LiquiSonic Series. LiquiSonic 20 and 30 LiquiSonic Lab Operating Manual. SensoTech

Transcription

1 LiquiSonic Series SensoTech LiquiSonic 20 and 30 LiquiSonic Lab Operating Manual Version: 17/27 10/2015 Firmware: Controller Sensor SensoTech GmbH, Steinfeldstr. 1, D Magdeburg-Barleben, Germany Tel.: , Web:

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3 Table of contents Table of contents General notes Product liability and guarantee Equipment connection Cleaning instructions Symbol explanation Measuring method Construction of measuring instrument LiquiSonic Variants Operation Main view Status line Limits Product designation Trend view Product selection Product calibration Basics Preparing the unit for product calibration point calibration point calibration Recording System menu Mounting and installation Mounting Mounting the controller Installing the sensor Electrical specifications Terminal assignment - controller Analog inputs Digital inputs Sensor-bus V option Analog outputs Digital outputs Supply voltage Auxiliary Voltage Output (AUX) Terminal assignment - sensor Sensor V LiquiSonic 20 and 30, Operating manual Page 3 of 60

4 Sensor V Electronic side of the sensor V Electronic side of the sensor V Connection of controller with sensors Topology Connection diagram Termination Bus cable Bus cable for sensor V Bus cable for sensor V Junction box for bus cable Terminal assignment Terminal box for sensor cable Recommendation for the connection Commissioning General Powering-up and search for sensors System menu Explanation of parameters and functions Changing date and time Changing display settings Changing product names Product switching Manual product selection Manual product selection with protected access External product switching Automatic product switching Copy product datasets Calibration data Analog outputs Assigning the measuring value Current during Error Behavior at No medium Scaling of measuring values Remote display Analog inputs Disturbance compensation Pressure compensation Digital outputs Logic level and switching behaviour Concentration, Temperature Range excess No Medium Flow/Stop Service Delay of digital outputs after powering-up Error delay...35 Page 4 of 60 LiquiSonic 20 and 30, Operating manual

5 Temperatures Data log Selection of log rate Assignment of measuring values Save data log on CF card Permanent external data recording on CF card Event log Application profile Configuration Manual switching External switching Attenuation measurement SonicGraph User administration User rights Configuration Changing password Login Data backup and recovery Creating a data backup Restore data Ethernet interface Configuration Services Access to stored process data Time synchronization over network Sensor validation / System adjustment Sensor validation / System adjustment Sensor validation System adjustment Adjustment of temperature measurement Several sensors Sensor assignment Change of sensor assignment Operation Options Sensor cooler Flow/Stop option LiquiSonic Lab PC software SonicWork...52 LiquiSonic 20 and 30, Operating manual Page 5 of 60

6 9. Trouble shooting Controller / sensor Error messages No sensor were found. Cannot start system Measuring conditions Status information Technical data Controller Ultrasonic sensors Immersion type sensors Flange type sensors...58 Page 6 of 60 LiquiSonic 20 and 30, Operating manual

7 1. General notes 1.1. Product liability and guarantee You have acquired a high-quality measuring instrument. We thank you for the trust you have put in us. Please keep in mind that it is within the operator's responsibility to ensure that the instrument will be suitable for a given measuring job and that it is used in conformity with the intended purpose. Any use beyond the scope of the intended purpose shall be deemed as being not in conformity with the intended purpose. The manufacturer cannot be held liable for any damage resulting there from. The associated risk shall be borne exclusively by the operator. Use in conformity with the intended purpose also includes compliance with the installation, commissioning and maintenance instructions. Read this Operating Manual as well as any other relevant additional instructions before installing, commissioning, operating and maintaining the unit. The installing and commissioning instructions are relevant to the whole LiquiSonic Series (20, 30, 40, 50 and Lab). Improper installation and operation of the measuring instrument may render the guarantee invalid. When the instrument is used in potentially explosive atmospheres, special regulations, which can be seen from the additional instructions, apply (enclosed only for explosion-protected equipment). This Operating Manual applies to the measuring instruments LiquiSonic 20 and LiquiSonic 30. Since LiquiSonic 30 incorporates all functions, only LiquiSonic 30 will be described in this manual. Some of the functions described herein are not provided in LiquiSonic 20 (see para. 2.1). We reserve the right to alter specifications without notice. There are no user-serviceable parts inside (for example fuses). The equipment is intended for use in an overall fire enclosure Equipment connection The instrument is to be connected with a cable size of 2.5 mm 2. Overcurrent protection of the instrument shall be realized by an external time lag fuse rated max 4 A, 250 V AC. Overcurrent protection devices (for example fuses) shall not be fitted in the protective conductor. It is recommended that a suitable disconnecting switch, rated min 4 A, 250 V AC, shall be mounted in near proximity of the equipment, within easy reach of the operator and it shall be marked as the disconnecting device for the equipment. The disconnecting device shall disconnect all current carrying conductors. If the device was bought with the AC option ( V AC) use an approved AC power supply cord (cord set) that complies with the relevant requirements and is accepted in the country in which the unit is sold. If the device was bought with a 24 V DC option, the appliance shall be powered with V DC, which is separated from hazardous live by double or reinforced insulation at the source of the supply Cleaning instructions Controller: The cleaning of the controller is only permitted on the front. Therefore, a soft cloth with water is to be used. Sensor: Sensors for pharmaceutical or food applications can be cleaned in an installed condition (CIP Cleaning In Place). With Sensors for pharmaceutical or food applications the end user should use FDA and 3-A compliant gaskets matched to the product and the cleaning concept. Maintenance intervals are to be defined. The gasket and the success of the cleaning are to be checked periodically. Page 7 of 60 LiquiSonic 20 and 30, Operating manual

8 1.4. Symbol explanation Attention! Danger of electric shock. Connection only by technical staff! PE Protective Earth 1.5. Measuring method The ultrasonic measuring instrument LiquiSonic is used for determining parameters of liquid media such as the concentration or density of liquids, but also phase changes or reaction patterns. The measuring method is based on the determination of the speed of propagation of ultrasonic waves in liquid media. Transmitter Receiver The ultrasonic measuring method is a continuous, contact less measuring technique, which is independent of the transparency of the medium and characterised by a high reliability. The sonic velocity of a medium depends on the concentration and density. This makes it possible, if the distance between the ultrasonic transmitter and receiver is known, to measure the duration and determine sonic velocity and thus concentration. Page 8 of 60 LiquiSonic 20 and 30, Operating manual

9 2. Construction of measuring instrument The measuring device consists of one or several sensors and one controller. The sensors are installed either in pipelines or in vessels and are used to measure the sonic velocity and temperature of liquids. The device is operated via the controller, which is provided with a large graphic display and can be controlled by four function keys, intuitively LiquiSonic Variants LiquiSonic instruments are available in 5 different variants. The variations between these variants are shown in the following table: LiquiSonic Lab Maximum number of sensors per controller Component-Analyse Special application crystallisation Special application polymerisation Casing stainless steel stainless steel stainless steel stainless steel aluminium Trend view Number of product datasets 16 32/256 32/256 32/256 32/256 External product switching Automatic product switching Product name editable Multi lingual operation data memory with 15,000 data records Event memory User management optional optional optional optional optional Digital outputs Analogue inputs Analogue outputs RS-232 interface SonicGraph optional optional optional optional optional Attenuation measurement optional optional optional optional optional Fieldbus interfaces (e.g. Profibus DP) optional optional optional optional optional Network integration (Ethernet) optional optional optional optional optional Web server optional optional optional optional optional Purge and degassing control optional optional optional optional LiquiSonic 20 and 30, Operating manual Page 9 of 60

10 3. Operation 3.1. Main view date and time status line product designation concentration trend view product selection product calibration system menu temperature of the liquid The Main view provides the user with all relevant data: Product name Concentration of liquid or other process variables Temperature of liquid In the upper part of the screen, a status line is displayed, which contains the following information: Sensor status Variant of product switching Date and time Using the function keys in the right-hand part of the screen, you can call up different functions. After approximately two seconds the keyboard layout changes and provides access to additional functions: SonicGraph Shows the sampled ultrasonic signal. Event view Shows the event log. Shift key for activating the second keyboard layer. System information and error messages are displayed in plain text. Trend view Shows course of measuring values Product selection Select various products or varieties. Product calibration Product calibration based on lab values. System menu Change system parameters. There is also a second keyboard layer, which can be activated by pressing and holding down the key Status line In the status line, in addition to date and time, the sensor status is displayed in the form of a symbol (icon): Page 10 of 60 LiquiSonic 20 and 30, Operating manual

