Greyline Instruments OCF-6.1 Operating Manual

www.greyline.com

USER'S GUIDE

Installation & Operation

Instructions

Open Channel Flow Monitor

Model OCF 6.1

Manual Series A.1.0

Note: This page has been left blank intentionally.

OCF 6.1 Open Channel Flow Monitor

INDEX
CONNECTIONS ................................................................................................	4
KEYPAD SYSTEM............................................................................................	6
CALIBRATION MENU.....................................................................................	7
ICONS.................................................................................................................	8
MAIN DISPLAY................................................................................................	9
MESSAGE ICON...............................................................................................	9
STATUS..............................................................................................................	9
PASSWORD.....................................................................................................	10
UNITS/MODE..................................................................................................	11
CALIBRATION................................................................................................	13
CHANNEL SETUP ..........................................................................................	16
RELAY PARAMETERS..................................................................................	19
DATA LOGGING ............................................................................................	20
SPECIAL FUNCTIONS...................................................................................	22
SENSOR MOUNTING METHODS................................................................	24
ERROR/WARNING MESSAGES...................................................................	29
FIELD TROUBLESHOOTING .......................................................................	30
APPLICATIONS HOTLINE............................................................................	34
PRODUCT RETURN PROCEDURE..............................................................	34
APPENDIX A - OPTIONS...............................................................................	36
MODBUS® COMMUNICATION...................................................................	40
CONVERSION GUIDE ...................................................................................	55
SPECIFICATIONS...........................................................................................	56

IMPORTANT NOTE: This instrument is manufactured and calibrated to meet product specifications. Please read this manual carefully before installation and operation. Any unauthorized repairs or modifications may result in a suspension of the warranty.

Available in Adobe Acrobat pdf format

Page 3

OCF 6.1 Open Channel Flow Monitor

CONNECTIONS:

POWER INPUT: The standard model requires AC power input between 100 to 240 VAC 50/60Hz. No adjustments are necessary for voltages within this range.

Optional DC: 9-32 VDC. Connect to + and - terminals.

Optional Thermostat and Heater modules are available rated for 115 VAC or 230 VAC.

IMPORTANT NOTE: To comply with CSA/UL electrical safety standards, AC power input and relay connection wires must have conduit entry to the instrument enclosure. Installation requires a switch, overcurrent fuse or circuit breaker in the building (in close proximity to the equipment) that is marked as the disconnect switch.

Risk of electric shock. Loosen cover screw to access connections. Only qualified personnel should access connections.

Note: Use of instrumentation over 40°C ambient requires special field wiring.

Page 4

OCF 6.1 Open Channel Flow Monitor

CONNECTIONS
				SENSOR
				CORE	SHLD
				WHT GRN
	SERIAL COMMUNICATION OPTION
				+ G
				RS-485
				Output
	EXTRA RELAYS OPTION
	NC C NO	NC C NO	NC C NO	NC C NO
	RLY3	RLY4	RLY5	RLY6
	AC
	POWER
	INPUT
	L N
4-20mA	–
	+
RLY2	NO	HEATER OPTION
	C
	NC
	NO
RLY1	C
	NC
	AC
	GND

Page 5

OCF 6.1 Open Channel Flow Monitor

KEYPAD SYSTEM

The OCF 6.1 uses a menu system. Arrows show the four directions to leave a menu box. Press a key to move to the next item in the direction shown. Move the cursor (highlighted) under numerals and increase or decrease numerals with the and keys.

To store calibration values permanently (even through power interruptions), press .

Page 6

OCF 6.1 Open Channel Flow Monitor

CALIBRATION MENU

- - Tec h’s Menu- - - - - - -

Di s t = Max	No
Bar r i er	No
St andpi pe	No
Long Pul s e	No
Gai n	115

This menu is accessed by pressing & simultaneously.

- - Uni t s / Mode- - - - - - - -
Mode	Fl ow
Li near	i n
Vol ume	USG
Mul t i pl i er	x 1
Dec i mal s	0
Fl ow	USG/ m
Dec i mal s	2
Temper at ur e	C

- - Cal i br at i on- - - - - - -
Range
Max	3 2. 00 f t
Mi n	1. 00 f t
Mode	Fl ow
20mA	28. 890 L/ s
4mA	18. 878 L/ s
Of f s et	0. 00 f t
LOE Ti me	3 0 s ec
Dampi ng
Mode	FI R
Per c ent	10%
Wi ndow	0. 08 f t
Mi n Fl ow	0. 00 L/ s

