Onicon F-1500 Installation And Operation Manual

F-1500 Series Insertion Turbine Flow Meter

Installation and Operation Guide

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

1018-6 / 35726

www.onicon.com • [e-mail]

02-18

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:

WARNING

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

CAUTION

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

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

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F-1500 Turbine Flow Meter Manual 02/18 - 1018-6 / 35726 Page 2

IMPORTANT NOTE

WARNINGS AND CAUTIONS

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!

WARNING

Consult the ow meter nameplate for specic ow meter approvals before any hazardous
location installation.

Hot tapping must be performed by a trained professional. U.S. regulations often require a hot
tap permit. The manufacturer of the hot tap equipment and/or the contractor performing the hot
tap is responsible for providing proof of such a permit.

All ow meter connections, isolation valves and ttings for cold/hot tapping must have the
same or higher pressure rating as the main pipeline.

For F-1500 series insertion ow meter installations, an insertion tool must be used for any
installation where a ow meter is inserted under pressure greater than 50 psig.

To avoid serious injury, DO NOT loosen a compression tting under pressure.

To avoid potential electric shock, follow National Electric Code or your local code when wiring
this unit to a power source. Failure to do so could result in injury or death. All AC power
connections must be in accordance with published CE directives. All wiring procedures must
be performed with the power Off.

Before attempting any ow meter repair, verify that the line is not pressurized. Always remove
main power before disassembling any part of the mass ow meter.

CAUTION

Calibration must be performed by qualied personnel. ONICON Incorporated, strongly
recommends that you return your ow meter to the factory for calibration.

In order to achieve accurate and repeatable performance, the ow meter must be installed with
at least the specied minimum length of straight pipe upstream and downstream of the ow
meter’s location.

When using toxic or corrosive gases, purge the line with inert gas for a minimum of four hours
at full gas ow before installing the ow meter.

For F-1500 series insertion ow meter installations, the sensor alignment pointer must point
downstream in the direction of ow.

The AC wire insulation temperature rating must meet or exceed 85° C (185° F)

No part of this publication may be copied or distributed, transmitted, transcribed, stored in a
retrieval system, or translated into any human or computer language, in any form or by any means,
electronic, mechanical, manual, or otherwise, or disclosed to third parties without the express
written permission of ONICON Incorporated. The information contained in this manual is subject
to change without notice.

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F-1500 Turbine Flow Meter Manual 02/18 - 1018-6 / 35726 Page 3

TABLE OF CONTENTS

1.0 INTRODUCTION .................................................................................................7

1.1 Purpose of This Guide ............................................................................... 7

1.2 ONICON F-1500 Series Insertion Turbine Flow Meters ...........................7

1.2.1 Using This Manual .....................................................................8

1.2.2 Receipt of System Components .................................................. 8

1.2.3 Technical Assistance ...................................................................8

1.2.4 Warranty .......................................................................................8

1.3 How the ONICON Insertion Turbine Mass Flow Meter Operates ............9

1.3.1 Velocity Measurement .................................................................9

Table 1. Measurable Range .....................................................9

1.3.2 Temperature Measurement .......................................................... 9

1.3.3 Pressure Measurement .................................................................9

1.4 Flow Meter Conguration .......................................................................10

1.4.1 Multivariable Options ...............................................................10

1.4.2 Line Size / Process Connections / Materials ............................10

1.4.3 Flow Meter Electronics ..............................................................10

2.0 INSTALLATION .................................................................................................11

2.1 Installation Overview ..............................................................................11

2.1.1 Flow Meter Installation Requirements .....................................11

2.1.2 Unobstructed Flow Requirements ............................................11

2.2 Flow Meter Installation ...........................................................................12

Figure 1. Isolation Valve Requirements ...............................12

2.2.1 Standard Installation Guidelines ..............................................13

2.2.2 Hot Tap Guidelines ....................................................................14

Figure 2. Hot Tap Sequence .................................................14

2.3 FLOW METER INSERTION .....................................................................15

2.3.1 Installing Flow Meters ...............................................................15

Figure 3. Insertion Calculation (Meter w Insertion Tool .....15

2.3.2 Flow Meters with Permanent Insertion Tool ............................16

Figure 4. Flow Meters with Permanent Insertion Tool .......16

2.3.3 Flow Meters with Removable Insertion Tool............................17

Figure 5. Flow Meters with Removable Insertion Tool .......17

2.3.4 Packing Gland Connection (No Insertion Tool) ........................19

Figure 6. Insertion Calculation (without Insertion Tool) ....19

2.3.5 Flow Meters with No Insertion Tool .........................................20

2.4 ADJUSTING THE DISPLAY ORIENTATION ..........................................20

Figure 7. Display/Keypad Viewing Adjustment ..................20

2.5 LOOP-POWERED FLOW METER WIRING CONNECTIONS ................21

Figure 8. Wiring Terminals for Loop-Powered Version ....... 21

2.5.1 Input Power Connections .......................................................... 21

Figure 9. DC Power Connections .........................................21

2.5.2 4-20 mA OUTPUT CONNECTIONS ..........................................22

Figure 10. Load Resistance Versus Input Voltage ................22

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F-1500 Turbine Flow Meter Manual 02/18 - 1018-6 / 35726 Page 4

