Greyline ISM 5.0 User guide

www.greyline.com

USER'S GUIDE

Installation & Operation

Instructions

Insertion Magmeter

Model ISM 5.0

Manual Series 1.2

Note: This page has been left blank intentionally.

ISM 5.0 INSERTION MAGMETER

Installation and Operation Guide

www.greyline.com

Page 2

SAFETY INFORMATION

Messages identified as “Caution” contain information regarding potential damage to the
product or other ancillary products.

Messages identified as “Important Note” contain information critical to the proper operation of
the product.

Messages identified as “Warning” contain information regarding the personal safety of
individuals involved in the installation, operation or service of this product.

! i !

This meter was calibrated at the factory before shipment. To ensure correct use of the meter, please read
this manual thoroughly.

Regarding this Manual:

•

This manual should be passed on to the end user.

•

Before use, read this manual thoroughly to comprehend its contents.

•

The contents of this manual may be changed without prior notice.

•

All rights reserved. No part of this manual may be reproduced in any form without
GREYLINE’s written permission.

•

GREYLINE makes no warranty of any kind with regard to this material, including, but
not limited to, implied warranties of merchantability and suitability for a particular
purpose.

•

All reasonable effort has been made to ensure the accuracy of the contents of this manual.
However, if any errors are found, please inform GREYLINE.

•

GREYLINE assumes no responsibilities for this product except as stated in the warranty.

•

If the customer or any third party is harmed by the use of this product, GREYLINE
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 with
specific WARNINGS given elsewhere in this manual violates safety standards of design,
manufacture, and intended use of the product. GREYLINE Instruments assumes no liability for the
customer’s failure to comply with these requirements. If this product is used in a manner not
specified in this manual, the protection provided by this product may be impaired.

The following symbols are used in this manual:

WARNING

CAUTION

IMPORTANT NOTE

Page 3

1.1

2.1

3.1

TABLE OF CONTENTS

INTRODUCTION ........................................................................................................................................................ 4

1.2

PURPOSE OF THIS GUIDE ..................................................................................................................... 4

1.3

TYPICAL INSERTION ELECTROMAGNETIC FLOW METER .................................................... 4

1.4

STANDARD FEATURES AND SPECIFICATIONS ......................................................................... 5

1.5

ADDITIONAL REQUIRED HARDWARE ................................................................................................. 5

1.6

ADDITIONAL HARDWARE THAT MAY BE REQUIRED .......................................................... 6

1.5.1 Grounding Rings ................................................................................................................................... 6

UNPACKING ......................................................................................................................................................................... 7

2.2

CHECKING THAT YOU HAVE RECEIVED EVERYTHING .............................................................. 7

INSTALLATION, REMOVAL & ADJUSTMENT ................................................................................................. 8

3.2

INSTALLATION SITE SELECTION .................................................................................................... 8

3.3

MECHANICAL INSTALLATION ................................................................................................................... 10

3.3.1

Installation Kit ................................................................................................................................... 11

3.3.2

GREYLINE Standard Installation Hardware Kit ................................................................. 11

4.1

3.3.3

GREYLINE Hot Tap Installation Hardware Kit ................................................................... 11

3.3.4

Customer Supplied Installation Hardware ........................................................................... 12

3.3.5

Confirming the Stack Height ....................................................................................................... 13

3.3.6

Installing Grounding Rings .......................................................................................................... 14

3.3.7

Installing the Flow Meter ............................................................................................................. 15

3.4

INSERTION OF THE METER .............................................................................................................. 16

3.4.1

Inserting the Flow Meter ............................................................................................................... 16

REMOVAL OF THE

3.5

WIRING CONNECTIONS ...................................................................................................................... 18

3.5.1

3.5.2

START-UP & COMMISSIONIING FOR GREYLINE INSERTION ELECTROMAGNETIC FLOW

METERS..................................................................................................................................................................... 21

4.2

HELPFUL HINTS FOR START-UP AND COMMISSIONING ................................................. 21

4.3

START-UP AND COMMISSIONING ................................................................................................ 22

4.4

START-UP AND COMMISSIONING WORKSHEET .................................................................. 23

METER……………………………………………………………………………………………………… 17

Signal and Power Wiring Connections ................................................................................... 18

Earth Connection ............................................................................................................................. 20

4.5

TROUBLESHOOTING GUIDE ............................................................................................................. 24

4.4.1 Earth Connections & Electrical Noise Reduction ................................................................. 24

APPENDIX

Conditions of Sale …………………………………………………………………………………………………………………26

Applications Hotline ……………………………………………………………………………………………………………..27

Product Return Procedure …………………………………………………………………………………………………….27

Page 4

water and steam systems, according to their individual trades. Death or permanent injury may
result from accidents with these systems.

!

SECTION 1.0: INTRODUCTION

We, at GREYLINE Instruments, would like to thank you for purchasing our quality American made
ISM 5.0 Insertion Magmeter. As our valued customer, our commitment to you is to provide
reliable service, while continuing to offer you quality products to meet your growing flow
measurement needs.

1.1 PURPOSE OF THIS GUIDE

fast

We have written this guide to provide the persons responsible for the installation, operation and
maintenance of your flow meter with the most specific equipment information they will need.
This is NOT an electrical or plumbing trade manual.

WARNING

Please do not permit persons to install, operate or maintain this equipment unless they have a

This guide is the basic reference tool for all GREYLINE ISM 5.0 Insertion Magmeters. 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 ELECTROMAGNETIC FLOW METER

Faraday’s Law of electromagnetic induction states that a voltage will be induced in a conductor
when it passes through a magnetic field, and the induced voltage will be directly proportional to
the velocity of the conductor.

