ZERO100FU fixed ultrasonic flow meter
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This document provides instructions for using an ultrasonic flow meter. It begins with an outline and contents section describing the manual's organization. It then covers starting measurement with the wall-mounted fixed style ultrasonic flow meter, display and operation including key functions and menu details, transducer installation methods for different types, installation checks, troubleshooting, warranty and service information. The manual aims to guide users on setup, operation and maintenance of the ultrasonic flow meter.
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600 1000 780 725 685 5 30×20 36
700 1100 860 810 775 5 24×25 32
800 1200 975 920 880 5 24×30 32
900 1300 1075 1020 980 5 24×30 34
1000 1400 1175 1120 1080 5 28×30 36
§4.8 check installation of transducers
After the completion of transducer installation, the user should check the following items to
see whether the installation is suitable,whether the received ultrasonic signal is correct,enough
strong,that could make the meter work normally and long time running. By checking the receiving
signal strength S, the signal quality Q value, the delta time, , the transit time
ratio R to assure whether the installation point is good or not. Normaly,apply couplant on the
transducers and attach them on the pipe ,so can obtain measurement results,but it is better to
check followings to ensure the flow meter is working properly and the results are reliable and
accurate.
§4.8.1 Signal Strength
Signal strength S (display on M90) indicates strength of sending and receiving signals from
upstream transducer and downstream transducer by a 3-digit number. [00.0] means there is
no signal detected, and [99.9] refers to the maximum signal strength that can be detected. When
installation,do best to adjust the position of transducers and check whether the couplant is
sufficient,to make sure to gain the strongest signal.Although the instrument works well
when the signal strength ranges from 60 to 99,when the signal strength is too low,you
should check the installation position ,installation space,whether the pipe is suitable to
install or change to install by Z method. stronger signal strength should be pursued, because
a stronger signal means a stable measurement results,long and reliable running..
§4.8.2 Signal quality(Q value)
:Signal quality is indicated as the Q value(display on M90) that represent the receiving
signal is good or not,ZERO100FU series use 00-99 digits to represent signal quality.00
represent the worst signal,99 represent the best signal,normally the signal quality should
be above 60. the reason of poor signal quality could be big interference,or worse installation
of transducers,or using bad quality,not professional signal cable.normally ,to adjust
transducers repeatly,check the couplant that is enough or not,until the signal is better.
§4.8.3 Total transit time,delta time
The total transit times (or traveling time) and delta time are displayed on menu window M93,they
can display whether the installation is suitable or not, They are
the basic two parameters for the flow meter’s internal measurement and calculation,. When the
data of delta time fluctuates too much,the showed flow rate and velocity will change quickly,under
such condition,it means the signal quality is not good,perhaps the conditions of pipe is not
good,not suitable installation of the transducers,or wrong parameters input.normally the
fluctuation of delta time is less than ±20％.but when the pipe diameter is too small or lower
flow velocity,the fluctuation of delta time may be higher.
§4.8.4 Transit time ratio
Transit-time ratio (visit on M91)is usually used to check whether the transducer
installation space is good .If the pipe parameters are correct and the transducers are
installed properly, the transit time ratio should be in the range of
100±3 %.when the ratio is over the range,you should check,
a) If the entered pipe parameters are correct?
b) If the actual space of the transducers is the same as or close to what shown on window
M25.](https://image.slidesharecdn.com/zero100fufixedultrasonicflowmeter-180305085517/85/ZERO100FU-fixed-ultrasonic-flow-meter-25-320.jpg)
ZERO100FU fixed ultrasonic flow meter
- 1. 1 ZERO100FU Ultrasonic Flow Meter Manual （original instructions）
- 2. 2 ZERO100FU MANUAL(VER. 18) CONTENTS 1. OUTLINE········································3 §1.1Preface·····································3 §1.2 Principle of Measurement ····························4 2. Starting Measurement··································4 §2.1 wall mounted fixed style ultrasonic flow meter··················4 3 display and operation··································6 §3.1.1 key function·································6 §3.1.2 detailed information of Menu·························6 §3.1.3 Work parameter solidification of the flow meter and option introduction··6 §3.1.4 Zero point setup and zero point solidification·············11 §3.1.5 Factory use the scaling factor solidification··············11 §3.1.6 analogue calculating function application················11 §3.1.7Analogue input interface as digit input interface method and introduction·11 §3.1.8 Introduction of serial peripheral extension interface··········11 §3.1.9Realize medium identifying function····················11 §3.2 The flow meter restore to factory default·················11 4.transducers installation·······························12 §4.1 Unpack checking································12 §4.2 Power supply and cable·····························12 §4.3 Required installation condition························13 §4.3.1 choosing measurement point······················13 §4.3.2 instrument well construction requirements ················15 §4.4 Quickly input pipe parameter steps:······················16 §4.5 Clamp on type transducer installation method ·················16 §4.5.1 Installation space··························17 §4.5.2 Installation method··························17 §4.6 Insertion type transducer installation method················18 §4.6.1 Installation tools···························19 §4.6.2 Installation space···························19 §4.6.3 Installation method··························19 §4.6.4 Locate the installation point·····················21 §4.6.5 Welding the base of the ball valves··················21 §4.6.6 hole-drilling·····························21 §4.6.7 inserting the transducers·················v·····22 §4.6.8 Length calculation of the part of transducer into the pipe inner wall: ··22 §4.6.9 wiring···23 §4.6.10 Transducer wiring picture·························23 §4.6.11 Maintenance······························23 §4.7 In-line type transducer installation method ··················23 §4.8 check installation of transducers························25 §4.8.1 Signal Strength·····························25 §4.8.2 Signal quality(Q value)·························25 §4.8.3 Total transit time,delta time······················25
- 3. 3 §4.8.4 Transit time ratio····························25 §4.8.5 Note the following questions when installing···············26 §5. Troubleshooting································26 §5.1 Hardware self-diagnosis errors and solutions after power on ··········26 §5.2 Working status errors code causes and solutions·················27 §6 Warranty and service ································28 §6.1 Warranty ····································28 §6.2 Service ·····································28 §6.3 Software Upgrade Service ····························29 §6.4 Important Notice for Product Return ·······················29 1.Outline §1.1 Preface: Welcome to use the new ZERO100FU series ultrasonic flow meter invented by Zero Instrument Co.,Ltd. up to date, the high function,low price,good reliability,power function,new series products enhanced greatly in the aspects of measurement accuracy,measurement stability,communication protocol,easy to use etc. easy and reliable production line,good conformity of the products that guarantee each instrument reach the best function before leaving factory. The main board is suitable for any kinds of transducers,including clamp-on type,insertion type, π in-line type,standard in-line type and same kinds of transducers from other manufacturers.the pipe parameters and calibration parameters of water meter and in-line pipe are input by manufacturer,users do not need to input any parameter,only need to connect with flow meter to work. Applied to on-line measure and system monitor for nearly all liquids from petrol chemical,metallurgy,electric power plant,irrigation,city water company,energy monitor fields,realize the functions of measuring and checking of flow velocity,flow rate,accumulation and heat quantity of different liquids,and flow rate on/off,liquids distinguish.
