Vse VSI+ High Definition Flow Meter Manuel utilisateur

Solutions for Fluid Technology

OPERATING MANUAL

for ﬂow meters of the product line “VSI+ High Deﬁnition Flow Meter“

1011

10110

11011

TABLE OF CONTENTS

Page

1. Important information and legal notices .........................................3

2. General function description of ﬂow meter ...................................... 4

3. General discription ......................................................... 4

4. Flow meter selection ........................................................ 4

5. Declaration of conformity .................................................... 4

6. General conditions for initial start-up ........................................... 4

7. Maximum operating pressure ................................................. 5

8. Information on EU Directive 2014/68/EU on pressure equipment ...................5

9. Flow meter range ........................................................... 6

10. Assembly of the ﬂow meter .................................................. 6

11. Cleaning and ﬂushing of pipe lines before initial start-up .......................... 7

12. Filtering of liquid .......................................................... 7

13. Flow meters with high deﬁnition .............................................. 8

14. Settings of the preampliﬁer .................................................12

15. Pulse ﬁltering ............................................................13

16. Indicating leds ...........................................................13

17. Technical speciﬁcations of preampliﬁer .......................................14

18. Plug assignment of preampliﬁer ............................................. 14

19. Maintenance, service life and warranty ....................................... 15

20. Storage, return and disposal ................................................ 15

21. Technical speciﬁcations VSI 0.04 – VSI 2 .....................................16

22. Flow response curves VSI 0.04 – VSI 2 .......................................17

23. Dimensions VSI 0.04 – VSI 2 ...............................................18

24. Dimensions supplates AP.0.2 – 1 ...........................................19

25. Type key. ...............................................................20

26. Plug assignment .........................................................21

27. Connection diagram ......................................................22

28. Certiﬁcate of Non-Objection ...............................................23

The current publication of this operating instruction supersedes all information from pre-

vious publications. VSE reserves the right to make changes and substitutions. VSE is not

liable for any printing errors. Reproduction, including excerpts, is permitted only after

written approval by VSE. VSE reserves the right to modify technical data at any time.

Last revised: 10/2021

Operating manual–no.: E04-07-69-002 vers. 5

1. IMPORTANT INFORMATION AND LEGAL NOTICES

Dear customer, dear user,

This operating instruction for volume sensors of the “VSI+ High Deﬁnition Flow Meter” series by VSE Volumen-

technik GmbH (VSE) contains information required to properly install and commission the ﬂow meter for the intended

purpose.

Any installation, commissioning, operation, maintenance and testing may only be carried out by trained and authorized

personnel. The operating instructions must be read and followed carefully to ensure a trouble-free, proper and safe

operation of the ﬂow meter. In particular, the safety instructions are essential.

These operating instructions must be kept safe and accessible for the authorized personnel at all times. At no time

should contents of the operating instructions be removed. A missing manual or missing pages must be replaced

immediately if lost. The operating instructions can be requested at any time from VSE or downloaded from our website

www.vse-ﬂow.com. The operating instructions must be passed on to each subsequent user of the ﬂow meter.

This operating instruction is not subject to any modiﬁcation service by VSE. VSE reserves the right to make technical

changes at any time without notice.

VSE makes no warranties, express or implied, with respect to commercial qualities and suitability for a particular

purpose.

VSE accepts no liability for damage and malfunctions resulting from operating errors, failure to observe these operating

instructions, improper installation, commissioning or maintenance as well as improper use of the ﬂow meter.

The opening of the ﬂow meter is absolutely not permitted. After an unauthorized opening or rebuilding as well as

after a single, incorrect connection of the ﬂow circuits of the ﬂow meter, the warranty as well as the product liability by

VSE expire.

1. The process ﬂuid

 Is the ﬂow meter suitable for the medium?

 Is the ﬂuid viscous or abrasive?

 Is the ﬂuid contaminated or is there solid matter in the ﬂuid?

 Which granular size does the solid matter possess and can it block the meter?

 Does the ﬂuid have ﬁllers or other additional material?

 Is it necessary to install a pre-switched hydraulic ﬁlter?

