Onicon F-1100 Series, Installation And Operation Manual

Page 1: ...1500 North Belcher Road Clearwater FL 33765 Tel 727 447 6140 Fax 727 442 5699 www onicon com sales onicon com TURBINE FLOW METER Installation and Operation Guide 05 13 0721 1 13518 ...

Page 2: ...or any third party is harmed by the use of this product ONICON assumes no responsibility for any such harm owing to any defects in the product which were not predictable or for any indirect damages Safety Precautions The following general safety precautions must be observed during all phases of installation operation service and repair of this product Failure to comply with these precautions or wi...

Page 3: ...ts 13 3 3 4 Customer Supplied Installation Hardware 14 3 3 5 Confirming the Stack Height 15 3 4 Installing the Insertion Meter 16 3 4 1 Adjusting of the Meter Insertion Depth 17 3 5 Removal of the Insertion Meter 17 3 6 Inline Flow Meter Straight Run Requirements and Mechanical Installation 19 3 7 Wiring Connections 20 4 0 START UP COMMISSIONING 21 4 1 Helpful Hints for Start up and Commissioning ...

Page 4: ...rate or maintain this equipment unless they have a complete knowledge of their trade skills and are competent to work on high pressure hot and cold water systems according to their individual trades Death or permanent injury may result from accidents with these systems This guide is the basic reference tool for all ONICON Turbine Flow Meters If you have not purchased all of the options there will ...

Page 5: ...Range Standard 140 F continuous 150 F peak High Temp 280 F continuous 300 F peak Insertion meters operating above 250 F require 316 stainless steel construction option Ambient Temperature Range 5 to 160 F 20 to 70 C Operating Pressure 400 PSI maximum Pressure Drop F 1100 F 1200 FB 1200 Series Less than 1 PSI at 20 ft s in 2 pipe decreasing in larger pipes and lower velocities F 1300 Series 3 PSI a...

Page 6: ... pulse For connection to ONICON display or BTU meter only Signal is too fast for most building control systems 0 500 Hz 10 Analog Output non isolated Provides both 4 20 mA and 0 10 V outputs Most commonly used output type 3 wire connection 11 Isolated Analog Output Provides both 4 20 mA and 0 10 V outputs Signal ground is isolated from power supply and pipe ground 4 wire connection 20 Divided Outp...

Page 7: ... documentation package which includes the following items Installation and Operation Guide Flow Meter Calibration Certificate Please notify the ONICON customer service department if any documents are missing The Flow Meter The flow meter was carefully packed prior to shipment and should arrive without any damage Prior to installation inspect for physical damage such as broken turbine blades or a d...

Page 8: ...s and heavy vibration The following information should be used as a guide to the proper location for installing the meter GENERAL PRACTICES 1 For best results install the flow meter in a straight run of pipe free of bends tees valves transitions and obstructions 2 Straight run requirements vary based on the nature of the upstream obstruction Review the following pages for guidelines in determining...

Page 9: ...Available Straight Run 23 36 Depending on pipe size CLEARANCE REQUIRED FOR INSTALLATION FLOW 20 80 Upstream Downstream Available Straight Run Vertical pipe position See following pages for model specific straight run requirements EVALUATING UPSTREAM PIPING CONDITIONS Straight Pipe Single Bend Pipe Reduction or Enlargement Outflowing Tees Multiple Bends in Same Plane Multiple Bends Out of Plane Inf...

Page 10: ...N Minimum upstream straight run distance 20 pipe diameters from any valve elbow fitting etc Minimum downstream straight run distance 5 pipe diameters to any valve elbow fitting etc Series F 1200 Dual Turbine Flow Meters FLOW DIRECTION GENERAL PRACTICES 1 For best results install the flow meter in a straight run of pipe free of bends tees valves transitions and obstructions for a distance of 10 pip...

Page 11: ...ers from any valve elbow fitting etc Minimum downstream straight run distance 10 pipe diameters to any valve elbow fitting etc FLOW DIRECTION SWITCH OPEN Insufficient Straight Run Guidelines for Bi directional Flow Applications If there is insufficient available straight run allow 50 of the run upstream and 50 of the run downstream If the total length of straight run is less than 20 diameters perf...

