Flow vision FC100 - CA Manuale utente

Flow Meter | FC100 - CA

USER MANUAL

M_FC100-CA_1121_e

GMBH

Flow Meter | FC100-CA

Equipment installation, connection and adjustment by qualiﬁed personnel only!

Important:

Please follow these instructions carefully. Failure to comply, or misuse of this equipment, could result

in serious damage both to the equipment itself and to the installation. FlowVision is unable to accept

responsibility for customer or third party liability, warranty claims or damage caused by incorrect

installation or improper handling resulting form non-observance of these instructions. All dimensions

are for reference only. In the interest of improved design, performance and cost-effectiveness the right

to make changes in these speciﬁcations without notice is reserved. Errors and omissions excepted.

The instructions cover ﬁrmware version 1.10.

FC100-CA | Flow Meter

GMBH

TABLE OF CONTENTS

Table of Contents

1 Description ..................................................... 6

1.1 Measuring procedure......................................................6

1.1.1 Calorimetric measuring procedure.....................................6

1.1.2 Physical principles of gas measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.1.3 Standard and operating volume ﬂow ...................................7

1.1.4 Measurements in compressed-air systems ..............................8

1.1.4.1 Consumption measurements .................................8

1.1.4.2 Leakage measurements .....................................8

1.2 System description........................................................9

1.2.1 User interfaces ...................................................10

2 Installation......................................................12

2.1 Installation of calorimetric monitoring heads...................................12

2.1.1 Selection of material...............................................12

2.1.2 Mechanical installation .............................................13

2.1.2.1 Thread-mounted monitoring head CST-11 ......................13

2.1.2.2 Insertion head CSP for sensor adapter TP- … or ball valve BV- … . . 14

2.1.2.3 Sensor adapter TP- … .....................................15

2.1.2.4 Ball valve BV- … ..........................................16

2.1.2.5 Push-in monitoring head CSF-11AM1/CSF-11AM2 ............... 17

2.1.3 Mounting instructions for monitoring head CST .........................18

2.1.3.1 Depth of immersion .......................................18

2.1.4

Mounting instructions for monitoring head CSP with sensor adapter TP or ball valve BV