11 Standard Sensor is connected and operates properly. Connection fault Sensor is not connected. STOP The medium on the sensor is not moving. No medium, gas bubbles The sensor is not immersed in the liquid medium, or gas bubbles, foam or solids are present on the sensor. Error There is a fault in the instrument. In addition, the chosen product switching variant is displayed: Manual product switching The products can be selected via the keyboard. The product selection can be protected with an access number, if necessary. External product switching The products 1-32 of sensor 1 can be selected via digital inputs. Automatic product switching The products are automatically selected, depending on the concentration range Limits In case of temperature and concentration crossing the limits, a symbol (icon) is displayed on the right side of the measurement value. The display will show, whether the measured data ranges in(side) or outside of the measuring range. Lower measuring range limit The concentration is below the lower limit. The limit value is shown in the display. Upper measuring range limit The concentration is above the upper limit. The limit value is shown in the display. Concentration below measuring range The concentration is too small and is outside of measuring range. The concentration is displayed but may be erroneous. Concentration above measuring range The concentration is too high and is outside of measuring range. The concentration is displayed but may be erroneous. Temperature below measuring range The temperature is to small and is outside of measuring range. The concentration may be erroneous. Temperature above measuring range The temperature is to high and is outside of measuring range. The concentration may be erroneous Product designation The product designation displays the name currently selected product. Other products can be selected via the product selection menu. The names of the products can be set during putting into operation or separately at a later time. The data sets of the products are based on measurements and calculations, which covers a specific temperature and concentration range. LiquiSonic 20 and 30, Operating manual Page 11 of 60

12 3.2. Trend view By pressing the key, one can branch to the Trend view. Here, the course of a selected data log channel is graphically displayed. The resolution can be scaled both horizontally (time axis) and vertically (measuring value axis). The devices are delivered by the manufacturer with the product calibration data being set to 0. By using these calibration data, differences in composition or contamination in the respective product can be compensated. Therefore, in the LiquiSonic it should be used a separate product data set for each observed product. Thus, products with varying composite can be calibrated individually, and can be distinguished by the usage of meaningful designation of the product in the device Product calibration Via the key can be changed. Via the key ended/closed., the display parameters, the trend display can be 3.3. Product selection By pressing the key, one can branch to the Product selection. In this list box, various products can be selected. The keys have the following functions: Key 1 Quit without changes. Key 2 Select the preceding product. Key 3 Select the following product. Key 4 Accept the selection and quit Basics The product calibration is designed to optimise the basic setting of the ultrasonic measuring instrument with respect to the composition of the product to be measured, because changes in the composition may affect the accuracy of the measurement. In the as-delivered state, the LiquiSonic calculates the concentration of the medium from the sonic velocity and temperature based on a product dataset. The product calibration function allows to compensate influence of varying process and media parameters to avoid affecting measuring accuracy. By using product calibration, one can calibrate the instrument for the concerned product by applying a linear equation to the raw values, i.e. the sonic values calculated with the instrument. LiquiSonic offers two ways for performing the calibration: 1-point calibration (offset calibration) 2-point calibration With 1-point calibration, the concentration value is adjusted by a certain offset. Up to 32 products can be stored. Each product has its own data set, and for its application it can be calibrated on up to four sensors. Page 12 of 60 LiquiSonic 20 and 30, Operating manual

13 100 % Concentration 0 % Offset SensoTech Preparing the unit for product calibration After operating the key enter the access code to obtain authorisation for performing the calibration. The access code for product calibration is Sonic value With 2-point calibration, the concentration can be shifted, and its steepness can be changed or fixed at 2 points. After entering the correct access number, one can select between 1-point calibration and 2-point calibration. 100 % Concentration Lab-Concentration 0 % Sonic Value A concentration value determined in the laboratory can be assigned to 2 sonic values each, usually numbers which lie in the proximity of the lower and upper limits, respectively, of the measuring range. When performing product calibration, keep in mind the following: Product calibration must be carried out separately for each product and for each sensor. The concentration and fluid temperature should be constant between sampling and reading of the sonic values. Calibration should be carried out only 20 to 30 minutes after switching on the instrument point calibration In 1-point calibration, first the product and then the calculated concentration are displayed. The desired concentration offset can be entered directly only under Enter difference. LiquiSonic 20 and 30, Operating manual Page 13 of 60

14 If, e.g., the displayed concentration is 2.9 wt %, and the laboratory has determined a concentration of 3.0 wt %, one have to select here. Shortly afterwards, a dialog field, which closes automatically, appears for a few seconds, indicating that product calibration is being carried out. Thereafter, the dialog field again displays the value 0. If it is not possible to achieve in just one single entry the offset to be set, the operation has to be repeated several times in succession. 1-point calibration is a relative calibration allowing to shift the curve further and further. One can also use 1-point calibration alternately with 2-point calibration point calibration 2-point calibration allows to fix the concentration at two points (two sonic values). One can precisely specify which concentration is to be calculated for the two sonic values. The sonic value corresponds to exactly the 100-fold value of the uncalibrated calculated concentration. The two sonic values by default are situated at the limits of the measuring range. In the dialog field: Product calibration point-calibration Read sonic value In the dialog field: Product calibration point-calibration Enter calibration values one can display and change the calibration points (sonic values) and the associated concentrations. Either is possible: change only the laboratory values and retain the sonic values or match the laboratory value and sonic value. During sampling, one always has to read and note down the current sonic value. Example 1: A laboratory analysis has shown that the concentration displayed in the upper region of the measuring range (0 to 15 wt %) is too high by 0.4 wt %. Therefore, the Lab value for upper concentration is reduced by 0.4 wt % to wt %. As a result, a concentration of 14.6 wt % is displayed for sonic value the sonic value can be read. Page 14 of 60 LiquiSonic 20 and 30, Operating manual

15 15.0 % 12.8 % Example 2: The sonic value is read and noted down briefly before sampling takes place: Concentration 0 % Sonic value Recording It is advisable to record the calibration parameters. This will facilitate monitoring of process-related product calibrations. Example: In the laboratory, the sample is found to have a concentration of 12.8 wt %. Consequently, the Sonic value for upper concentration and the Lab value for upper concentration are changed. Date Product 1 Sonic value lower Sonic value upper val- Lab ue val- Lab ue System menu The System menu is used for parameterization and configuring the overall system (controller and sensors). For detailed information, refer to section Commissioning. LiquiSonic 20 and 30, Operating manual Page 15 of 60

16 4. Mounting and installation Before mounting the controller and installing the sensors, carry out a visual inspection. Make sure that the data on the name plate of the controller are in conformity with the electrical specifications at the place of installation Mounting Mounting the controller The controller is installed in a control panel or switch cabinet. The control panel cut-out should be dimensioned 243 x 123 mm. SensoTech 280 Insert the casing from the front through the control panel opening. Following this, the six enclosed fasteners will be attached on the frame from the backside. To assure that the gasket, located on the back of the front panel, fits the whole length, and to warrant that an acceptable seal is kept up, it should be paid attention to an uniform surface pressure of all fasteners. Keep the controller away from direct solar radiation. Always maintain the specified ambient conditions (see Technical data). The controller is electrically connected from the rear Installing the sensor The sensor determines the speed of propagation of ultrasonic waves in a medium. To this end, the time it takes for the ultrasound to travel from the transmitter to the receiver is measured. With flange sensors, the transmitter and receiver are located in the two cylinders. With immersion sensors, they are located in the legs of the fork The measuring path (standard approx. 16 or 20 mm) is the space between the transmitter and the receiver. When installing the sensor, mind the following: The sensors are suited for internal and external installation. Flange sensors are fastened between two flanges (sandwich construction). Installation in vertical pipelines will provide optimum results when the medium flows from below upward. The measuring path should always be filled with the medium and not be drained. The sensor should not be installed at the outlet end of a pipe. Immersion sensors should be aligned so that the medium flows through the legs of the fork. The direction of the flow is marked with an arrow at the sensor flange. The installation location should be selected so that no gas bubbles occur, e.g., due to cavitation or pressure expansion (preventing degassing). If the medium contains solids or gas bubbles, the transducer areas (front end of cylinders or inside faces of fork legs) should be arranged vertically so that they cannot settle. Heavy mechanical vibrations and stresses should be avoided. If the temperature variates highly a minimal flow rate of 0.5 m/s is recommended, to ensure an optimal temperature compensation. The following chart shows the optimal installation variants. Sensors with 3-A certificate (food industry) should be installed in the installation points 2, 7 or 8. Page 16 of 60 LiquiSonic 20 and 30, Operating manual

