Onicon F-5400 Installation And Operation Manual

F-5400 Insertion and Inline
Thermal Mass Flow Sensor

Installation and Operation Guide

ONICON

Flow and Energy Measurement

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

2031-1 / 107032 Rev B

www.onicon.com • [e-mail]

07-18

Model F-5400

Notice

This publication must be read in its entirety before performing any operation. Failure

and/or damage to the equipment. Should this equipment require repair or adjustment

to understand and follow these instructions could result in serious personal injury

beyond the procedures given herein, contact the factory at:

ONICON

11451 BELCHER ROAD SOUTH

LARGO, FL 33773

TELEPHONE: [phone]

FAX: [phone]

EMAIL: [e-mail]

DISCLAIMER

Download Technical Data Sheets from our website:

www.onicon.com

ONICON believes that the information provided herein is accurate; however, be

advised that the information contained herein is NOT a guarantee for satisfactory

results. Specifically, this information is neither a warranty nor guarantee,

expressed or implied, regarding performance, merchantability, fitness, or any other

matter with respect to the products; nor recommendation for the use of the product/

process information in conflict with any patent. Please note that ONICON reserves

the right to change and/or improve the product design and specification without

notice.

ONICON F-5400 Manuals:

• ONICON F-5000 View™ Manual

All ONICON Manuals and software available in English only.

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F-5400 Thermal Mass Flow Meter Manual 12/16 - 2031 / 107032 Page 2

Table Of Contents

1. Introduction Page 5

a. Quick Start Guide Page 5

2. Installation (Mechanical) Page 9

a. Installation Depth Page 14

b. Orientation of Flowmeter Page 13

c. Rotating the Probe/Enclosure Page 14

d. Sensor Elements Page 14

e. Compression Fittings Page 16

3. Wiring (Electrical) Page 20

a. General Wiring Page 20

b. Signal Wiring Page 22

c. Pulse/Alarm Wiring (optional feature) Page 24

4. Operation (Standard Operation) Page 26

a. Start Up Page 8

5. Maintenance Page 27

a. Precautions Page 27

b. Troubleshooting Page 28

6. Appendices Page 32

a. Specifications Page 32

b. Agency Approvals Page 34

c. Dimensions Page 35

d. Warranty Page 35

e. Returning your meter Page 39

7. Glossary of Terms and Abbreviations Page 40

8. Index Page 41

Model F-5400

TABLE OF CONTENTS

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F-5400 Thermal Mass Flow Meter Manual 12/16 - 2031 / 107032 Page 3

Model F-5400

Introduction: Safety Information

This sensor was calibrated at the factory before shipment. To ensure correct use of the sensor, 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.

• 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:

DISCLAIMERINTRODUCTION

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 specific 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 specified in this manual, the protection provided by
this product may be impaired.

The following symbols are used in this manual:

Messages identified as "Note" or "Important Note" contain information critical to the

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proper operation of the product.

Messages identified as "Caution" (refer to accompanying documents) contain
information regarding potential damage to the product or other ancillary products.
Messages identified as "Warning" contain information regarding the personal safety of
individuals involved in the installation, operation or service of this product.

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F-5400 Thermal Mass Flow Meter Manual 12/16 - 2031 / 107032 Page 4

Model F-5400

Introduction: Quick Start Guide

Use the table and images below as a guide while using the worksheet on the next page to record your notes.
Note: Please read the entire Quick-start procedure before beginning installation.

1. Record inside diameter (ID). Ensure the actual
pipe ID matches the pipe ID shown on the
factory calibration certificate.

2. Record upstream and downstream straight-pipe
requirements based on information in the tables
for either insertion (p. 13) or inline (p. 19).

3. The arrow on the enclosure indicates the
direction of flow.

INSIDE
DIAMETER (ID)

FLOW

Downstream Upstream

FLOW

OUTER
DIAMETER (OD)

INTRODUCTION

ARROW ON ENCLOSURE MUST
POINT IN DIRECTION OF FLOW

4. Ensure correct probe depth setting. If using 1 ½"

PIPE

size pipe, please see note on p. 14.

