Compressed Air Alliance FLF User manual

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User Manual
Flow Meter –
Thermal Mass (Inline)
Model: FLF

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Flow Meter - Thermal Mass (Inline Style) User Manual v1.1
Table of Contents
Notices...........................................................................................................................................3
Warnings .......................................................................................................................................3
About Flow Meters .......................................................................................................................5
Specifications................................................................................................................................6
Flow Meter Pack ...........................................................................................................................8
Installation Overview ...................................................................................................................9
Installation –Mechanical...........................................................................................................10
Installation –Electrical ...............................................................................................................16
Using the Display........................................................................................................................18
Setting Up the Flow Meter.........................................................................................................20
Data Logging...............................................................................................................................28
Screen Shot.................................................................................................................................30
Warranty......................................................................................................................................31
Calibration...................................................................................................................................31
Trouble Shooting........................................................................................................................32

Flow Meter - Thermal Mass (Inline Style) User Manual v1.1
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Notices
Please read this manual in full and
carefully observe the notes and
instructions before and during
installation, operation and maintenance.
The manufacturer cannot be held liable
for any damage which occurs as a result
of noncompliance with this manual.
Do not tamper with device. Should the
device be tampered with in any manner
other than a procedure which is
described and specified in this manual,
the warranty is cancelled and the
manufacturer is exempt from liability.
The product is designed exclusively
for the described application. Use of
this product in conditions not specified
in this manual or, contrary to the
instructions provided by the
manufacturer, is considered improper
handling of the product and will void
your warranty. The manufacturer will
not be held liable for any damages
resulting from improper use of the
product.
This manual should be read carefully by
relevant personnel and the end user.
This manual should be kept with the
product and be made available as
needed. Once you install or use the
product, you accept that you have
read, understood and complied with
this manual.
Compressed Air Alliance endeavours to
make the content of this manual correct,
but is not responsible for omissions or
errors and the consequences caused. In
case of any doubts or questions
regarding this manual or the product,
please contact Compressed Air Alliance.
Warnings
Ignoring the warnings can lead to
serious injury and/or cause damage!
When handling, operating or carrying
out maintenance on this product,
personnel must employ safe working
practices and observe all local health &
safety requirements and regulations.
Improper operation or maintenance of
this product could be dangerous and
result in an accident causing damage to
machinery or injury or death.
The manufacturer cannot anticipate
every possible circumstance which may
represent a potential hazard. The
warnings in this manual cover the most
common potential hazards and are
therefore not all-inclusive. If the user
employs an operating procedure, an
item of equipment or a method of
working which is not specifically
recommended by the manufacturer they
must ensure that the product will not be
damaged or made unsafe and that there
is no risk to persons or property.
NEVER CHANGE ORIGINAL
COMPONENTS WITH ALTERNATIVES.

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Compressed Air
Safety
Any contact with quickly escaping air
or bursting parts of the compressed
air system can lead to serious injuries
or even death.
•Do not exceed the maximum
permitted pressure.
•Only use pressure rated
installation materials and parts.
•Avoid getting hit by escaping air
or bursting parts.
•The system must be pressure-less
during maintenance work.
Electrical Safety
Any contact with energised parts of
the product, may lead to an electrical
shock which can lead to serious
injuries or even death. The user shall
take all measures necessary to protect
against electrical shock.
Consider all regulations for electrical
installations.
The system must be disconnected
from any power supply during
maintenance work.
Any electrical work on the system is
only allowed by authorised qualified
personal.
Storage and transportation
•Make sure that the transportation
temperature of the sensor is
between -10°C to 60°C (14°F to
140°F).
•Please make sure that the storage
temperature of the sensor is
between -10°C to 50°C (14°F to
122°F) and the humidity is <90%,
no condensation. Avoid direct UV
and solar radiation during
storage.
Cleaning
If you need to clean the sensor it is
recommended to use a clean, dry
cloth. For stubborn marks, use
distilled water or isopropyl alcohol
only.
Please note: contamination on the
sensor tip will affect calibration and
accuracy of the sensor. Removal of the
contamination may not fix the issue.
Disposal
Electronic devices are recyclable
material and do not belong in the
household waste. The product,
accessories and its packing material
must be disposed according to local
statutory requirements.

