Sierra FLO 220 User Manual

Page 1
Series 220/221 Instruction Manual Table of Contents
Sierra Series 220 and 221
Innova-Flo™ Vortex Flow Meters
IMPORTANT: This manual is for use with 220/221 Vortex Products purchased February 2006 or later
Instruction Manual
Part Number IM-22
Feb. 2006 Rev. B
CORPORATE HEADQUARTERS
5 Harris Court, Building L Monterey, CA 93940
Phone (831) 373-0200 (800) 866-0200 Fax (831) 373-4402
www.sierrainstruments.com
EUROPE HEADQUARTERS
Bijlmansweid 2 1934RE Egmond aan den Hoef
The Netherlands
Phone +31 72 5071400 Fax +31 72 5071401
ASIA HEADQUARTERS
Rm. 618, Tomson Centre, Bldg A, 188 Zhang Yang Road
Phone: + 8621 5879 8521 Fax: +8621 5879 8586
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Table of Contents Series 220/221 Instruction Manual
Customer Notice
Unless you have specifically ordered Sierra’s optional O2 cleaning, this flow meter may not be fit for oxygen service. Sierra Instruments, Inc., is not liable for any damage or personal injury, whatsoever, resulting from the use of Sierra Instru­ments standard mass flow meters for oxygen gas. You are responsible for clean­ing the mass flow meter to the degree required for your oxygen flow application.
© COPYRIGHT SIERRA INSTRUMENTS 1997 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 Sierra Instruments. The information contained in this manual is subject to change without notice.
TRADEMARKS Innova-Flo™ is a trademark of Sierra Instruments, Inc. Other product and company names listed in this manual are trademarks or trade names of their respective manufacturers.
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Series 220/221 Instruction Manual Table of Contents
Table of Contents
Chapter 1 Introduction
Innova-Flo™ Vortex Flow Meters........................................................ 1-1
Using this Manual .........................................................................1-1
Note and Safety Information.........................................................1-2
Receipt of System Components ....................................................1-2
Technical Assistance.....................................................................1-2
How the Innova-Flo Vortex Flow Meter Operates..............................1-3
Velocity Measurement/Pressure Drop........................................... 1-3
Flow Meter Configurations.................................................................. 1-7
Chapter 2 Installation
Installation Overview........................................................................... 2-1
Flow Meter Installation Requirements..........................................2-1
Unobstructed Flow Requirements.................................................2-2
Series 220 In-Line Flow Meter Installation.........................................2-3
Wafer-Style Flow Meter Installation............................................. 2-4
Flange-Style Flow Meter Installation............................................ 2-5
Series 221 Insertion Flow Meter Installation....................................... 2-6
Cold Tap Guidelines......................................................................2-7
Hot Tap Guidelines ....................................................................... 2-8
Flow Meter Insertion ...........................................................................2-9
Installing Meters with a Compression Connection .....................2-10
Installing Meters with a Packing Gland Connection...................2-12
Installing Meters (Packing Gland), No Insertion Tool................2-15
Adjusting Meter Orientation.............................................................. 2-17
Display/Keypad Adjustment ....................................................... 2-17
Enclosure Adjustment................................................................. 2-18
Wiring Connections........................................................................... 2-19
Input Power Connections............................................................ 2-19
Pulse Output Connections...........................................................2-21
Remote Electronics Wiring......................................................... 2-22
Chapter 3 Operating Instructions
Flow Meter Display/Keypad................................................................ 3-1
Start Up................................................................................................ 3-2
Using the Setup Menus........................................................................ 3-3
Programming the Flow Meter....................................................... 3-3
Output Menu .................................................................................3-4
Display Menu................................................................................3-5
Totalizer Menu..............................................................................3-6
Units Menu....................................................................................3-7
Diagnostics Menu.......................................................................... 3-8
Calibration Menu .......................................................................... 3-9
Password Menu........................................................................... 3-10
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Table of Contents Series 220/221 Instruction Manual
Chapter 4 HART Communications
Wiring ................................................................................................. 4-1
HART Menus ...................................................................................... 4-2
Fast Key Sequence ..............................................................................4-3
Fast Key Sequence (continued) ..........................................................4-4
Chapter 5 Troubleshooting and Repair
Hidden Diagnostics Menus.................................................................. 5-1
Column One Hidden Diagnostics Values...................................... 5-2
Column Two Hidden Diagnostics Values..................................... 5-3
Analog Output Calibration ..................................................................5-4
Troubleshooting the Flow Meter .........................................................5-4
Symptom: Output at no Flow........................................................ 5-4
Symptom: Erratic Output.............................................................. 5-4
Symptom: No Output.................................................................... 5-5
Electronics Assembly Replacement..................................................... 5-6
Returning Equipment to the Factory.................................................... 5-7
Appendix A Product Specifications Appendix B Glossary
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Series 220/221 Instruction Manual Table of Contents
Warnings and Cautions
Warning!
Agency approval for hazardous location installations varies between flow meter models. Consult the factory for specific flow meter approvals before any hazardous location instal­lation. For explosion proof installations, you must use solid metal conduit and follow NFPA (or your local code) approved wiring methods.
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 flow meter connections, isolation valves and fittings for cold/hot tapping must have the same or higher pressure rating as the main pipeline.
For Series 221 insertion flow meter installations, an insertion tool must be used for any installation where a flow meter is inserted under pressure greater than 50 psig.
To avoid serious injury, DO NOT loosen a compression fitting under pressure. All wiring procedures must be performed with the power Off. Before attempting any flow meter repair, verify that the line is de-pressurized. Always remove main power before disassembling any part of the mass flow meter.
Caution!
Calibration must be performed by qualified personnel. Sierra Instruments, Inc., strongly rec­ommends that you return your flow meter to the factory for calibration.
In order to achieve accurate and repeatable performance, the flow meter must be in­stalled with the specified minimum length of straight pipe upstream and downstream of the flow 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 flow before installing the flow meter.
Wafer-style flow meter gaskets must be carefully aligned to ensure accurate flow meas­urement.
For Series 221 insertion flow meter installations, the sensor alignment pointer must point downstream in the direction of flow.
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Table of Contents Series 220/221 Instruction Manual
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Series 220/221 Instruction Manual Chapter 1 Introduction
Chapter 1 Introduction
Innova-Flo™ Vortex Flow Meters
The Sierra Instruments’ Series 220 In-Line and the Series 221 Insertion Innova-Flo™ Vortex Flow Meters provide a reliable solution for process flow measurement. From a single entry point in the pipeline, Innova-Flo meters offer precise measurements of mass or volumetric flow. The ve­locity sensor reduces the effects of pipeline vibration by incorporating a unique piezoelectric element that senses the vortex frequency. To extend rangeability at the low end of flow, the meter’s smart electronics calcu­lates the Reynolds number (Re) based on constant values of fluid density and viscosity stored in memory and automatically corrects for any non­linearity down to Re = 5,000.
Innova-Flo digital electronics allows reconfiguration for most gases, liq­uids and steam. The instrument is loop powered (12 to 36 VDC) with two output signals. The pulse output signal is proportional to volumetric flow rate; the analog linear 4-20 mA signal offers your choice of volu­metric flow rate or mass flow rate. The mass flow rate is based on a con­stant value for fluid density stored in the instrument’s memory. The local keypad/display provides instantaneous flow rate in engineering units or totalized flow.
The Sierra Series 220 and 221 Innova-Flo Meters simple installation combines with an easy-to-use interface that provides quick set up, long term reliability and accurate flow measurement over a wide range of flows and conditions.
Using This Manual
This manual provides the information needed to install and operate the Series 220 In-Line and Series 221 Insertion Innova-Flo Vortex Flow Me­ters. The four chapters of this manual cover these areas:
Chapter 1 includes the introduction and product description
Chapter 2 provides information needed for installation
Chapter 3 describes system operation and programming
Chapter 4 covers troubleshooting and repair
The product specifications are found in Appendix A. Appendix B con­tains a glossary of terms.
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Chapter 1 Introduction Series 220/221 Instruction Manual
Note and Safety Information
We use note, caution and warning statements throughout this book to draw your attention to important information.
Warning!
This statement appears with information that is important to protect people and equipment from damage. Pay very close attention to all warnings that apply to your application.
Caution!
This statement appears with information that is important for protecting your equipment and performance. Read and follow all cautions that apply to your application.
Receipt of System Components
When receiving a Sierra flow 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 first con­tacting Sierra Customer Service.
Technical Assistance
If you encounter a problem with your flow meter, review the configura­tion 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 Chapter 4, Troubleshooting, for specific information and recommendations.
If the problem persists after following the troubleshooting procedures outlined in Chapter 4, contact Sierra Instruments, Technical Support at (800) 866-0200 or (831) 373-0200 between 8:00 a.m. and 5:00 p.m. PST. When calling Technical Support, have the following information on hand:
the flow range, serial number and Sierra order number (all
marked on the meter nameplate)
the problem you are encountering and any corrective action
taken
application information (gas, pressure, temperature and pip-
ing configuration)
Note
This statement appears with a short message to alert you to an important detail.