- - Mes s ages - - - - - - - - - -

Dat a Log	St opped
Log Us ed	0 %
Sens or	Good
Temper at ur e	21 C

- - 24 hr l	og- - - - - - - - - -							USG/ m
Dat e	J un 22/ 2020						0.000
Max i mum	52. 20	USG/ m
Tot al	5013 8 USG
Av er age	3 4. 82	USG/ m
Max Ti me	11: 08: 00			Tot			2013 0. 8 USG
Mi ni mum	0. 000	USG/ m
				Rel ay s			1	2 3 4 5 6
Mi n Ti me	9: 15: 00
				- - St at us - - - - - - - - - - - -
				Range				1. 00f t
					Lev el			11. 00f t
					Fl ow			0. 00 USG/ m
					Mi n Fl ow			0. 00 USG/ m
					Ec ho Conf i denc e 100 %
					Rel ay s 1 2 3 4 5 6

-*- Pas s wor d- - - - - - - - - -

Pas s wor d

0000

OPTIONAL FEATURES

*Menu only appears if "New Password" has been changed from 0000 in "Special Functions" menu.

- - Menu Sel ec t i ons - - - -

Uni t s / Mode Cal i br at i on

Channel Set up Rel ay Par amet er s

Dat a Loggi ng Communi c at i on

Spec i al Func t i ons Si mul at i on

Conf i gur at i on

- - Channel	Set up- -- - - -
Ty pe	V- not c h
Si z e	22. 5°

- - Rel ay Par amet er s - -
Rel ay			1
Func t i on		Fl ow
On	10000 USG/ m
Of f	8000 USG/ m
LOE mode			Of f
- - Dat a Loggi ng- - - - - - -
Log Si t e I D			00
Mode		Fl ow
Fi l e For mat			. LG2
Dat e	J un 22/ 2020
Ti me		11: 27: 40
I nt er v al		10s ec
Dat a Log		Loggi ng
- - Communi c at i on- -			- - -
Pr ot oc ol		Modbus
Addr es s			001
BPS		9600
Par i t y		Ev en
St op Bi t s			1
- - Spec i al	Func t i ons -
Language		Engl i s h
Anal og Out		4- 20mA
Bac k l i ght			Hi gh
Res et Tot al i z er			NO
Capt ur e Par			NO
Res t or e Def aul t s			NO
New Pas s wor d			0000

- - Si mul at i on- - - - - - - -

Tes t	Ac t ual
Fl ow	250USG/ m
4- 20mA Fl ow	4. 00
Rel ay s 1 2	3 4 5 6

- - Conf i gur at i on- - - - -

Ser i al #

123 45

Ut i l i t y	1. 2 6. 2. 1
Sonar	1. 14. 0
CommBoar d	1. 22. 10
Rel ay s	6
Anal og Out	1

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OCF 6.1 Open Channel Flow Monitor

ICONS

1.		2.		Message waiting. Press .
				Data logging off.
1.		2.		Data logging on.
1.	2.	3.	4.	USB file download.
				File download completed.
				Download Error.
1.	2.		3.	Echo OK.
				Loss of Echo .

Page 8

USG/ m

0.000

Tot	2013 0. 8	USG
Rel ay s	1 2 3 4	5 6

- - Mes s ages - - - - - - - - - -

Dat a Log	St opped
Log Us ed	0 %
Sens or	Good
Temper at ur e	21 C

- - St at us - - - - - - - - - - - -

Range	1. 00f t
Lev el	11	. 00f t
Fl ow	0. 00	USG/ m
Mi n Fl ow	0. 00 USG/ m

Ec ho Conf i denc e 100 % Rel ay s 1 2 3 4 5 6

OCF 6.1 Open Channel Flow Monitor

MAIN DISPLAY

The main display shows the units selected from the Units/Mode menu, Level, Range, Flow, HRT, and Volume rate being measured, TOTALIZER and RELAY states. The OCF 6.1 will start-up with this display.

MESSAGE ICON

Press from the main display to view status of the data logger and error/warning messages provided by the instrument. The Message Icon will appear on the main display if error messages are being generated by the instrument. Refer to the manual section Error/Warning Messages for a description. Press to return to the main display.

STATUS

Press from the main display to view instrument status. Range will be displayed in linear units.

Range	Displays the current range measurement. The distance
	between the sensor face and the surface being measured.
Level	Displays the current level measurement. The difference
	between the Max Range programmed in the Calibration
	menu and the measured range.
Flow	Displays the current flow rate in engineering units set in
	the Units/Mode menu.
Min Flow	Displays the minimum flow rate set in the Calibration
	menu. Flow rates below the Min Flow will be shown as 0
	on the main display.
Echo Confidence	Displays Echo Confidence in percentage. 100% is ideal,
	but any percentage other than 0% is normal and means
	that echoes are being measured. Echo Confidence less
	than 100% means that not all echoes are returning to the
	sensor, which could be because of surface turbulence, a
	sensor not perpendicular to the water surface, foam,
	grease, or vapors in the atmosphere.