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About Flow Meters
Flow meters are very popular for
measuring compressed air and gas
systems. They can provide real time
information to help keep your system
under control and highlight any
unusual activity.
Benefits of monitoring flow include:
•Improve system efficiency
•Reduce system maintenance
•Reduce operating and energy
costs
•Increase system understanding
and operation
•Identify changes in system
performance
•Identify non-productive air
demand and leakage
•Identify peak and average
demand
Types of Flow Meters
There are a variety of flow meter
technologies including thermal mass,
pitot tube, vortex and venturi. In
compressed air and gas systems it is
important to avoid creating pressure
drops or restrictions that will decrease
system performance and increase
operating costs. Examples of flow
meters that cause pressure drops are
differential pressure plate, vortex and
venturi meters.
Thermal Mass Flow Meters
Thermal Mass flow sensors are
perfectly suited for measuring clean,
dry compressed air and inert gas
systems, where accuracy on smaller
pipe sizing is important. The
streamlined sensor tip is designed to
ensure minimal impact on gas flow
while maintaining accuracy over a
wide flow range.
Compressed Air Alliance’s thermal
mass flow meter measures standard
flow, mass flow, consumption and
temperature. It has full digital signal
processing instead of traditional
analog bridge design, making the flow
meter more accurate and able to
measure across a wider range.
Thermal mass flow meters are widely
used in industrial processes, chemical,
petrochemical, power engineering,
etc. They are suitable for temporary or
permanent installations.
Our thermal mass flow meters are
available as insertion style or inline
style.
•insertion type sensors which are
easy to install under pressure
through a 1/2″ ball valve.
•inline type sensors are more
suited to permanent installations
or where shutting down the
system to calibrate the sensor is
not a potential issue.

Flow Meter - Thermal Mass (Inline Style) User Manual v1.1
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Specifications
Thermal Mass Flow Meter - Inline
Technology
Thermal mass, Inline design
Dryer Type
Air, Argon, Carbon Dioxide, Helium, Hydrogen, Natural Gas,
Nitrogen, Nitrous Oxide, Oxygen
Gases
Clean and dry gas
Accuracy
±(1% reading + 0.3% full scale)
Accuracy is affected by the installation location, on-site conditions and
contaminants such as oil, high humidity or other impurities.
Measurement Ranges
Flow Measurement
0.1 to 120 Nm/sec
0.3 to 394 ft/sec
Pressure Measurement
0 to 16 bar (232 psi) or 0 to 40 bar (600 psi)
Gas Temperature
Measurement
-40°C to +150°C
40°F to +302°F
Outputs
Output
Analog: 4 to 20mA (4-wire, Isolated) / Pulse output
Digital: RS485 Modbus / RTU
Output Signals
Flow, mass flow, consumption, pressure and temperature
Power
Power Supply
18 to 30V / 5W@24V
Electrical Connection
2 x 5 pin M12, female
EMC
According to IEC 61326-1
Display & Data Logger
Display
2.8” LCD with touch panel
Data Logger
10,000,000 samples
Sampling Rate
> 10 samples / second
Other Information

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Thermal Mass Flow Meter - Inline
Bi-directional
No
Pipe Size
DN15 to DN80
Process Connection
R thread
Ambient Temperature
-30°C to +70°C
-22°F to +172°F
Installation Type
Permanent or temporary installation
Calibration Frequency
Every 2 years provided the sensor is not exposed to relative
humidity above 85%
Warranty Period
12 Months
Reference Conditions
20°C, 1bar(a), ISO1217 (Programmable)
Flow Range
Pipe Size
Flow Range (Nm3/h)
Flow Range (cfm)
DN
ID (mm)
Min Flow
Max Flow
Min Flow
Max Flow
15
15
0.06
76
0.04
45
20
20
0.1
135
0.06
79
25
25
0.2
212
0.12
125
32
32
0.3
347
0.18
204
40
40
0.5
542
0.29
319
50
50
0.7
848
0.41
499
65
65
1.2
1,433
0.71
843
80
80
1.8
2,171
1.06
1,277

Flow Meter - Thermal Mass (Inline Style) User Manual v1.1
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Flow Meter Pack
Each flow meter pack comes with:
✓1 x Thermal Mass Flow Meter –Inline style, configured for your gas type and
pressure range
Optional Accessories
The following accessories are available for the flow meter. Talk to your local dealer or
Compressed Air Alliance or pricing.
Inline style Flow Meter
Instruction manual
Available on the Compressed Air
Alliance website:
www.compressedairalliance.com/
products
CALMS –Cloud-based Data
Acquisition and Analysis software
Data Cables

