Johnson Controls MICROPROCESSOR BASED TURBINE FLOW METER User Guide

MICROPROCESSOR BASED TURBINE FLOW METER

Installation and Operation Guide

2013-3

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www.onicon.com • [e-mail]

04-18

SAFETY INFORMATION

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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 ONICON’s
written permission.

• ONICON 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 ONICON.

• ONICON 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, ONICON 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 specic WARNINGS given elsewhere in this manual violates safety standards of design,
manufacture, and intended use of the product. ONICON Incorporated assumes no liability for
the customer’s failure to comply with these requirements. If this product is used in a manner not
specied in this manual, the protection provided by this product may be impaired.

The following symbols are used in this manual:

Messages identied as “WARNING” contain information regarding the personal safety of
individuals involved in the installation, operation or service of this product.

Messages identied as “CAUTION” contain information regarding potential damage to the
product or other ancillary products.

WARNING

CAUTION

IMPORTANT NOTE

Messages identied as “IMPORTANT NOTE” contain information critical to the proper
operation of the product.

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Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page 2

TABLE OF CONTENTS

1.0 INTRODUCTION .............................................................................................................4

1.1 Purpose of This Guide ..........................................................................................4

1.2 Typical Turbine Flow Meters ...............................................................................4

1.3 Standard Features and Specications ..................................................................5

1.4 Model Numbering System ....................................................................................6

1.5 Additional Required Hardware ............................................................................6

1.6 Serial Number .......................................................................................................6

2.0 UNPACKING ................................................................................................................7

2.1 Checking That You Have Received Everything ...................................................7

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

3.1 Installation Site Selection ....................................................................................8

3.2 Insertion Meter Straight Run Requirements ......................................................10

3.3 Insertion Meter Mechanical Installation ............................................................11

3.3.1 Insertion Meter Installation Kits ...............................................................12

3.3.2 ONICON Dry Tap Installation Hardware Kits ...........................................12

3.3.3 ONICON Hot Tap Installation Hardware Kits ...........................................12

3.3.4 Customer Supplied Installation Hardware ...............................................13

3.3.5 Conrming the Stack Height .....................................................................14

3.4 Installing the Insertion Meter .............................................................................15

3.4.1 Installing the Meter With a Factory Supplied Depth Gage ......................16

3.4.2 Calculating Insertion Depth Using Conguration Utility ........................16

3.5 Removal of the Insertion Meter ..........................................................................17

3.6 Inline Flow Meter Straight Run Requirements and Mechanical Installation...19

3.7 Wiring Connections ............................................................................................20

4.0 START-UP & COMMISSIONING ...................................................................................21

4.1 Helpful Hints for Start-up and Commissioning ................................................21

4.2 Insertion Meter Start-up and Commissioning ...................................................22

4.3 Insertion Meter Start-up and Commissioning Worksheet .................................23

4.4 Inline Meter Start-up and Commissioning ........................................................24

4.5 Inline Meter Start-up and Commissioning Worksheet ......................................25

4.6 Troubleshooting Guide .......................................................................................26

5.0 ANALOG ADJUSTMENT PROCEDURE .......................................................................27

5.1 Diagnostic LEDs ..................................................................................................28

APPENDIX

A User Connections and Internal Wiring Diagrams

B Installation Hardware Instructions

C Insertion Turbine Assembly Detail Drawings

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Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page 3

SECTION 1.0: INTRODUCTION

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We, at ONICON Incorporated, would like to thank you for purchasing our quality, U.S. made, turbine
ow meter. As our valued customer, our commitment to you is to provide fast reliable service and
assistance, while continuing to offer you new products to meet your growing ow measurement needs.

1.1 PURPOSE OF THIS GUIDE

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

WARNING

Please do not permit any persons to install, operate or maintain this equipment unless they have a
complete knowledge of their trade skills and are competent to work on high pressure hot and cold
water systems, according to their individual trades. Death or permanent injury may result from
accidents with these systems.

This guide is the basic reference tool for all ONICON Turbine Flow Meters. 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 TURBINE FLOW METERS

ONICON’s Turbine Flow Meters measure the velocity
of owing liquids by counting the frequency at
which the blades of a rotating turbine pass a xed
electrode. Circuitry within the ow meter electronics
enclosure then converts the rotational rate to digital
and/or analog signals which are transmitted via
a connecting cable to any of ONICON’s display
devices, Btu meters and/or a data acquisition system.

Electronics Enclosure

Sweat or NPT

Process Connections

Insertion Meter

Inline Meter

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1.3 STANDARD FEATURES AND SPECIFICATIONS

(Refer to specication sheet for particular model to obtain additional details)

ACCURACY

Insertion Meters
± 0.5% of reading at calibrated velocity
± 1% of reading from 3 to 30 ft/s (10:1 range)
± 2% of reading from 0.4 to 20 ft/s (50:1 range)
Inline Meters
± 0.5% of reading at calibrated velocity
± 2% of reading from 0.8 to 38 GPM (50:1 range)

SENSING METHOD

Single- Turbine Meters

Single turbine electronic impedance sensing
(non-magnetic and non-photoelectric)

Dual-Turbine Meters

Dual turbine electronic impedance sensing
(non-magnetic and non-photoelectric) and
frequency averaging circuitry.

PIPE SIZE RANGE

Single-Turbine Insertion Meters

1¼” through 72” nominal

Dual-Turbine Insertion Meters

2½” through 72” nominal
Inline Meters
¾” or 1” NPT threaded or copper sweat process
connections

SUPPLY VOLTAGE

24±4 V AC/DC at 80 mA

LIQUID TEMPERATURE RANGE

Standard: 180° F continuous, 200° F peak
High Temp: 280° F continuous, 300° F peak
Insertion meters operating above 250° F require 316

stainless steel construction option

AMBIENT TEMPERATURE RANGE

-5° to 160° F (-20° to 70° C)

OPERATING PRESSURE

400 PSI maximum

PRESSURE DROP

Insertion Meters

Less than 1 PSI at 20 ft/s, decreasing
in larger pipes and lower velocities

Inline Meters

3 PSI at maximum ow rate

MATERIAL

Insertion Meters

Wetted metal components
Standard: Electroless nickel plated brass
Optional: 316 stainless steel

Inline Meters

Brass sensor body

ELECTRONICS ENCLOSURE

Standard: Weather-tight aluminum enclosure
(NEMA4)
Optional: Submersible enclosure (NEMA6)

ELECTRICAL CONNECTIONS

Standard: 10’ of PVC jacketed cable with ½”
NPT conduit connection
Optional: Indoor DIN connector with 10’ of
plenum rated cable

OUTPUT SIGNAL(S)

Standard: Calibrated frequency output
0-15 V pulse, Maximum Hz, Scaled Pulse/
Alarm Output (Field Congurable)
Optional: Analog and Iso Analog outputs also
available, based on model

APPROVALS

Optional

TURBINE INSERTION FLOW METER
NSF/ANSI 61 <MH60590>
ALSO CLASSIFIED
IN ACCORDANCE WITH
NSF/ANSI 372

For F-1100 / F-1200 Series Only,
maximum temperature 180° F (82° C)

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1.4 MODEL NUMBERING SYSTEM

METER ORDERING INFORMATION

Meter Model Number Coding = F-1ABB-CC-DD-EFGH

A = Number of Turbines E= Wetted Materials

1 = Single Turbine 1 = Electroless Ni Plated Brass

2 = Dual Turbine 2 = 316 SS

BB = Meter Type 3 = Bronze Body, Inline

00 = Insertion F= Electronics Enclosure

34 = ¾" Inline 2 = NEMA 4 Weathertight Enclosure

01 = 1" Inline 3 = NEMA 6 Submersible Enclosure

CC = Outputs G= Wiring Connection

00 = Freq. and Scaled Pulse 2 = 10’ PVC Jacketed Cable, Pig Tail with ½” Conduit Adapter

10 = Freq., analog and Scaled Pulse 5 = 10' Plenum Rated Cable, DIN Connector

11 = Freq., Iso. Analog, and Scaled Pulse 6 = 25' PVC Jacketed Cable, Pig Tail with ½" Conduit Adapter

DD = Meter Type and Pipe Size Range 7 = 10' Submersible Cable with Connector

A1 = 1.25 - 2.5” (F-1100 Only) H = Process Adapter

B2 = 2.5 – 4.0” (F-1100 Only) 1 = 1" NPT Adapter, Medium Temperature (Temp. </= 150° F)

C3 = 2.5 - 10” 2 = 1" NPT Adapter, High Temperature (Temp. </= 280° F)

D4 = 2.5 - 16” 3 = 1" NPT Adapter, NSF Rated for Domestic Water

E5 = 2.5 - 22” 9 = Inline, coupling adapters based on pipe material

F6 = 2.5 - 72”

00 = Inline

1.5 ADDITIONAL REQUIRED HARDWARE

All ONICON insertion type meters can be installed and removed via a 1” or
larger full port ball valve without stopping ow. The terms “Dry Tap” and
“Hot Tap” refer to the installation method of the isolation valve kit only.

Dry Tap Installation Hardware: For new construction or scheduled
shutdown; once kit is installed, the ow 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 dry tap vs. hot tap versions.

1.6 SERIAL NUMBER

Serial Number

The serial number of your ow meter is located on a label on the side of the electronics enclosure.
The model number is also listed on this label. The serial number is a unique identier that you
should refer to, along with the model number, whenever you contact ONICON for assistance
regarding your meter.

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Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page 6

SECTION 2.0: UNPACKING

Turbine ow meters are generally shipped in one package unless optional hardware or equipment is
ordered. This package may contain up to two complete meters along with the optional installation kits.
Any display equipment ordered with the meters, will be packed separately. Please open all packages
with caution to avoid damaging to their contents. In the event that anything is damaged when you
receive it, notify the shipping company immediately and the ONICON customer service department.
Most products are shipped insured unless the customer specically requests otherwise.

2.1 CHECKING THAT YOU HAVE RECEIVED EVERYTHING

The Documentation

Enclosed with each ow meter is a comprehensive documentation package which includes the
following items:

• Installation and Operation Guide

• Flow Meter Calibration Certicate

Please notify the ONICON customer service department if any documents are missing.

The Flow Meter

The ow meter was carefully packed prior to shipment and should arrive without any damage.
Prior to installation, inspect for physical damage such as broken turbine blades or a damaged
stem.

• Test the turbine(s) to see that they rotate freely when you gently blow on them parallel to
their shafts.

• Make sure that the threads on the insertion meter hot tap adapter have not been
damaged.

• Inspect the insertion meter stem for bends or other damage. The stem forms the seal
against liquid leakage as it slides through an ‘O’ ring inside the hot tap adapter. Deep
scratches may cause leakage.

• The serial and model numbers on the laminated wiring connection/calibration data tag
attached to the meter should match the numbers on the tag mounted directly on the ow
meter. Be sure that the unit was calibrated to the correct pipe size and ow range.

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SECTION 3.0: INSTALLATION, REMOVAL & ADJUSTMENT

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WARNING

Insertion ow meters may often 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
systems and related knowledge in the heating, cooling and uid metering elds should attempt to
install adjust or remove the ow meter. Carefully read the installation and removal instructions in
this manual before performing any work on these meters.

ONICON will be happy to assist with technical recommendations and to provide guidance
by telephone or e-mail. On-site eld engineering, installation and service is also available at
additional cost.

3.1 INSTALLATION SITE SELECTION

Install the ow meter where it will be accessible for personnel to perform necessary periodic
maintenance. The clearance required for insertion meter installations is typically 23”-36” from
the pipe wall to the nearest obstruction above the valve assembly. This clearance dimension will
increase with large diameter pipes. Allow at least 6” of clearance for inline meter installations.
The environment should be free of corrosive liquids/fumes, temperature extremes and heavy
vibration. The following information should be used as a guide to the proper location for
installing the meter.

GENERAL PRACTICES:

1. For best results, install the ow 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. Review
the following pages for guidelines in determining minimum upstream straight run
requirements based on the nature of the obstruction.

Note: Depending upon specic location details, more or less straight run may be
required to produce a satisfactory ow prole.

3. If there is insufcient straight run, allow 80% of the run upstream and 20% of the run
downstream.

IMPORTANT NOTE

Always use the maximum available straight run. When more than the minimum required
straight run is available, place the meter such that the excess straight run is upstream of the
meter location.

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INSERTION AND INLINE FLOW METER SITE SELECTION

GENERAL GUIDELINES

(Shown with Insertion Meter)

• Install in vertical or horizontal pipe.

• For horizontal pipe position meter
anywhere in upper 240°

CLEARANCE

CLEARANCE

REQUIRED

REQUIRED

FOR INSTALLATION

FOR INSTALLATION

23” - 36”

Depending on

23" - 36"

pipe size

Depending on

Allow at least

pipe size

6” for inline meters

FLOW

Downstream

20%

Available Straight Run*

Upstream

80%

Vertical Pipe

FLOW

Position

(Downward ow

is also allowed)

20%

Downstream

80%

Upstream

Available Straight Run*

*See following pages for model specic straight run requirements.

EVALUATING UPSTREAM PIPING CONDITIONS

Straight Pipe

Single Bend

Pipe Reduction or Enlargement
Outowing Tees
Multiple Bends in Same Plane
Multiple Bends Out of Plane
Inowing Tees
Control Valves

Worse Better

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FLOW DIRECTION

3.2 INSERTION METER STRAIGHT RUN REQUIREMENTS

Series F-1100 Single Turbine Flow Meters

FLOW DIRECTION

Minimum downstream

straight run distance

5 pipe diameters to any

valve, elbow, tting, etc.

GENERAL PRACTICES

1. For best results, install the ow meter in a straight run of pipe,
free of bends, tees, valves, transitions, and obstructions for a
distance of at least 20 pipe diameters upstream and 5 diameters
downstream.

2. Longer straight runs may be required in applications where the
meter is placed downstream from devices which cause unusual
ow prole disruption or swirl, for example, modulating valves or
two elbows in close proximity and out of plane, etc.

3. If there is not su󰀩cient straight run, allow 80% of the run upstream and
20% of the run downstream. If the total length of straight run is less
than 20 diameters, performance may seriously
degrade, and consideration should be given to
changing to the series F-1200 Dual Turbine
Flow Meter.

FLOW DIRECTION

Minimum upstream

straight run distance

20 pipe diameters from any

valve, elbow, tting, etc.

Series F-1200 Dual Turbine Flow Meters

GENERAL PRACTICES

1. For best results, install the ow meter in a straight run of pipe,
free of bends, tees, valves, transitions, and obstructions for a
distance of 10 pipe diameters upstream and 5 diameters
downstream.

Minimum downstream

straight run distance

5 pipe diameters to any

valve, elbow, tting, etc.

2. Longer straight runs may be required in applications where the
meter is placed downstream from devices which cause unusual
ow prole disruption or swirl, for example, modulating valves or
two elbows in close proximity and out of plane, etc.

3. If there is not su󰀩cient straight run, allow 80% of the run
upstream and 20% of the run downstream.

FLOW DIRECTION

Minimum upstream

straight run distance

10 pipe diameters from any

valve, elbow, tting, etc.

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3.3 INSERTION METER MECHANICAL INSTALLATION

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ONICON Insertion Turbine Flow Meters employ a hot tap adapter design that allows for insertion
and removal, when necessary, without interrupting ow and draining the pipe. To take advantage
of this feature, the ow meter must be installed through an isolation valve. The installation must
also allow for sufcient 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 ttings are full port and at least 1” in actual internal diameter.

CLEARANCE

REQUIRED

FOR INSTALLATION

Typically

30 - 40"

23”- 36”

depending on

pipe size and

height of valve

assembly.

Dry Tap Installation
Kit for Steel Pipe

Minimum Hole Size = 1"
Must be centered

1" Full port ball valve

1" Close nipple

1" Branch outlet

NOTE: Use stainless steel or brass
close nipple only.

1¼" for
hot tap

CAUTION

ONICON insertion style ow meters must be installed through a valve assembly. Failure to do so
negates the ability to remove the meter without shutting down ow and draining the system. It will
also result in an excessive amount of stem protruding from the pipe. Excessive stem lengths
unnecessarily expose the meter to incidental damage.

IMPORTANT NOTE

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Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page 11

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

3.3.1 Insertion Meter Installation Kits

ONICON offers a wide range of installation hardware kits for commonly used pipe
materials. The kits are specically designed for ONICON insertion ow meters, and their
use is recommended. Refer to Appendix B of detailed information regarding ONICON
installation hardware kits.

The use of ONICON installation hardware kits accomplishes two important objectives.
First, it ensures that the proper hardware is used. Second, it simplies order processing
by standardizing the dimensions of the installation hardware.

ONICON installation hardware kits consist of three separate component parts:

Some type of threaded

branch outlet,

An interconnecting

close nipple,

And a full port

isolation valve.

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

3.3.2 ONICON Dry Tap Installation Hardware Kits

Dry Tap 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, the close nipple and full port ball
valve. Once the isolation valve is installed, the piping system can be ushed, lled and
pressurized. The ow meter may now be inserted or removed by hand without having to
stop ow or drain the system. Please read all instructions before proceeding with meter
insertion.

3.3.3 ONICON Hot Tap Installation Hardware Kits

ONICON offers an alternative installation hardware kit when it is not practical to relieve
pressure and drain the system. In this case, a 1¼” branch outlet, a close nipple and a 1¼”
full port ball valve are installed rst. Then, a hot tap drilling apparatus is used to drill a 1”
diameter hole through the valve. This eliminates the need to stop ow and drain the pipe.
Please read all instructions before proceeding with meter insertion.

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Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page 12

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3.3.4 Customer Supplied Installation Hardware

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There are occasions where circumstances require that the customer provide the installation
hardware or that the ow meter be installed through existing hardware. In these cases, it is
important to conrm that the installation hardware is suitable for use with the ow meter
provided by ONICON before it is installed. The installation must allow for sufcient overhead
clearance to fully extract the meter, must not be too tall where the meter cannot reach the
appropriate depth, 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 ttings are full port and at least 1” in
actual internal diameter.

Installation hardware generally consists of three separate component parts:

Some type of threaded

branch outlet,

An interconnecting

close nipple,

And a full port

isolation valve.

IMPORTANT NOTE

Do not use threaded steel or slip PVC tees to provide the 1” opening in the pipe. Tees of this
type will cause signicant errors in the ow measurement.

CAUTION

In order to provide the ow meter with the correct stem length, ONICON must know the
overall 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.

CAUTION

Use stainless steel or brass nipple only.

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3.3.5 Conrming the Stack Height

STACK HEIGHT 8.5”

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

Insulation

Pipe

FOR S/N #250791

ANY OTHER METER

DO NOT USE FOR

READ OTHER SIDE OF THIS TAG BEFORE INSTALLING METER

GAGE LENGTH 10.937"

1) Pierce insulation until
gage tip touches pipe.

2) Insert flow meter until
bottom of electronics case
touches eye of depth gage.

Depth Gage

Flow Direction

Lock Nut

3) Confirm arrow is

aligned with flow
and tighten lock nut.

Prior to installing the meter, conrm that the stack height recorded on the tag is close to the
actual stack height. Flow meter stems are intentionally over sized to allow for variations of at
least 2” in the stack height. Contact ONICON prior to installation if there are any questions
regarding stack height or stem length. This will allow ONICON to offer you credit for your
meter if you decide to exchange the meter for one with a different stem length. Returns may
be subject to a restocking fee.

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