C

L

FLOW

0.73"
(18.5 mm)

5. Power on the flow meter

6. Check the remaining flow meter settings by accessing the meter settings by using the F-5000 View™
software tool. Record the settings in the spaces given for items A - D on the following page.

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F-5400 Thermal Mass Flow Meter Manual 12/16 - 2031 / 107032 Page 5

Model F-5400

Introduction: Quick Start Guide

Before powering on your meter, use this worksheet to record your notes.

Serial Number: Serial Number: Serial Number: Serial Number:

Item to verify

1. What is the Pipe ID? ID = ID = ID = ID =

2. Calculate the Upstream/
Downstream straight-pipe
requirements

3. Is the arrow on enclosure
pointed in direction of flow?

4. Is the probe depth setting
correct?

After powering on your meter, check items A - D below by accessing the meter settings through the F-5000
View software tool.

DISCLAIMERINTRODUCTION

A. Which flow units have been

set in meter? (SCFH, KG/H,
etc..)

B. Correct values for reference

temperature and pressure?

C. Confirm the pipe ID listed

above same as "Pipe_id="

D. Verify the 4mA and 20mA

meter settings

UP =
DN =

Y / N Y / N Y / N Y / N

Y / N Y / N Y / N Y / N

Y / N Y / N Y / N Y / N

4mA =
20mA =

UP =
DN =

4mA =
20mA =

UP =
DN =

4mA =
20mA =

UP =
DN =

4mA =
20mA =

Your Notes:

If you are experiencing any problems after completing this procedure, please call the ONICON Service
Department at 727-447-6140 to review this information.

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F-5400 Thermal Mass Flow Meter Manual 12/16 - 2031 / 107032 Page 6

Introduction

Model F-5400

Welcome

Product
Description

Thank you for purchasing the Model F-5400 Thermal Gas Mass Flow Meter from
ONICON. The Model F-5400 is one of the most technically advanced flow meters
in the world. An extensive engineering effort has been invested to deliver advanced
features, accurate measurement performance and outstanding reliability.

This Instruction Manual contains the electrical and mechanical installation instructions
as well as details for programming, maintaining and troubleshooting the meter.
This manual is divided into the following sections: Introduction, Installation, Wiring,
Operation, Maintenance, Troubleshooting, Appendices, Glossary and Index.

Theory of Operation

The Model F-5400 is an innovative Thermal Mass Gas Flow Meter and Temperature
Transmitter. It is microprocessor-based and field programmable. The F-5400 thermal
sensor operates on the law that gases absorb heat. A heated sensor placed in an air
or gas stream transfers heat in proportion to the stream’s mass velocity. There are
two sensor elements. One sensor element detects the gas temperature and a second
element is maintained at a constant temperature above the gas temperature. The
energy applied to the heated sensor to maintain a constant temperature differential

(constant ∆ T) is directly proportional to the mass flow velocity. The F-5400 flow

meter maintains accurate flow measurement over a large temperature and pressure
range.

INTRODUCTION

Mass Flow

DDC-Sensor™
Technology

Mass Flow

The Model F-5400 measures mass flow; an advantage over other flow meters which
measure volumetric flow. Volumetric flow is incomplete because temperature and
pressure are unknown and must be measured separately. For example, the mass
flow of a gas depends on its temperature and pressure. As temperature and pressure
changes, the gas volume changes but not its mass. Therefore a device measuring
mass flow is independent of temperature and pressure changes. The Model F-5400
provides a direct measurement of gas flow in Mass units (kg/hr, lb/hr), standard units
(SCFM, SLPM) or normal units (NM3/hr, NLPM) with no additional temperature or
pressure measurements required.

DDC-Sensor™ Technology Description
The ONICON DDC-Sensor™ is a new state of the art sensor technology used in the
ONICON Model F-5400 Thermal Gas Flow Meter. The DDC-Sensor™, a Direct Digitally
Controlled sensor, is unlike other thermal flow sensors available on the market.
Instead of using traditional analog circuitry, the DDC-Sensor™ is interfaced directly to
the F-5400 microprocessor for more speed and programmability. The DDC-Sensor™
quickly and accurately responds to changes in process variables by utilizing the
microprocessor to determine mass flow rate, totalized flow, and temperature.
ONICON’s DDC-Sensor™ provides a technology platform for calculating accurate gas
correlations.

