CONTOIL DN15-50 VZF / VZFA. Table of content. Mounting and operating instructions Page 3 43

Transcription

1 Mounting and operating instructions Page 3 43 CONTOIL DN15-50 VZF / VZFA Table of content 1 Safety 3 2 Scope of supply and accessories 6 3 Installation 7 4 Operation 15 5 Maintenance and Repair 25 6 Troubleshooting 28 7 Decommissioning, Dismantling and Disposal 31 8 Technical Data 32 9 Appendix 38 VD e

2 2 CONTOIL DN15-50

3 1 Safety 1.1 Intended Use The CONTOIL flow meter is designed and solely intended for the flow measurement of Diesel oil to Heavy Fuel Oil according to ISO Improper or non-intended use may lead to the reliability of the device and is no longer guaranteed. The manufacturer accepts no liability for any resulting damage to human and material. 1.2 Notes on safety rules and symbols The devices are designed to meet the latest safety requirements. They were tested and delivered in a condition that ensures safe operation. Improper or non-intended use of the devices, can however, be dangerous. Therefore pay particular attention to the safety instructions within this manual always shown by the following symbols: WARNING WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE NOTICE indicates a hazardous situation which, if not avoided, could result in property damage. NOTE NOTE indicates helpful tips and recommendations, as well as infor-mation for efficient and trouble-free operation. See doc VDxxxx, page ## or See section XX on page ## or WEB link to QR code QR code CONTOIL DN

4 1.3 Safety rules and precautionary measures The manufacturer accepts no responsibility if the following safety rules and precautions are disregarded. Modifications of the device implemented without preceding written consent from the manufacturer, will result in the immediate termination of product liability and warranty period. Installation, operation, maintenance and decommissioning of this device must be carried out by trained, qualified specialists, authorized by the manufacturer, operator or owner of the facility. The specialist must have read and understood these Installation and Operating Instructions and must follow the instructions here in. Check the voltage and the information on the type plate before installing the device Check all connections, settings and technical specifications of peripherals which may be present. Open the housing or parts of housings, which electric or electronic components included, only when the electric power is turned off. Do not touch any electronic components (ESD sensitivity). Expose the system with respect to the mechanical load (pressure, temperature, IP protection, etc.), only to a maximum of the specified classifications. During operations that involve mechanical components of the system, release the pressure in the pipe system or reduce the temperature of the medium to a safe level for humans None of the information stated here or elsewhere releases planners, installers and operators from their own careful and comprehensive assessment of the respective system configuration in terms of functional capability and operational safety The local labor, safety laws and regulations must be adhered to. 1.4 About the operation manual The manufacturer reserves the right to make changes to technical data without notice. The latest information and versions of these operating instructions, can be requested at your local dealer. WARNING The manufacturer accepts no responsibility if the instructions and procedures as described in this manual are not followed! NOTE This installation guide is intended for qualified personnel and therefore does not include basic working steps. Before operating the equipment or system, this Installation and Operating Instructions must be completely read and understood. Keep these instructions for later look up! 4 CONTOIL DN15-50

5 1.5 Handling, Transport and Storage We congratulate you on purchasing this high-quality instrument. Please check all components and parts delivered promptly after the receipt of goods. 1.6 Return of materials Never send a device/system back if you are not absolutely certain that all traces of hazardous substances have been removed, e.g. substances which have penetrated crevices or diffused through plastic. Costs incurred for waste disposal and injury (burns, etc.) due to inadequate declaration and/or cleaning will be charged to the delivering company or the operator. For a device that is sent back to Aquametro for repair or calibration the following point are an absolute must: Always enclose a duly completed "Declaration of decontamination form (FO0451e). Only in special cases (e.g. for the reconstruction of causes of errors) and only with the prior consent of the Aquametro AG, equipment must be returned in the unpurified state. In this case also the contact person at Aquametro AG, which has granted the approval to return a crude device must be stated. Only then Aquametro AG can transport, examine and repair a returned device. Use form FO0451e. CONTOIL DN

6 2 Scope of supply and accessories 2.1 General 1 Flow meter with appropriate display unit (electronic or mechanical counter). 1 mounting and operating instruction (this manual) 2.2 Flow meter configuration The CONTOIL flow meters consist of a hydraulic part and an electronic counter. The hydraulic part determines the nominal size of the flow meter. The electronic counter has all available output VZF / VZFA. The flow meters are calibrated before they leave the factory. Nevertheless, for optimal results of differential measurement, flow meters of VZFA with special calibration (pairing) should be used. Electronic counter VZF / VZFA local electronic display with pulse output and analog current loop Display unit Hydraulics FL: DN15-50 RC: DN15-40 For details, see the dimensional drawings in Appendix, chapter 9 on page CONTOIL DN15-50

7 3 Installation CAUTION The surfaces of the device and the medium may be hot. Risk of burns! Carry out work only on cooled systems. Work may only be performed by authorized specialists in accordance with the applicable regulations. Use appropriate protective equipment. WARNING The pipe and the device may be under pressure. Risk of severe injury! Carry out work only on non-pressurized systems. When working on the device watch out for leaking medium. Work may only be performed by authorized specialists in accordance with the applicable regulations. Use appropriate protective equipment, particularly safety googles. 3.1 Mounting Flow meter installation Easy access for reading the flow meter and controlling the ancillary equipment is important. Provided that the arrow on the housing is in the direction of flow, the flow meter can be installed in any position without any special modifications. The display is adjustable to the installed position. Exception: upside down installation. Flow conditioners are unnecessary. CONTOIL DN