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Series 220/221 Instruction Manual Chapter 1 Introduction
How the Innova-Flo Vortex Flow Meter Operates
Figure 1-1. Series 220 In-Line Vortex Flow Meter
Sierra Series 220 and 221 Innova-Flo™ Vortex Flow Meters use a unique velocity sensor head to monitor volumetric flow rate. The built-in flow computer calculates mass flow rate based on a constant value of fluid density stored in the instrument’s memory. To measure fluid velocity, the flow meter incorporates a bluff body (shedder bar) in the flow stream, and the velocity sensor measures the frequency of vortices cre­ated by the shedder bar. The velocity sensor head is located downstream of the shedder bar within the flow body.
Velocity Measurement
The Innova-Flo 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 flow measurement with vortex flow 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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Chapter 1 Introduction Series 220/221 Instruction Manual
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 Innova-Flo
Vortex Flow Meter computes the total
fluid volume.
Velocity sensor
Vortex shedder bar
Flow
Constant wave length
Vortices
Figure 1-2. Measurement Principle of Vortex Flow Meters
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 flowing downstream of the vortex shedder bar. The alternating electric charge generated by the piezoelec­tric element 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 flows, pressures and temperatures.
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Series 220/221 Instruction Manual Chapter 1 Introduction
Flow Velocity Range
To ensure trouble-free operation, vortex flow meters must be correctly sized so that the flow velocity range through the meter lies within the measurable velocity range (with acceptable pressure drop) and the linear range.
The measurable range is defined by the minimum and maximum velocity using the following table.
Vmin Vmax 300 ft/s 30 ft/s
Vmin Vmax 91 m/s 9.1 m/s
Gas Liquid
37
25
ρ
ft/s
ρ
m/s
1 ft/s
0.3 m/s
English
Metric
ρ
(lb/ft3)
ρ
(kg/m3)
The pressure drop for series 221 insertion meters is negligible. The pres­sure drop for series 220 in-line meters is defined as:
2
P = .00024 ρ V P = .000011 ρ V
English units (P in psi, ρ in lb/ft3, V in ft/sec)
2
Metric units (P in bar, ρ in kg/m3, V in m/sec)
The linear range is defined by the Reynolds number. The Reynolds num­ber is the ratio of the inertial forces to the viscous forces in a flowing fluid and is defined as:
Where
Re =
ρ V D
µ
Re = Reynolds Number ρ = mass density of the fluid being measured V = velocity of the fluid being measured D = internal diameter of the flow channel µ = viscosity of the fluid being measured
The Strouhal number is the other dimensionless number that quantifies the vortex phenomenon. The Strouhal number is defined as:
Where St = Strouhal Number
f = frequency of vortex shedding d = shedder bar width V = fluid velocity
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St =
f d
V
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Chapter 1 Introduction Series 220/221 Instruction Manual
As shown below, Innova-Flo™ Vortex Flow Meters exhibit a constant Strouhal number across a large range of Reynolds numbers, indicating a consistent linear output over a wide range of flows and fluid types. Be­low this linear range, the intelligent electronics in Innova-Flo automati­cally corrects for the variation in the Strouhal number. Innova-Flo’s smart electronics correct for this non-linearity by calculating the Rey­nolds number based on constant values of the fluid’s density and viscos­ity stored in the instrument’s memory. Innova-Flo Vortex Flow Meters automatically correct down to a Reynolds number of 5,000.
0.3
Corrected range
Linear range
0.2
0.1
Strouhal Number, St
0.0
34
10
10
5000
5
10 10
Reynolds Number, Re
10
6
10
7
8
Figure 1-3. Reynolds Number Range for the Innova-Flo Meter
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Series 220/221 Instruction Manual Chapter 1 Introduction
Flow Meter Configurations
Innova-Flo™ Vortex Flow Meters are available in two configurations:
Series 220 in-line flow meter (replaces a section of the pipeline)
Series 221 insertion flow meter (requires a “cold” tap or a “hot” tap
into an existing pipeline)
Both the in-line and insertion configurations are similar in that they both use identical electronics and have similar sensor heads. Besides installa­tion differences, the main difference between an in-line flow meter and an insertion flow meter is their method of measurement.
For an in-line vortex flow meter, the shedder bar is located across the en­tire diameter of the flow body. Thus, the entire pipeline flow is included in the vortex formation and measurement. The sensing head, which di­rectly measures velocity is located just downstream of the shedder bar.
An insertion vortex flow meter has its sensing head at the end of a 0.750 inch diameter tubular stem. The stem is inserted into the pipe until the sensing head is properly located in the pipe’s cross section. The sensing head fits through any entry port with an 1.875 inch minimum internal di­ameter.
The sensing head of an insertion vortex flow 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 flow meter computes the Reynolds number based on constant values of the fluid’s density and vis­cosity stored in its memory and then computes the total flow rate in the channel. The output signal of insertion meters is the total flow rate in the channel. The accuracy of the total flow rate computation depends on ad­herence to the piping installation requirements given in Chapter 2. If ad­herence to those guidelines cannot be met, contact the factory for specific installation advice.
Flow Meter Electronics
Innova-Flo electronics are available mounted directly to the flow body, or remotely mounted. The electronics housing may be used indoors or outdoors, including wet environments. The instrument requires 4-20 mA loop power (12 to 36 VDC). One analog output signal is available for your choice of volumetric flow rate or mass flow rate. A pulse output is available for totalization.
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Chapter 1 Introduction Series 220/221 Instruction Manual
The meter includes a local 2 x 16 character LCD display housed within the enclosure. Local operation and reconfiguration is accomplished using six push buttons. For hazardous locations, the six push buttons can be operated through the sealed enclosure using a hand-held magnet, thereby not compromising the integrity of the hazardous location certification.
The electronics include nonvolatile memory that stores all configuration information. The memory allows the flow meter to function immediately upon power up, or after an interruption in power.
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Series 220/221 Instruction Manual Chapter 2 Installation
Warning!
Consult the flow meter name-
plate for specific flow meter
approvals before any hazard-
ous location installation.
Chapter 2 Installation
Installation Overview
Innova-Flo™ meter installations are simple and straightforward. Both the Se­ries 220 In-Line and Series 221 Insertion type flow meter installations are covered in this chapter. After reviewing the installation requirements given below, see page 2-3 for Series 220 installation instructions. See page 2-6 for Series 221 installation instructions. Wiring instructions begin on page 2-19.
Flow Meter Installation Requirements
Before installing the flow meter, verify the installation site allows for these considerations:
1. Line pressure and temperature will not exceed the flow meter
rating.
2. The location meets the required minimum number of pipe di-
ameters upstream and downstream of the sensor head as illus­trated Figure 2-1.
3. Safe and convenient access with adequate overhead clearance
for maintenance purposes.
4. Verify that the cable entry into the instrument meets the specific
standard required for hazardous area installations.
5. For remote installations, verify the supplied cable length is suf-
ficient to connect the flow meter sensor to the remote electron­ics.
Also, before installation check your flow system for anomalies such as:
leaks
valves or restrictions in the flow path that could create disturbances in
the flow profile that might cause unexpected flow rate indications
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Chapter 2 Installation Series 220/221 Instruction Manual
Unobstructed Flow Requirements
Select an installation site that will minimize possible distortion in the flow profile. Valves, elbows, control valves and other piping components may cause flow disturbances. Check your specific piping condition against the ex­amples shown below. In order to achieve accurate and repeatable perform­ance install the flow 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 flow in the downward direction because the pipe may not be full at all points. Choose to install the meter with flow in the upward direction if possible.
AB
AB
C' C
Flow meter
Flow conditioner
(if used)
Example 1. One 90° elbow before meter
Flow meter
Example 4. Reduction before meter
AB
AB
C
C'
Example 2. Two 90° elbows before meter in one plane
Flow meter
Flow conditioner
(if used)
Example 5. Expansion before meter
C' C
Flow meter
Flow conditioner
(if used)
AB
AB
C
C'
Example 3. Two 90° elbows before meter out of plane (if three 90° bends present, double recommended length)
Flow meter
Flow conditioner
(if used)
C' C
Example 6. Regulator or valve partially closed before meter (If valve is always wide open, base length requirements on fitting directly preceding it)
Flow meter
Flow conditioner (if used)
Minimum Required
Upstream Diameters
No Flow
Conditioner
With Flow Conditioner
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 5 D 5 D 5 D 5 D 3 25 D 10 D 5 D 5 D 10 D 5 D 4 10 D 10 D 5 D 5 D 5 D 5 D 5 20 D 10 D 5 D 5 D 5 D 5 D 6 25 D 10 D 5 D 5 D 10 D 5 D
D = Internal diameter of channel. N/A = Not applicable
Minimum Required
Downstream Diameters
No Flow
Conditioner
With Flow
Conditioner
Figure 2-1. Recommended Pipe Length Requirements for Installation, Series 220 and 221
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Series 220/221 Instruction Manual Chapter 2 Installation
Series 220 In-Line Flow Meter Installation
Install the Series 220 In-Line Flow Meter between two conventional pipe flanges as shown in Figures 2-3 and 2-4. Table 2-1 provides the recom­mended minimum stud bolt lengths for wafer-style meter body size and dif­ferent flange ratings.
