Compressed Air Alliance FLP10000 Series User manual

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User Manual
Flow Meter -
Pitot Tube
Models:
FLP10000x
FLP20000x

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Flow Meter –Pitot Tube User Manual v1
Table of Contents
Notices............................................................................................................................................................... 3
About Flow Meters............................................................................................................................................ 4
Specifications..................................................................................................................................................... 5
Installation –Mechanical................................................................................................................................... 7
Installation –Electrical (Wiring) ...................................................................................................................... 16
Operating Instructions..................................................................................................................................... 17
Menu Structure ............................................................................................................................................... 18
Settings Menu.................................................................................................................................................. 19
Setting Up the Flow Meter .............................................................................................................................. 19
Communication Settings ................................................................................................................................. 21
Data Logging.................................................................................................................................................... 23
System Settings ............................................................................................................................................... 24
Other Settings.................................................................................................................................................. 26
Warranty.......................................................................................................................................................... 27
Calibration ....................................................................................................................................................... 27
Need help?....................................................................................................................................................... 27
Technical Support............................................................................................................................................ 28
Commissioning Report .................................................................................................................................... 32

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Flow Meter –Pitot Tube User Manual v1
Notices
Please read this user 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 non-
observance or noncompliance with this user
manual.
Should the device be tampered with in any
manner other than a procedure which is
described in this manual, the warranty is
cancelled and the manufacturer is exempt from
liability.
The device is designed exclusively for the
described application.
This user manual should be read carefully by the
technician / qualified personnel and the end
user. Once you install, use or maintain this
product, you accept that you have read,
understood and complied with this manual. This
manual should be kept with the flow meter and
made available to relevant personnel as needed.
Compressed Air Alliance endeavors to make the
content of this manual correct and well stated,
but is not responsible for omissions or errors and
the consequences caused thereby.
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 tight installation
material.
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.
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.
Installing the Flow Meter,
Calibration and Maintenance
The product must be installed properly and
frequently calibrated, otherwise it may lead to
the wrong measurement values, which can lead
to wrong results.
Always observe the direction of flow
when installing the sensor. The direction
is indicated on the housing.
Do not exceed the maximum operation
temperature at the sensors tip.
Avoid condensation on the sensor
element as this will affect the accuracy
enormously.
Please observe national regulations
before/during installation and operation.
Do not disassemble the product.
Always use a spanner to mount the
product properly.
Using the Flow Meter
Do not use this product in explosive
areas.
Do not exceed the permitted operating
parameters. Any operation exceeding
these parameters can lead to
malfunctions and may lead to damage on
the instrument or the system.
Do not exceed or go below the permitted
storage and operation temperature and
pressure.
This product should be maintained and
calibrated frequently, at least every 2
years.
Storage and transportation
Transportation temperature of the
sensor is between -10 °C ... 60 °C.
Storage temperature of the sensor is
between -10 °C ... 50 °C and the humidity
is <90%, no condensation. Avoid direct
UV and solar radiation during storage.

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Flow Meter –Pitot Tube User Manual v1
About Flow Meters
Flow meters are very popular for measuring
compressed air systems. Depending on where
they are installed, flow meters can tell you the
compressor output, system consumption, peaks
and troughs as well as average usage. When used
well, flow monitoring can help keep your system
under control and highlight any unusual activity
in your system.
Benefits of monitoring flow include:
Improves system efficiency
Reduces system maintenance
Reduces operating and energy costs
Increases system understanding and
operation
Identifies changes in system performance
Identifies non-productive air demand and
leakage
Identifies peak and average demand
Different types of flow meters should be used
depending on the specific location and purpose.
However, when it comes to compressed air, flow
meters such as vortex or orifice plates can create
a pressure drop within the system, ultimately
leading to increased operating cost of the entire
plant. As such, vortex or orifice plate flow meters
are not recommended for compressed air.
Pitot Tube Flow Meters
Pitot tube flow meters are ideally suited to wet,
dirty and high velocity gases. The extremely
sensitive differential pressure measurement
allows this sensor to be used over a wide flow
range. The patented anti condensation
technology enables the sensor to be used under
saturated conditions and ensures the sensor will
perform stable accurate measurements for years
to come.
Pitot tube flow sensor measure the upstream
dynamic pressure and downstream static
pressure. The pressure differential is a measure
of the velocity and flow rate.
Thanks to the online auto-calibration technology,
high reliability, long-term measurement and
accuracy can be guaranteed.
Pitot flow meters are widely used in industrial
processes, chemical, petrochemical, power
engineering, etc.
Pitot Tube flow meters are ideal for both
temporary or permanent installations.
Key Features of Pitot Tube Flow Meters
Insertion type sensor
Ideal for wet and dirty gases
Flow range of 10-300 Nm/s
Note: below minimum velocity flow meter
reading will be zero
Patented anti condensation technology
Integrated pressure and temperature sensor
Online auto-calibration function to
compensate for temperature and pressure
change
Easy to insert and remove through 1/2” valve,
even when under pressure
Two output types as standard -
oDigital - Modbus RTU and
oAnalog –4…20 mA + Pulse
Two shaft length options -
o250 mm or
o400 mm
Suitable for pipes from DN25-DN300
provided minimum velocity (> 1L/minute) is
maintained
Vibration proof
Low pressure drop
2.8" ultra-wide viewing angle LCD touch
screen
Data logging with up to 10,000,000 recording
points

