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SYSTEM-20

Onicon SYSTEM-20 Installation And Operation Manual

SYSTEM-20 BTU METER
Installation and Operation Guide
11451 Belcher Road South, Largo, FL 33773 • USA • Tel +1 (727) 447-6140 • Fax +1 (727) 442-5699
2051-1 / 36985
For Software Version 0.1.15 and Higher
www.onicon.com • sales@onicon.com
03-18
SAFETY INFORMATION
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This meter was calibrated at the factory prior to 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.
• 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.
IMPORTANT NOTE
TABLE OF CONTENTS
1.0 INTRODUCTION ...................................................................................................... 5
1.1 PURPOSE OF THIS GUIDE ........................................................................... 5
1.2 TYPICAL SYSTEM-20 BTU METER ............................................................. 5
1.3 STANDARD FEATURES AND SPECIFICATIONS ........................................ 5
1.4 ADDITIONAL REQUIRED HARDWARE ....................................................... 6
1.5 WORKING ENVIRONMENT ......................................................................... 6
1.6 WARRANTY & SERIAL NUMBER ................................................................ 7
2.0 UNPACKING ... .......................................................................................................... 7
2.1 CHECKING THAT YOU HAVE RECEIVED EVERYTHING .......................... 7
3.0 INSTALLATION ........................................................................................................ 8
3.1 SITE SELECTION ........................................................................................... 8
3.2 MECHANICAL INSTALLATION ................................................................... 9
3.2.1 Mounting the Enclosure ................................................................. 10
3.2.2 Thermowell Installation ................................................................. 11
3.2.2.1 Standard Thermowells ..................................................... 11
3.3.2.2 Hot Tap Thermowells ....................................................... 11
3.2.3 Temperature Sensor Installation .................................................... 13
3.2.3.1 ONICON Standard Temperature Sensor Installation ...... 13
3.3 POWER & SIGNAL WIRING CONNECTIONS ............................................ 15
4.0 SYSTEM-20 START UP & COMMISSIONING ...................................................... 16
4.1 START UP ..................................................................................................... 16
4.1.1 Single and Dual Mode Display Pages ............................................ 17
4.1.2 Additional Display Pages ............................................................... 17
4.2 COMMISSIONING ........................................................................................ 19
4.2.1 Commissioning Following Initial Power-up.................................. 19
4.3 SEALING THE METER ................................................................................ 22
5.0 DIAGNOSTIC FUNCTIONS ................................................................................... 22
6.0 BACnet
®
MS/TP ...................................................................................................... 23
6.1 BACnet® OBJECT TYPES ............................................................................. 23
6.2 PROTOCOL IMPLEMENTATION STATEMENT ........................................ 23
6.3 DEVICE OBJECT .......................................................................................... 24
6.4 ANALOG INPUT(S) ..................................................................................... 25
6.5 ANALOG VALUE(S) .................................................................................... 25
6.6 BINARY VALUE(S) ...................................................................................... 27
6.7 MULTI STATE VALUE .................................................................................. 28
6.8 TREND LOG MULTIPLE .............................................................................. 29
7.0 MODBUS
7.1 MODBUS
®
........................................................................................................ 30
®
MEMORY MAP ......................................................................... 31
7.2 DIAGNOSTIC FUNCTION CODE ................................................................. 38
7.3 REPORT SLAVE ID FUNCTION CODE ........................................................ 39
APPENDIX A
A-1 SYSTEM-20 WIRING DIAGRAM
A-2 SYSTEM-20 WIRING TABLES
A-4 CHANGING RS485 SETTINGS OR METER PROGRAMMING AFTER
COMMISSIONING
A-5 SYSTEM-20 DRILLING TEMPLATE
A-6 OUTDOOR THERMOWELL ASSEMBLY
SECTION 1.0: INTRODUCTION
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ONICON
1.1 PURPOSE OF THIS GUIDE
The purpose of this guide is to provide installation and commissioning procedures, and basic operating and servicing instructions for the ONICON System-20 BTU Meter.
WARNING
Only qualied service personnel should attempt to install or service this product. Serious injury may result from the improper installation or use of this product.
1.2 TYPICAL SYSTEM-20 BTU METER
ONICON’s System-20 is a true heat (Btu) computer, which accepts data from several sensors, performs a series of computations with that data, and displays and/or transmits the results as an indication of the amount of heat (Btus) being transferred per unit time or as a totalized amount.
ONICON F-3500
Flow Meter
(F-3500 must be
ordered separately)
Supply Temp
Sensor
Power / Output
24V AC/DC Power
RS-485
(BACnet or MODBUS)
3 Pulse Outputs 1 Analog Output
Up To Three
Pulse Inputs for
Water Meter
Gas Meter
Electric Meter
etc.