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Installation Overview
Step 1 –Find a suitable section of pipe
•The sensor must be installed vertically or horizontally, in clean, dry gas
•The sensor must be installed away from bends, edges, seams, changes in
pipe size and other obstructions
•Do NOT install the sensor in wet gas
Step 2 –Cut pipe to suit flow meter pipe section and install pipe unions
Step 3 –Fit flow meter
Step 4 –Wire the sensor (see ‘Installation –Electrical’)
Step 5 –Set sensor settings:
•Unit of Measurement
•Communication settings (RS485 or Analog)
•Optional –Confirm other sensor settings
Step 6 (optional) –Connect the sensor to your SCADA or energy management
system
Step 7 –Fill out the Commissioning Report (last page of this manual)

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Installation –Mechanical
WARNING! Incorrect installation can damage the sensor or cause it to work
incorrectly.
Notes
•Before installing the sensor, make sure it is rated for your system (refer to
the “Specifications” section).
oUse of the product outside specified ranges or operating parameters can
lead to malfunctions and may damage the product or system.
•Do not use this product in explosive areas.
•Close attention should be paid to the installation location and contamination
levels to ensure accuracy is maintained.
•The flow meter is not bidirectional. When installing and using the flow meter,
please pay attention to the direction of air flow and the alignment of the sensor.
The direction is indicated on the housing.
•Avoid condensation on the sensor element as this will affect the accuracy
enormously.
•The sensor is for indoor use only. If installed in an outdoor installation, the
sensor must be protected from sun and rain.
•Only use pressure rated materials and parts when installing and maintaining
the product.
•Do not disassemble the product.
•Please observe local and national regulations before/during installation and
operation.
•The product must be installed properly and calibrated regularly, otherwise it
may lead to inaccurate measurements.

Flow Meter - Thermal Mass (Inline Style) User Manual v1.1
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✓
✓
✓
Sensor installed
at 90° to the pipe
Step 1 –Find a suitable section of pipe
The sensor must be installed:
✓Vertically or horizontally,
✓away from bends, edges, seams, changes in pipe size and other obstructions,
✓dry gas (gas humidity should be less than 80% relative humidity (RH)).
✓in clean gas (the sensor should be installed after filters and dryers)
Make sure the insertion location has enough room around the pipe to install the
sensor.
Correct Installation
Incorrect Installation
Do NOT install the sensor before a dryer or in gases with a relative humidity above
80%.
Do NOT install the sensor upside down.

Sensor installed
in wet gases

Sensor installed
upside down

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Choose insertion location, away from obstacles
To achieve and maintain the accuracy stated in the technical data, the sensor must
be inserted away from bends, edges, seams, curve, changes in pipe size, control
valves, etc.
For best results, choose a long, absolutely straight, section of pipe that is free of
obstructions.
Pipe obstructions (eg bends, edges, seams, curves, changes in pipe size, control
valves, etc) change the velocity of compressed air / gasses and/or create turbulence
near the obstruction. Placing the sensor too close to the obstruction will result in
inaccurate readings.
Notes
•Pay careful attention to the distance between the sensor’s inlet and outlet
sections and points of turbulence (eg bends, valves, etc). Make sure that the
insertion location has enough straight pipe on either side of the sensor, as
shown in the diagrams on the next page.
•Obstructions can cause counter-flow turbulence as well as turbulence in the
direction of the flow.
•Do not increase or decrease the pipe diameter immediately before or after the
flow meter pipe section.

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Correct Installation
The diagrams below shows the minimum distances (in multiples of pipe diameters
(DNs)) that the sensor must be installed away from bends, changes in pipe size and
other obstructions.
✓
✓
✓
✓
✓
✓
DN = Pipe Diameter

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Examples
•To install a flow meter near 2 x 90°
bends, you need at least 30 DN of space
(25 DN on the inlet side + 5 DN on the
outlet side, see diagram on previous
page)
•Only 20 DN is available.
•Therefore the sensor should not be
installed in this location

Available Space
•To install a flow meter near a
control valve or pressure regulator,
you need at least 55 DN (50 DN on
inlet side and 5 DN on outlet side,
see diagram on previous page)
•This section of pipe has 65 DN on
the inlet side and 5 DN on the
outlet side
•Therefore the sensor can be
installed in this location
Available Space
70 x DN
65 x DN
✓
A flow sensor will be installed on a section of pipe,
just after a bend (as shown in the diagram on the
left). The pipe has a DN of 50 (ie, it’s a 2 inch or 50
mm pipe).
Therefore the sensor must be installed:
•
Inlet side: 20 x DN from the bend
= 20 x 2” = 40” or
= 20 x 50mm = 1,000mm = 1 meter
•Outlet side: 5 x DN from any other obstruction
= 5 x 2” = 10” or
= 5 x 50mm = 250mm
Minimum spacing on
inlet and outlet sides
for DN 50
1 meter
or 40”
250 mm
or 10”

