Onicon F-5100 Inline, Installation And Operation Manual

Page 1: ...F 5100 Insertion Thermal Mass Flow Meter Installation and Operation Guide sales mvandc com Phone 877 566 3837 Fax 925 407 2903 ...

Page 2: ...h 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 with specific WARNINGS given elsewhere in this manual violates safety standards of design manufacture ...

Page 3: ...ON REMOVAL AND ADJUSTMENT 11 3 1 INSTALLATION SITE SELECTION 11 3 2 MECHANICAL INSTALLATION 13 3 2 1 Installation Kits 13 3 2 2 Directions For Standard Installation new construction 14 3 2 3 Directions For Hot Tap Installation pressurized system 14 3 3 INSTALLING THE FLOW METER 15 3 3 1 Determining the Insertion Depth Inserting the Meter and Tightening the Compression Fitting 15 3 4 REMOVING THE F...

Page 4: ...L HINTS FOR START UP COMMISSIONING 23 4 4 START UP COMMISSIONING 24 4 5 START UP COMMISSIONING WORKSHEET 25 5 0 TROUBLESHOOTING GUIDE 26 APPENDIX A 1 REMOTE MOUNT MECHANICAL HARDWARE A 2 USE OF THE INSERTION DEPTH GAGE A 3 A 5 ZERO FLOW CALIBRATION TEST A 6 CONDITIONS OF SALE sales mvandc com Phone 877 566 3837 Fax 925 407 2903 ...

Page 5: ... If you have not purchased all of the options there will be references in this manual which are not applicable to your meter s 1 2 TYPICAL INSERTION THERMAL MASS FLOW METER Each ONICON thermal mass meter has a single pair of encapsulated platinum sensors that are in direct contact with the gas The sensors consist of highly stable reference grade platinum windings One sensor is self heated and serv...

Page 6: ...0 to 200 F Optional 200 to 300 F Optional 300 to 450 F Optional 450 to 700 F AMBIENT TEMPERATURE RANGE 5 to 150 F MAXIMUM OPERATING PRESSURE Standard 500 PSI Optional 1 000 PSI MATERIALS OF CONSTRUCTION Wetted metal components 316L stainless steel Sensor head Platinum windings encapsulated in 316L stainless steel Electronics enclosure Powder coat painted cast aluminum Remote mount enclosure Cast a...

Page 7: ...stainless steel compression fitting with PTFE ferrules INSTL69 Stainless steel installation kit for 1 and larger welded carbon steel pipe Maximum operating pressure 50 PSIG Maximum operating temperature 200 F full port SS ball valve SS close nipple to SS reducer bushing carbon steel weld on branch outlet stainless steel compression fitting with PTFE ferrules INSTL70 Installation kit for 1 and larg...

Page 8: ...le 80 flow conditioners Part Description 17381 1 Flow Conditioner Sch40 17382 1 Flow Conditioner Sch 40 17383 1 Flow Conditioner Sch40 17384 2 Flow Conditioner Sch40 17385 2 Flow Conditioner Sch40 17386 3 Flow Conditioner Sch40 17387 4 Flow Conditioner Sch 40 17388 6 Flow Conditioner Sch40 17389 8 Flow Conditioner Sch40 1 5 2 Additional Remote Mount Cable ONICON remote mount meters are provided wi...

Page 9: ...BER Warranty ONICON provides a 2 year warranty for this product Certain exclusions apply Please refer to Appendix A 6 ONICON s Conditions of Sale for details Serial Number The serial number of your F 5100 series flow meter is located on the nameplate attached to the top of the enclosure This serial number will also be located on the remote sensor for remote mount meters IMPORTANT NOTE ONICON F 500...

Page 10: ...re shipped insured unless the customer specifically requests otherwise Please notify the shipping company and ONICON immediately if any items are damaged in transit Save all packing material for inspection by the shipper 2 1 CHECKING THAT YOU RECEIVED EVERYTHING Standard Documentation Enclosed with each meter is a comprehensive documentation package that includes the following items Installation a...

