Compressed Air Alliance Vortex FLV User manual

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User Manual
Flow Meter –
Vortex
Model: FLV

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Flow Meter –Vortex User Manual v1
Table of Contents
Notices...........................................................................................................................................3
Warnings .......................................................................................................................................3
About Flow Meters .......................................................................................................................5
Specifications................................................................................................................................6
Flow Meter Pack ...........................................................................................................................9
Installation Overview .................................................................................................................11
Installation –Mechanical...........................................................................................................12
Installation –Electrical ...............................................................................................................20
Warranty......................................................................................................................................24
Calibration...................................................................................................................................24
Trouble Shooting........................................................................................................................25
Commissioning Report ..............................................................................................................26

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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 and venturi
meters.
Vortex Meters
Vortex meters are widely used in
industrial processes, manufacturing,
chemical, petrochemical, power
engineering, etc.
The Vortex flow meter is perfectly
suited for measuring flow and
consumption of inert gases and
steam, no matter how heavily
contaminated.
With built-in pressure and
temperature sensors, all parameters
of your gas or steam system are
monitored in one unit, saving you
install and maintenance costs.
Key features of the Vortex Flow Meter:
•No moving parts, making it both
durable and easy to maintain.
•Ultra-high sensitivity vortex probe
•Turndown ratio well beyond
traditional Vortex flowmeters
•Full digital signal processing for
higher precision and better
stability
•Full electrical isolation to filter out
disturbances
•Vibration resistant
•All-welded construction for
corrosion, high pressure and
temperature resistance
•Integrated display

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Specifications
Vortex Flow Meter
Technology
Karman vortex principle
Medium
Inert Gases (see below) and steam
Gas types
Air, Argon, Carbon Dioxide, Carbon Monoxide, Helium,
Hydrogen, Natural Gas, Nitrogen, Nitrous Oxide, Oxygen,
Sulfur hexafluoride (SF6)
Gas Quality
Wet and dry gas
Dry and clean gas
Accuracy
Flow: ±(1.5% 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
1.5 to 80 Nm/sec
5 to 24 ft/sec
Pressure Measurement
0 to 16 bar (1.6MPa, 232 psi)
0 to 63 bar (6.3 MPa , 913 psi)
Gas Temperature
Measurement
-40°C to +280°C
40°F to +536°F
Outputs
Output
Analog: 4 to 20mA / Pulse output
Digital: RS485 Modbus / RTU
Output Signals
Flow, consumption, pressure and temperature
Power
Power Supply
18 to 30V / 10W@24V
Electrical Connection
1 x 5 pin M12, female
EMC
According to IEC 61326-1
Display & Data Logger
Display
2.0” LCD with touch panel

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Vortex Flow Meter
Data Logger
Not available
Other Information
Bi-directional
No
Pipe Size
DN15 to DN300
Process Connection
Flange
Ambient Temperature
-40°C to +85°C
-40°F to +185°F
Installation Type
Permanent or temporary installation
Calibration Frequency
Every 2 years
Warranty Period
12 Months
Reference Conditions
20°C, 1bar(a), ISO1217 (Programmable)

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Flow Range
Pipe Size
Flow Range (Nm3/h)
Flow Range (cfm)
DN
Inches
Min Flow
Max Flow
Min Flow
Max Flow
15
1/2
1.0
50.9
0.6
30.0
20
3/4
1.7
90.4
1.0
53.2
25
1
2.6
141.3
1.5
83.2
32
1.25
4.3
231.5
2.5
136.3
40
1.5
6.8
361.7
4.0
212.9
50
2
10.6
565.2
6.2
332.7
65
2.5
17.9
955.2
10.5
562.2
80
3
27.1
1446.9
16.0
851.6
100
4
42.4
2260.8
25.0
1330.7
125
5
66.2
3532.5
39.0
2079.2
150
6
95.4
5086.8
56.2
2994.0
200
8
169.6
9043.2
99.8
5322.6
250
10
265.1
14130.0
156.0
8316.6
300
12
381.7
20347.2
224.7
11975.9