GREYLINE ISM 5.0 Insertion Magmeters generate pulsating magnetic fields that are used to induce
a voltage into the conductive fluid flowing through the pipe. Electrodes located on the flow meter
sensor head measure the induced voltage. Circuitry within the flow meter electronics
then converts the voltage to digital and analog signals that convey flow rate and total data via
connecting the cable to any of GREYLINE’s display devices, Btu meters and/or to a data
acquisition system.

complete knowledge of their trade skills and are competent to work on high pressure hot and cold

Typical Meter Installation

(New construction or scheduled shutdown)

Output sign al(s)

to control

system

Greyline
Displa y or
BTU Meter

(Optional )

Allow enough slack
in the flexibl e liquid­tight conduit to
permit th e meter to
be remov ed
from the val ve.

Custom er provided
conduit and adapters

Note: Installati on kits vary based on pipe material and application. For install ations in pressurized (live)

systems, use "Hot tap" 1¼ inch installation kit and drill hole using a 1 inch wet tap drill.

½" FNPT
conduit connection

Insertion depth
gage provided
with ea ch meter

Minim um Hole Size = 1"
Must be centered

•

Install in vertical or horizontal pipe

•

For horizontal pipe position meter
anywhere in upper 240˚

Standard Installatio n
Kit for Steel Pipe

1" Full port bal l valve

1" Close nippl e

1" Branch outl et

FLOW

FOR INSTALLATION

1¼" for
hot tap

CLEARANCE

REQUIRED

Typically
30" - 40"

dependi ng on

pipe size and

height of v alve

assembly.

enclosure

Page 5

1.3 STANDARD FEATURES AND SPECIFICATIONS

Accuracy

Sensing Method

Pipe Size Range

± 1.0% of reading from 2 to 20 ft/sec
± 0.02 ft/sec below 2 ft/sec

Electromagnetic, no moving parts

3” through 72” nominal

Input Power

20 - 28 VAC 50/60Hz, 250 mA maximum
20 - 28 VDC, 250 mA maximum

Liquid Temperature Range

15° to 250° F

Ambient Temperature Range

-5° to 150° F

Operating Pressure

400 PSI maximum

Pressure Drop

Less than 0.1 psi at 12 ft/s velocity in 3” and larger pipes

Materials of Construction

Wetted metal components - 316L stainless steel
Sensor head - Polystyrene
Electronics enclosure - Powder coat painted cast aluminum

Enclosure Rating

Watertight, airtight, dust proof powder coated cast aluminum.

Electrical Connections

25’ of PVC jacketed cable with ½” NPT conduit connection

Output Signal(s)

Analog output (Isolated), selectable 4-20 mA, 0-10 V or 0-5 V
Frequency output, 0-15 V peak pulse, 0-500 Hz maximum
Scalable pulse output, isolated dry contact, contact rating 50 VDC @ 100 mA

maximum, pulse duration: 0.5, 1, 2 or 6 seconds

This product is covered by one or more of the following patents: 6,431,011 and 6,463,807.

1.4

ADDITIONAL REQUIRED HARDWARE

All GREYLINE insertion type meters can be installed and removed via
a 1” or larger full port ball valve without system shutdown. The terms
“Standard” and “Hot Tap” refer to the installation method of the
isolation valve kit only.

Standard Installation Hardware: For new construction or scheduled
shutdown; once kit is installed, the flow meter can be installed
or removed without system shutdown.

Hot Tap Installation Hardware: For applications which require the
access hole in the pipe to be drilled through the valve using a
wet tap drilling machine while the hydronic system is
pressurized and operating.

NOTE: Installation hardware materials vary greatly based on pipe
material, pipe size and standard vs. hot tap versions.

Page 6

5/8

3/8

GROUNDING RING

DIMENSIONS

D

1/4

GROUNDING RING

ORDERING INFORMATION

C

Bore

1/8”

A

ANSI Class 150

316 Stainless Steel

Grounding Rings (pair)

Nominal

Size

GREYLINE

Part 1” 19265

1½” 19266

2” 19267

3” 19268

4” 19269

6” 19270

8” 19271

10” 19272

12” 19273

14” 19274

16” 19275

18” 19276

20” 19277

24” 19278

30” 19279

36” 19280

42” 19281

Grounding Rings

Grounding Ring Dimensions

Nominal Size

Bore A C D

1”

1 - 1/16

2 - 5/8

4 - 9/16

1 - 15/16

1.5”

1 – 9/16

3 – 3/8

5 - 5/16

1 - 15/16

2”

2 – 1/16

4 – 1/8

6 - 1/16

1 - 15/16

3”

3 – 1/16

5 – 3/8

7 - 5/16

1 - 15/16

4”

4 – 1/16

6 – 7/8

8 - 13/16

1 - 15/16

6” 6

8 – 3/4

10 - 11/16

1 - 15/16

8” 8

11

12 - 15/16

1 - 15/16

10”

9 – 1/2

13 – 3/8

15 - 5/8

2 - 1/4

12”

11 – 9/16

16 – 1/8

18 - 9/16

2 - 7/16

14”

13 – 1/2

17 – 3/4

20 - 3/8

2 - 5/8

16”

15 – 1/4

20 – 1/4

22 - 7/8

2 - 5/8

18”

17 – 3/8

21 – 5/8

24 - 1/4

2 - 5/8

20” 19

23 - 7/8

26 - 11/16

2 - 13/16

24” 23

28 – 1/4

31 - 1/8

2 - 7/8

30” 29

34 – 3/4

38

3 - 1/2

36” 35

41 – 1/4

45 - 1/4

4

42” 41

48

52 - 1/2

4 - 1/2

1.5 ADDITIONAL HARDWARE THAT MAY BE REQUIRED

1.5.1 Grounding Rings

Grounding rings may be required whenever meters are installed in non-metallic or lined pipes.
Grounding rings placed before and after the meter eliminate electrical noise that will interfere
with the proper operation of the meter. GREYLINE provides grounding rings as an optional
accessory. Grounding ring dimensional information and part numbers are listed below. For proper
operation, grounding rings are required before and after the meter.

Typical Installation

Non-conductive Pipe

Page 7

SECTION 2.0: UNPACKING

GREYLINE insertion magnetic flow meters are packed and shipped in individual cartons. An optional
installation hardware kit INSTL 1 or INSTL 2, if ordered, will be packaged with each meter. All other
installation hardware and peripheral devices, including Btu meters and display modules, will be
packaged and shipped separately.