2.1.5 Mounting instructions for push-in monitoring head CSF ...................19

2.1.5.1 Standard velocity proﬁles: ..................................21

2.1.6 Point of installation and steadying zones ..............................22

2.1.7 Condensate deposits ..............................................23

2.1.8 Electrical connection ..............................................23

2.2 Installation of electronic control unit FC100-CA ................................24

2.2.1 Mechanical installation .............................................24

2.2.1.1 Rail-mounted version FC100-CA-U1... (see ﬁg. 15) . . . . . . . . . . . . . . . 24

2.2.1.2 Surface mounted version FC100-CA-FH-U1... (see ﬁg. 16) .........25

2.2.2 Electrical connection ..............................................26

2.2.2.1 Circuit diagram FC100-CA (relay outputs) ......................29

2.2.2.2 Circuit diagram FC100-CA (transistor outputs (NPN)) .............30

2.2.2.3 Electrical connection - pulse output (version FC100-CA-U1T4…)....31

2.2.2.4 Electrical connection - totalizer reset..........................33

Flow Meter | FC100-CA

GMBH

TABLE OF CONTENTS

3 Operating system ................................................34

4 Operation and main menu ........................................ 36

4.1 Switch-on performance ...................................................36

4.2 Measuring cycle.........................................................36

4.3 Measuring Operation .....................................................37

4.3.1 Peak values......................................................38

4.3.2 Limit switches ......................................................40

4.3.3 Conﬁguration.......................................................40

4.3.4 Information ........................................................40

4.3.5 Low ﬂow suppression and zero alignment..............................41

4.3.6 Last error .......................................................42

5 Conﬁguration .................................................. 43

5.1 Language select.........................................................44

5.2 Sensor select ...........................................................45

5.3 Pipe size ...............................................................46

5.4 Gas selection ...........................................................47

5.5 Pressure range..........................................................48

5.6 Operating mode .........................................................49

5.7 Physical units ...........................................................50

5.8 Display select ...........................................................51

5.9 User outputs............................................................52

5.9.1 Analogue output – ﬂow velocity ......................................53

5.9.2 Analogue output – medium temperature ...............................53

5.10 Limit switches...........................................................54

5.10.1 Limit switches – switch-on/switch-off value .............................55

5.11 Pulse output for totalizer (frequency output) ...................................56

5.12 Measuring time..........................................................57

5.13 Scaling factor (ﬂowscale)..................................................57

5.13 Quitting the conﬁguration menu.............................................58

6 Errors ......................................................... 59

6.1 Test and diagnosis .......................................................59

6.1.1 Priority group I ...................................................59

6.1.2 Priority group II ...................................................59

6.1.3 Priority group III ..................................................59

6.2 Potential errors..........................................................60

FC100-CA | Flow Meter

GMBH

TABLE OF CONTENTS

7 Technical data .................................................. 62

7.1 Ambient conditions.......................................................62

7.2 Electrical characteristics ..................................................62

7.3 Analogue outputs ........................................................63

7.3.1 Voltage output V1 - 5 V FS..........................................64

7.3.2 Voltage output V2 - 10 V FS ........................................64

7.3.3 Current output C1 - 20 mA FS .......................................64

7.4 Signal outputs ..........................................................65

7.4.1 Relay outputs R2 (DC or AC) ........................................65

7.4.2 Transistor outputs (DC).............................................66

7.5 Metrological data .......................................................67

7.5.1 Flow rate measurement ............................................67

7.5.1.1 Monitoring head CSP with sensor adapter type TP-….............67

Flow measurement ranges:..........................................67

7.5.1.2 Monitoring heads CST and CSF-… ...........................68

7.5.2 Temperature measurement ..........................................68

7.5.3 Electronic control unit FC100-CA.....................................69

7.6 Sensor interface ........................................................69

Electrical data of the terminal for calorimetric monitoring heads ...................69

7.7 Maintenance............................................................70

8 Accessories.................................................... 70

Appendix ..........................................................71

Appendix 1 - Performance of the digital and analogue outputs during the operating and

error modes......................................................71

Appendix 2 - Menu structure of the FC100-CA .....................................72

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Flow Meter | FC100-CA

DESCRIPTION

1 Description

Flow Meter FC100-CA is suitable for compressed-air and other gas ﬂow measurements under

various pressure conditions. It operates on the calorimetric principle and is to be used together with

monitoring heads CSx-...

These quantities are made available to the user as analogue electrical signals, physically isolated, as

current or voltage output and may be monitored by means of a limit monitor.

As relay outputs or transistor outputs the digital signals enable the user to integrate the FC100-CA

into a control and monitoring system.

The transistor outputs enable the user to additionally process fault, status and volume pulse indi-

cations in the control system.

A RS232 interface enables communication with FC100-CA.

1.1 Measuring procedure

1.1.1 Calorimetric measuring procedure

The calorimetric measuring procedure is based on the physics of heat dissipation, i.e. a body with a

temperature higher than its surroundings supplies a medium ﬂowing past that body with energy in the

form of heat. The amount energy supplied is a function of temperature difference ∆ϑ and mass ﬂow.

Flow Meter FC100-CA operates on the CTD (Constant-Temperature-Difference) method:

The temperature difference ∆ϑ between the two sensors is kept constant and the mass ﬂow is deter-

mined by measuring the caloriﬁc power.

Fig. 1 is a schematic diagram of a CTD method based sensor. Two temperature-sensitive resistors

(sensor elements RS and RM) are immersed in the medium. Sensor RM assumes the temperature of

the medium ϑM whilst heater resistor RH heats element RS to temperature ϑS. As a function of the

medium, the temperature differential ∆ϑ = ϑS - ϑM is preselected as a reference variable by the

CTD control and is kept constant. The required caloriﬁc power is a function of mass ﬂow so that the

control variable y of the control can be used for evaluation.