8 NOTE The layout of piping must ensure that the flow meter is filled with liquid at all times and that no inclusions of air, foam or gas may occur. Aquametro AG recommends to install bypass valves. Tank Non-Return Valve Flow meter Tank Pump Flow meter The quantities from all consumers must be registered by the flow meter. Correct layout of flow meter and accessories If the flow meter is used for viscosities higher than 5 mpa.s, or if it is mounted on the suction side of a pump, the pressure loss and the flow rate that can still be attained should be determined with the help of the pressure loss curves provided in CONTOIL Technical Information. In addition, the pressure loss due to installed filters must be taken into consideration. Select the flow meter and ancillaries according to the working conditions listed below: Operating pressure and temperature Ambient temperature Material compatibility with medium Flow rate (maximum expected application flow rate = maximum continuous flow rate of flow meter Qcont) The flow meters must selected according to the flow rate and not according to the pipe diameter. If necessary, adapt the pipework. Non-Return-Valves In order to avoid backflow and draining, Non-Return-Valves must be mounted after the flow meter. Backflow and draining can cause faulty measurements and may damage the flow meter. Tank Filter Pump Flow meter Non-Return-Valve 8 CONTOIL DN15-50

9 Dirt filter, Safety filter Filters should be fitted to prevent any damage to the flow meter from impurities in the oil. Maximum mesh width for filters Nominal Flow meter type size VZF VZFA DN mm 0.100mm DN mm 0.100mm DN mm 0.250mm DN mm 0.250mm DN mm 0.250mm NOTICE The filter mounted in the flow meter inlet is only a safety filter and can not act as a dirt filter. Risk of malfunction or damage. If the medium contains dirt always have a dirt filter installed upstream of the flow meter. Heat insulation The electronic or mechanical counter must not be insulated. This could cause its permitted temperature range to be exceeded. No heat insulation in this area Heating coil (winding) Pipe Heat insulation The permitted temperature ranges for the flow meter must be observed. CONTOIL DN

10 Special requirements - differential measurements For differential measurements, one flow meter is installed in the supply line pipe and one in the return line pipe. The flow difference between these meters determines the consumption. If ordered with the "differential measurement" option, VZFA flow meters are calibrated in accordance with the indicated supply and return flow volumes. The flow meters are labeled SUPPLY and RETURN. Make sure that these flow meters are installed in the correct pipeline, i.e. the supply flow meter shall be installed in the supply line pipe and the return flow meter shall be installed in the return line pipe. Tank Flow meter Return Engine Filter Pump Flow meter Supply Special requirements - ships On ships, attention is required to ensure that the engine can continue to operate at full power even if there is heavy filter contamination or if the flow meter is damaged. A pressure switch can be used to switch over to the bypass and to draw attention for servicing. The engine then continues to operate but without consumption measurements. Ship classification societies require the installation of bypass pipes. The relevant regulations must be followed. 10 CONTOIL DN15-50

11 Installation of the flow meter on the suction side of a pump If the flow meter is installed on the suction side of a pump, consideration must be given to avoid air-intake or foam. Filter Flow meter on suction side Pump Installation of the flow meter on the pressure side of a pump Filter Pump Flow meter on pressure side Flushing of pipes If the pipes are to be flushed at a later stage, stop valves shall be provided on both sides of the flow meter. NOTICE Accumulation of debris will occure in front of the stop-valve during flushing. To eliminate this, replaced the flow meter with a spool piece. flushing measuring Special requirements - filling and dosing units For filling and dosing, the valve must be fitted between flow meter and discharge. The shorter the pipe section between valve and discharge, the higher the accuracy. Avoid water hammer if fast closing valve is installed. Filter Pump Flow meter Valve CONTOIL DN

12 3.2 Mechanical installation WARNING Leakage or rupture due to connections being made using force. Risk of severe injury! Risk of substantial property damage! Never attempt to overcome misalignments (lateral, angular, longitudinal, torsional) using force. Make sure the pipings are flexible enough, if not: use compensators. Consider the effects of thermal contraction and expansion. WARNING Leakage or rupture due to misuse of the mounting material. Risk of severe injury! Risk of substantial property damage! Regarding mechanical strength, with bolts, screws and nuts, use the prescribed dimensions. Use the full number of bolts, screws and nuts. Observe the prescribed thread lubrication (grease or dry!). Tighten the bolts and nuts in the proper sequence to the specified torque. If using flanged connections, the correct number of connector elements must be fitted and they must be tightened with the correct torque in accordance with the screw manufacturer s instructions. Comply with the permissible operating data as defined on the type plate. Make sure that no hazardous fumes can build up in the piping and in the flow meter during commissioning, decommissioning and dismantling. The flow meter must at all times be completely filled with liquid during operation. Check the flow meter periodically for tightness of the connections and for proper functioning. If work is to be done on the installation, before each intervention: release the pressure in the installation if hazardous liquids are used, wear protective clothing and safety goggles, place a collecting tray underneath the installation. Preparing for installation Check flow meters and installation material. Compare the data of the flow meter name plate with the expected maximum conditions of the installation. They may not exceed the flow meter specifications: Maximum continuous flow rate (Qcont l/h) Maximum operating pressure (PN bar) Maximum temperature ( C) Appropriate connections( threaded, or flanged) and seals (gaskets) Fasteners for the flow meter Resistance to liquid to be metered and temperature 12 CONTOIL DN15-50

13 CAUTION Unauthorized start-up while mounting. Risk of injury! Make sure that unauthorized start-up is not possible while mounting. Comply with the appicable working regulations during all work on the system. NOTE When existing systems are altered: Take the flow meter out of operation in order to flush the system clean of debris. Flushing information on page 11. Trial operation Start trial operation (without flow meter); open the stop valves slowly when doing this. Carry out a pressure test in the plant Check for leaks and tightness of all bolts Flush the pipework until clean (flow meter out of pipeline) Release the pressure and stop the system again This trial operation ensures that the pipework is tight and clean Installing the meter in the pipe Remove the protection plugs or caps from the flow meter (inlet and outlet). Insert the flow meter into the pipeline in the prescribed position and flow direction. The arrow on the flow meter should correspond with the direction of flow. Install mating flanges parallel and without tension in the pipe. Meter with flanged ends Meter with threaded ends X X For pipes made of copper or thin-walled steel pipes, the flow meter requires additional fastening. Use appropriate fasteners. CONTOIL DN

