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VPFlowMate User Manual
UK / Europe Office Tel: +44 (0)845 9000 601 Fax: +44 (0)845 9000 602 [email protected] www.omniinstruments.co.uk
Australia / Asia Pacific Office Tel +61 (0)282 442 363 Fax +61 (0)294 751 278 [email protected] www.omniinstruments.com.au
USA / Canada Office Tel +1-866-849-3441 Fax +1-866-628-8055 [email protected] www.omniinstruments.net
Do not continue without reading and under-standing of this message. Not following theinstructions may lead to damage of equipment,personal injury of death.
Important warning message.
Application hint.
v
vi CONTENTS
GENERAL WARNINGS
BY OPERATING THE VPFLOWMATE YOU CONFIRM THAT YOU HAVE READ
AND FULLY UNDERSTOOD THIS USER MANUAL AND YOU HAVE AGREED
WITH OUR WARRANTY STATEMENT.
FOLLOW ALL SAFETY PRECAUTIONS AND WARNINGS! NOT FOLLOWING
THE GUIDELINES COULD RESULT IN PERSONAL INJURY, DEATH AND
/ OR DAMAGE TO THE EQUIPMENT AND IT’S SURROUNDINGS.
NEVER USE THE VPFLOWMATE OUTSIDE THE SPECIFICATIONS AS
IT MIGHT DAMAGE THE INSTRUMENT OR GIVE MISREADINGS. ALWAYS
REFER TO THE SPECIFICATIONS OF YOUR FLOWMETER BEFORE USE!
TOLERANCES: UNLESS SPECIFIED OTHERWISE, ALL INDICATED
DIMENSIONS ARE NOMINAL.
VPINSTRUMENTS TAKES NO LIABILITY FOR ANY DAMAGES OR
MALFUNCTIONING OF THE FLOWMETER CAUSED BY MISUSE. IN ANY
CASE, WARRANTY IS LIMITED TO REPAIR OR REPLACEMENT OF THE
DEFECTIVE PRODUCT.
THE VPFLOWMATE IS NOT APPROVED FOR ANY FISCAL METERING
APPLICATION. CONSULT YOUR NATIONAL OFFICE FOR APPLICABLE
LAWS AND DIRECTIVES.
THE INFORMATION IN THIS MANUAL HAS BEEN REVIEWED AND
IS BELIEVED TO BE CORRECT. NO RESPONSIBILITY IS ASSUMED
FOR ANY INACCURACIES. THE MATERIAL IN THIS MANUAL IS FOR
INFORMATION PURPOSES ONLY AND SUBJECT TO CHANGE WITHOUT
NOTICE
viii CONTENTS
CE Declaration
DECLARATION OF CONFORMITY
Product type : Thermal mass flow
meter
Brand name(s) : VPInstruments,
VPFlowMate
Model numbers : VPF-R..-M..-D..-S...-E..
VPP-R..-M..-D..-S...-E..
Manufacturer : Van Putten
Instruments B.V.
Buitenwatersloot
335
2614 GS Delft
The Netherlands
Year of first
making
: 2001
Date of issue : November 21, 2001
The complete product family has been tested and found
to be compliant with the requirements of the following
European directives:
EN 61326-1EN 50082-1
Van Putten Instruments BV
⋆
Pascal F.A.M. van Putten
Director⋆ No signature has been printed for security reasons; contact us if a
hardcopy is required
UL/ C-UL Listing mark
The VPFlowMate is UL/cUL Listed in accordance with UL 508 (Industrial Con-trol Equipment) and CAN/CSA 14-95 (Industrial Control Equipment), UL FileE231429. Details can be found on the UL website
www.ul.com
Please refer to chapter 3, section 3.2 for UL compliant use of the product.
1
Chapter 1
Getting Started
Thank you for choosing the VPFlowMate digital mass flow meter. The VPFlow-Mate and the VPFlowMate insertion probe are easy to use mass flow meters forCompressed Air.
Check the packaging box for any inconsistencies. Should there be any ship-ping damage, notify the local carrier. At the same time a report should besubmitted to Van Putten Instruments BV, PO BOX 151, 2600 AD DELFT,The Netherlands.
