Greyline Portaflow PT400 User Manual

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PORTAFLOW PT400

Portable Ultrasonic Flowmeter

User’s Guide

www.greyline.com

Table of Contents

1: General Description ...................................................................................................................6

1.1 Introduction.......................................................................................................................6

1.2 Principles of Operation.....................................................................................................7

1.3 Supplied Hardware...........................................................................................................8

1.4 Portaflow PT400 Instrument.............................................................................................9

1.4.1 Connectors.............................................................................................................9

1.4.2 Keypad ..................................................................................................................10

1.4.3 Power supply and battery charging.......................................................................11

1.5 Transducers.....................................................................................................................11

2: Installation……………………………………………………………………………………………..12

2.1 Transducer Positioning....................................................................................................12

2.2 Transducer Attachment (Type ‘A’ & ‘B’)..........................................................................13

2.2.1 Preparation...........................................................................................................13

2.2.2 Attaching the guide rails.......................................................................................13

2.2.3 Fitting the transducers..........................................................................................14

3: Operating Procedures..............................................................................................................15

3.1 Setting-up the Instrument...............................................................................................16

3.1.1 Using the instrument for the first time ..................................................................16

3.1.2 Enabling/disabling the backlight...........................................................................17

3.2 Using the Quick Start Menu ............................................................................................17

3.3 Using the System at a Regularly Monitored Location.....................................................20

3.4 Managing Named Sites...................................................................................................22

3.4.1 Setting up a new site............................................................................................22

3.4.2 Changing a site name ..........................................................................................23

3.5 Instrument Calibration .....................................................................................................24

3.5.1 Adjusting the zero cut-off .....................................................................................24

3.5.2 Adjusting the set zero flow offset.........................................................................24

3.5.3 Adjusting the calibration factor.............................................................................25

3.5.4 Adjusting the roughness factor.............................................................................25

3.5.5 Adjusting the damping factor................................................................................27

3.6 Performing Monitoring Functions ....................................................................................28

3.6.1 How to measure totalised flows (manually) .........................................................28

3.7 Configuring the Portaflow PT400 Interfaces...................................................................30

3.7.3 How to turn the 4-20mA output OFF/ON .............................................................30

3.7.4 4-20mA signal calibration and ranging.................................................................30

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3.7.5 How to convert the measured current to flow rate ...............................................31

3.7.6 How to turn the pulse output OFF/ON..................................................................32

3.7.7 Pulse output signal calibration .............................................................................32

4: Maintenance & Repair..............................................................................................................33

5: Troubleshooting.......................................................................................................................34

5.1 Overview..........................................................................................................................34

5.2 General Troubleshooting Procedure ...............................................................................35

5.3 Warning & Status Messages...........................................................................................36

5.4 Test Block........................................................................................................................39

5.5 Microprocessor Reset Facility .........................................................................................39

5.6 Diagnostics Display.........................................................................................................40

5.7 Applications Hotline.........................................................................................................41

5.8 Product Return Procedure...............................................................................................41

5.9 Warranty..........................................................................................................................43

6: Appendix A Specifications......................................................................................................44

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1: General Description

1.1 Introduction

This manualdescribes the operation of the Greyline Portaflow PT400 portable flowmeter. The flowmeter is designed to work with clamp-on transducers to enable the flow of a liquid within a closed pipe to be measured accurately without needing to insertanymechanicalparts through the pipe wall or protrude into the flow system.

Using ultrasonictransittime techniques, the Portaflow PT400 is controlled by a micro-processor system which contains a wide range of data that enables it to beused with pipes with an outside diameter ranging from 13mm up to 1000mm and constructed of almost any material. The instrument will also operate over a wide range of fluid temperatures.

The PT400 series comprises two models which are identical in operation but designed to be used with a different range of pipe diameters. The PT400 can be used with pipesin the range 13mm – 115mm and the PT500 with pipes intherange 50mm – 1000mm.

Easy to operate, the Portaflow PT400 standard features are:

• Large, easy to read graphic display with backlighting

• Simple tofollowdual function keypad

• Simple ‘Quick Start’ set up procedure

• Continuous signal monitoring

• Pulse output

• 4-20mA, 0-20mAor 0-16mA output

• Rechargeable battery

• Battery management

• Diagnostics

Volumetric flowrates are displayed in l/h, l/min, l/sec, gal/min, gal/h, USgals/min, USgals/h, Barrel/h, Barrel/day, m³/s, m³/min, m³/h. Linear velocity is displayed in metres or feet persecond.

When operatinginthe‘FlowReading’ mode the total volumes, both positive and negative,are displayed up to a maximum 12-digit number.

The flowmeter can be used to measure cleanliquids or oils that haveless than 3% byvolume of particulate content. Cloudy liquids such as river water and effluent can be measured along with cleaner liquids such as demineralised water.

Typical PortaflowPT400 applications include:

• River water

• Seawater

• Potable water

• Demineralised water

• Treated water

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1.2 Principles of Operation

When ultrasound is transmitted through a liquid the speed at which the sound travels through the liquid is accelerated slightlyif it is transmitted in the same direction as the liquid flow and decelerated slightly if transmitted against it. The difference intime taken by the sound to travel the same distance but in opposite directions is therefore directly proportional to the flow velocity of the liquid.

The PortaflowPT400 system employs two ultrasonic transducers attached to the pipe carrying the liquid and compares thetime taken to transmit an ultrasound signal in each direction. If the sound characteristics of the fluid are known, the Portaflow microprocessorcanusethe results of the transit time calculations to compute the fluid flow velocity. Once the flow velocity is known the volumetric flow can be easily calculated for a given pipe diameter.

The Portaflowsystemcan be set up to operate in one of fourmodes determined mainly by the pipe diameter and the typeof transducer set inuse. The diagram below illustrates the importance of applying the correct separation distance between the transducers to obtain the strongest signal.

Fluid flow

Upstream

transducer

Separation

Distance

Separation

Distance

Separation

Distance

Separation

Distance

Reflex mode

This is the mode most commonly used. The two transducers (U & D) are attached to the pipe in line with each other and the signals passing between themare reflected by the opposite pipe wall. The separation distance is calculated by the instrument in response to entered data concerning the pipe and fluid characteristics.

Reflex mode (double bounce)

In this mode the separation distance is calculated to give a double bounce. This is most likely to occur if the pipe diameter is so small that the calculated reflex mode separation distance would be impractical for the transducers in use.

Reflex mode (triple bounce)

This illustration goes one step further to show a triple bounce situation. This would normally apply when working with very small pipes relative to the transducer range in use.

Diagonal mode

This mode might be selected by the instrument where relatively large pipes are concerned. In this mode the transducers are located on opposite sides of the pipe but the separation distance is still critical in order for the signals to be received correctly.

This mode might be used with the standard ‘A’ & ‘B’ transducer sets but for really large pipe installation the optional transducer set ‘D’ might be recommended.

Figure 1.1 Operating modes

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1.3 Supplied Hardware

The Portaflowequipmentis supplied in a rugged plastic carrying case fitted with a foam insert to give added protection fortransportation. The supplied components are shown in Figure 1.2.

TransducerCables

Chains (x2) Ultrasonic

Couplant

GuideRails (x2)

Transducers (Sensorsx2)

RuledSeparation bar

Test Block

4-20mA/

PulseOutput

Cable

Power Supply

(Batt. Charger)

Portaflow PT400

Instrument

Figure 1.2 Standard Portaflow equipment

Standard equipment

• Portaflow PT400 instrument with backlit graphic display

• Power supply - with UK, US, European adaptors. 110/240VAC

• 4-20mA/Pulse Output cable

• 2 lengths of chain each at 3.3 metres long

• Test block

• Transducer cables (x2) 2 metres long (one red and one blue)

• Transducer set 'A' (Transducers x2)

• Transducer set 'B' (Transducers x2)

• Set of guide rails for use with ‘A’ or ‘B’ transducers

• Ruled separation bar (2-piece)

• Manual

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1.4 Portaflow PT400 Instrument

The PortaflowPT400 is a microprocessorcontrolled instrument operated through a menu system using an inbuilt LCD display and keypad. It can be used to display the instantaneous fluid flow rate or velocity, together with totalised values.

The instrument can also provide a current or variable ‘pulse’ output proportional to the detected flow rate. These outputs, which can be used with a range of external interface devices such as those found in BMS or site monitoring systems, can be calibrated to suit a particular flow range.

1.4.1 Connectors

4-20mA / Pulse Output

Transducer Cables

Reset pin-hole LCD Display

Keypad

Battery Charger

Figure 1.3 Instrument details

Transducer connections

The transducers are connected to two colour-coded miniature coaxial sockets located on the top of the instrument. Using the red/blue connector cables provided, the upstream transducer shouldalways be connected to the RED socket and the downstream transducer to the BLUE one for a positive flow reading. It is safe to connect or disconnect the cable while the instrument is switched on.