14 3.3 Electrical Installation NOTICE Electrical connection to the mains voltage and/or connections to other systems. Risk of malfunction or damage Review of technical data, chapter 8.1, on page Electrical connection VZF VZFA VDC Pulse output Frequency output Switching output NOTE Keep out cable Out.1 Out.2 Sensor area! No cables, wires or other installation material must be present in this area. This can lead to incorrect measurements and damage to the meter. Solid stat relay R ON 100 Ohm, Ref OFF 10MOhm U max 48V AC/DC, I max 50mA NOTE Wire size for terminal 1 6 is mm2 / AWG The display can be rotated 360 in 90 steps during installation to improve readability. Factory setting of outputs Output 1: Out.1 Volume pulses: 50 ms, 1 Ltr/pulse (exception: DN15 is set to 0.1 Ltr/pulse) Output 2: Out.2 Volume pulses: 50 ms, 1 Ltr/pulse (exception: DN15 is set to 0.1 Ltr/pulse) Analog: disabled 3.5 Engineering notes Parameterizing ancillary devices Some ancillary units require programming of pulse values or frequency (see the relevant operating instructions). The maximum frequency is calculated with the following formula:. / CONTOIL DN15-50

15 4 Operation NOTE Modification of operation settings may result in faulty or wrong measuring results. 4.1 Operation and startup Startup and commissioning of mechanical part of flow meter (VZF and VZFA), without programming any electronic counter (VZF and VZFA). Open valves slowly, fill pipework gradually. Vent the installation well. Water hammer must be avoided in order not to damage the flow meter. Inclusions of air cause measuring errors in all types of flow meter and can damage them during operation. Check the tightness of the connections watch for leakages. Check if the flow rate of the installation correspond to the specification of the flow meter. Electronic display (VZF and VZFA): read the instantaneous value. Should the established flow rate be greater than the specification of the flow meter (Qcont), either a flow control valve (throttle) must be inserted behind the flow sensor or a larger size flow meter must be used. For RV and IN(A) pulse sensors: Check function of connected accessories. CONTOIL DN

16 4.2 Display (VZF and VZFA) Four different output functions are available, any of these functions can be used simultaneously. 2 potential-free digital outputs (Out.1 + Out.2), each freely programmable to one of five functions. (Volume, Flow/Frequency, Limit, State and disabled). Volume pulses; for external totalizer or monitoring systems. Flow / Frequency; output Hz corresponding to flow rate. Limiting switch; Switching function with programmable high and low flow rate (NO/NC). Status switch; control functions for Errors, Alarms and Supply Voltage (NO/NC). The passive current loop is also used to power the flow meter at the same time. Analog current loop 4-20 ma corresponding to current flow rate. 4.3 User interface The display shows 8-digits with a decimal point or text messages using letters. Units of measurement and additional items of information are shown with symbols or index indicators. The references to these in the text are shown in square brackets, e.g. [LIMIT MAX]. current value units flow bar options to current display Step key Enter key Use Step key Use Enter key to scroll the menu and to change field values. to enter submenus and to edit / confirm field entries. The display data and parameters are split into two menu groups: Main Menu: displays measured data, accesses other menus, tests display segments and displays error or alarm messages (if present). Setup Menu: displays parameter settings for the display, output signals, additional information about the flow meter and operating status. 16 CONTOIL DN15-50

17 4.4 Main Menu The Main Menu displays most important measured data and accesses the setup menu. The standard display of the Main Menu is the total volume. Use the Step key to go to the measured value for the resettable trip counter, the current flow rate and other menu items, as follows: Total volume [TOT] cannot be reset Standard display adopted by the flow meter after a time-out. If an error is signaled, the totalized value remains unchanged as long as the error is pending. Subtotal volume [SUBTOT] can be reset To reset press step and enter keys for 4 seconds simultaneously. Reset must be enabled in the Menu. If an error is signaled, the totalized value remains unchanged as long as the error is pending. Current flow rate Besides being displayed numerically, this value is also shown by a flow bar with graduation marks, each mark representing 5% of the maximum permitted flow rate. Enter the SEtUP section to allow the viewing and editing of all parameters. Display test All the segments are shown for 2 seconds. This test is also performed after switching on the unit. Device alarms and errors If a device alarm or error is detected during the periodic self-test, these messages are briefly shown every 2 seconds. Measuring accuracy could be impaired. Flow meter may supply incorrect values. Error and Alarm descriptions are spelled out in chapter 6, page 29. Return to beginning CONTOIL DN