 Are the pipe lines clean and free of assembly residues such as swarf, weld chips?

 Is the tank clean and is it ensured that no extraneous materials can get into the pipe line system from the tank?

 Is the ﬂuid often changed and is sufﬁcient ﬂushing performed in this case?

 Are the pipe lines and the entire system completely deaerated?

 Are the ﬂuid and the cleaning agent compatible with the seals?

Flow meters made by VSE Volumentechnik GmbH measure the volume

ﬂow of liquids according to the toothed wheel principle. A pair of very

precisely adjusted toothed wheels in the housing constitutes the meter.

A signal pick-up system registers meter rotation free of contact and

tooth by tooth. In ﬂow meters of high resolution (VSI), each tooth is out-

put as a multiple of digital pulses, depending on interpolation setting.

The gaps within the teeth of the meter wheels, form meter chambers in

the areas, in which they are completely enclosed by the housing walls;

these chambers digitalise liquid ﬂow depending on their chamber volume.

The liquid ﬂow within one meter rotation of a tooth division is divided

by the set interpolation factor. This gives the volume measurement per

pulse (Vm) and is deﬁned in cm3/pulse. It identiﬁes the constructional

size of a ﬂow meter (e.g. VSI 1/16).

3. GENERAL DISCRIPTION

Please follow all instructions in this operating manual; only this ensures

trouble-free operation of the ﬂow meters. VSE is not liable for any

damage ensuing from not following of these instructions.

Opening the devices during the term of warranty is only authorised

after consultation and approval of VSE.

4. FLOW METER SELECTION

The correct selection (version) of type and constructional size is crucial

for a trouble-free and safe operation of the ﬂow meters. Owing to

the great number of various applications and ﬂow meter versions, the

technical speciﬁcations in the VSE catalogue material are of a general

nature. Performance of the ﬂow meter depends on type, size and meter

range and on the liquid that is to be measured. Please consult VSE for

an exact description..

5. DECLARATION OF CONFORMITY

Flow meters of the “VSI” product line are tested for their electroma-

gnetic compatibility and interference transmission in terms of the law

on electromagnetic compatibility and correspond to the legal prescrip-

tions enforced by EMC directives. They may not be operated inde-

pendently and are to be connected via cable to a power source and

supply digital electric signals for electronic evaluation. A declaration

of conformity is submitted for all ﬂow meters, which you can request if

you require.

Since the electromagnetic compatibility of the total measuring system

depends on cable layout, correct connection of protective shielding

and each single connected device. You must ensure that all componen-

ts correspond to the electromagnetic compatibility directives and that

the electromagnetic compatibility of the total system, machine or plant

is assured.

All ﬂow meters are tested according to the valid, legally prescribed

electromagnetic compatibility directives and possess the CE-certiﬁca-

tion. The EC-declaration of conformity is the CE-label attached to all

ﬂow meters.

6. GENERAL CONDITIONS FOR INITIAL START-UP

Before assembly and before initial start-up, you have to note the fol-

lowing properties and aspects of the corresponding characteristics

of your system, so that a trouble-free and safe operation is possible.

2. GENERAL FUNCTION DESCRIPTION OF FLOW METER

2. The hydraulic properties of the system

 Is the max. operating pressure of the system lower than the max. permitted operating pressure of the ﬂow meter?

 Is the max. fall of pressure ∆p (on ﬂow meter) below the max. permitted fall of pressure?

 Does an excessively great fall in pressure ∆p occur on the ﬂow meter at max. ﬂow (e.g. with higher viscosity)?

 Does the ﬂow range of the ﬂow meter (depending on viscosity) correspond to the provided ﬂow?

 Note that ﬂow range decreases the greater the viscosity!

 Does the temperature range of the ﬂow meter correspond to the provided max. temperature of the medium?

 Is the cross section of the pipe line large enough and are the falls in pressure in the system not excessive?

 Is the hydraulic connection (supply and reverse ﬂow) correctly connected and leak-proof?

 Has the pump sufﬁcient power to operate the system?

 A blocked ﬂow meter can stop the ﬂow. Is a pressure control valve / bypass provided in the system?