17 An insulation of the sensor is necessary for a optimal temperature compensation. Therefore, an insulation including the flange of the sensor is recommended. LiquiSonic 20 and 30, Operating manual Page 17 of 60

18 4.2. Electrical specifications Terminal assignment - controller The electrical terminals are provided on the rear cover of the controller. They are arranged in two rows. Description on the rear cover of the LiquiSonic 30 controller ( V AC): Analog inputs The analog inputs (4 20 ma) are located on the pins 1 8. The pins labeled with 0 are electrically connected with each other. No. Designation Note 1 + AI1 Analog input 1, ma AI2 Analog input 2, ma AI3 Analog input 3, ma AI4 Analog input 4, ma 8 0 Description on the rear cover of the LiquiSonic 20 controller (24 V DC): Digital inputs The digital inputs are located on the pins These inputs are galvanically isolated. The inputs are designed for a voltage of 24 V. No. Designation Note Connection is realised via pluggable clamp contacts and can be easily effected by means of a screwdriver. For servicing purposes, the clamp connectors can be completely pulled off. 9 + DI DI DI DI DI DI DI DI Digital input 1, 24 V Digital input 2, 24 V Digital input 3, 24 V Digital input 4, 24 V Digital input 5, 24 V Digital input 6, 24 V Digital input 7, 24 V Digital input 8, 24 V Page 18 of 60 LiquiSonic 20 und 30, Operating manual

19 Sensor-bus The pins provide the short-circuitproof power supply for up to four sensors and the bus interface. No. Designation Note 25 C_H CAN-bus (high) 26 C_L CAN-bus (low) 27 C_GND CAN-bus (ground) 28 C_SCH CAN-bus (shield) 29 0 V V Power supply for sensors, max. 2 A V option If the device was bought with a 24 V option, then on the pins 58 and 59, the lead of the 24 V supply voltage takes place. No. Designation Note 58 0 V V supply voltage: V DC Analog outputs The analog outputs (0 20 ma) are located on the pins The pins labeled with 0 are electrically connected to each other. No. Designation Note 31 + AO AO AO AO Analog output 1, ma Analog output 2, ma Analog output 3, ma Analog output 4, ma The range 4 20 ma is used for the output of the measurement value. In order to differentiate the statuses collection error and no medium from each other and also from underrange (4 ma), current values smaller than 4 ma can be set Digital outputs The digital outputs are located on the pins The tolerable switching voltage is 24 V, the allowed current is 1 A. No. Designation Note 39 DO1 40 DO1 41 DO2 42 DO2 43 DO3 44 DO3 45 DO4 46 DO4 47 DO5 48 DO5 49 DO6 50 DO6 Digital output 1, 24 V 1 A Digital output 2, max. 24 V, max. 1 A Digital output 3, max. 24 V, max. 1 A Digital output 4, max. 24 V, max. 1 A Digital output 5, max. 24 V, max. 1 A Digital output 6, max. 24 V, max. 1 A Supply voltage The lead of the supply voltage is done via the pins The allowed voltage ranges from 100 to 240 V AC, Hz. When establishing the electrical connections for the controller and sensor, observe the applicable VDE and national regulations. The operating voltage and the voltage given on the name plate must be in agreement. Please note the two different types of connection. Light grey connector with spacing 5 mm No. Designation Note 55 L 56 PE 57 N supply voltage: V AC, Hz Grey connector with spacing 7.5 mm No. Designation Note 55 PE 56 L 57 N supply voltage: V AC, Hz For safety reasons it is not allowed to use plugs without fixing flanges! Auxiliary Voltage Output (AUX) The electrical terminals (push wire) from 51 to 54 are equipped with an auxiliary voltage LiquiSonic 20 and 30, Operating manual Page 19 of 60

20 of 24 V DC for supply of external devices (e.g. transducer, modem). No. Designation Note As PE, the terminal connection in the terminal area or on the outside of the sensor can be used V V 53 0 V V Connection I auxiliary voltage 24 V DC, max. 200 ma Connection II auxiliary voltage 24 V DC, max. 200 ma Sensor V Terminal assignment - sensor The sensor has its separate connection compartment. The sensor has two cable glands. If only one cable gland is used, the other one must be closed with a blanking cover (heavygauge conduit thread M20 x 1.5) Sensor V8 24 V DC 0 V DC The terminal assignment is shown in the following table (from top to bottom): C_ H C_ L C_ GND C_ SCH No. Designation Note 1 SHIELD CAN-Bus (Shield) 2 CAN-H CAN-Bus (High) 3 CAN-L CAN-Bus (Low) 4 CAN-GND CAN-Bus (Ground) 5 0 V DC 6 24 V DC 7 Term 8 Term supply voltage max. 2 A terminating resistor via jumper selectable 9 SHIELD CAN-Bus (Shield) The terminal assignment is shown in the following table (from top to bottom): No. Designation 1 24 V DC 2 0 V DC Note 3 free supply voltage max. 2 A 4 C_H CAN-bus (high) 5 C_L CAN-bus (low) 6 C_GND CAN-bus (ground) 7 C_SCH CAN-bus (shield) 10 CAN-H CAN-Bus (High) 11 CAN-L CAN-Bus (Low) 12 CAN-GND CAN-Bus (Ground) 13 0 V DC V DC supply voltage max. 2 A As PE, the terminal connection in the terminal box or on the outside on the sensor can be used. The CAN bus can be terminated by installing a jumper on the "term" clamp points with 120 Ω. Page 20 of 60 LiquiSonic 20 and 30, Operating manual

21 Electronic side of the sensor V8 On the opposite side of terminal area the electronics of sensor can be checked. Attention: Do not open the electronic side in hazardous conditions Connection of controller with sensors Topology Sensors have to be wired like a line connection. If the bus cable is longer than 1000 m, for having a star-shaped wiring and for galvanic isolation CAN repeater can be used for splitting the CAN bus into separate segments. In normal function the green LED on the left board and the yellow and blue LED on the middle board must permanent illuminate Electronic side of the sensor V10 On the opposite side of terminal area the electronics of sensor can be checked. Attention: Do not open the electronic side in hazardous conditions. In normal function the green LED on both boards must permanent illuminate Connection diagram The controller incorporates a 24 V DCpower supply module. It is possible to use this power supply module to supply sensors, depending on cable length and count of sensors. The characteristic wiring of a single sensor looks as follows: Sensor V8: 24 VDC 0 VDC C_H C_L C_GND C_SCH Sensor PE Controller VDC 0 VDC C_H C_L C_GND C_SCH Termination resistor LiquiSonic 20 and 30, Operating manual Page 21 of 60

22 Sensor V10: Termination The CAN Bus must be terminated at the last sensor. Several sensors are connected as follows: Sensor V8: Sensor 2 PE Sensor 1 PE Controller Enclosure type Die-cast housing (Aluminum) sensor V8 Die-cast housing (Aluminum) sensor V10 Stainless-steel housing sensor V8 and V10 Place / Time of termination in the connection compartment supplied circuit board with terminating resistor between the wires C_H (pink) and C_L (grey) in the connection compartment wire jumper between both Term. terminals (terminal 7 und 8) inside stainless-steel housing switch Stainless-steel housing with explosion protection Ex nr sensor V8 and V10 in the external terminal housing supplied terminating resistor Sensor V10: Bus cable The bus cable between controller and sensors serves for the exchange of data with CAN bus and can be used for power supply of sensors, depending on configuration. The required cross-section of supply wires of the cable is depending on the length of the cable (max m) and on the number of sensors used. It is possible to increase cross-section of supply wires by parallel connection of unused wires of bus cable. Please use an extra cable for sensor power supply, if cross-section of supply wires with more than 1.0 mm 2 is required. Alternatively a local available power supply 24 V DC 15 % can be used. 1 The CAN part of bus cable must comply with the following requirements: twisted pair of wires for C_H and C_L Characteristic impedance: 120 Shield The following or similar data cables can be used: Manufac- Description Note 1 Not permitted in North America (CSA US and C) Page 22 of 60 LiquiSonic 20 and 30, Operating manual