18 4.5 How to set the parameters In order to set the parameters, scroll to the [SEtUP] item from the Main Menu and press the Enter key. The parameter [Unit vol] will be displayed. Now press both keys ( + ) simultaneously for 4 seconds. The following will be displayed: [CodE0000] Press Enter again and the first right digit will start flashing, which means, the unit is ready for the entry of the first digit of the user code Enter the first digit by using the Step key. Press the Enter key to accept the value (in our case 1) and to move to the second right digit. Continue this way to enter all code digits. At the end of the procedure, you will be redirected to the [Unit vol] and a will be displayed. If no key is pressed within 1 minute, the device returns to the standard display but the Edit mode is still active (15 minute timeout). Any entries that have not been completed by pressing the Enter key are rejected. In order to change the parameters, the device must be unlocked ( ) with the user code. Setting the unit of measurement for volume [Unit Vol] (volume) Possible settings and subsequent parameters derived from them are as follows: liters [Unit Vol L]: pulse value in liters per pulse [LPP], flow in [l/time] cubic meters [Unit Vol m 3 ]: pulse value in liters per pulse [LPP], flow in [m3/time] US gallons [Unit Vol G]: pulse value in pulses per gallon [PPG], flow in [gal./time] Setting the unit of measurement for time [Unit Ti] (time) Possible settings and subsequent parameters derived from them are as follows: hours [Unit Ti h]: flow rate in [Volume/h] minutes [Unit Ti min]: flow rate in [Volume/min] seconds [Unit Ti s]: flow rate in [Volume/s] Parameterizing the flow meter data In order to guarantee accurate measurement, the electronic module of the flow meter requires adjustment. During factory calibration, the data for nominal size and the exact measuring chamber volume are entered for this purpose. These parameters cannot usually be changed again. They are displayed with the index [CAL] to document the calibrated condition. If the electronic counter has to be replaced, please mention the serial number of the defective counter in you forder. Spare parts are set to the appropriate hardware size (DN). 18 CONTOIL DN15-50

19 4.6 Setup menu Setup Menu: shows settings for display and output signals. Select the [SEtUP] item from the Main Menu and press the Enter key to enter the Setup Menu. Enter the user code as explained in section 4.5 If no code is entered, the menu can be scrolled through with the Step key and Submenu s viewed with the Enter key. Press Enter key again to return to main Setup menu. Navigation through the parameters of the [SEtUP]: (key description in section 4.3) 1. To move to the next parameter: press the Step key The actual value will be displayed, just as an info 2. To enter the edit mode of the displayed parameter: press the Enter key The active value will start to flash 3. To change the value of the active parameter: press the Step key Each available parameter/value will be shown 4. To save the changed value of the entered parameter: press the Enter key Changed value/parameter will be stored. An open lock unlocked. is displayed when the code for editing was entered and the device is UNCAL is displayed, when the hydraulic unit and the electronic counter are not paired. The correct measuring chamber volume was not measured on a test bench and therefore, not entered in the electronic counter. CAL is displayed, when the hydraulic unit and the electronic counter are paired. The correct measuring chamber volume was measured on a test bench and therefore, entered in the electronic counter. CONTOIL DN

20 Setup (see above to enter the SEtUP) Volume measurement unit [UnIt vol] to display volume of flow rate: [L] liters (factory setting), [M3] m3, [G] US gallons Time measurement unit [UnIt ti] to display time of flow rate: [H] hours (factory setting), [MIN] minutes, [s] seconds Nominal size DN15 DN50 [CAL] calibrated flow meter nominal size. Measuring chamber volume [VC] [CAL] calibrated volume of the flow meter Trip Reset [trip res] Disable volume subtotal reset [SUBTOT] Trip reset Subtotal can be reset [Yes] or [No] Flow meter low flow cut off [LFC] LFC is the minimum value where the flow meter starts counting Displays Output1 (r1) settings To display all options of this output press the Enter Key, use the step key to scroll through the options. [factory settings: ms50, LPP1 (DN15 is set to LPP0.1)] For details refer to output assignment settings, page 22. Displays Output2 (r2) settings To display all options of this output press the Enter Key, use the step key to scroll through all options. [factory settings: ms50, LPP1 (DN15 is set to LPP0.1)] For details refer to output assignment settings, page 22. Displays the Analog current loop settings To enabled the current loop, press the Enter key and change the flashing value with the Step key to [AnA EnA]. Press Enter to confirm and to display all settings. [factory settings: [AnA dis] (disabled) For details refer to Analog current loop assignment settings, page 24. Sensor Simulator The sensor simulator is only available for service technicians. For users, each output (r1, r2 and Analog) has its own simulator that can be used to simulate the output signal. 20 CONTOIL DN15-50

21 Once a simulator is turned ON, an Alarm message will be dis played in the main screen. Error message Displays no errors [no ErrS] when none is active Enter to display the active error code For a list of error codes please refer to page 29. Alarm message Displays no alarms [no ALmS] when none is active Enter to display the active alarm code For a list of alarm codes please refer to page 30. Used range is displaying the time and flow range the flow meter is running in. h0: Total hours of flow meter operation (HH:MM) h1: Hours of operation (HH:MM) in the optimal flow range, Qmin Qcont h2: Hours of operation (HH:MM) in the upper flow range, Qcont Qmax h3: Hours in operation (HH:MM) above Qmax h4: Duration (HH:MM) since last recorded flow 5: Maximum flow rate since starting operation [MAX Q] Calibration date [DD.MM.YY] [CAL] factory calibrated [UNCAL] delivered in uncalibrated state (spare part) Displays if the device has been factory calibrated and verified CE, custody transfer Note: Verification is an act that can only be executed by an accredited, certified verification center like Aquametro AG Switzerland. If this date is set, the access to the DN and volume chamber parameter is locked. Firmware Version electronic module firmware Checksum software Checksum Serial number Flow meter Serialnumber Defaults Reset all settings to factory or customer settings (only available for service technicians) Piston rotation info Additional piston rotational timing information for service technicians Return to main menu [SEtUP] Return to Main programming menu CONTOIL DN

22 4.7 Output assignment settings Use Step key to scroll through output1 / 2 options (volume, flow / frequency, limit, state and disabled) Output specifications can be found in chapter 8, page 32. Volume Flow / Freq Volume pulse width in ms lower flow rate value for frequency output Q1 for f1 pulse value of one volume pulse [LPP] in liters per pulse for volume unit [L] or [m3] [PPG] pulses per US gallon for volume unit [G] Optional signal output simulation Output simulation Select [on] to simulate this output lower frequency of frequency output f1 for Q1 upper flow rate value of frequency output Q2 for f2 upper frequency of frequency output f2 for Q2 Error behavior Simulated value Enter flow rate to simulate pulse indication [PULSE] appears as long as the pulse signal is present at the output Optional simulation of signal output Output simulation Select [on] to simulate this output (With a very fast pulse train, "PULSE" may be displayed continuously) Simulated value Enter flow rate to simulate current frequency output frequency for flow rate in Hz 22 CONTOIL DN15-50