Page 9

- - 24 hr l og- - - - - - - - - -

Dat e	J un 22/ 2020
Tot al		5013	8 USG
Av er age	3 4	. 82	USG/ m
Max i mum	52	. 20	USG/ m
Max Ti me		11:	08: 00
Mi ni mum	0. 000		USG/ m
Mi n Ti me		9:	15: 00

OCF 6.1 Open Channel Flow Monitor

24 HR LOG

Press from the main display to view a formatted flow report from instruments with a built-in data logger. Press to scroll down one day or repeatedly to scroll to a specific date. Up to 365 days can be stored. Newest date will overwrite the oldest. Press to return to the main display.

- - Pas s wor d- - - - - - - - - -

Pas s wor d

0000

PASSWORD
The	Password (a number from 0000 to 9999) prevents unauthorized access
to the	Calibration menu.

From the Main display press to get to Password. Factory default password is 0000 and if it has not been changed the meter will directly proceed to the Menu Selections screen.

If a password is required, press to place the cursor under the first digit and or to set the number, then to the second digit, etc. Press orto proceed to the Menu Selections screen.

A new password can be stored by going to Special Functions/New Password.

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- - Uni t s / Mode- - - - - - - -

Mode	Fl ow
Li near	i n
Vol ume	USG
Mul t i pl i er	x 1
Dec i mal s	0
Fl ow	USG/ m
Dec i mal s	2
Temper at ur e	C

OCF 6.1 Open Channel Flow Monitor

UNITS/MODE

At Mode, press the and then the or to select Flow or Velocity. Flow mode displays the flow rate in engineering units (e.g. gpm, litres/sec, etc.) Press the to store your selection then the to the next menu item.

At Linear press the key and then the or to select your units of measurement. The Linear units define what units the pipe/channel dimensions and level reading will be displayed in. Typically inches or mm is selected. Press the to store your selection then the to the next menu item.

At Volume, press the and then the or to select units for volume. Note: “bbl” denotes US oil barrels. Press the to store your selection then the to the next menu item.

At Multiplier, press the and then the or to select the totalizer multiplier. Multipliers are used when resolution down to single digit is not required, or when you don’t want to convert from gallons to thousands of gallons, as an example. Press to store your selection then to the next menu item.

At Decimal (Volume), press the and then the or to select the number of decimal points to be present on the totalizer display on the LCD screen. Default = 0. Options = 0, 1, 2. Press the to store your selection then theto the next menu item.

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- - Uni t s / Mode- - - - - - - -

Mode	Fl ow
Li near	i n
Vol ume	USG
Mul t i pl i er	x 1
Dec i mal s	0
Fl ow	USG/ m
Dec i mal s	2
Temper at ur e	C

OCF 6.1 Open Channel Flow Monitor

UNITS/MODE cont.

At Flow, press the and then the or to select the engineering units for flow rate. Press to store your selection then to the next menu item.

Available Flow Rate Engineering Units:

Abbreviation Description

USG/d	US gallons per day
USG/h	US gallons per hour
USG/m	US gallons per minute
USG/s	US gallons per second
ft3/d	cubic feet per day
ft3/h	cubic feet per hour
ft3/m	cubic feet per minute
ft3/s	cubic feet per second
bbl/d	barrels per day (1 bbl = 42 USG)
bbl/h	barrels per hour (1 bbl = 42 USG)
bbl/m	barrels per minute (1 bbl = 42 USG)
bbl/d	barrels per second (1 bbl = 42 USG)
USMG/d	US million gallons per day
USMG/h	US million gallons per hour
USMG/m	US million gallons per minute
USMG/s	US million gallons per second

Abbreviation	Description
L/d	liters per day
L/h	liters per hour
L/m	liters per minute
L/s	liters per second
m3/d	cubic meters per day
m3/h	cubic meters per hour
m3/m	cubic meters per minute
m3/s	cubic meters per second
IG/d	Imperial gallons per day
IG/d	Imperial gallons per day
IG/d	Imperial gallons per day
IG/d	Imperial gallons per day
IMG/d	Imperial million gallons per day
IMG/h	Imperial million gallons per hour
IMG/m	Imperial million gallons per minute
IMG/s	Imperial million gallons per second

At Decimal (Flow), press the and then the or to select the number of decimal points to be present on the flow rate display on the LCD screen. Default = 2. Options = 0, 1, 2 or 3. Press the to store your selection then the to the next menu item.