23 turer LAPPKABEL Li2YCY (TP) 4x2x0,22 Li2YCY (TP) 4x2x0,5 inside use only In potentially explosive atmospheres, all wires of the bus cable must be connected to the terminals. LAPPKABEL Helukabel Li2YCYv (TP) 4x2x0,22 Li2YCYv (TP) 4x2x0,5 Li2YCYv (TP) 4x2x1,0 Underground installation Bus cable for sensor V8 For reliable function of sensors 24 V DC 15 % with 6 W (max. 21 W with option sensor thermostat) power consumption are required. Cross-section table for sensor without sensor thermostat: Total length Cross-section of supply wire [mm 2 ] 1 sensor 2 sensors 4 sensors 100 m 0.44 (2x0.22) 1.0 (2x0.5) 1.5 (2x0.75) 200 m 1.0 (2x0.5) 1.5 (2x0.75) 3.0 (2x1.5) 400 m 1.5 (2x0.75) 2.0 (2x1.0) 5.0 (2x2.5) Power supply of the sensors possible through bus cable Power supply through separated cable or external 24 V DC Example for two sensors and 100 m cable length is Li2YCY (TP) 4x2x0.5: Pair Purpose Note Shield Shield 1 C_L, C_H 2 C_GND 3 24 V DC 2x0.5 mm 2 = 1.0 mm V 2x0.5 mm 2 = 1.0 mm 2 The bus cable with the required length ordered together with the equipment system has to be connected as follows: Bus cable for sensor V10 For reliable function of sensors a power supply of 24 V DC 15 % is required. Power consumption of each sensor is 3 W. Selection table for sensor V10: Total length Cross-section of supply wire [mm 2 ] 1 sensor 2 sensors 4 sensors 100 m 0.44 (2x0.22) 0.44 (2x0.22) 1.0 (2x0.5) 200 m 0.44 (2x0.22) 1.0 (2x0.5) 1.5 (2x0.75) 400 m 1.0 (2x0.5) 1.5 (2x0.75) 3.0 (2x1.5) Power supply of the sensors possible through bus cable Power supply through separated cable or external 24 V DC Example for two sensors and 100 m cable length is Li2YCY (TP) 4x2x0.22: Pair Purpose Note Shield Shield 1 C_L, C_H 2 C_GND 3 24 V DC 2x0.22 mm 2 = 0.44 mm V 2x0.22 mm 2 = 0.44 mm 2 In potentially explosive atmospheres, all wires of the bus cable must be connected to the terminals Junction box for bus cable Junction boxes can be used to connect the sensors with the bus cable. Li2YCY (TP) 4x2x0.5 Designation Controller Sensor C_H pink 25 pink C_L grey 26 grey C_GND white + brown 27 white C_SCH shield 28 black 0 V yellow + green 29 yellow 24 V red + blue 30 red LiquiSonic 20 and 30, Operating manual Page 23 of 60

24 Thereby, the stab cable should not exceed a length of 1 m. Please read the installation and maintenance instructions of the junction box for the use in potentially explosive atmospheres carefully Terminal assignment In order to ensure an optimum electromagnetic compatibility, the shield of the bus cable should be connected with the housing in the EMC cable gland. However, compensating currents because of potential differences between different component parts must be avoided. Therefore, the shield can be connected via terminal 7 and 8. The earth connection of the junction box has to be included in the local potential equalization Terminal box for sensor cable In order to simplify the installation for longer sensor cables, an Ex e terminal box is available for all sensors with separated sensor electronics. Terminal Designation Wire colour Li2YCY (TP) Remark V DC red + blue V yellow + green 7 8 (C_shield) (shield) See text C_GND C_L C_H white + brown grey pink Page 24 of 60 LiquiSonic 20 and 30, Operating manual

25 The terminal assignments should be made according to the table below: Terminal Designation I Color of strands Designation II 1 Receiver signal white 2 GND/ shield brown Receiver 3 Cable screen - Cable screen 4 Transmitter signal transparent 5 GND/ shield white Transmitter 6 unused 7 Temperature blue 8 sensor 1 blue 9 Temperature red 10 sensor 2 red 11 Line 1 black and white stripe Ground lines 12 Line 2 black For the use in potentially explosive areas, please read the enclosed installation and maintenance instructions for the terminal box! 4.3. Recommendation for the connection The controller has several analog and digital outputs. For connection of the controller to a PLC it is recommended to use at least 2 analog and 2 digital outputs with following assignment: Output Analog output 1 Analog output 2 Digital output 5 Digital output 6 Configuration Concentration Temperature Error No Medium Certainly, the configuration can be changed again later. However, practical experience confirm this configuration for good process and device monitoring. LiquiSonic 20 and 30, Operating manual Page 25 of 60

26 5. Commissioning 2-sensor view: 5.1. General Powering-up and search for sensors On power up the controller displays its start screen: 3-sensor view: The connection between the controller and one or more sensors is provided by a bus. Once started, the controller searches for sensors connected. Depending on the number of sensors installed, the controller will start with the 1-, 2-, 3- or 4-sensor view. 4-sensor view: 1-sensor view (main view): This is the so called main view. Out of the 2-, 3-, or 4-sensor view it can be switched to the main view by pushing the button for the selected sensor (highlighted), respectively. If the user had changed the sensor configuration (e.g. replacement of a sensor, installation of additional sensors), the dialog Sensor Assignment will be displayed immediately after power up. The sensor, which was replaced before will displayed as Assignment needed. Page 26 of 60 LiquiSonic 20 and 30, Operating manual

27 After pressing of the button a list box will be opened. The serial number of the new sensor will be displayed. On entering the access number, the Tree structure of the System menu is displayed: The keys have the following functions: Selection of sensors is made according to their respective serial numbers. After allocation of the new sensor the dialog field is left by pressing key System menu In the system menu, instrument settings can be checked and changed, if necessary. Pressing the key will take you to the system menu. First, you have to enter an access code to become authorised for further operation. Applicable access codes are: Input Status 0000 GUEST Is allowed to view status information from the controller CALIBRATION As GUEST, but is additionally allowed to calibrate, select products, change product names ADVANCED As CALIBRATION, but has additionally access to various instrument settings. Key 1 Goes to the next higher menu level or quits the Service menu. Key 2 Selects the previous menu entry. Key 3 Selects the following menu entry. Key 4 Confirms the selection. Activates the next lower menu level. Executes the respective dialog field Explanation of parameters and functions The operation of the unit will be explained with the help of the following examples Changing date and time In the dialog field: System 1911 Controller Settings Date and time date and system time can be set. LiquiSonic 20 and 30, Operating manual Page 27 of 60

28 Changing display settings In the dialog field: System 1911 / 2909 Controller Settings Display the language in which the texts are to be displayed on the display is selected. In addition, the backlight intensity of the display can be adapted to the ambient conditions Product switching In the dialog field: System 2909 Product Switching Kind of switching one of several product switching variants can be selected. In the above figure, the appearance of the dialog field Display after entering access code 1911 is shown. In contrast to the entry Backlight intensity, the entry Language is visible, but cannot be edited Manual product selection For manual product selection, one chooses a product by pressing the key and subsequently selecting the desired product. After entering access code 2909, it is allowed to change the language Changing product names In the dialog field: System 1911 Product Designation Product name Manual product selection with protected access If manual product selection with protected access is used, the access codes 1911 or 2909 must be entered before the desired product can be selected External product switching Using the external product switching mode, it is possible to change the product for up to four sensors from the outside. There are totally 8 digital inputs which can be assigned to 1, 2 or 4 sensors. the product name can be edited. Page 28 of 60 LiquiSonic 20 and 30, Operating manual

29 In this mode, binary encoding is used for the product assignment. Following tables show the relation between digital input and product for each configuration 1 x product 1-32 DI Sensor 1 Sensor 2 Sensor 3 Sensor Automatic product switching If the concentrations of the individual products differ considerably (e.g. by 1 wt %), it is also possible to make use of the automatic product switching. In this case, the device checks the current concentration and switches the product up or down, depending on the concentration. A precondition is that the product names 1 to x {x= 2, 3, 4, 5} are specified with increasing concentration of the products. Example: There are 3 products: 1. Mixture A with 6.0 to 7.0 wt % 2. Mixture B with 11.0 to 12.0 wt % 3. Mixture C with 15.0 to 16.0 wt % x product 1-16 DI Sensor 1 Sensor 2 Sensor 3 Sensor In the Product switching list box, Automatic until product 3 is selected. Next, thresholds have to be defined: System 2909 Product Switching Threshold x product 1-4 DI Sensor 1 Sensor 2 Sensor 3 Sensor By specification of a hysteresis (in sample 9.50/9.10, and 12.50/12.10 respectively) toggling will be avoided LiquiSonic 20 and 30, Operating manual Page 29 of 60