Please open all packages with care to prevent damage to their contents. Carefully inspect each item for
signs of damage in transit. The flow meter stem should be straight and free of blemishes or abrasions.
The sensor head should have a smooth continuous surface that is free of abrasions.

All GREYLINE products are shipped insured unless the customer specifically requests otherwise.
Please notify the shipping company and GREYLINE immediately if any items are damaged in transit.
Save all

2.1

packing material for inspection by the shipper.

CHECKING THAT YOU HAVE RECEIVED EVERYTHING

Standard Documentation

Enclosed with each meter is a comprehensive documentation package that includes the
following items:

Installation and Operation Guide
Flow Meter Certificate of Calibration

Please notify GREYLINE if any of these documents are missing.

ISM 5.0 Insertion Magmeter Flow Meters
Optional INSTL1 or INSTL2 Installation Hardware Kit, if ordered

Page 8

straight run is available, place the meter such that the excess straight run is upstream of the
meter location.

i

pipe size in inches equals “diameters of straight pipe.” For closed loop applications, consider both
the supply and return lines as possible locations.

to install, adjust, or remove the flow meter. Please read all instructions before attempting to
insert or remove a flow meter.

!

SECTION 3.0: INSTALLATION, REMOVAL AND ADJUSTMENT

WARNING

Insertion flow meters may be installed in pipes which are under high pressure. Accidents with
these systems can cause serious injury or death. Only persons experienced with high pressure

GREYLINE will be happy to assist with technical recommendations and to provide guidance by

systems and related knowledge in the heating, cooling and fluid metering fields should attempt

telephone or e-mail. On-site field engineering, installation and service is also available at additional cost.

3.1 INSTALLATION SITE SELECTION

Install the flow meter where it will be accessible for personnel to perform necessary periodic
maintenance. The clearance required for installation is typically 30”-40” from the pipe wall to
the nearest obstruction above the valve assembly. This clearance dimension will increase with
large diameter pipes. The environment should be free of corrosive liquids/fumes, temperature
extremes and heavy vibration. The following diagrams 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.
See the table on the following page for guidelines in determining minimum up
stream straight run requirements based on the nature of the obstruction.

Note: Depending upon specific location details, more or less straight run may be required to produce a satisfactory flow profile.

3.

If there is insufficient straight run, allow 80% of the run upstream and 20% of the
run downstream. If the total length of straight run is less than 70% of the
recommended length, performance may seriously degrade.

How To Determine The Available Straight Pipe Diameters:

For each application, locate the longest straight, unobstructed section of pipe (no bends, tees, valves,
other insertion probes, size transitions). The longest straight pipe run in inches divided by nominal

IMPORTANT NOTE

Always use the maximum available straight run. When more than the minimum required

Page 9

•

Upstream obstruction

(A) Minimum straight run required

upstream of meter location

Single bend preceded by ≥ 9 diameters of straight pipe

10 Diameters

Pipe size reduction / expansion in straight pipe run

10 Diameters

Single bend preceded by ≤ 9 diameters of straight pipe

15 Diameters

Outflowing tee / Pump outflow

20 Diameters

Multiple bends out of plane

30 Diameters

Inflowing tee 30 Diameters

Control / Modulating valve

30 Diameters

Acceptable to install in vertical pipe

Position
for horizontal pipe

CLEARANCE

FOR INSTALLATION

pipe size

5 Dia.

A

Available Straight Run*

•

meter anywhere in upper 240°

For 3” and larger pipe diameters

REQUIRED

30” - 40”

(76 - 100 cm)

Depending on

* Additional straight run may be required upstream of the upstream grounding ring based on the nature of

the upstream obstruction. Refer to the chart above to determine how much straight run is required.

5 DIA

Installation with Grounding Rings

with Non-conductive Pipe

Gaskets (4 pl)

*

10 DIA

Grounding Rings (2pl)

Page 10

Flow meters installed through oversized access holes will be subjected to undesirable turbulence
that may affect the accuracy of the meter.

i

will also result in an excessive amount of stem protruding from the pipe. Excessive stem lengths
unnecessarily expose the meter to incidental damage.

!

CLEARANCE

FOR INSTALLATION

Standard Installation
Kit

1"

1"

for

tap

1" Branch outlet

Minimum Hole Size = 1"
Must be centered

NOTE: Use stainless steel or brass

close nipple only.

3.2

MECHANICAL INSTALLATION

GREYLINE Insertion Electromagnetic Flow Meters employ a hot tap adapter design that allows
for

insertion and removal, when necessary, without interrupting flow and draining the pipe. To

advantage of this feature, the flow meter must be installed through an isolation valve. The

take
installation must allow for sufficient overhead clearance to fully extract the meter, and a full 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.

REQUIRED

Typically

30" - 40"

depending on

pipe size and

height of valve

assembly.

for Steel Pipe

Full port ball valve

Close nipple

1¼"

hot

CAUTION

GREYLINE 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 and draining the system. It

IMPORTANT NOTE

Page 11

3.2.1 Installation Kit

Some type of

threaded branch

An

interconnecting

GREYLINE offers a wide range of installation hardware kits for commonly used pipe
materials. The kits are specifically designed for GREYLINE flow meters, and their use is
recommended.

The use of GREYLINE installation hardware kits accomplishes two important objectives.
First, it ensures that the proper hardware is used. Second, it simplifies order processing
by standardizing the dimensions of the installation hardware. GREYLINE must have an
accurate measurement of the overall height of the installation hardware as measured from
the outside wall of the pipe to the top of the valve in order to determine the correct stem
length when assembling the meter in our factory. GREYLINE documents refer to this
dimension as the stack height.

GREYLINE installation hardware kits consist of three separate component parts:

And a full port

outlet,

close nipple,

isolation valve.

Different pipe materials require different branch outlets and may include additional
bushings to properly size the opening.

