Sage RIO SIX, Instruction Manual

Page 1: ...odels SIX and SRX ATEX Certified for Hazardous Service DOCUMENT NUMBER 100 0162 REVISION 10 SIX SRX SAGE RIO Make the Wise Choice Choose Sage Flow Meters SAGE METERING INC 8 Harris Court D1 Monterey CA 93940 1 866 677 SAGE 7243 Tel 831 242 2030 Fax 831 655 4965 www sagemetering com ...

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Page 3: ... Configuration for Utilizing Four Flow Meters for Large Round Pipes 16 In line Flow Meter Application 17 Terminal Hookup Rio Integral Series SIX 18 24 VDC Rio Integral Terminals Series SIX 19 AC Powered Rio and DC Powered Rio PLUS Integral Terminals Series SIX 20 Terminal Hookup Rio Remote Series SRX 21 24 VDC Rio Remote Terminals Series SRX 22 AC Powered Rio and DC Powered Rio PLUS Remote Series ...

Page 4: ...TION D Common Diagnostics 41 Diagnostics In Situ Calibration Check 44 SECTION E Limited Warranty 47 Warranties and Service Work Cancellation Return Policy 47 Returning Your Sage Flow Meter 49 Return Material Authorization Form 50 SECTION F Modbus Register Listing 53 Modbus Modbus Protocol Function Codes 54 Sage Register Output Format 59 Sage Addresser Software 59 Sage Addresser Typical Printout Ve...

Page 5: ...intenance have negligible pressure drop and have a turndown up to 100 to 1 and resolve as much as 1000 to 1 Sage Flow Meters can measure the mass flow rate and consumption of air oxygen natural gas nitrogen digester gas biogas flare gas hydrogen argon carbon dioxide and other gases and gas mixes Sage Rio is the latest addition to our family of high performance Thermal Mass Flow Meters It features ...

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Page 7: ...Section GETTING STARTED A ...

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Page 9: ...sensor elements the RTDs If any disassembly is necessary contact Sage Metering Inc for instructions In general it is recommended that your Sage Thermal Mass Flow Meter be returned to the factory if cleaning repair or recalibration is needed This is usually the most cost effective and reliable alternative CALIBRATION Sage Rio has continuous diagnostics The raw calibration milliwats mw is always dis...

Page 10: ... sticker on your meter The first three digits describe the basic model that you have Refer to the appropriate page numbers below for your wiring diagram 2 SIX see page 19 3 SRX see page 22 for input output terminals see page 24 Junction Box Wiring Terminals for Remote Style Meters 4 SIX SRX HART see page 64 65 WIRING Follow the instructions below to remove the rear cap for wiring CAUTION Do not op...

Page 11: ...ffec tively reduce the measurement area Direct thread ing together or with necessary bushings of the retractor assembly may be required In other cases the threadolet must be welded in place and a clear ance hole must be drilled through the pipe duct to accept the probe assembly If the pipe duct is under pressure during installation a hot tap drill not available through Sage Metering may be require...

Page 12: ...d at center to optimize measurement accuracy Refer to PROBE INSERTION GUIDELINE DRAWING and CHART pages 14 15 Insert the probe shaft tubing into the compression fitting to the position indicated in the Probe Insertion guidelines While holding the fitting body steady tighten the nut one and one quarter turns to the 9 o clock position INSTALLATION INSTRUCTIONS 1 Insert tubing into the tube fitting 2...

Page 13: ...LOW CONDITIONERS Can Be Installed in Conjunction with Insertion Style Flow Meters NOTE The larger of the two perforated plates of the Sage conditioning basket is positioned between two flanges and two gaskets as shown The smaller of the two perforated plates of the conditioner will freely slide into the application pipe facing downstream The compression will be placed one diameter downstream of th...

Page 14: ...file Allow for a minimum of 15 pipe diameters of straight run upstream and 5 diameters downstream depend ing on the conditions See chart on page 11 Note obstructions such as valves blowers expanders and PVC and HDPE pipes will require additional straight run contact factory for assistance Avoid if possible installations immediately downstream of bends fans nozzles heaters and especially valves or ...

