Page 1
Flowmax 242i
BA 007E/FM242i/02.18
Valid starting from
Hardware V 2.1
Software V 1.29
Ultrasonic flow
metering / dosing
device
Operating manual
Page 2
General safety instructions Flowmax 242i
IMPORTANT!
WARNING!
NOTICE!
WARNING!
General safety instructions
Please always observe the following safety instructions!
Please pay attention to the safety instructions with the following pictograms and
signal words in these operating instructions:
IMPORTANT! indicates situations or cases
which, if not avoided, could result in
damage or failure of the Flowmax 242i
equipment.
WARNING! indicates general hazardous
situations or cases which, if not avoided,
could result in serious injury or death.
NOTICE! is used to lead users to helpful
Intended use
The flow meter Flowmax 242i may only be used for measuring the flow of
pure, homogeneous liquids.
The volume flow meter Flowmax 242i is built operationally safe in
accordance with the latest state of the art technologized developments and
industry standard EN 61010 regulations (corresponds to VDE 0411 “Safety
specifications for electrical measurement, control and laboratory devices”).
The manufacturer is not liable for any injury, damage or harm due to
inappropriate or unintended use or modifications of the flow meter.
Conversions and/or changes to the flow meter may only be made, if they are
expressly performed in accordance with the operating instructions in this
operating manual.
Personnel for installation, commissioning and operation
Assembly, electrical installation, commissioning and maintenance of
the flow meter must be carried out by qualified, trained personnel. The
qualified personnel must have read and understood the operating
instructions in this operating manual and must follow the operating
instructions in this manual.
The installer has to ensure that the flow meter is correctly connected
according to the electrical connection diagrams in this operating
manual.
Serious injury or death from electric shock may occur if wiring,
installation, disassembly or remove of wires is performed while
electrical power is energized
Technological progress
The manufacturer reserves the right to revise, alter, or modify the flow meter to
the most current technology without special prior notice. Further information
about the latest updates and potential additions to these operating instructions
are available from the manufacturer.
information not related to personal injury.
2 M I B
Page 3
Flowmax 242i Tablet of contents
Tablet of contents
General safety instructions .......................................................................................................... 2
Tablet of contents ......................................................................................................................... 3
Table of figures ............................................................................................................................. 4
1. Planning information ............................................................................................................. 5
1.1 Areas of application.................................................................................................................................. 5
1.2 Measuring principle .................................................................................................................................. 5
1.3 Operational safety .................................................................................................................................... 6
2. Assembly and installation..................................................................................................... 6
2.1 Installation instructions ............................................................................................................................. 6
2.2 Assembly of the flow meter ...................................................................................................................... 7
2.3 Electrical wiring ........................................................................................................................................ 9
3. Commissioning .................................................................................................................... 11
3.1 Operation ............................................................................................................................................... 11
3.1.1 Display and user menu ................................................................................................................... 12
3.2 Functionalities of flow meter and default settings .................................................................................. 15
3.2.1 Language ........................................................................................................................................ 15
3.2.2 Dosing ............................................................................................................................................. 15
3.2.3 Media............................................................................................................................................... 15
3.2.4 Set Offset ........................................................................................................................................ 15
3.2.5 Creeping suppression ..................................................................................................................... 15
3.2.6 Basic Trim ....................................................................................................................................... 16
3.2.7 Filter ................................................................................................................................................ 16
3.2.8 Units ................................................................................................................................................ 17
3.2.9 Reset Counter ................................................................................................................................. 17
3.2.10 Diagnostic ..................................................................................................................................... 17
3.2.11 Analog output QA .......................................................................................................................... 18
3.2.12 Pulse value .................................................................................................................................... 19
3.2.13 Digital outputs ............................................................................................................................... 20
3.2.14 Digital output Q1 ........................................................................................................................... 21
3.2.15 Dosing function ............................................................................................................................. 22
3.3 Overview of default settings ................................................................................................................... 22
3.4 General Information ............................................................................................................................... 23
3.5 Function of Dongle ................................................................................................................................. 23
4. Exchange of flow meter ...................................................................................................... 24