4-20mA and Pulse output connection

The 4-20mA/ ‘pulse’ output cable should be connected to the green7-pin connector on the top of the flowmeter, as shown in Figure 1.3. A single cable that can be adapted for use for either of these output functions is included in the Portaflow PT400 kit.The ‘tails’ on thefreeendof the cable must be terminated to suit the intended application.

Red – 4-20mA positive Black – 4-20mA negative White – Pulse output Green – Pulse return Brown – Set Point (notinpresent use) Blue – Set Point return (not in present use) Thick Black – Cable screen

Battery charger connection

The suppliedbatterychargeris connected to the instrument by means of the grey 2-pin connector on the bottom of theunit, as shown in Figure 1.3.

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Note: The above connectors have different key-ways to prevent incorrect cable connection.

Numerical keypad

withdual function keys

ON/OFF

1.4.2 Keypad

The instrument is configured and controlled via a 16-key tactile membrane keypad, as shown in Figure 1.4.

ON/OFF Key

The ON/OFF key is shown on the top left of the keypad. When turned ON an initialisation screen is displayed on the LCDshowing theinstrument’sserialnumber and software revision. Once this appears, the instrument can be started bypressingthe ENTER key once – the initialization screen is then replaced by a MAIN MENU which provides accessto the remaining functions.

Menus and the menu selection keys

The PortaflowPT400 menus are arrangedhierarchally with the MAIN MENU being at the top level. Menu navigation is achieved by three keys on the right hand side of the keypadwhich are used to scroll UP and DOWN a menu list and SELECT a menu item. When scrolling through a menu an arrow-shaped cursor moves up and down the left hand side of the screen to indicate the active menu choice which can then be selected by pressing the ENTER (SELECT) key.

Scroll UP

ENTER (SELECT)

Scroll DOWN

Scroll LEFT Scroll RIGHT

Figure 1.4 Keypad

Some menushave more options than can be shownon the screen at the same time, in which case the ‘overflowed’ choices can be brought into view by continuing to scroll DOWN past the bottom visible item. Menus generally ‘looparound’if you scroll beyond the first or last items.

If you select Exit it usually results in taking you back one level in the menu hierarchy, but in somecasesitmay go directly to the ‘Flow Reading’ screen.

Some screens require you to move the cursor leftandrightalongthedisplayas well as up and down. This is achieved using keys 5 (scroll LEFT) and 6 (scroll RIGHT).

Dual function numerical keypad

The block of keys shown in the centre of the keypadin Figure 1.4 are dual function keys. They can be used to enter straight-forward numerical data, select the displayed flow units or provide quick access to frequently required control menus.

Note: Some of the features accessed by these keys are restricted in the Portaflow 220 model range. An “Option not available”message is displayed if you select a restricted function.

1.4.3 Power supply and battery charging

Operating power is provided by an internal battery thatcanbe charged from theutility supply using the supplied external charger.Whenyou first receive the unit you must put the battery on charge for a minimum of 6.5hrs

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before use. A fully chargedbattery will power the instrument for up to 20hrs depending on the output utilisation and backlight usage.

If the backlight has been enabled the display is illuminated for 10 seconds every time a key is pressed. If the backlight is active continuously it would reduce the available battery operating time to 8hrs. Similarly, if the 420mA output is used constantly at 20mA, the battery life would reduce by 50%. It is therefore beneficial to turn off the backlight and 4-20mA output facilities when they are not required.

When the instrument is operating in the ‘Flow Reading’ mode the percentage battery charge level is displayed symbolically ontheLCDscreen. A warning message is triggered if the charge falls to approximately 30%, at which point there is up to four hours of battery operation remaining, depending on usage. The battery can be charged both while the instrument is in use or when switched off. The instrument’s internal data is stored in nonvolatile memory and will not be lost even if the battery discharges completely.

Key Point: The battery is not a user-changeable item. The instrument must be returned to Greyline if the battery needs replacing.

Key Point: Only use the supplied charger, or special adaptor lead. Failure to comply with this will invalidate your warranty.

1.5 Transducers

Different transducersets are provided with the PF400A and PF400B Portaflow models and are not interchangeable.

Transducer set 'A'

Supplied as standard on PF400A for use on pipes 0.51” to 4.525” (13mm to 115mm) outside diameter.

Transducer set 'B'

Supplied as standard on PF400B for use on pipes 1.97” to 39.37” (50mm to 1000mm) outside diameter.

Key Point: Always use the transducers that were supplied with the instrument.

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2: Installation

Guide

20 x Diameter

10 x Diameter

Valid transducer location

The Portaflowequipment expectsa uniformflowprofile as a

2.1 Transducer Positioning

In many applicationsan even flow velocity profile over a full 360°is unattainable due, for example, to the presenceof air turbulenceat the top of the flow and possiblysludge in the bottom of the pipe. Experience has shown that the most consistently accurateresults are achievedwhen the transducer guide rails are mounted at 45° with respect to the top of the pipe.

Air

rail

45°

Possible sludge

Flow

distorted flow will produceunpredictablemeasurement errors. Flowprofile distortions can result from upstream disturbances such as bends, tees, valves, pumps and other similar obstructions. To ensure a uniform profile the transducers must be mounted far enough away from any causeof distortionsuch thatitno longer has an effect.

Uniform Flow Profile Distorted Flow Profile

Flow

Figure 2.1 Locating the transducers

To obtainthe most accurate results the condition of both the liquid and the pipe wall must be suitable to allow the ultrasound transmission along its predetermined path. It is importantalso that the liquid flows uniformly within the length ofpipe beingmonitoredand that the flow profile is not distorted by any upstream or downstream obstructions. This is best achieved by ensuring there is a straight lengthof pipe upstream of the transducers of at least 20timesthepipe diameter and 10 times the pipe diameter on the downstream side, as shown in Figure 2.1. Flow measurements can be made on shorter lengths of straight pipe, down to 10 diameters upstream and 5 diameters downstream,butwhen the transducers are positioned this close to any obstruction the resulting errors can be unpredictable.

Key Point: Do not expect to obtain accurate results if the transducers are positioned close to any obstructions that distort the uniformity of the flow profile.

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2.2 Transducer Attachment

The transducers are fitted to adjustable guide rails which are secured to the pipe using wrap-around chains and mechanically connectedtogether by a steel separation bar. The separation bar also acts as a ruler to allow the distance between the transducers to be accurately set to the value determined by the Portaflow instrument.

When fitting the guide rails it is easiest to assemble them onto the separation bar and adjust to the required separation distancebefore attaching them to the pipe.

2.2.1 Preparation

1. Before you attach the transducers you should first ensure that the proposed location satisfies the distance requirementsshownin Figure 2.1 otherwise the resulting accuracyoftheflowreadings may be affected.

2. Prepare the pipe by degreasing it and removing any loose material or flaking paint in order to obtain the best possible surface. A smooth contact between pipe surface and the face of the transducers is an important factor in achieving a good ultrasound signal strength and therefore maximum accuracy.

2.2.2 Attaching the guide rails

A B C

E F

A: Tensioningthumb-wheel. B: Tension bar. C: Separationbar securing

screw.

Figure 2.2 Guide rail attachment

1. Slide the separation bar (D) into the front of the left hand guide rail, align the front edge of the guide railwith ‘0’ on the ruler scale (E) and secure it in place by tightening the thumbscrew (C).

D: Separationbar. E: Ruler scale (0). F: Set Separationdistance. G: Securing chain.

2. Slide the other end of the separation barintothefrontof the right hand guide rail, align the front edge of the guide rail to the required separation distance (obtained from the Portaflow instrument) on the ruler (F), then secure itin place by tightening the thumbscrew.

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3 On each guide rail, attach one end of a securing chain to a hook on the tensioning bar (B), wrap the chain

around thepipe (G) and then attach it to the hook on the other end of the tensioning bar whilst keeping the chain as tight as possible.

4. Rotate the complete guide railassembly so that it is approximately 45° with respect to the top of the pipe. Then tighten the chain by turning the tensioning thumb-wheel (A) on each guide block until the assembly is securely attached to the pipe.

Note: If you are unable to get sufficient tension on the chain to hold the assembly in place, fully slacken the tensioning thumb-wheel and shorten the effective length of the chain wrapped around the pipe by connecting the tensioning bar to the next link in the chain, then re-tension.

2.2.3 Mounting the transducers

C: Transducer coverplatesecuringscrew.

B:Transducer locatingslot/lug.

D: Transducer cableconnection.

A:Transducer cover plate.

G:Chain.

E:Ultrasonic

couplant

application.

Figure 2.3 Mounting the transducers

1. Slide the transducer cover plate (A) fully towards the outside of the guide assembly to allow sufficient access to fit the transducer.

