precision flow insertion mass flow meter instruction manual

Precision FlowInsertion Mass Flow Meter

Instruction ManualBULLETIN F-41-PFSFR# R1-443055-00

102 Indiana Highway 212Michigan City, IN 46360 USA

(219) 879-8868 (219) 879-8000 Fax (219) 872-9057http://www.dwyer-inst.com

F-41-PFS 0-1

Table of Contents Series PFS Instruction Manual

Warnings and Cautions

Warning! Agency approval for hazardous locationinstallations varies between flow meter models. Consult thefactory for specific flow meter approvals before any haz-ardous location installation. For explosion proof installations,you must use solid metal conduit and follow NFPA (or yourlocal code) approved wiring methods.

Warning! All flow meter connections and fittings for pipetapping must have the same or higher pressure rating asthe main pipeline.

Warning! To avoid serious injury, DO NOT loosen a com-pression fitting under pressure.

Warning! All wiring procedures must be performed with thepower Off.

Warning! To avoid potential electric shock, follow NationalElectric Code safety practices or your local regulationswhen wiring this unit to a power source and to peripheraldevices. Failure to do so could result in injury or death.

Warning! Do not power the flow meter with the sensorjumper wires disconnected. This could cause over-heatingof the sensors and/or damage to the electronics.

Warning! Before attempting any flow meter repair, verifythat the line is depressurized.

Warning! Always remove main power before disassem-bling any part of the mass flow meter.

Caution! Before making adjustments to the SmartElectronics device, verify the flow meter is not actively mon-itoring or reporting to any master control system.Adjustments to the electronics will cause direct changes toflow control settings.

Caution! Adjusting zero or span will affect meter calibra-tion.

Caution! Printed circuit boards are sensitive to electrostat-ic discharge. To avoid damaging the board, follow theseprecautions to minimize the risk of damage:

• before handling the assembly, discharge your body bytouching a grounded, metal object

• handle all cards by their edges unless otherwise required• when possible, use grounded electrostatic discharge

wrist straps when handling sensitive components

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F-41-PFS 1-1

Series PFS Instruction Manual Chapter 1 Introduction

Chapter 1 Introduction

Series PFS Smart Air Velocity TransmitterDwyer’s Series PFS Smart Mass Flow Meter provides a reli-able solution for inert gas flow measurement applications.The meter’s thin-film sensor offers long-term reliability andfast 100 millisecond response to changes in flow rate. Theinstrument’s Smart electronics provides outstanding diag-nostic and field-adjustment capabilities.

The versatile microprocessor-based transmitter integratesthe functions of flow-range adjustment, meter validationand diagnostics in a probe-mounted NEMA 4X (IP65) hous-ing. Mass flow rate and totalized flow, as well as other con-figuration variables are displayed on the meter’s optional 2x 12 LCD display. The meter provides an optical/galvanicisolated flow output, two alarm outputs and one contactinput for range or gas selection. The programmable trans-mitter is easily configured via RS-232 and Dwyer’s SmartInterface software or through three push buttons built intothe device.

The Series PFS is suitable for pipes or ducts from one inchup to 48 inches (DN50 up to DN1200). The Series PFSMass Flow Meter’s simple installation combines with aneasy-to-use interface that provides quick set up, long termreliability and accurate mass flow measurement over a widerange of conditions.

Using This ManualThis manual provides information needed to install andoperate the Series PFS Smart Insertion Mass Flow Meter.The four chapters of this manual cover these areas:

• Chapter 1 includes the introduction and product descrip-tion

• Chapter 2 provides installation and wiring instructions• Chapter 3 describes system operation and programming• Chapter 4 covers troubleshooting and repair

The product specifications are found in Appendix A.

Chapter 1 Introduction Series PFS Instruction Manual

Note and Safety InformationWe use note, caution and warning statements throughoutthis book to draw your attention to important information.

Warning!This statementappears with infor-mation that isimportant to pro-tect people andequipment fromdamage. Pay veryclose attention toall warnings thatapply to your appli-cation.

Caution!This statementappears with infor-mation that isimportant for pro-tecting your equip-ment and perfor-mance. Read andfollow all cautionsthat apply to yourapplication.

NoteThis statementappears with ashort message toalert you to animportant detail.

Receipt of System ComponentsWhen receiving a Dwyer mass flow meter, carefully checkthe outside packing carton for damage incurred in ship-ment. If the carton is damaged, notify the local carrier andsubmit a report to the factory or distributor. Remove thepacking slip and check that all ordered components arepresent. Make sure any spare parts or accessories are notdiscarded with the packing material. Do not return anyequipment to the factory without a Return MaterialAuthorization (RMA, see Chapter 4).

Technical AssistanceIf you encounter a problem with your flow meter, review theconfiguration information for each step of the installation,operation and setup procedures. Verify that your settingsand adjustments are consistent with factory recommenda-tions. Refer to Chapter 4, Troubleshooting, for specific infor-mation and recommendations.