5. Technical specifications ..................................................................................................... 25
5.1 Dimensions and weight .......................................................................................................................... 25
5.2 Technical specifications ......................................................................................................................... 26
6. Accessories ......................................................................................................................... 27
7. Shipment .............................................................................................................................. 27
Appendix ..................................................................................................................................... 28
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Table of figures Flowmax 242i
Table of figures
Figure 1: Presentation of the principle of ultrasonic flow measuring ................................ ................ 5
Figure 2: Installation position of Flowmax 242i................................................................................ 6
Figure 3: Mounting examples for Flowmax 242i .............................................................................. 7
Figure 4: Mounting possibilities ....................................................................................................... 8
Figure 5: Fixing Flowmax 242i ........................................................................................................ 8
Figure 6: Pin code: Connection plug / socket for 5-pin version ....................................... 9
Figure 7: Operating with the key pad ............................................................................................ 12
Figure 8: Menu structure ............................................................................................................... 14
Figure 9: Function of the creeping suppression illustrated with 0.6 l/min ....................................... 16
Figure 10: Characteristic curve 0 to 20mA .................................................................................... 18
Figure 11: Characteristic curve 4 to 20mA .................................................................................... 19
Figure 12: Connecting Output Q1 to relay ..................................................................................... 21
Figure 13: Connecting output Q1 to counter ................................................................................. 21
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Flowmax 242i Planning information
1. Planning information
1.1 Areas of application
The flow measurement device in the Flowmax 242i designed to measure
dynamic flow in pipes and tubes. This flow meter is suitable for liquids only. The
Flowmax 242i is used in
Bio-processing applications
Chemicals supply for controlling, logistics, monitoring
Cooling systems, logistics, monitoring
Process equipment for control and monitoring of formulas
Valve control for continuous release of liquid volumes
Supply with de-ionized water
Very dynamic liquid processes with dosing times of below 1 second
Flowmax 242i has the following features and benefits:
No movable parts, therefore no wear
High repeatability
Easy to clean
Safe operation
Compact design
Integrated detection of empty conduits
Integrated dosing function with pre-set and adjustable amounts
Chemical resistant
Constant pipe cross-section over the entire measurement channel
1.2 Measuring principle
It usually takes more energy to swim against the flow than with the flow. The
ultrasonic flow measurement is based on the phase-difference approach:
Two ultrasonic-sensors located opposite from each other alternatively
transmitting and receiving ultrasonic signals. If there is no liquid flow both
sensors receive the transmitted ultrasonic signals in the same phase, i.e.
without phase difference. If liquid is flowing there is a phase shift. It differs when
measured in direction of the flow than when measured against the direction of
the flow. This phase difference is directly proportional to the flow rate.
Figure 1: Presentation of the principle of ultrasonic flow measuring
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Assembly and installation Flowmax 242i
NOTICE!
1.3 Operational safety
Comprehensive self-tests ensure highest possible safety.
Faults (process or system errors) are output on a digital output or displayed on
the display menu.
The protection class is IP 65.
Flowmax 242i meets the general EMC immunity requirements according to
CE, EN 61000-6-3, EN 61000-4-2, EN 61000-4-3, EN 61000-4-4, EN 61000-45, EN 61000-4-6.
Flowmax 242i meets the safety requirements concerning the Protective Extra
Low Voltage directive according to EN 50178, SELV, PELV.
Flowmax 242iM has the USP Class VI approval and is resistant to gamma
irradiation.
2. Assembly and installation
2.1 Installation instructions
The housing of the Flowmax 242i has an arrow, symbolizing the flow direction
of measurement. The flow meter has to be installed in a way so that the flowthrough is in the same direction as the arrow symbol.
Figure 2: Installation position of Flowmax 242i
For fastest possible bubble detection it is important to keep the pipe distance
from tank to Flowmax 242i as short as possible. Accurate measurement can
only be assured, if the pipe is completely filled and the liquid does not outgas.
Notwithstanding it may be advantageous for dosing applications to install the
Flowmax 242i as close as possible to the dosing valve, since soft pipes
increases the cross-section depending on the system pressure. This may lead
to repeatable differences.
Insure that no cavitations dissolve from the measured liquid. Depending on the
measured liquid it can be helpful to have enough back pressure on the outlet of
Flowmax 242i to avoid cavitations. Insure all mechanical connections are tight.
Particles present in the flow stream may result in measuring errors.
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Flowmax 242i Assembly and installation
Flowmax
Flowmax
Pump
Valve
Container
Valve
WARNING!
NOTICE!
When using pumps, Flowmax 242i must be installed in flow direction on the
pressure side, on order to ensure sufficient pressure. The maximum pressure
rating of Flowmax 242i has to be considered.
Do not exceed the maximum pressure allowance for of the Flowmax 242i
(see section 5.2 Technical specifications). Exceed the maximum pressure
can lead to destruction of the Flowmax 242i.
Flowmax 242i needs no inlet or outlet.
2.2 Assembly of the flow meter
The flow meter is mounted into a pipe system by using the mechanical
connection. Flowmax 242i should be mounted vertically into the pipe for the
best measuring performance. Do not install the flow meter after a dosing valve
where the flow meter can run empty. Placing the flow meter after a dosing valve
and allowing it to run empty will cause a measuring deviation at the next
measurement. To avoid bubbles in the liquid, Flowmax 242i should be installed
on the pressure side of the pump.
Figure 3: Mounting examples for Flowmax 242i
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Assembly and installation Flowmax 242i
Flowmax
Flowma
Process
Process
Valve
Valve
WARNING!
If it is not possible to mount the flow meter vertically, then mount the instrument
in a location where the pipe will be filled at all times. The best measuring result
is achieved if bubbles do not pass through Flowmax 242i.
