Micronics portaflow 220, PORTAFLOW 330 User Manual

PORTAFLOW 220

Portable Ultrasonic Flowmeter

User Manual

Micronics Ltd, Knaves Beech Business Centre, Davies Way, Loudwater,

High Wycombe, Bucks HP10 9QR.

Telephone: [phone] Facsimilie: [phone] E-mail: [e-mail]

www.micronicsflowmeters.com

Portaflow 220 User Manual i

(Issue 1.0)

Table of Contents

1: General Description 1

1.1 Introduction 1

1.2 Principles of Operation 2

1.3 Supplied Hardware 3

1.4 Portaflow 220 Instrument 4

1.4.1 Connectors 4

1.4.2 Keypad 5

1.4.3 Power supply and battery charging 6

1.5 Transducers 6

2: Installation 7

2.1 Transducer Positioning 7

2.2 Transducer Attachment 8

2.2.1 Preparation 8

2.2.2 Attaching the guide rails 8

2.2.3 Fitting the transducers 9

3: Operating Procedures 11

3.1 Setting-up the Instrument 12

3.1.1 Using the instrument for the first time 12

3.1.2 Enabling/disabling the backlight 13

3.2 Using the Quick Start Menu 13

3.3 Using the System at a Regularly Monitored Location 16

3.4 Managing Named Sites 17

3.4.1 Setting up a new site 18

3.4.2 Changing a site name 18

3.5 Instrument Calibration 19

3.5.1 Adjusting the zero cut-off 19

3.5.2 Adjusting the set zero flow offset 19

3.5.3 Adjusting the calibration factor 20

3.5.4 Adjusting the roughness factor 20

3.5.5 Adjusting the damping factor 21

3.6 Performing Monitoring Functions 22

3.6.1 How to measure totalised flows (manually) 22

3.7 Configuring the Portaflow 220 Interfaces 23

3.7.1 How to turn the 4-20mA output OFF/ON 23

3.7.2 4-20mA signal calibration and ranging 23

3.7.3 How to convert the measured current to flow rate 24

3.7.4 How to turn the pulse output OFF/ON 25

3.7.5 Pulse output signal calibration 25

:

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4: Maintenance & Repair 27

5: Troubleshooting 29

5.1 Overview 29

5.2 General Troubleshooting Procedure 30

5.3 Warning & Status Messages 31

5.4 Test Block 33

5.5 Microprocessor Reset Facility 34

5.6 Diagnostics Display 34

Appendix A: Specification 35

Portaflow 220 User Manual 1

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1: General Description

1.1 Introduction

This manual describes the operation of the Micronics Portaflow 220 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 220 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 1000mm (depending on model) and constructed of almost any material. The instrument will also
operate over a wide range of fluid temperatures.

The Portaflow 220 series comprises two models which are identical in operation but designed to be used with
a different range of pipe diameters. The PF220A can be used with pipes in the range 13mm – 115mm and
the PF220B with pipes in the range 50mm – 1000mm.

Easy to operate, the Portaflow 220 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 220 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 waves to travel the same distance but in
opposite directions is therefore directly proportional to the flow velocity of the liquid.

The Portaflow 220 system employs two ultrasonic transducers attached to the pipe carrying the liquid 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 transducer set in use. The diagram below illustrates the importance of applying the correct separation
distance between the transducers to obtain the strongest signal.

Figure 1.1 Operating modes

Fluid flow

Fluid flow

Fluid flow

Fluid flow

Fluid flow

U

U

U

U

D

D

D

D

Separation

Distance

Separation

Distance

Separation

Distance

Separation

Distance

Reflex mode

Reflex mode (double bounce)

Reflex mode (triple bounce)

Diagonal 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 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.

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.

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.

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.

Upstream

transducer

1: General Description

Portaflow 220 User Manual 3

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1.3 Supplied Hardware

The Portaflow equipment is supplied in a rugged polypropylene carrying case fitted with a foam insert to give
added protection for transportation. The supplied components are shown in Figure 1.2.