2. Clean the face of the transducer, removing alltracesof dirt and grease.

3. Apply a 1/8” (3mm) bead of ultrasonic couplant along the centre length of the transducer (E).

4. Fit the transducer into theguide block – ensuring the lugs on the sides of the transducer are correctly located into the slots on the sides of the guide block (B).

5. Slide the transducer cover plate (A) over the top of the transducer and tighten the thumbscrew (C) fingertight to secure the transducer in place. When securing the cover plate take care to leave sufficient room around the transducer connector (D) to connect the cable.

6. Repeat the above steps forthe second transducer.

7. Connect the transducers to the Portaflow instrument usingthe coaxial cables provided. The RED cable mustbe connected to theupstream transducer and the BLUE cable to the downstream transducer. If you observe negative flow, swap the red andblue cables at the sensors.

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3: Operating Procedures

Initial instrument setup

(Paragraph 3.1)

Battery charging, Set date/time, Language, Backlight

Connect and take basic flow readings

At a one-off location

(Paragraph 3.2)

QUICK START VIEW EDIT SITE DATA

Enter data

Attach sensors

FLOW READING

At a frequent location

(Paragraph 3.3)

Choose site / check data

Attach sensors

FLOW READING

Carry out any necessary calibration

(Paragraph 3.5)

How to adjust the Zero Flow Offset – Paragraph 3.5.2 How to adjust the Calibration Factor – Paragraph 3.5.3 How to adjust the Roughness Factor – Paragraph 3.5.4 How to adjust the Damping Factor – Paragraph 3.5.5

Set-up a monitoring or logging application

(Paragraph 3.6)

Manage site details

(Paragraph 3.4)

Set up a named site

Rename a site

Configure the interfaces

(Paragraph 3.7)

How to measure totalised flows – Paragraph 3.6.1 How to set up basic (manual) logging – Paragraph 3.6.2 How to set up auto-timed logging – Paragraph 3.6.3 How to set up logging ‘live’ to a PC– Paragraph 3.6.4 How to download saved data to a PC – Paragraph 3.6.5 How to print data – Paragraph 3.8

RS232 set-up – Paragraph 3.7.1 USB set-up– Paragraph 3.7.2 4-20mA ON/OFF – Paragraph 3.7.3 4-20mA Calibration – Paragraph 3.7.4 Pulse ON/OFF – Paragraph 3.7.6 Pulse calibration – Paragraph 3.7.7

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3.1 Setting-up the Instrument

3.1.1 Using the instrument for the first time

Before you use your Portaflow PT400 for the first time you should first charge the battery, then select the display language andset-up the internal clock, as described below.

Charging the battery

1. Connect the external battery chargerto the charger socket at the bottom of the instrument then switch ontheutilitysupply.

2. The instrument should indicate CHARGING and an animated battery symbol indicates that the battery is taking on charge.

3. Leave theinstrumentoncharge for 6.5 hours before using it for the first time.

Selecting a language

The first time you switch on the instrument you may be asked to select a user language.

1. Switch on the instrument bypressing the ON/OFF button.

2. If necessary, select the required language using the UP/DOWN scroll keys then press the ENTER key.

3. The selectedlanguage will be the default when the instrument is next used. To change the language againselectthe Change Language option inthe SETUP INSTRUMENT screen (see below)

4. The initialisationscreen will be displayed, giving details of the instrument’s serial number and software revision details.

CHARGING DD-MM-YY HH:MM:SS

Serial # V 00.00.00.00.00.00.00. 0000 27 Press to start

5. Press ENTER to start the instrument.

6. This is the MAIN MENU and is the starting point for all the operations described in this chapter.

MAIN MENU DD-MM-YY HH:MM:SS Quick start

View/Edit Site Data Data Logger Setup RS232 /USB

Setup Instrument

Read flow

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Setting the Date & Time

1. Select Setup Instrumentfrom the MAIN MENU. The screen shown here should be displayed.

2. Select Set Date & Time and click ENTER.

3. A flashingcursorshould appear underthe first date number. Enter the date sequence in dd-mmyy order then press ENTER.

4. Repeat this action to setthe time.

5. Select Exit then press ENTER to return to the MAIN MENU.

Note: If you make a mistake when entering the data press the Delete key to move the cursor back to the number you wish to change, then continue. If you enter an invalid number an ‘ERR:Invalid Date or Time!’ error message is displayed on the second lineof the screen. If this occurs repeat the set date/time procedure.

3.1.2 Enabling/disabling the backlight

When the backlight is enabledit will illuminate for 15 seconds every time a key is pressed so if it is not required it is recommended that you disable it to prolong the battery discharge time.

SETUP INSTRUMENT DD-MM-YY HH:MM:SS

Dim: mm

Set Date & Time : dd-mm-yy hh:mm:ss

Calibrate 4-20mA Pulse output Backlight : Disabled Factory settings

Change Language

Exit

1. Select Setup Instrument from the MAIN MENU.

2. Select Backlight from theSETUP INSTRUMENT screenthenpress ENTER.

3. Select Enableor Disable as required.

4. Press ENTER to return to the SETUP INSTRUMENT screen.

5. Select Exit then press ENTER to return to the MAIN MENU.

3.2 Using the Quick Start Menu

SETUP INSTRUMENT DD-MM-YY HH:MM:SS

Dim: mm Set Date & Time : dd-mm-yy hh:mm:ss Calibrate 4-20mA Pulse output

Backlight : Disabled

Factory settings Change Language

Exit

BACKLIGHT DD-MM-YY HH:MM:SS

Dim: mm

Enabled Disabled

If you want to perform a ‘one-off’ flow reading at a particular pipe location the Quick Start menu provides the quickest way to set up the Portaflow system and access the FLOW READING screen.

If the point at which you intend to take the measurement is likely to require regular monitoring it is best to set it up as a ‘Site’ within the Portaflow PT400, which then stores the site parameters (See Managing Named Sites).

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Before you can use the Portaflow system you need to obtain the following details (this information will be required when setting up the Quick Start menu):

• The pipe outside diameter

• The pipe wall thickness andmaterial

• The pipe lining thickness andmaterial

• The type of fluid

• The fluidtemperature

Entering the site data

1. Select Quick Start from the MAIN MENU and press ENTER. You will then be presented with a series of screens in which to enter the data mentioned above.

2. Select the dimension units (millimetres or inches) used to measure the pipe, then press ENTER.

3. Enter the pipe outside diameter dimension, then press ENTER.

4. Enter the pipe wall thickness dimension, then press ENTER.

DIMENSION UNIT DD-MM-YY HH:MM:SS

Select thedimension units:

mm

Inches

OUTSIDE DIAMETER DD-MM-YY HH:MM:SS Dimension: mm

Pipe outside diameter? 58.0

PIPE WALL THICKNESS DD-MM-YY HH:MM:SS

Dimension: mm Pipe outside diameter? 58.0

Pipe wall thickness? 4.0

5. If the pipe has a lining, enter the lining thickness. If nothingis entered the instrument automatically assumes there is no lining.

6. Press ENTER to continue.

7. Select the pipe wall material from the list provided, thenpressENTER.

If the material is notlisted select Other and enter the propagation rate of the pipe wall material in metres/sec. Contact Greyline if this is not known.

PIPE LINING THICKNESS DD-MM-YY HH:MM:SS

Dimension: mm Pipe outside diameter? 58.0

Pipe wall thickness? 4.0

Pipe lining thickness? 0.0

PIPE WALL MATERIAL DD-MM-YY HH:MM:SS

Select pipe wall material

Mild Steel S' less Steel 316 S' less Steel 303 Plastic

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Cast Iron Ductile Iron Copper Brass Concrete Glass Other (m/s)

8. If a lining thickness value was entered earlier, this screenis displayed to request that you enter the lining material type. If no lining thickness was entered this screen will be bypassed.

9. Select theliningmaterial from the list provided then press ENTER.

If the material is notlisted select Other and enter the propagation rate of the lining material in metres/sec. Contact Greyline if this is not known.

10. Select the fluid type from the list provided and press ENTER.

If the liquid is not listed select Other and enter a propagation rate in metres/second.

PIPE LINING MATERIAL DD-MM-YY HH:MM:SS

Select pipe lining material

Steel Rubber Glass Epoxy

Concrete Other (m/s)

FLUID TYPE DD-MM-YY HH:MM:SS

Select fluid type

Water Glycol/water 50/50 Glycol/water 30/70 Lubricating oil

Diesel Freon Other (m/s)

11. If you need to alterthe fluid temperature from that shown selecteither °C or °F with the cursor and press the ENTER key.

12. Enter thenewtemperature value and press the ENTER key.

13. The new temperature should now be indicated in both °C and °F.

14. Select Continue.. and press ENTER.

15. The SENSOR SEPARATION screen now displays a summary of the entered parameters and informs you of the typeof sensor to be used, the mode of operation and the distance to set up between thesensors. In this example it recommends type A-ST (A standard) sensors operatingin the ‘Reflex’ mode spaced at 32.2mm apart. Take a note of these details

FLUID TEMPERATURE DD-MM-YY HH:MM:SS

Enter Fluid Temperature

°C: 5.00 °F: 41.00

Continue..