Page 12: ...nd fittings are full port and at least 1 in actual internal diameter CAUTION ONICON insertion style flow meters must be installed through a valve assembly Failure to do so negates the ability to remove the meter without shutting down flow and draining the system It will also result in an excessive amount of stem protruding from the pipe Excessive stem lengths unneccessarily expose the meter to inc...

Page 13: ...is eliminates the need to stop flow and drain the pipe Please read all instructions before proceeding with meter insertion 3 3 1 Insertion Meter Installation Kits ONICON offers a wide range of installation hardware kits for commonly used pipe materials The kits are specifically designed for ONICON insertion flow meters and their use is recommended Refer to Appendix B of detailed infromation regard...

Page 14: ...1 opening in the pipe wall is required to clear the sensor head and allow for insertion Make sure that your valves and fittings are full port and at least 1 in actual internal diameter Installation hardware generally consists of three separate component parts CAUTION In order to provide the flow meter with the correct stem length ONICON must know the overall height of the installation hardware as ...

Page 15: ...w for variations of at least 2 in the stack height Contact ONICON prior to installation if there is any question regarding stack height or stem length This will allow ONICON to offer you credit for your meter if you decide to exchange the meter for one with a different stem length Returns may be subject to a restocking fee Depth Gage 1 Pierce insulation until gage tip touches pipe Lock Nut READ OT...

Page 16: ...ING THE CLAMPING NUT Damage to this nut or the clamping ring under the nut may prevent the assembly from properly holding the meter in the pipe The clamping nut is not part of the sealing mechanism Any leaks in this area indicate that the O ring is not sealing properly and you must contact the factory for assistance WARNING When you are ready to refill the system make sure that all lines are fille...

Page 17: ...g serious injury WARNING Prior to removal of the meter make sure that you are standing on a secure platform and have both hands available to manipulate the flow meter CAUTION Do not release the flow meter until you have tightened the position clamping nut enough to hold the flow meter in the desired position This will require less torque than you might think so be careful not to overtighten it and...

Page 18: ...ing the electronics enclosure firmly in hand BEFORE loosening the position clamping nut The effort required is the same as that required for insertion of the meter and should be calculated according to the formula in section 3 4 covering insertion of the meter This effort will be 0 11 times the pipe pressure If your footing is not secure or if your ability to hold the meter is limited for any reas...

Page 19: ...se note that ONICON strongly recommends the use of strainers upstream of the meter location d ONICON also recommends the installation of isolation valves and a bypass loop to accommodate servicing the meter Isolation Valve Normally Open 5 Dia Minimum Straight Run Downstream Isolation Valve Normally Open Bypass Valve Normally Closed 20 Dia Minimum Straight Run Upstream y Strainer Upstream of Flow M...

Page 20: ...nnecting wires FNPT conduit connection FLOW 3 7 WIRING CONNECTIONS Make connections to the 10 cable which is supplied by ONICON and is pre wired to the circuit board The most common cause of electronic failures are miswired connections If you are adding additional cable please record any substitution of wire colors If additional cable is purchased from ONICON the color code can be maintained Cable...

Page 21: ...duce a signal You can test the meter by holding the turbines under a faucet or carefully moving it back and forth in a bucket of water 3 When measuring analog output signals remember that current mA must be measured in series while voltage is measured in parallel If the 4 20 mA signal is already connected to a control system you must break the connection and measure the signal in series 4 When mea...

Page 22: ...4 4 V is available Serial Numbers 115692 and later can accept 24 V DC or AC but earlier meters required 24 VDC Note ONICON display module or BTU meter provide 24 VDC to the flow meter ONICON display modules and BTU meters are typically powered by 120 VAC however low voltage versions are also available 8 Connect power Wait approximately 45 seconds after power on before proceeding further The follow...

Page 23: ... display or BTU meter serial if ordered 6 Signal connections verified 7 Supply voltage verified 8 Connect power The following steps require flow in the pipe Flow signal readings should be taken while holding the flow rate con stant if possible otherwise take the various output readings as quickly as possible 9 Frequency output s Avg green Top white Bottom orange Avg Freq HZ Avg Freq VDC Hz VDC Hz ...

