Diessel IZM L

Instruction

Manual

Instrument Model Number

Instrument Serial Number

IZMLElectromagneticFlowmeter

Form Number AIC2041'March 2004

Revised: July 2009

Anderson Instrument Co. Inc..156 Auriesville RoadFultonville, NY 120721-800-833-0081Fax 518-922-8997

ww.andinst.comW

Table of Contents 1. General Description ....................................................................................... 4

1.1. Preface.......................................................................................................................4 1.2. Structure....................................................................................................................4 1.3. Function ....................................................................................................................4 1.4. Flow Tube..................................................................................................................5 1.5. Converter...................................................................................................................5 1.6. Technical Data ..........................................................................................................6

1.6.1. Converter ......................................................................................................6 1.6.2. Flow tube (Integral Design)...........................................................................6 1.6.3. Flow tube (Remote Design) ..........................................................................7

2. Locating The Meter ....................................................................................... 8 2.1. General ......................................................................................................................8 2.2. Specifics....................................................................................................................8 2.3. Dimensions and Weight...........................................................................................9 2.4. Conditions Required for the Flow Tube ...............................................................10

2.4.1. Air and Gases.............................................................................................10 2.4.2. Solids..........................................................................................................10 2.4.3. Mounting Position .......................................................................................11 2.4.4. Inlet and Outlet Pipe Sections ....................................................................12 2.4.5. Conductivity Conditions ..............................................................................12 2.4.6. Interference Fields......................................................................................12 2.4.7. Earthing/Grounding Conditions...................................................................13 2.4.8. Flow Tube Lining ........................................................................................13

2.5. Conditions Required for the Converter ................................................................14 2.6. Cable Lengths for the Remote Version ................................................................14

3. Installation ....................................................................................................15 3.1. Installation of the Flow Tube .................................................................................15 3.2. Installation of the Converter..................................................................................16

3.2.1. Wire Openings and Connectors..................................................................17 3.2.2. Connection of the Flow tube.......................................................................18

Electrical Connection of Peripherals................................................................................20 3.3. Retrofit of the 4/20 mA Add-on Board ..................................................................21

4. Start-up..........................................................................................................23 4.1. General ....................................................................................................................23 4.2. Check List before the Initial Start-up....................................................................24 4.3. Basic Settings for the Start-up..............................................................................26

4.3.1. Structure and Operating Elements .............................................................26 4.3.2. ZERO Key ................................................................................................27 4.3.3. ABORT Key..............................................................................................27 4.3.4. Parameter Switch S6..................................................................................27 4.3.5. Rotary-type Correction Switch S4...............................................................27 4.3.6. BUS Address Switches S1 and S2.............................................................27 4.3.7. Display Unit.................................................................................................28

4.4. Functional Control upon the Start-up...................................................................29 4.4.1. Converter without Display Unit ...................................................................29

4.4.2. Flow tube with Display................................................................................ 29

4.5. Flow Direction ........................................................................................................ 29 4.6. Zero Point Adjustment (ZERO Adjust).............................................................. 29 4.7. Volume Pulses........................................................................................................ 30 4.8. Metering Interruption (assignment of the digital input)...................................... 31 4.9. Flow Signal ............................................................................................................. 31 4.10. Metering with an Empty Meter Tube..................................................................... 32

4.10.1. Internal "EMPTY Pipe Detection" ............................................................... 32 4.10.2. External "EMPTY Pipe Detection".............................................................. 32

4.11. Metering at Low Conductivities ............................................................................ 32

5. Operation ..................................................................................................... 33 5.1. Basic Keyboard Functions.................................................................................... 33 5.2. Operating Structure of Display and Keyboard .................................................... 33

5.2.1. Zeroing the Single Quantity Counter V .................................................... 33 5.2.2. Zeroing the Total Quantity Counter V2 .................................................... 34 5.2.3. Deletion of Error Messages........................................................................ 34

6. Parameterization .......................................................................................... 35 6.1. Parameterization by Parameter Switch S6 .......................................................... 35 6.2. Setting via Keyboard and Display Unit ................................................................ 36 6.3. Adjustments ........................................................................................................... 40

7. Troubleshooting........................................................................................... 42 7.1. Error Diagnosis ...................................................................................................... 42

7.1.1. Error Diagnosis without a Display .............................................................. 42 7.1.2. Error Diagnosis via Display ........................................................................ 43

7.2. Typical Effects or Possible Malfunctions ............................................................ 45 7.2.1. Flow without Flow Rate Indication:............................................................. 45 7.2.2. No Pulse Transmission despite Displayed Flow ........................................ 45 7.2.3. No Analog Signal Available........................................................................ 45 7.2.4. Deviations of Measured Values.................................................................. 46

7.3. Fault Reset.............................................................................................................. 47 7.4. Flow tube Tests ...................................................................................................... 47

7.4.1. Insulation Test............................................................................................ 47 7.4.2. Symmetry Test ........................................................................................... 48 7.4.3. Visual Check .............................................................................................. 48

7.5. Table 6: Visual check............................................................................................. 48 7.5. 49

8. Maintenance ................................................................................................. 49 8.1. Safety Instruction for Maintenance Work ............................................................ 49 8.2. Maintenance ........................................................................................................... 49

8.2.1. Upkeep....................................................................................................... 49 8.2.2. Preventive Maintenance Steps................................................................... 51

8.3. Repairs .................................................................................................................... 51 8.3.1. Sending-in the Flow Meter to the Manufacturer ......................................... 51 8.3.2. Repair Work ............................................................................................... 52

8.3.2.1. Replacement of the Fuse ............................................................... 52 8.3.2.2. Replacement of the Main Board..................................................... 52 8.3.2.3. Replacement of the Power Supply Board ...................................... 52 8.3.2.4. Replacement of the Housing Cover ............................................... 52 8.3.2.5. Replacement of the Flow tube ........................................................52

8.4. Special Program Functions ...................................................................................53 8.4.1. Activation of Functions ...............................................................................53 8.4.2. Flow simulation...........................................................................................53 8.4.3. Hardware Test by the Parameter Switch ....................................................54 8.4.4. Simulation by the Display Unit ....................................................................54

9. Warranty and Return Statement .................................................................55

10. IZML HART Installation.......................................................................56

1. General Description

1.1. Preface This instruction manual should be carefully read before the operation of the equipment is started. It should be kept in the vicinity of the device described, easily accessible to all persons concerned. It is necessary to observe and follow the safety instructions. Anderson Instrument Company cannot assume any liability or legal responsibility for operating errors caused by the misuse of this product.

1.2. Structure This instruction manual is applicable to the following versions of electro-magnetic flow meters:

1. Integrated design IZML, which consists of the flow tube directly mounted and wired to the converter, i.e. it forms one single metering unit.

2. Remote design IZMLXXXXXXXRX, consisting of:

a. Converter type IZMLR in wall mount housing b. Flow Tube IZMS-XXX-BODY c. Connection cable for coil supply and electrode signal

The following options are available:

Equipped with an analog output for the electrical output of the flow rate Equipped with a display for indication of process information.

1.3. Function The IZML electromagnetic flow meter determines the flow rate and the volume of liquid streams at a high precision and is suitable for metering conductive liquids. The converter is a microprocessor-controlled device that supplies a switched and regulated coil current for the flow tube. A resulting signal is generated at the electrodes and is amplified in the converter, conditioned and processed both as a flow rate and volume information in the internal measuring registers. Standardized digital pulses (pulses per volume unit) are output. The flow rate of 0 - 100 % can be output as an analog 4 - 20 mA signal using an additional board. Apart from that, a display can be used to indicate the measured values.

When leaving the factory, the meter is usually specifically configured such that it is only necessary to connect the supply voltage and peripheral devices.

1.4. Flow Tube The flow tube is diagramed below. The flow tube housing the electronics or a field terminal box on top. A pair of connection adapters is attached to each end of the lined flow tube with a flat connection

gasket and held in place by a sanitary clamp. The flow tube incorporates two electromagnetic coils and a Teflon-lined flow tube in a stainless steel housing. Two electrodes are located inside the flow tube. The electrodes are centrally located and are diametrically opposed. The electrodes do not protrude into the flow tube and therefore will not disturb the fluid flow.

1.5. Converter

Mounted on the flow tube or remotely, the microprocessor-based converter changes electrical signals from the meter body into flow rate and total data. A coil drive circuit in the converter provides a switched and regulated constant coil current that excites a magnetic field within the flow tube. The signal induced at the electrodes is amplified, digitized, and processed by the converter. The converter produces one frequency output and an optional analog output is available that is proportional to the flow rate.