3.2.2 GREYLINE Standard Installation Hardware Kit

Standard installation hardware kits are designed to be installed on piping systems that
are drained and at atmospheric pressure. The access hole is drilled (1” minimum) prior
to installation of the branch outlet with 1” NPT threads, close nipple and full port ball
valve. Once the isolation valve is installed, the piping system can be flushed, filled and
pressurized. The flow meter may now be inserted or removed by hand without having to
drain the system. Please read all instructions before proceeding with meter insertion.

3.2.3 GREYLINE Hot Tap Installation Hardware Kit

GREYLINE offers an alternative installation hardware kit when it is not practical to
relieve
1¼” full
a 1”
pipe. Please read all instructions before proceeding with meter insertion.

pressure and drain the system. In this case, a 1¼” branch outlet, close nipple and

port ball valve are installed first. Then, a hot tap drilling apparatus is used to drill

diameter hole through the valve. This eliminates the need to shut down and drain the

Page 12

3.2.4 Customer Supplied Installation Hardware

Use stainless steel or brass nipple only.

!

over- all height of the installation hardware as measured from the outside wall of the pipe to
the top of the valve where the meter is installed.

!

Do not use threaded steel or slip PVC tees to provide the 1” opening in the pipe. Tees of this
type will cause significant errors in the flow measurement.

!

Some type of

threaded branch

outlet,

An

interconnecting

close nipple,

There are occasions where circumstances require that the customer provide the
installation hardware or that the flow meter must be installed through existing hardware.
In these cases, it is important to confirm that the installation hardware is suitable for use
with the flow meter provided by GREYLINE before it is installed. The installation must
allow for sufficient overhead clearance to fully extract the meter and a full 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:

And a full port

isolation valve.

CAUTION

CAUTION

In order to provide the flow meter with the correct stem length, GREYLINE must know the

CAUTION

Page 13

3.2.5 Confirming the Stack Height

GREYLINE insertion flow meter stem lengths vary according to the pipe diameter and the
height of the installation hardware stack. GREYLINE records the stack height dimension
provided by the customer at the time of order entry, and the information is used to size the
stem. The dimension is shown on the laminated insertion depth gage tag attached to the
meter.

Prior to installing the meter, confirm that the stack height recorded on the tag is close to
the actual stack height. Flow meter stems are intentionally oversized to allow for
variations of at least 2” in the stack height. Contact GREYLINE prior to installation if

is any question regarding stack height or stem length. This way GREYLINE can

there
offer you
different stem

credit for your meter if you decide to exchange the meter for one with a

length. Returns may be subject to a restocking fee.

Page 14

3.2.6 Installing Grounding Rings

Gaskets (4 pl)

5 DIA

*

10 DIA

Grounding Rings (2pl)

* Additional straight run may be required upstream of the upstream grounding ring based on the nature of the upstream obstruction. Refer to the chart in Section 3.1 on page 11 of this manual to determine how much straight run is required.

Grounding rings are used to suppress electrical interference at the installation location for
electromagnetic flow meters. They are provided in pairs and are installed upstream and downstream
of the flow meter. The use of grounding rings significantly reduces electrical noise and may be
necessary for proper operation of flow meters installed in lined or non-conductive pipes.

Installation Instructions

1. Install the rings upstream and downstream of the meter as shown above.
(Please note that the straight run requirements shown above are only for locating the
grounding rings with respect to the ISM 5.0 flow meter. The complete straight run
requirements for this meter are found in Section 3.1 on page 11 of this manual.)

2. Install each grounding ring sandwiched between (2) ANSI Class 150 flanges and (2)
gaskets.

3. Center each gasket on the grounding ring surface. Do not allow the gasket to protrude
into the flow stream.

4. Use the torque specifications provided with the gaskets when tightening the flange
bolts.

5. Wire the two grounding rings together as shown and connect them to the flow meter
earth wire. Connect this to a known good earth connection. See Section 3.2.5 on
page 21 of this manual for additional information on identifying an acceptable earth
connection.

Page 15

3.2.7 Installing the Flow Meter

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 GREYLINE for assistance.

!

• pipe thread sealant

head assembly. This flash over could also exceed the pressure ratings of the meter and the
assembly could fail allowing steam and hot water to escape causing serious injury.

!

WARNING

When you are ready to refill the system, make sure that all lines are filled with water before
inserting the meter into the flow stream. If the lines are not filled and this is a hot water
system, some water may flash to steam and exceed the high temperature limit for the sensor

Tools needed for standard installation:

• 1 5/16” wrench or adjustable wrench

•

5/8” wrench or small adjustable wrench

• pipe wrench (to hold valve in place)

Flush, fill and pressure test the piping system prior to installing the meter. Loosen
clamping nut to facilitate installation.

CAUTION

If there are any leaks around the clamping nut or stem, DO NOT ATTEMPT TO STOP THE
LEAKAGE BY OVERTIGHTENING 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

Page 16

apart causing a break in the water seal with the resultant loss of large amounts of water. The
hand effort required to hold the meter will be 0.11 times the pipe pressure.

!

3.3 INSERTION OF THE METER

SYSTEM MAY BE UNDER HIGH PRESSURE. When adjusting the meter position or removing
it, be sure to hold the electronics enclosure firmly by hand before SLOWLY loosening the
positioning clamping nut. Failure to do this will allow the pressure to suddenly and rapidly
force the meter from the pipe causing serious injury. The meter could also be damaged or break

WARNING

Begin by calculating the effort that will be required to hold the meter. Establish adequate footing
for this task, taking extra caution when working from a ladder or platform. Use the following
formula:

E=0.11 x P

Example: In a 300 PSI system, 33 pounds of effort is required to insert the meter into the pipe.

Where:

E = effort in pounds
P = system pressure in pounds per square inch

3.3.1 Inserting the Flow Meter

Page 17

In hot water systems, even a small amount of water can cause serious personal injury. Use extra
caution when working with hot water meters.

!

will clear any obstruction and permit the meter to withdraw completely. (Excessive build-up on
the stem may require the hot tap “O” ring to be lubricated with silicone.)

!

!