Figure 4: Mounting possibilities
For applications with a “clean design“ for which it is necessary to completely
drain the pipe system, we recommend mounting the flow meter in the vertical
position. Residual liquid may remain inside the device if flow meter is mounted
horizontally.
Vibrations or mechanical forces may decrease measuring accuracy. So if there
is due to vibration or mechanical movements it is necessary to fix Flowmax 242i
additionally, the instrument can be fixed on the lateral slot.
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Figure 5: Fixing Flowmax 242i
Flowmax 242i must be installed without mechanical tensions on the existing
pipe system. The flow meter may be damaged if there is tension on the existing
pipe system.
Non-compliance of the installation instructions may result in tearing of the
housing, liquid may leak out.
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Flowmax 242i Assembly and installation
Pin
Function
Description
1
L+
Voltage supply: 18...30 VDC
2
Pulse output Q1
alternative:
1. Empty-pipe output
2. Dosing output
3. Upper or Lower Limitoutput
4. Negative flow
Digital Output Q1
Freely adjustable ranging from 0.1 to 3000
ml/pulse in 0.1 ml/pulse steps, npnTransistor, max. load 30V/100mA. Max.
Voltage must be less than the supply voltage
Configurable output of 0V or 24V when pipe
is empty.
Configurable output of 0V or 24V
Configurable output of 0V or 24V when
reaching upper or lower limit
Configurable output of 0V or 24V when liquid
flows in negative direction
3
GND
Ground: 0 V
4
Communication
Communication interface A
5
Analog output QA
4....20mA; 0....20mA
Example: 0l/min => 4mA
36l/min => 20mA
Empty pipe Alert => 3.5mA
(4-20mA, depending on the configured limits)
WARNING!
WARNING!
2.3 Electrical wiring
The dongle must be connected before the Flowmax 242 is started.
It must never be screwed under power.
The dongle-check is performed when the device is started:
If no dongle is detected the display will show “No Dongle”
If a dongle has been recognized but not a measuring pipe it shows
“No Pipe”
If dongle and measuring pipe were detected but do not match it shows
“Wrong Dongle”
In all these messages, the device can not show the menu, can not
measure any flow or empty pipe. Everything is blocked as long as
Flowmax 242i starts with a valid measuring pipe and dongle.
If dongle and measuring pipe fit together the usual field with current flow
and counter is displayed and the menu is normally accessible.
Serious injury or death from electric shock may occur if wiring,
installation, disassembly or remove of wires is performed while electrical
power is energized.
Always shut off or disconnect electrical power at service panel and lock
switch or breaker and tag to prevent energizing electrical power during
work or while Flowmax 242i is not assembled and installed.
Wiring installation, disassembly and removal must be performed by
qualified persons experienced and knowledgeable about electrical work.
Figure 6: Pin code: Connection plug / socket for 5-pin version
Connector cable pin configuration defined by manufacturer.
The outputs may be re-programmed for specific applications.
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Assembly and installation Flowmax 242i
Pin
Function
Description
1
24 VDC
Voltage supply: 18...30 VDC
2
Digital output Q1
Functions
1. Pulse output
2. Empty pipe output
3. Dosing output
4. Upper or Lower Limit
output
5. Negative flow
Digital output Q1
Configurable npn-or pnp transistor, max. load
100mA*.
Max. voltage must be less than the supply
voltage
Freely adjustable ranging from 0.1 to 3000
ml/pulse in 0.1 ml/pulse steps,
Configurable output of 0V or 24V when pipe is
empty.
Configurable output of 0V or 24V
Configurable output of 0V or 24V when reaching
upper or lower limit
Configurable output of 0V or 24V when liquid
flows in negative direction.
3
GND
Ground: 0 V
4
Digital output Q2
Functions:
1. Empty pipe output
2. Dosing output
3. Pulse output
4. Upper or Lower Limit
output
5. Negative flow
Digital output Q2
Configurable npn- or pnp-transistor, max. load
100mA*.
Max. voltage must be less than the supply
voltage
Configurable output of 0V or 24V when pipe is
empty.
Configurable output of 0V or 24V
Freely adjustable ranging from 0.1 to 3000
ml/pulse in 0.1 ml/pulse steps.
Configurable output of 0V or 24V when flow
reaches upper or lower limit.
Configurable output of 0V or 24V when liquid
flows in negative direction.
5
Analog output QA
4....20mA; 0....20mA
Example: 0l/min => 4mA
6l/min => 20mA (depending on
diameter
Empty pipe Alert => 3.5mA
6
Communication
and
Set offset
Communication interface
The Offset is set by a signal of 0V for more
than 2 seconds. All the other time it has to be
high resistance.
7
No function
Not used.
8
Shielding
EMC safety
IMPORTANT!
