ONICON F-5100 User Manual

F-5100 Inline

Thermal Mass Flow Meter

Installation and Operation Guide

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

0686-11 / 18332

www.onicon.com • [e-mail]

05-15

SAFETY INFORMATION

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This meter was calibrated at the factory before shipment. To ensure correct use of the meter, please
read this manual thoroughly.

Regarding This Manual:

• This manual should be passed on to the end user.

• Before use, read this manual thoroughly to comprehend its contents.

• The contents of this manual may be changed without prior notice.

• All rights reserved. No part of this manual may be reproduced in any form without
ONICON’s written permission.

• ONICON makes no warranty of any kind with regard to this material, including, but not
limited to, implied warranties of merchantability and suitability for a particular purpose.

• All reasonable efforts have 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.

11451 Belcher Road South, Largo, FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
F-5100 Inline Thermal Mass Flow Meter Manual 05/15 - 0686-11 / 18332 Page 2

TABLE OF CONTENTS

1.0 INTRODUCTION ..................................................................................................5

1.1 PURPOSE OF THIS GUIDE .......................................................................5

1.2 TYPICAL INLINE THERMAL MASS FLOW METER ...............................5

1.3 STANDARD FEATURES AND SPECIFICATIONS .................................... 6

1.4 ADDITIONAL HARDWARE THAT MAY BE REQUIRED .........................7

1.4.1 Additional Remote Mount Cable ................................................7

1.4.2 Gaskets for Flanged Meters .........................................................7

1.5 WORKING ENVIRONMENT .....................................................................7

1.6 WARRANTY & SERIAL NUMBER ............................................................7

2.0 UNPACKING ...................................................................................................... 8

2.1 CHECKING TO SEE THAT YOU RECEIVED EVERYTHING ....................8

3.0 INSTALLATION ....................................................................................................9

3.1 INSTALLATION SITE SELECTION ..........................................................9

3.2 MECHANICAL INSTALLATION ............................................................. 12

3.2.1 Threaded Meter ..........................................................................12

3.2.2 Flanged Meter ............................................................................13

3.3 ELECTRICAL INSTALLATION ...............................................................15

3.3.1 Analog Output ...........................................................................15

3.3.2 Pulse Output ..............................................................................15

3.3.3 Integral Mount Wiring ...............................................................16

3.3.4 Using the Pulse Isolator Module ............................................... 17

3.3.5 Remote Mount Wiring ...............................................................18

4.0 START-UP & COMMISSIONING FOR ONICON INSERTION THERMAL

MASS FLOW METERS ....................................................................................... 19

4.1 DISPLAY ..................................................................................................19

4.2 POWERING THE METER ........................................................................19

4.3 HELPFUL HINTS FOR START-UP & COMMISSIONING ......................19

4.4 START-UP & COMMISSIONING ............................................................. 20

4.5 START-UP & COMMISSIONING WORKSHEET .....................................21

5.0 TROUBLESHOOTING GUIDE ............................................................................22

APPENDIX

A-1 REMOTE MOUNT MECHANICAL HARDWARE

A-2 CONDITIONS OF SALE

11451 Belcher Road South, Largo, FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
F-5100 Inline Thermal Mass Flow Meter Manual 05/15 - 0686-11 / 18332 Page 3

11451 Belcher Road South, Largo, FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
F-5100 Inline Thermal Mass Flow Meter Manual 05/15 - 0686-11 / 18332 Page 4

SECTION 1.0: INTRODUCTION

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We, at ONICON Incorporated, would like to thank you for purchasing our quality American made
F-5100 Series Thermal Mass Flow Meter. As our valued customer, our commitment to you is to
provide fast reliable service, while continuing to offer you quality 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 ow meter with the product specic information they will need. This is
NOT an electrical or plumbing trade manual.

WARNING

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

This guide is the basic reference tool for all ONICON F-5100 Inline Thermal Mass Flow Meters.
If you have not purchased all of the options, there will be references in this manual which are not
applicable to your meter(s).

1.2 TYPICAL INLINE THERMAL MASS FLOW METER

Each ONICON thermal mass meter has a single pair of encapsulated platinum sensors that are
in direct contact with the gas. The sensors consist of highly stable reference-grade platinum
windings. One sensor is self-heated and serves as the ow sensor. The other acts as a reference
sensor, and measures the gas temperature. Our proprietary sensor circuitry maintains a constant
temperature differential between the ow sensor and the reference sensor.

As gas ows by the heated sensor (ow sensor), the molecules of owing gas carry heat away
and the sensor cools. The sensor circuitry continuously compensates for this cooling effect and
maintains a constant temperature differential between the two sensors. The energy required to
maintain this temperature differential is directly proportional to the mass ow. There is no need
for additional temperature or pressure compensation.

Output signal(s)
to control system

Optional

ONICON

Display

Clearwater, FL USA

F-5000 Series

www.onicon.com

Flow

Built-in flow conditioner

11451 Belcher Road South, Largo, FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
F-5100 Inline Thermal Mass Flow Meter Manual 05/15 - 0686-11 / 18332 Page 5

1.3 STANDARD FEATURES AND SPECIFICATIONS

CALIBRATION

Every ONICON thermal mass ow meter is wet calibrated in a ow laboratory against standards that are directly
traceable to N.I.S.T. A certicate of calibration accompanies every meter. Each meter is calibrated for use with a specic gas.