3.4 REMOVAL OF THE METER

SYSTEM MAY BE UNDER HIGH PRESSURE. When removing the flow meter, be sure to hold
the electronics enclosure firmly by hand before slowly loosening the positioning clamping
nut. Failure to do this will allow the pressure in the pipe to suddenly and rapidly force the
meter from the pipe causing serious injury. The meter could also be damaged or break apart
causing a break in the water seal with the resultant loss of large amounts of water. The hand
effort required to hold the meter will be 0.11 times the pipe pressure.

WARNING

CAUTION

The main cause of damage to meters comes from accidentally closing the valve on the sensor
head. To avoid this, gently rotate the meter by twisting the electronics enclosure back and forth
(twist the stem, do not bend it) while you slowly close the valve. If the valve touches any part of
the meter, you will feel it as you are twisting the meter. If the valve touches anything, it means
the meter is not fully withdrawn. Usually a gentle twisting motion while withdrawing the meter

WARNING

Page 18

Do not attempt to remove the existing cable or to remove the factory installed connection fitting.
Doing so will compromise the weather tight integrity of the enclosure and will void the warranty.

to properly connect the ISM 5.0 power, signal or earth connections may result in damage to the
ISM 5.0 and/or to associated peripheral equipment.

!

!

3.5

WIRING CONNECTIONS

Make all connections to the attached 25ft cable.

The most common causes of electronic failures are miswired connections during installation.
When adding additional cable, record and carefully document any substitution of wire colors.
Additional cable may be purchased from GREYLINE that will allow you to maintain the existing
color coding.

All electrical connections to the ISM 5.0 must be made through the 25ft cable provided with the
meter. This cable is not designed to be removed in the field, and any attempt to do so will
compromise the weather tight integrity of the enclosure. A watertight cable junction box
should be used for above grade connections to extended cable length. Special care is
required to ensure that

the ISM 5.0 is connected to earth through the green/yellow earth wire.
This connection is required to prevent random electrical noise from interfering with the operation
of the meter. (See section 3.5.2 for details.)

CAUTION

CAUTION

Only qualified personnel should attempt to make electrical connections to the ISM 5.0. Failure

3.5.1 Signal and Power Wiring Connections

Customer provided
conduit and adapters

Output signal(s)

to control

system

Greyline

Display or

BTU Meter
(Optional)

above grade.

½" FNPT
conduit connection

Allow enough slack
in the flexible liquid­tight conduit
permit the meter
be removed
from the valve.

Install meter as shown using liquid- tight flex conduit and junction box. Leave sufficient slack in the
liquid-tight flex conduit to allow the meter to be removed without disconnecting cable. Run factory
installed meter cable to junction box above grade through liquid-tight flex conduit making connection to field
wires at this point.

to

to

Insertion dept h
gage provided
with each meter

FLOW

Page 19

Wire

Color

24±4 VAC 50-60 Hz @ 250 mA or
+24±4 VDC @ 250 mA

Connect to 24VAC transformer or
DC power supply positive

Connect to 24VAC transformer common
or DC power supply common

Green /

Yellow

See Section 3.5.2 for assistance in
locating a suitable building earth connection

Analog Output

4-20mA, 0-10V or 0-5V output

Scaled Pulse Output

50 VDC @100 mA maximum

Scaled output, isolated dry contact,
50 VDC @100 mA maximum

Frequency Output

Yellow

(-) Frequency output common

Alarm Output

50 VDC @100 mA maximum

50 VDC @ 100 mA maximum

Grounding Rings

Description

Red

Black (-) Isolated supply common

Earth connection (required to operate)

Blue (+) Isolated analog output

Brown (-) Analog output common Use for analog signal only

Gray

Violet

Green

Scaled output, isolated dry contact,

(+) Isolated frequency output,
0-500 Hz maximum

May configured as:

Dry contact scaled to provide one pulse
per volumetric unit. Examples:
1 pulse per 10 gal.
1 pulse per 100 gal.

Required when meter is connected to local
display or BTU meter

Note

Orange

White

Alarm output, Isolated dry contact,

Alarm output, Isolated dry contact,

Dry contact alarm output. Closed contact
indicates, empty pipe or excessive electrical
noise.

Earth wiring connections for use with grounding rings

Page 20

Earth Connections (stranded wire 14 – 18 AWG)

Best

Earth grounding rod driven into the ground

Earth wire connected directly to the building electrical service panel.

Worst

Earth wire connection inside an electrical outlet near the meter.

may increase the amount of electrical noise present at the meter. Contact GREYLINE for
technical assistance if you experience increased noise levels with the earth wire connected to
earth.

i

Failure to provide a proper earth connection to the meter may result in excessive electrical
noise that will interfere with the operation of the meter.

!

CAUTION

3.5.2 Earth Connection

ISM 5.0 Insertion Magmeters are designed to detect microvolt signal levels at the
electrodes located on the sensor head. These signals are generated as conductive fluids
flow through the magnetic field generated by the meter. If enough random electrical noise
is present at the electrodes, it can interfere with the flow measurement. Care must be
taken during installation to minimize the effects of electrical noise on the flow meter.

The most effective way to minimize the effects of electrical noise is to make sure that
the pipe, the fluid and the flow meter body are all connected to earth ground. This
accomplishes two important goals. First, it ensures that the pipe, fluid and flow meter are
all at the same electrical potential, and second, it ensures that this electrical potential is
the same as earth ground.

In order to be certain that the meter is properly connected to earth, the flow meter earth
cable should be run directly to a known earth connection. The length of this earth cable
should be as short as practically possible, preferably ≤25 feet in length. The table below
lists earth connections from best to worst. If necessary, a separate earth cable should be
connected to the metal pipe near the meter.

IMPORTANT NOTE

Under certain circumstances, connecting the meter to earth through the green/yellow earth wire

Page 21

SECTION 4.0: START-UP & COMMISSIONING FOR GREYLINE

INSERTION ELECTROMAGNETIC FLOW METERS

4.1 HELPFUL HINTS FOR START-UP AND 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 installation, start-up and
commissioning.

