Intek 100 User Manual

WARRANTY

Intek, Inc. warrants each Rheotherm product to be free from defects
in material and workmanship under normal use and service, Intek's
obligation under this warranty being limited to making good any part
or parts thereof which shall, within one (1) year after delivery of such
product to the original purchaser, be returned to Intek with
transportation charges prepaid and which Intek's examination shall
disclose to its satisfaction to have been thus defective; this warranty
being expressly in lieu of all other warranties, express or implied and
all other obligation or liabilities on Intek's part. The purchaser will
assume all responsibility and expense for removal, decontamination
and reinstallation of equipment.

Rheotherm flow meters are manufactured under United States patent numbers 4,255,968, 4,942,763, 4,949,578, 5,485,754 and. 5,752,411

Intek, Rheotherm, Rheovec, Rheomax and RheoVac are registered trademarks of Intek, Inc.

Intek, Inc.

751 Intek Way

Westerville, Ohio 43082-9057

TEL: [phone] • FAX: [phone]

TABLE OF CONTENTS

SECTION 1 ! GENERAL INFORMATION ........................................ - 1 -

1.1 INTRODUCTION ....................................................... - 1 -

1.2 DESCRIPTION OF OPERATION .......................................... - 2 -

1.3 PRECAUTIONS ........................................................ - 2 -

SECTION 2

! INSTALLATION ................................................. - 4 -

2.1 TRANSDUCER ......................................................... - 4 -

2.2 ELECTRONICS ........................................................ - 6 -

2.3 ELECTRICAL CONNECTIONS ........................................... - 7 -

SECTION 3

! OPERATION ..................................................... - 8 -

3.1 START UP ............................................................. - 8 -

3.2 GENERAL INFORMATION .............................................. - 8 -

3.3 OPTIONS .............................................................. - 8 -

3.4 OUTPUT CURVE ....................................................... - 9 -

3.5 TRANSDUCER & ELECTRONICS FUNCTIONAL TESTS ..................... - 9 -

Figure A. Transducer Continuity Check ........................................ - 11 -

Figure B. Transducer Isolation Check ......................................... - 11 -

Figure C. Dummy Transducer for Electronics Functional Check .................... - 11 -

SECTION 4

! MAINTENANCE ................................................ - 12 -

4.1 GENERAL MAINTENANCE ............................................. - 12 -

4.3 SPARE PARTS ........................................................ - 13 -

4.4 TROUBLE SHOOTING ................................................. - 13 -

TABLE I. TROUBLE SHOOTING GUIDE ..................................... - 13 -

SECTION 5

! CUSTOMER SERVICE .......................................... - 14 -

5.1 QUESTION ON EXISTING HARDWARE .................................. - 14 -

5.2 TROUBLE SHOOTING ................................................. - 14 -

5.3 FACTORY AND FIELD SERVICE ........................................ - 14 -

5.4 DECONTAMINATION OF EQUIPMENT .................................. - 14 -

5.5 QUESTIONS ON NEW EQUIPMENT ..................................... - 14 -

SECTION 6

! CUSTOM INFORMATION ....................................... - 15 -

6.1 UNIT IDENTIFICATION ................................................ - 15 -

6.2 CONFIGURATION ..................................................... - 15 -

6.3 SPECIAL INSTRUCTIONS .............................................. - 15 -

TABLE II. ORIGINAL CALIBRATION DATA ................................. - 16 -

Figure 1. Rheotherm® 100 Rev. B Signal Conditioner PCB Layout ..................... - 17 -

Figure 2. Flow Rate vs. Output Curve ............................................ - 18 -

©Intek, Inc. 2010

Manual no. A1009503 Rev. D

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1.1 INTRODUCTION

SECTION 1 ! GENERAL INFORMATION

Rheotherm

®

precision flow meters are designed to provide accurate linear or non-linear (depending on
the model) representation of fluid flow rate. This model 100 has a non-linear output. They are
manufactured exclusively by Intek, Inc. and employ a patented thermal technique used by industry since

1978. The unique transducer designs have protected sensors, are easy to install and require little or no
maintenance.

Each Rheotherm flow meter consists of two elements — a transducer and an electronics unit. The
transducers come in two basic designs, intrusive and nonintrusive (SECTION 2.1). Design selection is
based on application constraints or customer preference. The electronics, for signal processing, are
housed in one of four basic enclosure styles (SECTION 2.2). Again, selection is based on application
requirement.

Key features of Rheotherm instruments are:

• Nonintrusive flow measurement

— For pipe sizes from 0.030 to 2 inches, flow sensing can

be done from outside the flow tube.

• No moving parts

— There are no rotating, translating, undulating or oscillating parts to wear,

stick, break or fatigue.

• Chemical compatibility

— The wetted surface(s) can be any of a number of corrosion resistant

metals or alloys. There are no internal joints or seals in most TU type transducers.

• Flexibility

— Rheotherm meters can be ordered calibrated for mass or volumetric units or in
average velocity. Flow rate, totalization and fluid temperature displays or output signals are
available as well as rangeability up to 100:1 or more.

• Fluid pressure options

to 10,000 psi (check transducer tag for rating on your unit).