The meter 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.
Series 220 Meters require customer-supplied gaskets. When selecting gasket material make sure that it is compatible with the process fluid and pressure ratings of the specific installation. Verify that the inside diameter of the gas­ket is larger than the inside diameter of the flow meter and adjacent piping. If the gasket material extends into the flow stream, it will disturb the flow and cause inaccurate measurements.
Flange Bolt Specifications
Stud Bolt Lengths for Each Flange Rating (inches)
Line Size Class 150 Class 300 Class 600
1 inch 6.00 7.00 7.50
1.5 inch 6.25 8.50 9.00 2 inch 8.50 8.75 9.50 3 inch 9.00 10.00 10.50 4 inch 9.50 10.75 12.25
Table 2-1. 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.
1
34
2
1
8
6
5
34
7
2
4
10
4-bolt 8-bolt 12-bolt
1
12
8
6
5
9
3
7
11
2
Figure 2-2. Flange Bolt Torquing Sequence
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Chapter 2 Installation Series 220/221 Instruction Manual
Wafer-Style Flow Meter Installation
Install the wafer-style meter between two conventional pipe flanges of the same nominal size as the flow meter. If the process fluid 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 flow me­ters are not suitable for two-phase flows (i.e., liquid and gas mixtures). For horizontal pipelines having a process temperature above 300° F, mount the meter at a 45 or 90-degree angle to avoid overheating the electronics enclo­sure. To adjust the viewing angle of the enclosure or display/keypad, see page 2-17.
Caution!
When using toxic or cor-
rosive gases, purge the
line with inert gas for a minimum of four hours
at full gas flow before
installing the flow meter.
Figure 2-3. Wafer-Style Flow Meter Installation
When installing the meter make sure the section marked “inlet” is positioned up­stream of the outlet, facing the flow. This ensures that the sensor head is posi­tioned downstream of the vortex shedder bar and is correctly aligned to the flow. Installing the meter opposite this direction will result in completely inaccurate flow measurement. To install the meter:
1. Turn off the flow of process gas, liquid or steam. Verify that the line is
not pressurized. Confirm that the installation site meets the required minimum upstream and downstream pipe diameters.
2. Insert the studs for the bottom side of the meter body between the pipe
flanges. Place the wafer-style meter body between the flanges with the end stamped “inlet” facing flow. 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 flow profile. Obstructions in the pipeline will disturb the flow and cause inaccurate measurements.
4. Place the remaining studs between the pipe flanges. Tighten the nuts in the
sequence shown in Figure 2-2. Check for leaks after tightening the flange bolts.
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Series 220/221 Instruction Manual Chapter 2 Installation
Flange-Style Flow Meter Installation
Install the flange-style meter between two conventional pipe flanges of the same nominal size as the flow meter. If the process fluid 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 flow me­ters are not suitable for two-phase flows (i.e., liquid and gas mixtures). For horizontal pipelines having a process temperature above 300° F, mount the meter at a 45 or 90-degree angle to avoid overheating the electronics enclo­sure. To adjust the viewing angle of the enclosure or display/keypad, see page 2-17.
Caution!
When using toxic or cor-
rosive gases, purge the
line with inert gas for a minimum of four hours
at full gas flow before
installing the flow meter.
Figure 2-4. Flange-Style Flow Meter Installation
When installing the meter make sure the flange marked “inlet” is positioned up­stream of the outlet flange, facing the flow. This ensures that the sensor head is positioned downstream of the vortex shedder bar and is correctly aligned to the flow. Installing the meter opposite this direction will result in completely inaccu­rate flow measurement. To install the meter:
1. Turn off the flow of process gas, liquid or steam. Verify that the line is
not pressurized. Confirm that the installation site meets the required minimum upstream and downstream pipe diameters.
2. Seat the meter level and square on the mating connections with the flange
marked “inlet” facing the flow. Position a gasket in place for each side. Make sure both gaskets are smooth and even with no gasket material extending into the flow profile. Obstructions in the pipeline will disturb the flow and cause inaccurate measurements.
3. Install bolts in both process connections. Tighten the nuts in the sequence
shown in Figure 2-2. Check for leaks after tightening the flange bolts.
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Chapter 2 Installation Series 220/221 Instruction Manual
Series 221 Insertion Flow Meter Installation
Prepare the pipeline for installation using either a cold tap 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
An isolation valve is available as an option with Series 221 meters. If you supply the isolation valve, it must meet the following requirements:
1. A minimum valve bore diameter
of 1.875 inches is required, and the valve’s body size should be two inches. Normally, gate
2-inch min.
valves are used.
2. Verify that the valve’s body and
flange rating are within the flow
2-inch
valve size
meter’s maximum operating pressure and temperature.
Isolation Valve Requirements
3. Choose an isolation valve with
at least two inches existing between the flange face and the gate portion of the valve. This ensures that the flow meter’s sensor head will not in­terfere with the operation of the isolation valve.
1.875-inch min. valve bore
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Series 220/221 Instruction Manual Chapter 2 Installation
Caution!
When using toxic or
corrosive gases, purge
the line with inert gas for a minimum of four
hours at full gas flow
before installing the
flow meter.
Warning!
All flow meter connec-
tions, isolation valves and
fittings for cold tapping
must have the same or
higher pressure rating as
the main pipeline.
Cold Tap Guidelines
Refer to a standard code for all pipe tapping operations. The following tap­ping instructions are general in nature and intended for guideline purposes only.
1. Turn off the flow of process gas, liquid or steam. Verify that the line is
not pressurized.
2. Confirm that the installation site meets the minimum upstream and
downstream pipe diameter requirements. See Figure 2-1.
3. Use a cutting torch or sharp cutting tool to tap into the pipe. The pipe
opening must be at least 1.875 inches in diameter. (Do not attempt to in­sert the sensor probe through a smaller hole.)
4. Remove all burrs from the tap. Rough edges may cause flow profile dis-
tortions that could affect flow meter accuracy. Also, obstructions could damage the sensor assembly when inserting into the pipe.
5. After cutting, measure the thickness of the cut-out and record this num-
ber for calculating the insertion depth.
6. Weld the flow meter pipe connec-
tion on the pipe. Make sure this connection is within ± 5° perpen­dicular to the pipe centerline.
7. Install the isolation valve (if
used).
8. When welding is complete and all fittings are installed, close the isola-
tion 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 as described on the following
pages. Insert the sensor probe into the pipe.
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Chapter 2 Installation Series 220/221 Instruction Manual
Hot Tap Guidelines
Refer to a standard code for all pipe tapping operations. The following tap-
Warning!
Hot tapping must be
performed by a trained
professional. US. regula-
tions often require a hot
tap permit. The manufac-
turer of the hot tap
equipment and/or the
contractor performing the
hot tap is responsible for providing proof of such a
permit.
Warning!
All flow meter connec-
tions, isolation valves and
fittings for hot tapping
must have the same or
higher pressure rating as
the main pipeline.
ping instructions are general in nature and intended for guideline purposes only.
1. Confirm that the installation site meets the minimum upstream and
downstream pipe diameter requirements.
2. Weld a two inch 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 inches in diameter.
3. Connect a two inch 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 inches in diameter.
5. Hot tap the pipe.
6. Close the isolation valve. Run a static pressure check on the welds. If
pressure loss or leaks are detected, repair the joint and re-test.
7. Connect the flow meter to the isolation valve.
8. Calculate the sensor probe insertion depth as described on the following
pages. Insert the sensor probe assembly into the pipe.
Check upstream and downstream piping requirements
Weld mounting adapter
Connect process connection (flange or NPT)
Connect isolation valve
Hot tap pipe
FLOW
Test for leaks, purge pipe
Connect meter to valve, calculate insertion depth, install flow meter
Figure 2-5. Hot Tap Sequence
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Series 220/221 Instruction Manual Chapter 2 Installation
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 flow meters are applicable to pipes 2 inch and larger. For pipe sizes ten inches and smaller, the centerline of the meter’s sensing head is located at the pipe’s centerline. For pipe sizes larger than ten inches, the centerline of the sensing head is located in the pipe’s cross section five inches from the inner wall of the pipe; i.e., its “wetted” depth from the wall to the centerline of the sensing head is five inches.
Insertion flow meters are available in three probe lengths:
Standard Probe configuration is used with most flow meter process connec­tions. The length, S, of the stem is 29.47 inches.
Compact Probe configuration is used with compression fitting process con­nections. The length, S, of the stem is 13.1 inches.
12-Inch Extended Probe configuration is used with exceptionally lengthy flow meter process connections. The length, S, of the stem is 41.47 inches.
Warning!
An insertion tool must be
used for any installation
where a flow meter is
inserted under pressure
greater than 50 psig.
Use the Correct Insertion Formula
Depending on your flow meter’s process connection, use the applicable in­sertion length formula and installation procedure as follows:
Flow meters with a compression type connection (NPT or flanged) fol-
low the instructions beginning on page 2-10.