2.5.3 Frequency Output Connections ................................................ 22

Figure 11. Isolated Frequency Output External Power ....... 22

Figure 12. Non-Isolated Frequency Output External Pwr ...22

2.5.4 Optional Backlight Connection .................................................23

Figure 13. Backlight Using External Power Supply ............ 23

2.5.5 Remote Electronics Wiring ........................................................ 23

Figure 14. Loop-Powered Junction Box Connections .........23

Figure 15. Loop-Power Mass Box Sensor Connections ....... 23

2.6 HIGH POWER METER WIRING CONNECTIONS ..................................24

Figure 16. AC Wiring Terminals ..........................................24

2.6.1 Input Power Connections .......................................................... 24

Figure 17. AC Power Connections .......................................24

Figure 18. DC Wiring Terminals ...........................................25

Figure 19. DC Power Connections .......................................25

2.6.2 4-20 mA OUTPUT CONNECTIONS ..........................................25

Figure 20. Load Resistance Versus Input Voltage ................26

Figure 21. Isolated 4–20 mA Output External Power .........26

Figure 22. Non-Isolated 4–20 mA Output Input Power ...... 26

Figure 23. Isolated 4–20 mA Output Using Meter Power ... 26

2.6.3 Frequency Output Connections ................................................ 27

Figure 24. Isolated Frequency External Power .................... 27

Figure 25. Non-Isolated Frequency Output Input Power ....27

Figure 26. Isolated Frequency Provided Power Supply ......27

2.6.4 Pulse Output Connections ........................................................28

Figure 27. Isolated Pulse Output External Power ...............28

Figure 28. Non-Isolated Pulse Output Input Power ............ 28

Figure 29. Isolated Pulse Output Provided Power ..............28

2.6.5 Alarm Output Connections ....................................................... 29

Figure 30. Isolated Alarm Output External Power .............. 29

Figure 31. Non-Isolated Alarm Output Internal Power .......29

Figure 32. Isolated Alarm Output Provided Power ............. 29

2.6.6 Remote Electronics Wiring ........................................................ 30

Figure 33. High Power Junction Box Sensor Connections .. 30

2.6.7 Optional Input Electronics Wiring ............................................ 30

2.6.8 OPTIONAL ENERGY EMS RTD INPUT WIRING .....................31

Figure 34. Optional Energy EMS RTD Input Wiring ...........31

2.6.9 OPTIONAL EXTERNAL 4-20 mA INPUT WIRING ..................31

Figure 35. External 4-20 mA Input Wiring External Pwr ....31

Figure 36. External 4-20 mA Input Wiring - DC Powered...31
Figure 37. External 4-20 mA Input Wiring - AC Powered ..32

2.6.10 OPTIONAL CONTACT CLOSURE INPUT WIRING ................. 32

Figure 38. Optional Contact Closure Input Wiring .............32

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3.0 OPERATING INSTRUCTIONS ......................................................................... 33

3.1 FLOW METER DISPLAY/KEYPAD .........................................................33

Figure 39. Flow Meter Display/Keypad ............................... 33

3.2 START-UP ................................................................................................34

3.3 USING THE SET-UP MENUS .................................................................. 35

3.3.1 Programming the Flow Meter ....................................................36

3.3.2 Output Menu ..............................................................................37

3.3.3 Display Menu .............................................................................39

3.3.4 Alarms Menu .............................................................................40

3.3.5 Totalizer #1 Menu ......................................................................41

3.3.6 Totalizer #2 Menu ......................................................................42

3.3.7 Energy Menu – For Energy Meters Only ...................................43

3.3.8 Fluid Menu ................................................................................44

3.3.9 UNITS MENU ............................................................................45

3.3.10 TIME & DATE MENU ................................................................46

3.3.11 Diagnostics Menu ......................................................................47

3.3.12 Calibration Menu ....................................................................... 48

3.3.13 Password Menu ..........................................................................48

4.0. SERIAL COMMUNICATIONS .......................................................................... 49

4.1 HART COMMUNICATIONS....................................................................49

4.1.1 WIRING .....................................................................................49

Figure 40. Loop Powered Meter Wiring (HART) .................49

Figure 41. DC Powered Meter Wiring (HART) ....................50

Figure 42. AC Powered Meter Wiring (HART) ....................50

4.1.2 HART Commands with the DD Menu .....................................51

4.1.3 HART Commands with Generic DD Menu ............................... 55

4.2 MODBUS COMMUNICATIONS .............................................................58

4.2.1 Wiring ........................................................................................ 58

Figure 43. RS-485 Wiring (MODBUS) ..................................58

4.2.2 Menu Items ................................................................................58

Table 2. Byte Order ............................................................... 59

4.2.3 Register Denitions ....................................................................60

Table 3. Register Denitions .................................................60

4.3 BACnet MS/TP Communications ...........................................................65

4.3.1. BACnet MS/TP Description ......................................................65

4.3.2. Baud Rates on the MS/TP Bus ..................................................65

4.3.2.1. Baud Rate and MAC address conguration ................. 65

4.3.3. Supported BACnet Objects ........................................................65

4.3.3.1. Device Object: ...............................................................67

4.3.3.2. Analog Input Object ......................................................68

4.3.3.3. Binary Input Object ......................................................69

4.3.3.4. Binary Value Object ......................................................69

4.3.4. ANNEX BACnet Conformance Statement ................................69

APPENDIX

A-1 Ordering Information

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F-1500 Turbine Flow Meter Manual 02/18 - 1018-6 / 35726 Page 6

SECTION 1.0: INTRODUCTION

!