7. MAXIMUM OPERATING PRESSURE

Before assembling the ﬂow meter, you have to test that the max.

operating pressure of the system does not exceed the max. permitted

operating pressure of the ﬂow meter. Meanwhile, observe the top

pressures that can occur, when operating the system.

3. Electronic evaluation and electrical safety

 Have you selected the optimal ﬂow meter and is this equipped with the appropriate preampliﬁer?

 Does the power supply voltage of the ﬂow meter correspond to the provided voltage?

 Is the power supply voltage supplied by the mains or evaluation device sufﬁciently steady?

 Does the output of the power supply voltage correspond to the required power output?

 Has the electric connection been installed based on the enclosed connection plan?

 Is the cable protected by a shield?

 Is there a connection of the cable protective shielding via the round plug to the housing of the ﬂow meter?

 Is the ﬂow meter connected ﬁrmly to the earth conductor PE or is the cable protective shield connected to ground GND?

 Is the cable laid interference-free and is the installation secured from input of interference pulses?

 Is the round plug of the connection cable ﬁrmly screwed together with the plug of the ﬂow meter?

 Are the wires on the evaluation device correctly and properly connected?

 Is there a potential difference between the earth conductor PE on the ﬂow meter and the earth conductor PE

on the evaluation device?

 Does a correcting lead have to be laid to eliminate the potential difference between the ﬂow meter and the evaluation device?

 Does the entire system correspond to the directives of the electromagnetic compatibility laws (EMC)?

 Have all local valid regulations, applicable directives, guidelines and background conditions of the

electromagnetic compatibility laws been maintained and observed?

 Systems that can lead to personal injury through malfunction or failure are to be equipped with the appropriate safety devices.

The functioning of these safety devices is to be checked at regular intervals!

The following operating pressures are permitted depending on ﬂow

meter version:

 Flow meter in grey cast iron version pmax = 315 bar/4500 psi

 Flow meter in stainless steel version pmax = 450 bar/6500 psi

 Flow meter in special version pmax = 700 bar/10100 psi

Important:

Please consult VSE for all operating pressures > 450 bar / 6500 psi and for special versions.

8. INFORMATION ON EU DIRECTIVE 2014/68/EU ON PRESSURE EQUIPMENT

In terms of Article 2, No. 5 of the directive named above, VSE volume

sensors are so-called “pressuremaintaining components“ and this direc-

tive thereby relates to them. VSE volume sensors must thereby comply

with the technical requirements named in Section 4 of the directive in

accordance with Article 4, Paragraph (1d), Piping according to Para-

graph (1c). Typically, the ﬂuids measured fall into Group 2 in accord-

ance with Article 13, Paragraph (1b). The volume sensors sold by VSE

do not comply with the limit values deﬁned under Article 4, Paragraph

(1a). The technical requirements on volume sensors from VSE are there-

fore limited to the criteria deﬁned in Article 4, Paragraph (3). That me-

ans that the devices must be designed and manufactured in accord-

ance with the good engineering practices prevailing in the member

state. We hereby conﬁrm this. The paragraph also states that these

units may not bear the CE label named in Article 18. A CE declaration

of conformity is therefore not issued in accordance with 2014/68/EU.

The CE label of our volume sensors refers to Directive 2014/30/EU.

10. ASSEMBLY OF THE FLOW METER

The ﬂow meter should be mounted on an easily accessible location,

so that dismantling for cleaning the meter presents no problem. Since

ﬂow meters can work in any installation position and ﬂow direction, you

can mount it on any location of your system. Take care, when installing

the ﬂow meter that liquid always remains in the ﬂow meter, even at

system standstill and that it can never run empty. The outﬂow of the ﬂow

meter should therefore always show a certain back pressure, since this

clamps the ﬂow meter ﬁrmly in the liquid column (the meter supports

itself through this on the liquid column) and the pipe line cannot run

empty. In critical cases or when the pipe line is at standstill or standby

and can run empty, we recommend installing an extra non-return valve

in the outﬂow line.

Flow meters of the “VSI” product line can be mounted directly onto a

block or into the pipe line using four screws. Always select large cross

sections for the hydraulic supply and return ﬂow respectively for the

entire pipe line system (if possible). This lowers the fall in pressure and

the ﬂow rate in the total system.

VSE supplies subplates for all ﬂow meters of the “VSI” product line; they

have various pipe threads and side or rearside connection. Depending on

the provided conditions, the installed pipe line, the pipe cross section or

pipe thread, the operator can choose the suitable sub-plate and incorpo-

rate this into the system or machine without additional reductions.

The ﬂow meter is screwed onto the block or subplate with four DIN 912

cheese head screws. The screws are to be evenly pretensed crosswise with

the following torques.

When changing the fastening screws you must take great care that the

screws are of property class 10.9 and 12.9.

Important:

Make sure that the speciﬁed maximum permitted operating pressure of the ﬂow meter cannot be exceeded,

whatever the operating mode of the system. Note the ﬂow meter range that is dependent on the viscosity

of the ﬂuid to be measured.

Important:

Make sure that the ﬂow meter is always completely ﬁlled both in inﬂow and outﬂow and

that the outﬂow has a little back pressure. This prevents the meter being damaged by a sudden

and steep increase of ﬂow and at the same time improves measurement accuracy.

Flow meter size

(cast iron and 1.4305)

Torque

VSI 0.04; VSI 0.1; VSI 0.2 15 Nm

VSI 0.4; VSI 1; VSI 2 35 Nm

Table 1: Torque of fastening screws

Please note the special instructions for mounting sizes VSI 4 and VSI 10

(see appendix)

9. FLOW METER RANGE

The ﬂow meter range speciﬁed in the ﬂow meter data sheet (Qmin

– Qmax) refers to the testing ﬂuid “hydraulic oil“ with a viscosity of

21 mm²/s at a temperature of 20°C. For this ﬂow meter range, VSE

speciﬁes measurement accuracy of up to 0.3 % of the measurement

value and a repetition accuracy of 0.05 %.

For ﬂuids of lower viscosity (< 21 mm²/s) measurement accuracy dete-

riorates, while for ﬂuids of higher viscosity (> 21 mm²/s) it can improve.

Also note, however, that the ﬂow meter range is restricted in case of

higher viscosity (see “Technical speciﬁcations“).

Rückschlagventil

Tank

Volumensensor

Fig. 1: Flow meter installation with non-return valve

Non-return valve

Flow meter

Tank

12. FILTERING OF LIQUID

Strongly contaminated ﬂuids or extraneous material in the ﬂuid can

block, damage or even destroy the ﬂow meter. Always install an appro-

priate ﬁlter for these cases in front of the ﬂow meter to prevent damage

to the ﬂow meter. The necessary ﬁltering depends on size, bearing sys-

tem and model of ﬂow meter.

Important:

Please ﬂush out the pipe lines and the tank thoroughly, to prevent contamination within the ﬂow meter.

Important:

When mounting the ﬂow meter, you must take great care that the seals are not damaged and correctly placed

in the hydraulic connections oft the ﬂow meter. Wrongly installed or damaged seals lead to leakage redundancy,

which may have dire consequences. Please make sure that ﬂow meters with EPDM seals do not come into

contact with oil and greases on a mineral oil basis. These ﬂuids can decompose the seals. The yellow plastic

plugs in the hydraulic connections of the ﬂow meter protect the meter against dirt and contamination during

storage and shipping. Before mounting the ﬂow meter you have to remove these plugs so that in- and

outﬂow is free and open.

11. CLEANING AND FLUSHING OF PIPE LINES BEFORE INITIAL START-UP

Before initial start-up of the ﬂow meter, you must ﬂush and clean the

whole system. Contaminated ﬂuid can effect the correct function of the

ﬂow meter or seriously damage the meter.

After preparing and connecting up the system pipes, you must ﬁrst ca-

refully ﬂush and clean the whole pipe line system and the tank. To do

this, you have to mount a diversion plate onto the block or subplate

instead of the ﬂow meter, so that the ﬂuid can ﬂow through the diver-

sion plate and all extraneous material (e.g. swarf, metal chips, etc.)

can be ﬂushed out without obstruction. Use a ﬂuid as cleansing agent,

which is compatible with the ﬂuid being used later and which does not

cause un-desirable reactions. You can consult the suppliers and manu-

facturers of the ﬂuid or contact VSE for the corresponding information.

VSE supplies bypass plates for all VSI-ﬂow meter sizes. Flow meters

are measurement pick-up systems made with high-level precision. They

have a mechanical meter consisting of two toothed wheels, which is

adapted to the housing with narrow slots. Even the tiniest damage to

the toothed wheels and bearings can cause a measurement error. So

always make sure that no extraneous material gets into the meter and

that the ﬂuid ﬂowing through is always free from dirt and contamina-

tion. After the system has been carefully ﬂushed out and no extraneous

material is in the pipe line, you can mount the ﬂow meter and com-

mence the initial start-up.

Flow meter size Filter meter size for ball bearings

VSI 0.04 / 0.1 10 µm

VSI 0.2 / 0.4 20 µm

VSI 1 / 2 50 µm

Table 2: Pre-switched Filter

For information on ﬁlter size for ﬂow meters with plain bearings, in spe-

cial version, or with specially adjusted meter tolerances, please consult

VSE Volumentechnik GmbH.

Important:

A blocked ﬂow meter can stop the ﬂow. You must provide a control valve / bypass for the system.

The measuring volume of the ﬂow meter is determined by the mechani-

cally displaced liquid volume within a tooth gap and the set interpola-

tion. It is calculated from the size of the ﬂowmeter and the set division

factor or interpolation factor IPF. Vm = Vm*/ IPF (see Figure 2)

The IPF is selectable in different steps up to a maximum of 128, where-

by the resolution is adapted to the speciﬁc application in order to achie-

ve the most precise ﬂow or volume measurements (see table 3).

The output of the two 90° phase-shifted pulse signals via two channels

also enables an edge evaluation (see ﬁgure 3).

With this feature the following applications in particular can be rea-

lized:

 Measuring, controlling and regulating in the lower ﬂow range

 Measuring controlling and regulating in zero ﬂow

 Measuring, controlling and regulating in both ﬂow directions

 Measuring, controlling, dosing and ﬁlling of small volume

13. FLOW METERS WITH HIGH DEFINITION

0°

45°

90°

135°

180°

225°

270°

315°

360°

pulse signal from channel 1

pulse signal from channel 2

zero signal pulse (zero pulse)

one measurement value

interpolation factor IPF = 8

Vm* = Vm/ 8

1/2 Vm *

1/4 Vm*

pulse signal from channel 1 without interpolation

pulse signal from channel 2 without interpolation

0°

45°

0°

180°

360°

90°

270°

1 Vm*

Division of a single pulse into 360°.

All other signal pulses can be regarded in this way.

Evaluation electronics recognise flow direction from the channel offset of 90°.

Each individual pulse flank is offset 90° and has a value of 1/4 Vm*.

22.5°

11.25°

33.75°

1.pulse

12 345678

Fig. 2: Signal emission of the preampliﬁer with interpolation

(interpolation factor 8)

Fig. 2 shows the resolution of the volume measurement Vm with an in-

terpolation factor of 8. This resolves each volume measurement into

eight individual part volumes. A pulse on the signal output of channel

1 or channel 2 thus has a value of Vm* = Vm / 8 = 1/8 Vm per pulse.

In double evaluation (ﬂank evaluation of one channel) this results in a

value of 1/2 Vm* = Vm / 16 = 1/16 Vm and for quadruple evaluation

(ﬂank evaluation of both channels) the result is a value of 1/4 Vm* =

Vm / 32 = 1/32 Vm per ﬂank.

Evaluation electronics can recognise ﬂow direction from signals offset

90°. Hence you can program a resolution of 4 to 64 angular steps per

volume measurement Vm

(see ﬁg. 3). The frequency multiplication “f*”

lies between 1 and 16 (see table 3).