Flow meters with a packing gland type connection (NPT or flanged) con-
figured with an insertion tool, follow the instructions beginning on page 2-12.
Flow meters with a packing gland type connection (NPT or flanged)
without an insertion tool, follow the instructions beginning on page 2-
15.
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Chapter 2 Installation Series 220/221 Instruction Manual
Installing Flow Meters with a Compression Connection*
Use the following formula to determine insertion length for flow meters (NPT and flanged) with a compression process connection. The installation procedure is given on the next page.
Insertion Length Formula
I = S – F – R – t
Where: I = Insertion length. S = Stem length – the distance from the center of the sensor head to the base of the
enclosure adapter (S = 29.47 inches for standard probes; S = 13.1 inches for compact; S = 41.47 inches for 12-inch extended).
F = Distance from the raised face of the flange or top of NPT stem housing to the
outside of the pipe wall.
R = Pipe inside diameter ÷ 2 for pipes ten inches and smaller. R = Five inches for pipe diameters larger than ten inches. t = Thickness of the pipe wall. (Measure the disk cut-out from the tapping proce-
dure or check a piping handbook for thickness.)
Figure 2-6. Insertion Calculation (Compression Type)
Example:
To install a Series 221 meter with a standard probe (S = 29.47 inches) into a 14 inch schedule 40 pipe, the following measurements are taken:
F = 3 inches R = 5 inches t = 0.438 inches
The insertion length for this example is 21.03 inches. Insert the stem through the fit­ting until an insertion length of 21.03 inches is measured with a ruler.
*All dimensions are in inches
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Series 220/221 Instruction Manual Chapter 2 Installation
Insertion Procedure for Meters with a Compression Connection
Caution!
The sensor alignment
pointer must point
downstream, in the
direction of flow.
Warning!
To avoid serious injury,
DO NOT loosen the
compression fitting
under pressure.
Figure 2-7. Flow Meter with Compression Type Fitting
1. Calculate the required sensor probe insertion length.
2. Fully retract the stem until the sensor head is touching the bottom of the
stem housing. Slightly tighten the compression nut to prevent slippage.
3. Bolt or screw the flow meter assembly into the process connection. Use
Teflon tape or pipe sealant to improve the seal and prevent seizing on NPT styles.
4. Hold the meter securely while loosening the compression fitting. Insert
the sensor into the pipe until the calculated insertion length, I, is meas­ured between the base of the enclosure adapter and the top of the stem housing, or to the raised face of the flanged version. Do not force the stem into the pipe.
5. Align the sensor head using the sensor alignment pointer. Adjust the
alignment pointer parallel to the pipe and pointing downstream.
6. Tighten the compression fitting to lock the stem in position. When the
compression fitting is tightened, the position is permanent.
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Chapter 2 Installation Series 220/221 Instruction Manual
Installing Flow Meters with a Packing Gland Connection*
Use the formula below to determine the insertion depth for flow meters (NPT and flanged) 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 2-14.
Insertion Length Formula
I = F + R + t – 1.35
Where:
I = Insertion length.
F = Distance from the raised face of the flange or top of the
process connection for NPT style meters to the top out­side of the process pipe.
R = Pipe inside diameter ÷ 2 for pipes ten inches & smaller. R = Five inches for pipe diameters larger than ten inches.
t = Thickness of the pipe wall. (Measure the disk cut-out
from the tapping procedure or check a piping handbook for thickness.)
Figure 2-8. Insertion Calculation (Meters with Insertion Tool)
Example 1: Flange Style Meters:
To install a Series 221 Flow Meter into a 14 inch schedule 40 pipe, the fol­lowing measurements are taken:
F = 12 inches R = 5 inches t = 0.438 inches
The example insertion length is 16.09 inches.
Example 2: NPT Style Meters:
The length of thread engagement on the NPT style meters is also subtracted in the equation. The length of the threaded portion of the NPT meter is 1.18 inches. Measure the thread portion still showing after the installation and subtract that amount from 1.18 inches. This gives you the thread engagement length. If this cannot be measured use .55 inch for this amount.
F = 12 inches R = 5 inches
The example insertion length is 15.54 inches.
*All dimensions are in inches.
t = 0.438 inches
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Series 220/221 Instruction Manual Chapter 2 Installation
Insertion Procedure for Flow Meters with Permanent Insertion Tool
Caution!
The sensor alignment
pointer must point
downstream, in the
direction of flow.
Note
If line pressure is above 500 psig, it could require up to 25 ft lb of torque to
insert the flow meter.
Do not confuse this with
possible interference
in the pipe.
Figure 2-9. 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 flow meter until the sensor head is touching the bottom
of the stem housing. Attach the meter assembly to the two inch full-port isolation valve, if used. Use Teflon 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.
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Chapter 2 Installation Series 220/221 Instruction Manual
Insertion Procedure for Flow Meters with Removable Insertion Tool
Caution!
The sensor alignment
pointer must point
downstream, in the
direction of flow.
Note
If line pressure is above 500 psig, it could require up to 25 ft lb of torque to
insert the flow meter.
Do not confuse this with
possible interference
in the pipe.
Figure 2-10. 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 flow meter until the sensor head is touching the bottom
of the stem housing. Attach the meter assembly to the two inch full-port isolation valve, if used. Use Teflon 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 po-
5. Slowly open the isolation valve to the full open position. If necessary,
6. Turn the insertion tool handle clockwise to insert the stem into the pipe.
sition.
slightly tighten the two packing gland nuts to reduce the leakage around the stem.
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.
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Series 220/221 Instruction Manual Chapter 2 Installation
7. Tighten the packing gland nuts to stop leakage around the stem. Do not
torque over 20 ft-lbs.
8. Slide the stem clamp back into position. Torque stem clamp bolts to 15
ft-lbs. Replace the stem clamp nuts and torque to 10-15 ft-lbs.
9. Attach the safety chain from the stem clamp to the hook on the enclosure
adapter at the nearest link. To separate the insertion tool from the flow meter, remove four socket head cap bolts securing the upper and lower re­tractor brackets. Remove the insertion tool.
Installation of Meters with Packing Gland Connection (No Insertion Tool)*
Use the following formula to determine insertion depth for meters with a packing gland connection (NPT and flanged) without an insertion tool.
Insertion Length Formula
I = S – F – R – t
Where:
I = Insertion length.
S = Stem length – the distance from the center
of the sensor head to the base of the enclo­sure adapter (S = 29.47 inches for standard probes; S = 41.47 inches for 12 inch ex­tended probes).
F = Distance from the raised face of the flange
or top of NPT stem housing to the outside of the pipe wall.
R = Pipe inside diameter ÷ 2 for pipes ten
inches & smaller.
R = Five inches for pipe diameters larger than
ten inches.
t = Thickness of the pipe wall. (Measure the
disk cut-out from the tapping procedure or check a piping handbook for thickness.)
Figure 2-11. Insertion Calculation (Meters without Insertion Tool)
Example:
To install a Series 221 Flow Meter with a standard probe (S = 29.47) into a 14 inch schedule 40 pipe, the following measurements are taken:
F = 3 inches R = 5 inches
The example insertion length is 21.03 inches.
*All dimensions are in inches.
t = 0.438 inches
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Chapter 2 Installation Series 220/221 Instruction Manual
Insertion Procedure for Flow Meters with No Insertion Tool (Packing Gland Connection)
1. Calculate the required sensor probe insertion length.
Warning!
The line must be
less than 50 psig
for installation.
2. Fully retract the stem until the sensor head is touching the bottom of the
stem housing. Remove the two top stem clamp nuts and loosen two stem clamp bolts. Slide the stem clamp away to expose the packing gland nuts. Loosen the two packing gland nuts.
3. Align the sensor head using the sensor alignment pointer. Adjust the
Caution!
The sensor alignment
pointer must point
downstream, in the
direction of flow.
alignment pointer parallel to the pipe and pointing downstream.
4. Insert the sensor head into the pipe until insertion length, I, is achieved.
Do not force the stem into the pipe.
5. Tighten the packing gland nuts to stop leakage around the stem. Do not
torque over 20 ft-lbs.
6. Slide the stem clamp back into position. Torque stem clamp bolts to 15
ft-lbs. Replace the stem clamp nuts and torque to 10-15 ft-lbs.
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Series 220/221 Instruction Manual Chapter 2 Installation
Adjusting Meter Orientation
Depending on installation requirements, you may need to adjust the meter orientation. There are two adjustments available. The first rotates the position of the LCD display/keypad and is available on both in-line and insertion me­ters. The second is to rotate the enclosure position. This adjustment is only allowed on Series 220 In-Line meters.
Display/Keypad Adjustment (All Meters)
Figure 2-12. Display/Keypad Viewing Adjustment
The electronics boards are electrostatically sensitive. Wear a grounding wrist strap and make sure to observe proper handling precautions required for static-sensitive components. To adjust the display:
1. Disconnect power to the flow meter.
2. Loosen the small set screw which secures the electronics enclosure. Un-
screw and remove the cover.
3. Loosen the 4 captive screws.
4. Carefully pull the display/microprocessor board away from the meter
standoffs. Make sure not to damage the connected ribbon cable.