SENSOR SEPARATION DD-MM-YY HH:MM:SS Site : Quickstart

Pipe : 58.00 mm Wall : 4.00 Sensors : A-ST Reflex Temperature : 10.00°C 50.00°F Set sensorseparationto 32.2 mm

Press to continue, to select sens.

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Note: Do not press ENTER until the transducers are fitted and connected to the instrument.

0.000

Attaching and connecting the transducers

16. Fit the designated sensors to the pipe using the appropriate guide rails as described in

Paragraph 2.2. Take great care to set the separation distance as accurately as possible.

17. Connect the redandblue coaxial cables between the sensors and the test instrument, ensuring that the red connector on the instrument is connected to the ‘upstream’ sensor.

Taking a flow reading

18. Once thetransducers have been fitted and connected press the Enter key.

19. This will take you from the SENSOR SEPARATION screen to the FLOW READING screen via a signal-checking screen (shown here).

Please wait.. Checking signals

**************************************** * * ****************************************

20. Check thattheindicatedsignal strength on the left of the screen is at least 2 bars (ideally 3 or 4). If less than 2 bars are shown it indicates there could be a problem with the transducer spacing, alignment or connections; or itcould be due to an application problem.

Flow monitoring

The FLOW READING screen is the one most used during normal monitoring operation. It shows the instantaneous fluid flow together with totalised values (when enabled). In this mode you can select the flowrate measurement unitsby pressing keys 7 (litres), 8 (Gallons) or 9 (m³), or change the display to show velocity by pressing key 4.

FLOW READING DD-MM-YY HH:MM:SS Signal

+Total: 0.00 litres –Total: 0.00 litres

3.3 Using the System at a Regularly Monitored Location

Setting up the Portaflow system using the Quick Start method described in Paragraph 3.2 is easy andthe recommended methodtousein a ‘one-off’ situation. But if you have a site location that you want to monitor on a frequent basis it is better to set up a named ‘Site’ for that location so that you can recall it when needed and so avoid theneed to re-enter the site details every time you want to install the equipment there.

Note: See Paragraph 3.4 for details of how to set-up and manage site details.

Dim: mm

l/min

Use this procedure to installthe equipment at a named site.

1. Select View Edit Site Data from theMAIN MENU.

2. Select Choose from list of sites.

3. Select one of the sites listed and press ENTER.

4. The Site name will show the selected site and

VIEW EDIT SITE DATA DD-MM-YY HH:MM:SS

Dim: mm

Choose from list of sites

Site name : MySite

Dimension units : mm Pipe outside diameter : 58.00 Pipe wall thickness : 4.00 Pipe lining thickness : 0.00

Page 18 www.greyline.com

the site parameters will be listed on thescreen.

5. Scrolldown through the menu list and enter/change the data that might have changed since the last time the site was accessed.

6. When you are satisfied that the parameters are correct select Save current site & read flow.

Pipe wall material : Mild Steel Lining material : --------Sensor set : A-ST Sensor mode : Reflex Fluid type : Water

Save current site & read flow

Delete this Site Download & save current site Exit

7. If you need to alterthe fluid temperature from that shown selecteither °C or °F with the cursor and press the ENTER key.

8. Enter thenewtemperature value and press the ENTER key.

9. The new temperature should now be indicated in both °C and °F.

10. Select Continue.. and press ENTER.

11. The SENSOR SEPARATION screen now displays a summary of the entered parameters and informs you of the typeof sensor to be used, the mode of operation and the distance to set up between thesensors. In this example it recommends type A-ST (A standard) sensors operatingin the ‘Reflex’ mode spaced 32.2mmapart. Take a note of these details.

Note: If you press ENTER before the transducers are fitted and connected to the instrument, the instrument will detect a low signalstrength and may indicate an ERROR condition.

FLUID TEMPERATURE DD-MM-YY HH:MM:SS

Enter Fluid Temperature

°C: 5.00 °F: 41.00

Continue..

SENSOR SEPARATION DD-MM-YY HH:MM:SS Site : MySite Pipe : 58.00 mm Wall : 4.00 Sensors : A-ST Reflex Temperature : 10.00°C 50.00°F Set sensorseparationto 32.2 mm Press to continue, to select sens.

Attaching and connecting the transducers

12. Fit the designated sensors to the pipe using the appropriate guide rails as described in

Paragraph 2.2. Take great care to set the separation distance as accurately as possible.

13. Connect the redandblue coaxial cables between the sensors and the instrument, ensuring that the redconnectoron the instrument is connected to the ‘upstream’ sensor.

Taking a flow reading

14. Once thetransducers have been fitted and connected press the ENTER key.

15. This will take you from the SENSOR SEPARATION screen to the FLOW READING screen via a signal-checking screen (shown here).

Please wait.. Checking signals

**************************************** * * ****************************************

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16. Check thattheindicatedsignal strength on the

0.000

left of the screen is at least 2 bars (ideally 3 or 4). If less than 2 bars are shown it indicates there could be a problem with the transducer spacing, alignment or connections; or itcould be due to an application problem.

Flow monitoring

3.4 Managing Named Sites

If you want to monitor a particular site location frequently you can set up a named ‘Site’ tostore the installation details, suchas pipe dimensions and material, required toset-up the Portaflow PT400 system. These can then be recalled laterwhen revisiting that particularlocation.

The instrument can store up to 20 sites, the first site is reserved for QUICK START and cannot be renamed; subsequent sitesare initially named EmptySite1 through to EmptySite19.

FLOW READING DD-MM-YY HH:MM:S Signal Dim: mm

l/min

+Total: 0.00 litres

–Total: 0.00 litres

3.4.1 Setting up a new site

1. Select View Edit Site Data from the MAIN MENU.

2. Select Choose from list of sites.

3. Select one of the EmptySites from the presented list (e.g. EmptySite 1 as shown).

4. Select Site name and press ENTER.

5. This opens the ALTER NAME screen.

6. Select Alter theSite Name and you will be presented with a screen which allows you to enter a newnameinmuch the same way as when composing a mobile text message.

7. On completion press ENTER then select Exit. This will take you back to the VIEW EDIT SITE DATA screen.

VIEW EDIT SITE DATA DD-MM-YY HH:MM:SS

Dim: mm

Choose from list of sites Site name : EmptySite1

Dimension units : mm Pipe outside diameter : 58.00 Pipe wall thickness : 4.00 Pipe lining thickness : 0.00

ALTER NAME DD-MM-YY HH:MM:SS Site name : EmptySite1

Do you wish to:–

Alter the Site Name

Exit

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8. Scroll down through the menu list and enter/change the pipe parameters and other data pertaining to the site. Note thatthismenu allows you to choose a Sensor Set, unlike the QUICK START menu which recommended the sensor set to use. If you enter an inappropriate sensor set in this menu you will be presented with an error message later when you go to the SENSOR SEPARATION screen.

VIEW EDIT SITE DATA DD-MM-YY HH:MM:SS

Dim: mm Choose from list of sites Site name : MyNewSite Dimension units : mm Pipe outside diameter : 58.00 Pipe wall thickness : 4.00 Pipe lining thickness : 0.00

9. When all the data is correct you can either: a) Select Save current site & read

flow to continue fitting the transducers and opening the FLOW READING screen.

b) Select Delete this sitetodelete

the site name and values and restore itto the original EmptySite name.

c) Select Download & save current

site to save the site details and download them to a PC via RS232/USB provided the RS232/USB linkis connected and correctly set-up.

d) Select Exit to returnto the MAIN

MENU.

3.4.2 Changing a site name

To changea site name use the same method described above for generating a newsite: but in this case access a currentsitename to change rather than an EmptySite. If you change a site name while the site is logging the logging will stop.

Pipe wall material : Mild Steel Lining material : --------Sensor set : A-ST Sensor mode : Reflex Fluid type : Water

Save current site & read flow Delete this Site Download & save current site Exit

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3.5 Instrument Calibration

The Portaflowis fully calibrated before it leaves the factory; however the following adjustments are provided to allow you to further ‘fine tune’ your instrument to suit local conditions and application where necessary. Apart from the zero flow offset adjustment, these are normally carried out only where the instrument is to be used in a permanent or semi-permanent location.

3.5.1 Adjusting the zero cut-off

This adjustmentallows you to set a minimum flow rate (m/s) below which the instrument will indicate ‘0’. The default setting is 0.02 m/s but you may adjust this value if required.

1. With the instrument operating in FLOW READING mode, press the Options key to access the FLOW READING OPTIONS menu shown.