Page 11: ...will affect the orientation of the display F 5000 Series ONICON Flow Direction Flow Direction Flow Direction The drawings above illustrate the relationship between flow direction and display orientation for standard meters F 5000 Series ONICON F 5000 Series ONICON The drawings above illustrate the relationship between the integral display the flow direction and the orientation of the meter when in...

Page 12: ...n more than the minimum required straight run is available place the meter such that the excess straight run is upstream of the meter location The flow meter must be properly installed with respect to the direction of flow Installing the meter with the UPSTREAM label facing downstream will result in significant errors in the flow measurement i How to Determine the Available Straight Pipe Diameters...

Page 13: ...sive amount of stem protruding from the pipe Excessive stem lengths unnecessarily expose the meter to incidental damage 3 2 1 Installation Kits ONICON offers installation hardware kits for commonly used pipe materials The kits are specifically designed for ONICON flow meters and their use is strongly recommended The installation instructions contained in this manual assume that the pipe material i...

Page 14: ...tem 3 2 3 Directions For Hot Tap Installation A Pressurized System 1 Identify an appropriate location for the flow meter 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 or use Teflon tape 4 Use a hot tap drilling machine to create the 5 8 access hole 5 Remove the drill and clear all debris from the valve 6 Install the ...

Page 15: ...combustible gases 3 3 1 Determining the Insertion Depth Inserting the Meter and Tightening the Compression Fitting WARNING The following instructions assume that the pipe is pressurized Whenever the ball valve is open a firm grip must be maintained on the meter at all times until the insertion depth is set and the compression fitting is properly tightened WARNING Do not attempt to insert the meter...

Page 16: ...35 1 82 2 5 2 875 2 323 0 55 2 07 3 3 500 2 900 0 80 2 38 4 4 500 3 826 1 30 2 86 6 6 625 5 761 2 25 3 95 Inserting the Meter 1 Insert the flow meter stem into the compression fitting 2 Open the ball valve and carefully insert the flow meter until the end of the stem just contacts the opposite wall of the pipe 3 Mark the position of the stem where it exits the top of the compression fitting 4 With...

Page 17: ...ady tighten the nut one and one quarter 1 turns to the 9 o clock position CAUTION The compression fitting must be tightened as described in the following procedure Failure to do will likely result in fluid leaks and or permanent damage to the flow meter stem Collar Collar For high pressure kits position upper collar as shown and then tighten both collars to complete the installation sales mvandc c...

Page 18: ...rd meter installations 1 While firmly grasping the enclosure loosen the compression fitting 2 Slowly withdraw the stem until the flats located on the sensor are exposed 3 Close the ball valve and fully withdraw the flow meter Stop here at the flats on the sensor Removal instructions for meter installed with safety cable and retaining collars 1 Confirm that upper retaining collar is installed at th...

Page 19: ...lue Contact ONICON for assistance if the scaled pulse output requires reprogramming CAUTION Cable glands shipped with the meter are for shipping purposes only Remove and replace with approved glands when installing the meter WARNING If the meter is being installed in a Class 1 hazardous location the installation must comply with all appropriate electrical codes WARNING The meter must be connected ...

Page 20: ...T USED C2 RS 485 C3 RS 485 C4 24 VDC PULSE 0 TO 24 DC PULSE OUTPUT C5 4 20 mA 4 TO 20 mA ANALOG OUTPUT C6 VDC GND VOLTAGE DC GROUND TERMINAL BLOCK SIDE NPT USER ENTRY FOR WIRING ONE ON EACH SIDE DISPLAY SIDE FLOW NPT USER ENTRY FOR WIRING Factory installed jumper and resistor Do not remove 3 5 3 Integral Mount Wiring A B C A B C 1 2 3 4 5 6 1 2 3 4 5 6 Control System DC Pulse 4 20mA 24 VDC VDC Com...

Page 21: ...The Pluse Isolator Module is designed to be mounted inside the control system enclosure It converts to active DC pulse output from the flow meter into an isolated dry contact closure output Using the pulse isolator does not change the pulse rate or duration Scaled Pulse Isolator Connection to F 5100 Shown with Insertion Meter Control System Enclosure F 5100 Terminals Field Wiring sales mvandc com ...