5. Rotate the display/microprocessor board to the desired position. Maxi-
mum turn, two positions left or two positions right (180-degrees).
6. Align the board with the captive screws. Check that the ribbon cable is
folded neatly behind the board with no twists or crimps.
7. Tighten the screws. Replace the cover and set screw. Restore power to
the meter.
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Chapter 2 Installation Series 220/221 Instruction Manual
Enclosure Adjustment (Series 220 Only)
Figure 2-13. Enclosure Viewing Adjustment
To avoid damage to the sensor wires, do not rotate the enclosure beyond 180­degrees from the original position. To adjust the enclosure:
1. Remove power to the flow meter.
2. Loosen the three set screws shown above. Rotate the display to the de-
sired position (maximum 180-degrees).
3. Tighten the three set screws. Restore power to the meter.
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Series 220/221 Instruction Manual Chapter 2 Installation
Warning!
To avoid potential electric
shock, follow National Electric
Code safety practices or your
local code when wiring this
unit to a power source and to
peripheral devices. Failure to
do so could result in injury or
death. All wiring procedures
must be performed with the
power off.
Wiring Connections
The NEMA 4X enclosure contains an integral wiring compartment with one dual strip terminal block (located in the smaller end of the enclosure). Two 3/4-inch female NPT conduit entries are available for separate power and signal wiring. For all hazardous area installations, make sure to use an agency-approved fitting at each conduit entry. If conduit seals are used, they must be installed within 18 inches (457 mm) of the enclosure.
Input Power Connections
To access the wiring terminal blocks, locate and loosen the small set screw which locks the small enclosure cover in place. Unscrew the cover to expose the terminal block.
DC Power Wiring
Connect 4-20 mA loop power (12 to 36 VDC) to the +Pwr and –Pwr termi­nals on the terminal block. Torque all connections to 4.43 to 5.31 in-lbs (0.5 to 0.6 Nm). The DC power wire size must be 20 to 10 AWG with the wire stripped 1/2 inch (14 mm). The nominal voltage required to operate the 4-20 mA loop is 12 volts at the meter. The 4-20 mA loop is optically isolated from the flow meter electronics.
Figure 2-14. DC Power Connections
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Chapter 2 Installation Series 220/221 Instruction Manual
4-20 mA Output Connections
The Innova-Flo meter has a single 4-20 mA loop. The 4-20 mA loop current is controlled by the meter electronics. The electronics must be wired in series with the sense resistor or current meter. The current control electronics re­quire 12 volts at the input terminals to operate correctly.
The maximum loop resistance (load) for the current loop output is depend­ent upon the supply voltage and is given in Figure 2-16. The 4-20 mA loop is optically isolated from the flow meter electronics.
is the total resistance in the loop, including the wiring resistance (R
R
load
+ R
R
wire
maximum loop current, 20 mA. The voltage drop in the loop due to resis­tance is 20 mA times R Thus:
The maximum resistance R
). To calculate R
sense
, the maximum R
max
and this drop is subtracted from the input voltage.
load
load
= R
= 50 * (V
max
for the loop, use the
load
– 12V).
supply
load
=
Figure 2-15. Load Resistance Versus Input Voltage
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Series 220/221 Instruction Manual Chapter 2 Installation
Pulse Output Connections
The pulse output is used for a remote counter. When the preset volume or mass (defined in the totalizer settings, see page 3-6) has passed the meter, the output provides a 50 millisecond square pulse.
The pulse output requires a separate 5 to 36 VDC power supply. The pulse output optical relay is a normally-open single-pole relay. The relay has a nominal 200 volt/160 ohm rating. This means that it has a nominal on­resistance of 160 ohms, and the largest voltage that it can withstand across the output terminals is 200 volts. However, there are current and power specifications that must be observed. The relay can conduct a current up to 40 mA and can dissipate up to 320 mW. The relay output is isolated from the meter electronics and power supply.
Figure 2-16. Isolated Pulse Output with External Power Supply
Optional Backlight Connection
The Sierra Model 220 has an optional backlight connection provided. It is in­tended to be powered by a separate 12 to 36 VDC power supply or by the pulse power input. Both options are shown below.
The Sierra Model 220 has an optional backlight connection provided. It is in­tended to be powered by a separate 12 to 36 VDC power supply or by the pulse
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Chapter 2 Installation Series 220/221 Instruction Manual
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Series 220/221 Instruction Manual Chapter 2 Installation
Remote Electronics Wiring
The remote electronics enclosure should be mounted in a convenient, easy to reach location. For hazardous location installations, make sure to observe agency requirements for installation. Allow some slack in the interface cable between the junction box and the remote electronics enclosure. To prevent damage to the wiring connections, do not put stress on the terminations at any time.
The meter is shipped with temporary strain relief glands at each end of the cable. Disconnect the cable from the meter’s terminal block inside the junc­tion box–not at the remote electronics enclosure. Remove both glands and in­stall appropriate conduit entry glands and conduit. When installation is com­plete, re-connect each labeled wire to the corresponding terminal position on the junction box terminal block. Make sure to connect each wire pair’s shield. Note: incorrect connection will cause the meter to malfunction.
Figure 2-17. Junction Box Sensor Connections
Note: Numeric code in junction box label matches wire labels.
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Series 220/221 Instruction Manual Chapter 3 Operation
Chapter 3 Operating Instructions
After installing the Innova-Flo Vortex Meter, you are ready to begin op­eration. The sections in this chapter explain the display/keypad com­mands, meter start-up and programming. The meter is ready to operate at start up without any special programming. To enter parameters and sys­tem settings unique to your operation, see the following pages for in­structions on using the setup menus.
Flow Meter Display/Keypad
The flow meter’s digital electronics allow you to set, adjust and monitor system parameters and performance. A full range of commands are avail­able through the display/keypad. The LCD display gives 2 x 16 characters for flow monitoring and programming. The six push buttons are operable either directly on the display panel or with a hand-held magnet through the explosion-proof enclosure.
Display/Keypad
Commands
EXIT ENTER
×
INNOVA FLO™
SIERRA
INSTRUMENTS
ÕÖ
Ø
Figure 3-1. Flow Meter Display/Keypad
From the Run Mode, the ENTER key allows access to the Setup Menus (through a password screen). Within the Setup Menus, pressing ENTER activates the current field. To set new parameters, press the ENTER key until an underline cursor appears. Use the
רÕÖ keys to select new parameters.
Press ENTER to continue. (If change is not alllowed, ENTER has no effect.) All outputs are disabled when using the Setup Menus.
The EXIT key is active within the Setup Menus. When using a Setup Menu, EXIT returns you to the Run Mode. If you are changing a parameter and make a mistake, EXIT allows you to start over.
רÕÖ keys advance through each screen
The of the current menu. When changing a system parameter, all new parameters.
רÕÖ keys are available to enter
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Chapter 3 Operation Series 220/221 Instruction Manual
Start-Up
To begin flow meter operation:
Note
Starting the flow meter
or pressing EXIT will
always display the Run
Mode screens.
1. Verify the flow meter is installed and wired as described in Chapter
2.
2. Apply power to the meter. At start up, the unit runs a series of self-
tests that check the program configuration and all flow sensing com­ponents. After completing the self-test sequence, the Run Mode screens appear.
3. The Run Mode displays flow information as determined by settings en-
tered in the Display Menu (page 3-5). Press the ר arrow keys to view the Run Mode screens.
Press the ENTER key from any Run Mode screen to access the Setup Menus. Use the Setup Menus to configure the meter’s multi-parameter features to fit your application.
Run Mode
Screens
Mass Flow
Rate
Volume
Flow Rate
Total
Use keys to access each item
To operate the six push buttons through the display enclosure, use the hand held magnet as shown at right.
ENTER
Password
ENTER
Setup
Menus
Press EXIT to return to Run Mode
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Series 220/221 Instruction Manual Chapter 3 Operation
Using the Setup Menus
Run Mode
Screens
Mass Flow
Rate
Volume
Flow Rate
Total
ENTER
Password
Output
Menu
4-20 mA
Output 1
ENTER
Display
Menu
Cycle Time
(sec)
Number of
Digits
Display TC
(sec)
Display VFlow?
Display
MFlow?
Display
Total?
Setup Menus
Totalizer
Menu
Totaling
Unit per
Pulse
Reset Total
Units
Menu
Mass Flow
Unit
Volume
Flow Unit
Diagnostics
Menu
Sim Vor
Freq
Highest Velocity
Calibration
Menu
Meter Size
or Pipe ID
Meter Factor
Process
Temp (F)
Density
Ref Density
Viscosity
Vortek Coef
Ck
Low Flow
Cutoff
Serial
Number
Password
Menu
Set
Password
Programming the Flow Meter
1. Enter the Setup Menu by pressing the ENTER key until prompted for a password. (All
outputs are disabled while using the Setup Menus.)
2. Use the רÕÖ keys to select the password characters (1234 is the factory-set password). When the password is correctly displayed, press ENTER to continue.
3. Use the Setup Menus described on the following pages to customize the multi­parameter features of your Innova-Flo Vortex Meter. (The entire lower display line is available for entering parameters.)
