ONICON F-2600 User Manual

F-2600 & F-2700 Series Vortex

Flow Meter Installation

and Operation Guide

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

www.onicon.com • [e-mail]

02-150808-7 / 19204

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 the potential damage to the product
or other ancillary products.

IMPORTANT NOTICE

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

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F-2600 & F-2700 Vortex Flow Meter Manual 02/15 - 0808-7 / 19204 Page 2

WARNINGS AND CAUTIONS

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!

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-2700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.

WARNING

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thespeciedminimumlengthofstraightpipeupstreamanddownstreamoftheow

meter’s sensor head.

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-2700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)

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F-2600 & F-2700 Vortex Flow Meter Manual 02/15 - 0808-7 / 19204 Page 3

Customer Notice for Oxygen Service

Unless you have specically ordered ONICON’s optional O2 cleaning, this ow
meter may not be t for oxygen service. Some models can only be properly
cleaned during the manufacturing process. ONICON Incorporated is not liable
for any damage or personal injury, whatsoever, resulting from the use of ONICON
Incorporated’s standard mass ow meters for oxygen gas.

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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TABLE OF CONTENTS

1.0 INTRODUCTION ...............................................................................................11

1.1 F-2600 & F-2700 Series Vortex Mass Flow Meters ................................. 11

1.1.1 Using this Manual ......................................................................11

1.1.2 Receipt of System Components .................................................12

1.1.3 Technical Assistance .................................................................12

1.1.4 Warranty ..................................................................................... 12

1.2 How the ONICON Vortex Meter Operates ..............................................13

1.2.1 Velocity Measurement ...............................................................13

1.2.2 Vortex Shedding Frequency ...................................................... 14

1.2.3 Vortex Frequency Sensing ......................................................... 14

1.2.4 Flow Velocity Range ..................................................................15

1.2.5 Temperature Measurement ........................................................ 16

1.2.6 Pressure Measurement ...............................................................16

1.3 Flow Meter Congurations ......................................................................17

1.3.1 Multivariable Options ...............................................................17

1.3.2 Line Size / Process Conditions / Materials ............................... 18

1.3.3 Flow Meter Electronics ..............................................................18

2.0 INSTALLATION ................................................................................................19

2.1 Installation Overview ..............................................................................19

2.1.1 Flow Meter Installation Requirements .....................................19

2.1.2 Unobstructed Flow Requirements ............................................20

2.2 F-2600 Series In-Line Flow Meter Installation .......................................21

2.2.1 Wafer-Style Flow Meter Installation .........................................22

2.2.2 Flange-Style Flow Meter Installation ........................................23

2.3 F-2700 Series Insertion Flow Meter Installation ....................................24

2.3.1 Standard Installation Guidelines ..............................................25

2.3.2 Hot Tap Guidelines .................................................................... 26

2.4 Flow Meter Insertion ...............................................................................27

2.4.1 Installing Meters with a Packing Gland Connection ................ 28

2.4.2 Insertion Procedure with Permanent Insertion Tool ................ 29

2.4.3 Insertion Procedure with Removable Insertion Tool................30

2.4.4 Installing Meters (Packing Gland), No Insertion Tool .............. 31

2.4.5 Insertion Procedure for ow meters with no Insertion Tool .... 32

2.5 Adjusting Meter Orientation ...................................................................33

2.5.1 Display/Keypad Adjustment ..................................................... 33

2.5.2 Enclosure Adjustment ...............................................................34

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2.6 Loop-Power Flow Meter Wiring Connections ........................................ 35

2.6.1 Input Power Connections .......................................................... 35

2.6.2 4-20 mA Output Connections ...................................................36

2.6.3 Pulse Output Connections .........................................................37

2.6.4 Frequency Output Connections ................................................38

2.6.5 Optional Backlight Connections ...............................................38

2.6.6 Remote Electronics Wiring ........................................................39

2.7 High Power Flow Meter Wiring Connections .........................................41

2.7.1 Input Power Connections .......................................................... 41

2.7.2 4-20 mA Output Connections ...................................................43