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Specifications
Technical Data
Pitot Tube - Insertion
Technology
Anti-condensation
Gases
Air, Argon, Carbon Dioxide, Helium, Hydrogen, Natural Gas, Nitrogen,
Nitrous Oxide, Oxygen
Gas Quality
Wet and dry air
High velocities
Accuracy1
Flow:
±(1% reading + 0.3% full scale)
Pressure:
±0.5% full scale
Temperature:
±0.5°C
Measurement Ranges
Flow Measurement Range
10 –300 Ns/m
Pressure Measurement Range
0 to 16 bar
Gas Temperature Range
-40°C to +200°C
-40°F to +392°F
Outputs
Output
Analog: 4-20mA (4 wire, Isolated) / Pulse output
Digital: RS485 Modbus / RTU
Output signals
Flow, consumption, pressure and temperature
Power
Power Supply
18 to 30V / 6.5W@24V
Anti Condensate Power Up
18 to 30V / 24W@24V
EMC
According to IEC 61326-1
Display and Data Logging
Display
2.8” LCD with touch panel
Data Logger
10,000,000 samples
Other Information
Pipe Size
DN25 to DN60
Shaft Lengths
250 mm or 400 mm
Electrical Connection
2 x 5 pin M12, female
Process Connection
ISO G1/2" thread
Ambient Temperature Range
-20°C to +60°C
-4°F to +140°F
Installation Type
Permanent installation, or
Temporary installation
Calibration Frequency2
Every 2 years
Warranty Period
12 Months
Reference Conditions
20°, 1 bar(a), ISO 1217 (Programmable)
1The accuracy of the sensor is affected by on-site conditions. Contaminants such as oil, high humidity or other impurities can affect
the calibration and accuracy of the sensor.
2 Flow meters require calibration every 2 years (provided the sensor is not exposed to relative humidity above 85%).
Compressed Air Alliance can arrange calibration for you.

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Flow Range
Pipe Size
Flow Range (Nm3/h)
Flow Range (cfm)
Inches
DN
ID (mm)
Min Flow
Max Flow
Min Flow
Max Flow
1
25
25
8.8
530
311
18,709
1.25
32
32
14.5
868
512
30,640
1.5
40
40
22.6
1,357
798
47,902
2
50
50
35.3
2,120
1,246
74,836
2.25
65
65
59.7
3,583
2,107
126,480
3
80
80
90.5
5,428
3,195
191,608
4
100
100
141.4
8,482
4,991
299,415
5
125
125
220.9
13,253
7,798
467,831
6
150
150
318.1
19,085
11,229
673,701
8
200
200
565.5
33,929
19,962
1,197,694
10
250
250
883.6
53,014
31,191
1,871,394
12
300
300
1,272.3
76,340
44,912
2,694,802