4. To activate a parameter, press ENTER. Use the רÕÖ keys to make selections. Press
ENTER to continue. Press EXIT to save or discard changes and return to Run Mode.
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Chapter 3 Operation Series 220/221 Instruction Manual
Output Menu
Run Mode
ENTER
Password
ENTER
Output
Menu
4-20mA Output 1
More >
Use keys to access menus
< Measure >
None Mass
Volume
< 4mA = xxxx >
xxxx
< 20mA = xxxx >
xxxx
< TimeConst (sec)
xxxx
Example for Setting an Output
The following shows how to set Output 1 to measure volumetric flow with 4 mA = 0 gal/min and 20 mA = 100 gal/min with a time constant of 5 seconds. (All outputs are disabled while using the Setup Menus.)
First, set the desired units of measurement:
1. Use ÕÖ keys to move to the Units Menu (see page 3-8).
2. Press Ø key until Volume Flow Unit appears. Press
ENTER.
3. Press Ø key until gal appears in the numerator. Press Ö key to move the underline cursor to the
denominator. Press the Ø key until min appears in the denominator. Press
ENTER to select.
4. Press × key until Units Menu appears.
Second, set the analog output:
1. Use ÕÖ keys to move to the Output Menu.
2. Press the Ø key until 4-20mA Output 1 appears.
3. Press Ö key to access Measure selections. Press
4. Press Ö key to set the 4 mA point in the units you have selected for volume of gal/min. Press
and use רÕÖ keys to set 0 or 0.0. Press
5. Press Ö key to set the 20 mA point. Press
6. Press Ö key to select the Time Constant. Press
7. Press the
EXIT key and answer YES to permanently save your changes.
ENTER and press the Ø key to select Volume. Press ENTER.
ENTER
ENTER.
ENTER and use רÕÖ keys to set 100 or 100.0. Press ENTER.
ENTER and use רÕÖ keys to select 5. Press ENTER.
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Series 220/221 Instruction Manual Chapter 3 Operation
Display Menu
ENTER
Run Mode
Password
ENTER
Display
Menu
Cycle Time(se c)
0
Number of Digits
2
Display TC(sec)
1
Display VFlo w?
YES or NO
Display MFlow?
YES or NO
Display Total ?
YES or NO
Use keys to access menus
If Cycle Time is set to zero, manual advance is required
Used to set the number of digits displayed after decimal point
TC = Display Time Constant, used to smooth display
For each parameter: Select Yes to view parameter in Run Mode Select No to hide parameter in Run Mode
Use the Display Menu to set the cycle time for automatic screen sequencing used in the Run Mode, change the precision of displayed values, smooth the values or enable or disable each item displayed in the Run Mode screens.
Example for Changing a Run Mode Display Item
The following shows how to remove the mass flow screen from the Run Mode screens. Note: all outputs are disabled while using the Setup Menus.
1. Use ÕÖ keys to move to the Display Menu.
2. Press Ø key until Display MFlow? appears.
3. Press
4. Press Ø key until N appears. Press
5. Press EXIT and then
IM-22 3-5
ENTER to select.
ENTER to select.
ENTER to save changes and return to the Run Mode.
Page 43
Chapter 3 Operation Series 220/221 Instruction Manual
Totalizer Menu
Run Mode
ENTER
Password
ENTER
Totalizer
Menu
Totaling
Inactive
Mass
Volume
Use keys to access menus
Example: Maximum flowrate = 600 gallons per minute
(600 gallons per minute = 10 gallons per second)
(unit)/Pulse
xxxx
If unit per pulse is set to 600 gallons per pulse, the totalizer will pulse once every minute.
Reset Total?
YES or NO
If unit per pulse is set to 10 gallons per pulse, the totalizer will pulse once every second.
Use the Totalizer Menu to configure and monitor the totalizer. The totalizer output is a 50 millisecond (.05 second) positive pulse (relay closed for 50 milliseconds). The totalizer cannot operate faster than one pulse every 100 millisecond (.1 second). A good rule to follow is to set the unit per pulse value equal to the maximum flow in the same units per second. This will limit the pulse to no faster than one pulse every second.
Example for Setting the Totalizer
The following shows how to set the totalizer to track volu metric total gallons. (All outputs are disabled while using the Setup Menus.)
First, set the desired units of measurement:
1. Use ÕÖ keys to move to the Units Menu (see to page 3-8).
2. Press Ø key until Volume Flow Unit appears. Press
ENTER.
3. Press Ø key until gal appears in the numerator. Press Ö key to move the underline cursor to the
denominator. Press the Ø key until min appears in the denominator. Press
ENTER to select.
4. Press × key until Units Menu appears.
Second, set the pulse output:
1. Use ÕÖ keys to move to the Totalizer Menu.
2. Press the Ø key until Totaling appears.
3. Press
4. Press Ø key to set the gallons per pulse. Press
ENTER and press the Ø key to select Volume. Press ENTER.
ENTER and use רÕÖ keys to set the pulse
value equal to the maximum flow in the same units per second. This will limit the frequency to 1 Hz. Press
5. To reset the totalizer, press Ø key until Reset Total? appears. Press
the totalizer if desired. Press
6. Press the
ENTER.
ENTER and the Ø key to reset
ENTER.
EXIT key and answer YES to permanently save your changes.
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Series 220/221 Instruction Manual Chapter 3 Operation
Units Menu
ENTER
Run Mode
Password
ENTER
Units
Menu
Mass Flow Unit lb Ston Lton gram / kg
sec min
hr
day
Mton scf
3
nm
Volume Flow Unit gal MilG ImpG bbl / lit
sec min
hr
day
MilL
3
m
3
ft
Use keys to access menus
lb = pounds Ston = 2000 pou nds Lton = 2240 pounds gram = grams kg = 1000 grams Mton = Metri c Ton = 10 00 kg scf = standard cubic feet
3
= normal cubic meters
nm
gal = US gallons MilG = 1,000,000 US gallons ImpG = 1.20095 US gal lons bbl = barrels = 42 US gall o ns lit = liters MilL = 1,000,000 liters
3
= cubic meters
m
3
= cubic feet
ft
Use the Units Menu to configure the flow meter with the desired units of measurement. (These are global settings and determine what appears on all screens.)
IM-22 3-7
Page 45
Chapter 3 Operation Series 220/221 Instruction Manual
Diagnostics Menu
ENTER
Run Mode
Password
ENTER
Diagnostics
Menu
Sim Vor Freq
xxx
Highest Velocity
xxx
Use keys to access menus
Simulate Vortex Frequency (Hz)
Highest Recorded Veloci ty (ft/sec)
Use the Diagnostics Menu to simulate flow and review the highest recorded veloc­ity in ft/sec.
The simulated vortex frequency is used for testing the meter to verify that the programming is correct. Enter any value for the sensor input in Hz. The meter will calculate a flow rate based on the corresponding value and update the analog output and totalizer pulse output. Note: when your diagnostic work is complete, make sure to return the simulated frequency to zero to allow the electronics to use the actual value.
3-8 IM-22
Page 46
Series 220/221 Instruction Manual Chapter 3 Operation
Calibration Menu
Run Mode
ENTER
Password
ENTER
Calibration
Menu
Meter Size
or Pipe ID
Meter Factor
xxxx
Process Temp(°F)
xxx
Density
xxx
Ref Densit y
xxx
Viscosity
xxx
Use keys to access menus
Series 220 - meter size Series 221 - pipe internal diameter (inches)
Meter calibration constant Series 220 - pulses/ft Series 221 - pulses/ft
Used to correct Meter Factor for thermal expansion of meter body for Series 220
Units are lb/ft
Units are lb/ft3. Used for calculation of standard cubic meters, standard cubic feet, and normal cubic meters.
Units are centipoise (Cp)
3
3
Vortex Coef Ck
xx
Low Flow Cutoff
xx
Serial Number
xxxxxxxxx
Adaptive filter set ting
< Vol (xxx/xxx) >
xxx
Low Flow Cutoff setting displayed in volumetric flow units (view only)
< Mass (xxx/xxx)
xxx
Low Flow Cutoff setting displayed in mass flow units (view only)
The Calibration Menu contains the calibration coefficients for the flow meter. These values should by changed only by properly trained personnel. The Vortex Coef Ck and Low Flow Cutoff are set at the factory. Consult the factory for help with these settings if the meter is showing erratic flow rate. The units of measurement used in the Calibration Menu are preset and are as follows: Density = lbm/ft Viscosity = centipoise.
IM-22 3-9
3
, Reference Density = lbm/ft3,
Page 47
Chapter 3 Operation Series 220/221 Instruction Manual
Password Menu
ENTER
Run Mode
Password
ENTER
Password
Menu
Set Password
1234
Use keys to access menus
Use the Password Menu to set or change the system password. The factory-set password is 1234.
3-10 IM-22
Page 48
Series 220/221 Instruction Manual Chapter 4 HART Communications
Chapter 4 HART Communications
Warning!
Place controls in manual mode when making con­figuration changes to the
vortex meter.