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F-5400 Thermal Mass Flow Meter Manual 12/16 - 2031 / 107032 Page 7

Model F-5400

Introduction

Flow
Calibration

I/O Description

DISCLAIMERINTRODUCTION

Flow Calibration

The ONICON Calibration Lab maintains instrument calibration data on every flow meter.
Calibration files include details on process conditions, customer gas, line size and
other information. All NIST-traceable equipment utilized for the calibration procedure is
identified on the Calibration Certificate, which is sent with every flow meter.

Calibration records include details on process conditions, calibration fluid, line size and
other information. All NIST-traceable equipment utilized for the calibration procedure is
identified, as is the calibration history of all reference equipment.

In addition to the Calibration Certificate, a certified flow table that correlates current
outputs with scaled units of flow is produced for each calibrated device.

I/O Description

The F-5400 features a galvanically isolated 4-20mA analog output and a second output
for pulse. There is also a mini USB port for interfacing with a laptop or computer. The
4-20mA output can be configured for flow rate or process gas temperature and can be
scaled by the user. The pulse output can be used for pulse or alarm, is programmable
to represent flow rate and can be scaled for units per pulse at a maximum pulse output
frequency of 1Hz.

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USB Interface

F-5000 View™ interfaces to the USB port and is a free PC-based software program
that displays flow meter readings and permits flow meter configuration. The optional
D-100 flow display provides a local indication of rate and total and a network interface
for BACnet, MODBUS, LonWorks, JCI - N2 or Siemens - P1 FLN networks.

Note: The latest version of the F-5000 View software is available for download at http://
www.onicon.com/F5500.html.

USB Interface

The mini USB interface is a standard feature which allows communication with a
PC to monitor readings and configure settings. F-5000 View, is a free application
program from ONICON that connects to the USB interface and allows data monitoring,
configuration setting, data logging to Excel, and an option to save and recall F-5400
configuration data.

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F-5400 Thermal Mass Flow Meter Manual 12/16 - 2031 / 107032 Page 8

Installation: General

Model F-5400

Installation ­Model F-5400
Flow Meter

Scope

This section describes how to install the ONICON Model F-5400 Flow Meter and how to
get started:

1. Determine lateral position on the pipe

2. Ensure correct orientation of the meter and check alignment of the sensor elements

3. Determine the installation depth of the probe

4. Tighten compression fitting to complete installation

Installation procedures must be performed using a combination of the end user’s
best engineering practices, in compliance with local codes, and manufacturer’s
recommendations.

General Precautions

The following general precautions should be observed:

1. Exercise care when handling the flow meter to avoid damaging the probe, sensor or
enclosure.

2. The enclosure cover must be closed except during installation or configuration.

3. Mounting F-5400 in direct sunlight can cause the temperature inside the enclosure
to increase beyond design limits, resulting in reduced component life. It is
recommended that a sunshade be installed to avoid direct sunlight (see maximum
enclosure operating temperature specification on p. 33).

4. Ensure the arrow on the meter enclosure is in line with the direction of flow in the
pipe.

5. Do not install the F-5400 enclosure near an igniter, igniter-controller or switching
equipment.

6. Do not install an external power supply in a cabinet containing an igniter controller or
switching equipment.

7. For accurate flow measurement: review flow meter placement instructions before
installation to ensure a proper flow profile in the pipe.

INSTALLATION

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F-5400 Thermal Mass Flow Meter Manual 12/16 - 2031 / 107032 Page 9

Model F-5400

Installation: Insertion Type

Insertion Flow
Meter Lateral
Placement

INSTALLATION

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Instructions for Insertion Flow Meter Lateral Placement

Install the Model F-5400 Insertion style flow meter so that it is far enough away from
bends in the pipe, obstructions, or changes in line sizes to ensure a consistent flow
profile. Review the straight run requirements table on p. 13.

Note: The probe diameter is ¾".

