GreenPrima PROLEV700-H Clamp-On Ultrasonic Heat Meter

Overview

The GreenPrima PROLEV700-H is a clamp-on, transit-time ultrasonic heat meter engineered for non-intrusive, high-reliability thermal energy measurement in industrial hydronic systems. Unlike inline flowmeters requiring pipe cutting or system shutdown, the PROLEV700-H employs dual-sensor transducers mounted externally on the pipe wall—leveraging precise time-of-flight differential measurements of ultrasonic signals propagating with and against the fluid flow. This principle enables volumetric flow rate calculation with inherent immunity to pressure drop, mechanical wear, or fouling. When integrated with certified Class B Pt1000 temperature sensors (per EN 1434 and ISO 4064-1), the device computes thermal energy (kWh or MJ) in accordance with EN 1434-3 and MID Annex MI-004 requirements. Its design targets continuous operation in demanding process environments—including hot water distribution, chilled water circuits, district heating networks, and closed-loop cooling systems—where long-term stability, zero maintenance, and regulatory traceability are essential.

Key Features

• True clamp-on installation: No pipe penetration, no process interruption, no welding or valve isolation required—reducing commissioning time and lifecycle cost.
• Transit-time ultrasonic technology with automatic signal optimization: Adaptive gain control and cross-correlation algorithms ensure robust performance across varying pipe conditions, fluid turbidity, and low-flow regimes (down to 0.01 m/s).
• Dual-range thermal capability: The PROLEV700-H variant supports medium temperatures up to +100 °C, enabling use in high-temperature hot water and steam condensate return applications—unlike standard PROLEV700 (0–50 °C).
• Modular sensor mounting: Precision-machined aluminum clamps with micro-adjustment screws guarantee consistent transducer alignment and acoustic coupling across pipe diameters from DN32 to DN1000.
• Industrial-grade electronics: ABS housing rated IP65; sensor housings sealed to IP68; operating ambient range −10 °C to +50 °C; EMC compliant per EN 61326-1 for industrial environments.
• Integrated dual-channel analog output (4–20 mA) and pulse output (OCT, 0–5000 Hz) for simultaneous connection to DCS, PLC, or building management systems (BMS).

Sample Compatibility & Compliance

The PROLEV700-H is validated for clean, homogeneous liquids with minimum sonic transmission—primarily water, glycol-water mixtures (up to 50% concentration), and other low-viscosity aqueous media. It is incompatible with highly aerated, heavily particulate-laden, or gaseous fluids. Pipe material compatibility includes carbon steel, stainless steel (304/316), copper, cast iron, PVC, and GRP—provided wall thickness and acoustic impedance permit sufficient ultrasonic coupling. The device conforms to key international standards: EN 1434-1:2015 (heat meters), EN 1434-3:2015 (accuracy class B), MID Directive 2014/32/EU (Measuring Instruments Directive) for legal metrology in EU member states, and EN 61000-6-2/-6-4 for electromagnetic immunity and emissions. Optional factory calibration certificates include traceability to UKAS-accredited laboratories (ISO/IEC 17025).

Software & Data Management

Configuration and diagnostics are performed via GreenPrima’s PC-based FlowConfig Pro software (Windows-compatible), supporting real-time parameter adjustment, sensor alignment verification, signal quality assessment, and data logging. The embedded Modbus RTU interface (RS-485, two-wire) enables seamless integration into SCADA and MES platforms. All configuration changes—including flow unit selection, temperature compensation coefficients, and pulse scaling—are stored with timestamped audit trails. For regulated environments (e.g., pharmaceutical utilities or power plant QA/QC), optional firmware upgrade supports 21 CFR Part 11-compliant electronic signatures and user-access levels (admin/operator/viewer). Data export formats include CSV and XML, compatible with historian systems such as OSIsoft PI or Emerson DeltaV.

Applications

• District heating substation metering: Accurate tenant-level thermal billing per EN 1434 and local utility regulations.
• HVAC energy optimization: Real-time monitoring of chiller plant efficiency, boiler return temperature differentials, and pump energy consumption ratios.
• Power generation auxiliary systems: Condensate return flow verification, cooling tower make-up water accountability, and turbine gland steam condensate tracking.
• Pharmaceutical & biotech utilities: Monitoring of pure steam distribution loops (post-pressure reduction), WFI circulation flow consistency, and clean-in-place (CIP) solution volume reconciliation.
• Industrial process cooling: Closed-loop monitoring of die-casting mold coolant, laser cutting assist gas chillers, and extrusion barrel jacket flows.

FAQ

Can the PROLEV700-H be used on insulated or coated pipes?
Yes—provided insulation thickness does not exceed 50 mm and pipe coating materials (e.g., epoxy, bitumen) are acoustically transparent. Field verification using the built-in signal strength indicator is recommended prior to final commissioning.

Is field recalibration required after initial setup?
No. The transit-time method is inherently drift-free; no zero or span adjustments are needed during service life. Annual verification against a portable reference meter (e.g., wet calibration or master meter comparison) satisfies ISO 5167 and EN 1434-4 periodic verification requirements.

What is the maximum cable distance between sensor and transmitter?
Standard configuration supports 9 m; extended versions are available up to 305 m using shielded, twisted-pair cable meeting IEC 60227 specifications. Signal integrity is maintained via active differential signaling and onboard noise filtering.

Does the device support temperature sensor redundancy?
Yes—the host accepts dual independent Pt1000 inputs (supply and return), with configurable fault-handling logic (e.g., hold-last-valid, alarm-only, or default-to-zero-energy mode) per EN 1434-3 Annex C.