We at ONICON Incorporated, would like to thank you for purchasing our quality, U.S. made, Turbine
Flow 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, steam or pressurized gas 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 ONICON F-1500 Series 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 ONICON F-1500 SERIES INSERTION TURBINE FLOW METERS

The ONICON F-1500 Insertion Turbine Flow Meters provide a reliable solution for process
ow measurement. From a single entry point in the pipeline, F-1500 meters offer precise
measurements of mass or volumetric ow rates.

Multi-Parameter Mass Flow Meters
Mass ow meters utilize three primary sensing elements: a rotating turbine velocity sensor, an
RTD temperature sensor, and an optional solid state pressure sensor to measure the mass ow rate
of gases, liquids, and steam.

Meters are available as loop powered devices or with up to three 4-20 mA analog output signals
for monitoring your choice of the ve process variables (mass ow, volumetric ow, temperature,
pressure and uid density). The Energy Monitoring option permits real-time calculation of energy
consumption for a facility or process. BACnet MS/TP and MODBUS RTU RS485 interface options
are also available.

Volumetric Flow Meters
The primary sensing element of a volumetric ow meter is a rotating turbine velocity sensor.
Meters are loop powered. The analog 4-20 mA output signal offers your choice of volumetric
or mass ow rate. Mass ow rate is based on a constant value for uid density stored in the
instrument’s memory.

Both the mass and volumetric ow meters are provide with a local keypad / display which
provides instantaneous ow rate, total, and process parameters in engineering units. A pulse
output signal for remote totalization and BACnet MS/TP, MODBUS RTU RS485 or HART
communications are also available.

Digital electronics allow for easy reconguration for most gases, liquids and steam. ONICON
meters’ simple installation combines with an easy-to-use interface that provides quick set up,
long term reliability and accurate mass ow measurement over a wide range of ows, pressures
and temperatures.

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1.2.1 Using This Manual

This manual provides information needed to install and operate the F-1500 insertion style
ow meter.

Section 1 includes the introduction and product description.
Section 2 provides information needed for installation.
Section 3 describes system operation and programming.
Section 4 provides information on HART, MODBUS and BACnet protocols.
Section 5 covers troubleshooting and repair.

Appendix A - Product Specications
Appendix B– Flow Meter Calculations
Appendix C – Glossary of Terms
Appendix D – Terms & Conditions

1.2.2 Receipt of System Components

When receiving an ONICON ow meter, carefully check the outside packing carton for
damage incurred in shipment. If the carton is damaged, notify the local carrier and submit
a report to the factory or distributor. Remove the packing slip and check that all ordered
components are present. Make sure any spare parts or accessories are not discarded with the
packing material. Do not return any equipment to the factory without rst contacting ONICON
Customer Service.

1.2.3 Technical Assistance

If you encounter a problem with your ow meter, review the conguration information
for each step of the installation, operation and set up procedures. Verify that your settings
and adjustments are consistent with factory recommendations. Refer to Section 5,
Troubleshooting, for specic information and recommendations.

If the problem persists after following the troubleshooting procedures outlined in Section 5,
contact ONICON Incorporated Technical Support at
[phone] between 8:00AM and 5:00PM EST.

When calling Technical Support, have the following information on hand:
The serial number and model number (shown on the meter nameplate)
The problem you are encountering and any corrective action taken
Application information (uid, pressure, temperature and piping conguration)

1.2.4 Warranty

Warranty ONICON’s complete warranty is included in Appendix D of this manual as part of
the “Conditions of Sale”. ONICON provides a two-year warranty.

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1.3 HOW THE ONICON INSERTION TURBINE MASS FLOW METER OPERATES

ONICON F-1500 Series Insertion Turbine Mass Flow Meters are designed to monitor mass ow
rate by directly measuring uid velocity, temperature and when required, pressure. The built­in ow computer calculates the mass ow rate and volumetric ow rate based on these direct
measurements. The sensing head is built into the insertion turbine meter’s ow body. To measure
uid velocity, the ow meter incorporates a rotating turbine in the ow stream. The rotation
is converted into an electrical output that is proportional to the uid velocity. Temperature is
measured using a platinum resistance temperature detector (PRTD). When require, pressure
measurement is achieved using an integral solid state pressure transducer.

1.3.1 Velocity Measurement

Fluid passing through the turbine causes its rotor to spin. The rotor is fabricated from 17-4PH
stainless steel which is slightly magnetic, and is positioned in close proximity to a passive
magnetic pickup coil. As each blade rotates by the pickup coil, a small sinusoidal voltage is
generated. This sinusoidal voltage is then amplied, ltered, and shaped by the measurement
electronics. The frequency of the signal is proportional to the owing velocity.