2.7.3 Frequency Output Connections ................................................44

2.7.4 Pulse Output Connections .........................................................45

2.7.5 Alarm Output Connections .......................................................47

2.7.6 Remote Electronics Wiring ........................................................48

2.7.7 Optional Input Electronics Wiring ............................................49

2.7.8 Optional Energy EMS RTD Input Wiring..................................49

2.7.9 Optional External 4-20 mA Input Wiring .................................50

2.7.10 Optional Contact Closure Input Wiring ....................................51

3.0 OPERATING INSTRUCTIONS ........................................................................... 53

3.1 Flow Meter Display/Keypad ...................................................................53

3.2 Start-Up............ ........................................................................................ 54

3.3 Using the Setup Menus ...........................................................................56

3.3.1 Programming the Flow Meter ....................................................57

3.3.2 Output Menu ............................................................................58

3.3.3 Display Menu ............................................................................ 60

3.3.4 Alarm Menu .............................................................................. 61

3.3.5 Totalizer #1 Menu ...................................................................... 62

3.3.6 Totalizer #2 Menu ...................................................................... 63

3.3.7 Energy Menu .............................................................................. 64

3.3.8 Fluid Menu ................................................................................65

3.3.9 Units Menu ................................................................................66

3.3.10 Time and Date Menu .................................................................67

3.3.11 Diagnostics Menu ......................................................................68

3.3.12 Calibration Menu .......................................................................69

3.3.13 Password Menu ..........................................................................70

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4.0 SERIAL COMMUNICATIONS ............................................................................ 71

4.1 HART Communications ..........................................................................71

4.1.1 Wiring .........................................................................................71

4.1.2 HART Commands with the DD Menu ......................................73

4.1.3 HART Commands with Generic DD Menu ............................... 78

4.2 MODBUS Communications .....................................................................81

4.2.1 Wiring .........................................................................................81

4.2.2 Menu Items ................................................................................82

4.2.3 Register Denitions ....................................................................84

4.3 BACnet ................................................................................................... 90

5.0 TROUBLESHOOTING AND REPAIR.................................................................91

5.1 Hidden Diagnostics Menus .....................................................................91

5.1.1 Level One Hidden Diagnostics Values ...................................... 93

5.5.2 Level Two Hidden Diagnostics Values ......................................94

5.2 Analog Output Calibration .....................................................................95

5.3 Troubleshooting the Flow Meter ............................................................. 96

5.4 First Check Items .....................................................................................96

5.5 Record Values ..........................................................................................96

5.6 Determine the Fault .................................................................................97

5.6.1 Symptom: Output at No Flow ................................................... 97

5.6.2 Symptom: Erratic Output ..........................................................97

5.6.3 Symptom: No Output ................................................................99

5.6.4 Symptom: Meter Displays Temperature Fault ........................ 100

5.6.5 Symptom: Meter Displays Pressure Fault ...............................101

5.7 Electronics Assembly Replacement (All Meters) .................................102

5.8 Pressure Sensor Replacement (In-line Only) .......................................103

5.9 Returning Equipment to the Factory .....................................................103

A-1 APPENDIX A PRODUCT SPECIFICATIONS
B-1 APPENDIX B FLOW METER CALCULATIONS

C-1 APPENDIX C GLOSSARY

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D-1 APPENDIX D TERMS & CONDITIONS