CLEAR

ENTERM

1.6. Technical Data

1.6.1. Converter Electric power supply: 115/230 V, 50-60 Hz, (0.10A/0.05A) -15%/+10% 16 ... 34 V DC (0.4 ... 0.2A) Power consumption: 10 VA / 10 watts max. Electric fuse protection: AC supply T500 mA DC supply M2.5 A Digital pulse output: 1 x electrically isolated optocoupler output Maximum load: 30 V/80 mA / pulse sequence: 1000 Hz max. Analog output (option): 4 ... 20 mA (active), load 500 max. Digital input: 1 x electrically isolated optocoupler input; (count interruption) Serial interface: Hardware type: RS485 Diessel CS3-Bus protocol BUS connection: (option) Profibus DP Ambient temperature: -5F ... +130F

1.6.2. Flow tube (Integral Design)

Connections and nominal widths:

Clamp: 12 (1" connections), 112, 2", 3" (4" connections)

Meter tube: Material no.: 1.4301 Lining: PTFE Electrodes: Material no.: 1.4404 Flow tube housing: Material no.: 1.4301 (blasted) Connection housing: Cast aluminium (with special anticorrosive coat of varnish)

Materials:

System of protection: IP65

Product temperature: 176F max.

Product conductivity: 5 S/cm min.

Admissible pressure: 0.5 bar min. absolute at 68F, 10 bars max.

Flow velocities: 0.33 - 19.7 ft/s

1.6.3. Flow tube (Remote Design)

1.6.4. Measuring Ranges and Error Limits (All Models)

Connections and nominal widths:

Clamp: 12 (1" connections), 112, 2", 3" (4" connections)

Meter tube: Material no.: 1.4301 Lining: PTFE Electrodes: Material no.: 1.4404 Flow tube housing: Material no.: 1.4301 (blasted) Connection housing: Cast aluminium (with special anticorrosive coat of varnish)

Materials:

System of protection: IP65

Electric connection:

Coil supply of the flow tube 18ga. shielded Electrode signal to the flow tube: 16ga, shielded Typical standard cable length: 25 each (separated design) Coil resistance: 100 ohms

Product temperature: 300F max.

Product conductivity: 5 S/cm min.

Admissible pressure: 0.5 bar min. absolute at 68F, 10 bars max.

Flow velocities: 0.33 - 19.7 ft/s

Measuring tolerance DN Total measuring range [G/Min ]

Flow rate at a flow velocity of

1 m/s [ G ] < 0.25 % < 1 %

Uni

t

15 .29 - 15.90 2.82 > .57 > .29 G/M 25 .66 - 52.84 7.93 > 1.32 > .66 G/M 32 1.10 - 79.25 12.77 > 2.64 > 1.32 G/M 50 3.08 - 198.1 30.82 > 6.16 > 3.08 G/M 65 5.28 - 330.2 52.84 > 10.57 > 5.28 G/M 80 7.93 - 528.4 79.25 > 15.85 > 7.93 G/M 100 12.33 - 880.6 123.3 > 24.66 > 12.33 G/M

2. Locating The Meter

2.1. General The following points need to be observed to avoid damage to the flow meter or injuries during the transport of the device: Transport work is only allowed to be carried out: - by accordingly qualified and authorized persons, - by the aid of appropriate load suspension and fastening devices, - if any risk of lifting and/or moving the device can be fully excluded.

The packing of the flow meters is subject to the following labelling:

Fragile goods

Keep dry!

Check the packing list before you begin opening the package! Compare the contents to the packing list to confirm all of the parts are present or not! Treat sensitive parts with special care!

Please properly dispose of the packing material according to local regulations.

2.2. Specifics The stainless steel adapters on the ends of the flowtube need to stay attached to prevent damage to the internal Teflon lining of the flowtube.

When removing the packaging, see to it that the device (such as display or keyboard) are not damaged or destroyed.

2.3. Dimensions and Weight

1.6

2.55

B

A

3.9

4.8

C

6.6

7.63

6.50

6.57

FRONT VIEW

4.19

SIDE VIEW

Dimensions C

Sanitary Clamp

Connection A B Standard Option 1 Option 2 Option 3 Option 7

Combined Approx. Weight

1" / 3/4" 3.9" 6.3" 13.25" 9.88" 10.50" 13" 19 lb. 1-1/2" 3.9" 6.3" 13.25" 9.88" 13" 19 lb.

2" 5.1" 7.5" 13.25" 9.88" 13" 22 lb. 2-1/2" 6.5" 8.8" 13.25" 9.88" 13" 30 lb.

3" 6.5" 8.8" 13.25" 9.88" 13" 32 lb. 4" Flange 7.5" 9.8" 11.67" 13.67" 46 lb.

Shown with remote electronics terminal enclosure

Shown with integral converter

Remote converter

2.4. Conditions Required for the Flow Tube The installation of the flow meter depends on the version delivered: remote or integral design.

In any case the flow tube has to be installed in the product line and the converter has to be supplied with electric power.

When selecting the location for the installation of the flow meter you should ensure an optimum earth ground, if some welding work had to be performed, protect the flowmeter from any electrical cross-flows which could occur, as they could cause damage to the electronic portion of the meter.

In order to protect the flow tube against damages, Locate the device so that:

Caution

the process pressure is always kept below the admissible operating pressure the product temperature is always kept below the admissible temperature the flow tube is mechanically stabilized (e.g. to avoid vibration) the flow tube is not operated at negative pressure the flow tube can be emptied in case of the danger of frost integrated devices with built-in display are not permanently subject to direct sunlight the flow meter is not arranged straight above a gully or sink hole the connection housing is not permanently exposed to drip water

2.4.1. Air and Gases The electromagnetic measuring system can supply accurate results for pure liquids. Air slugs or deaeration in a liquid will lead to inaccuracies. Make sure that air slugs or other possible parts of gas are safely removed before the measuring device e.g. by air eliminators or that deaeration can be stopped by sufficient operating pressure. The measuring device will not be damaged by air slugs.

2.4.2. Solids Normally, solids do not have any negative influence on the volume measurement. The pipe diameter should always be chosen sufficiently large in order to prevent the meter tube from being clogged in the case of products with solid particles. Due to the fact that the flow velocity of solids is relatively lower than that of the liquid part of the product, a higher flow fluctuation could be caused while the flow rate is determined. The measurement of abrasive materials can cause a drifting of the measuring accuracies and, in the end, a deterioration of the flow tube liner.

2.4.3. Mounting Position Due to the measurement principle described, the installation position to a certain extent can be selected any way desired. The basic condition for accurate measuring results is, however, a full and gas-free meter tube. If possible, the electrode axis should be horizontally arranged, in order to avoid a collection of gas bubbles or solid particles on the surface of the electrodes. Therefore, a slightly ascending pipeline is advisable, preferably with a deaerating possibility at its highest position. For measuring devices equipped with a display the mounting position should be chosen in such a way that the display is easily read exposure to sunlight is minimized.

Guidelines

Installation Illustrations

A

Install in a horizontal pipe section at a low point before a rising pipeline to ensure flow tube remains full.

B

Install in a vertical pipe section with an upward direction of flow to ensure flow tube remains full.

C

Do not install in a horizontal pipe section located at the highest point of the pipeline. This location allows air to accumulate in the flow tube which causes measuring errors.

D

Do not install in a vertical pipe section with a downward direction of flow. This location allows air to accumulate in the flow tube which causes measuring errors.

E

In a horizontal pipe section, if possi-ble, configure a slightly rising section for meter body placement to keep flow tube full.

F

In a free inlet or outlet, install the meter body in a low section of the pipeline that has an equal rise on the inlet and outlet end of the meter body to keep flow tube full.

G

In a pipe section with a vertical flow downward of a length exceeding 16 feet (5 meters), install a vacuum breaker downstream of the meter body to protect it from vacuum.

2.4.4. Inlet and Outlet Pipe Sections For the installation of the electromagnetic flowtube a recommended inlet pipe section of 5 pipe diameters and an outlet pipe section of 2 pipe diameters are needed for undisturbed flow. For an irregular flow (e.g. distorted rotational flow profile) the inlet and outlet pipe sections have to be extended accordingly or a flow straightening device has to be installed in order to guarantee the specified measuring accuracy.

2.4.5. Conductivity Conditions The minimum conductivity of the product may not fall below 5 S/cm. A count suppressor for empty meter tubes is used for all standard meters . The empty pipe function will have to be switched off at conductivities below 50 S/cm.