Flow Velocity Range

To ensure trouble-free operation, turbine ow meters must be correctly sized so that the ow
velocity range through the meter lies within the measurable velocity range.

The measurable range is dened by the minimum and maximum velocity using the following table.

Gas or Steam

Minimum Velocity Maximum Velocity

ft/sec m/sec ft/sec m/sec

R40 3.5 1.07 43.0 13.11

R30 4.0 1.22 62.5 19.05

R25 5.0 1.52 80.0 24.38

R20 7.0 2.13 100.0 30.48

R15 8.5 2.59 134.6 41.03

R10 12.0 3.66 205.0 62.48

Table 1. Measurable Range

The pressure drop for F-1500 Series insertion meters is negligible.

1.3.2 Temperature Measurement

This ow meter uses a 1000 ohm platinum resistance temperature detector (PRTD) to measure
uid temperature.

1.3.3 Pressure Measurement

The F-1500 incorporates a solid-state pressure transducer isolated by a 316 SS diaphragm.
The transducer itself is micro-machined silicon, fabricated using integrated circuit processing
technology. A nine-point pressure/temperature calibration is performed on every sensor.
Digital compensation allows these transducers to operate within a 0.3% of full scale accuracy
band within the entire ambient temperature range of -40° F to 140° F (-40° C to 60° C).
Thermal isolation of the pressure transducer ensures the same accuracy across the allowable
process uid temperature range of -200° F to 750° F (-128° C to 400° C).

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1.4 Flow Meter Conguration

The F-1500 Insertion Turbine Mass Flow Meter has a sensing head which contains the turbine
rotor, temperature sensor, and pressure tap. The pressure sensor, if provided, is located in the
pressure transducer housing between the stem and electronics housing.

The meter is installed through a full block valve and mounting adapter having a clear,
cylindrical port diameter of 1.875” diameter. It can be installed during system downtime or
using standard “Hot Tap” procedures.

The meter directly monitors the velocity at a point in the cross-sectional area of a pipe, duct, or
stack. The velocity at a point in the pipe varies as a function of the Reynolds number. When a
uid ows through a pipe, the velocity generated is not constant across the diameter. The uid
velocity varies across the diameter of the pipe creating a “Velocity Prole”. That is, velocities
near the center of the pipe are faster than those nearer to the wall. In addition, the velocity prole
varies in concert with ow rate from the lowest to the highest ows. Mathematical descriptions
of this prole have been developed for over 100 years. By knowing the velocity prole and the
ow rate at a single point, the average ow rate can be determined. The accuracy of the ow rate
computation depends on adherence to the piping installation requirements given in Chapter 2. If
adherence to those guidelines cannot be met, contact the factory for specic installation advice.

1.4.1 Multivariable Options

Different versions of the meter are capable of providing the following ow measurement options:
Volumetric ow; Mass ow with temperature compensation; Mass ow with temperature and
pressure compensation; Steam energy ow with temperature compensation; Steam energy
ow with temperature and pressure compensation, Mass or Energy ow with temperature and
external pressure compensation and Net Energy using a second temperature sensor.

1.4.2 Line Size / Process Connections / Materials

The F-1500 can be used in line sizes 2” and greater and is built with a packing gland design
using 2 inch NPT, or 2 inch anged connections (ANSI 150, 300, 600, PN16, 40, or 64 class
anges). The packing gland design is available with a permanent or removable retractor.

1.4.3 Flow Meter Electronics

The ow meter electronics are available mounted directly to the ow body, or mounted remotely.
The electronics housing may be used indoors or outdoors, including wet environments. Available
input power options are: DC loop powered (2-wire), DC powered, or AC powered. Three analog
output signals are available for your choice of three of the ve process variables: mass ow rate,
volumetric ow rate, temperature, pressure or uid density. A pulse output signal for remote
totalization and BACnet, MODBUS or HART communications is also available.

Each meter includes a local 2 x 16 character LCD display housed within the enclosure.
Local operation and reconguration is accomplished using six push-button operated via
nger touch. For hazardous locations, the six buttons can be operated with the electronics
enclosure sealed using a hand-held magnet, thereby maintaining the integrity of the
hazardous location certication.

The electronics include nonvolatile memory that stores all conguration information. The
nonvolatile memory allows the ow meter to function immediately upon power up or after
an interruption in power. All ow meters are calibrated and congured for the customer’s
ow application.

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F-1500 Turbine Flow Meter Manual 02/18 - 1018-6 / 35726 Page 10

SECTION 2.0 INSTALLATION

!

2.1 INSTALLATION OVERVIEW

ONICON F-1500 Insertion Turbine Flow Meter installations are simple and straightforward. After
reviewing the installation requirements given below, see page 24 for installation instructions.
Wiring instructions begin on page 38.

2.1.1 Flow Meter Installation Requirements

WARNING

Consult the ow meter nameplate for specic ow meter approvals before any
hazardous location installation.