23 Limit State lower flow rate limiting value Limit Qmin Send status feedback on Error, Alarm or UCC upper flow rate limiting value Limit Qmax Working position of contacts [LOGiC NO] closed at event [LOGiC NC] open at event hysteresis [HYST] in percent of limiting values Working position of contacts [LOGiC NO] closed at limiting value [LOGiC NC] open at limiting value current state of output [Active] [inactive] Optional simulation of signal output Output simulation Select [on] to simulate this output Simulated value Enter flow rate to simulate current state of output [Active] [inactive] Disable Select to disable output CONTOIL DN

24 4.8 Analog current loop assignment settings Once analog current loop setting is enabled [AnA EnA], the following menu structure will be displayed. Output specifications can be found in chapter 8, page 32 & 37 Analog current loop output enabled Lower flow rate value Qmin for 4mA Decimal value: Qmin, Q0-Q20mA Upper flow rate value Qmax for 20mA Decimal value: Qcont, Q4mA- Qmax Damping of current output [tau] filtered output value: 4, 1-9 Current output in case of an error [Err High] 21.5mA; [Err Low] 3.5mA; [Err Act] actual value (error is ignored at current loop) Optional signal output simulation Output simulation Select [on] to simulate this output Simulated value Enter flow rate to simulate actual Analog current loop signal in ma. Displays the momentary value of the analog current signal 24 CONTOIL DN15-50

25 5 Maintenance and Repair 5.1 Calibration All our flow meters are calibrated in the factory. A recalibration is offered at Aquametro AG, this is usually dependent on customer, operator or regulation requirements. 5.2 Service maintenance CAUTION The surfaces of the device/system and the medium may be hot. Risk of burns! Carry out work only on cooled devices/systems. Work may only be performed by authorized specialists in accordance with the applicable regulations. Use appropriate protective equipment. WARNING The device/system may be under pressure. Risk of severe injury! Carry out work only on non-pressurized devices/systems. When working on the device/systems watch out for leaking medium. Work may only be performed by authorized specialists in accordance with the applicable regulations. Use appropriate protective equipment, particularly safety googles NOTICE Use of unsuitable cleaning agents and procedures. Risk of malfunction or damage Follow the cleaning instructions on the next page. Before working on the hydraulics: put the system or section out of operation close the stop valves release the pressure put a suitable tray underneath the connection to be worked on be prepared for spillage, have absorbent at hand CONTOIL DN

26 Cleaning of flow meter: do not use any aggressive solvents rinse hydraulic part of flow meter thoroughly Aquametro AG recommends to use the following cleaning solvents: Gasoline used for cleaning purposes Cleaner s naphtha Petroleum ether Dirt filter (not safety filter of flow meter) Dirt filters must be cleaned periodically, initially at short intervals. To restart the system: slowly open the stop valves, avoiding pressure surges ( water hammer ) vent the pipe well check tightness Maintenance NOTICE Warranty will be void, if the flow meter is being opened during the warranty period by a non Aquametro AG certified person. Check connections periodically for tightness and if necessary retighten. For control and cleaning, the measuring chamber and the ring piston of the flow meters DN15-50 can be removed without dismantling the flow meter from the pipe. Torque of measuring chamber screws Flow meter Screws Torque DN 15,20 M 6 6 Nm DN 25 M 8 16 Nm DN 40 M Nm DN 50 M Nm The cleaning and revision cycle depends largely on the conditions of operation. Under favourable conditions 5-10 years suffice. Check the units for corrosion. When ancillary equipment is used, observe their mounting and operation instructions. 26 CONTOIL DN15-50

27 NOTICE If opening is necessary: Risk of malfunction! Observe positions during disassembly Follow assembly instructions Check proper function at start up Recalibration is recommended after repair For more information about maintenance, request document VI See section 1.6 Return of material on page Spareparts NOTICE Use of wrong Spare parts Risk of malfunction or damage Use only original spare parts, supplied by Aquametro AG Spare part lists may be requested from Aquametro AG (VI14-419). CONTOIL DN

28 6 Troubleshooting backwards No reading / blank display2) Counter not running No flow rate indicated 2) Indicated quantity or flow rate too small Indicated quantity or flow rate too high pressure drop at meter too high No frequency signal 2) No current signal 2) No pulse output signal Legend: 1) Consult operating in structions 2) CONTOIL control VZF, VZFA only direction No power supply 2) Electronic counter defective 2) Flow rate outside allowed range (below Q min or above Q max of meter) Moving parts heavily worn out due to continuous overload Dirt trap / filter heavily soiled Safety filter in meter intake clogged Moving parts jammed Alignment of inner parts Separating plate broken by o Pressure hammer o Gas inclusions Meter positioned wrongly (e.g. at highest point) Gas or air inclusion in fluid Dirt trap or filter heavily soiled Flow meter s safety filter heavily soiled No flow Wrong parameterisation 2) Transducer defective 2) 6.1 For all CONTOIL flow meter Fault symptoms Possible causes Procedures 1) Pointers on roller This is normal at high flow No action required counter rotate irregularly rates and has no effect on accuracy of measurement Counter runs Meter mounted in wrong Install meter with arrow pointing in flow direction Check wiring Replace electronic counter Check flow rate If too high, reduce flow or install larger meter If too low, increase flow or install smaller meter install larger meter Clean dirt trap, replace filter Replace safety filter Install dirt trap / filter with correct mesh size clean measuring chamber, replace defective parts align cover and measuring chamber (rip to rip) Check and rectify operating conditions and meter position Fill pipes slowly De-aerate pipes thoroughly Check and rectify operating conditions and meter position De-aerate pipes carefully Clean dirt trap, replace filter Clean safety filter of flow meter Check flow using Indication Set correct parameters for outputs Replace transducer 28 CONTOIL DN15-50