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Installation –Mechanical
Before installing the sensor, make sure it is rated for your system (refer to the “ Specifications ” section
above). We suggest purging the pipeline before installation to prevent impurities from damaging the flow
meter or blocking the pressure pipe.
WARNINGS
Incorrect installation can damage the sensor or cause it to work incorrectly.
You need to maintain a minimum flow velocity of 10 Nm/S for the pitot tube to work correctly.
Below this minimum velocity, the flow meter reading will be zero.
Step 1 –Find a suitable section of horizontal pipe
The sensor must be installed:
on a horizontal pipe
upright, at 90° (±15°) to the pipe (ie vertically),
away from bends, edges, seams, changes in pipe size and other obstructions (see Step 2 below),
after the first filter or water separator (ie the sensor can not be installed directly on the outlet of the
compressor)
Make sure the insertion location has enough room above the pipe to install the sensor. If installing the
sensor outdoor, protection from sun and rain is necessary.
Installing the Pitot Tube Flow Meter on the compressor outlet
Non-Condensing gases - The pitot tube can be installed on the outlet of compressors
Condensing gases - The pitot tube can not be installed directly on the outlet of compressors.
If you want to install the pitot tube near the outlet of a compressor, a water separator or filter
is required to reduce the condensed liquid in the gas.
Install vertically to pipe
The sensor must be installed upright, at 90° +/- 15° (ie within 75° to 105° of vertical). Installing the sensor at
an angle can result in water accumulating in the shaft or head of the sensor. This can damage the sensor
and void the warranty.
75°
105°
Horizontal (0°)


Vertical (90°)

Sensor is within ±15°
of vertical

Sensor is not
vertical


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Correct Installation
Incorrect Installation
Do NOT install the sensor on a vertical pipe, upside down or at an angle, as shown below.
Do NOT let water get into the shaft or head of the sensor as this can damage the sensor or result in
incorrect readings.



Compressor
Dry Side
Wet Side
Filter
Dryer
Filter or
water separator

Sensor installed on
a vertical pipe
Sensor installed
upside down
Sensor installed at
an angle
Sensor installed
before first filter or
water separator
Dry Side
Wet Side
Dryer
Compressor




Filter
Filter or
water separator
Sensor installed
after first filter or
water separator
Sensor installed vertically
on horizontal pipe

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Step 2 - Choose insertion location, away from obstacles
To achieve and maintain the accuracy stated in the technical data, the sensor must be inserted vertically,
on a straight horizontal pipe section away from bends, edges, seams, curve, changes in pipe size, control
valves, etc. The sensor can not be installed directly on the outlet of the compressor.
For best results, choose a long, absolutely straight, horizontal section of pipe that is free of obstructions.
Pipe obstructions (eg bends, edges, seams, curve, 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.
Make sure that the insertion location has enough straight pipe on either side of the sensor, as shown in the
diagram on the next page.
WARNING! Inaccurate measurement may occur if the sensor is installed incorrectly
Pay careful attention to the distance between the sensor’s inlet and outlet sections and
points of turbulence (eg bends, valves, etc)
Obstructions can cause counter-flow turbulence as well as turbulence in the direction of
the flow.
The sensor is for indoor use only. If installed in an outdoor installation, the sensor must
be protected from sun and rain.
The figure 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.
The inlet side of the sensor must be at least 20 to 50 times the pipe diameter away from the
obstruction (depending on the type of obstruction –see figure below).
The outlet side of the sensor must be at least 5 times the pipe diameter away from the obstruction.
Correct Installation






DN = Pipe Diameter

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Incorrect Installation
Examples
Need at least 30 DN (25 DN on the
inlet side + 5 DN on the outlet side –
see picture 4 above) but only 20 DN
is available

Available Space
Need at least 50 DN on the inlet
side (see picture 6 above) but
only 25 DN is available

DN = Pipe Diameter
Available Space
30 x DN
A flow sensor will be installed on a section of pipe, just after
a bend (as shown in the diagram on the right). The pipe has a DN of
50 (ie, it’s a 2 inch or 50 mm pipe).
Using the reference diagrams on page 9, the sensor installation is similar to diagram 3 (90° Bend or T-
piece). Therefore, the sensor must be installed:
on a straight section of pipe
the Inlet side of the sensor must be at least 20 x DN away from the bend.
the outlet side of the sensor must be at least 5 x DN away from any other obstruction.
For pipe with DN 50 (2” or 50 mm pipe), the sensor must be installed:

Inlet side: 20 x 2” = 40” (imperial) or 20 x 50mm = 1,000mm = 1 meter (metric) away from the bend.
Outlet side: 5 x 2” = 10” (imperial) or 5 x 50mm = 250mm (metric) from any other obstruction
Example 1 –Installation near a bend