−

-x xd

Kp,Tn

m: mass flow

w: reference variable ()

x: actual value ( S-M)

xd: system deviation

y:control variable

IH: heater current

control loop

medium

Δϑ

ϑ ϑ fig. 1

GMBH

FC100-CA | Flow Meter

DESCRIPTION

Major beneﬁts of this method are:

• Fast response, particularly in the event of a sudden complete ﬂow stoppage.

• Medium temperature measurement, providing optimal temperature compensation.

• Increased safety because the sensor cannot be overheated during ﬂow standstill.

The ﬂow velocity is determined by mass ﬂow.

1.1.2 Physical principles of gas measurement

With the exception of Coriolis meters and calorimetric ﬂow meters, ﬂow meters used for gas meas-

urement are pure volume ﬂow meters that require density ρ to determine mass ﬂow Q from the

measured volume ﬂow V:

Q = V x ρ

Coriolis meters are used for higher mass ﬂow quantities and higher densities only, where density

is directly proportional to pressure and inversely proportional to temperature (related to absolute

Kelvin scale).

The quantity required in general practice is mass ﬂow as it indicates the exact gas quantity,

whereas volume ﬂow only deﬁnes the volume the gas has adopted during the measurement

procedure.

1.1.3 Standard and operating volume ﬂow

Standard volume ﬂow

The calorimetric measuring procedure measures the existing standard volume ﬂow or mass ﬂow without

requiring additional pressure and/or temperature measurements. Like velocity changes, pressure

ﬂuctuations cause ﬂuctuations in standard volume ﬂow which are indicated as such. The standard

volume ﬂow indicated relates to 1013 mbar/14.69 psi and a temperature of 0 °C/32 °F.

Operating volume ﬂow

The standard volume ﬂow value is converted into operating volume ﬂow by means of the “ideal gas

law”:

with P being pressure, V the volume and T the temperature (related to the absolute Kelvin scale).

The pressure to be set on the electronic control unit FC100-CA and the current temperature measured

are taken into account and used as a basis. Calculating operating volume ﬂow is only reasonable when

pressure is known and constant.

The assigned velocity rates (averaged on the pipe cross section) are converted from standard conditions

to operating conditions the same way as volume ﬂow.

P x V

T= constant

GMBH

Flow Meter | FC100-CA

DESCRIPTION

1.1.4 Measurements in compressed-air systems

The easy-to-ﬁt modular insertion system allows the FC100-CA with insertion head CSP-… to be inserted

in 6 different sensor adapters for diameters 1/2“, 3/4“, 1“, 1 1/4“, 1 1/2“ and 2“. This enables to

systematically monitor the entire compressed-air system for leakages by providing the appropriate

number of sensor adapters and only a few measuring systems. After elimination of the leakages the

measuring system can be used for consumption measurements on other measuring locations, e.g.

before main loads or in larger pipes of the compressed-air system. The measuring range covering

approx. 0 ... 50 Nm3/h to approx. 0 ... 480 Nm3/h allows the measurement of nearly all common ﬂow

rates as a function of pipe diameter.

Measurements in larger pipe diameters are possible by using the push-in monitoring head

CSF-11AM1.

1.1.4.1 Consumption measurements

The FC100-CA with CSx- monitoring head is suitable for compressed air and other gases. Its elec-

tronic control unit comprises two freely scalable linearised analogue outputs, i.e. one for tempera-

ture, the other for mass ﬂow, standard ﬂow or operating volume ﬂow. A pulse output and totalizer

for consumption measurements are other added features. The FC100-CA also provides limit value

monitoring of ﬂow and temperature, ensuring reliable operation of the load.

1.1.4.2 Leakage measurements

When monitoring compressed-air ﬂow at some selected points during a production-free period, you

will realise that even in carefully maintained compressed-air systems there is still compressed air

consumed. Reliably detecting even the smallest of such leakage losses can be facilitated by means of

the adjustable zero suppression of the FC100-CA. If the system is permanently monitored for leakage

ﬂow, leakages caused by valves left open etc. and new leakage points can easily be detected.