- 4. 4 §1.2 Principle of Measurement When the ultrasonic beam is transmitted through the flowing liquid, there will be a difference between the upstream and downstream transit time (travel time or time of flight), which is proportional to flow velocity,when fluid is flowing,counter-flow transit time is more than direct flow transit time. the formula as below. Remarks: θ The angle between the ultrasonic beam and the flow M Transit times of the ultrasonic beam D The internal diameter of the pipe Tup Transit time in the forward direction Tdown Transit time in the reverse direction ΔT=Tup –Tdown F=900×π×D2×V F 为瞬时流量（单位：立方米/小时） D 为管道的内径（单位：米） V 为流速（单位：米/秒） 其中 Tup·Tdown MD V T sin2 × 为声束与液体流动方向的夹角 M 为声束在液体的直线传播次数 D 为管道内径 Tup 为声束在正方向上的传播时间 Tdown 为声束在逆方向上的传播时间 T=Tup-Tdown 时差 其中 感器 流 向 管壁 衬里 F is instant flow rate(unit:m³/hour) D is inside pipe diameter(unit:m) V is flow velocity(unit:m/s) 2. Starting Measurement The new instruments are comprised of measuring main board,function extending module,and display operation terminal etc.users can choose the right configuration according to own requirements.the easiest configuration only needs a measuring main board and a pair of transducers to complete the function of flow measurement. §2.1 wall mounted fixed style ultrasonic flow meter transducers include clamp-on type,insertion type,in-line type.these series products have gained the best sales volume in our company,and are the favorable products in future,applied to measure on-line difference liquids in industry spot. Technology features: 1:operating power :AC 85—264V or isolation DC 8-36VDC 2:repeatability:better than 0.2%.accuracy:better than 1% 3:signal output :one channel standard isolation RS485 output One channel isolation 4-20mA or 0-20mA active output. One channel OCT output(programmed between the pulse width(6-1000ms),default before leaving factory (200ms)) One channel isolation relay output,with positive,negative,net accumulation pulses
- 5. 5 and different alarm signals. 4:signal input: two channel three wire system PT100 platinum resistor input loop,to make heat meter has the function of displaying heat quantity. Three channel 4-20mA input optional,accuracy:0.1%,has the ability to input the signals of pressure, liquid level, temperature and so on. 5::display:2*20 backlit LCD(Chinese and English optional) 6:operating:4*4 tactile keypad 7:other functions:automatic memory the positive,negative,net totaliser flow rate and heat quantity of the last 512 days,128 months,10years Automatic memory the time of power on/off and flow rate of the last 30 times, realize to replenish by hand or automatically,read the datas through Modbus communication protocol. 8:protection level:mainframe:IP65, transducer:IP:68 9:transducer: clamp-on type,insertion type,in-line type. Optional accessory: 1:clamp-on transducer(standard S1 style,standard M1 style,high temperature S1H,high temperature M1H) 2:insertion transducer(standard insertion B,cement insertion B) 3:in-line type transducer(hygienic style, Π style,standard style) 4: special shielded twisted pair cable 5:strap(applied with installation of transducers on cast iron,GRP,PVC,etc. that can not be welded directly). ■mainboard wiring map and outline size:
- 6. 6 ground wire （include upstream ground wire and downstream ground wire） 18 version mainboard 3 display and operation §3.1.1 key function The new ZERO100FU series ultrasonic flow meter can respectively or at same time use 16 key keyboard
- 7. 7 monitor. 16 key parallel or serial port key board,including 10 digit keys,2 up/down arrow key,1 Menu key(M),1 enter key,1 arithmetic point key,1 backspace key. The keyboard can make users operate quickly and conveniently 4 key keyboard has 2 up/down arrow key,1 menu key(M),1 enter key(ENT),inputing digits,characters,and arithmetic point is by using up arrow key to input many times,the use of down arrow key is to move to next digit position. For example :to use 16 keys keyboard. 0-9 and <•> are used to input digits or Menu number. ◄ key is used to left backspace or delete left character. <▲/+> and <▼/- > are used to enter upper and lower Menu,when inputing digits,it equals to plus or minus key. Menu key is used to visit Menu,firstly press this key and then press two digits keys to enter related Menu.for example,if to input outside pipe diameter,press Menu <1><1>. “11” is the address code of outside pipe diameter parameter. <ENT>key is used to ensure the input digit or chosen content.the other function is to press this key to enter “modify” status before inputing parameters. “bibi” sound of pressing keys of buzzer can be shut down by using M77 to choose 25 item. §3.1.2 detailed information of Menu flow rate/ flow total iser displ ay 00 display instant flow rate/net totalizer,adjust the units in M30-M32 01 display instant flow rate/instant flow velocity, adjust the units in M30-M32 02 display instant flow rate/positive totalizer, adjust the units in M30-M32 03 display instant flow rate/negative totalizer, adjust the units in M30-M32 04 display instant flow rate/date time 05 display heat flow rate/total heat quantity,adjust the units in M84 ,M88. 06 display temperature input T1,T2 07 display present battery voltage.(suitable to ZERO16) 07 display analogue input AI3,AI4 08 display system error code 09 display today net totalizer initi al setup 10 input outside perimeter of pipe *11 input pipe outer diameter,data range:0-18000mm *12 input pipe wall thickness *13 input pipe inner diameter *14 choose the kinds of pipe materials 15 input sound velocity of pipe material 16 choose kinds of liner 17 input the sound velocity of liner 18 input the thickness of liner 19 input inner pipe wall absolute degree of roughness *20 choose kinds of fluids
