Intek 200 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, RheoVac, Rheovec, Rheomax and RheoSmart are registered trademarks of Intek, Inc.

Intek, Inc.

751 Intek Way

Westerville, Ohio 43082-9057

TEL: [phone] • FAX: [phone]

website: www.intekflow.com

e-mail: [e-mail]

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 TRANSMITTER ELECTRONICS ........................................ -6-

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

SECTION 3 ! OPERATION..................................................... -13-

3.1 START UP.......................................................... -13-

3.2 GENERAL INFORMATION ........................................... -13-

3.3 OUTPUT SIGNALS .................................................. -13-

3.4 KEYPAD and DISPLAY............................................... -14-

3.5 OUTPUT CURVE .................................................... -16-

SECTION 4 ! MAINTENANCE ................................................. -17-

4.1 GENERAL MAINTENANCE........................................... -17-

4.2 FLOW CALIBRATION ADJUSTMENT .................................. -17-

4.3 SPARE PARTS ...................................................... -17-

4.4 TRANSDUCER & TRANSMITTER FUNCTIONAL TESTS . . . . . . . . . . . . . . . . . . -17-

4.5 TROUBLE SHOOTING ............................................... -20-

SECTION 5 ! CUSTOMER SERVICE ........................................... -23-

5.1 QUESTION ON EXISTING HARDWARE ................................ -23-

5.2 TROUBLE SHOOTING ............................................... -23-

5.3 FACTORY AND FIELD SERVICE ...................................... -23-

5.4 DECONTAMINATION OF EQUIPMENT ................................ -23-

5.5 QUESTIONS ON NEW EQUIPMENT.................................... -23-

SECTION 6 ! CUSTOM INFORMATION ........................................ -24-

6.1 UNIT IDENTIFICATION .............................................. -24-

6.2 CONFIGURATION ................................................... -24-

6.3 SPECIAL INSTRUCTIONS ............................................ -24-

TABLE OF ORIGINAL CALIBRATION DATA ................................ -25-

OUTPUT DEFINITION TABLE ............................................. -25-

APPENDIX Figure A-1 Flow Output Curve

©Intek, Inc. 2000

Manual no. A2009808 Rev. B

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1.1 INTRODUCTION

SECTION 1 ! GENERAL INFORMATION

The Model 200 is a “smart” instrument having performance characteristics described in SECTIONS 3,
4, and 6. 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 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 a transmitter 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 transmitter, for signal processing, is
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 rate at which heat is 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
method.

Nonintrusive transducer Example of Example of

(TU) single probe dual probe with

with NPT fitting flange fitting

1.3 PRECAUTIONS

!! CAUTION: Throughout the manual this caution notation indicates

that failure to execute the accompanying instructions
may cause the instrument or external equipment to
malfunction.

!! WARNING: A warning indicates that failure to execute the

accompanying instructions may cause permanent
damage to the instrument or external equipment.

1. Use proper input power — Check the label on the transmitter 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.

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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.

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 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

!! CAUTION: 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.

!! CAUTION: If you have more than one Rheotherm unit, make sure the
complete serial number of the transducer matches the complete serial
number of the transmitter. The transducer and transmitter are a matched
set. Components with different serial numbers should not be interchanged
unless specifically ordered as spares. 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 junction box, keep moisture out. Make sure the lid is tightly sealed and,
if supplied, the gasket is in place. Seal conduit lines at the junction box if conduit lines can become wet.

1. TU (nonintrusive) — TU '16 and TUc transducers particularly require special care in handling

1

and installing to avoid damage to sensor tube stubs.

!! WARNING: TU transducers are made with thin-walled tubing — use
care when installing.

All TU transducers (other than '16 & c inch) should have straight line input and output

1

sections, typically 20 pipe diameters on the inlet and 6 to 10 diameters on the outlet. If
installed vertically, the flow should be 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 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 '16" tube, as there is no assured seal between the '16" tube and the

11

sleeve.

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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.

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 212°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 recommend 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 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
the flow sporadic and difficult to measure. Control valves should be placed down stream of
the sensor.