30 Note: The automatic product switching affects all of the sensors connected to the controller, if a product was selected within the storage location 1 to 3. All storage locations from no. 4 are selectable, manually for each sensor. They will not be influenced by the automatic switching Copy product datasets In the dialog field: System 1911 Product Copy dataset one can copy existing product datasets to storage locations which have not yet been assigned. Moreover, if desired, this function is also suitable for changing the sequence of products. In the above figure, the current product Caustic soda is copied to storage location 08 which is still free. Note: The product calibration data are not copied but reset Calibration data In the dialog field: System 2909 Product Calibration Coefficients the current calibration data can be reviewed. The entry Concentration shows the calibrated value of the concentration, which finally will also be shown in the display. The entry Product name indicates the current product. However, since the product name is freely selectable, a unique, unchangeable dataset number is assigned to each product. The entry Copy to storage location enables you to select a storage location (01-32), to which the current product dataset is to be copied. The Sonic value corresponds to the internal calculated concentration multiplied by the factor The entries, Coefficient A0 and Coefficient A1, are the coefficients of the correction curve, which results from all of the calibrations adjusted. Whether it should be necessary, the product calibration can be set back to the initial state with the entry Reset Calibration. Page 30 of 60 LiquiSonic 20 and 30, Operating manual

31 If the safety request is accepted with the button, the calibration data for the current product will be set back Current during Error A value for the current, which is output in case of an error, can be adjusted. This valvalue can be set in the range from 0 20 ma Analog outputs The controller has four Analog outputs which can be separately configured. Configuring of each channel is performed in the dialogs Assignment and Scaling. Configuring will be explained by way of example of Analog output Assigning the measuring value In the dialog field: System 2909 Periphery Analog outputs Output 1 AO1 assignment a measuring value and the associated sensor (data source) are assigned Behavior at No medium It is possible to define a behavior during the state No medium. This state results from the following reasons: The pipe or the vessel is empty. Too many gas bubbles or particles are in the liquid. It is possible to define two different behaviors: 1. Hold last value The last measured concentration value is hold. 2. Use predefined value A current can be defined which is output during this state. This value can be set in the range from 0 20 ma. The entry Assigned value enables the output of the following values among others: Concentration, Temperature, Sonic velocity, Temperature T1, T2, T3, T4, Standard deviation, 1st Derivation (dv/dt, dt/dt) und Fixed current. The entry Data Source determines, which sensor the information results from. In the example above a current of 20 ma is put out in case of the state No medium. The current at no medium can be set in the range from 0 20 ma. LiquiSonic 20 and 30, Operating manual Page 31 of 60

32 Scaling of measuring values In the dialog field: System 2909 Periphery Analog outputs Output 1 AO1 scaling two values to which the range from ma is scaled are assigned to the output Analog inputs The controller has four separately configurable analog inputs. Configuring of each channel is carried out in the dialogs AIx Configuration and AIx Scaling. System 2909 Periphery Analog inputs Input 1 AI1 configuration AI1 scaling Primarily, the analog inputs are used for the compensation of external disturbances Disturbance compensation In the Disturbance compensation (Z-compensation) mode, the calculated concentration can be compensated with a measurable disturbance. Example: A typical example exists in the field of beer brewing where the original gravity of the beer has to be measured. The beer, however, also contains carbon dioxide (CO 2 ) which affects the concentration measurement. But it is possible to measure the CO 2 content and make it available as a 4 20 masignal. The CO 2 content is compensated by incorporating the disturbance in the calculation. The entry Current at Output displays the currently measured current Pressure compensation If the analog input is configured for Pressure compensation (VEL-compensation), pressure-related concentration changes can be compensated for Remote display It is also possible to output a measuring value at several analog outputs, which may, for example, be differently scaled. This makes it possible to output a partial range with a better accuracy or to connect a remote display unit. Page 32 of 60 LiquiSonic 20 and 30, Operating manual

33 In this case, a pressure sensor with a 4 20 ma-output must be located close to the measuring point. The Compensation value depends on the medium in question and can be obtained from the vendor. Scaling of the analog input is performed in the dialog AEx Scaling. In the figure below, the 4 20 ma-signal is mapped on the pressure range from 0 until 10 bar Digital outputs The controller has 6 digit outputs, which are freely configurable. In the dialog field: System 2909 Periphery Digital outputs Outputs 1 to 3 Output 1 Assignment Temperature Temperature value exceeds or falls below the set temperature range. This selection also affects all products. Range excess Value exceeds or falls below the set product-specific ranges. This selection can be set individually for all products. No medium No medium is present on the sensor or too many gas bubbles or particles are present. Stop Signals the flow/stop condition (whether medium flows or does not; option available for certain applications). Service menu Signals a service activity on the controller. Error Signals system errors. This is a group error, i.e. if the controller or at least one sensor signals an error, the output will be set. Error (only sensor) This selection also signals errors. But only the error status of the assigned sensor will be evaluated. If several sensors are connected, one sensor has to be assigned for sensor-specific parameters (e.g. concentration, temperature). Output x Assignment {x= 1, 2, 3,... 6} can be assigned with the following status information: Concentration Concentration value exceeds or falls below the set concentration range. This selection affects all products Logic level and switching behaviour The digital outputs offer a logic level (active, inactive) and a so-called switching behaviour, which converts the logic level into a physical level (relay contact opened or closed). LiquiSonic 20 and 30, Operating manual Page 33 of 60

34 The following tables illustrate this: Monitoring Concentration Temperature Range excess Active state The active state is characterized by a concentration value which is within the range defined by threshold 1 and threshold 2. The active state is characterized by a concentration value which is outside the range defined by lower/upper warning limit. Example: Concentration monitoring In the following example, the relay closes below 10.0 wt% and above 11.0 wt%. If a contactor with a lamp is connected to the relay, it is possible to signal thereby when the concentration is outside the range from 10.0 to 11.0 wt%. No Medium Stop Service Error The active state is given for the duration of this event. Logic level Switching behaviour inverse normal active inactive relay contact is opened 0 relay contact is closed 1 relay contact is closed 1 relay contact is opened Concentration, Temperature In the dialog field: System 2909 Periphery Digital outputs Outputs 1 to 3 Output 1 Settings Example: Dosage In the following example, a pump is to be activated with a relay via a contactor, and a 2-point control is to be realised. The set point is 10.0 wt%. When the concentration value falls below this point, the relay closes, and the pump is started. A hysteresis of 0.2 (i.e. ±0.1 above/below set point) wt% is set. As a result, the relay closes at 9.9 wt% and reopens only at 10.1 wt% Output x scaling {x= 1, 2, 3, 6} thresholds for monitoring the concentration or the temperature can be set. Furthermore, a hysteresis can be specified for the operating point to prevent toggling Range excess The monitoring of the range excess, basically, works like the observation of concentration and temperature. Admittedly, the boundaries can be, individually, pretended for each product. In the dialog field: Page 34 of 60 LiquiSonic 20 and 30, Operating manual

35 System 2909 Product Ranges & bounds Concentration the boundaries will be defined by the entries Lower warning limit and Upper warning limit Service With the help of that monitoring function, it is possible to follow, or to acquire service operations, or calibration procedures at the controller from a control system or a process control system Delay of digital outputs after powering-up In the dialog: System 2909 Periphery Digital outputs DO configuration a temporally delay, starting with powering up the controller, can be entered for the handling of all digital outputs No Medium This state occurs: if the sensor is not immersed in the liquid medium. if here are too many gas bubbles or solids or when a medium is characterised by high acoustic damping, so that it is not possible to receive signals. This output can also be used, e.g., for providing the information: Pipe empty. Within this delay time, all of the relay contacts are opened Error delay In the dialog: System 2909 Periphery Error delay the output of an error occurred can be temporally delayed Flow/Stop The option Flow/Stop is a flow sensor which automatically detects whether the medium at the sensor flows or stands. The information is displayed in the status line. Standard Medium is in motion. STOP Medium is not in motion. The signal can be output via a digital output and used in a control. This function is very helpful by using of the sensor in a bypass. The following items can be delayed: Error messages on the display, changing of current at analog output to value Current at Error, and switching of digital output. The delay time is given in seconds. It is advisable not to delay the displaying of an alarm message on the display, but only the effect on the current output and digital output. LiquiSonic 20 and 30, Operating manual Page 35 of 60