8-pin plug with 1-wire communication:
Figure 7: Pin code: Connection plug / socket for 8-pin version
Connector cable pin configuration defined by manufacturer.
The outlets may be re-programmed for specific applications.
*it applies: for Q1 + Q2 ≤ 100mA
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Flowmax 242i Commissioning
IMPORTANT!
Attention: Only operate the flow meter Flowmax 242i within the operating
limits stipulated on the product label and the operating manual / data
sheet. Use of the Flowmax 242i outside these conditions will lead to
overloads which cause permanent damage.
3. Commissioning
NOTE: If Flowmax 242i is used for a fluid other than water the "basic trim" has
to be carried out during commissioning. Therefore the device has absolutely be
filled with medium.
The basic trim can be done on the device display. During the adjustment the
medium may not flow as it affects the function.
3.1 Operation
If Flowmax 242i is used as a volume flow meter for water or water-like liquids it
will not require on-site calibration. Parameters for water are calibrated at the
factory. The Flowmax 242i may also be ordered with customized settings, but
customized settings must be requested when Flowmax 242i is ordered.
If necessary, e.g. if viscosity and/or speed of sound deviate significantly from
water, the pre-set parameters can be adjusted via the display. It is always
necessary to adjust the manufacturer pre-set parameters when using the
Flowmax 242i as a dosing device according to section 3.2 (Dosing 1. Flowmax
242i as a dosing device). Adjusting the manufacturer pre-set parameters
requires a display.
The following parameters may be changed to settings suitable for the individual
conditions:
- Digital output Q1, function and behavior
- Analog output QA, function and behavior
- Flow range, for which shall apply 4...20 mA
- Pulse value
- Creeping suppression
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Commissioning Flowmax 242i
IMPORTANT!
NOTICE!
3.1.1 Display and user menu
Flowmax 242i is equipped with a display to visualize actual measurement
values and to change parameters of the flow meter. Menu navigation and
parameter changes are controlled by the four keys on the keypad.
Figure 8: Operating with the key pad
Press the “Set” key to display the main menu. Different menu options can be
selected by using the two arrow keys.
To enter e.g. analog limits “Analog output – Upper limit” use the arrow keys to
change values and press “Set” to confirm. To switch back to the last menu level
press the “Esc” key. As soon as the operator tries to change values the user will
be prompted to enter a password. Password protection is used to ensure
changes to values or configurations are done by authorized personnel. The
default password for Flowmax 242i is 41414. The user level will remain active
for 5 minutes after the last press on any button.
The Password should only be shared with personnel authorized to make
changes to setting.
NOTE:
Always the first parameter of the menu appears in the display. This need not be
the adjusted enabled parameter. The enabled parameter appears inverted and
is possibly visible by scrolling.
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Flowmax 242i Commissioning
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Commissioning Flowmax 242i
Figure 9: Menu structure
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Flowmax 242i Commissioning
3.2 Functionalities of flow meter and default settings
3.2.1 Language
The language of the display can be changed. Available languages are English
and German.
3.2.2 Dosing
The Flowmax 242i can be configured for manually dosing by choosing the
dosing function via the user display. The Volume “Dosing Batch“ and the
“Dosing Time“ are freely adjustable. When the “Dosing Time“ is set to zero, the
timer control is inactive. A dosage can be started and stopped with the menu
function keys “Start“ and “Stop“.
Setting range “Dosing Batch”: 0 – 3500 Liters
Setting range “Dosing Time” 0 –30000 Seconds
Default setting “Dosing Batch”: 0 Liters
Default setting “Dosing Time”: 3 Seconds
3.2.3 Media
Flowmax 242i comes with a medium matrix with up to 8 interpolation values.
Different media can be managed in the sub menu “Media”. By using the sub
menu point “Correction” it is possible to correct the flow measurement in
percent. Example of operation see appendix.
3.2.4 Set Offset
In the sub menu “Set Offset” it is possible to set the actual offset of the flow
meter. Use this function only when Flowmax 242i is completely filled with liquid,
and there is no flow. If the offset is set while flow is present or when the pipe is
empty it will cause an offset drift what results in a faulty measurement. Example
of operation see appendix.
A small offset change, e.g. caused by variable temperatures, is automatically
done by the flow meter. It is also possible to set the offset via a signal of 0V for
more than 2 seconds at PIN 6. All the other time it has to be high resistance..
3.2.5 Creeping suppression
The creeping suppression excludes flow measurements that result from
convection in a narrow band around zero, even with a closed valve. At the
factory, the creeping suppression is set at a standard value in relation to the
cross-section of the flow meter. Changes to a smaller value of the parameter
may cause an offset drift what results in a faulty measurement.
There are higher tolerances below the standard default settings, see also section
5.2 measurement errors!
Setting range: 0.0...3 l/min, in 0.006 l/min steps
Default settings: 0.0025 l/min for DN 3
0.024 l/min for DN 5
0.09 l/min for DN 7
The creeping suppression works with a hysteresis of - 25%.