If the problem persists after following the troubleshootingprocedure outlined in Chapter 4, contact DwyerInstruments by fax or by E-mail (see cover). For urgentphone support you may call (800) 879-8000 or (219) 879-8868 between 8:00 a.m. and 5:00 p.m. CST. When contacting Technical Support, make sure to include this information:

• the model number, the flow range, and purchaseorder number

• the software version (visible at start up)• the problem you are encountering and any cor-

rective action taken

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F-41-PFS 1-3

The Series PFS Flow Sensing PrincipleDwyer’s thin-film sensor consists of two sensing elements-a velocity sensor and a temperature sensor that automati-cally corrects for changes in gas temperature. The trans-ducer electronics heats the velocity sensor to a constanttemperature differential above the gas temperature andmeasures the cooling effect of the gas flow. The electricalpower required to maintain a constant temperature differen-tial is directly proportional to the gas mass flow rate.

The fast-response sensor is located at the tip of a 0.375inch (3/8˝) diameter, 304 stainless steel probe. The Smartelectronics are packaged in a weather-proof NEMA 4X(IP65) enclosure mounted either directly on the sensingprobe or remotely up to 100 feet away.

Chapter 1 Introduction ` Series PFS Instruction Manual

Smart Electronics Features

Instrument ValidationTwo simple tests offer full “field-validation” of your Smartmass flow meter. The first test checks the system electron-ics, linearization and microprocessor functionality and isperformed by injecting a known input value and confirmingthat the flow meter outputs the expected value. The secondtest verifies that the instrument’s primary sensing elementshave not drifted or shifting from their original calibration andis accomplished by measuring the resistance of the veloci-ty and temperature sensors and comparing the results tothe NIST-traceable calibration data provided with the flowmeter. Together, these tests confirm that your meter isworking correcting and the calibration variables did not drift,shift or change values.

Dual Range or Dual Gas Calibration(Optional)Select one of two factory calibrated flow ranges using asimple external customer-supplied single contact closure.

User Full Scale Flow RateField-configure from 50% to 100% of the factory full scalesetting (factory full scale is normally set to 125% of the user-specified maximum flow rate). This adjustment can bemade for each flow range.

AlarmsProgram high and low or window alarm limits independent-ly for each flow range. The solid state contacts are isolatedwith one common.

K-Factor CorrectionChange the calibration correction factor to compensate forflow profile disturbances or specific application conditions.The K-factor is a multiplication factor applied to the lin-earized flow signal. You may set the K-factor individually foreach flow range.

Dual Output SignalsSmart flow meters offer two separate linear output signalsproportional to flow, 0-5 VDC (0-10 VDC optional) and 4-20mA. The 4-20 mA output can be field-configured as anactive loop powered by the flow meter or an optically isolat-ed passive loop requiring an external power supply.

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F-41-PFS 1-5

TotalizerWith the optional LCD display, actual mass flow appears online 1 and the totalized flow on line 2 both in the user-spec-ified engineering units. The totalizer counts only the select-ed range and when ranges are switched, the value of thenon-selected range is stored in memory. You may reset thetotalizer using the membrane buttons or by using a hand-held magnet.

Zero and Span OutputsValidate and adjust the settings to ensure output circuits arecorrect.

Time Response DelaySelect from a low response for faster tracking to a highresponse for a smoother output.

Enclosure OptionsFlow meter electronics are available mounted directly to theflow body, or remotely mounted up to 100 feet away. Theelectronics housing may be used indoors or out, includingwet environments.

Display options include a 2 x 12 character LCD display ofmass flow rate including totalized mass, or a single-digitLED located on the device printed circuit board. Local oper-ation and reconfiguration is accomplished using the threepush buttons operated via finger touch. Smart electronicsinclude nonvolatile memory that stores all configurationinformation. The memory allows the flow meter to functionimmediately upon power up, or after an interruption inpower.

Smart Interface™ SoftwareDwyer’s Smart Interface Windows™-based software is avail-able for connecting your PC directly to the mass flow meter.An RS-232 serial cable along with floppy disks containingthe program and system files are available from the factory.See the Smart Interface User Guide included with the soft-ware for operating instructions. (Order code for this pack-age is PFS60.)

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Chapter 2 Installation

Installation OverviewInstalling the Series PFS Air Velocity Transmitter is simpleand straightforward. Install the flow meter at a location witha consistent flow profile that meets the recommended pip-ing requirements. Locate the sensor head at the pipe’s cen-terline. The flow meter is factory calibrated to the specificpipe size shown on the meter’s Certificate of Calibration.This eliminates calculating the average flow across the pipeto determine the correct insertion depth. (If the pipe size dif-fers from the meter’s calibrated size, return the meter to thefactory for re-calibration.)

Warning! Agency approval for hazardous locationinstallations varies between flow meter models. Consult thefactory for specific flow meter approvals before any haz-ardous location installation.

Site SelectionBefore installing the flow meter, verify the installation siteallows for these considerations.

