Greyline Instruments PT400 Operating Manual
USER’S GUIDE
Installation & Operation
Instructions
Portaflow
Model PT400
Manual Series A.2
Note: This page has been left blank intentionally
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PORTAFLOW PT400
Portable Ultrasonic Flowmeter
User’s Guide
www.greyline.com
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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 ............................................................................................... 42
5.9 Warranty .......................................................................................................................... 43
6: Appendix A Specifications ...................................................................................................... 44
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1: General Description
1.1 Introduction
This manual describes 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 insert any mechanical parts through the pipe wall or protrude into the flow system.
Using ultrasonic transit time techniques, the Portaflow PT400 is controlled by a micro-processor system which
contains a wide range of data that enables it to be used with pipes with an outside diameter ranging from 13mm
up to 4000mm and constructed of almost any material. The instrument will also operate over a wide range of fluid
temperatures.
Easy to operate, the Portaflow PT400 standard features are:
• Large, easy to read graphic display with backlighting
• Simple to follow dual function keypad
• Simple ‘Quick Start’ set up procedure
• Continuous signal monitoring
• Pulse output
• 4-20mA, 0-20mA or 0-16mA output
• Rechargeable battery
• Battery management
• Diagnostics
Volumetric flow rates 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 per second.
When operating in the ‘Flow Reading’ mode the total volumes, both positive and negative, are displayed up to a
maximum 12-digit number.
The flowmeter can be used to measure clean liquids or oils that have less than 3% by volume of particulate
content. Cloudy liquids such as river water and effluent can be measured along with cleaner liquids such as
demineralised water.
Typical Portaflow PT400 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 slightly if it is transmitted in the same direction as the liquid flow and decelerated slightly if transmitted
against it. The difference in time 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 Portaflow PT400 system employs two ultrasonic transducers attached to the pipe carrying the liqu id and
compares the time taken to transmit an ultrasound signal in each direction. If the sound characteristics of the fluid
are known, the Portaflow microprocessor can use the 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 Portaflow system can be set up to operate in one of four modes determined mainly by the pipe diameter and
the type of transducer set in use. The diagram below illustrates the importance of applying the correct separation
distance between the transducers to obtain the strongest signal.
Upstream
transducer
U
Fluid flow
Fluid flow
Fluid flow
U
Fluid flow
U
Separation
Distance
Separation
Distance
Separation
Distance
Reflex mode
D
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 them are 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)
D
D
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.
U
Fluid flow
Separation
Distance
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.
D
Figure 1.1 Operating modes
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1.3 Supplied Hardware
The Portaflow equipment is supplied in a rugged plastic carrying case fitted with a foam insert to give added
protection for transportation. The supplied components are shown in Figure 1.2.
T ransducer Cables
Chains (x2)
Ultrasonic
Couplant
Guide Rails (x2)
T ransducers
(Sensors x2)
Ruled Separati on bar
Test Block
4-20mA/
Pulse Output
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
•
Transducer set 'A' (Transducers x2)
or
•
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 Portaflow PT400 is a microprocessor controlled 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.
4-20mA / Pulse Output
1.4.1 Connectors
Transducer Cables
Reset pi n-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 should always 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 green 7-pin connector on the top of the flowmeter,
as shown in Figure 1.3
in the Portaflow PT400 kit. The ‘tails’ on the free end of 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 (not in present use)
Blue – Set Point return (not in present use)
Thick Black – Cable screen
. A single cable that can be adapted for use for either of these output functions is included
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Battery charger connection
The supplied battery charger is connected to the instrument by means of the grey 2-pin connector on the bottom
of the unit, as shown in Figure 1.3
Note: The above connectors have different key-ways to prevent incorrect cable connection.
.
Numerical keypad
with dual func tion 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 LCD showing the instrument’s serial number and software revision. Once this appears, the instrument can be
started by pressing the ENTER key once – the initialization screen is then replaced by a MAIN MENU which
provides access to the remaining functions.