FIGURES

1 In-Line Vortex Multi-Parameter Mass Flow Meter ................................. 13

2 Measurement Principle of Vortex Flow Meters ...................................... 14

3 Reynolds Number Range of the Meter ....................................................16

4 Recommended Pipe Length Required for Installation ...........................20

5 Flange Bolt Tightening Sequence ............................................................21

6 Wafer-Style Flow Meter Installation .......................................................22

7 Flange-Style Flow Meter Installation ......................................................23

8 Isolation Valve Requirements .................................................................. 24

9 Hot Tap Sequence ....................................................................................26

10 Insertion Calculation (Meters with Insertion Tool) ................................ 28

11 Flow Meter with Permanent Insertion Tool ............................................29

12 Flow Meter with Removable Insertion Tool ........................................... 30

13 Insertion Calculation (Meters without Insertion Tool) ...........................31

14 Display/Keypad Viewing Adjustment ....................................................33

15 Enclosure Viewing Adjustment ...............................................................34

16 Loop-Power Wiring Terminals for Loop Powered Version ....................35

17 DC Power Connections ............................................................................ 35

18 Load Resistance Versus Input Voltage ....................................................36

19 Isolated Pulse Output Using External Power Supply ............................37

20 Non-Isolated Pulse Output Using External Power Supply ....................37

21 Isolated Frequency Output Using External Power Supply .................... 38

22 Non-Isolated Frequency Output Using External Power Supply ............ 38

23 Backlight Using External Power Supply .................................................38

24 Loop-Power Volumetric Flow Meter Junction Box ................................39

25 Loop-Power Mass Flow Meter Junction Box ..........................................40

26 AC Wiring Terminals ............................................................................... 41

27 AC Power Connections ............................................................................ 42

28 DC Wiring Terminals ...............................................................................42

29 DC Power Connections ............................................................................ 42

30 Load Resistance Versus Input Voltage ....................................................43

31 Isolated 4-20 Output Using External Power Supply ..............................43

32 Non-Isolated 4-20 Output Using Input Power Supply ........................... 44

33 Isolated 4-20 Output Using Meter Power Supply (AC only) .................44

34 Isolated Frequency Output Using External Power Supply .................... 45

35 Non-Isolated Frequency Output Using Input Power Supply .................45

36 Isolated Frequency Output Using Meter Power Sup. (AC only) ............45

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37 Isolated Pulse Output Using External Power Supply ............................46

38 Non-Isolated Pulse Output Using Input Power Supply ......................... 46

39 Isolated Pulse Output Using Meter Power Supply (AC only) ................46

40 Isolated Alarm Output Using External Power Supply ........................... 47

41 Non-Isolated Alarm Output Using Meter Power Supply ....................... 47

42 Isolated Alarm Output Using Meter Power Supply (AC only) ..............47

43 High Power Flow Meter Junction Box ...................................................48

44 Optional Energy EMS RTD Input Wiring ................................................49

45 External 4-20 mA Input Wiring – External Power Supply .....................50

46 External 4-20 mA Input Wiring – DC Powered Meter ............................ 50

47 External 4-20 mA Input Wiring – AC Powered Meter ............................51

48 Optional External Contact Closure Input Wiring ...................................51

49 Flow Meter Display/Keypad ...................................................................53

50 Loop-Powered Meter Wiring (HART) .....................................................71

51 DC Powered Meter Wiring (HART) ......................................................... 72

52 AC Powered Meter Wiring (HART) ......................................................... 72

53 RS-485 Wiring (MODBUS) ......................................................................81

54 Electronics Stack Sensor Connections .................................................... 98

55 Remote Feed Through Board Sensor Connections ................................. 98

56 Vortex Sensor Connector .........................................................................99

57 Temperature Sensor Connector ............................................................. 100

58 Pressure Sensor Connector .................................................................... 101

TABLES

1 Minimum Recommended Stud Bolt Lengths .........................................21

2 Byte Order (MODBUS) ............................................................................83

3 Register Denitions (MODBUS) ..............................................................85

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SECTION 1.0: INTRODUCTION

1.1 ONICON F-2600 & F-2700 SERIES VORTEX MASS FLOW METERS

The ONICON F-2600 Series In-line and F-2700 Series Insertion Vortex Flow Meters provide a
reliable solution for process ow measurement. From a single entry point in the pipeline, F-2600
meters offer precise measurements of mass or volumetric ow rates.

Multi-Parameter Mass Flow Meters

Mass ow meters utilize three primary sensing elements: a vortex shedding velocity sensor, an
RTD temperature sensor, and a 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.

Volumetric Flow Meters

The primary sensing element of a volumetric ow meter is a vortex shedding 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 can be ordered 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.

1.1.1 Using This Manual

This manual provides information needed to install and operate both the F-2600 Inline and
F-2700 insertion style ow meters.

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

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1.1.2 Receipt of System Components

When receiving an ONICON mass 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.