Figure 1.2 Standard Portaflow equipment

Standard equipment

• Portaflow 220 instrument with backlit graphic display.

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

• 4-20mA/Pulse Output cable, USB cable and RS232-C cable.

• 2 lengths of chain.

• Test block.

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

• Transducer set (x2) – type ‘A’ or type ‘B’ depending on model.

• Set of guide rails used for mounting the transducers.

• Ruled separation bar (2-piece).

• Ultrasonic couplant with syringe dispenser used when mounting the transducers.

• Manual (on CD).

4-20mA/

Test Block

Power Supply

Pulse Output

Cable

Transducer Cables (x2)

Chains (x2)

Guide Rails (x2)

Transducers
(Sensors x2)

Ultrasonic

Ruled Separation bar

Portaflow 220 Instrument

Couplant

(Batt. Charger)

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1.4 Portaflow 220 Instrument

The Portaflow 220 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 building
management or site monitoring systems, can be calibrated to suit a particular flow range.

1.4.1 Connectors

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

. A single cable that can be adapted for use for either of these output
functions is included in the Portaflow 220 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

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.

Keypad

LCD Display

Battery Charger

4-20mA / Pulse Output Transducer Cables

Reset pin-hole

1: General Description

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Figure 1.4 Keypad

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 220 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.

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 beyond the bottom visible item.
Menus generally ‘loop around’ if you scroll beyond the first or last items.

If you select Exit on any menu it usually takes you back up 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. Some of the features accessed by these keys are restricted in the Portaflow 220
model range.

ON/OFF

Scroll UP

ENTER

Scroll DOWN

Numerical keypad

Scroll LEFT

Scroll RIGHT

with dual function keys

(SELECT)

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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 supply 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 will reduce the available battery operating time to around 8hrs. Similarly, if
the 4-20mA 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 battery can be charged both while the instrument is in use or when switched off. The instrument’s
internal data is stored in non-volatile memory and will not be lost even if the battery discharges completely.

1.5 Transducers

Different transducer sets are provided with the PF220A and PF220B Portaflow models and are not
interchangeable.

Transducer set 'A'

Supplied as standard on PF220A for use on pipes 13mm to 115mm outside diameter.

Transducer set 'B'

Supplied as standard PF220B for use on pipes 50mm to 1000mm outside diameter.

Key Point: The battery is not a user-changeable item. The instrument must be
returned to your distributor 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.

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

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2: Installation

2.1 Transducer Positioning

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 the 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.

Flow

Valid transducer location

10 x Diameter 20 x Diameter

45°

The Portaflow equipment expects a uniform flow profile as a
distorted flow will produce unpredictable measurement
errors. Flow profile 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
cause of distortion such that it no longer has an effect.

Uniform Flow Profile Distorted Flow Profile

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
possibly sludge in the bottom of the pipe. Experience
has shown that the most consistently accurate results
are achieved when the transducer guide rails are
mounted at 45° with respect to the top of the pipe.

Possible
sludge

Air

Flow

Guide
rail

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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 otherwise the resulting accuracy of the flow readings 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

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 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 separa ti o n di stance (obtained from the Portaflow instrument) on the ruler
(F), then secure it in place by tightening the thumbscrew.

A

B

C

D
E

F

G

A: Tensioning thumb-wheel.
B: Tension bar.
C: Separation bar securing

screw.

D: Separation bar.
E: Ruler scale (0).
F: Set Separation distance.
G: Securing chain.

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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

(G) around the pipe 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 Fitting the transducers

Figure 2.3 Fitting 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 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 ar e 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.

A: Transducer cover plate.

B: Transducer locating slot/lug.

C: Transducer cover plate securing screw.

D: Transducer cable connection.

E: Ultrasonic

couplant

application.

G: Chain.

2: Installation

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