoffs trigger both for posi-tive and for negative flow directions. The flow direction signal also changes according to the preset cutoffs.

2.4.4. The Flowrate signal filter and Automatic flowrate setup module may be included in signal processing. Filter constant and parameters of the Au-tomatic flowrate setup module determine flowmeter’s time of response to changes in flowrate.

By default, the value of filter constant is factory set to 0, and the Automatic flowrate setup module is enabled with standard values of the parameters (see table 4).

2.5. Troubleshooting 2.5.1. The list of possible faults and alarm conditions detectable by the

flowmeter and indicated by <х> in the corresponding place of the status word (error message) is given in Table 7.

Table 7 Position number Explanation

7 Device not initialized 6 Measuring equipment failure 5 Flowrate exceeds Qmax 4 Repeated error during measuring 3 Value of Kp on the output N2 not correct 2 Value of Kp on the output N1 not correct 1 Single error during measuring 0 Flowrate value is outside the setpoints set for the current output

2.5.2. If <х> is displayed in position 6 or 7, the flowmeter shall be forwarded to the manufacturer for repair.

2.5.3. If <х> is displayed in other positions and/or no measurement data is displayed, check the following:

- Flow meter and secondary power source input voltage is present and conforms to the specifications

- Power circuits are reliably connected - Liquid is present and running through the pipeline - Air is not accumulated in the flowmeter’s location - Kp and flowrate cutoff values are correct (change if necessary).

If all the requirements listed above are met, contact the service centre (regional dealer) or manufacturer for the information about the device’s operability.

2.5.4. "AFLOWT MF" Flowmeter should be repaired by authorized dealers or by the manufacturer.

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3. MAINTENANCE

3.1. Maintenance check 3.1.1. After the flowmeter is put into operation it is recommended to check on

regular basis that: - Performance complies with the specifications - Operating conditions are met - Power supply voltage is present - No damages to external parts are detected - Electrical and mechanical parts are reliably connected.

Check periods depend on operating conditions but should not ex-ceed two weeks.

3.1.2. If operating conditions specified in section 1.2.3 are not observed, the flowmeter may fail to operate, or the permissible limits of relative measurement error may be exceeded.

External damages may also lead to deterioration in measurement accuracy. Therefore, when the above-specified external damages are detected, contact the Service Center or regional dealer for the infor-mation about device’s operability.

3.1.3. During the device’s lifecycle, it is necessary to check the PCF inner channel for dirt and/or sediment at least once a year. Thin layer of sed-iment that can be removed with a soft damp cloth is permissible.

If dirt and/or sediment of other type or in considerable amount are detected, it is necessary to clean the surface of PCF and send the flowmeter for unscheduled calibration.

In this case, it is recommended to clean the flow sensor immediate-ly after removing it from the pipeline with a clean moistened cloth and non-abrasive detergent.

3.1.4. Before dispatching the flowmeter for calibration or repair, clean the PCF inner channel from sediment and liquid residues after dismounting. Rests of aggressive liquid must be neutralized.

Mounting and dismounting of the flowmeter is regulated by the In-struction on installation.

When the flowmeter is sent for service, the Equipment Certificate must be enclosed. Please specify post details, phone/fax numbers along with the way and address for redispatching.

3.2. Calibration "AFLOWT MF" flowmeter shall undergo primary post-manufacture

calibration and calibration after each repair, and then regular calibra-tion shall be performed during operation.

Calibration interval is 4 years.

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4. PACKING, STORAGE AND TRANSPORTATION 4.1. The flowmeter is transported packed according to Table 2 (operating

documentation included) in the package of KU-2 packaging category (as per GOST 23170).

The set of fittings is delivered as an assembly or in bulk in a sepa-rate box.

4.2. The flowmeter should be kept in manufacturer's box in accordance with the requirements of GOST 15150, Group 1. The storeroom should be free from current-conductive dust, acid or alkali fumes and aggressive gases.

During storage the flowmeter does not require any special mainte-nance.

4.3. The flowmeters can be transported by road, rail, sea or air provided that the following requirements are met:

- Flowmeter is packed in the manufacture’s box - Protection against moisture is provided - Temperature is within the range of −30 to 50°С - Humidity does not exceed 98% at 35°С - Vibration is within the range of 10-500Hz with maximum 0.35mm ampli-

tude or 49m/s2 acceleration - Impact acceleration does not exceed 98m/s2 - Flowmeters are fixed to prevent damages.

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APPENDIX А. View of components

* - reference dimension 1 – display (if applicable); 2 – measuring block; 3 – flow sensor; 4 – protection

rings; 5 – signal cable gland; 6 – power supply cable gland; 7 – wires for connecting MF case and pipeline; 8 – electrodes.