Page 24: ...ICON display modules and BTU meters are typically powered by 120 VAC however low voltage versions are also available 6 Connect power Wait approximately 45 seconds after power on before proceeding further The following steps require flow in the pipe Flow signal readings should be taken while holding the flow rate constant if possible otherwise take the various output readings as quickly as possible...

Page 25: ... Control system programming 3 Match display or BTU meter serial if ordered 4 Signal connections verified 5 Supply voltage verified 6 Connect power The following steps require flow in the pipe Flow signal readings should be taken while holding the flow rate con stant if possible otherwise take the various output readings as quickly as possible 7 Frequency output s Avg green Top white Bottom orange ...

Page 26: ...lel with the pipe Verify correct wiring to control system see wiring diagram Confirm that output signals agree with each other frequency vs analog etc Confirm that control system is programmed for correct flow range or scale factor Check turbine s for debris Analog signal seems high or low and does not correspond to frequency output Check for ground loop or offset voltage Disconnect analog signal ...

Page 27: ...sing circuitry detects the rotation of a freely spinning axial turbine which is immersed in the flow stream As each turbine blade passes a fixed electrode an electronic pulse is produced by the circuitry In the case of single turbine meters the pulse rate is then calibrated in terms of the number of pulses per gallon for whatever size pipe the user has selected This number is referred to as the ME...

Page 28: ...entiometer on the analog card to produce a 10 V reading on the voltmeter NOTE The frequency ranges in the table below are a starting point and since they vary with electronic component tolerance it may be necessary to change the jumper position once rescaling is started If the range of adjustment of the span potentiometer is not sufficient to produce the desired 10 VDC change the jumper position a...

Page 29: ...500 North Belcher Road Clearwater FL 33765 Tel 727 447 6140 Fax 727 442 5699 sales onicon com Turbine Flow Meter Manual 05 13 0721 1 13518 Page 29 APPENDIX A User Connections and Internal Wiring Diagrams ...

Page 30: ...er DIAGNOSTIC SIGNALS ORANGE Bottom turbine frequency WHITE Top turbine frequency These signals are for diagnostic purposes connect to local display or BTU meter Connect to power supply positive F 1 1 0 0 S i n g l e T u r b i n e F 1 3 0 0 I n l i n e F 1 2 0 0 D u a l T u r b i n e F B 1 2 0 0 B i D i r e c t i o n a l FB 1200 Wiring Diagram Connections to ONICON Display or BTU Meter F 1100 F 12...

Page 31: ...INE F 1200 ONLY ORANGE WIRE FREQUENCY BOARD TOP TURBINE F 1200 ONLY WHITE WIRE EXTERNAL CABLE CONNECTIONS GREEN WIRE BOARD TO BOARD RED WIRE BOARD TO BOARD BLACK WIRE BOARD TO BOARD EXTERNAL CABLE NOTE INTERNAL CONNECTIONS OMITTED FOR CLARITY 1500 North Belcher Road Clearwater FL 33765 Tel 727 447 6140 Fax 727 442 5699 sales onicon com WIRING DIAGRAM INTERNAL CONNECTIONS FOR FREQUENCY OUTPUT FLOW ...

Page 32: ... Top turbine frequency These signals are for diagnostic purposes connect to local display or BTU meter Connect to power supply positive F 1 1 1 0 S i n g l e T u r b i n e F 1 3 1 0 I n l i n e F 1 2 1 0 D u a l T u r b i n e F B 1 2 1 0 B i D i r e c t i o n a l FB 1210 Wiring Diagram Connections to a Control System No Display or BTU Meter RED BLACK BLUE BROWN GRAY VIOLET 24 V COM SIGNAL GROUND A...

Page 33: ...OUTPUT GREEN WIRE COMMON GROUND BLACK WIRE 24V AC DC SUPPLY RED WIRE TOP TURBINE F 1210 ONLY WHITE WIRE BOTTOM TURBINE F 1210 ONLY ORANGE WIRE EXTERNAL CABLE NOTE CONNECTIONS OMITTED FOR CLARITY TEST SIGNAL INPUT RANGE JUMPER FACTORY SELECTED 4 mA ZERO ADJUST BLACK WIRE BOARD TO BOARD GREEN WIRE BOARD TO BOARD RED WIRE BOARD TO BOARD 10 V 20 mA SPAN ADJUST NON ISOLATED ANALOG OUTPUT For use with s...