Page 15: ...5 7 625 3 25 4 90 0 3171 10 10 750 9 750 4 25 6 00 0 5185 12 12 750 11 374 5 13 7 00 0 7056 14 14 000 12 500 5 70 7 50 0 8522 16 16 000 14 312 6 60 8 60 1 1172 18 18 000 16 124 7 50 9 60 1 4180 24 24 000 21 562 10 25 12 60 2 5357 S C H E D U L E 4 0 P I P E2 S C H E D U L E 8 0 P I P E 2 PIPE SIZE OD ID X Y PIPE AREA 1 1 5 1 900 1 610 20 1 56 0 0141 2 2 375 2 067 40 1 82 0 0233 2 5 2 875 2 469 60 ...

Page 16: ...e averaged by customer s PLC or other method to improve overall accuracy in measuring the flow rate For medium sized round pipes 18 to 36 two meters on the opposite side of the same diameter may be sufficient insert parallel to an upstream 90 degree bend for optimal benefit Note in this configura tion all sensors need to be averaged 3 4 NPT for User Entry 3 4 NPT explosion proof plug 3 4 NPT explo...

Page 17: ...mple 1 x8 flow body has an 8 length The length will be the same whether an NPT flow body or whether flanged If a flanged flow body the 8 dimension will be a Face to Face dimension FLOW CONDITIONING SCREENS FOR IN LINE FLOW BODIES 1 2 AND UP1 Screens shown with NPT fitting 1 Note Flow conditioning is also available for Insertion Meter applications see page 13 ing flanging welding etc DO NOT USE RED...

Page 18: ...ISPLAY VIEW 3 4 NPT for Probe Support DISPLAY SIDE FLOW TERMINAL BLOCK SIDE Power Switch 3 4 NPT for User entry ONE ON EACH SIDE Unit provided explosion proof plugs to be replaced with approved explosion proof fittings by user CAUTION The unit is provided with explosion proof plugs at user entry ports on each side of the enclosure The plug s is to be replaced with an Approved explosion proof cable...

Page 19: ...stomer power i e 24 VDC external power will result in a 24 VDC Pulse maximum of 50 mA 12 VDC external power will result in a 12 VDC Pulse 4 Pulse width 250 msec default adjustable with Addresser software 5 Using HART or Sage Addresser a Low Flow Cutoff LFC commonly referred to as Min Cutoff or Zero Cutoff can be entered into the FLOW MIN Functions In Versions 1 82 or higher the Low Flow Cutoff and...

Page 20: ...A Thus the 4 mA will always be zero based 6 ATEX II2G Ex d IIB H2 T6 Gb 7 24 VDC 10 8 Other DC voltages 5 VDC 12 VDC 48 VDC available on Rio PLUS Contact Sage 9 Assumes the 4 20 mA is Externally Powered 10 Modbus Ground becomes isolated from the B6 Power Supply Ground only on Rio PLUS version specify PLUS Grounding Lug 24 O 24 O DESCRIPTION TERMINALS NOTES AC Input Power B1 B2 Connect GroundWire 1...

Page 21: ... ON PAGES 63 65 FOR WIRING OF UNITS WITH HART INSIDE COVER VIEW DISPLAY VIEW 3 4 NPT for Remote Cable ON REMOTE STYLE SRX The cable provided is for bench testing only It is NOT approved ATEX approved cable gland strain relief is provided with unit 3 4 NPT for Probe Support Junction Box contains no electronics just terminals FLOW DISPLAY SIDE TERMINAL BLOCK SIDE 3 4 NPT Explosion Proof plug 3 4 NPT...

Page 22: ...f 50 mA 12 VDC external power will result in a 12 VDC Pulse 4 Pulse width 250 msec default adjustable with Addresser software 5 Using HART or Sage Addresser a Low Flow Cutoff LFC commonly referred to as Min Cutoff or Zero Cutoff can be entered into the FLOW MIN Functions In Versions 1 82 or higher the Low Flow Cutoff and the 4 20 mA Scaling are independent of each other For example A Low Flow Cuto...

Page 23: ...24 VDC Pulse maximum of 50 mA 12 VDC external power will result in a 12 VDC Pulse 4 Pulse width 250 msec default adjustable with Addresser software 5 Using HART or Sage Addresser a Low Flow Cutoff LFC commonly referred to as Min Cutoff or Zero Cutoff can be entered into the FLOW MIN Functions In Versions 1 82 or higher the Low Flow Cutoff and the 4 20 mA Scaling are independent of each other For e...