Menus and the menu selection keys
The Portaflow PT400 menus are arranged hierarchally with the MAIN MENU being at the top level. Menu
navigation is achieved by three keys on the right hand side of the keypad which 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
(SELE CT)
Scroll DOWN
Scroll LEFT Scroll RIGHT
Figure 1.4 Keypad
Some menus have more options than can be shown on 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 ‘loop around’ 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 some cases it may go
directly to the ‘Flow Reading’ screen.
Some screens require you to move the cursor left and right along the display as 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 keypad in 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.
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1.4.3 Power supply and battery charging
Operating power is provided by an internal battery that can be charged from the utility supp ly using the supplied
external charger. When you first receive the unit you must put the battery on charge for a minimum of 6.5hrs
before use. A fully charged battery 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. Similarl y, if the 420mA output is used constantly at 20mA, the battery life would reduce by 20%. 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 on the LCD screen. 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 batter y 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 transducer sets are provided with the PF400A and PF400B Portaflow models and are not
interchangeable.
Key Point: Always use the transducers that were supplied with the instrument.
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.
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2: Installation
2.1 Transducer Positioning
In many applications an even flow velocity profile over
a full 360° is unattainable due, for example, to the
presence of air turbulence at the top of the flow and
poss ib ly sludge in the bottom of the pi pe. Experience
has shown that the most con s is t entl y accurate results
are achieved when the transducer guide rails are
mounted at 45° with respect to the top of the pipe.
Air
Guide
rail
45°
Possible
sludge
Flow
The Portaflow equipment expects a u n iform flow pr ofile as a
distorted flow will produce unpredictable measurement
error s. Flow pro fi le distortions can result from upstream
disturbances such as bends, tees, valves, pumps and other
similar obs tru ct io ns. To ensure a unifo r m profile the
transducers must be mounted far enough away from any
cause of distortion such that it no longer has an effect.
Uniform Flow Profile Distorted Flow Profile
20 x Diameter10 x Diameter Valid transducer location
Flow
Figure 2.1 Locating the transducers
To obtain the 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 important also that the liquid flows uniformly within th e
length of pipe being monitored and that the flow profile is not distorted by any upstream or downstream
obstructions. This is best achieved by ensuring there is a straight length of pipe upstream of the transducers of at
least 20 times the pipe 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, but when 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 connected together 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 distance before 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
requirements shown in Figure 2.1
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
otherwise the resulting accuracy of the flow readings may be affected.
A
B
C
D
E
F
G
A: Tensioning thumb-wheel.
B: Tension bar.
C: Separation bar securing
screw.
Figure 2.2 Guide rail attachment
D: Separation bar.
E: Ruler scale (0).
F: Set Separ ation distance.
G: Securing chain.
1. Slide the separation bar (D) into the front of the left hand guide rail, align the front edge of the guide rail with
‘0’ on the ruler scale (E) and secure it in place by tightening the thumbscrew (C).
2. Slide the other end of the separation bar into the front of 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 it in 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 the pipe (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 rail assembly 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 cover plate securing screw.
B: Transducer locating slot/lug.
D: Transducer cable connection.
A: Transducer cover plate.
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 all traces of 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 the guide 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) finger tight
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 for the second transducer.
7. Connect the transducers to the Portaflow instrument using the coaxial cables provided. The RED cable must
be connected to the upstream transducer and the BLUE cable to the downstream transducer.
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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 –
How to adjust the Roughness Factor –
How to adjust the Damping Factor –
Paragraph 3.5.3
Paragraph 3.5.4
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 –
How to set up basic (manual) logging –
How to set up auto-timed logging –
How to set up logging ‘live’ to a PC –
How to download saved data to a PC –
How to print data –
Paragraph 3.8
Paragraph 3.6.1
Paragraph 3.6.3
Paragraph 3.6.2
Paragraph 3.6.4
Paragraph 3.6.5
RS232 set-up – Paragraph 3.7.1
USB set-up –
4-20mA ON/OFF –
4-20mA Calibration –
Pulse ON/OFF –
Pulse calibration –
Paragraph 3.7.2
Paragraph 3.7.3
Paragraph 3.7.4
Paragraph 3.7.6
Paragraph 3.7.7
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