Before installing the ow meter, verify the installation site allows for these considerations:

1. Line pressure and temperature will not exceed the ow meter rating.

2. The location meets the required minimum number of pipe diameters upstream and
downstream of the sensor head as illustrated in Figure 4.

3. Safe and convenient access with adequate overhead clearance for maintenance purposes.

4. Verify that the cable entry into the instrument meets the specic standard required for
hazardous area installations.

5. For remote installations, verify the supplied cable length is sufcient to connect the ow
meter sensor to the remote electronics.

Also, before installation, check your ow system for anomalies such as:

• Leaks

• Valves or restrictions in the ow path that could create disturbances in the ow
prole that might cause unexpected ow rate indications

• Avoid areas where high RF, EMI, or other electrical interference may be present.
Devices such as VFD’s (variable frequency drives), large AC motors, etc

2.1.2 Unobstructed Flow Requirements

Select an installation site that will minimize possible distortion in the ow prole. Valves,
elbows, control valves and other piping components may cause ow disturbances. Check
your specic piping condition against the examples shown below. In order to achieve
accurate and repeatable performance, install the ow meter using the recommended number
of straight run pipe diameters upstream and downstream of the sensor.

Note: For liquid applications in vertical pipes, avoid installing with ow in the downward
direction because the pipe may not be full at all points. Choose to install the meter with ow
in the upward direction, if possible.

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F-1500 Turbine Flow Meter Manual 02/18 - 1018-6 / 35726 Page 11

1.875-inch min.
valve bore

2- inch min.

2- inch

valve size

Flow

straightener

(if used)

Flow

straightener

(if used)

Flow straightener

(if used)

Flow straightener

(if used)

Flow straightener (if used)

Minimum Required

Upstream Diameters

No Flow

Straightener

Example A A C C’ B B

1 10 D N/A N/A N/A 5 D 5 D

2 15 D 10 D 8 D 2 D 5 D 5 D

3 30 D 15 D 13 D 2 D 5 D 5 D

4 10 D N/A N/A N/A 5 D 5 D

5 20 D 10 D 8 D 2 D 5 D 5 D

6 50 D 25 D 23 D 2 D 5 D 5 D

2.2 FLOW METER INSTALLATION

Prepare the pipeline for installation using either a standard or hot tap method described on the
following pages. Refer to a standard code for all pipe tapping operations. The following tapping
instructions are general in nature and intended for guideline purposes only. Before installing
the meter, review the mounting position and isolation value requirements given below.

Mounting Position

Allow clearance between the electronics enclosure
top and any other obstruction when the meter is
fully retracted.

Minimum Required

Downstream Diameters

With Flow Straightener No Flow

D = Internal diameter of channel.

Straightener

With Flow

Straightener

Isolation Valve Selection

Always install an isolation valve. If you supply
the isolation valve, it must meet the following
requirements:

1. A minimum valve bore diameter of 1.875”
is required, and the valve’s body size should
be 2”. Normally, gate valves are used.

2. Verify that the valve’s body and ange rating are within the ow meter’s maximum
operating pressure and temperature.

3. Choose an isolation valve with at least two inches existing between the ange face
and the gate portion of the valve. This ensures that the ow meter’s sensor head will
not interfere with the operation of the isolation valve.

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Figure 1. Isolation Valve Requirements

2.2.1 Standard Installation Guidelines

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CAUTION

When using toxic or corrosive gases, purge the line with inert gas for a minimum of
four hours at full gas ow before installing the ow meter.

Refer to a standard code for all pipe tapping operations. The following tapping instructions
are general in nature and intended as a guideline only.

1. Conrm that the installation site meets the minimum upstream and downstream pipe
diameter requirements. See Figure 4.

2. Turn off the ow of process gas, liquid or steam. Verify that the line is not
pressurized.

3. Use a cutting torch or sharp cutting tool to tap into the pipe. The pipe opening must
be at least 1.875” in diameter. (Do not attempt to insert the sensor probe through a
smaller hole.)

4. Remove all burrs from the hole. Rough edges may cause ow prole distortions
that could affect ow meter accuracy. Also, obstructions could damage the sensor
assembly when inserting into the pipe.

All ow meter connections, isolation valves and ttings for cold tapping must have the
same or higher pressure rating as the main pipeline.

After cutting, measure the thickness of the cut-out and record this number for
calculating the insertion depth.

5. Weld the ow meter pipe connection onto the pipe. Make sure this connection is
within ± 5° perpendicular to the pipe center line.
Install the isolation valve.

6. When welding is complete and all ttings are installed, close the isolation valve or
cap the line. Run a static pressure check on the welds. If pressure loss or leaks are
detected, repair the joint and re-test.

7. The rst time the sensor is inserted, install the check-disc tool on the ow meter
rather than the rotor.

8. Open the isolation valve and insert the check-disc tool. After successful insertion,
retract the sensor and remove the ow meter.

9. Install the rotor and connect the meter to the pipe process connection.

10. Calculate the sensor probe insertion depth and insert the sensor probe into the pipe
as described on the following pages.