Wiring
The diagram below details the proper connections required for HART communi­cations:
IM-22 4-1
Page 49
Chapter 4 HART Communications Series 220/221 Instruction Manual
HART Menus
Online Menu
1 Device Setup 2 PV 3 PV AO
1 Process Variables
2 Diag/Service
3 Basic Setup
1 Snsr 2 AI % Rnge 3 AO1
1 Test Device 2 Loop Test 3 Calibration 4 D/A Trim
1 Tag 2 PV unit 3 Range Values 4 Device Informat i o n 5 PV Xfer fnctn 6 PV Damp
1 4 mA 2 20 mA 3 Other 4 End
1 Apply Values 2 Enter Values
1 PV LRV 2 PV URV 3 PV LSL 4 PV USL
1 Distributor 2 Model 3 Dev id 4 Tag 5 Date 6 Write Protect 7 Descriptor 8 Message 9 PV snsr s/n Final assy # Revision #'s
1 4 mA 2 20 mA 3 Exit
1 PV LRV 2 PV URV 3 PV USL 4 PV LSL
1 Universal Rev 2 Fld dev Rev 3 Software Rev
4 PV LRV 5 URV
Use password 16363.
4 Detailed Setup 5 Review
1 PV LRV 2 PV URV
1 Sensors
2 Signal Condition
3 Output Condit i on
4 Device Informat i o n
1 PV 2 PV Sensor Unit 3 Sensor information
1 Snsr Damp 2 URV 3 AI LRV 4 Xfer Fnctn 5 AI % rnge
1 Analog Output 2 HART Output
1 Distributor 2 Model 3 Dev id 4 Tag 5 Date 6 Write Protect 7 Descriptor 8 Message 9 PV snsr s/n Final assy # Revision #'s
PV LSL, PV USL, PV Min span
1 PV LRV 2 PV URV
1 AO1 2 AO alarm typ 3 Loop test 4 D/A trim 5 Scaled D/A trim
1 Poll addr 2 Num req. preams 3 Burst mode 4 Burst option
1 Universal Rev 2 Fld dev Rev 3 Software Rev
1 4 mA 2 20 mA 3 Other 4 End
4-2 IM-22
Page 50
Series 220/221 Instruction Manual Chapter 4 HART Communications
Fast Key Sequence
Use password 16363.
Sequence Description Access Notes
1,1,1 Snsr View Primary variable value 1,1,2 AI % Rnge View Analog output % range 1,1,3 AO1 View Analog output, mA 1,2,1 Test Device N/A Not used 1,2,2,1 4 mA View Loop test, fix analog output at 4 mA 1,2,2,2 20 mA View Loop test, fix analog output at 20 mA 1,2,2,3 Other Edit Loop test, fix analog output at mA value entered 1,2,2,4 End Exit loop test 1,2,3,1,1 4 mA N/A Not used, apply values 1,2,3,1,2 20 mA N/A Not used, apply values 1,2,3,1,3 Exit Exit apply values 1,2,3,2,1 PV LRV Edit Primary variable lower range value 1,2,3,2,2 PV URV Edit Primary variable upper range value 1,2,3,2,3 PV USL View Primary variable upper sensor limit 1,2,3,2,4 PV LSL View Primary variable lower sensor limit 1,2,4 D/A Trim Edit Calibrate electronics 4mA and 20mAvalues 1,3,1 Tag Edit Tag 1,3,2 PV unit Edit Primary variable units 1,3,3,1 PV LRV Edit Primary variable lower range value 1,3,3,2 PV URV Edit Primary variable upper range value 1,3,3,3 PV LSL View Primary variable upper sensor limit 1,3,3,4 PV USL View Primary variable lower sensor limit 1,3,4,1 Distributor N/A Not used 1,3,4,2 Model N/A Not used 1,3,4,3 Dev id View Device identification 1,3,4,4 Tag Edit Tag 1,3,4,5 Date Edit Date 1,3,4,6 Write Protect View Write protect 1,3,4,7 Descriptor Edit Vortex flowmeter 1,3,4,8 Message Edit 32 character alphanumeric message 1,3,4,9 PV snsr s/n View Primary variable sensor serial number 1,3,4,menu Final assy # Edit Final assembly number 1,3,4,menu,1 Universal Rev View Universal revision 1,3,4,menu,2 Fld dev Rev View Field device revision 1,3,4,menu,3 Software Rev View Software revision 1,3,5 PV Xfer fnctn View Linear 1,3,6 PV Damp Edit Primary variable damping (time constant) in seconds 1,4,1,1 PV View Primary variable value 1,4,1,2 PV Sensor Unit Edit Primary variable units 1,4,1,3 Sensor Information View PV LSL, PV USL, PV Min span 1,4,2,1 Snsr Damp Edit Primary variable damping (time constant) in seconds 1,4,2,2,1 PV LRV Edit Primary variable low range value 1,4,2,2,2 PV URV Edit Primary variable upper range value 1,4,2,3,1 PV LRV Edit Primary variable low range value 1,4,2,3,2 PV URV Edit Primary variable upper range value 1,4,2,4 Xfer Fnctn View Linear 1,4,2,5 AI % rnge View Analog output % range 1,4,3,1,1 AO1 View Analog output, mA 1,4,3,1,2 AO alarm typ N/A Not used
Continued on next page
IM-22 4-3
Page 51
Chapter 4 HART Communications Series 220/221 Instruction Manual
Sequence Description Access Notes
1,4,3,1,3,1 4 mA View Loop test, fix analog output at 4 mA 1,4,3,1,3,2 20 mA View Loop test, fix analog output at 20 mA 1,4,3,1,3,3 Other Edit Loop test, fix analog output at mA value entered 1,4,3,1,3,4 End Exit loop test 1,4,3,1,4 D/A trim Edit Calibrate electronics 4mA and 20mAvalues 1,4,3,1,5 Scaled D/A trim N/A Not used 1,4,3,2,1 Poll addr Edit Poll address 1,4,3,2,2 Num req. preams View Number of required preambles 1,4,3,2,3 Burst mode N/A Not used 1,4,3,2,4 Burst option N/A Not used 1,4,4,1 Distributor N/A Not used 1,4,4,2 Model N/A Not used 1,4,4,3 Dev id View Device identification 1,4,4,4 Tag Edit Tag 1,4,4,5 Date Edit Date 1,4,4,6 Write Protect View Write protect 1,4,4,7 Descriptor Edit Vortex flowmeter 1,4,4,8 Message Edit 32 character alphanumeric message 1,4,4,9 PV snsr s/n View Primary variable sensor serial number 1,4,4,menu Final assy # Edit Final assembly number 1,4,4,menu,1 Universal Rev View Universal revision 1,4,4,menu,2 Fld dev Rev View Field device revision 1,4,4,menu,3 Software Rev View Software revision 1,5 Review N/A Not used 2 PV View Primary variable value 3 PV AO View Analog output, mA 4,1 PV LRV Edit Primary variable lower range value 4,2 PV URV Edit Primary variable upper range value 5,1 PV LRV Edit Primary variable lower range value 5,2 PV URV Edit Primary variable upper range value
4-4 IM-22
Page 52
Series 220/221 Instruction Manual Chapter 5 Troubleshooting & Repair
Chapter 5 Troubleshooting and Repair
*
f fi G A
A1 A2 A3 A4
Kc It
Kb
V
Re
Ck Lvl
Adj. Filter
xx dB
O
I
Pulse Out Queue
xxxxxxxxxx
TOF
G f
Sig. Rev
Micro Rev
AD R T
F PT V
4-20(1),Zero
xxxx
4-20(1),FScale
xxxx
Reynolds Corr.
Gain Control
Filter Control
Factory Defaults
Meter Type
Test Pulse Out
Warning!
Before attempting any flow
meter repair, verify that the
line is not pressurized.
Always remove main power
before disassembling any
part of the flow meter.
IM-22 5-1
Spi Err
Rcv Sent
Not Present on
*
220 models
Hidden Diagnostics Menus
The menus shown above can be accessed using the password 16363, then moving to the display that reads “Diagnostics Menu” and pressing ENTER (rather than one of the arrow keys).
Use the right arrow key to move to the second column. Press EXIT to move from the second column back to the first, press EXIT while in the first column to return to the setup menus.
Caution: password 16363 will allow full access to the configuration and should be used carefully to avoid changes that can adversely alter the function of the me­ter.
Each of the menus above will first be defined followed by specific troubleshoot­ing steps.
Page 53
Chapter 5 Troubleshooting & Repair Series 220/221 Instruction Manual
Column One Hidden Diagnostics Values
f = vortex shedding frequency (Hz). If an asterisk (*) is dis-
played after the f value, a valid vortex signal is being registered for the flow.
fi = adaptive filter – should be approximately 25% higher than
the vortex shedding frequency, this is a low-pass filter. If the meter is using the Filter Control (see below) in the manual mode, fi will be displayed as fm.
G = gain (applied to vortex signal amplitude). Gain defaults to
1.0 and can be changed using the Gain Control (see below).
A = Amplitude of the vortex signal in Volts rms.