1. Line pressure and temperature does not exceed theflow meter rating. Temperature should not varymore than 200°F (100°C) around the calibrationtemperature. Line pressure should not vary morethan 50 psi (3.4 bar) around the calibrated pressure.

2. The location meets the required minimum numberof pipe diameters upstream and downstream of thesensor head. (see Figure 2-1 for piping require-ments).

3. Safe and convenient access with adequate over-head clearance. Also, verify the meter is locatedwhere the gas is clean and dry.

4. For remote installations, verify the supplied cablelength is sufficient to connect the flow meter sensorto the remote electronics. (Do not extend or short-en the supplied cable between the probe and theelectronics.)

Also, before installation check your flow system for anom-alies such as:

• leaks• valves or restrictions in the flow path that could create

disturbances in the flow profile that might cause unex-pected flow rate indications

• heaters that might cause rapid excursions in the mea-sured temperature

Series PFS Instruction Manual Chapter 2 Installation

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Chapter 2 Installation Series PFS Instruction Manual

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Unobstructed Flow RequirementsSelect an installation site that will minimize possible distor-tion in the flow profile. Valves, elbows, control valves andother piping components may cause flow disturbances.Check your specific piping condition against the examplesshown below. In order to achieve accurate and repeatableperformance install the flow meter using the recommendednumber of straight run pipe diameters upstream and down-stream of the sensor.


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InstallationUse the following data as a guide to prepare the pipe forflow meter insertion. Refer to a standard code for all pipetapping operations. The following instructions are general innature and intended for guideline purposes only.

1. Turn off the flow of process gas. Verify that the lineis not pressurized.

2. Confirm that the installation site meets the minimumupstream and downstream pipe diameter require-ments. See Figure 2-1.

3. Use a cutting torch or sharp cutting tool to tap intothe pipe. The pipe opening must be at least .375inches in diameter. (Do not attempt to insert thesensor probe through a smaller hole.)

4. Remove all burrs from the tap. Rough edges maycause flow profile distortions that could affect flowmeter accuracy. Also, obstructions could damagethe sensor assembly when inserting into the pipe.

5. Mount the 3/8 inch compression fitting on the pipe.Make sure this connection is within ±5° perpendic-ular to the pipe centerline.

Warning! All flow meter connections and fittingsmust have the same or higher pressure rating as the mainpipeline.

6. When installed, cap the fitting. Run a static pressurecheck on the connection. If pressure loss or leaksare detected, repair the connection and re-test.

7. Insert the sensor probethrough the compression fit-ting into the pipe. The correctinsertion depth places thelarger hole in the probe at thepipe’s centerline. Do not forceinto the pipe.

8. Align the sensor head using the flow direction indi-cator. Adjust the indicator parallel to the pipe andpointing downstream in the direction of flow.

9. Tighten the compression fitting to lock the flowmeter in position. When the compression fitting istightened, the position is permanent (unless usingTeflon ferrules).

Warning! To avoid serious injury, DO NOT loosenthe compression fitting under pressure.

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Enclosure OptionsThe NEMA 4X enclosure contains an integral wiring com-partment with one dual strip terminal block for power andsignal connections and one dual strip terminal block forsensor connections. The enclosure has one 1/2 inch femaleNPT conduit entry. The terminal designations are labeledinside the enclosure cover.

Warning! All wiring procedures must be performedwith the power Off.

Enclosure OptionsDepending on the flow meter configuration, connect 11 to18 VDC or 18 to 30 VDC (625 mA load, maximum) to theterminals marked PWR+, PWR-. Confirm power configura-tion before applying power. See the flow meter nameplatefor input power rating.

Warning! To avoid potential electric shock, followNational Electric Code safety practices or your local codewhen wiring this unit to a power source and to peripheraldevices.


Output Signal WiringAll flow meters are equipped with either a calibrated 0-5VDC (0-10 VDC optional) or a calibrated 4-20 mA outputsignal. These linear output signals represent 0-100% of theflow meter user full scale.

DC Output WiringThe 0-5 VDC (0-10 VDC optional) signal can drive a load of1000 Ohms. The optional 0-10 VDC output signal is notavailable for power sources below 15 VDC. Depending onthe flow meter configuration, connect 0-5 VDC or 0-10 VDCto the terminals marked Vout (+) and Vout (-).

4-20 mA Output WiringThe 4-20 mA current loop output can be self-powered bythe flow meter’s power supply (non-isolated) or externallypowered (isolated) requiring a separate 12 to 36 VDC powersupply. The maximum loop resistance (load) for both typesof current loop outputs are dependent upon the supply volt-age and are given in Figure 2-5.

Rload is the total resistance in the loop, including the wiring

resistance. To calculate Rmax, the maximum Rload for the loop,

use the maximum loop current, 20 mA. The voltage drop inthe loop due to resistance is 20 mA times Rload and this drop

is subtracted from the input voltage. Thus:

Rmax the maximum load resistance = 50 x (Vsupply - 7.5V)

To use an external power supply for an isolated 4-20 mAoutput, connect as shown in Figure 2-6. For an internallypowered non-isolated 4-20 mA output, connect as shownin Figure 2-7.