36 Temperatures In the sensor, four temperatures are measured. In dialog: System 2909 Sensor Measurement Temperature Temperatures 1-4 they can be checked Selection of log rate In the dialog: System 1911 Controller Data log Settings the time interval (Log rate) between the writing of two successive data records is specified. Temperature T4 represents the inside temperature of the sensor casing. In applications where the temperature exceeds 65 C, a sensor cooler has to be installed. An error message will be displayed over 70 C Data log The controller is provided with an internal data log in which up to 15,000 data records with 32 values each can be stored. The data log is structured as a ring memory, i.e. it is always the oldest data record that will be overwritten when a new entry is made. The data are preserved also when the instrument is switched off. Using the Sonic- Work program, you can read out the data log and save it to a file for subsequent electronic processing. For more detailed information, refer to the SonicWork manual. The following table shows the relationship between the log rate and storage time. Log rate Storage time 1 second 4.2 hours 2 seconds 8.4 hours 5 seconds 21 hours 10 seconds 42 hours 30 seconds 5.2 days 1 minute 10.5 days 2 minutes 21 days 5 minutes 7.5 weeks 10 minutes 15 weeks 30 minutes 45 weeks 1 hour 90 weeks Page 36 of 60 LiquiSonic 20 and 30, Operating manual

37 Assignment of measuring values One can assign a measuring value and the associated data source to any one of the 32 channels. For channel 1, for example, this takes place in the dialog: System 1911 Controller Data log Data channel 1 The data log is a very good function for process monitoring. With the minimum storage time of one second it is helpful for monitoring and documentation of highly dynamic processes Save data log on CF card It is possible to save the current content of the data log on a CF card. System 1911 Controller Data log Settings To each one of the channels, the following measuring values can be assigned: Concentration, Second physical value (for disturbance compensation), Temperature, Sonic velocity, Sonic value, Error number of sensor, Temperature T1-T4, Transit time, Standard deviation of the transit time, Number of product dataset, 1. derivation (dv/dt), and 1. derivation (dt/dt). This requires that a CF card was identified when booting the system and the external data recording on request is selected. Important: The device has to be powered off before taking the CF card in or out of the controller! Permanent external data recording on CF card Parallel to the internal recording, the process values can also be saved on a compact flash card as.csv files. This requires that the network functionality (Windows network integration) is activated. In the dialog: System 1911 Controller Data log Settings the permanent external data recording must be selected. Important: This change will only become effective after restart of the device. LiquiSonic 20 and 30, Operating manual Page 37 of 60

38 When logging in with the access code 2909, the name of the data media can be changed or the card can be formatted. Important: When formatting the CF card, all data saved before will be deleted on the card. The files will be updated every 5 minutes. At a higher log rate (e.g. 10 s) the incoming data are cached in RAM to reduce the number of write accesses on the card. Process values recorded over many years can be saved on compact flash cards with a capacity of 1 GB or more (max. 32 GB) depending on the log rate and data log settings. However, the data should be read and saved on a regular basis over the network share. In the dialog: System 1911/2909 Controller CF card The status of the CF card can be controlled Event log The LiquiSonic 30 controller in addition provides an event log. Following events will be recorded: Successful and failed system login, manually product changes, Changes of date and time, product calibrations, system restarts as well as system errors. The event log can be called from the main view. The key has to be pressed and held down. After about two seconds the key assignment changes to its second level. By holding down the key and simultaneously pressing the key one gets to the event log viewer. The event viewer shows all occurred events in chronological descending order within a list view. The controller shows the free disk space and the status of the last access to the file. The meaning of the status values is: Status Meaning 0 No error -4 Drive not found -5 Too many files -8 Invalid file system -9 File not found -13 Damaged partition table -16 Access denied The list can hold more than 2000 entries. Thereafter oldest entries will be overwritten. Using the arrow keys one can navigate within the list. The controller button below is the so-called event button. By pressing the button, the system generates an entry in the event log. Page 38 of 60 LiquiSonic 20 and 30, Operating manual

39 This function can be used to create a time reference to a certain action (e.g. the sampling of a liquid). As each read-out data log usually contains a section with all events that have occurred, the time reference can also be created afterwards exactly to the second Application profile There are applications which requires both, fast detection of a changing medium and a high accuracy concentration measurement. Optionally the ultrasonic sensor can store two different application profiles, where every single profile is optimized for one specific application (e.g.: phase detection, concentration measurement). These profiles can be switched in operation by the controller. Switching can be done: manually via graphical user interface, by field bus (MODBUS, Profibus) and external by using digital inputs Configuration In dialog box: System 2909 Sensor Application External switching External switching is done by using digital inputs (DI) 1 4, where the assignment is as follows: DI sensor concentration measurement phase detection Note: External switching cannot be used while external product switching is already configured Attenuation measurement Attenuation measurements are performed to determine the extent to which a fluid weakens the ultrasonic signal magnitude. Attenuation measurement is activated in the dialog field below. System 2909 Sensor Measurement Attenuation Configuration the desired type of profile switching can be selected Manual switching If selected, the desired application profile can be selected manually via graphical user interface. The dialog displays the attenuation value as follows: LiquiSonic 20 and 30, Operating manual Page 39 of 60

40 System 2909 Sensor Measurement Attenuation Current values The attenuation value displayed is the value relative to the attenuation value in a reference fluid (usually distilled water). In attenuation measurements receiver amplification compensates for the fluidattenuated measuring signal displayed, and is adjusted by the sensor. The attenuation value is not updated until after the receiver amplification has been stabilised. The reference value is adjusted by measuring attenuation in the reference fluid. The receiver amplification for the reference value is set in the following dialog: System 2909 Sensor Measurement Attenuation Reference value 5.4. SonicGraph SonicGraph is an optional add-on function which is used to display the received ultrasonic signal. SonicGraph is useful to optimise the parameters of the sensor to achieve a high signal-to-noise ratio. SonicGraph is called up from the Main view. The Key has to be pressed and held down. After about two seconds the key assignment changes to its second level. By holding down the key and simultaneously pressing the key one gets to the SonicGraph view. SonicGraph works like a digital oscilloscope. The ultrasonic signal is sampled approx. once per second. In the upper part of the view, the following parameters are displayed: Name Temperature Duration Standard deviation Meaning Measured temperature of medium Measured duration of ultrasonic signal Standard deviation of the duration Sonic velocity Sonic velocity of medium This corresponds to a zero balance of the attenuation measurement in the current state. In the lower part of the view, the received signal is shown. In addition to the received signal, three other parameters are indicated: Comparator threshold (dark gray, continuous, horizontal line) Minimum or maximum valid sonic velocity (the invalid region is dark colored) Trigger point of the duration measurement (blue cross) Pressing the allows to edit the measurement parameters. Page 40 of 60 LiquiSonic 20 and 30, Operating manual

41 User rights Every user has to be assigned to one of four predefined user groups. Hereof the user rights are derived. user group Guest (0000) rights User is allowed to view status information of the controller. Using SonicGraph the effect can be monitored immediately User administration The user administration provides an alternative way for login. Instead of entering an access code, the user has to put in his user name and the appropriate password. Hereby an improved security level and a better tracking of system changes will be achieved. The user administration provides the following features: in total five configurable user accounts, user right assignment based on predefined user groups, editable user names as well as individual passwords. Existing accounts can be deactivated temporarily by an administrator. Calibration (1911) Power User (2909) Administrator User is not allowed to change his own password. Additional rights: - perform / reset product calibrations - switch products, edit product names, change concentration ranges (range excess), copy product data sets - configure the data log - perform a sensor validation - change its own password differs from Administrator by: - lacking of access to the user administration and - restricted access to some system parameters of controller and sensor. User has unrestricted access to the whole system Configuration Only administrators are allowed to change the configuration of user accounts. With factory settings only User #5 is activated. He has the name SYSTEM and belongs to the administrator group. The initial password is system. This password should be changed for security reasons immediately after the first login. Using this account, further user accounts can be configured. System Controller User administration User x LiquiSonic 20 and 30, Operating manual Page 41 of 60