Fig.A.1. View of PROFI-212, -212А flowmeters (with protection rings)

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* - reference dimension 1 – measuring block; 2 – signal cable gland; 3 – power supply cable gland;

4 – wires for connecting MF case and pipeline;

Fig.A.2. View of Measuring Block in metal case, PROFI-1хх, -1ххА, -1ххB, -

3хх, -3ххА, -3ххB flowmeters

Fig.A.3. View of PCF of PROFI-, -А, -B flowmeters without protec-tion rings

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Table A.1. Overall dimensions and weight of PROFI-1, -1А, -1B flowmeters, DN10…DN150 standard sizes

DN, mm D*, mm d*, mm L*, mm H*,

maximum, mm

Weight, maximum,

kg With protection

rings Without protection

rings 10 34 60 93 85 185 1.3 15 39 60 93 85 185 1.3 20 50 73 113 106 198 1.9 25 58 73 113 106 198 1.9 32 65 83 123 116 208 2.3 40 75 89 133 126 214 2.7 50 87 102 153 147 227 3.5 65 109 121 174 167 245 4.8 80 120 140 174 167 265 5.9

100 149 159 214 208 284 9.6 150 202 219 233 228 344 15.8

* - reference dimension

* - reference dimension 1 – display; 2 – measuring block; 3 – bracket for 35/7.5 DIN rack mounting;

4 – power supply cable gland; 5 – signal cable gland.

Fig.A.4. View of Block of the External Display, PROFI-3, -3А, -3B flowmeters

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* - reference dimension 1 – display (if applicable); 2 – measuring block; 3 – flow sensor; 4 – signal cable

gland; 5 – power cable gland; 6 – wires for connecting MF case and pipeline; 7 – elec-trodes.

Fig.A.5. View of PROFI-22, -22А, -22B flowmeters (DN25…DN150)

Table A.2. Overall dimensions and weight of PROFI-2, -2А, -2B flowmeters, DN10…DN150 standard sizes

DN, mm D*, mm D1*, mm L*, mm H*, maximum, mm Weight, maximum, kg 25 58 115 150 217 4.1 32 65 135 194 233 5.8 40 75 145 194 241 7.0 50 87 160 195 255 8.9 65 109 180 212 275 11.4 80 120 195 222 292 14.1

100 149 230 244 320 20.0 150 202 300 316 384 36.4 * - reference dimension

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* - reference dimension 1 – display (if applicable); 2 – measuring block; 3 – flow sensor; 4 – protection

rings; 5 – signal cable gland; 6 – power supply cable gland; 7 – wires for connecting MF case and pipeline; 8 – electrodes; 9 – ring bolts for flowmeter installation on the pipeline by means of the elevating mechanism.

Fig.A.6. View of PROFI-22, -22А, -22B flowmeters (DN200, DN300)

Table A.3. Overall dimensions and weight of PROFI-2, -2А, -2B flowmeters, DN200, 300 standard sizes

DN, mm D*, mm D1*, mm L*, mm H*, maximum, mm Weight, maximum, kg

200 257 358 362 440 59.0 300 360 485 514 557 121.0 * - reference dimension

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а) PROFI-2, -2А, -2B models

1 – RS-485 module; 2 – RS-485 terminal block; 3 – production terminal block.

б) PROFI-1, -3 models, with RS-485 module

ХР1 – connector for display module, RS-485 module or RS-232 adaptor cables; XS1 – DC 24 V power supply connector; ХТ2 – terminal block of general-purpose output N1; ХТ3 – terminal block of general-purpose output N2; ХТ4 – terminal block of control Input; J1, J3 – terminals used to set operation mode for output stage of general-purpose output N1; J2, J4 – terminals used to set operation mode for output stage of general-purpose output N2; J5 – terminal used to enable modification of calibration settings; J6 – terminal used to enable modification of service settings; ХР2, ХТ1, ХТ5 – service terminal blocks; Fig.A.7. View of Measuring Block with cover removed (view of processor

module)

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1 – flexible flat cable for connection to processor module; ХР1 – terminal block for connecting flexible flat cable to processor module; ХР2 – connector for power cable of display backlight; ХР3 – connector for RS-232 or RS-485 serial interfaces (for RS-485, pins are specified in brackets); ХР4 – current output connector. Fig.A.8. View of MB and BED display module

XP1 – DC 24 V power supply connector; ХР2 – RS-485 terminal block for connecting signal cable to MB; ХР6 – connector for connecting flexible flat cable of display module; ХP7 – terminal block of general-purpose output N1; ХP8 – terminal block of general-purpose output N2; ХP9 – terminal block of control input; J5 – terminal used to enable modification of service settings; J8, J9 – terminals used to set operation mode for control input; J10, J11 – terminals used to set operation mode for output stage, general-purpose output N1; J12, J13 – terminals used to set operation mode for output stage, general-purpose output N2; ХР5 – service terminal block; J6, J7 – service terminals.