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Commissioning Flowmax 242i
NOTICE!
IMPORTANT!
Figure 10: Function of the creeping suppression illustrated with 0.6 l/min
Example: Creeping suppression = 0.6 l/min
If the flow rate is lower than 0.45 l/min the pulse output/analog output
becomes inactive. If the flow rate exceeds 0.6 l/min a pulse is output
again and added to the totalizer. Similarly, a value is transmitted to
the analog output again.
3.2.6 Basic Trim
The “Basic Trim” function insures that the flow meter is conforming to the media
specific characteristics. To execute this function, Flowmax 242i runs a selfdiagnostic function which optimizes all important parameters. This process lasts
approximately 1 minute.
IMPORTANT!
To make sure the basic trim is correctly done, the flow meter has to be filled
with liquid without a flow.
When there is an error detected while performing the basic trim function, the
display shows “Error”. After successfully finishing the basic trim function, the
display will show “Done”
3.2.7 Filter
The function ”Filter“ averages the analog output signal. Possible settings: Soft,
Medium, Strong, Off
The analog output signal reacts faster to signal changes when average
determination is set to “soft”. Whereas the analog output signal reacts slower
when average determination is set to “strong”.
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Flowmax 242i Commissioning
Filter
100%
off
16ms
soft
0,3s
medium
1s
strong
4,2s
0
20
40
60
80
100
0 1 2 3 4
Wert [%]
Zeit [s]
aus
schwach
mittel
stark
IMPORTANT!
NOTICE!
3.2.8 Units
Flowmax 242i is able to show actual flow or the volume in different units.
Following units can be selected:
ml/s + l , Gal/min +Gal , l/min + l , l/min + m³.
The first letters correspond to the unit of the flow value. The letters after the +
correspond to the unit of the volume value.
3.2.9 Reset Counter
The volume counter of Flowmax 242i can be reset. Example of operation see
appendix.
IMPORTANT!
Once reset, counter values cannot be restored. After a reset the counter works
normally.
3.2.10 Diagnostic
The sub menu “Diagnostic“ shows the software/hardware version and other
helpful values for analysis. Actual values and the instrument´s present status are
important to analyze the measurement or failure by the manufacturer service.
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Commissioning Flowmax 242i
Value Current [mA]
Smaller 0% 0
0% (min Range) 0
Between 0% and 100% Linear interpolation from 0 to 20 mA
100% (max Range) 20
Bigger 100% 20
0
2
4
6
8
10
12
14
16
18
20
22
24
-20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120
Current [mA]
Value [%]
Current output 0...20mA
IMPORTANT!
3.2.11 Analog output QA
The analog output is available as current output 4-20mA or 0-20mA. This is
selected with the purchase order. As a standard it comes with current output 420mA. It can also be switched off by the device menu.
The current output ranges from 0 to 22.6mA measuring the flow rate or the
condition of the flow measurement.
The values here signify for 4-20mA configuration:
20 mA the upper limit of the relevant measurement
4 mA the lower limit of the relevant measurement
3.5 mA empty pipe
Upper and lower limit parameters can be set within the type-specific
measurement of the device. By default, zero flow is set at 4 mA and the
maximum flow is set at 20 mA.
Set point ranges: 0-20mA, 4-20mA, off
Output value: Flow, Temperature
When current output is used, the load must not be higher than 500Ohm. A
higher load prevents the device from providing the maximum current of 22.6mA.
Characteristic curves analog output
0 - 20mA
For the following graphic “min Range” is used for 0% and “max Range” is used
for 100%.
Figure 11: Characteristic curve 0 to 20mA
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Flowmax 242i Commissioning
Value Current [mA]
Empty pipe 3.5
Smaller -1.2% 3.8
Between -1.2% and 0% Linear interpolation from 3.8 to 4mA
0% (min Range) 4
Between 0% and 100% Linear interpolation from 4 to 20mA
100% (max Range) 20
Between 100% and 103% Linear interpolation from 20 to 20.5mA
Bigger 103% 22.6
0
2
4
6
8
10
12
14
16
18
20
22
24
-20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120
Current [mA]
Value [%]
Current output 4...20mA
4 - 20mA
For the following graphic “min Range” is used for 0% and “max Range” is used
for 100%.
Figure 12: Characteristic curve 4 to 20mA
Min Range
Here, the value is set at the 0 or 4 mA to be output.
Setting range: 0 to 8000ml/s in steps of 0.01
Default setting: 0 ml/s
Max Range
Here, the value is set at the 20 mA to be output.
Setting range: 0 to 8000ml/s in steps of 0.01
Default setting: max Flow of the flowmeter (depending on diameter)
DN 3: 17 ml/s
DN 5: 50 ml/s
DN 7: 100 ml/s
3.2.12 Pulse value
The pulse value determines the flow volumes for which an output pulse will be
emitted.