2.4.6. Interference Fields At the flow tube no masses of iron or strong permanent or electromagnetic fields may exist which could influence the flowmeters magnetic field, thus falsifying the signal.

H

Install a shutoff valve downstream (outlet side) of the meter body to prevent a vacuum condition on the liner of the meter body.

I

Do not install the meter body on the suction side of a pump to avoid liner damage due to vacuum.

J

The length of the pipe section on the inlet side of the meter body must be at least five pipe diameters of straight pipe in front of the meter body. The length of the pipe section on the outlet side of the meter body must be at least two pipe diameters of straight pipe from the meter body.

2.4.7. Earthing/Grounding Conditions Earth grounding of the flow tube is an essential requirement for a reliable and accurate measurement.

Inductive measuring method means that the metered liquid itself acts as an electric conductor, i.e. a correct and careful earthing/grounding ensures that no additional potentials will falsify the extremely low metering signal.

For that reason, the earthing/grounding resistance has to be definitely smaller than 10 ohms. The earth/ground wire used must not transfer any interference voltages, i.e. no other electric devices may be connected to that line. In case of the remote design, the earth ground between flow tube and converter is achieved by means of the shielding of the electrode cables and the coil supply cables.

Flow tube with clamp fitting: Assembly into a metal pipeline without electrically insulating lining. The clamp connections form the earth/ground connection to the liquid.

2.4.8. Flow Tube Lining A damaged lining will cause measuring errors or even a failure of the flow meter. Flow tubes with PTFE lining must not be operated at an absolute pressure of 122 F of the measured product. For that reason, when selecting the location for installation you should consider that no negative pressure can be caused, not even when the pump is switched off. An installation at the highest point of the pipeline has to be avoided for this reason. Due to the fact that PTFE can be cold-worked when being under pressure, proper elastomeric gaskets need to be installed into the mating clamp adapter connections.

The arrow on the name plate shows the calibrated flow direction for the flow meter. In principle, the flow meter can measure in both directions. Provided that the recommended inlet and outlet conditions are kept, the accuracy of the measurement in both directions may be slightly different.

2.5. Conditions Required for the Converter

In order to guard the converter against damages, always select a location so that:

Caution

the ambient temperature is within a range from 4...+130 F the field housing is mounted without any external stresses no moisture can enter the field housing through the electrical connections the housing is not permanently exposed to direct contact with product or water devices with built-in display are not permanently subject to direct sunlight

Apart from the above, please ensure that the housing can be easily opened for service purposes.

Measuring devices equipped with local displays have to be installed in such a way that they can be easily read off and operated.

2.6. Cable Lengths for the Remote Version The flow tube is installed into the pipeline. For reasons of EMC, the flow tube has to be installed at the shortest practical distance from the converter. The standard coil and electrode cables delivered are sized to cover a distance of 25 each. The following conditions have to be considered for larger distances: a. The cables have to be laid into a separate cable duct.

b. Laying the cables near to frequency converters or motors has to be avoided.

c. The maximum distance between flow tube and converter depends on the conductivity of the product. The following approximate values are recommended: Conductivity < 50 S/cm maximum distance: 15 Conductivity < 200 S/cm maximum distance: 75 Conductivity > 200 S/cm maximum distance: 150

d. The shielded cables supplied by the manufacturer have to be used or equivalent.

e. The shields have to be put onto the flow tube and the converter.

3. Installation Only qualified individuals with authorization of the user are to carry out the installation work. Current codes and regulations should determine the methods used for the installation.

The following points should be taken into account after completion of the installation work:

It has to be checked whether all external supply connections really meet the requirements specified in the technical data of the flow meter (e.g. pressure, temperature, etc.).

The pipelines have to be flushed and cleaned before production is started. All pipeline connections need to be checked that they are safe, leakage-free, and

nearly a stress-free connection to the flow tube.

Any process leaks need to be fixed.

The electric wiring of the voltage supply and the inputs and outputs of the control circuits has to be carried out according to the wiring diagram and required electrical codes.

3.1. Installation of the Flow Tube

Pay attention to the fact that the clamps are properly tightened. Otherwise, hot or caustic solutions may leak after installation. . If the flow tube is to be connected to existing process lines, those lines have to be unpressurized and free from product prior to installation.

The PTFE (Teflon) lining of the flow tube is extremely sensitive to impact and vacuum. The lining is flared over the clamp connection gasketing surface.

CAUTION! The gasketing surface can not be damaged or removed!

Do not forget to insert the gaskets into the adapter connections during assembly! In case of leaking pipe connections you should check the gasket. Never overtighten the clamp connection!

After installation of the flow meter it is important to ensure an optimum earth ground, if some welding work is required following installation the best solution is to remove the

complete flow meter from the piping to not allow an electrically conductive bridging-over of the pipe connections. Attach the grounding electrode of the welding device as close as possible to the joint being welded in order to avoid any stray currents within the pipe system and the flow meter. Always attach the grounding electrode of the welding device at the side of the weld and away from the flow meter (in that case the current will flow away from the flow meter).

3.2. Installation of the Converter In case of the integral design, the converter is mounted directly on the flow tube, i.e. it is located on the pipeline. For the remote design the field housing is typically configured for wall mounting. Cable glands always have to point downwards to reduce the likelihood of water intrusion.

When installing the flow meter pay special attention to the fact that no water can get onto the electronic boards when the cover is opened.

Metal particles, such as trimmed wires, drilling shavings, or residues from the cable shields have to be removed from the boards before the electric power supply is switched on. See to it that the pipelines are supported in such a way that no forces are exerted on the flow tube. Installation of the Electrical Power Supply

The following safety precautions have to be followed for a proper electrical installation : Intended use

The flow meter type IZML is exclusively designed for the: - Connection to an earthed/grounded monophase network - Use in industrial areas for reason of EMC (according to definition EN 50 081-2) Staff qualification

Necessary work to the flow meter type IZML is only allowed to be performed by trained and qualified personnel.

The name plate of the flow meter has to be observed for the electrical connection. The electrical power supply is connected to terminal X1 on the upper board: L/N/PE for alternating current (AC) +/- for direct current (DC) The nominal voltage has to be equal to the nominal voltage of the flow meter (see the sticker on the board and the specification on the type plate).

For alternating voltage the ground conductor is put in the PE terminal. For direct voltage only the PLUS- and MINUS terminals are connected. The cable shield has to be correctly terminated onto the designated terminal in order to guarantee an optimum operation of the device according to the EMC directives.

In case of hard-wired devices without any main switch it is necessary to install a power switch. That switch needs to be located near the device, easily accessible to the user and clearly marked as a disconnecting or isolating link for the device. The flow meter can be supplied by different voltages. Table 1 shows the possible nominal voltages and admissible tolerances.

Voltage type Tolerance Changeable Tolerance Part no. Fuse protection 24 V DC 16 ... 34 V ----- ----- 300-MB11DC M 2.5 A

230 V, 50 - 60 Hz 195 ... 253 V 115 V 98 ... 127 V 300-MB11AC T 315 mA

Table 1: Available types of supply voltages The supply voltage valid for the device is indicated on a yellow sticker affixed to the board. Apart from that, the supply voltage is shown on the name plate.

The 230 V versions can be changed to 115 V by means of soldered jumpers on the 300-MB11AC board. Normally, such a conversion is carried out at the factory only.

3.2.1. Wire Openings and Connectors Local code may require conduit for all or part of the wiring for the meter body and converter installation. However, whether conduit or direct cabling is used, the plugs on the meter body and converter must be removed and replaced with either cord grips or conduit adapters.

Plug

Each IZML meter is shipped with plugs and polyethylene seal rings at all entry points. When a plug is removed, transfer its seal ring to the corresponding cord grip or conduit adapter.

Cord Grip

When properly used, this connection offers high resistance to water intrusion by means of a sealing grommet which is compressed against the outer cable sheath. All connections must be tight and waterproof.

Conduit Adapter

This connection consists of a threaded adapter to mate directly with " NPT rigid conduit and liquid-tight conduit connectors. All connections must be tight and waterproof.

The recommended entry methods for cable or conduit are indicated below. Never enter the enclosure from the top or sides. Create a generous drip leg before each entry point to collect condensate from within the conduit or cable. After wiring, fill any void with an approved silicone sealant to ensure water tightness.

Use only the designated openings in the converter for the input and output wiring. Do not substitute connectors or create new openings.