At Temperature, press and then or to select engineering units for temperature. Press to store your selection then to go back to the Menu.

Page 12

- - Cal i br at i on- - - - - - -

Range

Max	3 2. 00 f t
Mi n	1. 00 f t
Mode	Fl ow
20mA	28. 890 L/ s
4mA	18. 878 L/ s
Of f s et	0. 00 f t
LOE Ti me	3 0 s ec
Dampi ng
Mode	FI R
Per c ent	10%
Wi ndow	0. 08 f t
Mi n Fl ow	0. 00 L/ s

OCF 6.1 Open Channel Flow Monitor

CALIBRATION

Press to Calibration and to enter. Use or to position before each menu item and to enter. When settings are completed press to store and return to the Calibration menu.

Min Range	Distance from the sensor face to highest expected level.
Max Range	Distance from sensor to Zero level.
MaxVol	For Volume and HRT mode only. Enter the maximum
	volume of the vertical or horizontal tank.
Mode	Shows the Mode set in the Units/Mode menu. Read-only.
20mA	Sets the 20mA output value, in engineering units set in the
	Units/Mode menu.
4mA	Sets the 4mA output value, in engineering units set in the
	Units/Mode menu.
Offset	Sets an Offset value, in engineering units set in the
	Units/Mode menu. This parameter can be used to be a one-
	point adjustment to the Range reading.
LOE Time	Press and or to change the number of seconds
	without receiving an echo before the OCF 6.1 displays ECHO
	LOSS, and Control relays change state as calibrated under
	Relay Parameters.
	Factory default is 30 seconds and is recommended for most
	applications, Minimum is 1 second and maximum is 99
	seconds.

Page 13

- - Cal i br at i on- - - - - - -

Range

Max	3 2. 00 f t
Mi n	1. 00 f t
Mode	Fl ow
20mA	28. 890 L/ s
4mA	18. 878 L/ s
Of f s et	0. 00 f t
LOE Ti me	3 0 s ec
Dampi ng
Mode	FI R
Per c ent	10%
Wi ndow	0. 08 f t
Mi n Fl ow	0. 00 L/ s

OCF 6.1 Open Channel Flow Monitor

CALIBRATION cont.

Damping Choose between OFF, FIR (Default), or LOW PASS.

When measured flows are outside the Window of the running average, the FIR filter will reduce the damping average so that a fast response can be made to the sudden change in flow rate.

The LOW PASS filter will ignore measured flow rates outside the Window, while holding the running average, until there are enough data points outside the Window to cause a step-response to the new measured value.

While measured flows are within the Window of the running average, both the FIR and LOW PASS filter behave the same.

Percent Set the damping value for level reading. Lower values provide fast response to changing levels, and higher values provide a slower response. Factory default value is 10%.

Window The Window sets a boundary around the running average, where if the measured value falls outside the window, the meter will make a more rapid response to the new value (FIR), or will hold the last reading until enough values are outside the window and then make a step response to the new value (LOW PASS).

Press to return to Menu Selections.

Page 14

Max Range

OCF 6.1 Open Channel Flow Monitor

CALIBRATION

- for Open Channel Flow

1. Before starting the calibration determine:

a)MAX RANGE = ____________________

(Maximum range = distance from the Sensor to Zero flow point)

b)MAX LEVEL = ____________________

(Maximum level of flow through flume or weir)

c)MIN RANGE = __________________

(Distance from sensor to Max Level)

Minimum range = MAX RANGE - MAX LEVEL

(must be at least 8" / 20.3 cm depending on sensor model).

2. Check the maximum range with the sensor installed by:

a)	When liquid is at zero level press to view the Range reading in
	the Status menu. Use this range measured by the OCF 6.1 as the
	Max Range setting.
	or

b)Carefully measure distance from sensor to zero level with a tape

measure, and use this measurement as the setting.

NOTE: The OCF 6.1 will not detect targets beyond user entered Max

Range.