Choose a configuration which will neither exceed the maximum output
frequency of the Flowmax 242i (10kHz) nor the maximum input frequency of the
control. If the maximum frequency is exceeded the Flowmax 242i will not output
pulses correctly.
Example: 2.0 ml/Pulse
This means: a pulse is emitted every 2.0 ml.
Setting range: 0.1...3000.0 ml/Pulse, in 0.1 ml/Pulse steps
Default setting: 1.0 ml/Pulse
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Commissioning Flowmax 242i
Flow
Pulse value
Frequency
Period
Duration of the pulse
ml/s
ml/Pulse
Hz s s
ms
1 1 1 1 0,5
500
100 1 100
0,01
0,005
5
1000
0,1
10000
0,0001
0,00005
0,05
100
10
10
0,1
0,05
50
0,5
10
0,05
20 1 1000
Empty pipe Filled, no flow
0V normal closed High resistant 0V
0V normal open 0V High resistant
24V normal closed High resistant 24V
24V normal open 24V High resistant
Empty pipe Filled, no flow Filled, flow
0V normal closed 0V 0V High resistance
0V normal open 0V 0V High resistance
24V normal closed High resistance High resistance 24V Pulses
24V normal open High resistance High resistance 24V Pulses
Below lower limit Between the limits Above upper limit
0V normal closed High resistance High resistance 0V
0V normal open 0V 0V High resistance
24V normal closed High resistance High resistance 24V
24V normal open 24V 24V High resistance
Below lower limit Betwenn the limits Above upper limit
0V normal closed 0V High resistance High resistance
0V normal open High resistance 0V 0V
24V normal closed 24V High resistance High resistance
24V normal open High resistance 24V 24V
Startup of device While dosing Before/after dosing
0V normal closed High resistance High resistance 0V
0V normal open High resistance 0V High resistance
24V normal closed High resistance High resistance 24V
24V normal open High resistance 24V High resistance
IMPORTANT!
In the last case every 20 seconds, a pulse of 1 second duration is put out.
IMPORTANT!
If Dosing Time =0 the time switch-off is inactive.
3.2.13 Digital outputs
All outputs switch over to high resistance when the supply is smaller than 16V.
When overload or short circuit is detected the digital outputs are switched off
after 100µs for a period of 2s. When time is up the outputs get applied again.
Empty pipe output
Pulse output
Upper limit output
Lower limit output
Dosing output
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Flowmax 242i Commissioning
IMPORTANT!
IMPORTANT!
IMPORTANT!
When using the dosing function the output should not be configured as normal
closed!
If the dosing output is configured as normal closed the valve will stay open
after the dosing batch.
3.2.14 Digital output Q1
Digital output Q1 may be used as pulse output, empty pipe detection, for
switching dosing valve or limit control. By using the Display the user can switch
between npn and pnp-transistor logic. In case of inductive load a diode has to
be connected antiparallel to the coil.
Example 1: Flowmax 242i via npn, external relay
Figure 13: Connecting Output Q1 to relay
Setting area: off, pulse output, empty pipe, dosing output,
lower limit, upper limit, negative flow
Example 2:Flowmax 242i via pnp, external counter e.g. PLC
Figure 14: Connecting output Q1 to counter
Setting area: off, pulse output, empty pipe, dosing output,
lower limit, upper limit, negative flow
IMPORTANT!
Inductive load on the digital outputs without an installed diode may cause
damage on the Flowmax 242i electronics.
M I B 21
Page 22
Commissioning Flowmax 242i
Function
Default settings
Digital output Q1
Pulse output as 24V normal open
Current output QA
Flow as 4-20mA signal
20mA -> 1 l/min at DN 3
3 l/min at DN 5
6 l/min at DN 7
Pulse value
1 ml/Pulse
Creeping suppression
0.0025 l/min at DN 3
0.024 l/min at DN 5
0.09 l/min at DN 7
WARNING!
3.2.15 Dosing function
Dosing controlled in different ways:
1. Flowmax 242i as dosing device (dosing control via Flowmax 242i)
Flowmax 242i controls the complete dosing function. The dosing quantity (e.g.
400 ml) is pre-set in the Flowmax 242i via the display. Dosing starts, as soon as
the digital input is wired to 24V, e.g. via a pushbutton. Flowmax 242i will open
the dosing valve via the output configured for it. When the pre-set dosing
quantity is released, the dosing valve is closed via the above output. The dosing
procedure can also be started and stopped by using the dosing user menu. The
second output can be used independently for signaling empty pipe, limit control
or flow direction.
2. Flowmax 242i as flow meter (dosing control via dosing equipment)
The dosing equipment controls the entire dosing function. The dosing quantity
is fixed in the dosing equipment control during commissioning by pre-selecting
the meter pulses. Dosing starts, when the relevant pushbutton of the dosing
equipment is pushed. The control will open the dosing valve. Once the button
is pushed Flowmax 242i will send a voltage pulse to release the metered
volume (e.g. per 1ml). Once the pre-selected metered volume is released, the
control closes the dosing valve. In this case, output 1 is used to send out
pulses.