WARNING

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2.2.2 Hot Tap Guidelines

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WARNING

Hot tapping must be performed by a trained professional. US regulations often require
a hot tap permit. The manufacturer of the hot tap equipment and/or the contractor
performing the hot tap is responsible for providing proof of such a permit.

Refer to a standard code for all pipe tapping operations. The following tapping instructions
are general in nature and intended as a guideline only.

1. Conrm that the installation site meets the minimum upstream and downstream pipe
diameter requirements.

2. Weld a 2” mounting adapter on the pipe. Make sure the mounting adapter is within ± 5°
perpendicular to the pipe center line (see previous page). The pipe opening must be at
least 1.875” in diameter.

3. Connect a 2” process connection on the mounting adapter.

4. Connect an isolation valve on the process connection. The valve’s full open bore must be
at least 1.875” in diameter.

5. Run a static pressure check on the welds. If pressure loss or leaks are detected, repair the
joint and re-test.

6. Connect the hot tapping equipment to the isolation valve, open the isolation valve and
drill at least a 1.875” diameter hole.

7. Retract the drill, close the isolation valve, and remove the hot tapping equipment.

8. The rst time the sensor is installed, install the check-disc tool on the ow meter rather
than the rotor.

9. Open the isolation valve and insert the check-disc tool. After successful insertion, retract
the sensor, close the isolation valve and remove the ow meter.

10. Install the rotor, connect the ow meter to the isolation valve and open the isolation valve.

11. Calculate the sensor probe insertion depth and insert the sensor probe into the pipe as
described on the following pages.

WARNING

All ow meter connections, isolation valves, and ttings for hot tapping must have the
same or higher pressure rating as the main pipeline.

Figure 2. Hot Tap Sequence

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2.3 FLOW METER INSERTION

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The sensor head must be properly positioned in the pipe. For this reason, it is important that
insertion length calculations are carefully followed. A sensor probe inserted at the wrong depth in
the pipe will result in inaccurate readings.

Insertion ow meters are applicable to pipes 2” and larger. For pipe sizes 10” and smaller, the
center line of the meter’s sensing head is located at the pipe’s center line. For pipe sizes larger
than 10”, the center line of the sensing head is located in the pipe’s cross section 5” from the inner
wall of the pipe; i.e., its “wetted” depth from the wall to the center line of the sensing head is 5”.

Insertion ow meters are available in two probe lengths:

• Standard Probe conguration is used with most ow meter process connections. The length,
S, of the stem is 28.67”.

• 12-Inch Extended Probe conguration is used with exceptionally lengthy ow meter process
connections. The length, S, of the stem is 40.67”.

Use the Correct Insertion Formula

Depending on your ow meter’s process connection, use the applicable insertion length formula
and installation procedure as follows:

• Flow meters with a packing gland type connection (NPT or anged) congured with an
insertion tool, follow the instructions beginning on page 29.

• Flow meters with a packing gland type connection (NPT or anged) without an insertion tool,
follow the instructions beginning on page 32.

WARNING

An insertion tool must be used for any installation where a ow meter is inserted under
pressure greater than 50 psig.

2.3.1 Installing Flow Meters *

Use the formula below to determine the insertion depth for ow meters (NPT and anged)
equipped with an insertion tool. To install, see the next page for instructions for meters with a
permanent insertion tool. For meters with a removable insertion tool, see page 17.

Figure 3. Insertion Calculation (Meters with Insertion Tool)

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Example 1: Flange Style Meters:
To install an F-1500 ow meter into a 14 inch schedule 40 pipe, the following measurements
are taken:
F = 12 inches
R = 5 inches
t = 0.438 inches

The example insertion length is 16.89 inches.

Example 2: NPT Style Meters:
The length of thread engagement on the NPT style meters is also subtracted in the equation. The
length of the threaded portion of the NPT meter is 1.18 inches. Measure the thread portion still
showing after the installation and subtract that amount from 1.18 inches. This gives you the
thread engagement length. If this cannot be measured use .55 inch for this amount.
F = 12 inches
R = 5 inches
t = 0.438 inches

The example insertion length is 16.34 inches.

*All dimensions are in inches.

2.3.2 Insertion Procedure for Flow Meters with Permanent Insertion Tool

Figure 4. Flow Meter with Permanent Insertion Tool

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1. Calculate the required sensor probe insertion length (see previous page). Measure from the

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depth marker arrow down the stanchion and scribe a mark at the calculated insertion depth.

2. Fully retract the ow meter until the sensor head is touching the bottom of the stem housing.

Attach the meter assembly to the full-port isolation valve. Use Teon tape or pipe sealant to
improve seal and prevent seizing on NPT style.

3. Loosen the two packing gland nuts on the stem housing of the meter. Loosen the stem lock

bolt adjacent to the sensor alignment pointer. Align the sensor head using the sensor align­ment pointer. Adjust the alignment pointer parallel to the pipe and pointing downstream.
Tighten the stem lock bolt to secure the sensor position.

4. Slowly open the isolation valve to the full open position. If necessary, slightly tighten the

two packing gland nuts to reduce the leakage around the stem.