- 8. 8 21 input fluid velocity 22 input fluid viscosity *23 choose the types of transducers,including more than 20 types to use *24 choose transducer installation method *25 display transducer installation space *26 parameter solidifying and setup 27 store and read installation parameters on installation point 28 When signal set turning poor,keep last datas,choosing”yes”means when the signal turning poor,the flow meter display last correct measured datas. 29 。Input signal strength when the pipe flow is set to be empty.for example:inputing 65 means when the signal strength is lower than 65,the flow meter will think that there is no liquid in the pipe and display the flow value as zero. flow unit setup 30 choose metric or imperial unit 31 choose instant flow rate unit 32 choose totalizer unit 33 choosing the totaliser multiplying factor which function is to multiply totaliser data rang,normaly set it as x1 34 net totaliser switch 35 positive totaliser switch 36 negative totaliser switch 37 restore parameters setup before leaving factory and reset totaliser 38 manual totaliser(the key to control on/off) 39 choose operating language,including 8 kinds of different languages for international users to use 3• setup the LCD display method,inputing 0 or 1 means regular displaying content.inputing 2-39 means automatically cycle displaying method,displaying the previous menu of 2-39,time interval is 8 seconds.when inputing accures ,displaying according to the inputing operation.when there is no inputing operation,it will automatically enter cycle displaying status.(detailed information in §3.1) Choos ing setup *40 damper coefficient *41 Input low flow velocity cutoff value 42 Setup static zero point 43 clear zero point setup and manually setup zero point,restore default before leaving factory. 44 Set up zero point deviant by hand 45 meter coefficient,rectification coefficient 46 input Network address identification number (IDN) 47 password protecting operation,after the meter was setup with password,only browse menus without any modification. 48 Input degree of linearity broken line rectification data.at most there is 12 segments broken line,used for users to rectify meter nolinear. 49 Network communication tester,on this window to visit the datas transfered from
- 9. 9 upper computer to judge the problems arised during communication. sched uled time outpu t 50 Optional setup of datas output at scheduled time,choose output content at scheduled time to print,more than 20 to selet 51 Setup output time at scheduled time 52 Printing data flow direction control.by default printing data will flow directly to the thermal printer hanged inside bus.setup printing data output to outside serial port(RS485 port) AI5 setup 53 display analogue input AI5(reserved for the ZERO16 mainboard) input and outpu t setup 54 Setup of OCT totaliser pulse output,pulse width,range:6 Ms-1000Ms. 55 choose current loop mode 56 corresponding data to output of current loop 4mA or 0mA 57 corresponding data to output of current loop 20mA 58 Verification of current loop output.applied to check whether current loop is normal or not. 59 present output of current loop 60 Date time and setup.the date time of the new flow meter is realized by CPU,when upgrading software,time will be slow,so after upgrading,recommend to adjust the date and time to display correctly 61 Software version information and Electronic Serial Number (ESN) 62 setup serial port parameter 63 Communication protocol choosing(including compatible protocol choosing),two options,choosing MODBUS-RTU means using binary system MODUS-RTU protocol.choosing MODBUS-ASCII+previous protocol means using ASCII protocol,at this time can support several protocols simultaneously,including MOSBUS-ASCII,previous 7 version protocol,FUJI protocol,Meter-BUSx protocol etc. 64 analogue input AI3 By inputing measuring range ,the flow meter will turn current signal into data range users need,so display related analogue input that corresponding to physical parameter data. 65 Analogue input AI4 66 Analogue input AI5 67 Setup frequency range of frequency output signal.frequency signal output represent instant flow rate value by signal frequency value.default:0-1000Hz， max-range:0-999Hz.output frequency signal by special frequency output unit. 68 setup lower limit flow of frequency signal output 69 setup upper limit flow of frequency signal output 70 LCD backlit control 71 LCD contrast ratio control 72 Work timer,logging work time of the meter by unit of second.it can reset. 73 setup lower limit flow of frequency signal output by setuping the lower and upper limit of alarm,confirm a range,when actual flow is over the range set in this window,then create a alarm signal output.alarm signal can be transferred to outside by setuping OCT or relay. 74 setup upper limit flow of frequency signal output 75 LCD backlit control
- 10. 10 76 LCD contrast ratio control 77 beeper setup options 78 setup Open Collector Transistor output(OCT) output options 79 setup relay(OCT2) output options 80 choose input signal of batch controller 81 batch controller heat quant ity measu ring 82 day/month/year totaliser,check the flow rate and heat quantity of the totalisers 83 。Automaticaly replenish flow switch during the period of power off,default status:off.this function is not available under special conditions. 84 Choosing heat quantity unit, 0.Gj(default) 2.Kcal 3.Kw 4.BTU (imperial unit) 85 Choose temperature signal origin,if choosing inputing temperature signal by AI3,AI4,then need temperature transmitter that can output 4-20mA current signal. 86 heat capacity,default: GB-CJ128 enthalpy potential method. Temperature difference method is available also. 87 heat quantity totaliser switch 88 Heat quantity multiplier factor. 89 display present temperature difference and setup temperature difference sensitivity. 8• Options of installation of heat meter on supply water pipe or return water pipe diagn osis *90 Display the signal strength and signal quality *91 Display the transit time ratio 92 Display the calculated fluid sound velocity . 93 Display the total transit time and the delta time 94 Display the Reynolds number and the pipe coefficient 95 Display positive,negative heat quantity totaliser,start cycle display function. added menu windo ws +0 Display the time of power on/off and flow rate +1 Display the total working time of the flow meter +2 Display the last time of power off. +3 Display the flow rate of last power off +4 Display total times of power on +5 Scentific calculator +6 Setup threshold value of fluid sound velocity +7 Net totaliser of this month +8 Net totaliser of this year +9 Operating time with trouble(including power off time) hardw are adjus tment menu windo ws .2 store static zero point .5 setup threshold value of Q value .8 max instant flow rate of this day and this month .9 serial port testing window with CMM direct output -0 circuitry hardware parameter adjusting entrance(only inputing password to enter following windows) -1 4-20mA current loop calibration