2. Select ZeroCutoff(m/s) and press ENTER.

3. Enter thevaluefor the Zero Cutoff (e.g. 0.06 m/s) thenpress ENTER.

4. Scroll down to select Exit and press ENTER to return to the FLOW READING screen.

3.5.2 Adjusting the set zero flow offset

The Portaflowinstrumentoperatesbycomparing the time taken to send an ultrasonic signal between two transducers in either direction. A Set zero flow offset adjustment is provided to compensatefor any inherent differences between the two sensors, noise pick-up, internal pipe conditions etc. It can be used to ‘zero’ the flow indication underno-flowconditions.

If you have adjusted the Zero Cutoff point to anywhere above ‘0’ you must reset it to ‘0’ before you can observe and adjust the Set zero flow offset, as its value is very small. Once the Set zero flow offset has been calibrated you can then reapply the Zero

Cutoff if required.

1. Stop theliquid flow.

2. With the instrument in FLOW READING mode press theVelocity function key and observe the reading (m/s). Any reading other than 0.000 indicates an offset errorandin practice this will typically be in the range ±0.005m/s (possibly higher onsmaller diameter pipes). If a greater figure is shown it is worth calibrating the offset to obtain a more accurate result. Continue as follows:

FLOW READING OPTION DD-MM-YY HH:MM:SS

Data review

Zero Cutoff (m/s) : 0.00

Set zero flow (m/s) : 0.00 Damping (secs) : 10 Totaliser : Run Reset +Total

3. Press the Options key to access the FLOW READING OPTION screen shown.

4. Select Set zero flow (m/s) and press ENTER.

5. Press ENTER on the subsequent screen to accept the change, which will return you to the screen shown.

6. Scroll down to select Exit and press ENTER to return to the FLOW READING screen.

FLOW READING OPTION DD-MM-YY HH:MM:SS Data review

Zero Cutoff (m/s) : 0.00

Set zero flow (m/s) : 0.00

Damping (secs) : 10 Totaliser : Run Reset +Total

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Key Point: In order to cancel any applied offset you must either read flow via Quick Start or switch the Portaflow instrument OFF & ON. Any value that you trim-out

using the offset adjustment will be added/subtracted from the flow reading across the whole range.

3.5.3 Adjusting the calibration factor

Key Point: USE THIS FACILITY WITH CARE & ONLY WHERE NECESSARY

The Portaflow instrument is fully calibrated before leaving the factory and under normal circumstances does not require further calibration when used on site.

This facility can be used to correct the flow indication where unavoidable errors occur due to the lack of a straight pipe or where the sensors are forced to be fitted close to the pipe-end, valve, junction etc.

Any adjustment must be made using a reference flowmeter fitted in the system.

With the system running:

1. Stop (Stall) the Portaflow’s totaliser facility and zero it (Paragraph 3.6.1).

2. Run the Portaflow’s totaliser to measure the total flow over a 30-60 minute period, and note the total flowindicated by the reference flow meter over the same period.

3. Calculate the % error between the Portaflow and reference meters. If the error is greater than ±1% calibrate the Portaflow as detailed below.

4. Press the Options key to access the FLOW READING OPTION screen shown.

5. Scroll down and select Calibration factor.

6. Change the calibration factor according to the error calculatedin step 3. For example, if the Portaflow was reading 1% high then increase the Calibration factor value by 0.010. Conversely, if the reading is 1% low thendecrease the calibration factor to 0.990.

7. Press Enter to apply the change.

8. Select Roughnessfactor or Exit as required.

3.5.4 Adjusting the roughness factor

FLOW READING OPTION DD-MM-YY HH:MM:SS

Data review Zero Cutoff (m/s) : 0.00 Set zero flow (m/s) : 0.00 Damping (secs) : 10 Totaliser : Run Reset +Total

Reset –Total

Calibration factor : 1.000

Roughness factor : 0.01 Diagnostics Exit

The roughness factorcompensates for the condition of the internal pipe wall, as a rough surface will cause turbulence and affects the flow profile of the liquid. In most situations it is not possible to inspect the pipe internally and the true conditionisnotknown. In these circumstances experience has shown that the following values canbe used:

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Pipe Material Roughness Factor

Non ferrousmetal Glass Plastics Light metal

Drawn steel pipes:

• Fine planed,polishedsurface

• Plane surface

• Rough planed surface

Welded steelpipes,new:

• Long usage,cleaned

• Lightly and evenly rusted

• Heavily encrusted

Cast iron pipes:

• Bitumen lining

• New, without lining

• Rusted / Encrusted

0.01

0.1

1.0

Page 24 www.greyline.com

With the system running in FLOW READING mode:

1. Press the Options key to access the FLOW READING OPTION screen shown.

2. Scroll down and select Roughness factor.

3. Change the roughness factor accordingto the pipe materialand condition as described above.

4. Press Enter to apply the change.

3.5.5 Adjusting the damping factor

By averaging-out the flow rate over several seconds, the Damping factor can be used to smooth out rapid changes in flow rate to prevent wild fluctuations in the displayed flow value. It has a range of 1 to 199, with a default setting of 10. With the system running in FLOW READNG mode:

1. Press the Options key to access the FLOW READING OPTION screen shown.

2. Scroll down and select Damping (secs).

3. Change the value of the Damping factor as required to remove any unwanted display fluctuations. Increasing the value applies a greater smoothing affect.

4. Press Enter to apply the change.

FLOW READING OPTION DD-MM-YY HH:MM:SS

Data review Zero Cutoff (m/s) : 0.00 Set zero flow (m/s) : 0.00 Damping (secs) : 10 Totaliser : Run Reset +Total

Reset –Total Calibration factor : 1.000

Roughness factor : 0.01

Diagnostics Exit

FLOW READING OPTION DD-MM-YY HH:MM:SS

Data review Zero Cutoff (m/s) : 0.00 Set zero flow (m/s) : 0.00

Damping (secs) : 10

Totaliser : Run Reset +Total

Reset –Total Calibration factor : 1.000 Roughness factor : 0.01 Diagnostics Exit

Key Point: If the damping factor is set too high the value displayed may appear stable but it may exhibit large step changes when the value is updated.

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3.6 Monitoring Functions

12.34

3.6.1 How to measure totalised flows (manually)

The basic measurement indicated on the FLOW READING screen is the instantaneous flow rate, which in some applications may vary over a period of time.Average flow rates are therefore often required in order to get a better understanding of an application’s true performance. This is simply achieved by noting the total flow over a specific period (for example 30-60 minutes) and then calculating the average flow rate over that period of time.

1. Press the Options key to access the FLOW

READING OPTION screen shown.

2. If the Totaliser is indicating Run, select it and

change it to Stall. Press ENTER.

3. Select Reset +Total and press ENTER.

4. Press ENTER on the subsequent screen to

accept the reset.

5. Press ENTER again to return to the FLOW

READING OPTIONS menu.

6. Select Reset –TotalandpressENTER.

7. Press ENTER on the subsequent screen to

accept the reset.

8. Press ENTER again to return to the FLOW

READING OPTIONS menu.

9. Note and record the current time.

10. Select Totaliserand change it to Run. Press

ENTER. Note: thetotalisers begin to count up as soon as Totaliser is put to Run.

FLOW READING OPTION DD-MM-YY HH:MM:SS

Data review Zero Cutoff (m/s) : 0.00 Set zero flow (m/s) : 0.00 Damping (secs) : 10

Totaliser : Stall Reset +Total

FLOW READING OPTION DD-MM-YY HH:MM:SS

Zero Cutoff (m/s) : 0.00

Set zero flow (m/s) : 0.00 Damping (secs) : 10

Totaliser : Run

Reset +Total

Reset –Total

11. Scroll down and select Exit to return to the

FLOW READING screen which will now indicate the instantaneous flow together with the totalised flow. Note thatinsomeinstallation the measured flow can be in either direction.Where this is the case the upstreamflowis shown separately in the – Total field.

FLOW READING DD-MM-YY HH:MM:S

Dim:mm

Signal

l/min

+Total: 300.0 litres

–Total: 0.00 litres

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Calculating the average flow

To calculatetheaverage flow wait for the allotted monitoring period to expire then divide the indicated total flow by the time taken. This will give you the average flow in m/s, galls/hours or whatever units you select.

Note thatina bi-directional flow situation you must calculate the difference between the indicated positive and negative flowtotalsbefore carrying out the average flow rate calculation.

How to stop the totaliser temporarily

If you want to stop the totaliser temporarily for operational reasons, set the Totaliser option to Stall in the FLOW READING OPTIONS screen as described above. This will stop the totaliser operation without affecting its current values.

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3.7 Configuring the Portaflow PT400 Interfaces

3.7.3 How to turn the 4-20mA output OFF/ON

1. With the instrument operating in the FLOW READING mode, press the 4-20mA function key. This will access the 4-20mA OUTPUT screen.