Standard Reference Conditions for Natural Gas: Standard Reference Conditions for Air:
Fluid: Methane Fluid: Air
Fluid Temperature: 60°F Fluid Temperature: 70° F
Fluid Pressure: 29.92” Hg (14.70 PSIA) Fluid Pressure: 29.92” Hg (14.70 PSIA)

Contact ONICON for reference conditions for other uid types.

ACCURACY

Natural Gas
± 1.0% of reading from 500 – 7000 SFPM
± 2.0 % of reading from 100 – 500 SFPM
Compressed Air
± 1.0 % of reading + 0.5% of scale over a
100:1 turndown

OVERALL FLOW RANGE

5 to 35,000 SFPM

SENSING METHOD

Thermal mass ow utilizing hybrid analog/digital sensing circuitry, no moving parts

INPUT POWER

Standard: 24 VDC ±10%, 100 mA maximum current
Optional: 90-265 VAC, 50/60 Hz
Optional: 12 VDC ±10%, 200 mA maximum current

FLUID TEMPERATURE RANGE

Standard: -40° to 200° F
Optional: 200° to 300° F
Optional: 300° to 450° F
Optional: 450° to 700° F

AMBIENT TEMPERATURE RANGE

-5° to 150° F

MAXIMUM OPERATING PRESSURE

Standard: 500 PSI
Optional: 1,000 PSI

MATERIALS OF CONSTRUCTION

Wetted metal components - 316L stainless steel
Sensor head - Platinum windings encapsulated in 316L stainless steel
Electronics enclosure - Powder coat painted cast aluminum
Remote mount enclosure - Cast aluminum

ENCLOSURE RATING
Weathertight, NEMA 4 (All versions)

APPROVALS
Integral and remote mount (24 VDC only) Class 1, Division 2, Groups B, C, & D,
(ATEX: Ex nA IIC T4X)

ELECTRICAL CONNECTIONS

Enclosed terminal blocks, cable access through two ½” NPT conduit ttings

PROGRAMMING / MEMORY

Factory programmed for specic application.
Non-volatile memory retains all program parameters and totalized values in the event of power loss.

OUTPUT SIGNAL(S)

Analog output: 4-20 mA
Scalable pulse output: Active 24 VDC pulse, 500ms duration

DISPLAY

Graphic OLED display indicates:
Bar graph indicating percentage of full scale ow
Flow rate: 7 digits
Flow total: 9 digits (Total rolls over to zero when maximum count is exceeded)
Fluid temperature: 3 digits
mWatts of energy used to heat ow sensor: 4 digits
Engineering units for rate and total

11451 Belcher Road South, Largo, FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
F-5100 Inline Thermal Mass Flow Meter Manual 05/15 - 0686-11 / 18332 Page 6

1.4 ADDITIONAL HARDWARE THAT MAY BE REQUIRED

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1.4.1 Additional Remote Mount Cable

ONICON remote mount meters are provided with 25 ft of cable. Additional cable lengths
of up to 1000 ft may be added without affecting the calibration of the meter.

Part # Description
17350 25 ft of additional mount remote cable
17351 50 ft of additional remote mount cable
17352 100 ft of additional remote mount cable

1.4.2 Gaskets for Flanged Meters

For F-5100 Inline Thermal Mass Flow Meters provided with ANSI class 150 or class 300
anges require gaskets for proper installation. ONICON does not supply gaskets.
Gaskets used must comply with all relevant AGA and ANSI standards.

1.5 WORKING ENVIRONMENT

F-5000 series meters are designed for installation and use in typical industrial environments that
are free of corrosive liquids and fumes, direct liquid exposure, heavy condensation, temperature
extremes and vibrations. Do not install the meter in direct sunlight.

The operating ambient air temperature range is -5° to 150° F.

The electrical power should be relatively clean, free of high frequency noise, large voltage
transients, and protected from power surges and brown outs.

1.6 WARRANTY & SERIAL NUMBER

IMPORTANT NOTE

ONICON F-5000 series ow meters are individually calibrated. Remote mount electronics
enclosures and sensors must share the same serial number and must be installed together as a
system. Mixing components from different meters will result in signicant errors in calibration.

Warranty

ONICON provides a 2-year warranty for this product. Certain exclusions apply. Please refer to
Appendix A-2, ONICON’s Terms and Conditions of Sale for details.

Serial Number

The serial number of your F-5100 series ow meter is located on the nameplate attached to the
top of the enclosure. This serial number will also be located on the remote sensor for remote
mount meters.

11451 Belcher Road South, Largo, FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
F-5100 Inline Thermal Mass Flow Meter Manual 05/15 - 0686-11 / 18332 Page 7

SECTION 2.0: UNPACKING

ONICON Insertion Thermal Mass Flow Meters are packed and shipped in individual cartons. All other
peripheral devices will be packaged and shipped separately.

Please open all packages with care to prevent damage to their contents. Carefully inspect each item
for signs of damage in transit.

All ONICON products are shipped insured unless the customer specically requests otherwise. Please
notify the shipping company and ONICON Customer Service immediately if any items are damaged in
transit. Save all packing material for inspection by the shipper.

2.1 CHECKING TO SEE THAT YOU RECEIVED EVERYTHING

Standard Documentation

Enclosed with each meter is a comprehensive documentation package that includes the following
items:

• Installation and Operation Guide

• Flow Meter Calibration Certicate

• Product Data Sheet

• Scaled Pulse Isolator Module

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

Product

• F-5100 Inline Thermal Mass Flow Meter

11451 Belcher Road South, Largo, FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
F-5100 Inline Thermal Mass Flow Meter Manual 05/15 - 0686-11 / 18332 Page 8