29 6.2 Error messages VZF / VZFA The electronic module performs a self-test about every 5 minutes. If an error is detected which impairs the reliability or accuracy of the measurement, the [ERROR] warning will appear every 2 seconds on the display. Error messages are messages from the electronic module. [no ErrS] no error is active Action: none [E-FLOW] maximum permitted flow rate (Qmax) exceeded The flow meter is mechanically overloaded and is no longer measuring accurately. Action: reduce the flow rate or use the next higher nominal size. [E-POWER] (supplied) voltage is to low. Faulty data processing, flow meter supplies incorrect measured values. Action: check the voltage supply and eliminate the cause of the error (if applicable). [E-Prom] error with the Checksum of the Software saved in ROM. Action: Please contact the supplier. [E-SENSOR] signal error from flow sensor to electronic module, flow meter supplies incorrect measured values. Action: electronic module must be replaced. Please contact the supplier. [E-EEP R1] EEPROM error in output 1 parameters Action: Go to [DEFAULTS] correct output1 memory block (under USER Code). [E-EEP R2] EEPROM error in output 2 parameters Action: Go to [DEFAULTS] correct output2 memory block (under USER Code). [E-EEPANA] EEPROM error in Analog current loop parameters Action: Go to [DEFAULTS] correct analog current loop memory block (under USER Code). [E-EEPDEV] EEPROM error in device parameters Action: measurement transducer must be replaced. Please contact the supplier. [E-EEPTOT] EEPROM error in Totalizer. Totalizer value may be incorrect. Action: Go to [DEFAULTS] correct Totalizer memory block (under USER Code). CAUTION, Totalizer value is lost. [E-EEPTRP] EEPROM error in Trip Totalizer. Trip Totalizer value may be incorrect. Action: Go to [DEFAULTS] correct Trip Totalizer memory block (under USER Code). CAUTION, Trip Totalizer is lost.. [E-EEPFAT] EEPROM error in File System. Action: measurement transducer must be replaced. Please contact the supplier. CONTOIL DN

30 6.3 Alarm messages VZF / VZFA The electronic module performs a self-test about every 5 minutes. If an alarm condition is detected, the [ALARM] message will appear on the display every 2 seconds. Alarm messages are messages from the parameter settings [no ALmS] no alarm is active Action: none. [A-SEnSSI] alarm when sensor simulation is activated (Service Technician only). Action: none. CAUTION Totalizer and Trip Totalizer accumulate the simulated value. [A-R1 SI] alarm when relay output 1 simulation is activated. Action: turn off when not required anymore. [A-R2 SI] alarm when relay output 2 simulation is activated. Action: turn off when not required anymore. [A-ANA SI] alarm when Analog current loop outputsimulation is activated. Action: turn off when not required anymore. [A-R1 LI] alarm when relay output 1 is over its limit. Action: adjust the settings of output1. [A-R2 LI] alarm when relay output 2 is over its limit. Action: adust the settings of output2. [A-AnA LI] alarm when Analog current loop outputis over its limit. Action: adust the settings of analog current loop output. 30 CONTOIL DN15-50

31 7 Decommissioning, Dismantling and Disposal CAUTION The surfaces of the device/system and the medium may be hot. Risk of burns! Carry out work only on cooled devices/systems. Work may only be performed by authorized specialists in accordance with the applicable regulations. Use appropriate protective equipment. WARNING The device/system may be under pressure. Risk of severe injury! Carry out work only on non-pressurized devices/systems. When working on the device/system watch out for leaking medium. Work may only be performed by authorized specialists in accordance with the applicable regulations. Use appropriate protective equipment, particularly safety googles 7.1 Decommissioning Disconnect all sources of energy. Remove the flow meter from system Follow disposal instruction Dismantling Not required. 7.3 Disposal At the end of the life cycle, this product should be disposed of according to local regulations regarding waste recycling or disposal. Batteries and rechargeable batteries shall be recycled separately. The separate collection and recycling of old products will help to conserve natural resources and ensure that they are disposed of in a manner ensuring the protection of environment and nature. CONTOIL DN

32 8 Technical Data 8.1 Hardware characteristics Hydraulics Nominal pressure: 16, 25, 40bar (based on model) VZF / VZFA Temperature: ambient temperature C, storage temperature C Humidity: storage humidity max 95% none condensing Safety: CE, vibration and shock test to DIN IEC 68 (electronic counter) Data preservation: by non-volatile memory (EEPROM) Protection class: IP 66 (IEC 60529) against dust and heavy seas Passive analog (terminal 1-2) Voltage range (U): 6-30 VDC Resolution: 16 Bit Max. error: ±0.2 ma Update interval: <0.1 s Maximum Load (RL): 0 to 1116 Ω, depending on the external supply voltage of the power supply unit 6 ;.. : 1116@ Digital (terminal 3-4, 5-6) Output (Out1 & Out2): 2 potential-free contacts Max. voltage Umax: 48 VAC/VDC Max. current Imax: 50 ma Max. output frequency fmax: 200 Hz Update interval: <1 ms ON-resistance R0 : 50 Ω OFF-resistance R : 10 MΩ Isolation voltage: >100 VAC/VDC 32 CONTOIL DN15-50

33 8.2 Parameterizing the VZF / VZFA outputs In order to set the parameters, the device must be unlocked with the user code Volume pulse output for summing the flow volume (totalizer) Setup menu: function for Output1 or Output2 Pulse width (t): ms The pulse width can be set between 2 500ms (example: 20ms). The actual pulse width is dynamically adjusted based on the current flow, but at least the set value. The duty cycle is 50%. Signal behavior: The signal is defined as 50% ON and 50% OFF: Parameters that can be set: Pulse value for liters [LPP]: 0, Ltr / pulse Pulse value for m 3 [LPP]: 0, Ltr / pulse Pulse value for US gallons [PPG]: pulse / gallon (factory setting: DN20 50 are set to 50 ms and 1 LPP) DN15 is set to 0.1LPP) Example: If the period is 100ms, the pulse width will be 50ms (50% of the period) and the pulse pause is 50ms. CONTOIL DN

34 Flow / Frequency output according to flow rate Setup menu: function for Output1 or Output2 Frequency range and proportionality of the signal across the desired flow rate measurement range Q1 - Q2 Signal behavior: If the flow falls below the set lower flow rate value, a proportional decrease to 0Hz will occur, which is then maintained until the flow rises over the lower flow rate again. If the flow exceeds the set upper flow rate value, a proportional increase to 200Hz will occur, which is then maintained until the flow falls below the lower flow rate again. On Error, select between [Err FmA] (frequency max; sends max. frequency) or [Err Act] (actual value; error ignored) Parameters that can be set: Lower flow rate [MIN]: Q1 0 (factory setting: Qmin ) Lower frequency [Hz]: f1 0 (factory setting: 20 Hz) Upper flow rate [MAX]: Q2 Qmax. (factory setting: Qcont ) Upper frequency [Hz]: f2 200 Hz (factory setting: 160 Hz)Error (factory setting: Err FmA) Notice: Qmin, Qcont and Qmax are dependent on the nominal size of the flow meter. Example: Lower flow rate: 30 ltr. (Q1) by a frequency of 20Hz (f1) Upper flow rate: 2000 ltr. (Q2) by a frequency of 160Hz (f2) We have a flow range of 1970 liter ( ) and a frequency range of 140Hz (160-20). The flow range will be spread accross the range of 140Hz. That means, 1970 ltr. / 140Hz = 14.1 ltr/hz. In other words, from Hz to Hz you have an increase of 14.1 ltr. 34 CONTOIL DN15-50

35 Limiting output according to settings Setup menu: function for Output1 or Output2 The function Limit allows you to set an alert whenever predefined flow rates are exceeded. Signal behavior: Limit defines upper (Q Lim max ) and lower (Q Lim min ) flow rate thresholds which, when exceeded, activate a switch (alert). In order to prevent oscillating between active and inactive states when the flow rate fluctuates about a threshold, hysteresis bands (see adjacent diagram) can be defined in which the switch will remain active once it has been triggered to this state. When the flow rate passes below or above these bands, the switch will be deactivated. The hysteresis bands are calculated as a percentage of the threshold values (Q Lim). The switch can be used for remote control or alarm systems. Parameters that can be set: Lower flow rate [LIMIT MIN]: QLim min 0 (factory setting: Qmin ) Upper flow rate [LIMIT MAX]: QLim max Qmax (factory setting: Qcont) Hysteresis [HYST]: 0-9% (factory setting: 1%) The switches that are activated by the above parameters can be set to NO (Normally Open) or to NC (Normally Closed). This choice is dependent on your needs. Limit switch [NO]: Contact opens when the limits are exceeded. Limit switch [NC]: Contact closes when the limits are exceeded. Example: If the limit [LIMIT MIN] is set to 100 l/h and [HYST] is set to 5%, then the hysteresis is 5% of 100 l/h or 5 l/h. This means that as soon as the flow rate rises above 105 l/h the switch will be deactivated if it is active. If the limit [LIMIT MAX] is 200 l/h and [HYST] is set to 5%, then the hysteresis is 5% of 200 l/h or 10 l/h. If the switch is active then it will be deactivated as soon as the flow falls below 190 l/h. CONTOIL DN

36 State output according to signal faults Setup menu: function for Output1 or Output2 When ever an fault occurs, you can send it with this selected output. Any fault (Error, Alarm or power loss) can be sent to a remote control or alarm system. Parameters that can be set: Available fault setting: Select contact logic: [Err, ALm or UCC (UCC = power loss)] (factory setting: Err) [NO] or [NC] (factory setting: NO) 36 CONTOIL DN15-50

37 Analog current loop (4-20mA) according to flow rate Setup menu: Analog current loop The current signal is proportional to the flow rate of the range of Q1 to Q2 I 4 : current 4mA I 20 : current 20mA Q 1 : chosen min. flow rate Q 2 : chosen max. flow rate Vol/h : flow Signal behavior: when a relevant flow meter error occurs Value falls below the set lower flow rate value Q1: proportional decrease to 3.8mA which is then maintained. Value exceeds the set upper flow rate value Q2 proportional increase to 20.8mA which is then maintained. Error signal for measurement relevant flow meter error (sensor, ROM, supply voltage, etc.) For HIGH error behavior: output 21.5mA For LOW error behavior: output 3.5mA For ACT error behavior: no error signal, (continuing output of actual value). Damping of the signal [tau] on rapidly changing values. Note: The higher the time constant, the more sluggish the signal. This parameter is used to avoid jumps of the signal Parameters that can be set: Q1 may not be lower than the min. flow rate of the used flow meter (factory setting is 0). Q2 may not be higher than the max. flow rate of the used flow meter (factory setting Qcont.) [tau] Damping value (Tau) 1 (no damping) 9 (max. damping) (factory setting: 4) Example: Q 1 is 50 l/h and Q 2 is 500 l/h By 50 l/h a signal of 4 ma is being sent By 275 l/h a signal of 12 ma is being sent By 500 l/h a signal of 20 ma is being sent the flow range of 450 l/h, will be distributed across the range of 16mA (20mA-4mA). CONTOIL DN