Made in the USA
SYSTEM-20
BTU METER
FLOW
Heat Exchanger
Supply
Return Temp
Sensor
Return
1.3 STANDARD FEATURES AND SPECIFICATIONS
• Single mode Btu calculations, in either the heating or cooling mode, are totalized, and displayed.
• Two-pipe dual mode Btu calculations in both the heating mode and the cooling modes, are totalized and displayed.
®
• A single isolated RS485 serial interface is provided for BACnet
MS/TP or MODBUS® RTU.
• Three eld congurable pulse outputs may be used for totalization, alarm indication and mode status.
• Three auxiliary pulse inputs may be used to totalize data from external devices. This data may also be transmitted via the network interface and viewed on the local display.
• A single eld congurable isolated analog output is provided for energy rate, ow rate or temperature.
1.4 ADDITIONAL REQUIRED HARDWARE
The System-20 must be connected to a suitable volumetric ow meter and a matched pair of temperature sensors in order to calculate and report heat data.
Flow Meter Model Line Sizes
F-1100 Single Turbine Insertion Flow Meter
F-1200 Dual Turbin Insertion Flow Meter
F-1300 Inline Turbine Flow Meter
F-3500 Insertion Electromagnetic Flow Meter
F-2600 Series Vortex Flow Meter
F-3000 Series Inline Electromagnetic Flow Meters
F-4300 Clamp-on Ultrasonic Flow Meter
F-4600 Inline Ultrasonic Flow Meter
1 ¼" and larger 25
2 ½" and larger 15
¾" and 1" 25
1 ¼" and larger See manual
1" - 12" See manual
¼" and larger 5
2" and larger See manual
½" - 2 ½" See manual
Straight Run
Required
Notes
Can be used in 1" copper lines
For use in higher temperature applications
Please refer to ONICON’s ow meter literature, or contact ONICON for help in selecting the ow meter that will best t your requirements.
Temperature/Sensors
ONICON Standard Temperature Sensors (32° – 200° F)
Pair of solid state temperature sensors with 0 – 20 mA outputs. Suitable for use with uid temperatures up to 200° F.
Platinum RTD Temperature Sensors (32° – 250° F)
Pair of 4-wire 1000 Ω Platinum RTD temperature sensors. Suitable for use with uid temperatures up to 250° F.
Please refer to ONICON’s System-20 product literature, or contact ONICON for help in selecting the temperature sensors and thermowells that will best t your requirements.
1.5 WORKING ENVIRONMENT
The System-20 was designed for installation and use in typical domestic and commercial environments that are free of corrosive liquids and fumes, direct liquid exposure, temperature extremes and vibrations.
The System-20 may be installed outdoors in protected spaces away from direct sunlight, rain, sleet or snow.
The operating ambient air temperature range is -13° F to 140° 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
Warranty
ONICON provides a 2-year warranty for this product. Certain exclusions apply. Please refer to ONICON’s Conditions of Sale for details.
Serial Number
The serial number of your System-20 is located on the top and inside the enclosure. The serial number is a unique identier for the product. Please have this number available when contacting ONICON for assistance.
SECTION 2.0: UNPACKING
The System-20 is generally shipped in one package unless optional hardware or equipment is ordered. (Thermowells may have been shipped in advance.)
2.1 CHECKING THAT YOU HAVE RECEIVED EVERYTHING
Please notify ONICON immediately if any of these items are missing.
• Standard Documentation Includes:
The System-20 BTU Meter Installation and Operation Guide The System-20 Certicate of Calibration
• The System-20 Remove the System-20 from the shipping carton and inspect it for physical damage. Notify the freight carrier and ONICON immediately if any items are damaged in transit. Save all packaging.
Btu meters ordered with a ow meter and temperature sensors will be delivered congured and programmed for use together as a system. The System-20 and the temperature sensor serial numbers will match. The ow meter serial number will be shown on the certicate of calibration and on the System-20 display.
• Temperature Sensors
If ordered, temperature sensors will generally be packed in the same carton with the System-20. Inspect the sensors and cables for damage. Each sensor will have a label attached with a serial number.
• Flow Meter
If ordered, the ow meter will be packaged in a separate carton. The ow meter ordered with this Btu meter came complete with an instruction manual. Please refer to it for detailed information regarding its installation, commissioning, and operation.
• Flow Meter & Temperature Sensor Installation Hardware
Installation hardware is ordered separately from the System-20, temperature sensors and ow meter. Note that this hardware is frequently shipped in advance of the meter(s).
SECTION 3.0: INSTALLATION
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The System-20 BTU Meter should be installed by personnel with related knowledge and experience in the heating, cooling, and uid metering elds. ONICON is available to assist with technical recommendations and to provide guidance by telephone and/or e-mail during the installation and commissioning process. On-site eld engineering, installation, and service are also available at an additional cost. The installer should use good trade practices and must adhere to all state and local building codes.