Page 34: ...gnostic purposes connect to local display or BTU meter Connect to power supply positive F 1 1 1 1 S i n g l e T u r b i n e F 1 3 1 1 I n l i n e F 1 2 1 1 D u a l T u r b i n e F B 1 2 1 1 B i D i r e c t i o n a l FB 1211 Wiring Diagram Connections to a Control System No Display or BTU Meter F 1111 F 1211 F 1311 Wiring Diagram Connections to a Control System No Display or BTU Meter NOTES 1 Seria...

Page 35: ... 447 6140 Fax 727 442 5699 www onicon com E mail sales onicon com 0068 2 EXTERNAL CABLE NOTE INTERNAL CONNECTIONS OMITTED FOR CLARITY TOP TURBINE F 1211 ONLY WHITE WIRE BOTTOM TURBINE F 1211 ONLY ORANGE WIRE ISOLATED GROUND YELLOW WIRE 4 20 mA OUTPUT BLUE WIRE 0 10 V OUTPUT BROWN WIRE FREQUENCY OUTPUT GREEN WIRE COMMON GROUND BLACK WIRE 24V AC DC SUPPLY RED WIRE TEST SIGNAL INPUT RANGE JUMPER FACT...

Page 36: ...Contact closed when flow is in direction of arrow on meter DIAGNOSTIC SIGNALS ORANGE Bottom turbine frequency WHITE Top turbine frequency These signals are for diagnostic purposes connect to local display or BTU meter Connect to power supply positive F 1 1 2 0 S i n g l e T u r b i n e F 1 3 2 0 I n l i n e F 1 2 2 0 D u a l T u r b i n e F B 1 2 2 0 B i D i r e c t i o n a l FB 1220 Wiring Diagra...

Page 37: ... Florida 33765 Tel 727 447 6140 Fax 727 442 5699 www onicon com E mail sales onicon com 0069 1 AVAILABLE BINARY DIVIDER SELECTIONS SELECT ONLY ONE VALUE OR THE DIVISION WILL NOT BE CORRECT TOP TURBINE F 1220 ONLY WHITE WIRE BOTTOM TURBINE F 1220 ONLY ORANGE WIRE BROWN WIRE DIVIDED OUTPUT SWITCH BLUE WIRE FREQUENCY OUTPUT GREEN WIRE COMMON GROUND BLACK WIRE 24V AC DC SUPPLY RED WIRE EXTERNAL CABLE ...

Page 38: ...ORANGE Bottom turbine frequency WHITE Top turbine frequency These signals are for diagnostic purposes connect to local display or BTU meter Connect to power supply positive F 1 1 3 0 S i n g l e T u r b i n e F 1 3 3 0 I n l i n e F 1 2 3 0 D u a l T u r b i n e F B 1 2 3 0 B i D i r e c t i o n a l FB 1230 Wiring Diagram Connections to a Control System No Display or BTU Meter F 1130 F 1230 F 1330...

Page 39: ...0 7 6 5 3 1 TO ON VAL SW 1 1 1 2 1 4 1 8 1 2048 1 1024 1 512 1 256 1 128 1 64 1 32 1 16 NOTES 8 22 00 1500 North Belcher Road Clearwater Florida 33765 Tel 727 447 6140 Fax 727 442 5699 www onicon com E mail sales onicon com 0070 1 DESIRED RATIO 629 Subtract the largest possible switch value CONTACT CLOSURE DURATION JUMPER SETTING DIVISION RATIO EXTERNAL CABLE NOTE INTERNAL CONNECTIONS OMITTED FOR ...

Page 40: ...1500 North Belcher Road Clearwater FL 33765 Tel 727 447 6140 Fax 727 442 5699 sales onicon com Turbine Flow Meter Manual 05 13 0721 1 13518 Page 40 APPENDIX B Installation Hardware Instructions ...

Page 41: ... and reduced accuracy 0536 1 15950 9 5 08 This kit must be installed prior to lling the system or into a section of pipe that is isolated from pressure and Àow Once installed this kit allows for insertion and removal of the Àow meter without a system shutdown Do not substitute threaded tees for the welded branch outlet Contact ONICON if you need installation hardware for threaded pipe For Use With...