5. Turn the insertion tool handle clockwise to insert the sensor head into the pipe. Continue

until the top of the upper retractor bracket aligns with the insertion length position scribed
on the stanchion. Do not force the stem into the pipe.

6. Tighten the packing gland nuts to stop leakage around the stem. Do not torque over 20 ft-lb.

CAUTION

The sensor alignment pointer must point downstream, in the direction of ow.

IMPORTANT NOTE

If line pressure is above 500 psig, it could require up to 25 ft lb of torque to insert the
ow meter. Do not confuse this with possible interference in the pipe.

2.3.3 Insertion Procedure for Flow Meters with Removable Insertion Tool

Figure 5. Flow Meter with Removable Insertion Tool

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1. Calculate the required sensor probe insertion length. Measure from the depth marker

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arrow down the stanchion and scribe a mark at the calculated insertion depth.

2. Fully retract the ow meter until the sensor head is touching the bottom of the stem
housing. Attach the meter assembly to the full-port isolation valve. Use Teon tape or
pipe sealant to improve seal and prevent seizing on NPT style.

3. Remove the two top stem clamp nuts and loosen two stem clamp bolts. Slide the stem
clamp away to expose the packing gland nuts.

4. Loosen the two packing gland nuts. Loosen the stem lock bolt adjacent to the sensor
alignment pointer. Align the sensor head using the sensor alignment pointer. Adjust the
alignment pointer parallel to the pipe and pointing downstream. Tighten the stem lock
bolt to secure the sensor position.

5. Slowly open the isolation valve to the full open position. If necessary, slightly tighten
the two packing gland nuts to reduce the leakage around the stem.

6. Turn the insertion tool handle clockwise to insert the stem into the pipe. Continue until
the top of the upper retractor bracket lines up with the insertion length mark scribed on
the stanchion. Do not force the stem into the pipe.

CAUTION

The sensor alignment pointer must point downstream, in the direction of ow.

IMPORTANT NOTE

If line pressure is above 500 psig, it could require up to 25 ft lb of torque to insert the
ow meter. Do not confuse this with possible interference in the pipe.

7. Tighten the packing gland nuts to stop leakage around the stem. Do not torque over 20 ft-lbs.

8. Slide the stem clamp back into position. Torque stem clamp bolts to 15 ft-lbs. Replace the
stem clamp nuts and torque to 10-15 ft-lbs.

9. To separate the insertion tool from the ow meter, remove four socket head cap bolts
securing the upper and lower retractor brackets. Remove the insertion tool.

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2.3.4 Installation of Meters with Packing Gland Connection (No Insertion Tool)*

Use the following formula to determine insertion depth for meters with a packing gland
connection (NPT and anged) without an insertion tool.

Figure 6. Flow Meter with Removable Insertion Tool

Example:
To install the F-1500 ow meter with a standard probe (S = 28.67) into a
14 inch schedule 40 pipe, the following measurements are taken:
F = 3 inches
R = 5 inches
t = 0.438 inches
The example insertion length is 20.23 inches.

*All dimensions are in inches.

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2.3.5 Insertion Procedure for Flow Meters with No Insertion Tool

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1. Calculate the required sensor probe insertion length.

2. Fully retract the stem until the sensor head is touching the bottom of the stem housing.
Remove the two top stem clamp nuts and loosen two stem clamp bolts. Slide the stem
clamp away to expose the packing gland nuts. Loosen the two packing gland nuts.

3. Align the sensor head using the sensor alignment pointer. Adjust the alignment pointer
parallel to the pipe and pointing downstream.

4. Insert the sensor head into the pipe until insertion length, I, is achieved. Do not force the
stem into the pipe.

5. Tighten the packing gland nuts to stop leakage around the stem. Do not torque over 20 ft-lbs.

6. Slide the stem clamp back into position. Torque stem clamp bolts to 15 ft-lbs. Replace
the stem clamp nuts and torque to 10-15 ft-lbs.

WARNING

The line pressure must be less than 50 psig for installation.

CAUTION

The sensor alignment pointer must point downstream, in the direction of ow.

2.4 ADJUSTING THE DISPLAY ORIENTATION

Depending on installation requirements, you may need to rotate the position of the LCD
display / keypad. The orientation of the display / keypad may be changed in 90 degree
increments for easier viewing.

Figure 7. Display/Keypad Viewing Adjustment
The electronics boards are electrostatically sensitive. Wear a grounding wrist strap and make
sure to observe proper handling precautions required for static-sensitive components. To
adjust the display:

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1. Disconnect power to the ow meter.

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LOOP

POWER

+ -

FREQ

OUT

PULSE

OUT

--

+

+

OPTIONAL
BACKLIGHT
POWER

+ -

2. Loosen the small set screw which secures the electronics enclosure cover. Unscrew and

remove the cover.

3. Loosen the four captive screws.

4. Carefully pull the display/microprocessor board away from the meter standoffs. Make

sure not to damage the connected ribbon cable.

5. Rotate the display/microprocessor board to the desired position. Maximum turn, two

positions left or two positions right (180°).

6. Align the board with the captive screws. Check that the ribbon cable is folded neatly

behind the board with no twists or crimps.