Please read these helpful hints before proceeding with the start-up and commissioning procedure
on the next page.

1.

2.

3.

GREYLINE flow meters are individually calibrated for a particular application.

sure to verify the pipe size and location.

Be
The electronic flow sensing systems will not work in air.
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

4.

measure the signal in series.
When measuring frequency outputs in Hz, take your multimeter out of “autorange
mode” and manually set the range for a voltage level above 15 VDC. This will
prevent false readings when signal is not present.

5.

All wiring connections should be made at the end of the factory cable. Do not
attempt to remove the factory installed cable or change the orientation of the

6.

electronics enclosure.
Never connect power to analog or frequency output signal wires. GREYLINE ISM

Flow meters are not “loop powered” devices.

5.0

Page 22

Confirm flow meter

2.

Confirm pipe size.

Confirm that the meter is tagged for the pipe size in which it is installed. When in doubt,

3.

Confirm insertion depth and

Each flow meter comes with an attached insertion gage and instruction tag. Ensure that

4.

Confirm control system
programming.

Confirm that the control system input point is properly configured for the analog range
or Btu meter (if ordered).

doubt, contact GREYLINE for assistance 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.

11.

Compare various output

Compare the flow rates calculated in steps 9 and 10 to each other and to the flow rate

End of standard start-up and commissioning. Please contact GREYLINE with any questions.

4.2

START-UP AND COMMISSIONING

Please read the entire procedure before proceeding. A worksheet for checking off the following steps and
recording measured values is located on the next page.

1.
location. Confirm adequate
straight pipe run to achieve
desired results.

Is the meter located in the correct location as required by the plans?
Compare actual straight pipe upstream and downstream of the meter location to
recommended distances identified in this manual. Contact GREYLINE’s technical
support department to discuss specifics of your application.

measure the circumference of the pipe. Pipe O.D. = (circumference / 3.14) – (insulation
thickness x 2).

orientation.

Confirm connection to

5.
correct GREYLINE display

6. Verify wiring before
connecting power.

7.

Confirm

8. Connect power. Wait approximately 45 seconds after power-on before proceeding further.

Measure and record

9.
frequency output.

Measure and record

10.
analog or pulse outputs.

correct supply voltage. Verify that 24 (±4) V is available.

the meter is inserted to the correct depth and that the electronics enclosure is parallel with
the pipe with the arrow in the direction of flow.

(or scale factor) identified on the calibration tag & certificate.

Confirm that the flow meter serial number matches the GREYLINE display or Btu meter
serial number (when ordered together).

Prior to connecting the power, verify that the wiring is correct as shown in this manual and/
or the additional wiring diagram provided with GREYLINE display or Btu meter. If in

The frequency output signal is a 0-15 VDC pulsed output ranging up to 200 Hz and must
be measured with a multimeter. Measure DC frequency (Hz) from GREEN (+) to
YELLOW (-). Also measure DC volts on same wires. Five to 7 VDC is normal for a
pulsating output. Zero VDC indicates no output.

GPM = frequency in Hz X 60

meter factor in ppg (Refer to calibration tag for meter factor.)

Refer to flow meter wiring diagram for wire colors for the various outputs available, based
on your particular flow meter model. Use the following formulas to calculate flow rate from
measured analog signals:

Current Output:

Voltage Output:

Scaled Output:

signals to each other and to
the flow rate displayed by the
control system.

GPM = (measured current in mA - 4) X Full Scale Analog Flow Rate

16

GPM = measured VDC X Full Scale Analog Flow Rate

10

Each contact closure = unit volume identified as “Scale Factor” (measure and record time
interval between contact closures)

indicated by the control system. Refer to troubleshooting guide when readings are
inconsistent.

Page 23

STEP

TEST/MEASUREMENT

S/N:

S/N:

S/N:

S/N:

1. Meter location:

2. Confirm pipe size:

3. Insertion depth
and orientation:

4. Control system
programming:

5.

Match display or Btu
meter serial number
(S/N) 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
constant if possible, otherwise, take the various output readings as quickly as possible.

9. Frequency output(s):
Avg = green

Calculated flow rate:

GPM

GPM

GPM

GPM

10. Analog or pulse
output(s)

Calculated flow rate:

GPM

GPM

GPM

GPM

11. Flow rate displayed
by control system:

GPM

GPM

GPM

GPM

4.3

START-UP AND COMMISSIONING WORKSHEET

Please read all installation instructions carefully prior to proceeding with these steps. Use the
following worksheet for checking off the commissioning steps and recording measured values.
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.

Average frequency (Hz):

Average frequency
(VDC):

4-20 mA signal:

0-5 / 0-10 V signal:

Scaled output interval:

Hz

VDC

mA

VDC

Hz

VDC

mA

VDC

Hz

VDC

mA

VDC

Hz

VDC

mA

VDC

Page 24

REPORTED PROBLEM POSSIBLE SOLUTIONS

No signal

• Verify that the meter is properly inserted into the pipe.

• Verify that the electronics enclosure is parallel with the pipe.

• Low conductivity water (≤ 20 µsiemens) may activate the empty pipe
detector and/or increase the potential for electrical noise problems.

Reading is too high or
low

• Verify pipe size. Contact GREYLINE if pipe size is different
from calibration tag.

• Verify that the meter earth cable is connected to earth. A poor earth
connection can lead to excessive noise that can affect the flow reading.

Analog signal seems
high or low and does

• Check for ground loop or offset voltage:

• Disconnect analog signal input from control system and measure analog

these readings indicates a potential ground loop or offset voltage. Please
contact GREYLINE for further assistance.

Control system displays
flow rate, but no flow

local display module or
Btu meter

• Verify that all wires from the flow meter are connected to the display
module or Btu meter.

any GREYLINE display or Btu meter.

4.4

TROUBLESHOOTING GUIDE

NOTE: Also refer to the START-UP AND COMMISSIONING GUIDE located on page 19.

• Verify 24 V supply voltage.

• Verify correct wiring to control system (see wiring diagram).