1.1.3 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 8:00 a.m.
and 5:00 p.m. 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)

1.1.4 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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1.2 HOW THE ONICON VORTEX MASS FLOW METER OPERATES

Figure 1. In-Line Multi-Parameter Vortex Mass Flow Meter

ONICON F-2600 Series & F-2700 Series Vortex Mass Flow Meters use a unique sensor
head to monitor mass ow rate by directly measuring three variables. uid velocity,
temperature and pressure. The built-in ow computer calculates the mass ow rate
and volumetric ow rate based on these three direct measurements. The sensing head
is built into the vortex meter’s ow body. To measure uid velocity, the ow meter
incorporates a bluff body (shedder bar) in the ow stream and measures the frequency of
vortices created by the shedder bar. Temperature is measured using a platinum resistance
temperature detector (PRTD). Pressure measurement is achieved using a solid-state
pressure transducer. All three elements are combined into an integrated sensor head
assembly located downstream of the shedder bar within the ow body.

1.2.1 Velocity Measurement

ONICON’s vortex velocity sensor is a patented mechanical design that minimizes the
effects of pipeline vibration and pump noise, both of which are common error sources
in ow measurement with vortex ow meters. The velocity measurement is based on the
well-known Von Karman vortex shedding phenomenon. Vortices are shed from a shedder
bar, and the vortex velocity sensor located downstream of the shedder bar senses the
passage of these vortices. This method of velocity measurement has many advantages
including inherent linearity, high turndown, reliability and simplicity.

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1.2.2 Vortex Shedding Frequency

Von Karman vortices form downstream of a shedder bar into two distinct wakes.
The vortices of one wake rotate clockwise while those of the other wake rotate
counterclockwise. Vortices generate one at a time, alternating from the left side to the right
side of the shedder bar. Vortices interact with their surrounding space by over-powering
every other nearby swirl on the verge of development. Close to the shedder bar, the
distance (or wave length) between vortices is always constant and measurable. Therefore,
the volume encompassed by each vortex remains constant, as shown below. By sensing
the number of vortices passing by the velocity sensor, the F-2600 & F-2700 Flow Meter
computes the total uid volume.

Figure 2. Measurement Principle of Vortex Flow Meters

1.2.3 Vortex Frequency Sensing

The velocity sensor incorporates a piezoelectric element that senses the vortex frequency.
This element detects the alternating lift forces produced by the Von Karman vortices
owing downstream of the vortex shedder bar. The alternating electric charge generated by
the piezoelectric elements is processed by the transmitter’s electronic circuit to obtain the
vortex shedding frequency. The piezoelectric element is highly sensitive and operates over
a wide range of ows, pressures and temperatures.

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1.2.4 Flow Velocity Range

To ensure trouble-free operation, vortex ow meters must be correctly sized so that the
ow velocity range through the meter lies within the measurable velocity range (with
acceptable pressure drop) and the linear range.

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

Vmin

Gas Liquid

25 ft/s

√ ρ

1 ft/s

English ρ (lb/ft

3

)

Vmax

300 ft/s

30 ft/s

37 ft/s

Vmin

Vmax

√ ρ

91 m/s

0.3 m/s

9.1 m/s

Metric ρ (kg/m

3

)

The pressure drop for F-2700 insertion meters is negligible. The pressure drop for F-2600
in-line meters is dened as:

∆P = .00024 ρ V2 English units (∆P in psi, ρ in lb/ft3, V in ft/sec)
∆P = .000011 ρ V2 Metric units (∆P in bar, ρ in kg/m3, V in m/sec)

The linear range is dened by the Reynolds number. The Reynolds number is the ratio of
the inertial forces to the viscous forces in a owing uid and is dened as:

Where
Re = Reynolds Number
ρ = mass density of the uid being measured
V = velocity of the uid being measured
D = internal diameter of the ow channel
 = viscosity of the uid being measured

Re =

ρVD



The Strouhal number is the other dimensionless number that quanties the vortex
phenomenon. The Strouhal number is dened as:

Where
St = Strouhal Number
f = frequency of vortex shedding
d = shedder bar width
V = uid velocity

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St =

f d

V

As shown in Figure 3, F-2600 & F-2700 meters exhibit a constant Strouhal number across
a large range of Reynolds numbers, indicating a consistent linear output over a wide
range of ows and uid types. Below this linear range, the intelligent electronics in the
meter automatically corrects for the variation in the Strouhal number with the Reynolds
number. The meter’s smart electronics corrects for this non-linearity via its simultaneous
measurements of the process uid temperature and pressure. This data is then used to
calculate the Reynolds number in real time. The meter automatically corrects down to a
Reynolds number of 5,000.

