Intek 100FS 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]

www.intekflow.com

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 .................................................. - 5 -

2.3 ELECTRICAL CONNECTIONS ..................................... - 6 -

SECTION 3

3.1 START UP ....................................................... - 7 -

3.2 GENERAL INFORMATION ........................................ - 7 -

3.3 ADJUSTING THE TRIP POINT ..................................... - 7 -

3.4 CHANGING THE TRIP POINT RANGE .............................. - 8 -

3.5 TRANSDUCER FUNCTIONAL TESTS ............................... - 8 -

Figure A. Transducer Continuity Check ...................................... - 9 -

Figure B. Transducer Isolation Check ....................................... - 9 -

SECTION 4

4.1 GENERAL MAINTENANCE ....................................... - 10 -

4.2 SPARE PARTS .................................................. - 10 -

4.3 TROUBLE SHOOTING ........................................... - 11 -

TABLE I. TROUBLE SHOOTING GUIDE .................................. - 11 -

SECTION 5

5.1 QUESTION ON EXISTING HARDWARE ............................ - 12 -

5.2 TROUBLE SHOOTING ........................................... - 12 -

5.3 FACTORY AND FIELD SERVICE .................................. - 12 -

5.4 DECONTAMINATION OF EQUIPMENT ............................ - 12 -

5.5 QUESTIONS ON NEW EQUIPMENT ............................... - 12 -

! OPERATION ..................................................... - 7 -

! MAINTENANCE ................................................ - 10 -

! CUSTOMER SERVICE .......................................... - 12 -

SECTION 6

! CUSTOM INFORMATION ....................................... - 13 -

6.1 UNIT IDENTIFICATION .......................................... - 13 -

6.2 CONFIGURATION ............................................... - 13 -

6.3 SPECIAL INSTRUCTIONS ........................................ - 13 -

Figure 1. Rheotherm® 100 Rev. B Signal Conditioner PCB Layout ..................... - 14 -

Figure 2. Rheotherm® Flow Switch Add-on Option ................................. - 15 -

Intek, Inc. 2010

Manual no. A100AFS9505 REV B

I:\OFFICE\WPMANUAL\Rheotherm\Model 100\MOD100FS.RVB

SECTION 1 ! GENERAL INFORMATION

1.1 INTRODUCTION

Rheotherm flow switches offer reliable flow switch protection in liquids, gases and slurries. They can
be used for flow/no flow detection, or specific low and/or high level alarms over a given 10 to 1 flow
range. 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 100FS flow switch 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 two basic enclosure styles (SECTION 2.2). Again, selection is based on application
requirement.

Key features of Rheotherm flow switches and flow meters are:

Nonintrusive flow monitoring
outside the flow tube.

No moving parts There are no rotating, translating, undulating or oscillating parts to wear,
stick, break or fatigue.

Chemical compatibility
metals or alloys. There are no internal seals in a TU type transducer. Most sensors are 316
SS or 316 SS and nickel braze.

Flexibility
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

Withstands over ranging
flow rates many times higher than originally specified.

Immunity to shock and vibration

Rheotherm meters can be ordered calibrated for mass or volumetric units or in

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

to 10,000 psi.

For pipe sizes from .030 to 1 inch, flow sensing is done from

No damage or change in operation will occur due to excessive

.

Optional nuclear radiation hardening

Range of application
ducts.

includes measurements in capillary tubes to large diameter pipes or

.

- 1 -

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. Intek, Inc. is licensed to use this patented and trademarked flow measurement technique.

Nonintrusive transducer

(TU)

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

4. 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.

Example of single probe

with NPT fitting

Example of dual probe

with flange fitting

- 2 -

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

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

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

These instructions coverinstallation, operationand maintenance of Rheotherm flow switches 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.

- 3 -

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,

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.

Straight run for a flow switch is not a requirement, but for best repeatability some straight run
is useful, such as 10 to 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

Typically, TU
should always be made to the
the sleeve.

'16 transducers are sleeved with a c" tube for added support. Connection

1

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

1

'16 tube and

- 4 -