2. The ON/OFF status of the 4-20mA output is shown on line 2 ofthedisplay.

3. To changetheON/OFF status select Output Range and press ENTER.

3.7.3

4. Select Off, to turn OFF the 4-20mA Output or select one of the output ranges to turn it ON.

5. Press ENTER to return to the 4-20mA OUTPUT screen.

3.7.4 4-20mA signal calibration and ranging

4-20 mA OUTPUT DD-MM-YY HH:MM:SS 4-20 mA O/P is ON Dim: mm

mA OutputReading : 0.00

Output Range : 4-20

Units : l/min Flow at max. output : 0.00 Flow at min. output : 0.00 Output mA for error : 22.00

Exit

4-20 mA OUTPUT DD-MM-YY HH:MM:SS

Dim: mm Off 4-20mA 0-20mA 0-16mA

3.7.4

Key Point: The 4-20mA output has been calibrated in the factory and should not require further adjustment. In the rare event that re-calibration is necessary, this procedure should be carried out only by a trained engineer.

This procedure describes how to calibrate the 4-20mA output and ‘scale’ it to operate over a defined flow-rate range.

Signal calibration

1. Select Setup Instrumentfrom the MAIN MENU, to access the SETUP INSTRUMENT screen.

2. Select Calibrate4-20mA.

SETUP INSTRUMENT DD-MM-YY HH:MM:SS

Set Date & Time : dd-mm-yyhh:mm:ss

Calibrate 4-20mA

Pulse output Backlight : Disabled Factory settings Change Language

Exit

Dim: mm

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3. Connect a calibrated ammeter to the 4-20mA output andadjusttheUP/DOWN Scroll keys (Coarse) andLEFT/RIGHT Scroll keys 5 & 6 (fine) until theoutput is exactly 4.0mA. The DAC should indicate approximately 8000.

4. Press ENTER when done.

CALIBRATE 4mA DD-MM-YY HH:MM:SS

Dim: mm

Adjust theoutputcurrent to 4mA

Use  to set, 5/6 to trim

DAC Value: 8000

Press  when done

5. With the meter still connectedto the 4-20mA output adjusttheScrollkeys to obtain an output of exactly 20mA. The DAC should indicate approximately 40000.

6. Press ENTER when done.

CALIBRATE 20mA DD-MM-YY HH:MM:SS

Dim: mm

Adjust theoutputcurrent to 20mA

Use  to set, 5/6 to trim

DAC Value: 40000

Press  when done

4-20mA Signal scaling

Note: The 4-20mA can be set to represent a particular flow range. It is also possible to enter a negative figure for the minimum outputandthis would enable a reverse flow to be monitored.

7. With the instrument operating in the FLOW READING mode, press the 4-20mA function key. This will access the 4-20mA OUTPUT screen.

4-20 mA OUTPUT DD-MM-YY HH:MM:SS 4-20 mA O/P is ON Dim: mm

mA OutputReading : 0.00 Output Range : 4-20

8. Select Flow at max. output and enter a value of the flowrate that you want to associate with a 20mA output.

Units : l/min Flow at max. output : 0.00 Flow at min. output : 0.00 Output mA for error : 22.00

9. Select Flow at min. output and enter a value of the flowrate that you want to associate with a 4mA

Exit

output. This could be ‘0’.

10. Select Output mA for error and enter a value (max of about 23mA) that you want the 4-20mA output to produceintheevent of an error (e.g. if the flow-rate is outside the set range).

11. Upon completion press ENTER to return to the FLOW READING screen.

3.7.5 How to convert the measured current to flow rate

Assume the maximum flow rate is F

(l/min) and the minimum flow rate F

max

Page 29 www.greyline.com

is ‘0’ (l/min), as shown.

min

max

Flow (l/min)

min

4 8 12 16 20

To calculatetheflowrate (l/min) for a measured current I(mA) then:

[0-16mA scale]

[0-20mA scale]

[4-20mA scale]

I (mA)

0-20mA

Flow rate

I F

------------------------------------------- F

– 

maxFmin

min

Flow rate

3.7.6 How to turn the pulse output OFF/ON

1. With the instrument operating in the FLOW READING mode, press the Pulse function key to access thePULSE OUTPUT screen.

2. A Pulse output is ON message appears in the second lineof the display.

3. Select Exit and press ENTER to return to the FLOW READING screen.

3.7.7 Pulse output signal calibration

1. With the instrument operating in the FLOW READING mode, press the Pulse function key to access thePULSE OUTPUT screen.

2. To changetheflowmeasurement units select Flow units and press the required units function key (7), (8), (9).

0-16mA

I F

------------------------------------------- F

– 

maxFmin

PULSE OUTPUT DD-MM-YY HH:MM:SS Pulse output is ON Dim: mm Flow units : litres Output : Off Vol perpulse : 10.00 Pulse width (ms) : 10

Exit

PULSE OUTPUT DD-MM-YY HH:MM:SS Pulse output is ON Dim: mm

Flow units : litres

Output : Off

Vol per pulse : 10.00 Pulse width (ms) : 10

Exit

min

Flow rate

4-20mA

I 4–  F

--------------------------------------------------------- F

– 

maxFmin

16 

min

3.7.7

3. Select Volper pulse and enter the required value. (In the example shown, a pulse is produced every 10 litres of flow).

4. Select a Pulse width (inms) to suit theparticular application – e.g. electro-mechanical counter. Refer to the manufacturer’s data sheet for the minimum pulse width.

5. Select Exit and press ENTER to return to the FLOW READING screen.

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4: Maintenance & Repair

This instrumentdoes not contain any user-serviceable parts. The following notes are provided as a guide to general equipment care

Do not disassemble this unit unless advised by Greyline.

Return the unit to an approved service agent or place of purchase

WARNING

1. Ensure the unit is switched off and disconnected from the mains, then wipe the exterior of the instrument with a clean, damp cloth or papertowel. The use of a solvent may damage the surface.

2. The instrument contains a rechargable battery,dispose safely and inaccordance with the local regulations in force in the country of operation.

3. Ensure allcables and connectors are kept clean and free from grease or contaminants. Connectors may be cleaned with a general purpose cleaner if necessary.

4. Avoid theuseofexcessive grease/ultrasonic couplant on the sensors as this may impair the performance of the equipment. Excessive grease/couplant can be removed from the sensors and guide rails using anabsorbent paper towel and a general purpose solvent cleaner.

for further advice.

5. We recommend that the ultrasonic couplant is replaced on the sensors every 6 months, especially onpipes where the application is too hot to touch. If the signal level drops below 30% this is also an indication that the sensors need re-greasing.

6. Regularly checkall cables/parts for damage.Replacementparts are available from Greyline.

7. Ensure the person who services your instrument is qualified to do so. If in doubt, return the instrument to Greyline with a detailed report on the nature of any problem.

8. Ensure thatsuitable precautions are taken when using any materials to clean the instrument/sensors.

9. The instrument andsensors should be calibrated at least once every 12 months. Contact Greyline or your local service agent for details.

10. When returning product to Greyline make sure it is clean and please notify Greyline if the instrument has been in contactwith any hazardous substances.

11. If the instrument was supplied with dust or dirt caps make sure they are re-fitted when the instrument is not in use.

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5: Troubleshooting

5.1 Overview

If you have a problem with your flow monitoring system it can be due to any of the following:

Faulty instrument

If you suspect the instrument is faulty you can check it out using a test block as described in Paragraph 5.4.. This will establish that the instrument is functional and receiving a healthysignal from the connected transducers.

Incorrect setup

A low, or zero, signal could be caused byincorrect set-up such as:

• Incorrect sitedata entered into the instrument.

• Incorrect or non-matching ultrasonic transducers selected for use.

• Incorrectly fittedtransducers – lack of couplant applied, incorrect spacing, insecure

attachment.

• Poor connectionsbetween the probes and the instrument.

Application problem

If you are certain thatthe instrument is healthy and suitably set-up for the current site; and the probes are properly assembledandfittedcorrectly, there could be an application problem concerned with the site.

Check suchconditions suchas:

Poor pipe outer surface quality

• Uneven surface preventing good surface contact with the transducer.

• Flaking paint (should be removed).

• Variable air gap in concrete-covered pipes affecting the ultrasonic signal quality.

Poor internal pipe construction

• Rough internal pipe walls affecting fluid flow (see roughness factor).

• Internal welds positioned in the transducer signal path affecting the signal quality.

• The ‘drippings’in galvanised-dipped pipes or other irregularities interferingwith the signal

path.

Incorrect probelocation

• Transducers locatedtoocloseto bends or valves,disturbing the flow profile.

• Transducers locatedtoocloseto insertion probes, disturbing the flow profile.

• For horizontal pipework transducers should not be positioned on the top of the pipe.

Poor fluid conditions within the pipe

• Fluid containsbubbles, high particle density or sludge.

• Air in the top of the pipe.

Low fluid flow within the pipe

• Pipe obstructions.

• Malfunctioning valve not opening fully (or closed inadvertently).