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A flow sensor will be installed on a section of pipe near
an s-bend (2 x 90° bends) and a control valve (see diagram on the
right). The pipe has a DN of 50 (ie, it’s a 2 inch or 50 mm pipe).
Using the reference diagrams on page 9, the sensor installation is a combination of diagram 4 (2 x 90°
Bends) and diagram 6 (Control Valve). Since the sensor is adjacent to the control valve, we will use
those dimensions. The sensor must be installed:
on a straight section of pipe
the Inlet side of the sensor must be at least 50 x DN away from the control valve.
the outlet side of the sensor must be at least 5 x DN away from any other obstruction.
For pipe with DN 50 (2” or 50 mm pipe), the sensor must be installed:
Inlet side: 50 x 2” = 100” (imperial) or 50 x 50mm = 2,500mm = 2.5 meter (metric) away from the
control valve.
Outlet side: 5 x 2” = 10” (imperial) or 5 x 50mm = 250mm (metric) from any other obstruction.
Example 2 –Installation near an S-Bend and a Control Valve
A flow sensor will be installed on a section of pipe between
a bend and an expansion joint (as shown in the diagram on the right).
This section of pipe is 1 meter long. The pipe has a DN of 50
(ie, it’s a 2 inch or 50 mm pipe) and is being expanded to an 80 DN pipe
(ie a 3” pipe).
Using the reference diagrams on page 9, the sensor installation is similar to diagram 3. Therefore, the
sensor must be installed:
on a straight section of pipe
the Inlet side of the sensor must be at least 20 x DN away from the bend.
the outlet side of the sensor must be at least 5 x DN away from the expansion joint.
For pipe with DN 50 (2” or 50 mm pipe), the sensor must be installed:

Inlet side: 20 x 2” = 40” (imperial) or 20 x 50mm = 1,000mm = 1 meter (metric) away from the bend.
Outlet side: 5 x 2” = 10” (imperial) or 5 x 50mm = 250mm (metric) from any other obstruction.
Therefore, the total length of pipe needs to be at least 50” long (40” on the inlet side + 10” on the outlet
side) or 1.25m long (1 meter on the inlet side + 0.25 meters of the outlet side).
Since the pipe is only 1 meter long, and you need at least 1.25m of pipe to install the sensor,
you can not install the sensor at this location. If you do, you may end up with inaccurate data.
Example 3 –Installation between a bend and an expansion

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Step 3 –Install the socket and ball valve
To install the sensor, you need a ball valve or a nozzle with the following specifications:
The inner thread must be G 1/2"
The diameter of the hole must be ≥ 13mm, otherwise the shaft can not be inserted into the pipe.
Step 4 –Insert sensor and align tip with the centre of the pipe
Place O-Ring on sensor shaft gland nut.
Screw the sensor into the valve then open the valve.
Place O-Ring on sensor
shaft gland nut
Valve
(diameter of the hole must be
≥ 13mm)
Sensor shaft gland nut

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Step 5 –Align tip with the centre of the pipe
Use the depth scale on the sensor shaft to place the tip of the sensor in the middle of the pipe.
Once the tip is in the centre of the pipe, tighten the gland nut to hold the sensor in place.
The Insertion Depth = x + y = 𝑂𝐷
2+ y.
OD = outer diameter of pipe
Y = ball valve height.
Correct Installation
The sensor tip must be in the center of the pipe / tube.

Sensor tip in the
centre or the pipe

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Incorrect Installation
Note: Inaccurate measurement may occur if the sensor is installed incorrectly.
Example
Sensor tip too low
Sensor tip too high
Sensor tip not in
centre of pipe
Example –Finding the centre of the pipe / tube
The sensor is being installed in a cooper tube with a DN of 100. This equates
to an outer diameter (OD) of 100mm. The ball valve is 87mm high.
The Insertion Depth = 𝑂𝐷
2+ y where y = height of the ball valve.
Therefore, the Insertion Depth = 100mm / 2 + 87mm = 137mm.
Push the sensor shaft into the cooper tube until the “Insertion Depth”
reads 137mm at the top of the ball valve
Push in sensor until Insertion
Depth = 137mm
OD
Y = ball valve