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Alarm Output WiringTwo alarm outputs (Low Alarm and High Alarm) are includ-ed on the flow meter terminal block. The alarm outputsrelays are normally-open-single-pole-relays with a commonground.

There are two connection options for alarm outputs-the firstwith a separate power supply (isolated) and the secondusing the flow meter power supply (non-isolated). Use aseparate power supply if a specific voltage is needed for thealarm output. Use the second (non-isolated) configuration ifthe voltage at the flow meter’s power supply is an accept-able driver voltage for the load connected. (Take intoaccount that the current used by your alarm loads have tocome from the flow meter’s power supply.) In either case,the voltage of the alarm output is the same as the voltagesupplied to the circuit.

To use an external power supply for an isolated alarm out-put, connect as shown in Figure 2-8. To use the internallypowered, non-isolated alarm output connect as shown inFigure 2-9. For a window alarm connect both outputstogether.

Warning! Before operation, verify that the voltageand current do not exceed the flow meter’s contact specifi-cations.

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Remote Sensor Probe WiringUse only factory supplied cables when connecting the sen-sor probe to a remotely mounted flow meter enclosure. Theelectronics, sensors and interconnecting cables supplied bySierra Instruments are calibrated as a complete precision airvelocity transmitter circuit. Changing the length of cables orinterchanging sensors or sensor wiring will affect the accu-racy of the flow meter. You cannot add or subtract wirelength without returning the meter to the factory for recali-bration. To connect the sensor probe to a remotely mount-ed electronics enclosure, see Figure 2-10. To make wiringconnections from a sensor probe junction box to a remote-ly mounted enclosure, see Figure 2-11.


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Range Selection WiringIf your meter is equipped with an optional second range cal-ibration, connect a contact switch as shown below. Whenthe switch is closed the device changes to Range 2. Openthe switch to return to Range 1.

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Series PFS Instruction Manual Chapter 3 Operation

F-41-PFS 3-1

Chapter 3 OperationUsing the Smart Electronics BasicFeaturesThree push buttons allow selection and adjustment of thebasic user functions. Use the push buttons to enter alarmparameters, change the user full scale, adjust the K-factor,adjust the time response speed or reset the totalizer. Youmay view parameters using the optional LCD front paneldisplay or by selecting functions on the single-digit LED andviewing the 0-5 VDC output with a digital voltmeter (DVM).

Before making any changes or adjustments, press theFUNCTION key to view and record the factory settings.When pressing FUNCTION the optional LCD displayprompts for a password. If you only want to view the para-meters, press FUNCTION again skipping the password. Ifyou want to make changes, at the password prompt, pressthe UP arrow until 11 is displayed. Press FUNCTION to con-tinue.

When entering new parameters, the Smart electronics willreturn to the Run Mode after 12 seconds of no activity withthe new settings immediately in effect. When using the sin-gle-digit LED for programming, if the unit “times-out” pressFUNCTION again to resume adjustments (only on unitswithout a LCD front panel display).

Caution! Before making any adjustment to theSmart electronics device, verify the flow meter is not active-ly monitoring or reporting to any master control system. Anyadjustment to the electronics will cause direct changes toflow control settings.

Chapter 3 Operation Series PFS Instruction Manual

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Flow Meter Start UpWhen applying power to a flow meter equipped with theoptional LCD display you will see the product name, thesoftware version, unit serial number, the current flow rate,the totalized flow, the range number and the user full scale(UFS). Any active alarm will flash on the screen every fewseconds. For meters not equipped with the optional display,when power is applied the on-board single-digit LED flash-es the revision number of the software in a series of 3 dig-its, followed by the range number.

Using the Single-Digit LED for Programming

Software versionshown in series

of 3 digits.

Range in use

Press FUNCTION to view orchange settings.

Use the UP or DOWN button toenter new parameters. PressFUNCTION to continue.

After 12 seconds of non-activity,the settings are saved and themeter returns to the Run Mode.

Version

RangeNo.

Run ModeFUNCTIONAssignments

1

2

3

4

5

6

7

8

9

PressFUNCTION

Voltage Zero

Voltage Span

Current Zero

Current Span

High Alarm

Low Alarm

K-Factor

User Full Scale

Time ResponseDelay

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F-41-PFS 3-3


Using the LCD Display for Programming


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Entering Alarm ParametersUse the High Alarm and Low Alarm function to set or adjustalarm trip points. The alarms have a minimum hysteresis of3% to avoid “chattering.” When setting a window alarm, thealarm setpoints must be at least twice the hysteresis valueapart. We suggest at least a 10% separation between win-dow alarm setpoints. If you choose not to use the highalarm for a specific alarm function, Sierra recommends thatyou set the high alarm at 100% of the user full scale settingwhich creates an “over-range” indicator. Your flow meter willcontinue to indicate flow and generate a signal if the flow isover the maximum range, but will not operate within thespecified accuracy.

Caution! The flow meter must not be reporting ormeasuring gas flow during adjustments.