- 11. 11 -2 AI3 inputing calibration of analogue input 4 mA -3 AI3 inputing calibration of analogue input 20mA -4 AI4 inputing calibration of analogue input 4mA -5 AI4 inputing calibration of analogue input 20mA -6 AI5 inputing calibration of analogue input 4mA -7 AI5 inputing calibration of analogue input 20mA -8 zero point setup of PT100 at lower temperature(<40℃) -9 PT100 setup zero point at higher temperature（>55℃） -A PT100 standard calibration at 50℃ -B PT100 standard calibration at 84.5℃ :* means common used menus,red color means new added or changed functions,blue color means the menus related with heat quantity measurement §3.1.3 Work parameter solidification of the flow meter and option introduction The new ZERO100FU has 3 work parameter areas.respectively called:present parameter data block,solidification parameter data block,user pipe parameter data block. Present parameter data block is built in internal RAM,if outside power supply and spare battery are off together,then lost the present work parameter. Solidification parameter data block is built in internal FLASH,normaly it will not loose. for long time stable work application,after setuping all the work parameters,using the function of solidification parameter in M26 to solidify the parameter data block in RAM to FLASH,and setup recalling the work parameter in FLASH to present parameter data block when power on for each time.for the application of modifying the parameters frequently(like portable flow meter),pls choose “0. use parameter in RAM area”option in M26.when power on,then keep the parameters in RAM to use directly.if the data block in RAM exists verification errors,then it will go on to recall the work parameter in FLASH User parameter data block is able to store 9 sets commonly used pipe parameters.the access operation is in M27 §3.1.4 Zero point setup and zero point solidification The new transducers have a “zero point”,its meaning is when fluid flow velocity is zero,the flow meter will display a non-zero flow value.this value will repeated add to indicating value of the flow meter under any flow velocity,for example,assume that the zero point is 1m3/h,present flow velocity is 10m3/h,then the indicating value of the flow meter is 11m3/h.so newly install or change transducers,normaly need to adjust zero point and log zero point value,minus this zero point value from indicating value for calculating later. To adjust zero point in M42.but the zero point value after adjusting is only stored in RAM parameter area temporarily ,is not solidified in FLASH.if the spare battery is off or choosing the solidification parameters in FLASH as work parameters when power on,the zero point value will loose.in order to keep the zero point value forever,users must use M.2 to store the zero point after adjusting zero point for each time. §3.1.5 Factory use the scaling factor solidification Same as the priciple of storing zero point value,factory scaling factor need be solidified after calibration before leaving factory.it is in M.1 ,use two grade passwords to visit.
- 12. 12 §3.1.6 analogue calculating function application When setuping pipe diameter is zero,display the instant flow velocity :1.2345678m/s(4.0504ft/s),instant flow rate=0 ,and display “R”status.inputing a set value in M44 can obtain changable totaliser output.using this function to achieve the function of test of the flow meter and adjustment of network software without connecting transducers. §3.1.7Analogue input interface as digit input interface method and introduction The new ZERO100FU series’ analogue input interface can work as digit input interface ,but note that the loop input current should not be over 20 mA.when outer digital quantity voltage is 5V,you should series connect a 1k resistor in return circuit.if the digital quantity voltage is 12V,then series connect a 2k resistor. §3.1.8 Introduction of serial peripheral extention interface Serial peripheral extention interface is like USB interface,it has input,output,power supply+,power supply- ,totally 4 lines.for each measuring,it can output instant flow,instant heat flow,positive total,4-20mA value,frequency value and printing data etc.different function model can take down datas according to requirements.the serial bus use 4800 baud rate. §3.1.9Realize medium identifying function For example:application in mixture fluid of oil and water,to judge the medium in pipe is water or oil,you could input lower limit of water flow in M+6,it is 1400m/s for this example.when the fluid flow velocity measured by the flow meter is lower than 1400m/s,a internal signal created,used to indicate that the fluid is another medium.this signal can be output by OCT or read by MODBUS protocol.but you assure that the two fluid flow velocity can not exist overlap. §3.2 The flow meter restore to factory default If like to clear all set parameters to restore original factory default,only use serial port or parrallel port keyboard to enter M37 to click <•><◄>,so can restore default set parameters before leaving factory. Attention:except of first installation,normaly not use this function. 4.transducers installation §4.1 Unpack checking :Check whether the spare parts comply with packing list,enclosure is broken or not during transportation?did screw drop?connecting line is loose or not?if have questions,pls cotact factory. §4.2 Power supply and cable When users place an order,pls inform factory what kinds of power supply is needed,normaly the power supply of the flow meter have following options: One : AC85~264V second: DC24V or DC8~36V :Draw operator attention:if connect the mainframe powered supply by direct current or low voltage AC (DC8-36V) with AC220V,the flow meter will be destroyed. Transducers signal cable of ZERO100FU series ultrasonic flow meter adopts high frequency special