Fig. 2.1: Upstream and Downstream Pipe IDs for Insertion Meters

Proper
Flow
Prole

FLOW

Downstream

Upstream

Do not substitute threaded tees for

the welded branch outlet. Contact

ONICON if you need installation

hardware for threaded pipe.

Irregular Flow
Prole

Note: An irregular flow profile may affect sensor accuracy.

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F-5400 Thermal Mass Flow Meter Manual 12/16 - 2031 / 107032 Page 10

Installation: Insertion Type

Model F-5400

Installation
Hardware

Installation Hardware

ONICON F-5400 Insertion Thermal Mass Flow Meters employ a process adapter
fitting design that allows for insertion and removal without interrupting flow. To take
advantage of this feature, the flow meter must be installed through an isolation valve.
The installation must allow for sufficient overhead clearance to fully extract the meter,
and a full 7/8" hole in the pipe wall is required to clear the sensor head and allow for
insertion. Make sure that your valves and fittings are full port and at least 1" in actual
internal diameter.

Fig. 2.2: Installation Requirements

Standard Installation
Kit for Steel Pipe

CLEARANCE

REQUIRED

FOR INSTALLATION

Typically 30” - 40”

depending on pipe size and

height of valve

assembly.

1” Full Port Ball Valve
1” Close Nipple
1” Branch Outlet

INSTALLATION

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Flow
Conditioners

Minimum Hole Size = 7/8”
Must be centered

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

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

Flow Conditioners

Flow conditioners may be required when an insufficient straight run of pipe is available
upstream of the proposed sensor location. ONICON provides flow conditioners as an
optional accessory.

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F-5400 Thermal Mass Flow Meter Manual 12/16 - 2031 / 107032 Page 11

Flow

Minumum upstream

straight run distance

with conditioner

Minumum

downstream

straight run

distance

Minumum upstream

straight run distance

without conditioner

A

Optional

Flow Conditioner

Model F-5400

Installation: Insertion Type

Optional Flow
Conditioners

INSTALLATION

Fig. 2.3: Placement of Optional Flow Conditioners in Pipe

A

Schedule 40 Flow Conditioners

Nom. Dia. Dimension A

Flow

Flow conditioning

assembly inserted

here

ANSI class flanges

(user supplied)

1½" 6.00"

2" 6.00"

2½" 9.00"

3" 9.00"
4" 9.00"
6" 12.00"

ONICON flow conditioners are designed to be installed between two flanges (provided
by installer) that are located a specific distance upstream of the flow sensor. The use
of flow conditioners significantly reduces the upstream straight pipe length requirement
for flow sensor. The size of the flow conditioner must match the pipe size.

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Installation: Insertion Type

Fig. 2.4: Straight Run Requirements for Upstream Obstructions - Insertion

Model F-5400

Straight run required

Upstream obstruction

Single bend preceded by ≥ 9

diameters of straight pipe

Pipe size reduction in straight pipe
run

Multiple bends in plane with < 9
diameters of straight pipe between
them

Pipe size expansion in straight run 30 Diameters 10 Diameters 5 Diameters

Tees 30 Diameters 10 Diameters 5 Diameters

Multiple bends out of pipe 40 Diameters 10 Diameters 5 Diameters

Modulating or regulating valve 40 Diameters 10 Diameters 5 Diameters

upstream of meter location
without flow conditioner

15 Diameters 3 Diameters 5 Diameters

15 Diameters 3 Diameters 5 Diameters

20 Diameters 9 Diameters 5 Diameters

Straight run required
upstream of flow
conditioner mounting flange

Straight run required
downstream of meter
location

Important Note: Always use the maximum available straight run. When more than

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the minimum required straight run is available place the meter such that the excess
straight run is upstream of the meter location.

Sensor

Fig. 2.5: Orientation of Flow Meter

Orientation
Direction of
Flow

INSTALLATION

ARROW ON ENCLOSURE
INDICATES DIRECTION OF
FLOW

PIPE

FLOW

Install the meter with the flow direction arrow on the enclosure pointing in the direction
of flow in the pipe.

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F-5400 Thermal Mass Flow Meter Manual 12/16 - 2031 / 107032 Page 13