The customer has to provide an emergency stop and an overfilling stop to
prevent hazardous situations. Both functions must perform safety shut
down of pumps and closing of valves.
3.3 Overview of default settings
22 M I B
Page 23
Flowmax 242i Commissioning
IMPORTANT!
3.4 General Information
Please check the following before powering the flow meter for the first time:
Check the electrical connections and cable allocations.
Check wether the belonging to the measuring pipe dongle is plugged in
Check the installation position of the flow meter. Is the direction of the
arrow on the housing/name plate and the actual flow direction in the pipe
congruent?
Is the measurement pipe completely filled with fluid?
Check the back pressure in the system.
Is the green cable from the electronic being connected to the measuring
channel?
When everything has been checked, switch on power. After 30 minutes with
power running the measuring device reaches the maximum accuracy.
Flowmax 242i is operational!
3.5 Function of Dongle
a) If no dongle and no measuring pipe is connected in the display
appears “No dongle”
Connect the measuring pipe and the belonging to the measuring
pipe dongle to the electronics
b) If no measuring pipe is connected in the display appears ”No pipe”
Connect the measuring pipe to the electronics
c) If dongle and measuring pipe don’t belong to each other in the display
appears “Wrong dongle”
Connect the belonging to the measuring pipe dongle to the
electronics
M I B 23
Page 24
Exchange of flow meter Flowmax 242i
WARNING!
WARNING!
WARNING!
4. Exchange of flow meter
Switch off power before disconnecting the electrical connections or
screw the dongle!
Wiring installation, disassembly and removal must be performed
by qualified persons experienced and knowledgeable about
electrical work.
Serious injury or death from electric shock may occur if wiring,
installation, disassembly or remove of wires is performed while
electrical power is energized
Please note that after replacing the flow meter
a) Specific programming of the previous flow meter should be noted and
programmed to the new flow meter
b) when using the dosing function, set a quantity
Repair, hazardous substances
Before sending the flow meter Flowmax 242i for repair, the following
precautions must be taken:
Clean all process chemicals from the device. Fully rinse the flow
path. Please pay close attention to the process fittings. All media
must be removed before returning. This is particularly important, if
the medium to be measured is health hazardous.
Devices judged to be insufficiently cleaned will be returned to sender. No
inspection of device will be done until proper cleaning is completed by user.
Costs due to inadequate cleaning of the instrument for possible disposal or
injury (burns, etc.) will be charged to the sender of the meter into account.
With the flow meter send a detailed report describing the failure,
the application and the physical-chemical properties of the medium
parameters. (e.g. a decontamination declaration).
In order to be able to process your repair order quickly and smoothly it is
important that you provide a technical contact person including phone and fax
number as well as e-mail address.
24 M I B
Page 25
Flowmax 242i Technical specifications
Height Depth Width Weight
[mm] [mm] [mm]
[g]
PE-HD
DN 3 / 5 /7 148 82,5 42 390
Nominal
diameter
Height Depth Width Weight
[mm] [mm] [mm]
[g]
PSU
165 48 42 340
5. Technical specifications
5.1 Dimensions and weight
Dimension Flowmax 242iM (Measuring Channel)
Dimension Flowmax 242iE (Electronics)
M I B 25
Page 26
Technical specifications Flowmax 242i
5.2 Technical specifications
Measuring Pipe Housing (Flowmax 242iM)
Nominal diameters DN 3, 5, 7
Mechanical Connection inner thread G1/2
Medium temperature 0...+50°C
Protection class IP 65
Pressure nominal 7 Bar
Material PE-HD (Polyethylene)
Flowmax 242iM has the USP Class VI approval and is resistant to gamma irradiation.
Dongle (Flowmax 242iD)
Connection Plug 5 pins
Electronics (Flowmax 242iE)
Power supply 18...30VDC
Power input at 24VDC = 3.6W
Connection Plug 5 pins, option plug 8 pins
Ambient temperature 0....+50°C
Storage temperature 0....+50°C
Current output QA 0/4...20 mA,
Lower- and upper limit adjustable,
Ground connected to supply ground
Error Signal according to NAMUR NE43 with 4…20mA
Digital output Q1 via transistor npn- and pnp-logic
output voltage according to DIN 19240:
≤5V means LOW
≥12V means HIGH
Short cut resistant
Frequency 0....10kHz
Data interface and Data interface for parameterize
Set offset The Offset is set by a signal of 0V for more than 2 seconds.