• Withstands over ranging — No damage or change in calibration will occur due to excessive
flow rates many times higher than calibration range.

• Immunity to shock and vibration

• Optional nuclear radiation hardening

• Range of application

includes measurements in capillary tubes to large diameter pipes or

.

.

ducts.

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1.2 DESCRIPTION OF OPERATION

Rheotherm flow meters are available with various nonintrusive and intrusive transducer designs, but
they all use the same thermal sensing technique. Two temperature sensors are used — one is in thermal
equilibrium with the fluid and provides a fluid temperature reference, while the second temperature
sensor is located near a heater so that its temperature is slightly above that of the fluid. In a TU
transducer, the temperature sensors and heater are attached to the outside of the flow tube, whereas the
probe transducers have the sensors and heater located in the probe(s) that are inserted into the stream.
The amount of heat removed from the heated sensor by the stream is related to fluid velocity. Hence,
the measured temperature differential between the reference sensor and heated sensor is a function of
flow rate. For the Model 100 the non-linear output is approximately proportional to the logarithm of
flow. Intek, Inc. is licensed to use this patented and trademarked flow measurement technique.

Nonintrusive transducer Example of Example of

(TU) single probe dual probe with

with NPT fitting flange fitting

1.3 PRECAUTIONS

1. Use proper input power — Check the label on the electronics for the input power
requirements.

2. Use reasonable care in handling the transducer. Do not try to disassemble the transducers;
there are no removable parts.

TU — excessive twisting or bending can damage the sensor. The flow tubes are thin-walled

tubing.

Probes (NPT/2I, NPT/I, BF/2I, BF/I, etc.) — take care not to bend the probes or damage the

tips. Do not try to remove or turn the conduit junction box.

3. All TU sensors under TU¼ should be supported by the sensor shell, not the tube stubs. TU
sensors using GALB junction boxes or sensors without junction boxes can be supported with
pipe clamps or some other appropriate means. TU s with ____ can be supported using the
brackets machined into the junction box. Additionally, Intek sells separate support brackets.

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4. Check the transducer maximum temperature rating — do not operate a transducer at or subject
it to a temperature above its specified limit.

5. Keep moisture out of the electronic enclosure and sensor junction box. Once cable
connections are made in the junction box, make sure the lid is tightly closed. Seal conduit
lines if they can become wet inside.

6. Keep transducer wetted surfaces clean and free of permanent layer build-up.

7. Do not exceed pressure limits of the tube or fittings.

8. Maintain a thermally stable environment (short-term) for the transducer and adjacent line.
(See SECTION 2 — INSTALLATION.)

These instructions cover installation, calibration and maintenance of Rheotherm meters in standard
configurations. Any special information pertaining to your unit is covered under CUSTOM
INFORMATION (SECTION 6). Time should be taken to carefully read these instructions prior to
installation of the equipment. Should any questions arise or problems occur, call Intek for immediate
assistance.

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SECTION 2 ! INSTALLATION

2.1 TRANSDUCER

. IMPORTANT: All transducers have a directional arrow on the tag

and/or etched into a metal part. Before installing a sensor, please note
proper flow direction. This is critical to sensor operation.

. IMPORTANT: If you have more than one Rheotherm unit, make sure

the complete serial number of the transducer matches the complete serial
number of the electronics. The transducer and electronics are a matched
set. Components with different serial numbers should not be
interchanged. The transducers have no user serviceable parts, so do not
try to disassemble, as permanent damage may result.

The transducer style supplied with your meter is listed in the model code number in SECTION 6.
Proper installation of the sensor is necessary for achieving accuracy and repeatability. Installation
suggestions for each type of standard transducer are given here. For custom transducer installations,
refer to CUSTOM INFORMATION — SECTION 6.

Be sure wetted surfaces are clean before installing. If cleaning is needed, use non-residue solvent and
wipe dry. If the sensor has a connector box, keep moisture out. Make sure the lid is tightly sealed and,
if supplied, the gasket is in place. Seal conduit lines at the connector box if conduit lines can become
wet.

1

1. TU (nonintrusive) — TU

'16 and TUc transducers, unless they have optional ¼" O.D. ends,

particularly require special care in handling and installing to avoid damage to sensor tube
stubs.

. CAUTION: TU transducers are made with thin-walled tubing — use

care when installing.

All TU transducers (other than
sections, typically 20 pipe diameters on the inlet and 6 to 10 diameters on the outlet. If
installed vertically, the flow should be going up through the sensor. Connection in the line
is via compression fittings, hose with clamp, threaded fittings or flanges, whichever is
appropriate. Care must be taken not to transmit a twisting force through the transducer's
midsection. The TU transducer, whether flanged or not, must not be used to pull other piping
together or to make up angular mismatch of fittings. The transducer junction box (if supplied)
should never be rotated for any reason.

1

TU

'16 transducers may be sleeved with a c" tube for added support. Connection should

always be made to the

1

'16" tube, as there is no assured seal between the

sleeve.

Some TU transducers have an integrally mounted cable; do not pull on this cable, or attempt
to remove the fitting where the cable enters the sensor shell.

1

'16 and c inch) should have straight line input and output

1

'16" tube and the

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