Figure 3. Reynolds Number Range for the meter

1.2.5 Temperature Measurement

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

1.2.6 Pressure Measurement

Both versions of the meter incorporate 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 -330°F to 750°F (-200°C to 400°C).

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1.3 Flow Meter Congurations

Our vortex mass ow meters are available in two model congurations:
In-line F-2600 Series Flow Meters (replaces a section of the pipeline)
Insertion F-2700 Series Flow Meters (requires a tap into an existing pipeline)

Both the in-line and insertion congurations are similar in that they both use identical electronics
and have similar sensor heads. Besides installation differences, the main difference between an
in-line ow meter and an insertion ow meter is their method of measurement.

For an in-line vortex ow meter, the shedder bar is located across the entire diameter of the
ow body. Thus, the entire pipeline ow is included in the vortex formation and measurement.
The sensing head, which directly measures velocity, temperature and pressure, is located just
downstream of the shedder bar.

Insertion vortex ow meters have a shedder bar located across the diameter of a short tube. The
velocity, temperature and pressure sensor is located within this tube just downstream of a built­in shedder bar. This entire assembly is called the insertion sensing head. It ts through any entry
port with a 1.875 inch minimum internal diameter.

The sensing head of an insertion vortex ow meter directly monitors the velocity at a point in
the cross-sectional area of a pipe, duct, or stack (referred to as “channels”). The velocity at a
point in the pipe varies as a function of the Reynolds number. The insertion vortex ow meter
computes the Reynolds number and then computes the total ow rate in the channel. The output
signal of insertion meters is the total ow rate in the channel. The accuracy of the total ow rate
computation depends on adherence to the piping installation requirements given in Section 2. If
adherence to those guidelines cannot be met, contact ONICON for specic installation advice.

1.3.1 Multivariable Options

The both 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.

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1.3.2 Line Size / Process Connections / Materials

The in-line model is built for line sizes ½" through 4" wafer or ½" through 8" anged
design using ANSI 150, 300, 600, PN16, 40, or 64 class anges.

The insertion model can be used in line sizes 2" and greater and is built with a packing
gland design using 2" NPT, or 2" anged connections (ANSI 150, 300, 600, PN16, 40, or 64
class anges). The packing gland design can be ordered with a permanent or removable
retractor.

The standard in-line model is built with 316L stainless steel, A105 carbon steel and
Hastelloy C-276 versions are available via special order. The insertion model is built with
316L stainless steel.

1.3.3 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 pushbuttons operated via
nger touch. For hazardous locations, the six buttons can be operated with the electronics
enclosure sealed using a hand-held magnet, thereby not compromising 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 owmeters are calibrated and congured for the customer’s
ow application.

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SECTION 2.0 INSTALLATION

!

2.1 INSTALLATION OVERVIEW

ONICON F-2600 & F-2700 Vortex Flow Meter installations are simple and straightforward.
Both the in-line and the insertion type ow meter installations are covered in this chapter.
After reviewing the installation requirements given below, see page 21 for in-line installation
instructions. See page 24 for insertion style 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

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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.

Flow straightener

(if used)

Flow straightener

(if used)

Flow straightener

(if used)

Flow straightener

Minimum Required

Upstream Diameters

No Flow

Straightener

(if used)

Downstream Diameters

With Flow Straightener No Flow

Straightener

Flow straightener (if used)

Minimum Required

With 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

D = Internal diameter of channel.