- 13. 13 shielded twisted pair cable.because sending and receiving circuit adopts balanced transmitting and balanced receiving principle.so to increase the anti-interference function,little signal consumable ,ensure the device work well in longer term.so the special signal cable supplied by factory is the best choice for you.if using coaxial shielded radio frequency cable or poor quality twisted pair cable,it could lower accuracy and the function of the device.when there is bigger interference signal from outside,the device could not measure normally. §4.3 Required installation condition Installation of The new ZERO100FU series is the easiest and convenient way in the installation of all flow meters,just choosing a suitable measurement point,input the pipe parameters of this pipe point to the flow meter,then fix the transducers on the pipe. §4.3.1 choosing measurement point To ensure measurement accuracy and stability,the installation point of tranducers should be on the straight pipe full of well distributed fluid(when installing,the pipe must be full of liquid),comform to following principle: 1.Pipe must be full of liquid that is uniform and easy to travel the ultrasonic beam(vertical pipe or horizontal pipe) 2.Upstream transducer should be installed at the place where the upstream length of the straight pipe is at least 10D and the downstream length is at least 5D where install the downstream transducer,so the pipe length should be straight without any valve,pump,angle head, D stands for pipe ouside diameter. The installation point should stay away from valves,pump,high pressure current,transformers interference source etc. 3.Avoid to install on the highest point of pipe system or vertical pipe with free exit(flow down)
- 14. 14 4.For the opened pipe or half full pipe,the transducers should be installed on U pipe. 5.The temperature and pressure on the installation point should be within the work ability of the transducers. 6.Pay more attention to the pipe scaling in inner pipe wall,do best to choose the pipe without scaling to install,if it is impossible ,then consider the scaling as liner to achieve better accuracy. 7.The two transducers must be installed in horizontal direction to pipe axis plane,within ±45°of axis line horizontal plane, to prevent bubbles or not full in upper pipe or sediment in down side of pipe to influence transducer measurement normaly.if there is space limit of installation that could not install horizontal symmetry,then install the transducers vertically or dip angle under the condition of no bubbles in upper parts of pipe.
- 15. 15 §4.3.2 instrument well construction requirements If need to install transducers in instrument well,there must be enough installation room,convenient for people to stand up to work,distance between pipe wall and well wall is at least above 550mm,width is more than (D+550*2)mm,cement pipe width is more than (D+700*2)mm,instrument well axial width L is more than D+1200mm.when installing transducers,avoid the place of flange,welding line,reducing,do best to install transducers in the range of +/-45° of horizontal position of pipe axis.
- 16. 16 :Attention:1,Do best to install transducers in the range of +/-45° of horizontal position of pipe axis . 2,Connect the mainframe enclosure with ground. 3, Avoid the installation place of flange,welding line,reducing 4, Enough installation room,convenient for people to stand up to work §4.4 Quickly input pipe parameter steps: Need input following parameters when normaly measuring 1. pipe outer diameter 2. pipe wall thickness 3. pipe material 4. liner parameter(if has liner,then include liner thickness and sound velocity) 5. fluid types 6. tansducers tpye(mainframe can support many kinds of transducers) 7. transducers installation method 8. solidificaiton parameter §4.5 Clamp on type transducer installation method Before installation,choose density pipe to install transducers,and clean the installation area,clear away rust,paint,anti-rust layer,it is the best to use angle grinder to polish,use cleaning cloth with alcohol or acetone to clear oil and dust,coat enough couplant around the center of installation area,attach the transducers on the pipe and fix it without air bubbles or sand between transducers and pipe wall.
- 17. 17 High temperature S2H type High temperature M2H type High temperature L2H type Standard S2 type Standard M2 type Standard L2 type transducer Standard S2 type Standard M2 type Standard L2 type High temperature S2H type High temperature M2H type High temperature L2H type Suitable pipe diameter DN15-DN100 DN50-DN700 DN300-DN6000 DN15-DN100 DN50-DN700 DN300-DN6000 Fluid temperature 0℃～70℃ 0℃～70℃ 0℃～70℃ 0℃～160℃ 0℃～160℃ 0℃～160℃ Outer size 45×30×30mm quality 75g :Remarks:users input transducers parameters by yourself §4.5.1 Installation space Installation space of clamp on type transducer is inner edge distance of the two transducers(face to face),after inputing the required parameters in Menu,check the display on M25,that is the installation space. §4.5.2 Installation method The method has 2 kinds: V method,Z method Normaly,V method is suitable to the pipe diameters within the range: DN15-DN200mm .when using V method can not measure the signal or the signal is poor,try to use Z method that is suitable to the diameters are more than DN200mm or measuring cast iron. V method(commonly used method) Normaly,V method is standard installation method,convenient to use with precise measurement,when installation,the two transducers horizontally align,its centre line is horizontal with pipe axis line,suitable pipe diameter range to measure is DN15mm-DN400mm。
- 18. 18 Z method (the most commonly used method) When the pipe diameter is wide,or there are suspended matters in fluid,too thick scaling or liner inside pipe inner wall,that can make the flow meter can not work normaly and signal poor by using V method installation,so need to use Z method to install,its features are direct transfering without reflection(called sigle sound path),little signal attenuation. Attention:1,when installation,it is a must to clear the pipe area where to install transducers,showing metal color 2,shield line of ultrasonic signal cable can not be connected,but not short circuit with positive and negative pole(red and black line) 3,after transducers are connected with circuits,must apply enough sealant to prevent water in. 4,after covering the transducers,must screw and lock tightly the hole for shield line of transducers to prevent water in. 5,use strap(stainless steel band) to fix on the center part of transducers,to make it weighted uniform,no moving. 6,apply enough couplant around the area ， so that transducers touch pipe to prevent air,sands,rust in,that influence the beam transfering. §4.6 Insertion type transducer installation method The new ZERO100FU series insertion type transducer incorporates the advantages of clamp on type and in line type transducers,its features: Transducers can be installed directly on pipes of carbon steel or stainless steel by welding; while for those pipes of materials like cast iron, glass fiber reinforced plastic, PVC and cement which cannot be welded directly, special straps should be used for installation. For those users who are in similar situation, please inform us of the precise outside diameter