Entering Alarms with the LCD DisplayEnter alarms setpoints directly in engineering units.

1. Select the desired range. Press FUNCTION, enterthe password. Press FUNCTION until High Alarm orLow Alarm appears on the display.

2. Use the UP or DOWN arrow keys to enter the highor low alarm setpoint value in engineering units.

3. Press FUNCTION to advance to the next option, orafter 12 seconds of non-activity the meter returns tothe Run Mode and the new parameters are ineffect.

Entering Alarms without the LCD DisplayWhen using a DVM to set alarms, the setpoint is a percent-age of the flow meter’s user full scale.

VOLTS = (ALARM PERCENT x 5.0)

If you want to alarm at 25% of user full scale, used in Step3 below, press the UP or DOWN button until 1.25 VDC ispresent on the DVM. If you want to alarm at 75% of user fullscale, press the UP or DOWN button until 3.75 VDC is pre-sent on the DVM.

1. Set the DVM to voltage mode and connectbetween Vout+ and Vout- on the flow meter termi-nal block.

2. Select the desired range. Press the FUNCTION but-ton until a solid “5” (high alarm) or solid “6” (lowalarm) appears on the LED.

3. Adjust the UP or DOWN button until the DVM indi-cates the desired setpoint voltage as describedabove.

4. Press FUNCTION again to advance to the nextoption, or after 12 seconds of non-activity the meterreturns to the Run Mode and the new alarm para-meters are in effect.

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K-Factor AdjustmentEntering a K-factor adjusts the meter’s output signal withoutaffecting the factory calibration curve. Use the K-factor cal-ibration offset for additional flow profile compensation (thefactory includes an initial flow profile correction in the cali-bration curve of the unit).


Entering a K-factor with the LCD DisplayA K-factor value of 1.000 means the output value is notaffected and is the factory default setting. You may enterany number from 0.500 to 5.000.

1. Select the desired range. Press FUNCTION enterthe password. Press FUNCTION until K-factorappears on the display.

2. Use the UP or DOWN arrow keys to enter thedesired K-factor value in engineering units.

3. Press FUNCTION to advance to the next option, orafter 12 seconds of non-activity the meter returns tothe Run Mode and the new K-factor is in effect.

Entering a K-factor without the LCD DisplayA K-factor value of 1.000 VDC means the output value isnot affected and is the factory default setting. You may enterany value from 0.500 to 5.000 VDC in Step 3 below. If thedevice indicated output is 3.0 VDC and you know it shouldbe 3.8 VDC then you could “force” the output to the desired3.8 VDC by adjusting the K-factor to indicate 1.27 VDC(1.27 = 3.8/3.0). Use this formula to determine the desiredK-factor voltage:

VOLTS = DESIRED/INDICATED


2. Select the desired range. Press the FUNCTION but-ton until a solid “7” appears on the LED.

3. Adjust the UP or DOWN button until the DVM indi-cates the desired K-factor value as describedabove.

4. Press FUNCTION to advance to the next option, orafter 12 seconds of non-activity the meter returns tothe Run Mode and the new K-factor is in effect.


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User Full Scale AdjustmentThe user full scale (UFS) feature adjusts the flow meter out-put range anywhere within 50% to 100% of the factory fullscale (FFS). This feature allows you to re-range the voltageor current output of the meter to accommodate differentflow rates. When entering a new user full scale setting forRange 2, it cannot be less than 10% of the Range 1 userfull scale setting.


Changing the User Full Scale with the LCD DisplayThe factory full scale is shown on the flow meter label. If youwant a UFS equal to the FFS, adjust the display to matchthe FFS. If you want to use 50% of FFS, adjust the displayto read 50% of the FFS.

1. Select the desired range. Press FUNCTION enterthe password. Press FUNCTION until User FullScale appears on the display.

2. Use the UP or DOWN arrow keys to enter thedesired UFS value in engineering units.

3. Press FUNCTION to advance to the next option, orafter 12 seconds of non-activity the meter returns tothe Run Mode and the new UFS is in effect.

Changing the User Full Scale without the LCD DisplayIf the FFS is set to 11,000 sfpm and UFS is set to output 5.0VDC, or 100%, the flow meter will indicate 5.0 VDC when11,000 sfpm is present on the probe. If you want 6,000sfpm for UFS, used in Step 3 below, adjust the UFS to6000/11000 or 54.55% of factory full scale. Adjust the volt-age to 2.73 VDC (2.73 = 5 x .5455). Use this formula todetermine the desired UFS voltage:

VOLTS = 5 x User Full Scale/Factory Full Scale


2. Select the desired range. Press the FUNCTION but-ton until a solid “8” appears on the LED.

3. Adjust the UP or DOWN button until the DVM indi-cates the desired user full scale as describedabove.

4. Press FUNCTION to advance to the next option, orafter 12 seconds of non-activity the meter returns tothe Run Mode and the new UFS is in effect.