Page 24: ...rminals for Remote Style Meters Series SRX THERE ARE NO ELECTRONICS INSIDE JUNCTION BOX SEE THE PREVIOUS PAGE FOR THE OTHER END OF THE REMOTE WIRING HOOKUP the electronics side Blue Green Red Orange Black White CUSTOMER SIDE1 Wired at Installation site Metal Conduit is recommended with appropriate grounding to minimize effects from external noise sources CAUTION Strip wires 3 8 and do not crimp in...

Page 25: ...Section STYLES AND FEATURES B ...

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Page 27: ...r until it is a constant temperature differ ential above the reference sensor The electrical power required to maintain a constant temperature differential is directly proportional to the gas mass flow rate and is linearized to be the output signal of the meter Principle of Operation of the Thermal Mass Flow Meter It is essential that this constant temperature differ ential be maintained even if t...

Page 28: ...ound in the popular Sage Prime with the added ATEX Zone 1 Flameproof approvals The Rio features a bright high con trast photo emissive OLED Organic LED display of Flow Rate Total and Temperature in an explosion proof dual sided IP66 NEMA 4X enclosure The Flow Rate is also displayed graphically in a horizontal bar graph format The rear compartment is completely separated from the electronics and ha...

Page 29: ...age for further information STYLE Insertion Mass Flow Meter PROBE STYLE LENGTH 1 2 OD Probe Lengths 6 to 36 FLOW CONDITIONING Captive Flow Conditioners available upon request with meter purchase SAGE METERING is a manufacturer of high performanceThermal Mass Flow Meters which measure the flow rate and consumption of gases for multiple industrial appli cations Frequently used for energy management ...

Page 30: ... use a flashlight The Flow Meter displays for two minutes then the Screen Saver resumes 1 Raw Calibration milliwatts mw for Diagnostics and Periodic Zero Flow Calibration Check 2 Graphical Indication of Percentage of Full Scale Flow Rate 3 Flow Rate 4 Totalized Flow Consumption Value is Retained during Power Outage or Power Cycling 5 Flashes with each pulsed output of consumption 6 Engineering Uni...

Page 31: ...O Rings for 40 C which are certified under DEMKO 07 ATEX 0622294U UL Certification No 20141219 E464988 USL CNL Class I Div 1 Groups B C and D Hazardous Locations CONFORMANCE EN 60079 0 2009 EN 60079 1 2007 REQUIREMENTS The cable entry holes shall be fitted with suitably certified cable glands or suitably certified stopping plugs that are capable of maintaining the IP rating of the equipment Do not...

Page 32: ...S A G E M E T E R I N G I N C O p e r a t i o n s a n d I n s t r u c t i o n M a n u a l 32 REV 10 SIX SRX ...

Page 33: ... AC Enclosure depth is 5 35 CAUTION Do not rotate the Enclosure of In Line Style Meters relative to the Flow Tube or the calibration may be effected since the sensors may become misaligned 3 4 NPT for User Entry ONE ON EACH SIDE The plug s is to be replaced with an Approved explosion proof cable gland strain relief End user is also responsible for providing ATEX Zone 1 approved cable for power and...

Page 34: ...F G Class III 4X 7BCD 9EFG FM Standard 3615 UL Standard 1203 CSA Standard C22 2 No 30 and NEMA Compliance Junction Box is Explosion Proof Class 1 Div 1 2 Group B C D Zone 1 NO ELECTRONICS 3 4 NPT Explosion Proof plug with unit 3 4 NPT Explosion Proof plug CAUTION Do not rotate the Junction Box of In Line Style Meters relative to the Flow Tube or the calibration may be effected since the sensors ma...

Page 35: ...mote Bracket Layout MOUNTING OPTIONS 1 Overhead with U bolts customer supplied across pipe on each leg 2 Vertically as shown 3 Horizontally APPROVED CORD GRIP or NPT PLUG as req d 266 DIA HOLES 3 4 NPT User Entry for Wiring two hole 3 4 NPT User Entry for Wiring single hole 3 4 NPT User Entry for Wiring 2 5 06 2 00 7 38 ...