- 19. 19 of the pipe to be installed to prevent leakage. insertion B type（insert directly） Insertion B type (for sement pipe ) Suitable diameter Above DN80mm Above DN80mm Installation room ≥550mm ≥700mm Fluid temperature -40℃-160℃ -40℃-160℃ Transducer material 316L stainless steel 316L stainless steel §4.6.1 Installation tools Special hole-drilling positioning tools made by our company (Zero Instrument Development Co., Ltd), 400w handle rotary drill (high speed adjustable is preferable), spanner and screwdriver are needed for installing insertion transducers. §4.6.2 Installation space Insertion style transducers spacing is calculated based on the distance between the centers of the two transducers along the pipe axis. The space will be shown on menu M25 when necessary data are put into the menu, and the transducers should be installed according to this space. §4.6.3 Installation method There is only one way to install insertion style transducers which is called Z-method installation and can be applied for all pipes which diameter is more than DN80mm. §4.6.4 Locate the installation point Input the pipe parameters on the mainframe, the installation space L (L=inside diameter－9.113mm) will be calculated. (the two sensors must be located in the same axis plane), the installing space L should be the distance between the centers of the two sensors horizonally. A. Making a fixed position paper: take a 4D (D refers to the pipe inner diameter) long and 200mm (or D) wide rectangular paper (according to actual situation on spot, the paper tape can also be replaced by moisture-and-corrosion resistant materials), and draw a line about 100mm from the edge;
- 20. 20 B. Wrap the fixed position paper on the cleaned surface of the pipe, making sure that the two paper sides are overlapping and aligned and thus the line drawn may be parallel with the pipe axis; C. Extend the line on the fixed position paper to the pipeline and the cross-point between the vertical side of the fixed position paper and the extended line is A D. Starting from A and along the edge of the position paper, the length of half of the pipe perimeter is measured and the cross point is C; then draw a line at C to be parallel to the axis (that is, to be parallel with the line on the position paper); E．Removing the fixed position paper and starting from C, the installation space L should be measured along the line, draw on the pipe ,the point is B. Thus, A and B are the points where the transducers are to be installed. For example, L=280mm. Then two bases of ball valves should be welded respectively on A and B, making sure the centers of bases overlap A and B respectively.
- 21. 21 §4.6.5 Welding the base of the ball valves For pipes that can be welded (such as steel and stainless steel, etc.), just weld the base on the pipe (Stainless steel pipe should be welded to stainless base, please indicate in your order). Before welding, the rust and paint on the section where the sensors are to be installed shall be cleaned up by using an angle grinder, and the oil dirty and dust should be cleaned by using acetone or alcohol. to prevent water leakage,so the work of welding is very important, making sure the centers of bases overlap A and B respectively,no air bubbles. For pipes which material cannot be welded directly (such as cast iron and cement, etc.), special hoops (with airproof rubber pads) should be used. The bases of the ball valves have been welded on the hoops. These hoops are directly fixed on the pipe and make sure that the centers of the ball valves overlap A and B respectively. Finally, the ball valves should be closely fixed on the bases welded on the hoops to prevent water leakage. §4.6.6 hole-drilling Connect the sealed sheath of the hole-drilling machine and the outer screw thread of the tailor-made ball valves,screw tightly,open the ball valves,push the drill pipe to touch the outer surface of pipe; then the drill pipe shall be locked to the handle rotary drill before the drill is switched on. During drilling, the drill machine should work in a low speed to avoid sticking or even drill bit breaking.after drilling through pipe wall,pull back the drill pipe until the head of drill bit reach the ball valves spool,turn off the ball valves,take down hole-drilling machine.
- 22. 22 §4.6.7 inserting the transducers screw the screw mut to a position under the bottom of the transducer and screw the transducer through the ball valve to ball valve spool. Open the ball valve and continue to screw the transducer until the head of transducer passes the inner wall of the pipe. Before the wires are connected, the angle of the transducer should be adjusted to make sure that the head of two transducers can be in face to face position so as to send and receive the signals properly(the hole for line of two transducers should be upward or downward at same time).and then fix the screw mut,connect the wires,use silicon rubber to seal the connection place. §4.6.8 Length calculation of the part of transducer into the pipe inner wall: Insertion style transducer is made of stainless steel by casting. As the transducer's length A and the pipe wall's thickness B are known, and the length part of transducer left outside the pipe can be measured, the length of the inner part of the transducer can be calculated through the formula: L=A-B, C=0 Note: the length A of different types of transducers are: Standard insertion type B: A=170mm; Standard insertion type C: A=220mm, and Cement insertion type B: A=310mm. ①transducer ②ball valve base ③tailor-made ball valve ④screw thread ⑤locknut ⑥connecting box ⑦signal cable ①Pipe ②Ball valve base ③Tailor-made ball valve ④Locating drill pipe bit ⑤19 super hole cutter ⑥Seal gland ⑦Drill pipe ⑧Hole-drilling machine