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Step 6 –Align sensor with the direction of flow
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.
Incorrect Installation
Note: Inaccurate measurement may occur if the sensor is installed incorrectly.
Use the alignment tool to align the sensor with the pipe. Ensure the arrows on the sensor match the
direction of flow.
Direction of gas flow
Sensor alignment
Direction of gas flow
Sensor alignment

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Installation –Electrical (Wiring)
The flow sensor is equipped with two M12 connector plugs - “A” and “B”. Cables are connected to the
sensor through the M12 connector plugs.
Do not screw the M12 connector using force. Otherwise, it may damage the connection pins.
Connector A (Modbus)
Connector B (Pulse & Analogue)
Pin 1
RS845, Data + (A)
Pin 1
4-20mA +
Pin 2
RS845, Data - (B)
Pin 2
4-20mA -
Pin 3
N/A - Not Used
Pin 3
Pulse
Pin 4
+18-30 vDC
Pin 4
Pulse
Pin 5
0 vDC (Ground for Modbus)
Pin 5
N/A - Not Used
Connector B
Connector A
Micro USB Connection

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Operating Instructions
Interface
The flow meter has a touch screen interface.
1. Menu options
2. Settings
3. Data
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 Setting)
Home Screen
The home screen has three pages, as shown by
the three dots ( ... ) at the bottom of the screen.
Move the screen left or right to move between
screens.
Menu Options
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
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.
1
2
3
4
Scroll left or right to see
other screens

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Flow Meter –Pitot Tube User Manual v1
Menu Structure
Main Menu
Sub Menu 1
Sub Menu 2
Sub Menu 3
Home
Camera
Notepad
Set up Data logging
Start logging
Stop Logging
Eject Micro USB
Settings
Pipe diameter
Units of measurement
Flow
Velocity
Consumption
Pressure
Temperature
Gas type
Logging
Logging
Set up Data logging
Start logging
Stop Logging
History
Download / Export
Data
Delete Data
Screen Shot
Export Pictures
Delete Picture
Normalisation
RS485 Settings
Baud Rate
Parity
Stop Bits
Response Delay
Device Address
Analog Output
4-20mA Channel
4-20mA Scaling
Pulse Out Mode
Cubic Meter / Pulse
System Settings
Screen Settings
Screen Rotation
Screen Brightness
Screen Timeout/
Lock
Language Setting
System Information
System Update
Advanced Settings

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Flow Meter –Pitot Tube User Manual v1
Settings Menu
Press the settings icon ( ) in the top right
corner of the screen to access the settings screen.
Move the page up and down to see other
settings.
Press an item to access that setting.
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
Systems settings.
1. Screen name
2. Screen options. Press an item to access that
setting.
3. Scroll bar
Setting Up the Flow
Meter
Before you use the flow meter, you
must set:
Inner Pipe Diameter
Unit of Measurement
Gas Type
Communication settings (RS485 or Analog)
Inner Pipe Diameter
To change the Pipe Diameter, go to Settings
( ) > Pipe Diameter.
To change the Inner Pipe Diameter:
Press the diameter size, in millimeters (mm)
Enter new diameter for the inner pipe
Press OK
Press the arrow ( ) to return to the previous
screen.
Pipe diameter in the settings menu refers
to Inner Pipe diameter. Not the outer
diameter.
1
2
3

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Unit of Measurement
To change the Unit of Measurements, go to
Settings ( ) > Unit Setting
You can change the units of measurement for
Flow, velocity, consumption and temperature.
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
Pressure
Pa, hPa, kPa, Mpa
mbar, Bar
PSI
Temperature
°C, °F
Gas Type
To change the Gas type, go to Settings ( ) > Gas
Type.
To change the gas type:
Select the desired gas type
oYou might need to scroll up or down to
see all options
Press the arrow ( ) to save your setting
and return to the previous screen.
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.
You can select from the following gas types:
Air,
Argon (Ar),
Butane (C4C10),
Carbon Dioxide (CO2),
Carbon Monoxide (CO),
Ethane (C2H6),
Helium (He),
Hydrogen (H2),
Methane (CH4),
Nitrogen (N2),
Nitrous oxide (N2O),
Oxygen (O2),
Propane (C3H8),
Sulfur Hexafluoride (SF6).