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Time Response Delay Adjustment

Changing the Time Response Delay with the LCDDisplay

1. Press FUNCTION, enter the password. PressFUNCTION until Time Response appears on thedisplay.

2. Use the UP or DOWN button to adjust the timeresponse delay from 0.10 to 7.2 seconds.

3. Press FUNCTION to advance to the next option, orafter 12 seconds of non-activity the meter returns tothe Run Mode and the new time response setting isin effect.

Changing the Time Response Delay without the LCDDisplay

1. Set the DVM to voltage mode and connectbetween Vout+ and Vout- on the flow meter termi-nal block. Select the desired range. Press theFUNCTION button until a solid “9” appears on theLED.

2. Adjust the UP or DOWN button until the DVM indi-cates the desired voltage (as shown in the followingtable).

3. Press FUNCTION to advance to the next option, orafter 12 seconds of non-activity the meter returns tothe Run Mode and the new time response delaysetting is in effect.

Totalizer ResetIf your device is equipped with the optional LCD display,reset the totalizer using the keypad. If you are unable toopen the flow meter enclosure, use a magnet to reset thetotalizer as shown below.

1. Select the desired range. Enterthe pass word. Press FUNCTIONuntil Total Reset? appears on thedisplay.

2. Press the UP button and thenthe DOWN button until thedisplay reads “ResettingTotalizer.”

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Using the Smart Electronics AdvancedFeaturesZero and span (Function 1 through 4) can be used to vali-date system operation and calibrate the digital to analogsignals on the Smart electronics device. Additionally, thesefunctions can compensate for resistance in long signalcables connected to your data collection or indicating sys-tem.

Caution! Adjusting zero or span will affect metercalibration.

You must use a certified digital voltmeter to adjust zero andspan as the voltmeter acts as a standard. We recommendrecording the current values as shown on the LCD displayor DVM before making any changes to the zero and spansettings. Note: when adjusting zero the voltage signal will bedriven to 0 VDC and when adjusting span the voltage sig-nal will be driven to 5 VDC (or 10 VDC).

Voltage Zero AdjustmentIf needed, use Zero Volts (Function 1) to adjust the 0-5 VDCoutput to 0.0 VDC, or optional 0-10 VDC to 0.0 VDC.

1. Set the DVM to voltage mode and connectbetween Vout+ and Vout-.

2. Press FUNCTION, enter the password (if soequipped). Press FUNCTION until Zero Voltsappears on the LCD display or a solid “1” appearson the LED. Adjust the UP or DOWN button untilthe DVM indicates between 0 and .01 VDC (no lessthan 0.005). The Smart electronics device cannotdrive negative values.

3. After 12 seconds of non-activity, the meter returnsto the Run Mode and the new parameter is in effect.

Voltage Span AdjustmentIf needed, use Span Volts (Function 2) to adjust the 0-5 VDCoutput to 5.0 VDC, or optional 0-10 VDC to 10 VDC.

1. Set the DVM to voltage mode and connectbetween Vout+ and Vout-.

2. Press FUNCTION, enter the password (if soequipped). Press FUNCTION until Span Voltsappears on the LCD display or a solid “2” appearson the LED. Adjust the UP or DOWN button untilthe DVM, indicates between 4.99 and 5.01 VDC.(For 0-10 VDC devices, the target value is 9.99 to10.01.)


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Note: when adjusting zero the current signal will be drivento 4 mA and when adjusting span the current signal will bedriven to 20 mA. We recommend recording the current val-ues before making any changes to the current zero or spansettings.

Current Zero AdjustmentIf needed, use Zero mA (Function 3) to adjust the 4-20 mAoutput to 4.0 mA.

1. Disconnect the 4-20 mA (+) loop wire. Set the DVMto current mode and connect the positive lead tothe wire you just disconnected. Connect the nega-tive lead to the 4-20 mA (-) on the flow meter termi-nal block.

2. Press FUNCTION, enter the password (if soequipped). Press FUNCTION until Zero mA appearson the LCD display or a solid “3” appears on theLED. Adjust the UP or DOWN button until the DVMindicates between 3.95 and 4.05 mA. Set DVMback to voltage mode when adjustment is com-plete.


Caution! Adjusting zero or span will affect metercalibration.

Current Span AdjustmentIf needed, use Span mA (Function 4) to adjust the 4-20 mAoutput to 20.0 mA.

1. Disconnect the 4-20 mA (+) loop wire. Set the DVMto current mode and connect the positive lead tothe wire you just disconnected. Connect the nega-tive lead to 4-20 (-) on the flow meter terminalblock.

2. Press FUNCTION, enter the password (if soequipped). Press FUNCTION until Span mAappears on the LCD display or a solid “4” appearson the LED. Adjust the UP or DOWN button untilthe DVM indicates between 19.95 and 20.05 mA.Set DVM back to voltage mode when adjustment iscomplete.