Figure 4. Recommended Pipe Length Requirements for Installation

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2.2 F-2600 SERIES IN-LINE FLOW METER INSTALLATION

Install the in-line ow meter between two conventional pipe anges as shown in Figures 6 and

7. Table 1 provides the recommended minimum stud bolt lengths for wafer-style meter body size
and different ange ratings.

The meter's inside diameter is equal to the same size nominal pipe ID in schedule 80. For
example, a 2” meter has an ID of 1.939” (2” schedule 80). Do not install the meter in a pipe with
an inside diameter smaller than the inside diameter of the meter. For schedule 160 and higher
pipe, a special meter is required. Consult the factory before purchasing the meter.

In-line meters require customer-supplied gaskets. When selecting gasket material, make sure that
it is compatible with the process uid and pressure ratings of the specic installation. Verify that
the inside diameter of the gasket is larger than the inside diameter of the ow meter and adjacent
piping. If the gasket material extends into the ow stream, it will disturb the ow and cause
inaccurate measurements.

Flange Bolt Specications

Stud Bolt Lengths for Each Flange Rating (inches)

Line Size

Class 150
and PN16

Class 300
and PN40

Class 600
and PN64

1 " 6.00 7.00 7.50

1½ " 6.25 8.50 9.00

2 " 8.50 8.75 9.50
3 " 9.00 10.00 10.50
4 " 9.50 10.75 12.25

Table 1. Minimum Recommended Stud Bolt Lengths for Wafer Meters

The required bolt load for sealing the gasket joint is affected by several application-dependent
factors; therefore, the required torque for each application may be different. Refer to the ASME
Pressure Vessel Code guidelines for bolt tightening standards.

Figure 5. Flange Bolt Tightening Sequence

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2.2.1 Wafer-Style Flow Meter Installation

!

Install the wafer-style meter between two conventional pipe anges of the same nominal
size as the ow meter. If the process uid is a liquid, make sure the meter is located where
the pipe is always full. This may require locating the meter at a low point in the piping
system. Note: Vortex ow meters are not suitable for two-phase ows (i.e., liquid and gas
mixtures). For horizontal pipelines having a process temperature above 300° F, mount the
meter at a 45 or 90 angle to avoid overheating the electronics enclosure. To adjust the
viewing angle of the enclosure or display/keypad, see page 34 and 35.

Figure 6. Wafer-Style Flow Meter Installation

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.

When installing the meter make sure the section marked with a ow arrow is positioned
upstream of the outlet, with the arrow head pointing in the direction of ow. (The mark
is on the wafer adjacent to the enclosure mounting neck.) This ensures that the sensor
head is positioned downstream of the vortex shedder bar and is correctly aligned to the
ow. Installing the meter opposite this direction will result in completely inaccurate ow
measurement. To install the meter:

1. Conrm that the installation site meets the required minimum upstream and
downstream pipe diameters. Turn off the ow of process gas, liquid or steam. Verify
that the line is not pressurized.

2. Insert the studs for the bottom side of the meter body between the pipe anges. Place
the wafer-style meter body between the anges with the end stamped with a ow arrow
on the upstream side, with the arrow head pointing in the direction of ow. Center the
meter body inside the diameter with respect to the inside diameter of the adjoining
piping.

3. Position the gasket material between the mating surfaces. Make sure both gaskets are
smooth and even with no gasket material extending into the ow prole. Obstructions
in the pipeline will disturb the ow and cause inaccurate measurements.

4. Place the remaining studs between the pipe anges. Tighten the nuts in the sequence
shown in Figure 5. Check for leaks after tightening the ange bolts.

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2.2.2 Flange-Style Flow Meter Installation

!

Install the ange-style meter between two conventional pipe anges of the same nominal
size as the ow meter. If the process uid is a liquid, make sure the meter is located where
the pipe is always full. This may require locating the meter at a low point in the piping
system. Note: Vortex ow meters are not suitable for two-phase ows (i.e., liquid and gas
mixtures). For horizontal pipelines having a process temperature above 300° F, mount the
meter at a 45° or 90° angle to avoid overheating the electronics enclosure. To adjust the
viewing angle of the enclosure or display/keypad, see page 34 and 35.