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Step 2 - Cut pipe and install pipe unions
This step will depend on the pipe material and available fittings. Match the thread of
the pipe to the flow meter and install pipe unions on both ends.
Do not increase or decrease the pipe diameter immediately before or after the flow
meter pipe section.
Step 3 –Fit Flow meter
The flow meter is not bidirectional. When installing and
using the flow meter, please pay attention to the direction
of air flow and the alignment of the sensor.
The direction is flow is marked by 4 green arrows on the
back of the sensor and underneath the sensor.
Correct Installation
The sensor is aligned in the same direction as the gas flow.
Direction of gas flow
Inlet side
(longer section of pipe)
Outlet side
(shorter section of pipe)
Direction of gas flow

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Installation –Electrical
WARNING! Incorrect wiring can damage the sensor or cause it to work
incorrectly.
Notes:
•Do not screw the M12 connector using force, otherwise it may damage the
connection pins.
•Always check the M12 connectors to make sure they are wired correctly.
•Consider all local and national safety requirements and regulations for electrical
installations.
•The system must be disconnected from any power supply during
installation and maintenance work.
•Any electrical work on the system is only allowed by authorised and qualified
personal.
The flow sensor has two x 5 pin M12 connector plugs - “A” and “B”. Cables are
connected to the sensor through the M12 connector plugs.
•Connector Ais used for power and Modbus
•Connector Bis used for 4-20mA and pulse
Connector B
4-20mA & Pulse
Connector A
Power & Modbus
Micro USB
Connection

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If you ordered a cable with the sensor, the cables will be coloured coded as shown
in the table below.
Connector A (Power & Modbus)
Cable Colour
Connector B (Pulse & Analogue)
Pin 1
RS845, Data + (A)
Brown
Pin 1
4-20mA +
Pin 2
RS845, Data - (B)
White
Pin 2
4-20mA -
Pin 3
N/A - Not Used
Blue
Pin 3
Pulse
Pin 4
+18-30 vDC
Black
Pin 4
Pulse
Pin 5
0 vDC (Ground for
Modbus)
Grey
Pin 5
N/A - Not Used

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Flow Meter - Thermal Mass (Inline Style) User Manual v1.1
Using the Display
The flow meter has a touch screen
interface.
1. Menu options
2. Settings
3. Data / Measurement Readings
4. Locked screen icon
To navigate the interface:
•scroll up and down to see other
options
•scroll left and right to see other
screens
•Press an item to access that
feature
Unlock the screen
The screen is set to automatically lock
after 60 seconds.
If the lock screen symbol is
present, press the symbol, hold and
drag it to the right of the screen.
You can change the timing for the lock
screen in the “Screen Settings” menu
(Settings > System Settings > Screen
Settings)
1
2
3
4

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Home Screen
The home screen has two pages, as
shown by the two dots ( .. ) at the
bottom of the screen. Move the
screen left or right to move between
screens.
When you press the Menu icon
( ) a pop up screen
appears. Press:
✓The Home icon ( ) to return to
the home screen
✓The Camera icon ( ) to take a
screen shot of that screen
oTo access screen shots, go to
the Settings Menu ( ) >
System Setting.
✓The Notepad icon ( ) to access
the Data Logging information
✓If you have a micro USB installed,
press the USB icon ( ) to
safely remove the USB.
Settings Menu
Press the settings icon ( ) in the
top right corner of the screen to
access the settings screen.
In the Settings Menu you can change /
set up:
✓Pipe diameter
✓Units of measurement
✓Gas type
✓Data logging
✓RS485 settings
✓Analog output
✓Screen shots
✓Normalisation and
✓System settings.
Click on an item to view /
change settings
Scroll left or right to see other screens

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Flow Meter - Thermal Mass (Inline Style) User Manual v1.1
Setting Up the Flow Meter
Before you use the flow meter, you must set:
•Unit of Measurement
•Communication settings (RS485 or Analog)
We also recommend you check the gas type and pipe diameter.
Note: The flow meter is calibrated in air. If you select another gas type, the flow
meter will automatically adjust its readings to match the gas selected.
Unit of Measurement
You can change the units of
measurement for Flow, velocity,
consumption and temperature.
To change the Unit of Measurements,
go to Settings ( ) > Unit Setting
To change the units of measurement:
•Select the desired unit of measure
•Press the arrow ( ) to save
your setting and return to the
previous screen.
Measure
Units
Flow
Nm3/h, Nm3/min,
Nm3/s
Nl/min, Nl/s, Ncfm
Kg/h, Kg/min, Kg/s
Velocity
Nm/s, Nft/s
Consumption
m3, ft3, kg
Temperature
°C, °F