38 9 Appendix 9.1 Dimensional drawings Flow meters All flow meters with threaded ends are according to ISO DN15, 20, 25: with threaded ends DN40: with threaded ends All flow meters with flanges are according to EN , ASME B16.5 or JIS B2220 DN15, 20, 25: with flanged ends DN40, 50: with flanged ends Nomial size L B a Ø F b h1 p r DN G 3/4 G 1/2 DN G 1 G 3/4 DN G 1 1/4 G 1 DN G 2 G 1 1/2 DN Dimensions in mm *h2 is explained on next page 38 CONTOIL DN15-50

39 Dimensions of electronic counter VZF(A) Dimensional drawing VZF/VZFA 9.2 Display of evaluation units VZF/VZFA CONTOIL DN

40 9.3 Default settings VZF/VZFA Total counter unit selected in Unit volume Trip counter unit selected in Unit volume Current flow unit selected in Unit volume and Unit time Setup menu Unit volume L, m3, G Unit time s, min, h Nominal size 15, 20, 25, 40, 50 Measuring chamber default: per selected DN size, or calibrated value Trip Reset Reset yes / no yes, no Low flow cut off Qstart, L/h Output 1 Volume, Flow, Limit, State, disabled Volume output Pulse width 50ms 2-500ms Pulse value 1LPP LPP / PPG / LPP [DN15 is set to 0.1LPP] Simulation off, on Sim value value to be simulated Actual output display flashes [Act Pulse] when active Flow output Min Flow Qmin, 0-Qmax Min Frequency 20Hz, 1-200Hz Max Flow Qcont, 0-Qmax Max Frequency 160Hz, 1-200Hz Error behavior FMA, Act (frequency max; actual value) Simulation off, on Sim Value value to be simulated Actual output displays actual frequency on output [Act Hz] when active Limit output Limit min Qmin, 0-Qmax Limit max Qcont, 0-Qmax Hysteresis 1%, 1-9% Logic position LOGiC NO, LOGiC NC Simulation off, on Sim value value to be simulated Actual output displays actual state on output [active] / [inactive] State output State behavior Error, Alarm, UCC Logic position LOGiC NO, LOGiC NC Actual output displays actual state on output [active] / [inactive] Output disabled Output 2 Volume, Flow, Limit, State, disabled Same as output 1 40 CONTOIL DN15-50

41 Analog current loop Disabled [AnA dis], enabled [AnA EnA] Min Value 0, 0-Qmax Max Value Qcont, 0-Qmax tau value 4, 0-9 Error behavior off, High, Low Simulation off, on Sim value value to be simulated Actual output Dispalys actual current output (ma) when active Simulation Sensor off, on Sim value value to be simulated Errors Error messages. see appendix Alarms Alarm messages see appendix User Code enabled U Code enable / disable user access code (user cannot change any settings) Used Range h0 total operating time t h1 t in preferred flow range (Qmin Qcont) h2 t in upper flow range (Qcont Qmax) h3 t above Qmax h4 t since last flow 5 Peak flow since installation Cal Date Date value dd.mm.yy, Verification Date Date value dd.mm.yy, Firmware 3.xx.xx Checksum Software checksum Serial number Defaults All parameters reset of all parameters Active Error reset of active error (see section 6.2 for details) Customer parameters reset of customer parameters (default set after calibration) Save parameters Save of customer parameters in field Piston Rev timing advanced mechanical information about the piston rotation timing Display test displays all characters that are possible to display Alarm Information message if an alarm is active Error Information message if an error is active *Default settings are in bold italic letters CONTOIL DN

42 9.4 Certificates All the below mentioned certificats / approvals, can be found on our web site Class Approvals German Lloyd Lloyds Register Det Norske Veritas Polish Register of Shipping Versions with type approval and metrological CE approval These versions of the CONTOIL oil flow meter bear the number of the type test certificate in accordance with Directive 2004/22/EU (MID) and the metrological CE mark. This means they can be used for custody transfer in accordance with local law / regulations. For details please request document VD4-319def. 42 CONTOIL DN15-50

43 CONTOIL DN

44 HEAD OFFICE: AQUAMETRO AG Ringstrasse 75 CH-4106 Therwil Phone Fax AQUAMETRO Messtechnik GmbH Kurt-Schumacher-Allee 2 D Bremen Phone Fax info.amd@aquametro.com AQUAMETRO BELGIUM SPRL Dalaan, 67 B-1933 Sterrebeek Phone Fax info.amb@aquametro.com Änderungen vorbehalten / Sous réserve de modifications Modification rights reserved / Copyright Aquametro AG AQUAMETRO ME JLT Jumeirah Lake Towers Jumeirah Bay X3, Office 1807 P.O. Box Dubai / UAE Phone yasuhiko.takahashi@aquametro.com aquametro@korea.com customersupport@aquametro.com.sg 44 CONTOIL DN15-50 info.amme@aquametro.com AQUAMETRO JAPAN , Nakane Meguro-ku Tokyo / Japan Phone Fax AQUAMETRO KOREA LTD #501, Centum IS Tower 1209 Jaesong-Dong Haeundae-Gu Busan / Korea Phone Fax AQUAMETRO (S.E.A.) PTE LTD 190 Woodlands Industrial Park E5 #07-15 Woodlands BizHub Singapore Phone Fax AQUAMETRO (CHINA) PTE LTD Sales Office 190 Woodlands Industrial Park E5 #07-15 Woodlands BizHub Singapore Phone Fax sales.china@aquametro.com.sg Art. Nr