Page 36: ...is 3 16 for SVA07 1 2 BORE SINGLE PIECE COLLAR CLAMPS7 3 4 x1 5 PIPE NIPPLES 3 4 x3 BALL VALVE SVA05 SERIES ISOLATION VALVE ASSEMBLY DETAIL5 6 Cut away view of probe inserted through isolation ball valve assembly 1 2 3 4 BALL VALVE WELDMENT WITH 1 2 TUBE TO PIPE COMPRESSION FITTING 3 4 x1 HALF COUPLING THREADOLET MOUNTING PLATE FOR THIN WALLED DUCTS INCLUDES STCF05 COMPRESSION FITTING NOTE User ne...

Page 37: ...olation Valve Assembly NOTES AND CAUTIONS Suitable for low pressure Air or Natural Gas applications maximum 50 PSIG Assumes 1 2 Insertion Probe inserted to center of a Pipe see Sage Probe Insertion Guidelines Teflon Ferrule permits ease of Probe insertion or removal Exercise caution when loosening Ferrule nut during insertion and removal of Probe since this model has no Safety Chain Note maximum u...

Page 38: ... n s t r u c t i o n M a n u a l 38 REV 10 SIX SRX UPSTREAM FLOW Flanged Ends for In Line Meter OPTIONAL Flanges for 31 2 pipe sizes and up have 8 bolt holes Flanges for 3 pipe sizes and smaller have 4 bolt holes Flanged Mounting for Insertion Meter OPTIONAL ...

Page 39: ...Section DIAGNOSTICS D ...

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Page 41: ...prevent subsequent problems if a Remote Style Meter move the enclosure as far away as possible from the source the Motor or VFD c If an Integral Style Meter mount the meter in a different location further from the source or move the source further from the meter SYMPTOM Erratic Readings on a Remote Meter POSSIBLE CAUSE In some cases analog noise is induced into the Remote cable causing erratic or ...

Page 42: ...less than 20 degrees causes meter to over report a greater rotation actually blocks the sensor and causes meter to under report f A downstream valve too close to the meter flow may be reflecting back g Possibly caused by water droplets condensing out of gas stream which generally causes output to spike but if droplets are near continuous output may rail h Meter is miswired especially in Remote Sty...

Page 43: ...ample at constant volume an increase in gas temperature will lower the mass flow SCFM That is completely normal j On most models the Totalizer will not start count ing for 10 seconds after power up so any flow data will not be accumulated during this time k Insufficient power supply most products require minimum 100 ma l Excessive load on the 4 20 ma To check if prob lem is due to 4 20 ma output d...

Page 44: ...or more of the following factors gas composition pressure dirt non zero conditions and sensor orientation Any of these factors can have an effect on mWo It is a very sensitive data point that is why it is such a good check 5 Note if all of the above factors were remedied it would be expected that the mW zero would report less than or equal to 5 milliwatts 6 Note in some cases contamination of the ...

Page 45: ...Section WARRANTIES AND SERVICE WORK E ...

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Page 47: ...warranty damage due to corrosion GENERAL TERMS AND CONDITIONS Detailed General Terms and Conditions can be found on the Sage website www sagemetering com on a link General Terms on the Footer of any page on the website CANCELLATION RETURN POLICY Cancellation or Return After issuance of a purchase order by phone mail e mail or fax or a credit card order by phone mail e mail or fax there will be a c...

Page 48: ...returned after 1 month of ship ment unless authorized by a representative at Sage Metering Inc The Sage representative will issue a Return Material Authorization RMA at that time and will advise of the restocking fee Returned package must be insured by cus tomer and must reference proper RMA on outside of package or package may be rejected i e package will be returned unopened Customer is responsi...

Page 49: ...at has been contaminated without writ ten evidence of decontamination and has instituted the following Return Repair conditions Strict adher ence to these conditions is required Returned equip ment that does not conform to the requirements list ed below will not be processed If Sage Metering finds evidence of contamination we may at our option have the unit returned at your expense For your ref er...

Page 50: ...ION OF SYMPTOMS All non warranty repairs could be subject to a minimum evaluation charge Recommended steps to be used to duplicate problem symptoms Sage Metering Technical Contact Take special care when packaging your meter for return to the factory The sensor in particular may easily be damaged if not prevented from shifting around within the package and if the sensor itself is not cov ered to ke...

Page 51: ...Section MODBUS F ...