Before you begin, clean the external surfaces of all pipes at the installation sites so that they are free of debris, foreign matter, solids, leak inhibitors, and chemically aggressive substances. Flush the entire system so that it is free of ux, solder, pipe and tube cuttings and any other debris.
3.1 SITE SELECTION
Careful attention to the site selection for the system components will help ensure an accurate energy measurement, help the installers with the initial installation, reduce start-up problems, and make future maintenance easier. For example, do not install the ow meter where it will be difcult for personnel to perform periodic maintenance. When selecting a site for mounting the components, refer to Section 1.5: WORKING ENVIRONMENT, as well as the following:
IMPORTANT NOTE
Proper site selection is critical to the performance of this Btu meter. Both the ow sensor and the temperature sensors must be properly located within the piping system in order to ensure an accurate energy measurement.
• The System-20
Find an easily accessible location where eld wiring connections can be made and meter readings can be taken from oor level. Mount the enclosure on a vibration free surface. Avoid locations such as the plenum of a fan coil, heat exchanger or any housing that may contain electric motors or other strong sources of electrical interference.
• The Flow Meter
When properly installed, the ow meter will only measure ow associated with that portion of the piping system for which the energy measurement is being made. The ow meter may be installed in either the supply or return line. Choose the location with the longest straight run of unobstructed pipe. Please refer to the ow meter installation manual for specic information regarding the straight run requirements for the ow meter.
• The Temperature Sensors
The two temperature sensors must be located so they accurately measure only the temperature of the supply line entering and the return line leaving the portion of the piping system for which the energy measurement is being made.
If possible, nd an easily accessible location where eld wiring connections can be made from oor level. This will facilitate future service. Place the temperature sensors away from strong sources of electrical noise that might affect the performance of the sensors.
One temperature sensor thermowell will need to be placed in the same pipe with the ow meter. It must be located at least ve pipe diameters downstream of the ow meter leaving enough clearance to remove either sensor from the pipe without interference from the other sensor.
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7 5/8"
5 1/2"
5"
∅ 0.875" 5pl
∅ 0.200" 4pl
SYSTEM-20
BTU METER
!
3.2 MECHANICAL INSTALLATION
IMPORTANT NOTE
The components of the ONICON System-20 BTU Measurement System must be congured, programmed and installed together as a system. Mixing components from different systems may result in signicant measurement errors.
• Find an easily accessible location where electrical connections can be made and meter readings can be taken from the oor level.
• Mount the Btu meter on a vibration-free surface. Avoid sites such as the plenum of a fan coil, heat exchanger, or other housings containing motors.
• The meter must be installed in protected spaces away from direct sunlight, rain, sleet or snow.
DO NOT drill holes in the enclosure. Use only the openings that are provided.
CAUTION
3.2.1 Mounting the Enclosure
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Use four screws for mounting the Btu meter. The mounting surface must be structurally sound and capable of withstanding a minimum weight of 40 lbs (18 kg).
Use the following screws for mounting.
• Four Machine screws - #10-24 X 1.5”
• Four Wood screws - No. 10 X 1.5”
• Four Concrete screws - 3/16” X 1.5” with ¼" maximum hex, Phillips or slot heads
Four mounting holes have been provided in the base of the enclosure shown below. Push out the rubber seals by inserting the mounting screws. Use the drilling template provided in Appendix 5 of this manual to drill the 4 holes required to mount the enclosure.
Mounting Holes
A DIN rail mounting hardware kit has been provided with this meter. Mount the DIN rail clips as shown below.
CAUTION
DO NOT USE THE ENCLOSURE AS A TEMPLATE FOR DRILLING HOLES. Do not drill holes in the enclosure. Use only the openings that are provided.
3.2.2 Thermowell Installation
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It is important that no dirt or other foreign material be allowed into the thermowells as this could affect the thermal response of the system.
3.2.2.1 Standard Thermowells
Standard thermowells are for new construction or scheduled shutdown. The most common installation methods are shown below. Refer to Appendix A-6 for thermal insulator installations. Consult ONICON for special applications.
IMPORTANT NOTE
NOTES: 1. Thermowell length varies with pipe size.
2. Use no additional bushings to ensure that tip of thermowell is inserted into ow stream.
3.2.2.2 Hot Tap Thermowells
Hot tap thermowells are designed for retrot applications where it is not practical to isolate and drain the pipe section prior to installation. The thermowell is installed through a 1” full port ball valve as shown in the drawing on next page. A wet tap drilling machine equipped with a installation.