3.2.2. Connection of the Flow tube In case of the remote design the coil cable and the electrode cable has to be installed after the installation of the flow tube into the pipeline and after the mounting of the converter housing. The electrical connection between the flow tube and converter has to be carried out before the measuring device is switched on. Pay attention to the following: the supply voltage in the converter is switched off while the flow tube is installed. no moisture may drip onto any of the electronics. no metal particles, e.g. of the shielding, can fall into the electronic unit. Function: The magnet coils of the flow tube are supplied straight from the converter. The ground and the two electrode signals E1 and E2 of the converter are led to the converter. The following cable types have to be used: Coil cable 18ga shielded Electrode cable 16ga shielded

Connection of the flow tube and converter (Remote Design)

26 2221

+ -6 5

AnalogOutput

L N PE

IZM-L

242332313433 25

OptionalOperatingVoltageDecal

RedWhi

te

Whi

te

Shi

eld

Blac

k

Blac

k

Meter Body

EarthGround Lug

EarthGroundCustomer

supplied ringterminal &ground wire

111216 1814

L N

24 VDC

Input Power

EarthGround

AC

check flowmeter forvoltage requirements

BlackWhite

Shield

WhiteRed

Black

Shield

12 1116 14 18 13 13

CB

L-IS

-03-

BD

66

CB

L-P

B-0

2-R

D01

Electrical Connection of Peripherals

The following signal input and outputs are available:

1 x digital output for volume pulses 1 x digital input for measuring interruption 1 x analog output of 4...20 mA for the flow rate

(optionally by an additional board) 1 x internal BUS interface

Optocoupler: Passive External voltage: 10 ... 30 V DC / 80 mA max.

1. Digital output Terminal:

X2 / no. 26 PLUS X2 / no. 25 MINUS

26 2221

+ -6 5

AnalogOutput

L N PE

I ZM-L

242332313433 25

OptionalOperatingVoltageDecal

111216 1814

26 25

SIGCOM

Open CollectorPulsed Output

+ -6 5

ACTIVE AnalogOutput 4-20mA

Max Load 500 ohmfor all elements on Control Loop

+

+

30 VDC/80 mA(pulse sequence1000 Hz max)

{{

32 31

+10 to 30 VDC

(energized statefor count inhibit)

externally powered

+ -

Count Inhibit Input

BUS-signallight

BUSidentifi-cationswitch

CS3-BUS connector

FuseAC T315 mADC M2.0 A

BlackWhite

Shield

WhiteRed

Black

Shield

These volume pulses can specifically be suppressed by a digital input, e.g. during cleaning or in case of failed measurements while the meter tube is empty.

Optocoupler: Passive External voltage: 10 ... 30 V DC

Terminal: X2 / no. 32 PLUS X2 / no. 31 MINUS 2. Digital input

Function: Voltage ON Volume pulses are suppressed An analog output of 4-20 mA for a flow rate indication is made available by application of a plug-in type add-on board (option: no. 300-MBLC).

Active 4 mA 0 % flow rate 20 mA 100 % flow rate (see table of measuring ranges) 3. Analog output No. 6 PLUS No. 5 MINUS

add-on board terminal X1

The analog works in both flow directions!

3.3. Retrofit of the 4/20 mA Add-on Board The add-on board type MBLC provides the analog output of the measured values of 4 20 mA corresponding to 0 100% for the flow rate. The board is mechanically installed by means of the screw included with the board and electrically by plug X11 on the upper board. Disconnect the power supply before you begin the installation! There is no additional setting or adjustment of the add-on board that is necessary. The output is active and supplies a current of 20 mA max. The maximum load of the source of current (burden) can be 500 ohms. The allocation of: 20 mA = Qmax (= 100% flow) depends on the nominal width of the flow tube and is usually fixed by parameter S6. The allocation is shown in the corresponding table. Position S6[5] of the 8-pole parameter switch S6 can only be used to double or halve the range for each nominal width. A different allocation is only possible by parameterization by the aid of the display/keyboard.

PA

GE

22

Para

met

ersw

itch

S6

Ana

log

outp

utbo

ard

4-20

mA

20m

A-

outp

utsig

nalb

y:

Inst

alla

tion

ofth

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size

DN

S6[5

]=

OFF

S6[5

]=

ON

[mm

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h][l/

h]w

ork

setti

ng

25 40 50 65 80 100

3.00

010

.000

15.0

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.000

35.0

0050

.000

6.00

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.000

30.0

0050

.000

70.0

0010

0.00

0

4. Start-up

4.1. General The measuring device may only be operated by trained persons who have got the necessary authorization from the user of the system. The operators have to be familiar with the process, able to recognize possible dangers, and in a position to take the necessary steps for the removal of accident risks.

Safety Measures for Start-up Caution Caution

Both an orderly performed installation and a correct electric connection are prerequisites for the start-up work.

Pay attention to the following points upon the initial start-up of the flow meter:

Close the housings of flow tube and converter. - Personal injury by electric shock can be caused, if the electric lines are touched. - Instrument damages can be caused by moisture or metal parts on the electronic unit.

Ensure that all connections at the flow meter and in the direct vicinity are tight. If parameter settings have to be made through the service display unit MSD, the

connector is only allowed to be plugged in while the device is switched off.

4.2. Check List before the Initial Start-up

Table 2: Check list

Advice for Starting-up the IZML

1. The meter has to be installed into the pipeline

Check the flow direction The flow range adjusts itself automatically. After the electrical start-up a ZERO-Adjust should be carried out by means of the typical

liquid to be measured (full meter tube and no flow!). 2. Which supply voltage is necessary for an IZML?

The standard voltage is: 115 V alternating current (AC) If a different supply network exists at the customers, the following possibilities could be

used: - Replacement of the upper board by the version of: 24 V direct current (DC) - Replacement of the upper board by the version of: 115 V alternating current (AC) - Change of the upper 115V board by soldering to: 230 V alternating current (AC)

3. Which parameterizing possibilities are normally provided for the IZML?

The standard parameterization of the IZML is only carried out by means of the 8-pole parameter switch S6 on the upper board.

The efficiency of the parameter switch is fixed by the position S6 [8], i.e. the switch is normally set to "OFF".

An individual parameterization is possible by the help of the Service Display Unit MLD or the PC software IVON. For the individual parameterization it is necessary to set the parameter switch S6 [8] = OFF.

4. How can the volume pulses be connected, set, and checked?

The digital output for the volume pulses is passive as an Optocoupler with both an emitter connection (+) and a collector connection (-), i.e. a DC voltage (typical 24V!) has to be supplied from the outside. A maximum current of 80 mA is allowed to flow.

The yellow pilot lamp on the upper board shows when a volume pulse is put out. Volume pulses are generated in the forward direction. The pulse value can be changed by the first 3 positions of the parameter switch S6. The output can be set between 0.001 and 10,000 pulses per gallon;

The black "ABORT key" has to be depressed after the setting of the desired pulse output. In order to verify the function, volume pulses can be generated without any flow by the flow

simulator.

5. How can the analog output be put into operation?

The supply power needs to be disconnected before the add-on board with the analog output is inserted. The board has to be attached by means of the included screw.

The analog output is plugged onto the upper board as an add-on board. Dependent on the flow rate the analog output produces an active current between 4 and

20mA.

The allocation of the flow range 20mA = Qmax for the analog output of the IZML is set by the parameter switch position S6[5]. Dependent on the nominal width the flow range can be doubled or halved:

e.g. DN50: 4 - 20 mA 0 150 g/min or 4 - 20 mA 0 300 g/min. The volume pulses do not have any influence on the change of the flow range. The flow simulation can be set for a functional check.

6. Which other conditions should be taken into consideration?

During a faultless operation the green BETR. lamp should be permanently on. After switching on the measuring device the red ERR. lamp may also be lighting for 30 seconds max., but after that short period it has to go out.

Is a simulation required for the setting of external devices (PLC, digital counter, etc.)? A simulation of a 50 % flow rate can be started by parameter switch S6[7] (the ABORT key has to be depressed after positioning the parameter switch!).

Too low product conductivity? Below 50 S/cm the internal empty-pipe detection has to be set by parameter switch position S6[4] = OFF and the ABORT key has to be depressed.

Is the analog output too unsteady? The flow filter can be switched on by parameter switch position S6[6]; the time constant for the analog output now changes from 1 to 5 seconds.

4.3. Basic Settings for the Start-up At the factory the electromagnetic flow meter is adjusted by using water. Normally, the

settings of parameter switch S6 are inactive.