42 The entry Name specifies the login name for this user. The length of a user can be up to 31 characters, blanks are allowed. In contrast to the password, the use of upper or lower case makes here no difference. The entry Rights assigns the user to one of the four predefined user groups Changing password In dialog box: System Controller User administration Password every user (except guest users) can change its own password. The entry Password stores the password entered by the user. The password will not be displayed in plain text. Independent from the actual length always 8 asterisks are displayed. The length can be up to 31 characters. It will be distinguished between upper and lower case. The entry Status serves for the activation or deactivation of an user account. A login only can be performed using an active account. Therefore unused accounts should always be deactivated Login Prior accessing the system (system menu, product calibration and, if necessary product switching) the has to log in. Therefore it is required to enter both, a valid user name and the appropriate password. Also an existing account can be deactivated to close the account temporarily. User name and password are hereby not affected. If login succeeds, system access is granted. Otherwise an error message will be displayed and the procedure has to be repeated. Page 42 of 60 LiquiSonic 20 and 30, Operating manual

43 5.6. Data backup and recovery The controller offers the possibility to back up the latest settings, in order to be able to restore them, if necessary. System 2909 Controller Backup Creating a data backup The data can be stored optionally in the device (internal memory) or on a CF-card. The successful data recovery will be shown in a message window for a few seconds. The data backup can take a few seconds. A message shows the completion of data backup. Finally, the system is restarting automatically. When creating a new data backup, the last stored data retain. Only when the maximum number of data backups (20 internal, 100 on CF-card) has been achieved, the eldest backup file will be deleted Restore data The restored data can be selected from a list of available data backups. LiquiSonic 20 and 30, Operating manual Page 43 of 60

44 5.7. Ethernet interface The controller has a built in Ethernet interface. Using this interface requires a valid configuration Configuration If a DHCP (Dynamic Host Configuration Protocol) server is present within the network, the controller can be configured to obtain the configuration from this server. This is the default setting. If no DHCP server is present, valid values for IP address, Subnet mask and Default gateway must be filled in. System 2909 Controller Settings Network Configuration These information can be obtained from the network administrator. System 2909 Controller Settings Network Services For the web server, the rate, with which the screen display should be refreshed in the Browser, is adjustable Access to stored process data The controller provides the content of its CompactFlash (CF) card in the network using the SMB (Server Message Block) protocol. Network clients possessing this protocol (e.g. Windows PC s) can access the network share. All controllers appear in the network neighborhood in the group LiquiSonic. Please note that changes take effect after the next system restart Services The network interface provides the following services: - SMB Server, - Telnet Server and - Web Server (optional) When deliver the controller, these services are activated via default setting. Within this group, all present controllers are listed starting with prefix C, followed by its serial number. Every device provides a network share with the name CF. To access the share, a valid user name and the appropriate password are required. Page 44 of 60 LiquiSonic 20 and 30, Operating manual

45 Following users are valid: User Password Rights GUEST 0000 has read access to the resource USER 2909 has full access (read, write and delete) to the resource It is not recommended to open the data files directly from the network resource. The better approach is to copy the stored process data at first to a different location Time synchronization over network The controller time can be adjusted (synchronized) over the network with a NTP time source. In the dialog: System 2909 Controller Settings Network Time synchronization the time synchronization can be activated. After activating or deactivating this function, the system has to be restarted for the changes to become effective. The other parameters can be changed during the operation. The controller synchronizes its time only once at each system start and after that periodically in the defined synchronization interval. LiquiSonic 20 and 30, Operating manual Page 45 of 60

46 5.8. Sensor validation / System adjustment Sensor validation All ultrasonic sensors are calibrated to an absolute sonic velocity based on the sonic velocity of pure water which is unique and traceable. An error in the sonic velocity measurement or in the temperature measurement, results in an error in the calibration characteristic (the equation which converts sonic velocity and temperature to concentration of the liquid). This is shown in the following diagrams. An error in the measurement of the sonic velocity (green) affects a difference value to the ultrasonic calibration curve. An error in the temperature measurement (red) affects in a difference to the calibration characteristic too. Errors in both, sonic velocity and temperature influences the Difference to water value. The calibration of the sensors can be easily checked with de-ionized water. The ability of the measurement system is guaranteed according to DIN ISO 9001 and EN ISO Options for sensor validation: 1. It may be possible to run de-ionized water through the sensor while in the process stream. (Pipeline, tank) 2. The sensor can be removed from the process, and immersed into a vessel with de-ionized water. The water needs to be stirred to avoid temperature gradients. If the temperature is kept constant, in the dialog: System 1911 Sensor Validation the value Difference to water can be verified. Page 46 of 60 LiquiSonic 20 and 30, Operating manual

47 System adjustment For sensors made of plastic (PE, PVC, and PFA); the distance between the transmitter and receiver may be changed marginally due to assembling conditions. This change of the distance results in an extension of the difference to water. The system calibration concerning the temperature, however, is still valid. In the dialog: System 2909 Sensor Validation The dialog box: System 2909 Sensor Measurement Temperature Adjustment Read temperature value displays the serial number of the sensor, the current raw value of the temperature and the temperature deviation as a function of time (dt/dt). the Difference to water can be verified, and can be adjusted, if necessary. The entry Difference to water displays the difference of the measured sonic velocity related to the sonic velocity of de-ionized water. The item Temperature, raw value displays the measured value to be noted down together with the relating reference value for subsequent entry. The entry Adjust difference accomplishes an adjustment after confirmation of a safety request. The entry Reset settings allows it to reset all of the adjustments accomplished before. The sensor then is conditioned in the delivery status again Adjustment of temperature measurement Temperature measurement can be optionally adjusted for applications with high measuring accuracy requirements exceeding even the installed high basic accuracy of 0.1 K. To this end, the user needs a suitable reference instrument. The 1st Derivation (dt/dt) value is displayed for control purposes. Care must be exercised as to ensure that the sensor is thermally balanced and the fluid temperature is stable. To this end, values in a range of 0.1 K/h are desirable. After the data of two points at the limits of the application range have been obtained, adjustment operations can be carried out in a second step. The dialog box: System 2909 Sensor Measurement Temperature Adjustment Enter adjustment values serves to enter both data pairs consisting of the temperature measured by the sensor and the relating reference temperature. LiquiSonic 20 and 30, Operating manual Page 47 of 60

48 Data is transmitted to the sensor as soon as the dialog box is exited. Adjustment is effective immediately after data transmission. The adjustment result can be viewed in the dialog box: If the user had changed the sensor configuration (e.g. replacement of a sensor, installation of an additional sensor), the dialog Sensor assignment will be displayed immediately. System 2909 Sensor Measurement Temperature Adjustment Overview One sensor each can be assigned to the logic measuring unit 1 to 4. The selection of measuring unit is to be made with the arrow keys. After pressing button a list box will be open. It displays the additional sensor. Typically, both temperatures exhibit different values with different coefficients (0.0, 1.0) of the correction curves (A0 and A1). The item Reset adjustment serves to reset an adjustment made before Several sensors Sensor assignment Up to four sensors can be connected by a controller. After powering up, the controller searches for the sensors connected. Selection of sensors is made according to their respective serial numbers. On completion of assignment of sensors to the measuring units, the dialog for the sensor assignment is left by pressing the key. When the controller is started now, the main view corresponding to the number of sensors will be displayed. Assignment of sensors to the measuring units can also be changed subsequently. Page 48 of 60 LiquiSonic 20 and 30, Operating manual

49 Change of sensor assignment In the dialog: System 2909 Controller Settings Sensor assignment assignment of sensors to the measuring units can be changed also subsequently. Depending on the number of assigned sensors the controller will display the 2-, 3-, or 4-sensor view Operation In the 2-, 3-, or 4-sensor view each single sensor can be selected with the arrow keys. After pressing the button, it appears the main view for the selected sensor. The icon of the current sensor in the status line will be shown highlighted. Current sensor Out of the main view, the operation is identical to the 1-sensor version. LiquiSonic 20 and 30, Operating manual Page 49 of 60