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Page 53: ... Type Description format flag modbus_unit_id output mode sel fix_pt selection bRun bTotal bEEProm bReset bLeadEn bDACIo bDAChi CAL_VAL K FACTOR VREF LOAD RES COEFF A COEFF B COEFF C COEFF D DISP A DISP B DISP C DISP D COEFF A COEFF B COEFF C COEFF D COEFF E COEFF F 302 304 306 308 310 312 314 316 318 320 550 552 554 556 558 578 580 582 584 586 588 590 592 594 596 598 600 602 806 808 810 812 814 83...

Page 54: ...vice address The second field contains the function code The third field contains the data and byte counts The fourth field contains the CRC value ADDRESS FIELD The address field contains one byte Sage Rio Meters will transmit response packets to addresses which are between 1 to 240 decimal inclusive Modbus packet writes may be sent to broadcast address 00 however the Rio will not reply with a res...

Page 55: ...r 0x04 READ MULTIPLE INPUT REGISTERS QUERY RESPONSE SA SLAVE ADRESS SA 04 FUNC CODE 04 RH REG ADDR HI BC of data bytes to follow RL REG ADDR LO DATA0 00 OF REGS HI DATA1 CT OF REGS LO DATAn CH CRC MSB CH CRC MSB CL CRC LSB CL CRC LSB REG ADDR HI RH is set to 01 for INTEGER access of integral values 02 for IEEE754 floating point 03 for Scaled x1000 long integer of floating point value REG ADDR LO R...

Page 56: ...ERS QUERY RESPONSE SA SLAVE ADRESS SA 0x10 FUNC CODE 0x10 16 FUNC CODE RH REG ADDR HI RH REG ADDR HI RL REG ADDR LO RL REG ADDR LO 00 OF REGS HI 00 REGS HI CT OF REGS LO CT REGS LO BC BYTES COUNT CH CRC MSB DATA0 CL CRC LSB DATA1 DATAn CH CRC MSB CL CRC LSB REG ADDR HI RH is set to 01 for INTEGER access of integral values 02 for IEEE754 floating point 03 for Scaled x1000 long integer of floating p...

Page 57: ...RS RUN STATUS INDICATOR 0xFF ASCII Text SAGE Rio v1 81x CH CL Response The Sage Rio will respond with an echo of the slave address and function code The byte count will be 19 0x13 to allow the master to account for all the remaining bytes that follow REPORT SLAVE ID Example Slave Address 0x30 48 default Master Query 30 11 D5 BC Rio Response 30 11 13 5A FF 53 61 67 65 20 50 72 69 6D 65 20 76 31 2E ...

Page 58: ...ul to be able to write to an unknown slave address with a simple broadcast command Be sure only one Sage Rio is connected during any broadcast writes using slave address 0 Writing into unspecified registers not defined above can render the unit non functional or overwrite fac tory calibration data yielding incorrect operation EXAMPLE MODBUS PACKET Query This packet will request of the addressed sl...

Page 59: ...IMAL REPRESENTATION Computer systems hosting a MODBUS network may choose represent single precision floating point val ues as scaled long integers 32 bit values The Sage Rio will convert floating point registers to integral units by multiplying the value by 1000 Ex Floating point value 1234 567 will be converted to integral value 1234567 All registers addressed above 768 0x0300 0x03FF will transfe...

Page 60: ... M E T E R I N G I N C O p e r a t i o n s a n d I n s t r u c t i o n M a n u a l 60 REV 10 SIX SRX Sage Addresser Typical Printout Version 3 14 Units SCFM Modbus 0x31 Copyright 2012 Sage Metering Inc 1 of 1 ...

Page 61: ...Section HART G ...

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Page 63: ...A output is externally powered A minimum resistance of 250 ohms is required between the power supply and the flow meter Next to the Temperature units of measurement C or F there are three pixel points See illustration above The top indicator is lit if HART is active Middle indicator lit or flashes during active data transfer The bottom is lit when the instrument is under HART control for manual se...

Page 64: ...2 4 watts b Connect the positive lead to terminal B5 and the Negative lead to B6 INPUT POWER SUPPLY VOLTAGE 24 VDC 23 4 WATTS B5 POSITIVE B6 NEGATIVE Loop Power Supply HART field calibrator 4 Connect 4 20 mA a Connect isolated positive lead to B4 b Connect isolated negative lead to C5 5 Connect a HART field calibrator as shown insuring that there is a minimum of 250 ohm resistance in the top loop ...