4.3.1. Structure and Operating Elements The converter type IZML consists of the terminal board type 300-MB11 and the main board type 300-MBL1.

The following operating elements are available besides the input/output terminals: 1. ZERO key S4 on the upper board 2. ABORT key S5 on the upper board 3. 8-pole parameter switch S6 on the upper board 4. Rotary-type correction switch S4 on the lower board 5. Display/keyboard (option) 2 x 16 characters display / 8 keys The upper board is equipped with additional pilot lamps for the signalization of the different states of the measuring device.

4.3.2. ZERO Key The ZERO key S4 is located on the upper board (300-MB11). A hydraulic zero adjustment is activated when the key is depressed.

4.3.3. ABORT Key When activated, the ABORT key will reset the system to the initial status of the program sequence. It has always to be activated when a change has been made at parameter switch S6 or at the rotary-type correction switch S4.

4.3.4. Parameter Switch S6 Some settings of the device can be changed by the 8-pole parameter switch S6. A simulation can be carried out for test purposes. It should be taken into account that after changing the switch position the desired function will only be switched on after activation of the ABORT key. The whole setting of the parameter switch can be disabled by switch position S6[8] = OFF.

4.3.5. Rotary-type Correction Switch S4 The rotary-type correction switch S4 is located on the lower board. Switch S4 can be used to adjust the measured value within a range from -1.4% ... +1.4%.

4.3.6. BUS Address Switches S1 and S2 For the use of the internal BUS communication it is necessary to allocate an address to the IZML:

S1 low-order Standard: 0 S2 high-order Standard: 2

i.e. the standard address is 20. If several users are interconnected, it will be necessary to provide the different IZML with consecutive numbers (21, 22, etc.). Double addresses are not allowed.

4.3.7. Display Unit

Figure 1: Integrated display unit (option) The following measures can be taken if the IZML is equipped with an integrated display unit (option): Parameter settings Resetting the counters to zero Use of service functions Display of service data Calibration

4.4. Functional Control upon the Start-up The functional control depends on the flow meter version: a. Without display unit b. With display unit or with service display unit type MLD

4.4.1. Converter without Display Unit The housing cover has to be opened for the functional control. The red ERR lamp and the green BETR lamp has to be observed during the start-up process:

Status duration BETR (green) ERR (red)

0 sec. OFF OFF 0.5 sec. ON/OFF ON/OFF 3 sec. ON ON*

30 sec. ON OFF

* If the device had been switched off for a longer period than 5 minutes, the red ERR lamp will not light up after the switching-on process, i.e. that status is not applicable!

4.4.2. Flow tube with Display After switching on the device you will see the following message on the display:

Auto-Test IZML Type V1.09

Normally, the IZML is not equipped with a storage battery. If so, the internal volume registers are not stored and always starting at zero.

V 0.0 gal Q 0g/min

In case of power failures of less than 3 minutes the last measured values will be kept. In that case the first line can show the message warning 901 as a hint at the power failure occurred. Usually, that text is automatically cleared after 30 seconds.

4.5. Flow Direction The IZML measures the flows in both flow directions.

In the standard setting the digital output works in the indicated direction of flow. If the device is equipped with a display, negative flows or quantities will be shown with a MINUS sign.

4.6. Zero Point Adjustment (ZERO Adjust) Upon the first start-up of the flow meter it is recommendable to carry out a zero point adjustment (ZERO adjust) for the adaptation of the flow meter to the existing conditions. Normally, a zero adjustment is not required for the integrated version.

ATTENTION ! The following conditions have to be observed for a ZERO adjust: (1) The device has to have reached its working temperature, i.e. it should have switched

on at least 5 minutes before.

(2) The cables between flow tube and converter have to be permanently mounted in consideration of the EMC rules.The flow tube has to be filled with the typical liquid free of air.

(3) No flow is allowed to occur during the ZERO adjust measurement (flow = zero).

ZERO adjust 95 %

The zero point adjustment is started by activating the "ZERO" key on the upper board.

While the ZERO point measurement is running the green BETR. lamp is flashing in a 1 second cycle.

If the IZML is equipped with a display, the sequence can be started by the selection of the ZERO adjust function without opening the housing.

During the adjustment the status message appears and the up-to-date progress of the function is shown counting down from 100% to 0%.

4.7. Volume Pulses

The measured volume is output in an evaluated pulse sequence by pulse output OUT1 (terminal X2 no. 25 and no. 26). The different outputs for an individual pulse are selected by parameter switch S6 by means of the switches S6[1], S6[2], and S6[3]. It should be taken into account that the parameter switch S6[8] should be set to ON. Otherwise, the internal parameter setting is not effective.

Changes at parameter switch S6 have to be acknowledged by the ABORT key on principle.

Switch position S6[1] S6[2] S6[3]

Pulse output OUT1

OFF OFF OFF 1 pulses/gallon

ON OFF OFF 0.001 pulses/ gallon

OFF ON OFF 0.01 pulses/gallon

ON ON OFF 0.1 pulses/ gallon

OFF OFF ON 10 pulses/ gallon

ON OFF ON 100 pulses/ gallon

OFF ON ON 1000 pulses/ gallon

ON ON ON 10000 pulses/ gallon

Table 3: Parameter switch S6 [1] S6 [3]

The IZML is able to output 1,000 pulses per second max. (= 1kHz). If that pulse frequency is shortly exceeded, a maximum number of 10,000 pulses is intermediately stored and put out on the next occasion, so that no pulse fault will be caused. However, in case of a longer exceeding (more than 10,000 pulses) the storage will be cleared and pulse faults are caused. The following calculation should be carried out for an estimation of the pulse frequency:

Example: DN80, pump capacity: approx. 400 gal/min

Setting: S6[1] = ON S6[2] = OFF S6[3] = ON = 100 p/gal (100 pulses per gallon) The set pulse output results in a maximum pulse frequency of 667Hz, this setting is possible without an error occurring. Even when the flow rate is increased up to 500 g/min, no pulse errors will occurr. If, however, a flow rate of 700 g/min is reached, a total quantity of 116 pulses (1.166 kHz) will be missing in each second because of the restriction of the output frequency to 1 kHz. After about 86 seconds a total quantity of 10,000 will be buffered with the effect that the pulse error will occur!

The upper board is equipped with a yellow pilot lamp PULSE for checking the volume pulses. Unless flow is available, the lamp is either permanently ON or OFF. If flow is available, the lamp will be blinking in representation of the pulse output selected.

4.8. Metering Interruption (assignment of the digital input) For the external interruption of the measurement, e.g. during cleaning, a digital signal can be connected to input IN1 on the upper board. The input is activated by a direct current voltage between 10 V ... 30 V DC at terminal X2 with PLUS to no. 32 and MINUS to no. 31. When activating input IN1 (lamp D21 is lighting) the transmission of the volume pulses is suppressed.

4.9. Flow Signal Optionally, a small additional board can be mounted to connector X11 on the upper board. For the flow range of 0 ... 100% a current of 4 ... 20 mA is generated via terminals no. 5 and no. 6. The preset value of 100 % depends on the nominal width. Normally, it refers to the quantity unit Gallons. By default the 100 % value can only be changed via parameter switch S6 with code switch no. 5 as a doubling or halving, respectively.

Desired flow rate (gal/min) Pulse frequency = x set pulse output (p/gal) 60 (s)

Nominal width DN [mm]

S6[5] = OFF Max. flow rate

S6[5] = ON Max. flow rate

15 500 US gal/min 250 US gal/min 25 1,600 US gal/min 800 US gal/min 32 2,400 US gal/min 1,200 US gal/min 50 8,000 US gal/min 4,000 US gal/min 65 13,000 US gal/min 6,500 US gal/min 80 18,000 US gal/min 9,000 US gal/min

100 26,000 US gal/min 13,000 US gal/min

Table 4: Standard measuring ranges of the analog output

4.10. Metering with an Empty Meter Tube Metrologically perfect flow measurements are only possible, if the meter tube is completely filled with liquid. In order to avoid an undefined counting in case of an empty meter tube, the IZML offers both an internal and an external possibility for suppression:

4.10.1. Internal "EMPTY Pipe Detection" The IZML is equipped with a special EMPTY pipe detection ("pipe detect"). The setting is made by parameter switch S6[4]. Usually, the EMPTY pipe detection is switched on, i.e. an undefined count will be suppressed in case of an empty meter tube. At the following situations the internal EMPTY pipe detection has to be switched off by parameter switch S6[4] = OFF:

- At a product conductivity of less than 50S/cm. - At a heavily pulsating flow (piston, membrane or hose pumps).