The ideal installation will provide the sensor with well established smooth flow, uniform
system temperature and consistent fluid media.

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2. Intrusive Probes —

!! IMPORTANT: Recommended straight run for best accuracy is a

minimum 20 diameters up stream and 10 diameters down stream.

The various probe transducers are mounted through a threaded collar (NPT/2I and NPT/I) or
flanged tee (BF/2I or BF/I). Other fittings and sensor designs are also available and are
discussed on the Custom Information page. Generally the probes are sized so the tips extend
½ to 1 inch beyond the pipe center line when properly installed. There are exceptions to this
in certain applications; see CUSTOM INFORMATION (SECTION 6) as it applies.

Proper alignment of the sensor with flow is important; the flow direction is indicated on the
transducer tag and/or etched into the transducer. All dual probe transducers (NPT/2I, BF/2I)
are installed so that the two probes are side-by-side across the fluid stream. Never rotate the
junction box that houses the terminal cable connection. If this occurs the transducer could be
damaged and/or installed misaligned with the flow direction.

For high temperature applications, the sensor and surrounding line should be well insulated.
Leave a portion of the transducer neck un-insulated to allow heat dissipation before reaching
the junction box.

2.2 TRANSMITTER ELECTRONICS

Various types of transmitter housings are available. These include NEMA 4, laboratory bench type,
explosion proof, and panel mount enclosures as well as special models to meet customer requirements.
These come in different sizes to accommodate options and special features.

1. NEMA 4 — The standard industrial housing, this enclosure is watertight (non-submersible)
when the door is properly clamped shut. The housing should be mounted such that wire/cable
ports are located at the bottom of the housing, to reduce problems associated with water spray,
condensation and settling of dust and dirt. An all stainless steel version (NEMA 4X) for
corrosive environments is also available.

2. NEMA 7 — For use in hazardous (class I) environments. The lid should be closed and all
bolts tightened before the unit is powered up. If a NEMA 7/NEMA 4 enclosure was ordered,
the unit will have a rubber gasket in a groove in the top of the enclosure base. Conduit seals
are frequently required, so applicable code requirements should be met when installing the
conduit into the box.

3. Laboratory — This table-top unit is NEMA 1 only; do not spill liquid on it or use in a wet
environment. This unit typically has a grounded power cord, and all transducer and output
connections are located on the back of the enclosure.

4. Panel Mount — For use in a control panel, mounted so the enclosure face is flush with the
panel surface. Most or all connections are made on the back of the enclosure. This unit is
NEMA 1 only; do not use in a wet environment.

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The transmitter housing should be installed keeping in mind the length and routing of the transducer
cable. Standard cable length is six feet but it can be specified up to 200 feet. If, after calibration of the
unit, the cable length is changed (a portion cut off or additional cable spliced on), there may be a shift
in the calibration due to the change in cable resistance. The size of this effect depends on the amount

of change. If a noticeable shift occurs, it may be necessary to adjust the output as described in the
calibration instructions in SECTION 4.2.

Unless otherwise specified, normal ambient environment for the transmitter is 0-120°F. Recommended
maximum temperature is 135°F.

2.3 ELECTRICAL CONNECTIONS

1. Verify/configure the input power. The input power requirement is listed on the tag on the
transmitter enclosure. Be sure the input power source to be used is properly selected in the
unit. Input power can be either 115 Vac or 230 Vac single phase, 50-60 Hz. The power
configuration may be changed in the field. Using Figure 1, locate the power select switch on
the lower printed wiring board and slide the power select switch to either the 115V or the
230V position. Do not apply power to the instrument until all other connections and

optional selections have been made.

!! CAUTION: The following output signals, both ! and +, are isolated
from the transducer and power ground. However, the outputs are not
isolated from each other. All of the 4 to 20 mA receiver channels must
have independently isolated inputs. Again, the 4-20 mA, RS232/422, and
status outputs are all common to each other.

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Figure 1 - Transmitter Hardware Configuration

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