Figure 7. Flange-Style Flow Meter Installation

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.

When installing the meter make sure the ange marked with a ow arrow is positioned
upstream of the outlet ange, with the arrow head pointing in the direction of ow. (The
mark is on the ange adjacent to the enclosure mounting neck.) This ensures that the
sensor head is positioned downstream of the vortex shedder bar and is correctly aligned to
the ow. Installing the meter opposite this direction will result in completely inaccurate
ow measurement. To install the meter:

1. Conrm that the installation site meets the required minimum upstream and

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

2. Seat the meter level and square on the mating connections with the ange stamped

with a ow arrow on the upstream side, with the arrow head pointing in the direction
of ow. Position a gasket in place for each side. Make sure both gaskets are smooth
and even with no gasket material extending into the ow prole. Obstructions in the
pipeline will disturb the ow and cause inaccurate measurements.

3. Install bolts in both process connections. Tighten the nuts in the sequence shown in

Figure 5. Check for leaks after tightening the ange bolts.

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2.3 F-2700 SERIES INSERTION 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.

Isolation Valve Selection

Always install an isolation valve with insertion style meters. 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.

Figure 8. Isolation Valve Requirements

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2.3.1 Standard Installation Guidelines

!

!

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.

WARNING

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

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

6. Weld the ow meter pipe connection onto the pipe.
Make sure this connection is within ± 5°
perpendicular to the pipe centerline.

7. Install the isolation valve.

8. 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.

9. 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.

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2.3.2 Hot Tap Guidelines

!

!

FLOW

xxxxxxxxxxxxxxxxxxxx
xxxxxxxxxxxxxxxxxxxx
xxxxxxxxxxxxxxxxxxxx
xxxxxxxxxxxxxxxxxxxx

Check upstream and downstream
piping requirements

Weld mounting adapter

Connect process connection
(flange or NPT)

Connect isolation valve and
test for leaks

Hot tap pipe

Purge pipe

Connect meter to valve, calculate
insertion depth, install flow meter

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 centerline (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. Connect the ow meter to the isolation valve and open the isolation valve.

9. 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 9. Hot Tap Sequence

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2.4 FLOW METER INSERTION

!

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
centerline of the meter’s sensing head is located at the pipe’s centerline. For pipe sizes larger than
10", the centerline 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 centerline 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 29.47".

12-Inch Extended Probe conguration is used with exceptionally lengthy ow meter process
connections. The length, S, of the stem is 41.47".

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.

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2.4.1 Installing Flow Meters with a Packing Gland Connection*

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 33.

Insertion Length Formula

I = F + R + t – 1.35

Where:

I

I = Insertion length.

F = Distance from the raised face of the ange or top of
the process connection for NPT style meters to the
top outside of the process pipe.

F

t

R

R = Pipe inside diameter ÷ 2 for pipes ten" & smaller.

R = Five" for pipe diameters larger than ten".

t = Thickness of the pipe wall. (Measure the disk
cutout from the tapping procedure or check a piping
handbook for thickness.)

Figure 10. Insertion Calculation (Meters with Insertion Tool)

Example 1: Flange Style Meters:

To install an insertion style ow meter into a 14" schedule 40 pipe, the following
measurements are taken:

F = 12"
R = 5"
t = 0.438"

The example insertion length is 16.09".

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". Measure the thread portion
still showing after the installation and subtract that amount from 1.18". This gives you the
thread engagement length. If this cannot be measured use .55" for this amount.

F = 12"
R = 5"
t = 0.438"

The example insertion length is 15.54".

*All dimensions are in inches.

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2.4.2 Insertion Procedure for Flow Meters with Permanent Insertion Tool

!

! i !

Figure 11. Flow Meter with Permanent Insertion Tool

1. Calculate the required sensor probe insertion length (see previous page). Measure
from the 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 2" full-port isolation valve, if used. 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.

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2.4.3 Insertion Procedure for Flow Meters with Removable Insertion Tool

!

! i !

Figure 12. Flow Meter with Removable Insertion Tool

1. Calculate the required sensor probe insertion length. Measure from the 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 2" full-port isolation valve, if used. 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.

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