4.10.2. External "EMPTY Pipe Detection" An external EMPTY pipe detection can be reached by an appropriate assignment of digital input "IN1", e.g. by an additional level sensor, a system-specific control contact, etc. In that case the internal EMPTY pipe detection should be switched off. With regard to metrological aspects, the external EMPTY pipe detection achieves a better measuring accuracy.

4.11. Metering at Low Conductivities The IZML is capable of measuring liquids from a minimum conductivity of 5S/cm. In order to obtain results at conductivities of less than 50S/cm, the internal EMPTY pipe detection has to be switched off by parameter switch S6[4] = OFF.

5. Operation If the flow meter is optionally equipped with a display unit, the operation during normal measurement is restricted to the zeroing of the volume registers.

5.1. Basic Keyboard Functions The 8 keys on the keyboard serve for the following basic functions: CLEAR

key Return from the functional or parameter level to the main display ENTER

key 1. Entering the selected level (function, parameter, service, etc.) 2. Acknowledgement of the input

M key MENU processing with the selecting possibility for function, parameter, service

key Input opening for the modification of the displayed parameter type

key LEFT/RIGHT and UP/DOWN:

1. Selection of the desired processing of: Function --- Parameter --- Service

2. Setting or selection of the desired sequence of numbers

5.2. Operating Structure of Display and Keyboard The following possibilities can be used for the operation of the IZML by display and keyboard:

Reading the measured values Selecting the different functions Parameterization Service display

5.2.1. Zeroing the Single Quantity Counter V The 1st display line shows the volume counter V. Possible errors appear here blinking and overlaid on one another. Zeroing is a function that can be done without any code input.

V 1530.9 LQ 0 G/min

Function: Zeroing the single quantity counter

M key ENTER key ENTER key

menu function

function 1 reset V

V 0.0 L Q 0 G/min

5.2.2. Zeroing the Total Quantity Counter V2 The total quantity counter V2 is reset to zero in the same way, with the only difference that the second counter has to be displayed to be reset.

Function: Zeroing the total quantity counter

M key ENTER key key ENTER key

function 1 reset V2

5.2.3. Deletion of Error Messages Possible error messages are erased by resetting the volume counters.

At the factory the IZML is provided with application specific parameters. The yellow sticker shows the existing software version: (e.g. V1.09).

6. Parameterization Take into account that changing the parameters of the flow meter while production is running could lead to some undefined results. It is possible to modify the set parameters: By parameter switch S6 By the keyboard and the display unit By the service display unit type MLD By the PC software program IVON

6.1. Parameterization by Parameter Switch S6 In the basic version of the IZML a display unit is not available. Modifications to parameters can only be achieved via the 8-fold parameter switch S6. Keep in mind that using S6 disables the factory set application specific parameters Qmax,and PV. The coding switches of parameter switch S6 have got the following meaning:

1, 2, 3 Pulse output for volumes between 0.001 ... 10,000 pulses/litre 4 Internal EMPTY pipe detection pipe detect switched ON or OFF 5 Selection for the 4 20 mA analog output: Flow velocity range of 0.2 2 m/s or 0.4 4 m/s 6 Flow signal filter switched ON or OFF 7 Metering or simulating mode for test purposes (Flow: 50%) 8 Parameters of the switch settings valid/invalid

Factory settings of the parameter switch:

Parameter switch

S6[x] Setting Meaning

S6[8] Right / OFF Factory setting is not activated

S6[7] Right / OFF Simulation mode is switched OFF

S6[6] Right / OFF Flow signal filter is switched OFF

S6[5] Right / OFF Setting of the lower measuring range 0.4 4 m/s

S6[4] Right / OFF Internal EMPTY pipe detection is switched OFF

S6[3] Right / OFF

S6[2] Right / OFF

S6[1] Right / OFF

Pulse output set to 1 pulse per gallon

O N O F F

Unless a customers specifications have changed, editing parameters should be unchanged, the upper settings correspond to the usual factory-set status upon the delivery of the flow meter.

ATTENTION !

The settings of the parameter switch are only effective, if the parameter switch S6 [8] is in the ON position!

The following table shows the effect of the different switch positions:

Pulse output of the volume pulses

EMPT

Y pi

pe

dete

ctio

n Fl

ow ra

nge

Sign

al fi

lter

Sim

ulat

ion

Para

met

er

stat

us

1 2 3 4 5 6 7 8

Position of parameter switch S6[x]

Remarks

0 0 0 X X X 0 1 Pulse output OUT1 1 Pulses/ gallon 1 0 0 X X X 0 1 Pulse output OUT1 0.001 Pulses/gallon0 1 0 X X X 0 1 Pulse output OUT1 0.01 Pulses/gallon1 1 0 X X X 0 1 Pulse output OUT1 0.1 Pulses/gallon0 0 1 X X X 0 1 Pulse output OUT1 10 Pulses/gallon1 0 1 X X X 0 1 Pulse output OUT1 100 Pulses/gallon0 1 1 X X X 0 1 Pulse output OUT1 1000 Pulses/gallon1 1 1 X X X 0 1 Pulse output OUT1 10000 Pulses/gallonX X X 0 X X 0 1 Internal EMPTY pipe detection OFF no pipe detect OFF X X X 1 X X 0 1 Internal EMPTY pipe detection ON pipe detect ON X X X X 0 X 0 1 4 20 mA (flow velocity) 4 m/s X X X X 1 X 0 1 4 20 mA (flow velocity) 2 m/s X X X X X 0 0 1 Flow signal filter OFF time constant 1 s sec. X X X X X 1 0 1 Flow signal filter ON time constant 5 s sec. X X X X X X 0 1 Measuring mode ON measuring mode ON X X X X X X 1 1 Simulation ON (Flow: 50%) simulation mode OFF X X X X X X 0 0 Parameter switch data effective values of switch S6 ignored invalid X X X X X X 0 1 Parameter switch data ineffective values of switch S6 are valid valid 0 switch position OFF 1 switch position ON X switch position without any influence

bold print: corresponds to the factory setting

6.2. Setting via Keyboard and Display Unit If the IZML is delivered with a display unit, the parameters are set so they can be modified using the keypad and display. This means that if S6 is activated the value will be displayed that is activated by the switch position. Consequently, that value cannot be changed.

Parameter 1 switch S6 active

If a change is required, the use of the parameter switch will have to be invalidated. For that purpose, the 8th position of switch S6[8] has to be set to OFF, followed by a reset. Now all types of parameters can be changed as desired.

The different types of parameters are filed in the parameter blocs Parameter 1 up to Parameter 4 as shown in the operating structure. Meaning of the different types of parameters: Parameter type 1 Maximum flow value (for the 4 ... 20 mA output) Qmax Output for the volume pulses pv1 Field Calibration factor m spe Count suppression when meter tube is empty pipe detect Dampening of the analog output (option) tp3 Parameter type 2 Metering unit for the volume unit Selection for the analog output (0/20 or 4/20)(optional) curr 4...20mA Restriction of the pulse length for volume pulses tp1 Low-flow suppression lfs Averaging the flow average Number of decimal places for the volume reading V-format Parameter type 3 Setting the address as a Profibus participator (optional) pdpadre Format of the real values for the Profibus transfer (optional) realtype Parameter type 4 (additional code required) Flow tube constant (factory-set calibration value) span Flow tube constant (factory-set calibration value) offset Nominal width of the flow tube DN Signal at zero flow (value can be input) zero Particularity of the unit parameter! When selecting the volume units US Gallons and Litres you should take into account when activating the parameter switch S6 (8) that fixed flow ranges are valid for the 4-20mA output based on the flow tube diameter.

List of the set STANDARD parameters for the unit Gal Designation Function Standard Changeable

unit Unit of volume Gallons different units

lfs Low flow suppression 2.00 % 0 ... 10%

average Flow signal filter (averaging) 4 64

currmode Analog output range 0/4 mA 4 20 mA 0 20 mA

pipe detect Internal EMPTY pipe detection pipe detect no pipe detect

Qmax 100% flow value for 20 mA and LFS dependent on the nominal width pv1 Output of the volume pulses per litre 1 0.001...99999

tp1 Pulse length of the digital output 125 ms 0 9999 ms

tp3 Time constant for the 4...20 mA output 1.0 sec 99

m spe Calibration factor (-10% ... + 10%) 1.0000 0.900...1.100

How to change a parameter A parameter change is possible when the desired parameter type is indicated in the 2nd line.