• Verify that there is flow in the pipe.

• Verify that the meter earth cable is connected to earth.

• Check to see if the alarm contact closure output is closed (orange &
white wires). A closed contact could indicate either an empty pipe or
excessive electrical noise, possibly due to a poor earth ground.

• Verify that the meter is properly inserted into the pipe.

• Verify that the electronics enclosure is parallel with the pipe.

• Verify correct wiring to control system (see wiring diagram).

• Confirm that the output signals are consistent with each other
(frequency vs. analog, etc).

• Confirm that the control system is programmed for correct flow range or
scale factor.

not correspond to
frequency output

rate is indicated on the

output directly from the flow meter. Reconnect signal input to control
system and measure the analog signals again. Any difference between

• The frequency output wires (green and yellow) must be connected for

4.4.1 Earth Connections & Electrical Noise Reduction

Introduction

ISM 5.0 Insertion Magmeters are designed to detect microvolt signal levels at the
electrodes located on the sensor head. These signals are generated as conductive fluids
flow through the magnetic field generated by the meter. If enough random electrical noise
is present at the electrodes, it can interfere with the flow signal measurement. Care must
be taken during installation to minimize the effects of electrical noise on the flow meter.

Page 25

Minimizing Electrical Noise

Earth Connections (stranded wire 14 - 18 AWG)

Best

Earth grounding rod driven into the ground to the depth of the water table.

Earth wire connected directly to the building electrical service panel.

Worst

Earth wire connection inside an electrical outlet near the meter.

Earth Connection at
Flow Meter

Pipe / Fluid Earth
Connection

Expected
Noise
Level

Possible Remedies
Good earth connection
≤ 25 feet from flow meter

Pipe & fluid are
connected to earth

Low

None required

Good earth connection

meter

Pipe & fluid are not
connected to earth

A separate earth connection can be
made directly to the metal pipe or to the

grounding rings installed upstream and
downstream of the meter location.

Removing the earth connection at the
flow meter may reduce the noise level.

better earth connection for the flow
meter.

Poor earth connection

Pipe & fluid are not
connected to earth

High

Locate a better earth connection for the
flow meter. If noise level is still too
high, locate a better earth connection
for the pipe or fluid.

be required for proper operation. Refer to section 1.5.1 and section 3.1 of this manual for
additional information on the use of grounding rings.

i

The most effective way to minimize the effects of electrical noise is to make sure that
the pipe, the fluid and the flow meter body are all connected to earth ground. This
accomplishes two important goals. First, it ensures that the pipe, fluid and flow meter

all at the same electrical potential. Second, it ensures that this electrical potential is

are
the same as earth ground.

In order to be certain that the meter is properly connected to earth, the flow meter earth
cable should be run directly to a known earth connection. The length of this earth cable
should be as short as practically possible, preferably ≤25 feet in length. The table below
lists earth connections from best to worst. If necessary, a separate earth cable should be
connected to the metal pipe near the meter.

IMPORTANT NOTE

Non-metallic pipes are more susceptible to electrical noise. Grounding rings installed upstream
and downstream of the meter location to reduce the electrical noise present in the pipe may

Diagnosing Electrical Noise Problems

When diagnosing electrical noise problems, it is important to understand that one of four
possible conditions is likely to exist. They are as listed in the table below. In order to minimize
the effects of noise, it is helpful to understand which of the following conditions are present.

≤ 25 feet from flow

Poor earth connection

Pipe & fluid are
connected to earth

Moderate

Moderate

fluid. Non-metallic pipes may require

If this is a long wire run, break the
connection where the wire connects to
the cable coming out of the flow meter.

noise level is still too high, locate a

If

Page 26

1. ACCEPTANCE: The following Conditions of Sale apply to all sales of GREYLINE’s products. These provisions shall apply

CONDITIONS OF SALE

even if GREYLINE fails to object to provisions appearing on, Instruments by, referenced in, or attached to Buyer’s purchase
order form. Buyer’s acceptance of delivery of GREYLINE’s products constitutes its acceptance of these Conditions of Sale.

2. DELIVERY AND TITLE: All product shipments are Ex Works shipping point and title passes to the Buyer at the time GREYLINE
delivers the merchandise to the carrier. Risk of loss or damage to the product passes to the Buyer at the time GREYLINE delivers
the product to the carrier. The Buyer immediately upon receipt should inspect all shipments, and should there be any evidence of
damage or loss in transit, Buyer must file claims or tracers upon carrier. GREYLINE will assist in tracing shipments upon request.

3. LIMITED WARRANTY: GREYLINE warrants that for a period of two (2) years following the date of original shipment of an
GREYLINE product: (i) the product will conform to GREYLINE’s standard written specifications applicable to such product in
effect on the date of Buyer’s order, or as modified by GREYLINE’s quotation or Buyer’s purchase order accepted by
GREYLINE, (ii) the product will be free from defects in workmanship, and (iii) that GREYLINE has title to the product prior to
shipment to the Buyer; provided, however, that the warranties provided herein shall be void and may not apply in the event
Buyer misuses or damages a product, including, but not limited to, any use by the Buyer of a product for an application other
than one of a type approved by GREYLINE. GREYLINE’s sole liability and Buyer’s sole remedy for any breach of the
foregoing warranty is for GREYLINE to repair or replace, at GREYLINE’s option, any defective product that is returned to
GREYLINE during the warranty period. EXCEPT AS MAY BE SPECIFICALLY AGREED BY GREYLINE IN WRITING IN
RELATION TO EACH SALE, NO OTHER WARRANTIES SHALL APPLY, WHETHER EXPRESSED, IMPLIED OR
STATUTORY, AND THERE SHALL BE NO IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE.