Liquid content problems

• Multiple liquidcontentsdo not comply accurately to expected sound speed criteria.

• Very hot pipe almost turns water to steam and therefore exhibits the wrong speed

characteristics –could be due to reduced pipe pressure.

• Flashover – liquid turns into a gas because of lower than required pressure.

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5.2 General Troubleshooting Procedure

Yes

Ensure sufficient acoustic couplant been applied to

If triple reflex modeis selected try double or single

START

Are any

status messages

Note any active messages.

Yes

Is the display blank?

Is the display scrambled or

hung-up?

Recharge the battery.

If battery won't recharge then replace the charger (if faulty) or return the instrument for repair.

Turn instrument OFF/ON.

If the displayis still scrambled/hung

up press the microprocessor reset

button. Return instrument for repair

if fault still present.

shown?

Measurement differsfrom expected value. Unstable measurements. No (or poor) signal.

Ensure temperature is set correctly. Ensure transducer cables are connected correctly.

Ensure transducers are positioned in accordance with the recommended distance from bends etc.

Ensure flow velocity >0.01m/s.

Problem probably due to non-constant fluid flow.

Ensure pipe data beenentered correctly.

Ensure fluid type been entered correctly.

Ensure correct transducer type been selected.

Ensure transducer separation distance correct.

Ensure transducers are aligned correctly.

Ensure pipe diameterwithin specifications of the

selected transducers.

Ensure the pipe is completely full.

Ensure pipe surface is not corroded, or protective

surface loose.

Check for particles in the fluid.

Refer to the message table in this

chapter to interpret themessage

and view suggested response.

the transducers?

reflex instead.

Check instrument using test block.

Figure 5.1 Troubleshooting chart

Page 33 www.greyline.com

5.3 Warning & Status Messages

FLOW RATE ERRORS

No flowsignal

Flow signal is poor

Zero cut-offerror!

Damping error!

Totaliser beyondmaximum!

Interpretation: This message appears when the transducers cannot send or

receive signals to each other.

Response: Firstly check that all cables are connected, transducers are on the pipe

correctly with sufficient couplant on the face. This conditioncouldalso be due to a partially empty pipe, aerated liquid, particulate content too high or when the condition of the pipe beingmeasuredispoor.

Interpretation: This warning appears when the signal is lower than 25%. Response: This could be dueto an application problem, a poor quality pipe – see

also theconditions for No flow signal (above). Check for sufficient couplant.

Interpretation: You have entered anout-of-range value in the Zero cutoff field in

the Optionsmenu.

Response: Entera valid number.

Interpretation: You have entered anout-of-range value in the Damping field in the

Options menu.

Response: Entera valid number.

Interpretation: The totaliser has overflowed its maximum count. The counter will

roll-over and restart from zero but this message alerts you to the fact.

PULSE ERRORS

Pulse Rate > Max

Pulse volume error!

Pulse width error

Response: Reset the totaliser as described in Paragraph 3.6.1.

Interpretation: The flow rate exceeds the capability of the pulse output – i.e. too

many pulses per second are required than can be achieved.

Response: Narrowthe pulse width timeor increase the volume per pulse, as

described in Paragraph 3.7.7.

Interpretation: You have entered anout-of-range value in the Pulse volume error

field in the PULSE OUTPUT menu – see Paragraph 3.7.7.

Response: Entera valid number.

Interpretation: You have entered anout-of-range value in the Pulse width error

field in the PULSE OUTPUT menu – see Paragraph 3.7.7.

Response: Entera valid number.

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4-20mA ERRORS

mA out> Max

Interpretation: The actual flow is higher than the maximum set on the mA range. Response: Re-scale the 4-20mA output to be able to cope with the higher flow –

see Paragraph 3.7.4.

Calibration 20mA Error! NOTE: The 4-20mA output is calibrated before the instrument leaves the factory

and should not require further adjustment.

Interpretation: You have adjusted the DAC outside its accepted range when

calibrating the 20mA signal output.

Response: Re-calibratethe4-20mAoutput – see Paragraph3.7.4.

Calibration 4mAError! NOTE: The 4-20mA output is calibrated before the instrument leaves the factory

and should not require further adjustment.

Interpretation: You have adjusted the DAC outside its accepted range when

calibrating the 4mA signal output.

Response: Re-calibratethe4-20mAoutput – see Paragraph3.7.4.

BATTERY ERRORS

Battery Low

Interpretation: The battery has discharged to below 30% remaining. This leaves

the instrument with approximately 4 hours remaining, depending on power usage, before it needs recharging.

Battery Exhausted

SET-UP ERRORS

Pipe OD out of range

Wall thickness out of range

Lining thickness out of range

Response: Rechargetheinternal battery at the earliest opportunity. Do not leave

the instrument for a prolonged period with a fully discharged battery.

Interpretation: The battery is approaching a fully discharged state and the

instrument is about to store the internal data and shut-down.

Response: Rechargethebattery.

Interpretation: You have entered anout-of-range value for the pipe outside

diameter dimension – i.e. larger or smaller than the unit or sensor can be used on.

Response: Entera valid number.

Interpretation: You have entered anout-of-range value for the pipe wall thickness

dimension – accepted range is 0.04” - 2.95” (1mm - 75mm).

Response: Entera valid number.

Interpretation: You have entered anout-of-range value for the lining thickness

dimension – acceptable range is 0” – 0.39” (0mm - 10mm).

Response: Entera valid number.

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Temperature range

Interpretation: You have entered anout-of-range value for the fluid Temperature.

Accepted temperature range -4°F to 572°F (-20°C to +300°C).

Response: Entera valid number.

Invalid Date or Time

Sensors: INVALID

Mode: Err Typ

Interpretation: The entered Date or Time is invalid, or when setting up ‘timed’ data

logging the Stop time is set earlier than the Start time.

Response: Entera valid Date and Time.

Interpretation: The selected temperature is higher than the maximum allowed for

the sensor type.

Response: Selectalternative sensors or change the temperature.

Interpretation: The selected sensors are invalid and the mode cannot be verified. Response: Selecta valid sensor typeand choose a modethat gives a non-zero

separation distance.

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Test Block

A testblockis included with the Portaflow PT400 equipmentto allow the transducers and inter-connecting cables to be functionally checked.

1. Switch ON the instrument.

2. Select Quickstartandentertheparameters shown in the table belowfor the appropriate transducer type (A or B):

Parameter A Sensors B Sensors

Pipe outside diameter 1.02” (26.0mm) 2.09” (53.0mm)

Pipe wall thickness 0.24” (6.0mm) 0.28” (7.0mm)

Pipe lining thickness 0.0 0.0

Pipe wall material Mild Steel Mild Steel

Fluid type Water Water

Temp 68°F (20°C) 68°F (20°C)

Figure 5.2 Test block

3. When the above data is entered, the SENSOR SEPARATION screen will be displayed.

4. Use the UP/DOWN scroll keyto go to the SENSOR SELECTION menu.Select the appropriate sensor (the default will be"A")and press ENTER to return to the SENSOR SEPARATION menu.

5. Select Sensormode and position the cursor at Diagonal and press ENTER to return to the SENSOR SELECTION menu.

6. Select Exit and press ENTER to return to the SENSOR SEPARATION screen.

7. Check thattheparametersdisplayed are correct.

8. Apply acoustic couplant to thesensors and attach them to the test block with the connectors positioned towards the centre of the test block as shown, and temporarily secure them in place using elastic bands or tape.

9. Connect the sensors to the Portaflow PT400 instrumentusing the cables provided.

10. Press ENTER to go to the FLOW READING screen.

11. Select the Options key to go to the FLOW READING OPTION menu and set the Damping to at least 10seconds.

12. Select Exit and press ENTER to return to the FLOW READING menu.

13. The flow reading value displayed is not important. The fact that a reading is obtained indicates that the instrument is functioning. This value may fluctuate but this is normal.

14. The signal strength indicator at the left of the display should show 3–4 bars.

5.5 Microprocessor Reset Facility

In therare event that thePortaflow PT400 instrument appears to totally hang-up, or displays total gibberish, you can reset its microprocessor by carefully inserting a straightened paperclip into the pinhole located in the right-

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hand side of the instrument to operate the internal reset switch. Hold the paperclip perpendicular to the instrument while doing this.

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5.6 Diagnostics Display

This feature is designed for advanced users and is intended to provide information that will aid the user to diagnose problems– e.g. no signal strength.

When operatinginthe FLOW READING mode you can access a diagnostics screen by pressing the Options function key and then selecting Diagnostics from the FLOW READING OPTIONS screen. This will display the operating values for the following parameters.

Calculated time (µs)

This is a value theinstrument predicts will be the time in µsecs that it should take for the acoustic wave to propagate acrossa particular pipe size. This value is ascertained from the data entered by the user. i.e. Pipe size, material, sensorsetetc.