Interpolation

factor

Imp/VmMax. resolution

(evaluation of

signal ﬂanks)

Resolution Vm*

(volume

measurement Vm*)

[ml]

Max. resolution

(angle degrees)

Frequency fmax*

1 1 4 Vm / 4 90° fmax x 1

4 4 16 Vm /16 22,5° fmax x 4

8 8 32 Vm /32 11, 2 5° fmax x 8

10 10 40 Vm /40 9° fmax x 10

16 16 64 Vm /64 5,625° fmax x 16

32 32 128 Vm /128 2,8125° fmax x 32

64 64 256 Vm /256 1,40625° fmax x 64

128 128 512 Vm /512 0,703125° fmax x 128

Table 3: Interpolation factor and resolution

Only the marked lines are illustrated in the diagram of ﬁg. 3

Alternatively, the interpolation factors 2, 3, 5, 12, 24, 50, 100 can also be set (from software version 1B). See page 14.

Column 1: Selectable interpolation factor IPF.

Column 2: Pulses per volume measurement Vm.

Column 3: Maximum resolution of the signal ﬂanks. The signal ﬂanks of channels 1 and 2 are evaluated.

Column 4: Volume measurement Vm* resulting from the maximum resolution of the signal ﬂanks.

Column 5: Maximum resolution in angle degrees at resolution of signal ﬂanks.

Column 6: Maximum frequency fmax* at maximum ﬂow Qmax and programmed interpolation factor IPF

In practice, the maximum ﬂow Qmax of the ﬂow meter is seldom run, so that a lower frequency can be calculated.

The maximum frequency is then calculated according to the following formula:

fmax

^ Maximum frequency of the ﬂow meter signals

Qmax

^ Maximum ﬂow attained in the case of application described here

IPF Programmed interpolation factor

Vm Volume measurement of the ﬂow meter

Example: Flow meter VSI 1/10… max. ﬂow the system can be run on at a maximum

max

^ = 40 l/min = 666.667 ml/sec; IPF = 10; Vm = 1 ml/pulse; fmax

^ = 6666.67 Hz = 6.66667 kHz

At max. ﬂow Qmax

^ = 40 l/min, the ﬂow meter VSI 1/10… outputs a frequency of fmax

^ = 6666.67 Hz.

fmax^ =(Qmax^) •IPF Formula 1

Fig. 3: Interpolation of the volume measurement Vm

Vm / 1

Vm / 4

Vm / 8

Vm / 16

channel

2. channel

1. channel

2. channel

channel

1. channel

2. channel

0° 180°45° 90° 135° 225° 270° 315° 360°/0° 45° 90° 135° 180°

22,5°

0°

22.5°

5,625°

11.25°

16.875°

If the resolution is sixteen-fold, this gives

a recognition of 22.5° (360° / 16)

This results in a resolution of 5.625° (22.5° / 4)

when evaluating the flanks of channel 1 and 2

The highest resolution permits recognition of a

measurement volume of 1 / 512 Vm.

one measurement volume Vm

360° angle degrees

pulse

3. 1. 2. 4. 5. 6. 7. 8. 9. 10 11 12 13 14 15 16

1. 2.

{

1. pulse

Important:

Test the connected evaluation electronic system as to whether it can process the maximum frequency fmax*

of the ﬂow meter. Check the data from the following table for the relevant ﬂow meter, or calculate the

maximum frequency data fmax° with formula 1.

At initial start-up of the system, you have to program the volume

measurement Vm* or the correct K-factor (see table 4, column 4) in

your evaluation electronics as parameter value (e.g. multiplier). The

evaluation electronics then multiply every pulse the ﬂow meter outputs

by the volume measurement Vm* and thus calculates the ﬂow and the

volume. For ﬂow meters with high resolution, the parameter value vo-

lume measurement Vm* is dependent on volume measurement Vm (see

table 4, column 2) and on the programmed interpolation factor IPF

(see table 4, column 3). Please consult this ﬁrst of all for the volume

measurement Vm* or the K-factor and program this value as parameter

into your evaluation electronics.

The maximum ﬂow rates with the corresponding frequencies are listed

in columns 4 and 8 of table 4.

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