7. Tighten the screws. Replace the cover and set screw. Restore power to the meter.

2.5 LOOP-POWERED FLOW METER WIRING CONNECTIONS

WARNING

To avoid potential electric shock, follow National Electric Code safety practices or your local code
when wiring this unit to a power source and to peripheral devices. Failure to do so could result in
injury or death. All wiring procedures must be performed with the power off.

The NEMA 4X enclosure contains an
integral wiring compartment with one dual
strip terminal block (located in the smaller
end of the enclosure). Two ¾" female NPT
conduit entries are available for separate
power and signal wiring. For all hazardous
area installations, make sure to use an
agency-approved tting at each conduit
entry. If conduit seals are used, they must
be installed within 18" (457 mm) of the

enclosure.

2.5.1 Input Power Connections

To access the wiring terminal blocks, locate and loosen the small set screw which locks
the small enclosure cover in place. Unscrew the cover to expose the terminal block.

DC Power Wiring

Connect 4-20 mA loop power (12 to 36 VDC at 25 mA, 1W max.) to the +Loop Power and –
Loop Power terminals on the terminal block. Torque all connections to 4.43 to 5.31 in-lbs (0.5
to 0.6 Nm). The DC power wire size must be 20 to 10 AWG with the wire stripped ¼" (7 mm).

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Figure 8. Wiring Terminals for Loop-Powered Version

Figure 9. DC Power Connections

2.5.2 4-20 mA OUTPUT CONNECTIONS

Freq. Out -

Freq. Out +

Freq. Out voltage = +V
Select resistor so that current
through Freq. Out <= 40 mA

Freq. Out voltage = +V
Select resistor so that current through Freq. Out <= 40 mA

Freq. Out +

Freq. Out -

The loop powered meter has a single 4-20 mA loop. The 4-20 mA loop current is
controlled by the meter electronics. The electronics must be wired in series with the sense
resistor or current meter. The current control electronics requires at least 12 volts at the
input terminals to operate correctly.

The maximum loop resistance (load) for the current loop output is dependent upon the
supply voltage and is given in Figure 18. The 4-20 mA loop is optically isolated from the
ow meter electronics.

R

is the total resistance in the loop, including the wiring resistance (R

load

To calculate R

, the maximum Rl

max

from the supply voltage and divide by the maximum loop current, 20 mA. Thus:

= R

for the loop, subtract the minimum terminal voltage

oad

load

wire

+ R

sense

).

The maximum resistance R

load

Figure 10. Load Resistance Versus Input Voltage

2.5.3 Frequency Output Connections

The frequency output is used for a remote counter. It can be scaled to output a 1 to 10 kHz
signal proportional to mass or volume ow, temperature, pressure or density.

The frequency output requires a separate 5 to 36 VDC power supply and there are current
and power specications that must be observed when using this output. The output can
conduct a current up to 40 mA and can dissipate up to 200 mW. The output is isolated
from the meter electronics and power supply.

= R

max

= (V

– 12V) / 0.020 A

supply

Figure 11. Isolated Frequency Output Using External Power Supply

Figure 12. Non-Isolated Frequency Output Using External Power Supply

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2.5.4 Optional Backlight Connection

12 to 36 VDC

35 mA max.

RED 1

BLK 1

BLK 2
RED 2

SHLD 1&2

SENSOR V1

VORTEX

GND

PWR

SENSOR V2

SHIELD

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!

PRESSURE

TEMPERATURE

RED 2
SHLD 1&2

BLK 2

SHIELD

SHIELD

SENSOR V

2

SHIELD

SENSOR V

1

VORTEX

BLK 1

PWR

S

1

E

1

S

2

T

2

T

1

T

3

E

2

T

4

GND

RED 1

P

3

P

1

P

2

P

4

SHLD 3&4

SHLD 5&6
RED 6
BLK 6
BLK 5
RED 5

BLK 3
BLK 4
RED 4
RED 3

The loop power meter has an optional backlight connection provided. It is intended to be
powered by a separate 12 to 36 VDC at 35 mA max. power supply or by the pulse power
input. Both options are shown below.

Figure 13. Backlight Using External Power Supply

2.5.5 Remote Electronics Wiring

The remote electronics enclosure should be mounted in a convenient, easy to reach
location. For hazardous location installations, make sure to observe agency requirements
for installation. Allow some slack in the interface cable between the junction box and the
remote electronics enclosure. To prevent damage to the wiring connections, do not put
stress on the terminations at any time.

The meter is shipped with temporary strain relief glands at each end of the cable.
Disconnect the cable from the meter’s terminal block inside the junction box - not at the
remote electronics enclosure. Remove both glands and install appropriate conduit entry
glands and conduit. When installation is complete, re-connect each labeled wire to the
corresponding terminal position on the junction box terminal block. Make sure to connect
each wire pair’s shield. Note: Incorrect connection will cause the meter to malfunction.

Figure 14. Loop-Powered Volumetric Flowmeter

Junction Box Sensor Connections

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Figure 15. Loop-Power Mass Flowmeter

Junction Box Sensor Connections

IMPORTANT NOTE

Numeric code in junction box label matches wire labels.