Page 42: ...emoval of the flow meter without a system shutdown For Use With Kits INSTL2 INSTL6 INSTL31 Directions 1 Identify an appropriate location for the flow meter see pages 2 4 2 Weld the branch outlet onto the pipe 3 Install the close nipple and ball valve as shown below Use a paste type thread sealant DO NOT use Teflon tape 4 Use a hot tap drilling machine with a 1 hole saw to drill the access hole 5 R...

Page 43: ...ter without a system shutdown For Use With Kits INSTL3 1 INSTL4 INSTL9 Directions 1 Identify an appropriate location for the flow meter see pages 2 4 2 Solder or braze the copper tee and adapter provided 3 Install the ball valve as shown below Use a paste type thread sealant DO NOT use Teflon tape 4 Flush and fill the system prior to installing the meter NOTE Before installing the flow meter read ...

Page 44: ...tem shutdown For Use With Kit INSTL3 1 Directions 1 Identify an appropriate location for the flow meter see next page 2 Solder or braze the copper tee and adapters provided 3 Install the ball valve as shown below Use a paste type thread sealant DO NOT use Teflon tape 4 Flush and fill the system prior to installing the meter NOTE Before installing the flow meter read the entire installation manual ...

Page 45: ...This kit must be installed prior to filling the system or into a section of pipe that is isolated from pressure and flow Once installed this kit allows for insertion and removal of the flow meter without a system shutdown Directions 1 Identify an appropriate location for the flow meter see pages 2 4 2 Clamp the saddle onto the pipe refer to manufacturer s instructions 3 Drill a 1 minimum access ho...

Page 46: ...B 1200 Series Insertion Turbine Flow Meters This kit can be installed on a pressurized pipe A hot tap drilling machine is used to create a one inch opening in the pipe wall Once installed this kit allows for insertion and removal of the flow meter without a system shutdown Directions 1 Identify an appropriate location for the flow meter see pages 2 4 2 Clamp the saddle onto the pipe refer to manuf...

Page 47: ...w Once installed this kit allows for insertion and removal of the flow meter without a system shutdown Directions 1 Identify an appropriate location for the flow meter see pages 2 4 2 Install the threaded pipe nipple close nipple and ball valve as shown below Use a paste type thread sealant DO NOT use Teflon tape 3 Flush and fill the system prior to installing the meter NOTE Before installing the ...

Page 48: ...1500 North Belcher Road Clearwater FL 33765 Tel 727 447 6140 Fax 727 442 5699 sales onicon com Turbine Flow Meter Manual 05 13 0721 1 13518 Page 48 APPENDIX C Turbine Assembly Detail Drawings ...

Page 49: ...ast 015 of movement TUNGSTEN CARBIDE TURBINE SHAFT 1500 North Belcher Road Clearwater Florida 33765 Tel 727 447 6140 Fax 727 442 5699 www onicon com E mail sales onicon com Replace turbines in the same end for end relationship to the direction of flow Mark one end of the turbine and the same end of the upper support with a permanent felt tip marker After re assembly test the turbine for free rotat...

Page 50: ...RBIDE TURBINE SHAFT NON REMOVABLE SUPPORT POST Replace turbines in the same upper or lower location and in the same end for end relationship to the direction of flow Mark one end of each turbine and the same end of the upper support with a per manent felt tip marker After re assembly test the turbines for free rotation by gently blowing on the tur bines PARALLEL TO THEIR SHAFTS The turbines must s...

Page 51: ...1500 North Belcher Road Clearwater FL 33765 Tel 727 447 6140 Fax 727 442 5699 sales onicon com Turbine Flow Meter Manual 05 13 0721 1 13518 Page 51 APPENDIX D Conditions of Sale ...

Page 52: ...the sale or shipment of the products under this contract will be added to the purchase price Buyer agrees to reimburse ONICON for such tax or charge or provide ONICON with an acceptable exemption certificate Payment of invoices will be due 30 days from the date of shipment of the products contained therein In the event that payment of an invoice is not received by the invoice due date ONICON will ...

Page 53: ...1500 North Belcher Road Clearwater FL 33765 Tel 727 447 6140 Fax 727 442 5699 sales onicon com Turbine Flow Meter Manual 05 13 0721 1 13518 Page 53 ...