Page 22: ... FOR WIRING ONE ON EACH SIDE FLOW NPT USER ENTRY FOR WIRING 1 2 3 4 5 6 1 2 3 4 5 6 A B C 1 RED AC1 COM 1 2 GREEN AC2 B 2 3 BLUE NU A 3 4 WHITE NU 4 5 BLACK 4 20mA 5 6 ORANGE SIG GND6 A B C 24VDC PULSE VDC IN VDC GND REMOTE TERMINAL BLOCK SIDE NO CUSTOMER ACCESS DO NOT OPEN THIS SIDE JUNCTION BOX NPT FOR REMOTE CABLE NPT FOR REMOTE CABLE JUNCTION BOX CONTAINS NO ELECTRONICS JUST TERMINALS NPT FOR ...

Page 23: ...mode screen If the meter is installed in a pipe with flow the meter will begin displaying flow and temperature data After one minute of no movement the screen saver message will appear 4 3 HELPFUL HINTS FOR START UP COMMISSIONING A step by step procedure and companion worksheet are located on the next two pages Please read all installation instructions carefully before proceeding with start up and...

Page 24: ...splay Confirm that the flow meter serial number matches the ONICON display when ordered together 6 Verify wiring before connecting power Prior to connecting the power verify that the wiring is correct as shown in this manual and or on additional wiring diagrams provided with the ONICON display If in doubt contact ONICON for assistance before proceeding further 7 Confirm correct supply voltage Veri...

Page 25: ...s 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 constant if possible Otherwise take the various output readings as quickly as possilbe 9 Analog or pulse output s 4 20 mA signal Scaled output interval Calculated flow rate __________mA ____________ _______SCFM __________mA ____________ ...

Page 26: ...ge or pulse scale factor Verify that the meter cable shield is connected to earth at the control system Lack of proper shielding can lead to excessive noise that can affect the flow reading Verify that the meter is connected to earth Check for ground loop or offset voltage Disconnect analog signal input from control system and measure analog output directly from the flow meter Reconnect signal inp...

Page 27: ...APPENDIX A 1 REMOTE MOUNT MECHANICAL HARDWARE A 2 USE OF THE INSERTION DEPTH GAGE A 3 A 5 ZERO FLOW CALIBRATION TEST A 6 CONDITIONS OF SALE sales mvandc com Phone 877 566 3837 Fax 925 407 2903 ...

Page 28: ...REMOTE MOUNT MECHANICAL HARDWARE sales mvandc com Phone 877 566 3837 Fax 925 407 2903 ...

Page 29: ...the other side of this tag 2 Tighten the nut until the stem will not turn by hand or move ax 3 Mark the nut at the 6 o clock position 4 While holding the fitting body steady tighten the nut one and turns to the 9 o clock position Depth Gage Insulation Pipe Compression Fitting Top Bottom Collar LOW PRESSURE HIGH PRESSURE SYSTEM MAY BE UNDER HIGH PRESSURE When inserting removing or adjusting the met...

Page 30: ...f scheduled annual factory calibrations IMPORTANT NOTE The original factory zero flow calibration was performed with a vertically oriented meter installed through a valve located on the top of a horizontal test pipe If the meter is installed in a different orientation the output at zero flow will be slightly different Depending on the orientation meters inserted horizontally into a pipe may increa...

Page 31: ...til the bottom of the flats located on the sensor is just exposed 3 Re tighten the compression fitting to turn beyond hand tight 4 Carefully close the ball valve 5 Wait up to 2 3 minutes to allow the meter reading to stabilize at zero and note the mW reading on the display 6 Compare the reading to that stamped on the nameplate The two readings should agree within 5mW 7 At the conclusion of the tes...

Page 32: ...CLIMATE ACTION RESERVE LANDFILL PROJECT PROTOCOL VER 4 0 JUNE 29 2011 ONICON s zero flow calibration test complies with the requirements of section 6 2 for field checking the flow meter for calibration accuracy Percent drift can be determined by multiplying the mW change from factory value see 2 by 1 0 i e each mW change equals 1 drift The Climate Action Reserve is a national offsets program worki...

Page 33: ...or 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 assess a late fee not to exceed 1 5 per month or 18 per year or the maximum allowableby law whichever is lower 6 CANCELLATION B...