1.1 Principle of operation
The VPFlowMate uses the Thermal Mass Flow principle. The sensor is madeof silicon, just like a computer chip.
Flow induces a temperature gradient in the silicon sensor. This gradient canbe measured with on-chip sensing elements. A heating element keeps the sensorat a constant temperature. Our silicon flow sensors have the following uniquefeatures:
• High dynamic range;
• High sensitivity and resolution;
• High reproducibility and stability over time.
3
Chapter 2
Mechanical Installation
WARNING
VPInstruments TAKES NO LIABILITY FOR ANY DAMAGES OR
MALFUNCTIONING OF THE FLOWMETER CAUSED BY POLLUTION,
DIRT, DUST, WATER, OIL OR ANY OTHER CONTAMINATION OF
THE MEDIUM IN WHICH YOU ARE USING THE FLOWMETER.
DIRT, RUST PARTICLES, SAND, OIL DROPLETS OR DUST MIGHT
DAMAGE THE SENSOR, SO MAKE SURE THAT ALL PIPING AND
THE AIR IS CLEAN!
2.1 Introduction
The VPFlowMate is designed in such a way that it should be very easy for youto install. However, it is important to read all installation instructions, especiallywhen the product is new to you. The VPFlowMate intended for use with cleanair in light industrial environments (non hazardous). Experience with processcontrol equipment, sensors and other transducers is required.
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6 CHAPTER 2. MECHANICAL INSTALLATION
2.2 Applications
WARNING
These devices are only for use with air, nitrogen and
other non hazardous fluids or non combustible gases.
The maximum working pressure is 16 bar g.
Main applications of the VPFlowMate are: Compressed air flow measure-ment, air flow monitoring, metering, energy monitoring, testing of pneumaticsystems. Take a look at our Website www.vpinstruments.com for applicationexamples.
2.3 Installation guidelines
• Refer to the installation drawing or technical drawing for up- and down-stream length guidelines.
• Refer to the user manual and instructions of the Swagelok process con-nectors for instructions.
• Check the PIPING TABLE before installation of the flowmeter!
• Make sure that no Teflon tape is trapped within the tubing!
2.4 Leak testing
Perform a leak test at all times! Leakage can lead to dangerous situations orbad measurements.
Check the system on leaks using leak testing liquid or leak testing equipment.
2.5 Installation of In-line type flow meters
Depending on the in-line model you have, the VPFlowMate requires at least20D straight piping at the inlet and 5D at the outlet.
2.5.1 In-line flow conditioner
Your VPFlowMate can be equipped with built-in flow conditioners. These con-ditioners will reduce the required upstream and downstream length.
2.5. INSTALLATION OF IN-LINE TYPE FLOW METERS 7
2.5.2 Quick couplings
Your VPFlowMate can be equipped with quick couplings for compressed airapplications. Follow the instructions of the quick coupling manufacturer.
2.5.3 Compression fittings
Follow the instructions of the fitting manufacturer.
2.5.4 Flanges
Flanges may be screwed into the threaded openings of the in-line VPFlowMate.Use Teflon tape or use O-ring sealed flanges. NEVER use liquid sealant, becausethey might permanently damage the screw thread!!!!
8 CHAPTER 2. MECHANICAL INSTALLATION
2.6 Installing the VPP insertion probe
The VPFlowMate insertion mass flow meter is designed to operate under a widevariety of conditions. To ensure its longevity of operation, precautions shouldbe taken before and during its installation.
WARNING
INSERTION SENSORS CAN BECOME DANGEROUS
PROJECTILES!
THE IMPROPER USE OF INSERTION PROBES UNDER HIGH
PRESSURES (ANYTHING ABOVE AMBIENT PRESSURE)
IS VERY DANGEROUS. USE A SAFETY CHAIN UNDER
OPERATING CONDITIONS.
PLEASE KEEP CLEAR OF THE METER WHEN THE LINE
IS BEING PRESSURIZED. THIS IS A GOOD SAFETY
PROCEDURE FOR THE INSTALLATION OF ANY EQUIPMENT
IN A PRESSURIZED LINE.
DO NOT LOOSEN THE NUT UNLESS THE LINE IS
DEPRESSURIZED OR A HOT-TAP MECHANISM HAS BEEN
INSTALLED PROPERLY ON THE METER SHAFT.