Then depress the key and input the correct code number via the arrow keys. It is possible to set the parameter. Example: The pulse output shall be individually changed to 50 pulses per gallon:

M key key ENTER key key key

Now the code number has to be input again:

4 x key key 1 x key key 5 x key key ENTER key

codeno: _____415pv1 10.00 p/gal

When the code number has been accepted, the desired sequence of numbers has to be

input in the same way for the pulse output and acknowledged by the ENTER

key.

The modification is finished by the following activation of the CLEAR

key

parameter 1 pv1 50.00 p/gal

Notice ! The new value for the parameter type is only valid if the 8th position of parameter switch S6 [8] is set to OFF. Please check whether the other parameters which can normally be set by the parameter switch have the desired value.

6.3. Adjustments

Normally, the IZML needs no adjustment. Usually, the zero point adjustment (ZERO-Adjust) is carried out during the start-up only. Should, however, some deviations need to be compensated for e.g. a comparison with a calibration vessel or a scale: - an adjustment via the correcting switch S4 or - an adjustment via the factor m spe could be made. Before you will start carrying out an adjustment you should have clarified the following questions:

Are you sure that the reference standard (master meter, scale, or calibrated vessel) does really deliver the correct amount?

Is the quantity of the diffence always equal from measurement to measurement? Take into account that differently emptying pipelines, a missing break-off edge for the liquid or temporary air bubbles will lead to errors during the measurement!

Is the liquid really conveyed during the measurement without any air or gas? Is the unit operated within the flow rate limits? Is the conductivity of the product within the required tolerance? An adjustment is only reasonable if similar (reproducible) deviations have been ascertained during the measurements. Adjustment by Correcting Rotary Switch S4 Adjustments by the correcting switch S4 are only possible within a range from -1.4 % up to +1.4%.

An adjustment is possible in steps of 0.2 %, i.e. the instantaneous flow rate is increased or reduced by 0.2% per switch position.

Upon the delivery, the correcting rotary switch S4 is set to 0, i.e. no correction is preset. After each change of the correcting rotary switch S4, the new correction becomes active after depressing the ABORT key.

ATTENTION !

The adjustment set in this way will only be active if the parameter switch S6[8] is to the ON position !

The following table shows the function of the correcting rotary switch S4:

Position Direction of correction Correction of the measured value Check with simulating

function

0 or 8 0.0 % 12,000 mA

1 ... 7

+ 0.2 % ... + 1.4 % 12,016 ... 12,112 mA

F ... 9 - 0.2 % ... 1.4 % 11,984 ... 11,888 mA

Table 5: Correcting rotary switch S4 Example: Upon a control measurement with a master meter, a difference of +27 gallons is determined for an IZML080 at a total measured quantity of 5,000 gallons.

Consequently, the deviation corresponds to a relative error (F) of: 5,027 5,000 F = 5,000 x 100 % = + 0.54 %

The best correction would be -0.6 %, i.e. the correcting rotary switch has to be set to position D. In the best way, the IZML would afterwards show 4,997 gallons, i.e. it still had a relative error of -0.06 %.

Adjustment by Calibration Factor "m spe" The adjustment can even be set more accurately by the calibration factor m spe either by means of the service display unit type MLD or the built-in display. For this purpose, the parameter switch S6[8] should first be set to OFF in order to enable a parameter input.

The calibration factor is calculated by the formula:

Vref desired volume (e.g. calibration vessel, scale, or the like) Vdis IZML display Example: A deviation F of +0.54% is determined upon a comparative measurement.

Calibration vessel: Vref = 5000 G Display: Vdis = 5027 G

5,000 m spe = 1.0 = 0.9946 5,027

-

+

ATTENTION! After changing the position of the parameter switch S6 [8] to ON, this correction is still kept, but: If an additional adjustment is made by the correcting rotary switch S4 in the parameterizing position S6 [8] = ON, that adjustment will superimpose the adjustment of the m spe factor!

7. Troubleshooting

7.1. Error Diagnosis The IZML is equipped with an integrated self-monitoring function. Malfunctions are recognized and automatically removed.

In case of devices without a display, the error type can only be determined using the green BETR. lamp and the red ERR lamp. Devices with display show error codes.

7.1.1. Error Diagnosis without a Display In case of this device version an error diagnosis is only possible within certain limits by the reaction of the green BETR. lamp and the red ERR lamp. The yellow pilot lamp PULSE directly shows the reaction of the pulse output, i.e. the lamp shortly flashes.

Stat

us

LED BETR (green)

LED ERR (red) Description

1 OFF X No measurement possible. (Check the power supply, fuse F1, simulation mode or BUS address or device error). 2 ON OFF Normal measurement, all okay.

3 ON ON For 30 seconds max., after a short voltage cut-off. The red lamp has to go out. 4 1 sec. ON 1 sec. OFF OFF

Shows the current zero adjustment (ZERO-Adjust); the signal sequence has to be finished after 15 seconds max.

5 ON ON General error message (possible for 30 seconds max.), followed by an automatic deletion in the switch-on phase. 6 ON 2 sec. ON 2 sec. OFF

Signalizes that the internal EMPTY pipe detection is active. This signal sequence will only occur if no display is connected!

7 ON 0.5 sec. ON 0.5 sec. OFF The zero-signal (ZERO-Adjust) is out of tolerance. Check the flow conditions and the installation with earthing/grounding.

8 ON 1 sec. ON 1 sec. OFF The output set for the output of the volume pulses is too high (pulse frequency is higher than 1 kHz!). Pulse losses are caused. This error message is not reset automatically.

9 OFF 2 sec. ON 2 sec. OFF

The calibration values are not plausible. Order the MEMbox for the serial number of the device at the factory and insert it into plug X4 on the upper board. After ABORT the error message has to go out; otherwise the whole device should be replaced.

10 OFF 4 sec. ON 4 sec. OFF One of the calibration factors is zero. Order the MEMbox for the serial number of the device at the factory or input the calibration value via the keyboard.

11 OFF 6 sec. ON 2 sec. OFF The electronic unit is not initialized. Exchange the main board.

Normally, the error messages are automatically deleted after 30 seconds.

In case of a pulse loss (status 8) it should be taken into account that the message is only erased by using the ABORT key. That means at a very high pulse output set e.g. after a cleaning process at a high flow velocity this error message could be generated and permanently displayed.

If you want to check a possible pulse loss, you will have to observe the red ERR lamp over a longer period during the normal process operation.

Calculate for control purposes the maximum pulse frequency expected.

7.1.2. Error Diagnosis via Display Displayed messages could support the fault location in case of malfunctions or failed measurements.

Normally, the message is displayed in a flashing state in the 1st line:

warning 901 Q 10983 G/min

Usually, all displayed messages are automatically deleted after a maximum period of 30 seconds.

In case of a permanent malfunction the message is generated again and again.

In addition to the displayed message the red error lamp on the upper board is lighting or starts flashing according to the error detected.

The following messages are possible:

Warning 901 Message stating that the measurement was interrupted:

By a power failure (Power-Fail) By a RESET (e.g. after a simulation) By a parameter change By an activation of the digital input (stop of the count)

Measure None Error 963 Message stating that the volume pulse output was exceeded;

i.e. pulse losses are caused.

ATTENTION ! This message is only automatically deleted, if a display unit is connected. In case of versions without any display unit, the error message will be kept, i.e. the red error lamp is flashing in a 1-second cycle!

Measure: If a correct pulse output is required even in case of an

increased flow rate, the pulse output will have to be reduced!

Error 3041 Error message of the system: No measurement possible.

Measure: Exchange of the electronic unit. Error 3050 Message, stating that the flow rate is outside the measuring range;

i.e. failed measurements are caused (reading too low!). Measure: Reduce the flow rate or use an IZML of a larger nominal width or

use an IZMS (up to 10m/s). Error 3063 Message, stating that the pulse output set could involve an

overdriving of the pulse output (output frequency >1 kHz at the maximum flow rate). If the output frequency is exceeded the message error 963 will appear (see above).

Measure: None, if the increased pulse valance is desired for the working

range. In case of failed measurements, the pulse valance has to be adapted accordingly.

Error 3070 Message stating that the calibration factor is set to zero. Measure: Input of the respective factor (e.g. span). Error 3072 Message stating that the coil current is failed. Measure: 1st Exchange the upper supply board. 2nd Exchange the main board. 3rd Exchange the whole measuring device. Error 3083 Message stating that the ZERO-Adjust measurement carried out

has not been accepted:

The flow rate was not ZERO during the measurement. The cable connections were not in order. The earthing/grounding of the flow tube is failed. Moisture in the flow tube or in the electronic part.

