Intek 111D 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, 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 ...................................................... - 10 -

3.5 TRANSDUCER & ELECTRONICS FUNCTIONAL TESTS .................... - 10 -

Diagram A. Transducer Continuity Check ...................................... - 11 -

Diagram B. Transducer Isolation Check ........................................ - 11 -

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

SECTION 4

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

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

4.2 SINGLE POINT FIELD CALIBRATION ................................... - 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. Transducer/Electronic/Electrical Interface Drawing .......................... - 17 -

Figure 2. Rheotherm® Signal Conditioner PWB Layout .............................. - 18 -

Figure 3. Flow Rate vs. Output Curve ............................................ - 19 -

©Intek, Inc. 2011

Manu al no. A114960 9 Rev. C

I:\OFFICE\WPMANUAL\Rheotherm\MAN114 REV C.wpd

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. They are manufactured exclusively by Intek, Inc. and
employ a patented thermal technique used by industry since 1978. The unique transducers have
protected sensor design, 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 1.5 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 tube 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 temperature options

• Fluid pressure options

• Withstands over ranging

to 500°F.

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

— 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 tube style
transducers, 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 tube transducer Example of Example of

probe probe with
with NPT fitting flange for mounting

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.

Tube (TU, TUL, TUS, etc.) — 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 tube sensors under ¼” should be supported by the sensor shell, not the tube stubs. Tube
sensors using junction boxes or sensors without junction boxes can be supported with the pipe
clamps or some other appropriate means. Tube sensors with junction box can be supported
using the brackets machined into the junction box.

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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

. 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.

. IMPORTANT: If you are installing Rheotherm instruments in outdoor

environment, it is highly recommended that a “roof,” “shelter” or
protective cover to be provided to shield the transducer and electronics
from direct impact of environment conditions. Sudden and large changes
in temperature can affect instrument performance. Heat from the outside
can build up the temperature inside electronics enclosures, and can exceed
the temperature ratings for the electronics within.

2.1 TRANSDUCER

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. Tube (nonintrusive) —

1

'16 and c 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: Tube transducers are made with thin-walled tubing —

use care when installing.

1

All tube transducers (other than
sections, typically 20 pipe diameters on the inlet and 6 to 10 diameters on the outlet.
Installation locations for tube style transducers should be selected to ensure a continuous and
uniform fluid flow within the sensing tube. Vertical or angled installations should be in
locations where the fluid is flowing 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

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

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tube 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

The

'16" tube 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 flow tube and

the c” support sleeve.

Some tube 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.

Fluid temperatures other than ambient require special attention. Thermal gradients from one
end of the transducer to the other, as well as along the radius of the connection pipe, are
undesirable. Therefore, effective insulation should be installed around the inlet and outlet
straight line runs. Gradients which may exist in the line further up stream can be removed if
an insulated elbow is installed in the line prior to entering the straight line portion of the
plumbing. Metallic support braces for the sensor or adjoining plumbing can act as a heat sink
and cause operational problems in high temperature applications. The support braces should
be thermally isolated from the line to avoid large heat conduction effects.

If the transducer is for use above 300°F, it will have a side arm and connector box, where the
internal high temperature wiring is connected to the lower temperature transducer cable. Free
air should be allowed to flow around the side arm and connector box to keep the box cool.
The side arm can be insulated up to one third of its length from the transducer body.

In these applications, proper thermal control is vital to accurate meter performance. Non­uniform heat tracing, relay on/off temperature controllers and oscillating proportional type
control should always be avoided. Steam trace lines with good pressure regulation or properly
tuned proportional temperature control systems are effective in maintaining uniform fluid
temperature. A box around the sensor and inlet tubing is highly recommended for operating

temperatures higher than room ambient. Allow enough inlet tubing inside the box to allow
the fluid temperature to become the same temperature as the surrounding air. Separately
control the box air temperature at the same temperature as the incoming fluid temperature
to minimize thermally induced indication errors.

Flow stream conditioning must also be considered to maximize meter performance. Avoid
upstream protrusions and short distance straight runs. Flow pulsations, such as those created
by metering pumps, may cause the instrument to differ from the factory calibration.
Furthermore, if the flow is varied by stroke and by pump speed adjustment, the indication will
most likely be non-repeatable. If you are using a pump of this type, it is recommended that
a pulsation dampening device be used to provide smooth continuous flow. A second choice
would require readjustment of the instrument calibration (cal) potentiometer after installation
(See SECTION 4.2).

For liquid measurement systems using high pressure gas to force flow, the effects of the
absorbed gas must be considered. In these cases, sudden pressure drops up stream of the
sensor such as line size expansions, control valves, and pressure dropping regulators must be
avoided. Sudden pressure drops can cause the absorbed gas to release into the liquid, making

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