USE HOT TAPPING EQUIPMENT WHICH IS RATED FOR THE
OPERATING PRESSURE OF YOUR COMPRESSED AIR LINE.
REFER TO THE MANUAL OF THE HOT TAPPING EQUIPMENT
BEFORE USE.
REFER TO YOUR PLANT SAFETY MANUAL FOR ADDITIONAL
SAFETY MEASURES.
Installation is a four step process. This four step approach can be regardedas a checklist for mobile measurements and air audits.
1. Select the proper installation site; follow all piping guidelines;
2. Prepare the installation (mount an insertion point for the Swagelock cou-pling, prepare electrical connections and power supply);
3. Insert and fix VPFlowMate;
2.6. INSTALLING THE VPP INSERTION PROBE 9
4. Configure the VPFlowMate (this step may be done before step 2 if theinstallation site is completely known).
2.6.1 Selecting the installation point
• A) The VPFlowMate insertion flow meter requires minimum upstream anddownstream piping. Refer to the piping table for details!
• B) Choose a site with minimal mechanical vibrations.
• C) Avoid areas of high humidity or corrosive atmosphere where possible.
• D) When installing the meter choose a site which is accessible, and allowsease of wiring and maintenance.
2.6.2 Piping guidelines
To ensure the high accuracy of flow measurement specified on the identificationsheet, piping and installation instructions must be followed carefully.
• A) The pipe immediately up and down stream of the flow meter must beof sufficient length, straight and free of obstructions. Refer to the formerparagraph and to the piping table (figure 2.1);
• B) Weld beads on the internal wall of the pipe before or after the flowmeter should be ground flush with the pipe wall before the meter is in-stalled;
• C) Proper style and proper size gaskets should always be used when in-stalling the flow meter;
• D) The meter can be placed horizontally. When placed in a vertical linewith low air velocities, thermal convection which is caused by the flowsensor may give wrong readings.
Refer also to the ISO 14511:2001 (”Measurement of fluid flow inclosed conduits- Thermal mass flow meters”) International standard.
2.6.3 Other sensors and transducers
Any other transducer should be installed 5 times D downstream the VPFlowMateinsertion flow meter, because they might cause distortion of the flow profile.
10 CHAPTER 2. MECHANICAL INSTALLATION
Fig. 2.1. In the piping table, you can find the requirements for the minimum pipinglength up- and downstream of the flow meter. Note that regulator valves shouldalways be installed downstream the flow sensor!
2.6. INSTALLING THE VPP INSERTION PROBE 11
2.6.4 Determination of the insertion depth
Refer to the technical drawing provided with your VPFlowMate to determinethe insertion depth. The bottom of the measurement head should be in themiddle of the tube.
In de-pressurized lines, the internal diameter depth can be measured usinga caliper. A piece of tubing or a pencil can be used to mark the insertion depthon the probe.
2.6.5 Prepare the installation
Make sure the installation point is made according the technical drawings pro-vided on the VPInstruments Web site! If possible, place a 3
4inch ball valve,
so that the VPFlowMate insertion probe can be retracted and inserted underpressurized conditions.
2.6.6 Sensor fixation
SAFETY FIRST: START WITH MOUNTING THE SAFETY LINE!
The VPFlowMate inserts through a 1/2 inch compression fitting. Watchout with steel compression fittings as they might damage the sensor tube. Ifyou are planning to use the flowmeter at different places, use a Teflon ferruleinstead of the stainless steel ferrule. NEVER over-tight the fitting, because itmay damage the sensor tube.
2.6.7 Sensor alignment
After installing the meter, check for alignment. The flowmeter is shaped in away that alignment is very easy. Alignment ”by the eye” is sufficient.
2.6.8 Insertion depth
Check the insertion depth and make sure the sensor is inserted properly. Thebottom of the probe should be aligned with the middle of the tube. NOTE thatin small tubes, wrong insertion depth can result in large measurement errors,because of the blockage effect.
2.6.9 Software configuration
The VPSuite software can be used to set the pipe diameter and the outputunits. Refer to the VPSuite manual.
Chapter 3
Electrical installation
The VPFlowMate complies with the CE requirements as stated in the ce dec-laration. CE compliance can only be achieved when grounding and shieldingdirections are followed and proper cables and connector assemblies are used.