3-10 F-41-PFS

Instrument ValidationSystem electronics are verified by injecting a known inputvalue and confirming that the flow meter outputs theexpected value. This test confirms that the microprocessor,analog to digital and digital to analog converters, the lin-earizer and the display are working properly. Sensor valida-tion is accomplished by measuring the resistance of thevelocity and temperature sensors and comparing the resultsto the NIST-traceable calibration data provided with the flowmeter. These tests confirm that your meter is working cor-rectly and the calibration variables did not drift, shift orchange values.

To perform the instrument validation procedures you willneed these items:

• certified digital multimeter with minimum 4 char-acter resolution, accuracy of at least ±0.1% orrange

• Calibration Certificate supplied with the flowmeter

• small pot adjusting tool (screwdriver)

Before beginning the validation procedures, review Figure3-2 and Figure 3-3 to familiarize yourself with the compo-nent locations.

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F-41-PFS 3-11


Electronics Validation Procedure

Caution! Before beginning this procedure, makesure the flow meter is not actively monitoring or reporting toany master control system. Any adjustment to the electron-ics will cause direct changes to flow control settings.

1. Verify the flow meter is off line from any remotecommunications. Make sure the meter’s user fullscale setting is the same as the factory full scalesetting. If not, enter the user full scale value asneeded.

2. Locate the Calibration Certificate supplied with theflow meter. Record in Table 3-1 the five bridge volt-age values, the output (VDC or mA) values and theindicated flow values.

3. Remove power from the flow meter. Remove thecover of the flow meter enclosure to access thewiring terminal block and the Smart electronicsdevice.

4. Set the multimeter to the 20 volt range. Connect toBV (+) and BV (-) terminals on the flow meter termi-nal block.

5. Move the J1 Cal/Run jumper on the Smart elec-tronics device to the CAL position.

6. Locate potentiometer VR3 on the Smart electronicsdevice. Turn on power to the flow meter.

7. Adjust potentiometer VR3 until the multimetermatches the first bridge voltage point (the valuemust be ±0.002 VDC of the bridge voltage point).

8. Record the resulting flow shown on the optionalLCD display in Table 3-1. If not using a display or ifyou prefer to validate one of the analog output sig-nals, move the multimeter + connection to Vout (+).Record the resulting output voltage in Table 3-1. Ifusing a 4-20 mA calibrated meter, set the multime-ter to read current and connect the meter to readthe mA signal in your connected loop. Record theresulting current output in Table 3-1.

9. Repeat Step 7 and Step 8 to record the results ofthe remaining four bridge voltage validation points.

10. Compare the results recorded in Table 3-1.Indicated values must be within the flow meter’sstated accuracy shown on the CalibrationCertificate.

3-12 F-41-PFS


11. When data collection is complete, turn off power tothe flow meter. Disconnect the multimeter from theflow meter terminal block.

12. Place the J1 Cal/Run jumper in the RUN position.Make sure the jumper is securely in place beforeresuming flow meter operation. Replace the flowmeter cover.

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F-41-PFS 3-13


Sensor Validation Procedure

Warning! Do not power the flow meter with thesensor jumper disconnected. This could cause over-heatingof the sensors and/or damage to the electronics.

1. Locate the Ro temperature (measured resistance at0°C) value and the Alpha Ro value shown on theCalibration Certificate supplied with the flow meter.

2. Turn off power to the flow meter. Allow a 6minute cool-down before continuing.

3. Remove the cover of the flow meter enclosure toaccess the sensor connection points. Remove thefour-position jumper from J5, J6, J7 and J8. (SeeFigure 3-3 on previous page for location.)

4. Set the multimeter to read Ohms in the 2K range.Connect the multimeter to the left-side terminals ofJ5 and J6 (temperature sensor). Measure the resis-tance between J5 and J6 and record the tempera-ture sensor resistance (in Ohms) in Table 3-2.

5. Connect the multimeter to left-side terminals of J7and J8 (velocity sensor). Measure the resistancebetween J7 and J8 and record the velocity sensorresistance (in Ohms) in Table 3-2.

6. Use the measured resistace values and the Ro andAlpha Ro values from the Calibration Certificate tocalculate the temperature for each sensor as fol-lows:

7. Compare the results recorded in Table 3-2. Thesensors are validated if they are within 10 degreesCelsius of each other.

8. Disconnect the multimeter and replace the four-position jumper on the sensor terminals. Makesure the jumper is securely in place beforeapplying power. Replace cover.

T =R–R0

Alpha x R0

WhereT = degrees CelsiusR = measured sensor resistanceR0 = resistance at 0°C (from the Calibration Certificate)Alpha = value unique to each sensor (from the Calibration Certificate)

Series PFS Instruction Manual Chapter 4 Troubleshooting & Repair

Chapter 4 Troubleshooting &Repair

Troubleshooting the Flow MeterBegin hardware troubleshooting by verifying the followingfacilities issues are correct. These areas impact systemoperation and must be corrected prior to performing anyflow meter inspections.

Warning! Before attempting any flow meter repair,verify that the line is not pressurized.

Always remove main power before disassembling any partof the mass flow meter.