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Dimensions
Sizing for PN16
Pipe Size
Measurement (mm)
DN
Inches
D
D1
K
H
L
M
n
d
40
1.5
40
150
110
410
200
18
4
18
50
2
50
165
125
420
200
20
4
18
65
2.5
65
185
145
430
200
20
4
18
80
3
80
200
160
440
200
20
8
18
100
4
100
220
180
450
200
22
8
18
125
5
125
250
210
460
200
22
8
18
150
6
150
285
240
480
200
24
8
22

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Flow Meter Pack
Each flow meter pack comes with:
✓1 x Vortex Flow Meter with flange connection
✓Gaskets and bolts to suit the flow meter
✓Data cable
Optional Accessories
The following accessories are available for the flow meter. Talk to your local dealer or
Compressed Air Alliance or pricing.
CALMS –Cloud-based Data
Acquisition and Analysis software
Vortex Flow
Meter
Data Cable
Gaskets and
Fastening bolts

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Installation Overview
Step 1 –Find a suitable section of pipe
•The sensor must be installed vertically or horizontally
•The sensor must be installed away from bends, edges, seams, changes in
pipe size and other obstructions
•Do NOT install the sensor upside down
Step 2 –Cut out section of pipe
Step 3 –Fit flow meter
Step 4 –Wire the sensor (see ‘Installation –Electrical’)
Step 5 (optional) –Connect the sensor to your SCADA or energy management
system
Step 6 –Fill out the Commissioning Report (last page of this manual)
Tools and Equipment needed for installation
(not included with Flow Meter Pack)
Wrench /
Spanner
Welder
Pipe Cutter

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Installation –Mechanical
WARNING!
•Incorrect installation can damage the sensor or cause it to work incorrectly.
•Avoid contact with corrosive gases
Notes
•You need to maintain a minimum flow velocity of 1.5 Nm/s (5 ft/sec)
for the vortex flow meter to work correctly. Below this minimum velocity,
the flow meter reading will be zero.
•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.
•If there is strong vibration along the pipework, additional fixing measures
will be needed. Too much vibration can damage the flow meter.
•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 gas / steam flow and the
alignment of the sensor. The direction is indicated on the housing.
•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.

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Step 1 –Find a suitable section of pipe
✓away from bends, edges, seams, changes in pipe size and other obstructions,
✓at 90° to the pipe
✓vertically or horizontally,
ohorizontal installation is recommended when the steam / gas
contamination is relatively large
•Make sure the insertion location has enough room around the pipe to install
the sensor.
Do NOT install the sensor upside down. This can result in water and
contaminants affecting the sensor. This can damage the sensor, result in
incorrect measurements and void the warranty.
Sensor installed
horizontally
Sensor installed
upside down
Sensor installed
vertically

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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 / gas / steam 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.
•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.

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Correct Installation
Gas / Steam flow direction

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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 on the inlet side.
•Therefore the sensor should not be
installed in this location

Available Space
20 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”
•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 70 DN
•Therefore the sensor can be installed in
this location
Available Space
70 x DN

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Step 2 –Cut the Pipe
WARNING! Make sure the gas or steam is turned off and the pipe is
depressurised before cutting.
Calculate the width of the pipe cut:
L = A+2B+2C
Where:
L = width of pipe section to be cut out
A = flow meter width (outer edges)
B = gasket thickness
C = flange thickness

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Step 3 - Fit Flow Meter
•Place the gaskets in the flange slots
•Clamp the vortex flowmeter and bolt the flowmeter.
•Spot weld the flange at the cut surface to confirm the flange is installed
firmly
•Remove the vortex flowmeter and gasket and fully weld the left and right
flanges
Spot welding
location
Make sure the flange
holes are aligned
Full welding
location

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•After the weld has cooled, place a gasket on each side of the flange
•Clamp the flowmeter
oMake sure the direction indicated on the flowmeter and the direction of gas
/ steam flow are the same.
•Fix the flowmeter with the fastening bolts,
Gasket location
Fastening bolts

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Installation –Electrical
WARNING! Incorrect wiring can damage the sensor or cause it to work
incorrectly.
Notes:
•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.
Unscrew the back cover (clockwise) to access the terminals
•The side with the LCD screen is the front
•The head can be rotated, please do not use the direction of the metal
threaded pipe
Back
Cover
Inlet
Cable