3.1 Electrical connection guidelines- UL 508 Listing for
USA & Canada
The VPFlowMate is intended to be used with a Class 2 power source or Class2 transformer in accordance with UL1310 or UL1585.
As an alternative a LVLC (Low Voltage Limited Current) power source, withthe following properties shall be used:
• The device shall be used with an suitable isolating source such that themaximum open circuit voltage potential available to the product is notmore than 24 Vdc and the current is limited to a value not exceeding 8amperes measured after 1 minute of operation;
• A fuse in accordance with the UL248 series and rated max 4A shall beInstalled in the 24Vdc power supply to the device in order to limit theavailable current.
WARNING Wrong connections will damage or DESTROY the
instrument. Check ALL wiring diagrams!
14 CHAPTER 3. ELECTRICAL INSTALLATION
3.2 Electrical connection guidelines: general remarks
Make sure that the following conditions are met:
• USE GALVANIC INSULATED POWER SUPPLIES: Switched mode powersupplies might generate a high voltage, high-frequency noise. They alsomight cause ground loops, which could affect the current loop output ofthe flowmeter.
• For portable, non-critical applications, a switched mode 12 V DC, 1Apower adapter may be used.Low cost or poor quality switched mode powersupplies might affect the accuracy!
• PAY EXTRA ATTENTION TOP RS232 PORTS. These are often sourcesof noise and other pollution, since some PC manufacturers do not takeEMC requirements seriously.
• ALWAYS GROUND THE INSTRUMENT HOUSING. GROUND the in-strument, as switched mode power supplies sometimes inject a high volt-age on the metal parts of the flowmeter.
• BEWARE OF GROUND LOOPS. User either one of the proposed groundpoints. Using both ground points might cause ground loop effects.
3.3 IO description
The VPflowMate features the following IO. Please note that the some outputsare optional; refer to the product type number to determine which IO yourVPFlowMate offers.
3.3. IO DESCRIPTION 15
Power supply : 12 to 24 VDC (24V ±10%) Class 2. Seealso appendix B.1.
Serial interface : This is a standard RS232 interface, usingthree wires. Refer to figure ?? for wiringdetails
4..20 mA output : This is a passive, optical isolated linearoutput 4 mA corresponds with zero flow,20 mA corresponds with the maximumflow. See the flowmeter calibration reportfor the maximum flow value. See alsoappendix ?? and ??.
Pulse output : This is a passive, optical isolated low fre-quency pulse output. 0 mA = low and20 mA is high. It can be directly con-nected to pulse based energy counterswith active (12..24 volt powered) inputswhich work according to the DIN43864(S0) standard. Depending on the con-figuration of the flowmeter (see vpfcon-fig software) one pulse is equal to a fixedvolume, for example 1 normal cubic me-ter.
Depending on the model, the following electrical outputs are available. Pleasenote that the connections are based upon colors of the individual leads. Thenumbering of connectors may differ.
16 CHAPTER 3. ELECTRICAL INSTALLATION
A separate leaflet indicating different or special wiring may be issued withthe product!
3.4 Connecting the VPFlowMate to your PC
WARNING: Wrong connection of the power supply may destroy theRS232 input of your laptop! Never apply +12..24 Volt to any of thepins of the SUB D connector!
In order to connect your VPFlowMate to a personal computer, you will need theVPK02 interface kit, or you can use the RS232 connection on the VPFlowTer-minal. From here, a standard RS232 connection cable is used to make theconnection.
3.4.1 Connecting the power supply
Always use a proper power supply. Refer to the specifications to make sure yourpower supply is +12..24 Volt Class 2. Connect the black wire to the 0 Volt sideof your DC power supply. Connect the red wire to +12..24 Volt side of yourpower supply.
3.4.2 Connecting the RS232
In order to connect your VPFlowMate to a personal computer, you will needthe VPK02 interface kit, which splits the cable into RS232 and power supply.Alternativelu, you will use the RS232 connection on the VPFlowTerminal. Astandard RS232 connection cable is used to make the connection.
Chapter 4
Measurement & Data readout
4.1 Power and Warm up time
Before switching on the power check if all connections have been made accordingto figures in chapter 3. Check gas connections again and make sure there is noleakage.