1. Verify the incoming power to the flow meter is pre-sent and of the correct voltage and polarity.

2. Check the flow meter wiring for correct connectionsas described in Chapter 2.

3. Verify the flow meter is installed with the correctnumber of upstream and downstream pipe diame-ters as shown on page 2-2.

4. Verify the flow direction indicator is correctly alignedpointing downstream of flow.

5. Make sure there are no leaks in the line being mea-sured.

After verifying the factors above, follow the troubleshootingprocedures outlined on the next page. If you need to returnthe flow meter to the factory, see the page 4-3 for ReturnMaterial Authorization (RMA) and shipping instructions.

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Chapter 4 Troubleshooting & Repair Series PFS Instruction Manual

4-2 F-41-PFS

Problem

Velocity measure-ment is erratic orfluctuating

Velocity measure-ment seems toohigh or low

No response to flowfrom sensor assem-bly

Possible Cause

Very erratic or non-uniform flow

Flow meter installedwith less thanrequired minimumpipe diametersupstream and down-stream

Insertion sensorprobe not mountedsecurely

Sensor componentbroken

Malfunction in systemelectronics

Ground loop

Sensor assembly notaligned correctly toflow

Sensor probe notinserted to the properdepth

No power

Printed circuit assem-bly defective

Sensor failure

Low flow cutoff toohigh

Flow rate belowmeter’s minimum flowrating

Flow has exceededthe maximum rangeof the flow meter

Solution

Follow installationrequirements shownin Chapter 2

Follow installationrequirements shownin Chapter 2

Sensor probe mustbe mounted securelywithout vibration

Return to factory forreplacement

Return to factory forevaluation

Check wiring, seeChapter 2

Correct alignmentwith the flow indicatorpointing downstreamin the direction of flow

Verify sensing point islocated on the center-line of the pipe

Turn on power to theflow meter



Correct low flow cut-off programmingusing the SmartInterface software

Contact factory forinstructions

Reduce flow belowthe maximum rangeshown on the meter’snameplate or contactthe factory for re-cali-bration advice

Series PFS Instruction Manual Appendix A Specifications

Appendix A Product SpecificationsPerformance Specifications

Accuracy ±1% of full scale

Repeatability ±0.2% of full scale

Temperature Coefficient ±0.02% of reading per °F within ±50°F of cus-tomer specified conditions±0.03% of reading per °F within ±50°F to100°F of customer specified conditions±0.04% of reading per °C within ±25°C ofcustomer specified conditions±0.06% of reading per °C within ±25°C to50°C of customer specified conditions

Pressure Coefficient Negligible when within ±50 psi (±3.4 bar) ofcustomer specified conditions

Response Time 100 milliseconds to 63% of final velocity value

Operating Specifications

Gases Air, nitrogen and other non-combustible, non-corrosive gases

Mass Flow Rates 0 to 200 sfpm (0 to 1 nmps) minimum, 0 to20,000 sfpm (0 to 100 nmps) maximum for airand nitrogen (maximum full scale varies withgas)

Dual Calibration User-selectable dual ranges or two differentgases (the user full scale for Range 2 two can-not be less than 10% of the full scale forRange 1)

Gas Pressure 150 psig (10 bar) maximum

Pressure Drop Negligible

Gas & Ambient Temperature Gas………-40° to 250°F (-40° to 120°C)Ambient…32° to 120°F (0° to 50°C)

Power Requirements 11 to 18 VDC (regulated), 625 mA maximum18 to 30 VDC (regulated), 625 mA maximum

Output Signal Linear 0-5 VDC or 0-10 VDC proportional topoint mass flow rate or velocity, 1000 Ohmsminimum load resistance, or Linear 4-20 mAproportional to point mass flow rate or veloci-ty, 700 Ohms maximum resistance (powersupply dependent), optically isolated (isolationis an input-to-output isolation of 1500 VAC for1 minute)

Alarms User-adjustable low, high or window alarmsDeadband adjustable with Smart Interface™

softwareRelay rating……Maximum 42 VAC or 42VDC, 140 mA, 27 Ohm maximum on-resis-tance, optically isolated (isolation is an input-to-output isolation of 1500 VAC for 1 minute)

Display Alphanumeric 2 x 12 digit backlit LCDAdjustable variables via on-board membranebuttons or with Smart Interface softwareAdjustable variables……Full scale adjustment(50 to 100%)Time delay response (0.1 to 7.2 seconds)Correction factor setting (0.5 to 5)Zero and span adjustments

Totalizer Eight digits (99,999,999) in engineering units,resetable by user

Software Smart Interface™ Windows™-based software,minimum 8 MB of RAM, preferred 16 MB ofRAM, RS-232 communication

Physical Specifications

Wetted Materials Probe: 304SS; Sensor: high temperatureglass filled polyester-plastic epoxy and ceram-ic

Enclosure NEMA 4X (IP65) powder-coated cast alu-minum enclosure

Mounting (optional) 3/8˝ tube compression fitting with 1/2˝ maleNPT

Certifications CE approved

F-41-PFS A-1

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precision flow insertion mass flow meter instruction manual

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