The FC100-CA also allows the detection of leakages on duty by comparing two equal loads with each

other. The difference measured can be directly assigned to the leakage ﬂow.

Note:

• Please see the accuracy speciﬁcations of FC100-CA with insertion head CSx.

GMBH

FC100-CA | Flow Meter

DESCRIPTION

1.2 System description

The system comprises the following hardware functional modules:

1 Input voltage: DC supply (terminal XV)

2 User interfaces: 2.1 signal outputs, 2-way or 4-way signal outputs (terminal XAH)

2.2 analogue outputs (terminal XAO)

2.3 RS232 interface (terminal XSE)

2.4 external totalizer reset (terminal XRE)

3 Keyboard and display: keypads

liquid crystal display

4 Sensor interface: calorimetric monitoring head type CS x_ (terminal XSK)

5 Microcontroller system: signal processing, communication and monitoring

1Input voltage:2.1User interface 1:2.2User interface 2:3Keyboard/Display:4Sensor interface:5Controller system:DC 10 … 40 Vrelay outputs:2 limit valuestransistor outputs:2 limit values + 1 error indication + 1 busy signal or pulse output (software selected) analogue outputs: temperature and flowcurrent or voltage2.3User interface 3:RS232 interface 2.4User interface 4:totalizer reset: edge controlled potential free, normally open contact or voltage pulse DC10 … 4

0 V

keypadsLC display2 x 16 digits backlight (can be switched off)calorimetric monitoring head type CSxsignal processingI/O - controllingmonitoringparameter memorycommunication

Power supply DC/DCKeyboard and displayMicrocontrollersystemUserinterface 1Userinterface 2Userinterface 3Userinterface 412.12.2453Sensorinterfacecalorimetricmonitoringhead CSx2.32.4fig. 2

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Flow Meter | FC100-CA

DESCRIPTION

The analogue outputs and the signal outputs are galvanically isolatated from the other electronics.

The two analogue output channels are not galvanically isolated from each other.

There is no electrical isolation between power supply, controller system, sensor interface, monitoring

head and RS232 interface.

The monitoring heads are connected by means of precut cables.

Cables and user interface connections are shown in chapters 2.2.2 and circuit diagrams 2.2.2.1/

2.2.2.2/2.2.2.3.

System conﬁguration and parameter settings can be modiﬁed by means of the keyboard if default

values need to be changed (see chapter 5).

This mainly applies to monitoring head selection, signal outputs (switch point setting) and analogue

outputs (zero point setting and scaling).

1.2.1 User interfaces

Signal outputs: 1. R2 - Relay outputs (2 limit values)

(optional) Two-channel galvanic isolation

Contact Form: Single pole double throw (SPDT)

The channels may be assigned in menu “CONFIGURATION”, either individu-

ally or in pairs, to the physical quantities of temperature or flow. The switch

on and off values can be set as desired (yet within the measuring range) for

each contact.

Please see chapter 7.4.1 for electrical connection.

2. T4 – Transistor outputs (2 limit values + 2 status outputs or 2 limit values +

1 status output + 1 pulse output)

Four-channel galvanic isolation, transistor output (NPN) – collector/emitter

freely connectable

Channel 1: common error signal

Channel 2: busy signal or pulse output

Channels 3 and 4: Both channels may be assigned individually or in pairs to

the physical quantities of temperature or flow. The switch on or off values of

each transistor output can be set as desired.

Please see chapter 7.4.2 for electrical connection.

Analogue outputs: Galvanic isolation, current or voltage output

Please see the ordering number to find out whether it is a current or voltage

output.

Output quantities: 0/1 - 5 V FS (option V1)

0/2 - 10 V FS (option V2)

0/4 - 20 mA FS (option C1)

These FS (full scale) output quantities apply to both channels as standard.

20% zero elevation and FS value can be programmed. (see chapter 5.9)

Shield connections are ungrounded.

The shields of the signal cables should be applied on one side only.

Indice

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