All the other time it has to be high resistance
Measuring deviation ± 2% of reading ± 3mm/s, option ± 1% of reading ± 3mm/s
Measuring range 0.0025 – 1 l/min DN 3
0.024 – 3 l/min DN 5
0.09 – 6 l/min DN 7
Repeatability: 0.5%
Connection to the measuring pipe via a green cable, length 0,5, 1,5 or 2,0m.
The measuring system Flowmax 242i meets the general EMC immunity
requirements according to CE, EN 61000-6-3, EN 61000-4-2, EN 61000-4-3,
EN 61000-4-4, EN 61000-4-5, EN 61000-4-6. It is in conformity with the
requirements of the EC directives and has the CE label.
26 M I B
max. 30V/100mA
Reference conditions (VDE/VDI 2642)
Page 27
Flowmax 242i Accessories
Display text
Description
Behavior
No Dongle
No dongle is detected
Connect dongle
No Pipe
A dongle has been recognized but no measuring
pipe
Connect measuring
pipe
Wrong Dongle
Dongle and measuring pipe were detected but do
not match
Connect measuring
pipe and dongle that
match
Empty Pipe
When “Empty Pipe” is detected, no flow
measurement.
Display flashing + text
Low Voltage
When power supply is less than 16V the outputs
are inactiv.
Display flashing + text
Short Circuit
When over load of the digital outputs is detected
(>100mA), outputs are inactive.
only text
Lower Limit
When the flow is less than an adjustable limit and
the output is configured for limit control. At the same
time the configured output is switched.
only text
Upper limit
When the flow is more than an adjustable limit and
the output is configured for limit control. At the same
time the configured output is switched.
only text
Sonic Speed
Actual sonic speed out of specified value. Run
basic trim!
only text
Possible error text Flowmax 242i
6. Accessories
Flowmax connection socket
Flowmax connection socket is used to power and connect Flowmax 242i to an
external control unit.
Ordercode 507321 (Socket 5 pins)
Ordercode 800845 (Socket 8 pins)
Flat sealing EPDM (11 x 19 x 2) USP ClassVI: 801383
Nozzle for hose (all USP ClassVI):
DN3 PEHD 908998
6mm PVDF 908976
8mm PVDF 908978
7. Shipment
Flowmax 242iE (Electronic)
Flowmax 242iM (Measuring Pipe)
Flowmax 242iD (Dongel)
M I B 27
Page 28
Appendix Flowmax 242i
Appendix
Examples of operation:
Enter Password
Key Display picture
Set Password
4 x Λ 40000
Set X0000
Λ X1000
Set XX000
4 x Λ XX400
Set XXX00
Λ XXX10
Set XXXX0
4 x Λ XXXX4
Set
Set Offset
Use this function only when Flowmax 242iM is completely filled with liquid, and
there is no flow. If the offset is set while flow is present or when the pipe is
empty it will cause an offset drift what results in a faulty measurement.
Set Dosing
Media
General Adjustment
Display
Analog Output QA
Λ Language
Dosing
Media
General Adjustment
Display
Set Media
Set Offset
Set Media
Set Offset
Start ?
Set Media
Set Offset
Start ?
Done
28 M I B
Page 29
Flowmax 242i Appendix
1-point correction
With the 1-point correction, the meter is calibrated to an operating point. Given
an arbitrary amount of volume is filled into a container and measured with a
weight. Attention: subtract the weight of the container.
With inclusion of the density of the medium, the volume (volume = mass /
density) is obtained. This has to be compared with the meter display.
Shows the meter for instance 2% more than determined by the scale a value of
-02.0% must entered for the 1-point correction.
Set Dosing
Media
General Adjustment
Display
Analog Output QA
Λ Language
Dosing
Media
General Adjustment
Display
Set Media
Set Offset
V Media
1-Point-Correction
Set Media
1-Point-Correction
-00.0%
Setting the sign
Setting the value
Set Media
1-Point-Correction
Done
To enable the correction back to delivery, a correction of 00.0% is to be entered.
M I B 29
Page 30
Appendix Flowmax 242i
Display rotate 90°
Set Dosing
Media
General Adjustment
Display
Analog Output QA
V Media
General Adjustment
Display
Analog Output QA
Digital Output Q1
Set Display
Units
2 x V Display
Rotate Display
Set Display
Rotate Display
0°
3 x V Display
Rotate Display
90°
Set Display
Rotate Display
90°
Done
To return your display to its delivery, choose Rotate Display 0°.
Reset Counter
Set Dosing
Media
General Adjustment
Display
Analog Output QA
Set General Adustment
Reset Counter
Set General Adjustment
Reset Counter
Start?
Set General Adjustment
Reset Counter
Done
30 M I B
Page 31
Flowmax 242i Appendix
M I B 31
Page 32
MIB GmbH
Messtechnik und Industrieberatung
Bahnhofstr. 35
D-79206 Breisach
Tel. 0049 / (0)7667 / 20 777 90
Fax 0049 / (0)7667 / 20 777 99
E-Mail: [email protected]
Internet: www.flowmax.de
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