- 23. 23 §4.6.9 wiring After wires being connected, screw the mut on the hole for wires (do not lose packing seal),at last,screw seal cover tightly to prevent water leakage. §4.6.10 Transducer wiring picture §4.6.11 Maintenance The maintenance is easy,exchange the old transducer with the new transducer according to the reverse process. Attention: 1 during the process of welding the base of the ball valves,avoid the phenomenon of slag inclusion,sand hole,water leakage. 2. The bases of the two ball valves should be welded on the same axis plane to prevent poor receiving of ultrasonic waves; 3. after The holes having been drilled through, the impurities such as iron filings in the ball valve should be cleaned up so that the transducer probe may not get stuck or its thread get adhered;if so,still to screw hardly,and do not stop,the transducer will be destroyed and not work well. 4. Make that the ultrasonic emitting surfaces of the two transducers are face to face (that is, the holes for wires are in the same direction and either upward or downward); 5. After the transducer is installed, the screw mut should be screwed tightly to avoid transducer move. The seal cover should be screwed tightly to prevent water after wires being connected.. §4.7 In-line type transducer installation method In-line type transducer of new ZERO100FU series is characterized by easy installation and high-accuracy measurement. When ordering, customers need to provide the actual parameters of the pipe. The parameters of the transducer have been put into the flowmeter before leaving factory and there is no need to input them when installing. There are two types of pipe transducers for selection: 1. π-type transducer(DN15-DN40MM) 2. Standard pipe transducer(DN50-DN1000MM) Parameters π-type transducer Standard pipe transducer
- 24. 24 Material Stainless steel Carbon steel(stainless steel is optional) Pipe size DN15-DN40MM DN50-DN6000MM Connection: Flange type Flange type Application of temperature -40℃～160℃ Protection class IP68(can work in water, and water depth≤3 meter) Rated pressure please refer to following table dimension please refer to following table Nominal diameter(m m)DN Rated pressur e(Mpa) π-type Standard-pip e Flange dimension(mm) L1 L2 D D1 D2 f Ｎ-Φ Flange thicknes s 15 2.5 320 95 65 45 2 14×4 14 20 360 105 75 55 2 14×4 16 25 390 115 85 65 3 14×4 16 32 450 140 100 76 3 18×4 18 40 500 150 110 84 3 18×4 20 50 1.6 200 160 125 100 3 18×4 22 65 200 180 145 120 3 18×4 24 80 225 195 160 135 3 18×8 24 100 250 215 180 155 3 18×8 26 125 250 245 210 185 3 18×8 28 150 300 280 240 210 3 23×8 28 200 350 335 295 265 3 23×12 30 250 450 405 355 320 3 25×12 32 300 500 460 410 375 4 25×12 32 350 550 520 470 435 4 25×16 34 400 600 580 525 485 4 30×16 38 400 1.0 600 565 515 482 4 25×16 30 450 700 615 565 532 4 25×20 30 500 800 670 620 585 4 25×20 32
- 25. 25 600 1000 780 725 685 5 30×20 36 700 1100 860 810 775 5 24×25 32 800 1200 975 920 880 5 24×30 32 900 1300 1075 1020 980 5 24×30 34 1000 1400 1175 1120 1080 5 28×30 36 §4.8 check installation of transducers After the completion of transducer installation, the user should check the following items to see whether the installation is suitable,whether the received ultrasonic signal is correct,enough strong,that could make the meter work normally and long time running. By checking the receiving signal strength S, the signal quality Q value, the delta time, , the transit time ratio R to assure whether the installation point is good or not. Normaly,apply couplant on the transducers and attach them on the pipe ,so can obtain measurement results,but it is better to check followings to ensure the flow meter is working properly and the results are reliable and accurate. §4.8.1 Signal Strength Signal strength S (display on M90) indicates strength of sending and receiving signals from upstream transducer and downstream transducer by a 3-digit number. [00.0] means there is no signal detected, and [99.9] refers to the maximum signal strength that can be detected. When installation,do best to adjust the position of transducers and check whether the couplant is sufficient,to make sure to gain the strongest signal.Although the instrument works well when the signal strength ranges from 60 to 99,when the signal strength is too low,you should check the installation position ,installation space,whether the pipe is suitable to install or change to install by Z method. stronger signal strength should be pursued, because a stronger signal means a stable measurement results,long and reliable running.. §4.8.2 Signal quality(Q value) :Signal quality is indicated as the Q value(display on M90) that represent the receiving signal is good or not,ZERO100FU series use 00-99 digits to represent signal quality.00 represent the worst signal,99 represent the best signal,normally the signal quality should be above 60. the reason of poor signal quality could be big interference,or worse installation of transducers,or using bad quality,not professional signal cable.normally ,to adjust transducers repeatly,check the couplant that is enough or not,until the signal is better. §4.8.3 Total transit time,delta time The total transit times (or traveling time) and delta time are displayed on menu window M93,they can display whether the installation is suitable or not, They are the basic two parameters for the flow meter’s internal measurement and calculation,. When the data of delta time fluctuates too much,the showed flow rate and velocity will change quickly,under such condition,it means the signal quality is not good,perhaps the conditions of pipe is not good,not suitable installation of the transducers,or wrong parameters input.normally the fluctuation of delta time is less than ±20％.but when the pipe diameter is too small or lower flow velocity,the fluctuation of delta time may be higher. §4.8.4 Transit time ratio Transit-time ratio (visit on M91)is usually used to check whether the transducer installation space is good .If the pipe parameters are correct and the transducers are installed properly, the transit time ratio should be in the range of 100±3 %.when the ratio is over the range,you should check, a) If the entered pipe parameters are correct? b) If the actual space of the transducers is the same as or close to what shown on window M25.