4. REMEDIES: GREYLINE’s OBLIGATION UNDER THE FOREGOING WARRANTIES IS LIMITED SOLELY TO REPAIR OR
REPLACEMENT, AT GREYLINE’s OPTION, OF DEFECTIVE OR NONCONFORMING PRODUCTS. GREYLINE SHALL NOT
BE LIABLE FOR CONSEQUENTIAL, INDIRECT, PUNITIVE, INCIDENTAL, OR SPECIAL DAMAGES WHETHER FOUND ON
CONTRACT, TORT OR ANY OTHER THEORY OF LAW. No products shall be returned to GREYLINE without its prior consent
and transportation and insurance costs shall be prepaid. Any repair or replacement of GREYLINE’s products under the
foregoing warranty will be at no charge to the Buyer provided such repair is done at the GREYLINE factory or authorized
service center. GREYLINE products that are repaired or replaced under this warranty will be returned to Buyer via the same
method of shipment use to return the product to GREYLINE. Repair or replacement of GREYLINE products is conditioned upon
GREYLINE’s acknowledgement of any alleged defect or nonconformance during the warranty period and issuance of a Return
Authorization number. All product returns must reference the Return Authorization number on the outside of the shipping carton
and on any paperwork referencing the return.

5. PRICES AND PAYMENT TERMS: The prices set forth in the most recent quote or acknowledgement as applicable, supersede
all previous prices or quotations. All quotations are subject to change or withdrawal without notice except as may be specifically
noted on the face of the quotation. The prices shown do not include sales, excise or government charges payable by GREYLINE
to Federal, State, or local authority. Any such tax or charge now or hereafter imposed upon the sale or shipment of the products
under this contract will be added to the purchase price. Buyer agrees to reimburse GREYLINE for such tax or charge or provide
GREYLINE 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, GREYLINE will assess
a late fee not to exceed 1.5% per month or 18% per year, or the maximum allowable by law whichever is lower.

6. CANCELLATION: Buyer may cancel its order, or any part of it, by sending written notice of cancellation to GREYLINE and
paying a reasonable cancellation fee as determined by GREYLINE. The reasonable cancellation fee will reflect, among other
factors, the expenses already incurred and commitments made by GREYLINE, sales and administrative costs and profit as
determined by GREYLINE. If Buyer received a reduced price based on the quantity of products ordered, but has not
purchased the applicable quantity at the time of cancellation, Buyer will pay the price it would have paid had GREYLINE’s
sale price been based on the quantity actually purchased.

7. CHANGES: If Buyer makes any changes in its drawings, designs, or specifications applicable in any contract with GREYLINE that cause an
increase or decrease in the cost of performance of the contract, or if such changes result in rework or obsolescence, an equitable adjustment
shall be made to the contract. Such changes are subject to GREYLINE’s prior written consent.

8. EXCUSABLE DELAY: GREYLINE shall under no circumstance be responsible for failure to fill any order or orders when due to: fires,
Floods,

riots, strikes, freight embargoes or transportation delays, shortage of labor, inability to secure fuel, material supplies, or power
at current price or on account of shortages thereof, acts of God or of the public enemy, any existing or future laws or acts of the
Federal or State Government (including specifically, but not exclusively, and orders, rules or regulations issued by any official or
agency of any such government) affecting the conduct of GREYLINE’s business with which GREYLINE in its judgment and discretion
deems it advisable to comply as a legal or patriotic duty, or due to any cause beyond GREYLINE’s reasonable control.

9. PATENTS: GREYLINE shall defend all suits or proceedings brought against Buyer or its customers arising from claimed
infringements of any patent, trademark, service mark or copyright for any product furnished by GREYLINE and shall indemnify
it against all costs, fees, and damages on the condition Buyer promptly notifies GREYLINE in writing and provides information
and assistance to enable GREYLINE to conduct the defense, provided that GREYLINE shall have no such obligation in case of
infringement resulting from GREYLINE’s conformance to special requirements of Buyer. If GREYLINE is not able to settle any
such suit or proceeding on acceptable terms, GREYLINE may, at its option, require return of the infringing product and refund
the purchase price to Buyer less a reasonable allowance for depreciation or use.

10. FAIR LABOR STANDARDS ACT: GREYLINE represents that all products delivered under this contract are furnished in accordance
with the applicable provisions of the Fair Labor Standards Act as amended.

11. APPLICABLE LAW: This document and any resulting contract shall be governed by and construed in accordance with the
laws of the State of Florida. The courts of the State of Florida and the federal courts located in Florida shall have jurisdiction
and venue with respect to litigation to this contract. In the event of litigation, the prevailing party shall be entitled to recover
attorney’s fees and costs from the non-prevailing party, including appellate attorney’s fees.

12. MODIFICATIONS: These Conditions of Sale along with the prices, quantities, delivery schedules and other provisions and
instructions in applicable quotations by GREYLINE or Buyer’s purchase orders accepted by GREYLINE shall constitute the entire
agreement between GREYLINE and Buyer pertaining to any resulting contract. They can be modified only in writing.

Page 27

APPLICATIONS HOTLINE

For applications assistance, advice or information on any Greyline Instrument contact your Sales
Representative, write to Greyline or phone the Applications Hotline below:

United States: Tel: [phone] Fax: [phone]
Canada: Tel: [phone] Fax: [phone]
Toll Free: 888-473-9546
Email: [email protected]
Web Site: www.greyline.com

Greyline Instruments Inc.

Canada USA:
16456 Sixsmith Drive 11451 Belcher Road South
Long Sault, Ont. K0C 1P0 Largo, FL 33773

PRODUCT RETURN PROCEDURE

Instruments may be returned to Greyline for service or warranty repair.

1 Obtain an RMA Number from Greyline -

Before shipping a product to the factory please contact Greyline by telephone, fax or email to obtain an
RMA number (Returned Merchandise Authorization). This ensures fast service and correct billing or
credit.

When you contact Greyline please have the following information available:

1. Model number / Software Version

2. Serial number

3. Date of Purchase

4. Reason for return (description of fault or modification required)

5. Your name, company name, address and phone number

2 Clean the Sensor/Product -

Important: unclean products will not be serviced and will be returned to the sender at their expense.

1. Rinse sensor and cable to remove debris.

2. Wipe the outside of the enclosure to remove dirt or deposits.

3. Return to Greyline for service.