Page 15

CHANNEL SETUP

- - Channel	Set up- -- - - -
Ty pe	V- not c h
	Cus t om
	Vent ur i
	Khaf agi
Rec t Wei r		w/ EC
	Rec t	Wei r
	Tr apezoi dal
		RBC
	Mont ana
	Cut t hr oat
	HL Fl ume
	H Fl ume
	HS Fl ume
Leopl d- Lagc o
Pal mer Bowl us
	Par s hal l
- - Channel	Set up- -- - - -
Ty pe	V- not c h
Si z e		22. 5°
		120°
		90°
		60°
		45°
		3 0°

- - Channel Set up- -- - - -

Ty pe	Rec t Wei	r w/ EC
Wi dt h	0	. 000i n

- - Channel	Set up- -- - - -
Ty pe	RBC
Si z e	50mm
	200mm

150mm

100mm

75mm

OCF 6.1 Open Channel Flow Monitor

- - Channel	Set up- -- - - -
Ty pe	Vent ur i
°

- - Channel	Set up- - - -
Ty pe	Rec t Wei r
Wi dt h	0. 000i n

- - Channel	Set up- -- - - -
Ty pe	Mont ana
Si z e	50mm
	200mm

150mm

100mm

75mm

- - Channel	Set up- - - - - -
Ty pe	Khaf agi
Wi dt h	0. 000i n

- - Channel	Set up- -- - - -
Ty pe	Tr apezoi dal
Si z e Ex t r a l ar ge 60°
	Lar ge 60°
	Smal l 60°
12i n 45° SRCRC
	2i n 45° WSC
	8i n 60°
- - Channel	Set up- -- - - -
Ty pe	Cut t hr oat
Si z e	18” x		1”
	108” x 72”
	108” x 48”
	108” x 24”
	108” x 12”
	54” x 24”
	54” x 12”
	54	” x	6”
	54” x		3”
	3 6” x 16”
	3 6	” x	8”
	3 6	” x	4”
	3 6	” x	2”
	18	” x	8”
	18	” x	4”
	18	” x	2”

Page 16

OCF 6.1 Open Channel Flow Monitor

CHANNEL SETUP cont.

- - Channel	Set up- -- - - -		- - Channel		Set up- -- - - -				- - Channel	Set up- -- - - -
Ty pe	HL Fl ume		Ty pe		H Fl ume				Ty pe	HS Fl ume
Si z e	3 . 0f t		Si z e		0. 5f t				Si z e	0. 4f t
	4. 0f t				4. 5f t					1. 0f t
					3 . 0f t					0. 8f t
					2	. 5f t				0. 6f t
					2	. 0f t				0. 4f t
					1	. 5f t
					1	. 0f t
					0. 75f t
- - Channel	Set up- -- - - -		- - Channel		Set up- -- - - -				- - Channel	Set up- -- - - -
Ty pe	Leopl d- Lagc o		Ty pe	Pal mer Bowl us					Ty pe	Par s hal l
Si z e	3 6i n		Si z e			48i n			Si z e	12f t
	3 0i n					42i	n			10f t
	24i n					3 6i n				8f	t
	18i n					3 0i n				6f	t
	12i n					27i	n			5f	t
	10i n					24i	n			4f	t
	8i n					21i	n			3 f	t
	6i n					18i	n			2f	t
						15i	n			18i n
						12i	n			12i n
						10i	n			9i	n
						8i n				6i	n
						6i n				3 i	n
						4i n				2i	n
										1i	n

Page 17

OCF 6.1 Open Channel Flow Monitor

CHANNEL SETUP cont.

CHANNEL SETUP

Type	Custom. Used to configure the OCF for a flume/weir
	type not already selectable in the meter.
K & n	Format: Flow = K * H^n; Where H = head
	Use the Greyline Find K&n software (included on Flash
	drive shipped with meter) to determine the K&n values
	to use. The K&n software requires that you enter up to
	10 head points and the corresponding flow rates for
	each point. A curve fit is performed, and the software
	provides the K and n values to program into the meter.
	You can also contact a Greyline technician for these
	values.

IMPORTANT: The OCF requires that the K & n coefficients are from a flow equation where flow is in units of CFS, and head in units of feet. If you determined a K & n coefficient outside the use of the Greyline Find K&n software, be sure that the coefficients are in these units, otherwise you will need to convert them before entering them in the meter. The Units/Mode settings in the meter can be configured to whatever units you desire for flow rate and total. The meter will automatically convert the K&n in CFS to the programmed units in the Units/Mode menu for the flow rate and totalizer display.

IMPORTANT: If you are uncertain about how to convert your K and n constants please contact our technical support team and we’ll be happy to assist.

Example: For a 2 foot Parshall flume, the discharge equation for a flow rate in GPM, and head in feet, is GPM = 3590 * H^1.55. Since head is already in feet, we only need to convert GPM to CFS. 1 CFS = 448.8 GPM, so dividing by 448.8 give us CFS = 8.0 * H^1.55. This is the equation we would enter into the OCF 6.1 for this flume.

Page 18