50 6. Options 6.1. Sensor cooler Sensors can also be used at higher ambient temperatures. In such cases, the sensors are provided with a cooler which ensures that the sensor casing temperature will not exceed 65 C. A liquid cooler is available for cooling. The following table shows at which ambient and liquid temperatures a sensor cooler will have to be used. Temperature Ambient Liquid > 30 C > 130 C > 40 C > 100 C > 50 C > 70 C > 60 C > 20 C > 70 C > 0 C The sensor casing temperature (temperature T4) can be checked during commissioning (cp. section ). The cooling water temperature and the flow rate of the cooling water should be chosen so that the sensor casing temperature will not exceed 60 C. When the sensor casing temperature exceeds 65 C, an error message appears Flow/Stop option The option Flow/Stop is a flow guard which automatically detects whether the medium at the sensor is in motion or not. It, thus, shows, for example, whether a bypass arrangement allows proper flowing or is clogged. The information is displayed in the status line. STOP Medium is not in motion. The signal can be output via digital output and used in a control. Page 50 of 60 LiquiSonic 20 and 30, Operating manual

51 7. LiquiSonic Lab LiquiSonic Lab has been specifically designed for use in labs and as a mobile instrument in process plants. The system is provided with a splash-proof housing, and hence is also suited to harsh environment applications. The electronic components of the evaluation unit and of the sensor are integrated in the housing with a connected lab sensor. The sensor may be produced from various materials. This mobile device has the following dimensions: 280 x 138 x 240mm (WxHxD). An external switching power supply is provided to connect it to the mains. An RS232 and, optionally, an Ethernet connection serve as interfaces. Thus, it is possible to connect a computer with the SonicWork software program to the system to visualize and store collected data. LiquiSonic 20 and 30, Operating manual Page 51 of 60

52 8. PC software SonicWork SonicWork is a PC program with the following functions: Inquiry of system parameters, Loading of product datasets, Loading of device configuration files, Reading and storing of data log Reading and storing of screen content (hardcopy) Online trend view of measured values Remote control of the controller (only full version) Calculation of product datasets (add-on for the full version) For more detailed information on the program, refer to the SonicWork manual. The free of charge version SonicWork LE with reduced functionality (see above) is downloadable from SonicWork offers a very convenient procedure for loading further product datasets to the controller. It, thus, allows to achieve an optimum configuration of the LiquiSonic also under changed operating conditions, including new products or new measuring ranges. Page 52 of 60 LiquiSonic 20 and 30, Operating manual

53 9. Trouble shooting 9.1. Controller / sensor The measuring instrument is provided with an automatic self-monitoring system. Any faults or system errors occurring are detected and displayed. If the display does not light when the voltage supply is turned on, or if no text is visible on the display, the voltage supply for the controller should be checked No sensor were found. Cannot start system After power on of the system the controller scans the bus for existing sensors. Scanning bus... Reading sensor configuration... Assigning sensor... If there are any problems with the bus connection the following error message appears: 9.2. Error messages System faults and errors are displayed in plain text by the controller: Possible causes are described in the table above. The function of the sensor itself can be checked by watching the LED s on the electronic side of the sensor. The following table gives an overview of important error messages and their causes: Attention: Do not open the electronic side in hazardous conditions. Message / error Cause No Medium The sensor is not immersed in the liquid medium. No sensors were found. Cannot start system. Too many gas bubbles or solids present on the sensor. Strong dampening of ultrasonic signal. Sensors are not connected to controller. The bus cable is defective or wrong connected. The 120 ohm resistor is not correct connected. The sensor is not compatible. (The serial number of the sensor must be greater than 43000). Lost connection to sensor x Sensor is no longer connected to controller. Bus cable is defective. If it is not possible to eliminate a fault or if errors occur which are not listed in the table, get in contact with your local dealer. The green LED on the left board and the yellow and blue LED on the middle board must permanent illuminate. LiquiSonic 20 and 30, Operating manual Page 53 of 60

54 9.3. Measuring conditions If your measured concentration values are inaccurate, it is advisable to check the measuring conditions (measuring range). The product datasets are defined for a specified concentration and temperature range. Outside of this range, the measuring error becomes greater, or the dataset is possibly no longer defined. Whether the specified limits are exceeded is shown in the display Status information The unit supplies so-called status information that allow a remote diagnosis. If errors occur, note down the associated status information and submit this information when contacting the manufacturer or your authorised dealer. Page 54 of 60 LiquiSonic 20 and 30, Operating manual

55 10. Technical data Measuring method Determination of: temperature, sound velocity of the liquid as a measure of the concentration of components. Sensor connection Ultrasonic sensors are connected to the controller via bus cable Controller Analog outputs 4 x 4 20 ma, isolated with respect to unit R bmax = 600 Analog inputs 4 x 4 20 ma, isolated with respect to unit R b = 200 Digital outputs 6 x 1 A, 24 V AC/DC, LC free load Digital inputs (product selection) Code: binary 8 digit Switching level: 1 ( H ) 19 V DC 0 ( L ) 17 V DC Interface RS-232, Baud, 8n1 Displayed values Product name, Concentration with the respective associated unit Temperature of medium Functions Management of up to 32 products Setting of specific product names Setting of national languages Graphic trend display Definition of product-specific operating points Storage of up to 15,000 data records in the data log Display TFT 320 x 240 pixels, backlighted Operation keypad with 4 keys Casing Casing designed for panel mounting Size: 243 (w) x 123 (h) mm Mounting depth: 160 mm Material: aluminium, stainless steel Protection: front IP65 Weight: approx. 3.5 kg Optional: 19 slide-in casing Size: 3 HE, 84 TE Material: stainless steel, aluminium Protection: front IP65 Weight: approx. 4.0 kg Electrical specifications Voltage: V AC, Hz optional: 24 V DC (19 32 V DC) Power input: max. 65 VA Operating conditions Ambient temperature range: 0 to 40 C Rel. Humidity (non-cond.): 20 bis 80 % Max. length of bus cable: 1000 m Pollution dregee: 2 Installation category: II Altitude for use: up to 2000 m Shipping / Storage temperature range: -10 to 75 C Relative Humidity: 20 to 85 % LiquiSonic 20 and 30, Operating manual Page 55 of 60

56 10.2. Ultrasonic sensors Temperature range of medium -20 to 120 C extended temperature range optional Ambient temperature range Sensor V8: -10 to 40 C or 50 C Sensor V10: -20 to 60 C extended temperature range optional Maximum pressure 16 bar higher pressure optional Sonic velocity range 1000 to 3000 m/s 100 to 3000 m/s optional Material tangent media Immersion sensor: stainless steel optional Hastelloy, Monel, Inconel, Tantalum, Titanium, Zirconium and a lot more Tube sensor: stainless steel optional PFA, Halar (E-CTFE), Tantalum Case / Protection Aluminum die-cast case / IP 65 optional stainless steel case / IP 68 Power supply 24 V DC 15% Power consumption sensor V8: max. 6 W Power consumption sensor V10: max. 3 W Installation length immersion sensor Depends on sensor type optional up to 3 m Installation tube sensor Pipeline DN80 or 3 Mechanical strength The maximum permitted static load for immersion sensors is as follows: Max. bending force F max [N] Material L m m HC m m Max. flow velocity v max [m/s] of aqueous liquids Material L m 7,4 3,5 2 m 3,7 1,7 HC m 8,4 5,3 2 m 4,2 2,7 Page 56 of 60 LiquiSonic 20 and 30, Operating manual

57 Immersion type sensors The table below shows a selection of standard immersion type sensors. Special designed sensors can request from SensoTech. Type Art. No. Flange Sensor Flange Immersion type sensor L Flange DN 50 DIN Immersion type sensor L Flange DN 50 DIN Immersion type sensor L Flange DN 50 DIN Immersion type sensor Varivent DN Tuchenhagen Varivent Immersion type sensor Varivent DN Tuchenhagen Varivent Immersion type sensor APV DN APV flange Immersion type Clamp DN Clamp flange DIN Immersion type sensor GF G 2 ¼ thread Immersion type sensor Milchrohr DN Cone with groove nut DIN Immersion type sensor Pharma Clamp flange DN 50 DIN Immersion type sensor without flange without flange 40 - Immersion type sensor with separated electronic without flange with connector 25mm IP Immersion type sensor L092 (art no ) LiquiSonic 20 and 30, Operating manual Page 57 of 60

58 Flange type sensors In the following table, the flange data are listed in addition to the outside diameters of the flange type sensors. Type DN 80 Art. No. Inside Outside Hole circle Hole Height Length A B C D E Flange type sensor Flange type sensor Halar Flange type sensor PFA Flange type sensor PFA jacked Flange type sensor Tantalum , Flange type sensor DN 80 Halar (art. no ) Page 58 of 60 LiquiSonic 20 and 30, Operating manual