Actual time (µs)

This is the value the instrument measures as the time taken for the acoustic wave to propagate across the pipe. It is used to see if the signal is being taken from the burst, at the correct time to get the strongest signal. This value is normally a few µs below the calculated µs value. If, however, this value is much greater than the calculated time thenthere is a problem with the set-up.

Flow (m/s)

This displaysflowvelocityinm/secto 3 decimal places.

Signal strength

This is the averaged valueof Signal and should be a value between 800 and 1600 – where 800 is approximately 50%, and 1600 is approximately 100%.

UP/DN time difference

The differenceintransittimesbetween the upstream and downstream signals due to the fluid flow.

Propagation µs

Not currently in use.

Signal propagation

Not currently in use.

Fluid propagation rate

This is the sound speed of the fluidcalculated using the data entered by the user.

Fluid propagation rate

Calculated from the input dataconcerning the fluid type and temperature.

Sensor separation

The same value as displayedin the setup screen.

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5.7 APPLICATIONS HOTLINE

For applications assistance,advice or information on any Greyline Instrument contact your Sales Representative, write to Greyline orphone the Applications Hotline below:

United States: Tel: 315-788-9500 Fax: 315-764-0419 Canada: Tel: 613-938-8956 Fax: 613-938-4857 Toll Free: 888-473-9546 Email: info@greyline.com Web Site: www.greyline.com

Greyline Instruments Inc.

Canada: USA: 16456 Sixsmith Drive 11451 Belcher Road South Long Sault, Ont. K0C 1P0 Largo, FL 33773

5.8 PRODUCT RETURN PROCEDURE

Instruments maybereturned to Greyline for service or warranty repair.

1. Obtain an RMA Number from Greyline -

Before shipping a product to the factory please contact Greyline by telephone, fax or email to obtain an RMA number (Returned Merchandise Authorization). This ensures fast service and correct billing or credit.

When you contact Greyline please have the following information available:

1. Model number / Software Version

2. Serial number

3. Date of Purchase

4. Reason for return (description of fault or modification required)

5. Your name, company name, address and phone number

2. Clean the Sensor/Product -

Important: unclean products will not be serviced and will be returned to the sender at their expense.

1. Rinse sensor and cable toremove debris.

2. If the sensor has been exposed to sewage, immerse both sensor and cable in a solution of 1 part household bleach (Javex, Clorox etc.) to 20 parts water for 5 minutes. Important: do not immerse open end of sensor cable.

3. Dry with paper towels and pack sensorandcablein a sealed plasticbag.

4. Wipe theoutside of the enclosure to remove dirt or deposits.

5. Returnto Greyline for service.

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LIMITED WARRANTY

_____________________

Greyline Instruments warrants, to theoriginal purchaser,its products to be free from defects in material and workmanship for a period of one year from date of invoice. Greyline will replace or repair, free of charge, any Greyline product if it has been proven to be defective within the warranty period. This warranty does not cover any expensesincurred intheremovalandre-installationoftheproduct.

If a product manufactured by Greyline shouldprove defective within the first year, return it freight prepaid to Greyline Instruments along withacopy ofyourinvoice.

Thiswarrantydoesnotcoverdamages duetoimproper installation or handling, actsof nature, or unauthorized service.Modifications to or tampering with any part shall void this warranty. This warranty does not cover any equipment used in connection with the product or consequentialdamages duetoadefectin the product.

Allimpliedwarrantiesare limited to thedurationof this warranty. This is the complete warranty by Greyline and no other warranty is valid against Greyline. Some states do not allow limitations on how long an implied warranty lasts or limitation of incidental or consequential damages, so the above limitations or exclusions may not apply to you.

This warranty givesyou specific legal rights, andyou may also have otherrights whichvaryfromstateto state.

GreylineInstrumentsInc.

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Appendix A: Specifications

GENERAL

NEW! DSP Measurement Technique:

Timing Resolution: 50 pico-second, continuous signal level indication on display.

Improved! Flow Velocity Range:

Turn Down Ratio: 100:1

Accuracy: ±0.5% to ±2% of flow reading for flow rate >0.2m/s and Pipe ID >75mm.

Repeatability: ±0.5% of measured value or ±0.02m/s whichever is the greater.

NEW! Reynolds Number Correction:

Response Time: < 400ms depending on pipe diameter.

Selectable Flow Units: VELOCITY: m/sec, ft/sec.

Selectable Volume Units: l, gal, USgals, Barrel, m³.

Total Volume: 12 Digits - forward and reverse.

Transit time.

Minimum Velocity 0.1m/s; Max Velocity 20m/s: Bi-directional.

±3% of flow reading for flow rate >0.2m/s and Pipe ID in range 13mm - 75mm. ±6% of flow reading for flow rate < 0.2m/s.

Flow velocity corrected for Reynolds number over entire velocity range.

VOLUME: l/s, l/min, l/h, gal/min, gal/h, USgals/min, USgals/h, Barrel/h, Barrel/day, m³/s, m³/min, m³/h.

APPLICABLE FLUID TYPES

Fluid Condition: Clean liquids or oils that have less than 3% by volume of particulate content. Applications include river water,

sea water, potable water, demineralised water, glycol/water mix, hydraulic systems and diesel oil.

APPLICABLE PIPE TYPES

Pipe Materials: Any sonic conducting medium such as Carbon Steel, Stainless Steel, Copper, UPVC, PVDF, Concrete,

Galvanised Steel, Mild Steel, Glass, Brass. Including Lined Pipes - Epoxy, Rubber, Steel, Plastic.

Pipe Dimension (outside diameter):

Pipe Wall Thickness: 1mm - 75mm.

Pipe Lining: Applicable pipe linings include Rubber, Glass, Concrete, Epoxy, Steel.

Pipe Lining Thickness: 0mm – 10mm.

Pipe Wall Temperature Range:

Min 13mm; Max 4000mm with D sensorset.

Standard sensor operating temperature is -4°F to 275°F (-20°C to +135°C). Optional high temperature sensor operating temperature is -4°F to 392°F ( -20°C to +200°C).

TRANSDUCER SETS

Standard: Temperature Range -4°F to 275°F (-20°C to +135°C)

PF400A – Type 'A-ST' (2MHz) PF400B – Type 'B-ST' (1MHz)

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LANGUAGES

Standard Supported Languages:

OUTPUTS

Analog Output:

Resolution: Alarm Currents: Isolation: Maximum Load:

Pulse Output TTL:

Pulse Repetition Rate: Pulse Width:

Max Current:

ELECTRICAL

Supply Voltage:

Input Voltage Range: 9–24Vdc.

Power Consumption: 10.5W.

English, French, German, Italian, Spanish, Portuguese, Russian, Norwegian, Dutch.

4–20mA, 0–20mA, 0–16mA.

0.1% of full scale. Any between 0–26mA. 1400V Opto-isolated. 620 Ohms.

Number Available: One open collector opto-isolated digital output. Up to 400 pulses/sec (depending on pulse width). 400ms for 1 pulse/sec. 5ms for 100 pulses/sec. 150mA.

Battery:

Technology: 5-cell NiMH.

Capacity: 3.8AHr.

Operating time: Typically 20 hours continuous with backlight and 4-20mA output OFF.

Recharge Time: 6.5 Hours.

Service Life: >400 charge/discharge cycles.

Power Supply/Charger:

Manufacturer: ECOPAC Model ECO-181WP12.

Input Voltage Range: 90–264Vac.

Input Frequency Range:

Output Voltage: 12Vdc.

Max. Output Current: 1.5A.

Approvals: UL, CUL, TUV, CB & CE.

47–63Hz.

MECHANICAL

Carrying case:

Rating: All components are contained in a hard-wearing polypropylene carrying case with a protective moulded foam

insert.

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Enclosure:

Material: Flame retardant injection moulded ABS.

Dimensions: 264mm x 168mm x 50mm.

Weight (Including Battery):

Protection: IP54.

Keypad:

No. Keys: 16.

Display:

Format: 240 x 64 pixel graphic display, high contrast black-on-white, with backlight.

Viewing Angle: Min 30°, typically 40°.

2.5lbs (1.1 kg).

ENVIRONMENTAL

Operating Temperature: -4°F to 122°F (–20°C to +50°C).

Storage Temperature: -13°F to 149°F (–25°C to +65°C).

Operating Humidity: 90% RH MAX at 122°F (+50°C).

APPROVALS

Safety: BS EN 61010.

EMC: BS EN 61326 - 1:2006, BS EN 61326-2-3:2006.

Battery Charger: EN61204 - 3.

SHIPPING INFORMATION

Box Dimensions: 16.15” x 8” x 14” (410mm x 205mm x 355mm).

Weight: 16.5lbs (7.5 kg).

Volumetric Weight: 11lbs (5. kg).

Greyline Instruments reserves the right to alter specifications without notice.

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PIPE CHARTS

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Greyline Portaflow PT400 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual