Johnson Controls MICROPROCESSOR BASED TURBINE FLOW METER User Guide

MICROPROCESSOR BASED TURBINE FLOW METER

Installation and Operation Guide

2013-3

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone]

www.onicon.com • [e-mail]

04-18

SAFETY INFORMATION

i

!

!

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.

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
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

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page 3

SECTION 1.0: INTRODUCTION

!

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

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page 4

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)

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page 5

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.

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
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.

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page 7

SECTION 3.0: INSTALLATION, REMOVAL & ADJUSTMENT

!

! i !

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.

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page 8

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

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page 9

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.

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page 10

3.3 INSERTION METER MECHANICAL INSTALLATION

!

! i !

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

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
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.

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page 12

!

3.3.4 Customer Supplied Installation Hardware

!

! i !

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.

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page 13

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.

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page 14

3.4 INSTALLING THE INSERTION METER

!

!

WARNING

SYSTEM MAY BE UNDER HIGH PRESSURE. When installing the meter, adjusting its position
or removing the meter, be sure to hold the electronics enclosure rmly by hand before SLOWLY
loosening the positioning clamping nut. Failure to do this will allow the pressure to suddenly and
rapidly force the meter from the pipe causing serious injury. The meter could also be damaged or
break apart causing a break in the water seal with the resultant loss of large amounts of water. The
hand effort required to hold the meter will be 0.11 times the pipe pressure.

Begin by calculating the effort that will be required to hold the meter. Establish adequate footing for
this task, taking extra caution when working from a ladder or platform. Use the following formula:

E=0.11xP Where: E = effort in pounds
P = system pressure in pounds per square inch

Example: In a 300 PSI system, 33 pounds of effort is required to insert the meter into the pipe.

WARNING

When you are ready to rell the system, make sure that all lines are lled with water before inserting
the turbine assembly into the stream. If the lines are not lled, air may interrupt the owing stream
and damage the turbine assembly. A greater danger is that if this is a hot water system, some water
may ash into steam and exceed the high temperature limit for the turbine and its mechanical
assembly. This ash over could exceed the pressure ratings of the meter and the assembly could fail
allowing steam and hot water to escape causing serious injury.

1. After tting the necessary plumbing hardware, ush the
entire system so that it is free of ux, solder and slag.

2. Prepare to install the ow meter by loosening the clamping
nut and withdrawing the turbine assembly fully into the
hot tap adapter.

3. Next, thread the adapter on to the ball valve using a paste
type thread sealant. Do not use Teon tape as torn strands
of the tape may wind around the turbine, slowing down or
even stopping the turbine.

4. Check the installation for leaks by slightly opening the
ball valve. An ‘O’ ring in the adapter seals the meter stem
against leakage. If there are any leaks around the clamping
nut or stem, DO NOT ATTEMPT TO STOP THE LEAKAGE

BY OVERTIGHTENING THE CLAMPING NUT. Damage to
this nut or the clamping ring under the nut may prevent
the assembly from properly holding the meter in the pipe.

The clamping nut is not part of the sealing mechanism.
Any leaks in this area indicate that the ‘O’ ring is not
sealing properly and you must contact the factory for
assistance.

Hot Tap
Adapter

Apply Paste
Type Sealant
to Threads

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page 15

3.4.1 Installing the Meter with a Factory Supplied Depth Gage:

!

!

! i !

1. Open valve completely, loosen the position
clamping nut, and insert the meter until the
bottom of the electronics case touches the eye
of the depth gage. (Pierce insulation with gage
until the tip touches the pipe.)

2. Position the electronics enclosure parallel to the
pipe in the proper direction relative to the ow.
This will position the turbine with its axis in
line with the ow and in the correct direction.

Insertion Depth

Gage provided

with each meter

Position

Clamping Nut

3. Tighten the position clamping nut. Contact
ONICON for assistance when installing a meter
without a depth gage.

FLOW

CAUTION

Do not release the ow meter until you have tightened the position clamping nut enough to hold the
ow meter in the desired position. This will require less torque than you might think, so be careful
not to overtighten it and risk damaging the adapter, nut or stem.

IMPORTANT NOTE

For installations with a limited straight run of pipe (less than the recommended distances
shown on pages 10), adjustments in insertion depth may be needed to compensate for velocity
ow prole variations. Please contact the factory for information on velocity ow proling for
determining the average velocity location in undeveloped ow locations.

WARNING

If adjustment of the meter depth is required, the same procedure must be followed as if the meter
were being removed. Please carefully read the section below on removal of the meter. Remember, the
meter may be under high pressure and failure to follow the procedure may result in serious injury.

3.4.2 Calculating Insertion Depth Using Conguration Utility

Inserting the ONICON turbine meter to the proper depth is critical in ensuring that the meter
is measuring at the average velocity point in the pipe.

If the turbine meter is provided without a depth gauge, or if the calibrated pipe size is
changed in the eld, the insertion depth can be acquired with the use of the Smart Turbine
Meter Conguration Utility.

This utility can be acquired for free from ONICON’s website:

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page 16

www.onicon.com/TurbineMeter_Conguration.html

A complete guide to the utility can also be acquired from ONICON’s website. The manual you
are currently reading will not describe in detail how to install and use the utility in whole.

In the “Pipe Selection” tab of the Smart Turbine Meter Conguration Utility, the “Gauge
Length” will dynamically change based on the pipe size programmed into the meter. This is
the distance required to properly set the depth at installation.

!

!

If the insertion meter is to be installed on a pipe with insulation, the insulation thickness can be

Gauge Length

*Gauge Length - Insulation Thickness

Insulation Thickness

subtracted from the “Gauge Length” to acquire the measured distance needed to properly insert
the meter.

3.5 REMOVAL OF THE INSERTION METER

WARNING

Remember, the meter may be under high pressure. And while removal of the meter is basically the
reverse of the insertion procedure detailed above, care must be taken to ensure that the meter is
supported against the pipe pressure before the position clamping nut is loosened. Failure to do this
will allow the pressure to suddenly and rapidly force the meter from the pipe causing serious injury.

Prior to removal of the meter, make sure that you are standing on a secure platform and have both
hands available to manipulate the ow meter.

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page 17

WARNING

Position

Clamping Nut

First support the ow meter against the pipe pressure by

!

holding the electronics enclosure rmly in hand BEFORE
loosening the position clamping nut. The effort required is the

same as that required for insertion of the meter and should be
calculated according to the formula in section 3.4 covering
insertion of the meter. This effort will be 0.11 times the pipe
pressure. If your footing is not secure, or if your ability to

hold the meter is limited for any reason, DO NOT loosen the
clamping nut.

SLOWLY loosen the position clamping nut and carefully and
slowly allow the pressure to force the meter out of the pipe. This

Position
Clamping Nut

is not at all difcult, but you must not let go of the meter until
it is fully withdrawn into the hot tap adapter. DO NOT attempt
to close the ball valve until you are certain that the turbine
assembly is fully withdrawn into the hot tap adapter.

A common cause of damage to meters comes from accidentally
closing the valve and crushing the turbine assembly. To
avoid this, gently rotate the meter back and forth by using the
electronics enclosure, while closing the valve slowly. If the valve
touches any part of the meter, you will feel it as you are moving
the meter. If the valve touches anything, it means the meter is
not fully withdrawn. Usually a gentle twisting motion while
withdrawing the meter will clear any obstruction and permit the
meter to withdraw completely. (Excessive build-up on the stem
may require the hot tap ‘O’ ring to be lubricated with silicone.)

Continue to hold the meter in place after the valve is completely closed to prevent the turbine
assembly from slipping back into the valve body. Slowly unscrew the hot tap adapter from the
valve. Once the adapter is loosened, allow pressure to vent from inside the hot tap adapter before
removing it from the valve. There will be a small amount of water inside the hot tap adapter. A
small container can be held under the valve to catch any spilled water. Once the meter has been
moved to its new depth, tighten the position clamping nut. Next, place several turns of electrical
tape around the stem just above the clamping nut so that at a later time, when the meter is
removed for service, it can be easily replaced at the same depth.

WARNING

In hot water systems, even a small amount of water can cause serious personal injury. Use extra
caution when working with hot water meters.

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page 18

3.6 INLINE METER STRAIGHT RUN REQUIREMENTS AND MECHANICAL INSTALLATION

Locating the meter

Install process connections (sweat or threaded end pieces) making certain to leave adequate
straight unobstructed pipe runs upstream and downstream of the meter location.

1. The minimum upstream straight run should be at least 10 diameters and the downstream
straight run should be at least 5 diameters in length.

2. If more than 15 diameters of straight run are available at the installation site, the excess
straight run should be upstream of the meter location.

3. Please note that ONICON strongly recommends the use of strainers upstream of the meter
location.

4. ONICON also recommends the installation of isolation valves and a bypass loop to
accommodate servicing the meter.

TYPICAL INLINE METER INSTALLATION

Isolation Valve
Normally Open

5 Dia. Minimum

Straight Run
Downstream

20 Dia. Minimum

Straight Run

Upstream

Bypass Valve

Normally Closed

Isolation Valve
Normally Open

Upstream of

Flow Meter

Installing the meter body

1. Make sure the unions are free of nicks or scratches on either end of the ow meter body
and on the process connections.

2. Spray the union faces with a silicone spray or apply a thin coat of beeswax to enhance
seating. Do not use paste thread sealant on union faces.

3. Recommended torques for union seal: 70 ft/lbs minimum

4. Make sure alignment of pipe does not put lateral stress on either joint.

y-Strainer

Process

Connection

Process

Connection

Unions

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page 19

!

3.7 WIRING CONNECTIONS

Make connections to the 10’ cable, which is supplied by ONICON and is pre-wired to the circuit
board.

CAUTION

Do not attempt to make any connections inside the electronics enclosure, or to remove factory
installed cable, strain relief or conduit tting. Damage resulting from these actions will not be
covered under warranty.

The most common cause of electronic failures are mis-wired connections. If you are adding
additional cable, please record any substitution of wire colors. If additional cable is purchased
from ONICON, the color code can be maintained. Cable from other sources will most likely have a
different set of colors. Please refer to Appendix A for wiring diagrams and factory color codes.

Only qualied service personnel should make connections between the ow meter and the user’s
external equipment. Any misapplication of power and/or ground can result in improper operation
or damage to the ow meter circuitry, and to any externally connected equipment.

Output signal(s)

to control

system

(if ordered)

Connect factory wires

to field wires in appropriate

ONICON
Display or
BTU Meter

(Optional)

junction box.

Leave sufficient slack in conduit

and cable to allow the meter to be

removed without disconnecting wires.

½” FNPT

conduit connection

FLOW

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page 20

SECTION 4.0: STARTUP & COMMISSIONING FOR ONICON

TURBINE FLOW METERS

Leave sufficient slack in conduit

and cable to allow the meter to be

removed without disconnecting wires.

Position

Clamping Nut

4.1 HELPFUL HINTS FOR START-UP AND COMMISSIONING

Step-by-step procedures and companion worksheets are located on the next four pages. Please
read all installation instructions carefully before proceeding with start-up and commissioning.

1. ONICON Insertion Turbine Flow Meters are individually congured for a particular
application. Be sure to verify the pipe size and location. Use the Smart Turbine Meter
Conguration Utility to change congural pipe size.

2. The electronic sensing systems will not work in air. Blowing on the turbine(s) will
not produce a signal. You can test the meter by holding the turbines under a faucet or
carefully moving it back and forth in a bucket of water.

3. When measuring analog output signals, remember that current (mA) must be measured in
series, while voltage is measured in parallel. If the 4-20 mA signal is already connected to
a control system, you must break the connection and measure the signal in series.

4. When measuring frequency outputs in Hertz, take your multimeter out of “auto-range
mode” and manually set the range for a voltage level above 15 VDC. This will prevent
false readings when no turbine signal is present.

5. All wiring connections should be made at the end of the factory cable. Do not attempt to
remove the factory installed cable or change the orientation of the electronics enclosure.

6. Never connect power to analog or frequency output signal wires. ONICON turbine ow
meters are not “loop-powered” devices.

7. Allow up to 45 seconds for signals to stabilize following power up.

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page 21

4.2 INSERTION METER START-UP AND COMMISSIONING

Please read the entire procedure carefully before proceeding. Wiring diagrams are located in the
appendix. A worksheet for checking off the following steps and recording measured values is
located on the following page.

Is the meter located in the correct location as required by the plans?
Conrm meter location
and adequate straight

1

pipe run to achieve
desired results.

2 Conrm pipe size.

Conrm insertion depth

3

and orientation.

Conrm control system

4

programming.

Conrm connection
to correct ONICON

5

display or Btu meter
(if ordered).

Verify wiring before

6

connecting power.

Conrm correct supply

7

voltage.

8 Connect power. Wait approximately 45 seconds after power-on before proceeding further.

The following steps require ow in the pipe. Flow signal readings should be taken while holding the ow rate constant if possible;
otherwise, take the various output readings as quickly as possible.

Compare actual straight pipe upstream and downstream of the meter location to recommended distances

identied in the installation manual. Note: The manual is very conservative, assuming worst-case pipe

obstructions. Contact ONICON to discuss specics of your application. If straight pipe run is very short, consult

factory PRIOR to installing a single turbine meter to discuss possibility of upgrade to a dual turbine meter.

Conrm that the meter is programmed for the pipe size in which it is installed. When in doubt, measure

the circumference of the pipe. Pipe O.D. = (circumference / 3.14) – (insulation thickness x 2). Use the Smart

Turbine Meter Conguration Utility to change the meter’s pipe size.

Ensure the meter is inserted to the correct depth shown in the Smart Turbine Meter Conguration Utility and

that the electronics enclosure is parallel with the pipe, with the arrow in the direction of ow.

Conrm that the control system input point is properly congured for the analog range (or digital pulse

factor) identied in the Smart Turbine Meter Conguration Utility or calibration certicate.

Conrm that the ow meter serial number matches the ONICON display or Btu meter serial number (when

ordered together).

Prior to connecting the power, verify that the wiring is correct as shown in this manual (and/or with the

additional wiring diagram provided with ONICON display or Btu meter.) If in doubt, call ONICON for

assistance before proceeding further.

Verify that 24 (+/- 4) V is available. Serial Numbers 115692 and later can accept 24 V DC or AC, but earlier

meters required 24 VDC. Note: ONICON display module(s) or Btu meter(s) provide 24 VDC to the ow meter.

ONICON display modules and Btu meters are typically powered by 120 VAC; however, low voltage versions

are also available.

The average frequency output signal is a 0-15 VDC pulsed output ranging up to 500 Hz and must be

measured with a frequency counter or oscilloscope. Measure DC frequency (Hz) from GREEN(+) to BLACK(-).

Also measure DC volts on same wires. Five to seven VDC is normal for a spinning turbine, 0 or 14+ VDC

indicates a stopped turbine. (A reading of 1 to 4 VDC could indicate a problem)

Measure and record

9

frequency output(s)

Measure and record
analog or digital
outputs.

10

Compare various
output signals to each

11

other and to the ow
rate displayed by the
control system.

End of standard start-up and commissioning. Please contact ONICON at [phone] with any questions.

Current Output:

Voltage (0-10V) Output:

Scaled Output:

GPM = Frequency in Hz X 60

Meter Factor in ppg

(Refer to certicate of calibration or Smart Turbine Meter Conguration Utility for meter factor.)

For dual turbine models, also measure and record the top and bottom turbine signals.

TOP: WHITE(+) to BLACK(-) BOTTOM: ORANGE(+) to BLACK(-)

Refer to ow meter wiring diagram for wire colors for the various outputs available based on your particular

ow meter model. Use the following formulas to calculate ow rate from measured analog signals:

GPM = (measured current in mA - 4) X Full Scale Analog Flow Rate

16

GPM = measured DC volts X Full Scale Analog Flow Rate

10

Each contact closure = unit volume identied as “Scaled Output Multiplier” in the Smart Turbine Meter

Conguration Utility (measure and record time interval between contact closures.)

The top and bottom turbine frequencies (dual) should ideally be within about 20% of each other and their

average should equal the average frequency output.

Compare the ow rates calculated in STEPS 9 and 10 to each other and to the ow rate indicated by the

control system. Refer to troubleshooting guide when readings are inconsistent.

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page 22

4.3 INSERTION METER START-UP AND COMMISSIONING WORKSHEET

Please read all installation instructions carefully prior to proceeding with these steps. Wiring
diagrams are located in the appendix. Use the following worksheet for checking off the
commissioning steps and recording measured values:

STEP TEST / MEASUREMENT S/N: _______ S/N: _______ S/N: _______ S/N: ______

1 Meter location

2 Conrm pipe size

3 Insertion depth and orientation

4 Control system programming

5 Match display or Btu meter serial#

(if ordered)

6 Signal connections veried

7 Supply voltage veried

8 Connect power

The following steps require ow in the pipe. Flow signal readings should be taken while holding the ow rate
constant if possible; otherwise, take the various output readings as quickly as possible.

9 Frequency output(s):

Top = white Bottom = orange

Avg = green,

Avg freq. (HZ):

Hz

Hz

Hz

Hz

Avg freq. (VDC):

Top turbine (HZ):

Top turbine (VDC):

Bottom turbine (HZ):

Bottom turbine (VDC):

Calculated ow rate:

10 Analog or digital outputs

4-20 mA signal:

0-10 V signal:

Scaled output time interval

Calculated ow rate:

11 Flow rate displayed by control

system

VDC

Hz

VDC

Hz

VDC

GPM GPM GPM GPM

MA

VDC

GPM GPM GPM GPM

GPM GPM GPM GPM

VDC

Hz

VDC

Hz

VDC

MA

VDC

VDC

Hz

VDC

Hz

VDC

MA

VDC

VDC

Hz

VDC

Hz

VDC

MA

VDC

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page 23

4.4 INLINE METER START-UP AND COMMISSIONING

Please read the entire procedure carefully before proceeding. Wiring diagrams are located in the
appendix. A worksheet for checking off the following steps and recording measured values is
located on the following page.

Conrm meter location
and adequate straight

1

pipe run to achieve
desired results.

Conrm control system

2

programming.

Conrm connection
to correct ONICON

3

display or Btu Meter (if
ordered).

Verify wiring before

4

connecting power.

Conrm correct supply
voltage.

5

6 Connect power. Wait approximately 45 seconds after power-on before proceeding further.

The following steps require ow in the pipe. Flow signal readings should be taken while holding the ow rate constant if possible;
otherwise, take the various output readings as quickly as possible.

Measure and record
frequency output(s):

7

Measure and record
analog or digital
outputs.

Current Output:

8

Voltage Output:

Scaled Output:

Compare various
output signals to each

9

other and to the ow
rate displayed by the
control system.

End of standard start-up and commissioning. Please contact ONICON at [phone] with any questions.

Is the meter located in the correct location as required by the plans?

Compare actual straight pipe upstream and downstream of the meter location to recommended distances
identied in the installation manual. If straight pipe run is very short, consult ONICON PRIOR to installing
the meter.

Conrm that the control system input point is properly congured for the analog range (or digital pulse
factor) identied in the Smart Turbine Meter Conguration Utility or calibration certicate.

Conrm that the ow meter serial number matches the ONICON display or Btu meter serial number (when
ordered together).

Prior to connecting the power, verify that the wiring is correct as shown in this manual (and/or with the
additional wiring diagram provided with ONICON display or Btu meter.) If in doubt, call ONICON for
assistance before proceeding further.

Verify that 24 (+/- 4) V is available. Serial Numbers 115692 and later can accept 24 VDC or AC, but earlier
meters required 24 VDC. Note: ONICON display module(s) or Btu meter(s) provide 24 VDC to the ow
meter. ONICON display module(s) and Btu meter(s) are typically powered by 120 VAC; however, low voltage
versions are also available.

The frequency output signal is a 0-15 VDC pulsed output ranging up to 500 Hz and must be measured with
a frequency counter or oscilloscope. Measure DC frequency (Hz) from GREEN(+) to BLACK(-). Also measure
DC volts on same wires. Five to seven VDC is normal for a spinning turbine, 0 or 14+ VDC indicates a
stopped turbine. (1 to 4 VDC could indicate a problem)

GPM = Frequency in Hz X 60
Meter Factor in ppg

(Refer to certicate of calibration of Smart Turbine Meter Conguration Utility for meter factor)

Refer to ow meter wiring diagram for wire colors for the various outputs available based on your particular
ow meter model. Use the following formulas to calculate ow rate from measured analog signals:

GPM = (measured current in mA - 4) X Full Scale Analog Flow Rate
16
GPM = measured DC volts X Full Scale Analog Flow Rate
10
Each contact closure = unit volume identied as “Scaled Output Multiplier” in the Smart Turbine Meter
Conguration Utility (measure and record time interval between contact closures.)

Compare the ow rates calculated in STEPS 7 and 8 to each other and to the ow rate indicated by the
control system. Refer to troubleshooting guide when readings are inconsistent.

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page 24

4.5 INLINE METER START-UP AND COMMISSIONING WORKSHEET

Please read all installation instructions carefully prior to proceeding with these steps. Wiring
diagrams are located in the appendix. Use the following worksheet for checking off the
commissioning steps and recording measured values:

STEP TEST / MEASUREMENT S/N: _______ S/N: _______ S/N: _______ S/N: ______

1 Meter location

2 Control system programming

3 Match display or Btu meter serial#

(if ordered)

4 Signal connections veried

5 Supply voltage veried

6 Connect power

The following steps require ow in the pipe. Flow signal readings should be taken while holding the ow rate
constant if possible; otherwise, take the various output readings as quickly as possible.

7 Frequency output(s): Avg = green,

Top = white Bottom = orange

Avg Freq. (HZ):

Avg Freq. (VDC):

Calculated Flow Rate:

8 Analog or digital outputs

4-20 mA signal:

0-10 V signal:

Scaled output time interval

Calculated Flow Rate:

9 Flow rate displayed by control

system

Hz

VDC

GPM GPM GPM GPM

MA

VDC

GPM GPM GPM GPM

GPM GPM GPM GPM

Hz

VDC

MA

VDC

Hz

VDC

MA

VDC

Hz

VDC

MA

VDC

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page 25

4.6 TROUBLESHOOTING GUIDE

NOTE: Also refer to the START-UP and COMMISSIONING GUIDE located on the preceding pages.

REPORTED PROBLEM POSSIBLE SOLUTIONS

Verify that meter is inserted correctly into the pipe.

• Verify that the electronics enclosure is parallel with the pipe.

• Verify 24 V supply voltage.

No signal

• Verify correct wiring to control system (see wiring diagram).

• Check turbine(s) for debris.

• Check diagnostics in Smart Turbine Meter Conguration Utility
to see if you are getting turbine pulses. LED lights inside meter
enclosure will also ash if the turbines are spinning.

• Conrm that there is adequate straight pipe run upstream of the
meter. Verify pipe size. Contact factory if pipe size is different
from calibration tag.

• Verify that meter is inserted correctly into the pipe.

• Verify that the electronics enclosure is parallel with the pipe.

• Verify correct wiring to control system (see wiring diagram).

Reading is too high or too low

• Conrm that output signals agree with each other (frequency vs.
analog, etc.)

• Conrm that control system is programmed for correct ow range
or scale factor.

• Check turbine(s) for debris.

• Check pipe sized programming is Smart Turbine Meter
Conguration Utility.

Check for ground loop or offset voltage:

• Disconnect analog signal input to control system and measure

Analog signal seems high or
low and does not correspond
to frequency output

analog outputs directly from the ow meter.

• Re-connect signal input to control system and measure the analog
signals again.

• Any difference between these readings indicates a potential
ground loop or offset voltage.

• Please contact ONICON for further assistance.

Control system displays
ow rate, but no ow rate
indication on local display
module or Btu meter

• Verify that all wires from ow meter were connected to the
display module or Btu meter.

• The frequency output wire (green) must be connected for any
ONICON display or Btu meter.

For technical assistance, contact ONICON at [phone].

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page 26

SECTION 5.0: FIELD PROGRAMMING & DIAGNOSTICS

The Microprocessor Based Turbine Flow Meter enables the end-user with the ability to change
various parameters which affect the meter’s calibration, as well as provide diagnostic data which
can be useful in determining if the meter has/had a problem.

These parameters and diagnostic data can be accessed via the Smart Turbine Meter Conguration
Utility running on a PC interfaced with the meter’s Micro B USB port inside the electronics
enclosure.

Some of the calibration parameters which can be changed include:

• Set switch output to either Scaled Pulse or Alarm

• Pipe Size

• Analog output range and engineering units

• Scaled pulse scaling and engineering units

• Frequency output scaling

Some of the diagnostic data which is available:

• Top, Bottom, and Average turbine pulses

• Total Top, Bottom, and Average turbine pulses over the life of the meter

• Run time

• User-resettable totalizer

• Current frequency and analog output values to compare against control system

The Smart Turbine Meter Conguration Utility and the instructions for its use can be downloaded
at www.onicon.com/TurbineMeter_Conguration.html.

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page 27

5.1 DIAGNOSTIC LEDS

! i !

The Microprocessor Based Turbine Meter features diagnostic LEDs, inside the electronics enclosure
on the meter’s electronics, which can be used to determine the status of the meter without the use of
a multimeter.

WHITE- Pulse Output From The Top Turbine (F-1200)

GREEN- Average Pulse Rate Of The Top And Bottom Turbine Outputs (F-1200)
or The Pulse Rate Turbine Output (F-1100)

ORANGE- Pulse Output From The Bottom Turbine (F-1200)

BLUE- Meter Status Indicator

How to read the blinking pattern:

Status LED (BLUE)

• Normal Status – 500ms ON, 500ms OFF

• Warning Status – 2 rapid blinks, then 500ms OFF

• Alarm Status – 3 rapid blinks, then 500ms OFF

• Error Status – 4 rapid blinks, then 500ms OFF

IMPORTANT NOTE

Connect the turbine meter to the Smart Turbine Meter Conguration Utility if receiving specic
warning/ alarm/ error message to get additional information.

Top Turbine LED (WHITE)

• This LED will blink at a rate proportional to the speed of the top turbine signal (F-1200
only).

• If this light is not blinking, yet the green and orange LEDs are, this could mean the top
turbine is bound or damaged. Remove the meter to inspect the top turbine.

Average Turbine LED (GREEN)

• This LED will blink at a rate proportional to the speed of the average turbine signal.

• For dual turbine meters, the average turbine signal is the average of the top and bottom
turbine speed.

• For single turbine meters, the average turbine signal is the speed of the single turbine.

Bottom Turbine LED (ORANGE)

• This LED will blink at a rate proportional to the speed of the bottom turbine signal
(F-1200 only).

• If this light is not blinking, yet the green and white LEDs are, this could mean the bottom
turbine is bound or damaged. Remove the meter to inspect the bottom turbine.

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page 28

APPENDIX A

User Connections and Internal Wiring Diagrams

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page A-1

FLOW METER WIRING INFORMATION

User Connections for Models with Frequency Output
Models: F-1XXX-00

ONICON

Flow and Energy Measurement

Wiring Information

WIRE COLOR CODE NOTES

(+) 24 ± 4 V AC/DC
supply voltage

RED

BLACK

(–) Common ground
(Common with pipe ground)

Connect to power supply
negative

GREEN

(+) Frequency output signal:
0-15 V peak pulse

SCALED PULSE OUTPUT

ORANGE

Dry Contact

WHITE

Dry Contact

Connect to power supply
positive

√

F-1XXX-00

FLOW METER

Max Hz can be set in
Smart Turbine Meter
Configuration Utility

Scaled Pulse Output

√

√

√

√

ON

I

CON

Flow and Energy Measurement

FLOW METER WIRING INFORMATION

User Connections for Models with Frequency Output

Models: F-1XXX-00

Wiring Information

WIRE COLOR CODE NOTES

(+) 24 ± 4 V AC/DC
supply voltage

(–) Common ground
(Common with pipe ground)

(+) Frequency output signal:
0-15 V peak pulse

SCALED PULSE OUTPUT

Dry Contact

Dry Contact

Connect to power supply
positive

Connect to power supply
negat i ve

Max Hz can be set in
Smart Turbine Meter
Configuration Utility

Scaled Pulse Output

F-1XXX-00

√

√

√

√

√

RED

BLACK

GREEN

ORANGE

WHITE

F-1XXX-00 WIRING DIAGRAM

Flow Meter Connections to ONICON Display or Btu Meter

F-1XXX-00 Wiring Diagram

Flow Meter Connections to ONICON Display or Btu Meter

RED

NOTES:

1. Black wire is common with the pipe (typically earth ground).

2. For ONICON display module or Btu meter, connect all wires provided. Refer to wiring
diagram provided with display or Btu meter

GREEN

BLACK

ORANGE

WHITE

ONICON Display

or BTU Meter

+ 24 V

FREQUENCY INPUT

GROUND

DRY CONTACT

DRY CONTACT

SHIELD

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page A-2

ONICON

Flow and Energy Measurement

FLOW METER WIRING INFORMATION

User Connections for Models with Frequency Output
Models: F-1XXX-00

FLOW METER WIRING INFORMATION

User Connections for Models with Frequency Output

Models: F-1XXX-00

OUTPUT BOARD

SENSOR BOARD

MICRO B USB

(For configuration utility interface)

BOARD TO BOARD
CONNECTOR

DIAGNOSTIC LEDs
BLUE - STATUS
WHITE - TOP PULSES
ORANGE - BOTTOM PULSES
GREEN - AVERAGE PULSES

TOP TURBINE:
F-1200 ONLY

NOT USED

BOTTOM TURBINE:
F-1200 ONLY

NOT USED

DRY CONTACT
(ORANGE WIRE)

DRY CONTACT
(WHITE WIRE)

FREQUENCY OUTPUT
(GREEN WIRE)

COMMON GROUND
(BLACK WIRE)

+24V AC/DC SUPPLY (RED WIRE)

NOTES:

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page A-3

FLOW METER WIRING INFORMATION

User Connections for Models with Non-Isolated Analog Outputs
Models: F-1XXX-10

ONICON

Flow and Energy Measurement

Wiring Information

WIRE COLOR CODE NOTES

(+) 24 ± 4 V AC/DC
supply voltage

RED

BLACK

(–) Common ground
(Common with pipe ground)

Connect to power supply
negative & analog input
ground

GREEN

(+) Frequency output signal:
0-15 V peak pulse

Required when meter
is connected to local
display or Btu meter

BLUE

(+) Analog signal

Jumper selectable
(4-20 mA / 0-10 V / 0-5 V)

BROWN

(-) Analog signal

SCALED PULSE OUTPUT

ORANGE

Dry Contact

WHITE

Dry Contact

Scaled Pulse Output

Connect to power supply
positive

F-1XXX-10

F-1XXXX-10 Wiring Diagram

Connections to a Control System (No Display or Btu Meter)

FLOW METER

√

√

√

√

√

√

√

ON

I

CON

Flow and Energy Measurement

!

FLOW METER WIRING INFORMATION

User Connections for Models with Analog Output

Models: F-1XXX-10

Wiring Information

F-1XXX-10

√

√

√

√

√

F-1XXX-10 WIRING DIAGRAM

Flow Meter Connections to ONICON Display or Btu Meter

√

√

BROWN

ORANGE

WIRE COLOR CODE NOTES

RED

BLACK

GREEN

BLUE

BROWN

ORANGE

WHITE

BLACK

BLUE

WHITE

(+) 24 ± 4 V AC/DC
supply voltage

(–) Common ground
(Common with pipe ground)

(+) Frequency output signal:
0-15 V peak pulse

(+) Analog signal

(-) Analog signal

Dry Contact

Dry Contact

RED

SCALED PULSE OUTPUT

Power

Source

+ 24 V

COM

+ ANALOG

- ANALOG

DRY CONTACT

DRY CONTACT

Connect to power supply
positive

Connect to power supply
negative & analog input
ground

Required when meter
is connected to local
display or Btu meter

Jumper selectable
(4-20 mA / 0-10 V / 0-5 V)

Scaled Pulse Output

Control System

NOTES:

1. Black wire is common with the pipe (typically earth ground).

2. For ONICON display module or Btu meter, connect all wires provided. Refer to wiring
diagram provided with display or Btu meter

CAUTION

This is NOT a “loop-powered” instrument. DO NOT connect power to any of the signal output
wires (blue, brown, green, orange or white)

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page A-4

SENSOR BOARD

COMMON GROUND
(BLACK WIRE)

SCALED / ALARM (ORANGE WIRE)

+24V AC/DC SUPPLY (RED WIRE)

OUTPUT BOARD

DIAGNOSTIC LEDs
BLUE - STATUS
WHITE - TOP PULSES
ORANGE - BOTTOM PULSES
GREEN - AVERAGE PULSES

BOARD TO BOARD
CONNECTOR

SCALED / ALARM (WHITE WIRE)

FREQUENCY OUTPUT
(GREEN WIRE)

MICRO B USB

(For configuration utility interface)

BOTTOM TURBINE:
F-1200 ONLY

TOP TURBINE:
F-1200 ONLY

ANALOG OUTPUT TYPE JUMPER
(4-20 mA, 0-10 V, 0-5 V)

- ANALOG

(BROWN WIRE)

NOT USED

+ ANALOG

(BLUE WIRE)

NOT USED

NOT USED

ONICON

Flow and Energy Measurement

FLOW METER WIRING INFORMATION

User Connections for Models with Non-Isolated Analog Outputs
Models: F-1XXX-10

FLOW METER WIRING INFORMATION

User Connections for Models with Analog Output

Models: F-1XXX-10

NOTES:

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page A-5

FLOW METER WIRING INFORMATION

User Connections for Models with Isolated Analog Outputs
Models: F-1XXX-11

ONICON

Flow and Energy Measurement

Wiring Information

WIRE COLOR CODE NOTES

(+) 24 ± 4 V AC/DC
supply voltage

RED

BLACK

(–) Common ground
(Common with pipe ground)

Connect to power supply
negative

GREEN

(+) Frequency output signal:
0-15 V peak pulse

Required when meter
is connected to local
display or BTU meter

BLUE

(+) Analog signal

Jumper selectable
(4-20 mA / 0-10 V / 0-5 V)

BROWN

(-) Analog signal

SCALED PULSE OUTPUT

ORANGE

Dry Contact

WHITE

Dry Contact

Scaled Pulse Output

Connect to power supply
positive

F-1XXX-11

F-1XXX-11 Wiring Diagram

Connections to a Control System (No Display or BTU Meter)

FLOW METER

√

√

√

√

√

√

√

!

FLOW METER WIRING INFORMATION

User Connections for Models with Isolated Analog Output

Models: F-1XXX-11

F-1XXX-11 WIRING DIAGRAM

F-1XXX-11

√

√

√

√

√

√

√

WIRE COLOR CODE NOTES

RED

BLACK

GREEN

BLUE

BROWN

ORANGE

WHITE

Wiring Information

(+) 24 ± 4 V AC/DC
supply voltage

(–) Common ground
(Common with pipe ground)

(+) Frequency output signal:
0-15 V peak pulse

(+) Analog signal

(-) Analog signal

SCALED PULSE OUTPUT

Dry Contact

Dry Contact

Connect to power supply
positive

Connect to power supply
negative

Required when meter
is connected to local
display or BTU meter

Jumper selectable
(4-20 mA / 0-10 V / 0-5 V)

Scaled Pulse Output

Flow Meter Connections to ONICON Display or Btu Meter

RED

BLACK

NOTES:

BLUE

BROWN

ORANGE

WHITE

1. Black wire is common with the pipe (typically earth ground).

2. For ONICON display module or Btu meter, connect all wires provided. Refer to wiring
diagram provided with display or Btu meter

CAUTION

Power

Source

+ 24 V

COM

Control System

+ ANALOG

- ANALOG

DRY CONTACT

DRY CONTACT

This is NOT a “loop-powered” instrument. DO NOT connect power to any of the signal output
wires (blue, brown, green, orange or white)

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page A-6

ONICON

Flow and Energy Measurement

FLOW METER WIRING INFORMATION

User Connections for Models with Isolated Analog Outputs
Models: F-1XXX-11

FLOW METER WIRING INFORMATION

User Connections for Models with Isolated Analog Output

Models: F-1XXX-11

OUTPUT BOARD

*

ANALOG OUTPUT TYPE JUMPER

- ANALOG

(BROWN WIRE)

NOT USED

+ ANALOG

(BLUE WIRE)

MICRO B USB

(For configuration utility interface)

BOARD TO BOARD
CONNECTOR

DIAGNOSTIC LEDs
BLUE - STATUS
WHITE - TOP PULSES
ORANGE - BOTTOM PULSES
GREEN - AVERAGE PULSES

SENSOR BOARD

TOP TURBINE:
F-1200 ONLY

NOT USED

BOTTOM TURBINE:
F-1200 ONLY

NOT USED

DRY CONTACT
(ORANGE WIRE)

DRY CONTACT
(WHITE WIRE)

FREQUENCY OUTPUT
(GREEN WIRE)

COMMON GROUND
(BLACK WIRE)

+24V AC/DC SUPPLY (RED WIRE)

*

4-20 mA
0-5 V
0-10 V

NOTES:

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page A-7

APPENDIX B

Installation Hardware Instructions

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page B-1

2070

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page B-2

2070

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page B-3

2070

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page B-4

2071

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page B-5

2071

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page B-6

APPENDIX C

Turbine Assembly Detail Drawings

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page C-1

0098-2

04-18

TURBINE ASSEMBLY DETAILS FOR

UPPER SUPPOR

SAPPHIRE JEWEL

ON

I

CON

11451 Belcher Road South, Largo, FL 33773 • USA • Tel [phone] • Fax [phone]

www.onicon.com • [e-mail]

Flow and Energy Measurement

Turbine must be free to slide

back and forth on the shaft with

at least .015” of movement.

TUNGSTEN CARBIDE

TURBINE SHAFT

Replace turbines in the same end-for-end relationship to the direction

of flow. (Mark one end of the turbine and the same end of the upper

support with a permanent felt tip marker)

After re-assembly, test the turbine for free rotation by gently blowing

on the turbine PARALLEL TO ITS SHAFT. The turbine must spin

freely and must have a minimum of .015” of free end play.

SAPPHIRE JEWEL RADIAL BEARINGS

If these bearings are removed from the turbine or

loosened at all, the flow meter must be returned to the

factory for recalibration or the turbine must be replaced.

ALL MODELS IN F-1100 SERIES

T

SUPPORT POST

2-56 Stainless, Philips Head Screws.

Clean philips head grooves with a sharp

instrument befor trying to loosen screws

in a meter which has been in service.

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page C-2

THRUST BEARINGS

TURBINE ROTOR

LOWER SUPPORT

0099-2

04-18

UPPER SUPPORT

REMOVABLE

SUPPORT POST

SAPPHIRE JEWEL

THRUST BEARINGS

TURBINE

ROTORS

LOWER

SUPPORT

TUNGSTEN CARBIDE

TURBINE SHAFT

NON-REMOVABLE

SUPPORT POST

TURBINE ASSEMBLY DETAILS FOR

ALL MODELS IN F-1200 SERIES

ON

I

CON

Flow and Energy Measurement

11451 Belcher Road South, Largo, FL 33773 • USA • Tel [phone] • Fax [phone]

www.onicon.com • [e-mail]

2-56 Stainless, Philips Head Screws.

Clean philips head grooves with a sharp

instrument befor trying to loosen screws

in a meter which has been in service.

Turbine must be free to slide

back and forth on the shaft with

at least .015” of movement.

Replace turbines in the same end-for-end

relationship to the direction of flow. (Mark

one end of the turbine and the same end

of the upper support with a permanent felt

tip marker)

After re-assembly, test the turbine for free

rotation by gently blowing on the turbine

PARALLEL TO ITS SHAFT. The turbine

must spin freely and must have a

minimum of .015” of free end play.

SAPPHIRE JEWEL RADIAL BEARINGS

If these bearings are removed from the turbine or

loosened at all, the flow meter must be returned to the

factory for recalibration or the turbine must be replaced.

11451 Belcher Road South, Largo FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
Microprocessor Turbine Flow Meter Manual 04/18 - 2013-3 Page C-3