Page 65: ...im of 2 4 watts b Connect AC1 to pin B1 and AC2 to pin B2 and AC Gnd to enclosure Gnd Lug Loop Power Supply HART field calibrator B1 B2 250 500Ω B4 C5 4 Connect 4 20 mA a Connect isolated positive lead to B4 b Connect isolated negative lead to C5 5 Connect a HART field calibrator as shown insuring that there is a minimum of 250 ohm resistance in the top loop 6 For Pulsed output connect B4 to C4 AC...

Page 66: ...ow Rate 4 Loop Current Bargraph 2 Total 5 Percent Range Bargraph 3 RTD Power 6 Dynamic Variables Chart 4 Temperature 5 Flow Rate Units 6 Total Units 2 Hart Identification 1 Tag 2 Long Tag 3 Manufacturer 4 Model 5 Dev Id 1 Field Device has m 2 DIAGNOSTICS 1 Device Status 2 A reset or self test 3 Field device has m 4 PV Analog Channe 5 PV Analog Channe 6 Process applied to 7 Process applied to 2 Sen...

Page 67: ...tput 2 Totalizer 1 Total Units 2 Total 3 Pulse Output 1 Pulse Count 2 Pulse Duration 4 HART 1 Poll addr 2 Loop current mode 3 Num req preams 3 Device Info 1 Tag 2 Long tag 3 Descriptor 4 Message 5 Date 6 Meter S N 1 Universal rev 7 Final asmbly num 2 Fld dev rev 8 Revision 3 Software rev 4 Hardware rev 1 Flow Coeff A 4 Factory 1 Flow Factors 2 Flow Coeff B 3 Flow Coeff C 4 Flow Coeff D 5 Flow Coef...

Page 68: ...ing Fast Key 1 1 2 4 Primary Variable Damping factor Used to smooth out normal occurring fluctuations in the flow rate Values range between 001 and 999 which represents no smoothing Lower values increase damping K Factor Fast Key 1 1 2 5 K Factor is a linear adjustment factor which may be used to adjust the flow rate for various reasons requested by the user Default is 1 Dynamic Variables Flow Rat...

Page 69: ...tor which will provide a linear adjust ment of the flow rate May be used to correct for dif ferent pipe size varying gas composition or installa tion effects which change the performance of the flow meter PV Damping Fast Key 3 1 2 Provides smoothing of normally occurring flow fluc tuations Value between 0 001 to 0 999 the lower the value providing greater smoothing time averaging Low Flow Cutoff F...

Page 70: ...s required by the instrument for HART com munication DEVICE INFORMATION Tag Fast Key 3 3 1 Enter a 8 digit tag which can be used to identify the instrument Long Tag Fast Key 3 3 2 Enter up to a 32 digit tag which can be used for any purpose desired by the user Descriptor Fast Key 3 3 3 A 16 character entry which can be used for addition al identification of the instrument Message Fast Key 3 3 4 A ...

Page 71: ...G Section APPENDIX H ...

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Page 73: ...sume that the initial cali bration was set up for 60 CH4 and 40 CO2 a 65 CH4 and 35 CO2 Multiply reading by 0 982 to correct it for new composition b 70 CH4 and 30 CO2 Multiply reading by 0 965 to correct it for new composition c 55 CH4 and 45 CO2 Multiply reading by 1 0185 to correct it for new composition For smaller changes the corrections are linear in between d Also if 100 saturated with H2O ...

Page 74: ...a t i o n s a n d I n s t r u c t i o n M a n u a l 74 REV 10 SIX SRX J Box and Upstream Orientation 4 50 3 50 4 85 NOTE ATEX approved cable gland strain relief provided with unit LOOKING DOWNSTREAM FRONT VIEW FLOW DIRECTION FLOW DIRECTION ...

Page 75: ... C sheath for industrial environments One of the RTDs See Diagram below is self heated by the circuitry and serves as the flow sensor The other RTD acts as a reference sensor and measures the gas temperature Essentially it is used for tem perature compensation The Sage proprietary sensor drive circuitry main tains a constant overheat between the flow sensor and the reference sensor As gas flows by...