Install the valve assembly as shown in the drawing on the next page and then drill the been installed and the hole has been drilled, the thermowell can be inserted into the ow stream without a system shutdown.
7/8” hole using the wet tap drilling machine. Once the valve assembly has
7/8” drill is required to perform this type of
WARNING
SYSTEM MAY BE UNDER HIGH PRESSURE. Be sure to hold the conduit box rmly by hand before
slowly loosening the position clamping nut when installing, adjusting or removing the thermowell. Failure to do this will allow the pressure to suddenly and rapidly force the thermowell from the pipe, potentially causing serious injury. The thermowell could also be damaged or break apart causing a break in the water seal resulting in the loss of large amounts of water.
INSERTION OF THE HOT TAP THERMOWELL
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1. Calculate the insertion force (lbs) required by multiplying the system pressure (psig) by 0.11. The person inserting the thermowell should ensure adequate footing for the force required prior to opening the valve.
2. After applying thread seal tape, thread the hot tap adapter into the valve. Firmly grasp the wiring enclosure, loosen the position clamping nut, open the valve, and carefully push the thermowell into the ow stream. Use the at­tached gauge to set the insertion depth.
CAUTION
Excessive vibration can damage the thermowell. Insert the thermowell to the proper depth using gauge supplied as shown. Reduce the insertion depth as necessary if strong vibrations are felt during insertion, making certain that the tip of the thermowell remains fully in the ow stream.
3. Carefully tighten the position clamping nut that is located at the top of the 1" NPT hot tap adapter tting. Do not release the wiring enclosure until the position clamping nut has been tightened.
CAUTION
DO NOT OVER TIGHTEN THE POSITION CLAMPING NUT. If uid leaks, do not attempt to correct by tightening this nut further. An internal o-ring seals the uid. Contact ONICON for assistance in the event of a leak.
REMOVAL OF THE HOT TAP THERMOWELL
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WARNING
Maintain a rm hold on the wiring enclosure until the thermowell is completely withdrawn and the valve is closed.
1. System pressure will try to push the thermowell out of the ow stream when the clamping nut is released. Be sure to establish safe footing prior to loosening the clamping nut. The force pushing out against the thermowell is the same as the insertion force.
2. Grasp the wiring enclosure rmly, holding the thermowell in the pipe and then loosen the position clamping nut. Slowly withdraw the thermowell from the pipe.
3. After the thermowell is completely withdrawn, carefully close the isolation valve.
IMPORTANT NOTE
Rotating the thermowell as you slowly withdraw it through the valve will ensure that the lower tip is fully withdrawn and completely free of the valve. If resistance is felt when closing the valve, open valve fully and rotate the well as you pull it further out of the pipe.
3.2.3 Temperature Sensor Installation
When ordered with the System-20, temperature sensors are factory matched and tagged by serial number to a specic Btu meter. ONICON standard temperature sensors are also designated and labeled as the SUPPLY or RETURN sensor and must be installed per these labels.
3.2.3.1 ONICON Standard Temperature Sensor Installation
ONICON standard temperature sensors must be used as a pair to maintain differential accuracy. They are also designated and labeled as the SUPPLY or RETURN sensor and must be installed accordingly. To install, apply a thin coat of thermal compound to the sensor tip area and insert it all the way into the thermowell until it contacts the bottom of the cavity. Gently tighten the retainer nut. DO NOT OVER TIGHTEN. The thermowell completely seals the plumbing system without the retainer nut. The only purpose for the nut is to ensure that the sensor tip will remain in contact with the bottom of the thermowell.
STANDARD THERMOWELL ASSEMBLY
FOR SYSTEM-10 BTU METER
SHOWN WITH TEMPERATURE SENSOR
TEMPERATURE
SENSOR
PLASTIC
END PIECE
SPACER SLEEVE (Length varies with thermowell length)
ELECTRONICS
MODULE
SUPPLY
S/N 123456
SIGNAL
(RED)
REFERENCE
(BLACK)
!
TEMPERATURE SENSOR
TEMPERATURE SENSOR INSTALLED IN THERMOWELL
PLACE ELECTRONICS MODULE IN BOX AFTER CONNECTING WIRES.
RETAINING NUT (Do NOT Overtighten)
REFERNECE (BLACK)
SIGNAL
S/N 123456
SUPPLY
(RED)
PROVIDE #18-22 TWISTED
1/2” HOLE FOR CONDUIT OR STRAIN RELIEF FITTING
SHIELDED PAIR. COIL ONE
FOOT OF EXTRA CABLE IN CONDUIT BOX.
CAUTION
DO NOT OVERTIGHTEN. The thermowell completely seals the plumbing system. Screwing in the sensor just ensures that the sensor tip will remain in contact with the bottom of the thermowell.
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