- 26. 26 c) If the transducers are installed properly in the same axis plane of pipe? d) If the mounting location is good, if the pipe has changed shape, or if the pipe is too old (i.e., too much corrosion or liner inside the pipe)? e) If there is any interference source around the flow meter? §4.8.5 Note the following questions when installing 1，input pipe parameters must be correct,conform to actual facts,otherwise the flow meter will not work. 2,when installing clamp on type transducers,apply enough couplant to make the transducers attach on the pipe,check the signal strength and signal quality displayed on the screen while moving the transducers around installation point to receive the best signal and signal quality.the diameter of pipe is more wider,the range of moving transducers is more larger.then ensure whether the installation space is the same with that on M25,whether transducers are installed in the same axis line of pipe.if the signal streghth is 0.00,that means no receipt of ultrasonic beam,check whether the input parameters are correct or not, choosing installation method is correct or not,whether the pipe is too old,liner is too thick,is there fluid in pipe？the space is too near valves,angle head?too many air bubbles in fluid?if not these reasons,still no signal,so have to try another point,or use insertion type transducers. 3,ensure whether the flow meter work normally:signal streghth is bigger,signal quality is higher,the displayed flow rate is more reliable,the meter can work for long time.if there is too bigger environment electromagnetic interference or lower receiving signal,then the flow rate displayed is poor,not be able to work normally for long time. 4,after installation,enter M26 to solidify parameters,power on again,check results are correct or not. 5. Troubleshooting ZERO100FU designed perfect self-diagnosis function.The errors are displayed on the upper right corner of the menu window via identification code in a timely order. Display orderly all the existing errors on M08 Hardware self-diagnosis is conducted every time when power is on. Some errors can even be detected during normal operation. For those errors undetectable due to incorrect settings or improper testing conditions, the flow meter will also display useful information to help the user to quickly debug the error and solve the problems according to following listed methods. Displayed errors of ZERO100FU have two kinds:one is circuit hardware errors information,arising possible problems and solve method can refer to table 1.if finding problems when power is on,and in the state of measuring,it will display “* F”on the upper left corner of screen.power on again,check the displayed information,adopts measures according to following table.if the problems still exist,contact manufacturer. The other is error information about measurement.refer to table 2. Table 1. Hardware self-diagnosis errors and solutions after power on LCD display information Causes Solution ROM verification Error * ROM operation illegal / error * Contact the manufacturer. Logger reading error * Stored parameters are wrong *power on again/contact the manufacturer.
- 27. 27 System logger error * System stored data area has error *power on again/contact the manufacturer. Measuring circuit hardware error * Sub-CPU circuit errors *power on again/contact the manufacturer. Cpu clock speed error * System timer has errors *power on again/contact the manufacturer. Date time error * System date and time are wrong * reset date and time No Display. Erratic or Abnormal Operation * Problem with wiring * check wiring connections.no influence of measuring normally No response to key pressing * Keypad is locked * Bad plug connection * input password to unlock keyboard,or check wiring connections,no influence of measuring normally Table2. Working status errors code causes and solutions code M08 displaying causes solutions *R system work normaly * normal system *J Circuit Hardware Error * Hardware problem * Contact the manufacturer *I No Signal * Unable to receive signal * Loosen contact or not enough couplant between transducer and pipe surface. * Transducers installed improperly * scaling on inner pipe wall is too thick. * new changed liner * Make sure the transducer is in tight contact with pipe surface, the couplant is enough . * Polish the pipe surface and clean the pipe surface. Clear paint,rust. * Check original installation parameter settings * Clear the scaling or change the pipe with thick scaling,normally change to another measurement point that has little scaling,the meter can work normally. * Wait until the liner has been solidified and then test. *H lower signal strength received * lower signal * causes are the same with code “I” * solutions are the same with code “I”。 *H poor signal quality received * poor signal quality * include above all caused * include above all solutions *E The current of Current Loop is Over 20mA (not influence the measurement if not using current * 4-20mA current loop output overflow 100% * Improper settings for current loop output 。 * Check current loop settings on M56. or Confirm if the actual flow rate is too high.
- 28. 28 output) *Q Frequency Output is Over the set value(not influence the measurement if not using frequency output) * 4-20mA current loop output overflow 120% * Improper settings for current loop output 。 * Check frequency output settings(refer to M66-M69). or Confirm if the actual flow rate is too high. *F Listed in table 1 * find problems when power on and self-diagnosis * permanent hardware errors * power on again,check the information showed on screen,handled according to table 1,if not solved ,contact manufacturer. * contact manufacturer. *G Adjusting Gain >S1 Adjusting Gain >S2 Adjusting Gain >S3 Adjusting Gain >S4 （ displayed on M00,M01,M02,M03） Instrument is in the progress of adjusting the gain to prepare the measurement. If stopped at S1or S2 or switched between S1 and S2,that means the too lower receiving signal or not good wave. *K Empty pipe ,setup in M29 no liquid in pipe or wrong setup. if there is liquid actually,input 0 value in M29 Attention:the codes of *Q,*E displayed do not affect measurement,only means current loop and frequency output have problems 6 Warranty and service §6.1 Warranty The products manufactured by Zero Instrument.are warranted to be free from defects in materials and workmanship for a period of one year from the date of shipment to the original purchaser. Zero Instrument' obligation should be limited to restoring the meter to normal operation or replacing the meter, at Zero Instrument' choice, and shall be conditioned upon receiving written notice of any alleged defect within 10 days after its discovery. Zero Instrument will determine if the return of the meter is necessary. If it is, the user should be responsible for the one-way shipping fee from the customer to the manufacturer. Transportation: buyers are responsible for the freight from our factory to destination. §6.2 Maintenance Service
- 29. 29 For operational problems, please contact the technical support department by telephone, fax, email or internet. In most cases, problems could be solved immediately. For any hardware failure of the instrument, we recommend our customers to send back the instrument for service. Please contact the technical support department with the model number and serial number of the unit before sending the unit back to us. Both numbers can be found on the product label. For each service or calibration request, we will issue a Return Materials Authorization (RMA) number. Take notice that the cost for repairing can only be determined after receipt and inspection of the instrument. A quotation will be sent to the customer before proceeding with the service. Normally,buyer is responsible for the transportation of meters and freight §6.3 Software Upgrade Service We provide free-of-charge software upgrade services. Please contact the factory for any lately developed software. §6.4 Important Notice for Product Return Before returning the instrument for warranty repair or service, please read the following carefully: 1. If the return item has been exposed to nuclear or other radioactive environment, or has been in contact with hazardous material which could pose any danger to our personnel, the unit cannot be serviced. 2. If the return item has been exposed to or in contact with dangerous materials, but has been certified as hazard-free device by a recognized organization, you are required to supply the certification for the service. 2. If the return item does not have a RMA# associated, it will be sent back without any service conducted.