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Fig.A.9. View of Block of External Display with cover removed (view of proces-sor module)

* - reference dimension 1 – power source; 2 – bracket for 35/7.5 DIN rack mounting; 3 – terminal block

for DC 24V output voltage; 4 – Secondary Power Source indicator; 5 – contact hole for adjustment of output voltage; 6 – terminal block for connection to mains (AC 220V, 50Hz). Fig.A.10. Secondary Power Source ADN-1524

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APPENDIX B. Wiring diagrams 1. General-purpose outputs

To match output stages to inputs of different types, the output stages (Fig.B.1) are designed to work with either the internal galvanically isolated power source (active mode) or an external power source (passive mode). In standard supply configuration the output stages are in the passive mode.

Fig.B.1. Universal outputs, circuit diagram of output stages

To connect the output stage to the internal power source +5V, it is necessary to use jumpers between the terminal blocks located on the board of the MB and BED processor module (Table B.1).

Table B.1. General-purpose outputs, connection components of output stages

Name Output Terminals Terminal blocks

MB Output 1 J3 J1 XT2/1 (TSOUT+) XT2/2 (TSOUT+) Output 2 J4 J2 XT3/1 (DIR+) XT3/2 (DIR-)

BED Output 1 J10 J11 XP7/1 (TSOUT1+) XP7/2 (TSOUT1-) Output 2 J12 J13 XP8/1 (TSOUT2+) XP8/2 (TSOUT2-)

In the active mode, in case of no pulse or at logic High, output voltage is 2.4...5.0V. In the presence of pulse or at logic Low, output voltage is maximum 0.4V. External load resistance shall be of 1kOhm as a minimum.

In the passive mode, power from an external power source with output DC voltage from 5 to10V can be applied. Permissible value of external load current is no more than 10mA. The output stages can be powered from an external DC power source with voltage of up to 24V. Amplitude of output pulses is limited by suppressor's triggering voltage at 15V level.

For the universal outputs, length of signal cables should be up to 300m.

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2. Current output The MB and BED current output can be connected to an external

load of up to 800Ohm in (0-20)mA or (4-20)mA operating ranges or up to 2.5kOhm in (0-5)mA operating range.

Permissible length of a signal cable connected to the current out-put depends on resistance of the corresponding signal circuit. The condition is that the sum of input resistance of a connected input and signal circuit resistance must not exceed the above-specified external load resistance.

The current output is powered from the flowmeter's secondary power source (Fig.B.2). The secondary power source is connected in parallel with the flowmeter's power input on the MB and BED processor module's boards respectively.

Galvanic isolation of the current output is provided by applying (24±1.2) DC voltage from the external power source.

Fig.B.2. Current output terminal block ХР4 on the board of MB and BED dis-

play module

CAUTION! To enable the MB current output, set the active mode for the general-purpose N2 output stage by placing jumpers on J4 and J2 terminals of the processor module.

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3. MB Control Input Circuit diagram for the MB control input is given in Fig.B.3.

Fig.B.3. Circuit diagram for MB input stage

As a control signal for ХТ4/2-ХТ4/1 circuit, (0.5-20)mA current pulse signal is used.

If control signal is not applied, current in the circuit must not ex-ceed 0.2mA.

Control signal may also be generated on closing ХТ4/3 and ХТ4/2 contacts (e.g. by pressing a button) under condition that external circuit resistance is no more than 100Ohm.

Galvanic isolation of input circuit is provided in both cases.

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4. BED Control Input BED input stage (Fig.B.4) are designed to work with either the in-

ternal galvanically isolated power source (active mode) or an external power source (passive mode). In standard supply configuration input stage is in the active mode.

Fig.B.4. Circuit diagram for BED input stage

In the active mode, the input stages are connected to the internal power source +5V.

To connect the output stage to the internal power source +5V, it is necessary to use jumpers between J8 and J9 the terminals located on the board of the BED processor module.

Control signal may be generated on closing ХР9/1 and ХР9/2 con-tacts (e.g. by pressing a button) under condition that external circuit re-sistance is no more than 100Ohm.

In the passive mode, powering from an external power source (DC 5...24V) is allowed. The power is applied via an external resistor providing current in the range of 8.0...20mA in ХР9/1-ХР9/2 circuit. Thus, resistance of the external resistor shall be at least 100Ohm at +5V power voltage, +24V power voltage requires an external resistor of no less than 800Ohm.

If control signal is not applied, current in the circuit must not ex-ceed 0.2mA.

re_mf_PROFI_2_eng.doc