Measure: Repeated attempt to carry out the ZERO-Adjust measurement.

Unless successful, verification and removal of possible error sources.

7.2. Typical Effects or Possible Malfunctions Disturbances or malfunctions can normally be recognized by means of the display unit.

7.2.1. Flow without Flow Rate Indication:

(a) Is the conductivity higher than 5 S/cm?

(b) Has the internal EMPTY pipe detection to be switched off?

Check whether there is error indication Status 6 or whether 0 G/min is shown while the flow is running. If a display is available select the menu service.

If adsum 0 is displayed, the internal EMPTY pipe detection is active. This is the case, when The conductivity of the liquid is below 50 S/cm. The type of flow tube connected is smaller than DN 15. A heavily pulsating flow is available.

To make sure that the electronics are working correctly, use the simulating function (hardware or software) for further diagnosis of the digital or analog output.

7.2.2. No Pulse Transmission despite Displayed Flow

(a) Check the electric circuit (the IZML outputs have to be supplied by an external voltage of 24 V DC).

(b) Is the polarity of the pulse counter correctly connected?

(c) Check the parameters:

- Is the pulse output too low? (Switch position or parameter)

- Are the settings made by parameter switch S6 really effective?

Use the simulating function for your further diagnosis (hardware or software).

7.2.3. No Analog Signal Available If no analog signal or a failed analog signal is measured, the following checks are recommended to be carried out: a. Check whether the additional board is correctly installed. b. First the connected measuring system (digital display, PLC or the like) has to be

disconnected from the IZML. The analog output signal has to be checked by the simulating function by the aid of an ammeter:

If the analog output is ZERO at a 50% simulation, the electronic part is defective, i.e. it will be necessary to replace: the additional board type MBLC o r the main board o r the complete converter.

- If the analog output remains constant on 20 mA, the internal curr mode parameter could be wrong. A verification is only possible by means of the display unit or the service display unit type MLD.

c. If the problem only occurs with the external display,PLC. it should be checked:

- if the resistance of the whole current loop is higher than 500 ohms? (Observe the technical data sheets of the connected devices!)

- is the input of the external evaluating device configured for an active analog

output?

Errors can especially occur with a connection to a PLC due to the fact that it might both have an active and a passive configuration.

d. If nonlinearities occur over the whole range from 0 - 100%, it should be checked:

- Whether the load of the whole current loop is higher than 500 ohms? If those values are correct, it will be necessary to replace the analog board 300-MBLC, since there is no adjusting possibility.

7.2.4. Deviations of Measured Values (a) Is there a time-related connection between the occurrence of the problem and some

modifications to a system in the vicinity of the measuring device?

(b) Does the error show more or less similar values or a constant shift or does it heavily scatter into the positive or negative direction?

(c) Has something been repaired or exchanged?

(d) Does the error always occur at a certain point of time (e.g. on Mondays at the start of production, on the early shift, or the like) or at certain process steps?

(e) If a display unit is connected, the measuring signals can be checked by means of the service data menu service while the flow is static. Change the display to the presentation of the measured values adksum which

may be fluctuating between -300 ... +300 units at a maximum. If you carry out several zero point measurements (ZERO-Adjust): The displayed value is not allowed to change by more than 10 units among the

repeated measurements. Unless stability exists, the earthing/grounding of the flow tube will have to be checked. The wiring between flow tube and converter has to be shielded through the metal cable gland.

(f) The same verification has to be carried out with a full meter tube while the flow tube is removed as a whole. In that status any influences by electrical disturbances or a leaking pipe system can be excluded.

(g) In case of moisture or other errors in the flow tube or converter it will be necessary to replace the flow meter.

(h) Check the pipe path for by-pass lines or air occlusions (failed gaskets).

(i) Check the reference measuring methods or the test procedure (reference meter, e.g. a scale): Take into account the temperature compensation of the volume. If different products are compared with the value of the scale, the conversion

will have to be carried out by means of the density.

Or the same volume differences always occur e.g. at different quantities! If so, possible reasons could be: A start and stop of the measurement while the meter tube is empty. An undefined limitation of quantity due to the absence of a break-off edge. An undefined dropping-off behaviour due to the absence of an appropriate

draining sieve.

7.3. Fault Reset Error messages can be reset: (a) By zeroing the quantity counter (b) Automatically after 30 seconds max., unless any further fault did occur.

7.4. Flow tube Tests

7.4.1. Insulation Test The test is carried out by means of an ohmmeter. The meter tube of the flow tube has to be completely emptied before. The inner tube has to be absolutely dry, especially for measurements a) and b).

Figure 2: Insulation test

field coil

field coil

liner

electrode

tube

terminals

ohmmeter

16 14

Flow tube

1218 11

ohmmeter to terminal

required resistance

70 ... 120 ohms

abc

ed

11 / 18

14 / 18

12 / 18

16 / 18

11 / 12

> 20 megohms > 20 megohms

> 20 megohms > 20 megohms

7.4.2. Symmetry Test

For the symmetry test the flow tube has to be filled with the liquid to be metered and connected as shown in the figure below. The metered alternating currents of measurements 2 (electrode 1 - ground) and 3 (electrode 2 - ground) have to be equal within a tolerance of 3 %. On no account the individual current values may be drifting over a longer period (5 minutes) during the measurement!

Figure 3: Symmetry test

7.4.3. Visual Check The flow tube can be optically checked while being disassembled:

Reason Action

Humidity in the connection housing Dry the housing and perform an insulation test subsequently.

Damaged Teflon liner Replace the flow tube; check the gasket.

Table 6: Visual check

14 16 18 14 16 18 14 16 18

Symmetry Test (filled meter tube)

electrode 1 - electrode 2 ground - electrode 2 electrode 1 - ground

ammeter(mA-)

ammeter (mA - )

ammeter(mA-)

alternating voltageU = 10V ... 40V -

alternating voltage U = 10V ... 40V - alternating voltage U = 10V ... 40V -

8. Maintenance

8.1. Safety Instruction for Maintenance Work Maintenance and repair work may only be carried out by skilled personnel with the required authorization from the user.

The persons concerned have to be familiar with the process and be able to recognize possible dangers and to take all necessary steps to remove imminent risks of accidents.

CAUTION:

First ensure your personal safety before you will start carrying out any service and maintenance work!

Appropriate measures have to be taken to guarantee safety (approved ladders, lifting platforms, safety harnesses, etc.).

Applicable tools and personal protective measures are necessary. Before you start working at electrical or rotating equipment, make absolutely sure

that the equipment concerned is disconnected from the power supply network. An unintended restart has to be avoided by suitable safety precautions (e.g. information signs, padlocks).

Fittings and instruments and their contents can be hot! First permit them to cool down before you will start working at such parts.

If fittings and instruments have to be removed from the pipe system, the whole pipe system has to be completely emptied, depressurized, and protected by some appropriate shut-off fittings.

Rinse the pipe system with clear water before the disassembly of fittings or instruments in order to remove possible residuals of chemicals.

8.2. Maintenance

8.2.1. Upkeep On normal operating conditions the flow meter type IZML does not require any special maintenance work.

Nevertheless, we wish to give you some recommendations for maintenance steps:

Cleaning

Deposits in the meter tube or at the electrodes will cause measuring errors or malfunctions.

Thus, ensure a regular and careful cleaning of both the pipelines and the flow meter.

See to it during the external cleaning that e.g. no high-pressure steam-jets are directed to the housing parts.

In case of flow meters with integrated display the external cleaning temperature may not exceed 120 F.

Keyboard and display should only be cleaned by means of water and a soft cloth.

The IZML flow tube is suitable for CIP.

Regarding the cleaning, disinfecting, and flushing agents and procedures we refer to the manufacturers and the relevant guidelines of the food processing industry.

Gaskets

The flow meter itself is equipped with two gaskets. One is located at each adapter connection. Periodic replacement will increase flow tube service life.

Stainless Steel Connection Adapter Part Number

Meter Length Code

IZML Model

Process Clamp

Connection 0 1 2 7

Flat

Connection Gasket Part

Number Set of 2

-15

5/8"

/ 1" 300-15S 300-15PD 300-15S-2

300-15-CBIF

300-15-CBIM

300-16

-25

1"

1" 300-25S 300-25PD

300-25-CBI

Documents

Diessel IZM L