Turn on the power. The instrument will start up and performs a self-calibration. Then it initializes. After this sequence, the instrument is partiallywarmed up. Complete warm-up time depends on the temperature of the sur-roundings and the flowmeter temperature. It may take up to one hour forcomplete warm-up.
4.2 Zero check
The VPFlowMate needs no zeroing as long as you keep the instrument clean.
4.3 Reading the flow value (analog and digital signals)
After warming up the instrument is ready to use. Generally, you can immediatelyread out the flow value. In some circumstances you might want to wait for afew seconds until the flow is stabilized. For instance, when the gas temperatureis changing.
4.4 Reading the flow value (display)
On the built-on display, you can see the flow on the first row. Total gas con-sumption is shown on the second row. The small underscore or minus sign onthe right indicates whether the flow is in ln/minute or m3n/hour. If an asterisk
17
18 CHAPTER 4. MEASUREMENT & DATA READOUT
(*) is shown instead, the output is in m/sec, and the total count (second rowon the display) WILL NOT BE UPDATED.
Generally, you can immediately read out the flow value.In some circumstances you might want to wait for a few seconds until the
flow is stabilized. For instance, when the gas temperature is changing.
4.5 Time constants
Your VPFlowMate has a time constant, which depends on the flow rate. Whengoing from zero flow to a certain flow value, the sensor’s response is a fewseconds, since it is cooled down by the flow.
When you abruptly shut off the flow, it generally takes longer to stabilize,since the sensor has to cool down using thermal conduction to the non-movingair, which is a slower process.
Chapter 5
Software
VPSuite is provided with your flowmeter. A SEPARATE MANUAL is issuedwith the software.
5.1 System requirements
System requirements are:
• PC or Laptop with at least Windows 95;
• Pentium or faster model;
• True color VGA screen, at least 1024x768;
• One free COM port;
• No PDA, modem, cellular phone software or other serial software activeduring measurements, as these might interfere with the COM port.
Install the software according to the instruction manual which can be foundon the CD.
5.2 Purpose
The VPFlowMate software package is designed to ease the installation of in-sertion probes in different tube diameters. It also enables you to change theflowmeter configuration. You can change sample frequency, zero cutoff value,span and so on.
The software also contains a data logger feature, for direct on site measure-ments with your laptop.
19
Chapter 6
Maintenance
6.1 General maintenance
The VPFlowMate is a LOW MAINTENANCE product, as long as it is used inthe right way, with clean gases.
6.2 Cleaning the VPFlowMate
In case of extreme pollution you can clean the flowmeter by gently purging withnitrogen or clean air.
6.3 Calibration
Calibration is performed at VPInstruments.
6.4 Symptoms & causes & solutions
Use the table below to check on basic failures. Contact us if you have any otherproblem not stated in this table.
21
22 CHAPTER 6. MAINTENANCE
Table 6.1. Possible Solutions to common Basic Failures.
Symptom Possible causes Action
No output signals No power supply Check powerBad cable Check cableWrong connections Check wiring diagramGeneral failure Consult factoryWrong installation The flow is too low to be
detected or the flowme-ter is mounted in a wrongway
Wrong output signal Out of calibration Consult factoryExtreme pollution Consult factoryWrong installation Check alignment of
probeCheck up- and down-stream lengthsCheck for obstructions inflow pipe
Offset signal at zero flow Extreme pollution 1. Wipe sensor clean2. Remove any particles3. Gently dry with cleancompressed air or Nitro-gen, or let product dry toAir.
No display or wrong dis-play
TX and RX wire swapped Check wiring
Display shows
O&@*&-
RX Line open Connect RX line (white)to ground
Appendix A
Nomenclature
Table A.1. Nomenclature; x can be any letter/number
VPF -Rxxx -Pxxx -Dx -Sxxx -ExxxI II III IV V VI
Table A.2. Explanation of Nomenclature
I. Basic Type Designation VPP Insertion probeVPF In-line meter
II. Range Rxxx 0..xxx (mn/sec)III. Probe length: Pxxx 0..xxx (Length in mm)
or in-line meter diameter: Mxxx 0..x.xx inch diameter tubeIV. Display options Dx 0 or 1