A1, A2, A3, A4 = A/D counts representing the vortex signal
amplitude. Each stage (A1-A4) cannot exceed 512. Beginning with stage A1, the A/D counts increase as the flow rate in­creases. When stage A1 reaches 512, it will shift to stage A2. This will continue as the flow rate increases until all 4 stages read 512 at high flow rates. Higher flow rates (stronger signal strength) will result in more stages displaying 512.
Kc, It, Kb = profile equation (factory use only). Series 221
only.
V = calculated average pipe velocity (ft/sec).
• Re = calculated Reynolds number.
Ck = calculated Ck at current operating conditions. Ck is a
variable in the equation that relates signal strength, density, and velocity for a given application. It is used for noise rejec­tion purposes. Ck directly controls the fi value (see above). If the Ck is set too low (in the calibration menu), then the fi value will be too low and the vortex signal will be rejected resulting in zero flow rate being displayed. The calculated Ck value in this menu can be compared to the actual Ck setting in the cali­bration menu to help determine if the Ck setting is correct.
Lvl = threshold level. If the Low Flow Cutoff in the calibra-
tion menu is set above this value, the meter will read zero flow. The Lvl level can be checked at no flow. At no flow, the Lvl must be below the Low Flow Cutoff setting or the meter will have an output at no flow.
Adj. Filter = adjustable filter. Displays the filtering in deci-
bels. Normally reads zero. If this value is consistently –5 or –10, for example, the Ck or density setting may be wrong.
• O, I = factory use only.
5-2 IM-22
Page 54
Series 220/221 Instruction Manual Chapter 5 Troubleshooting & Repair
Pulse Out Queue = Pulse output queue. This value will ac-
cumulate if the totalizer is accumulating faster than the pulse output hardware can function. The queue will allow the pulses to “catch up” later if the flow rate decreases. A better practice is to slow down the totalizer pulse by increasing the value in the (unit)/pulse setting in the totalizer menu.
• TOF, G, f = factory use only.
Sig. Rev = Signal board hardware and firmware revision.
Micro Rev = Microprocessor board hardware and firmware
revision.
• AD, R, T, F, PT, V = factory use only.
SPI Err, Rcv, Sent = factory use only.
Column Two Hidden Diagnostics Values
4-20(1), Zero = Analog counts to calibrate zero on analog output.
4-20(1), FScale = Analog counts to calibrate full scale on analog
output.
Vor Freq Direct? = Frequency output setting, used by factory dur-
ing calibration. Set to NO if totalizer is used.
Reynolds Corr. = Reynolds number correction for the flow profile.
Set to Enable for series 221 insertion and set to Disable for series 220 inline.
Gain Control = Manual gain control (factory use only). Leave set at
1.0.
Filter control = Manual filter control. This value can be changed to
any number to force the fi value (which will be displayed as fm) to a constant. A value of zero activates the automatic filter control which sets fi at a level that floats above the f value.
Factory Defaults = Reset to factory defaults. If you change this to
YES and press ENTER, all factory configuration is lost and you must reconfigure the entire program. Consult the factory before per­forming this process, it is required only in very rare cases.
Meter Type = Insertion (model 221) or Inline (model 220) meter.
Test Pulse Out = Force totalizer pulse. Set to YES and press
ENTER to send one pulse. Very useful to test totalizer counting equipment.
Analog Output Calibration
To check the 4–20 mA circuit, connect a DVM in series with the output loop. Select zero or full scale (from the second column of the hidden di-
IM-22 5-3
Page 55
Chapter 5 Troubleshooting & Repair Series 220/221 Instruction Manual
agnostics) and then actuate the enter key twice. This action will cause the meter to output its 4 mA or 20 mA condition. If the DVM indicates a current greater than ± 0.006 mA from 4 or 20, adjust the setting up or down until the output is calibrated. Note: these settings are not for adjust­ing the output zero and span to match a flow range, that function is lo­cated in the Output Menu.
Troubleshooting the Flow Meter
Symptom: Output at no Flow
1. The low flow cutoff is set too low. At no flow, go to the first column
of the hidden diagnostics menu and record Lvl value. The low flow cutoff must be set above this value. Example: at no flow, Lvl = 25. Set the low flow cutoff in the Cali­bration Menu to approximately 28 and the meter will no longer read a flow rate at no flow.
Symptom: Erratic Output
1. The flow rate may be too low, just at the cutoff of the meter range,
and the flow cycles above and below the cutoff making an erratic output. The meter range is stamped on the label on the outside of the electronics enclosure cover (based on application conditions when the meter was ordered). Consult the factory if necessary to confirm the meter range based on current operating conditions. It may be possible to lower the low flow cutoff to increase the meter range. See the example above for output at no flow, only this time the low flow cutoff is set too high. You can lower this value to increase the meter range as long as you do not create the output at no flow condi­tion previously described.
2. Mechanical installation may be incorrect. Verify the straight run is
adequate as described in Chapter 2. For in-line meters, make sure the meter is not installed backwards and there are no gaskets protrud­ing into the flow stream. For insertion meters, verify the insertion depth and flow direction.
3. The meter may be reacting to actual changes in the flow stream. The
output can be smoothed using a time constant. The displayed values can be smoothed using the time constant in the Display Menu. The analog outputs can be smoothed using the time constant in the Out­put Menu. A time constant of 1 will result in the change in value reaching 63% of its final value in one second. A time constant of 4 is 22%, 10 is 9.5% and 50 is 1.9% of the final value in one second. The time constant equation is shown below (TC = Time Constant).
4. The vortex coefficient Ck may be incorrectly set. The Ck is a value
% change to final value in one second
in the equation used to determine if a frequency represents a valid vortex signal given the fluid density and signal amplitude. In prac-
= 100 (1 – e
(-1/TC)
)
5-4 IM-22
Page 56
Series 220/221 Instruction Manual Chapter 5 Troubleshooting & Repair
tice, the Ck value controls the adaptive filter, fi, setting. During flow, view the f and fi values in the first column of the hidden diag­nostics. The fi value should be approximately 25 % higher than the f value. If you raise the Ck setting in the Calibration Menu, then the fi value will increase. The fi is a low pass filter, so by increasing it or lowering it, you can alter the range of frequencies that the meter will accept. If the vortex signal is strong, the fi value will increase to a large number – this is correct.
Symptom: No Output
1. For remote mounted electronics, carefully check all the wiring con-
nections in the remote mount junction box. There are 6 connections that must be correct, verify each color (black and red), shield, and wire number.
2. Check the density value in the Calibration Menu to see if it is correct
for the current operating conditions.
3. Using ESD precautions and hazardous area precautions, remove the
electronics enclosure window cover. Disconnect the vortex sensor from the Signal board. Measure the resistance from each Sensor pin to the meter ground - each should be open, ( see drawing below). Measure the resistance from the Ground pin to the meter ground – this should be grounded to the meter. With the sensor still discon­nected, go the first column of the hidden diagnostics and display the vortex shedding frequency, f. Hold a finger on the four exposed pins on the Signal board. The meter should read electrical noise, 60 Hz for example. If all readings are correct, re-install vortex sensor wires.
4. Verify all meter configuration and troubleshooting steps previously
described. There are many possible causes of this problem, consul­factory if necessary.
IM-22 5-5
Page 57
Chapter 5 Troubleshooting & Repair Series 220/221 Instruction Manual
Electronics Assembly Replacement (All Meters)
The electronics boards are electrostatically sensitive. Wear a grounding wrist strap and make sure to observe proper handling precautions re­quired for static-sensitive components.
1. Turn off power to the unit.
Warning!
Before attempting any flow
meter repair, verify that the
line is not pressurized.
Always remove main power
before disassembling any
part of the mass flow meter.
4. Locate and loosen the small set screw which locks the smaller enclo-
5. Remove the screws that hold the black wiring label in place, remove
6. Locate the 4 Phillips head screws which are spaced at 90-degrees
7. Carefully remove the electronics stack from the opposite side of the
8. Repeat steps 1 through 6 in reverse order to install the new electron-
2. Locate and loosen the small set screw which locks the larger
enclosure cover in place. Unscrew the cover to expose the electronics stack.
3. Locate the sensor connector that comes up from the neck of
the flow meter and attaches to the circuit board. Use small pliers to pull the connector off of the circuit board.
sure cover in place. Unscrew the cover to expose the field wiring strip. Tag and remove the field wires.
the label.
around the terminal board. These screws hold the electronics stack in the enclosure. Loosen these screws (Note: that these are captive screws, they will stay inside the enclosure).
enclosure. If the electronics stack will not come out, gently tap the terminal strip with the screw driver handle. This will loosen the rub­ber sealing gasket on the other side of the enclosure wall. Be careful that the stack does not hang up on the loose sensor harnesses.
ics stack.
5-6 IM-22
Page 58
Series 220/221 Instruction Manual Chapter 5 Troubleshooting & Repair
Returning Equipment to the Factory
Before returning any Innova-Flo meter to the factory, you must re­quest a Return Material Authorization (RMA) number. To obtain an
RMA number and the correct shipping address, contact Customer Ser­vice at:
(800) 866-0200 or (831) 373-0200 in the USA, or +31(0)20-6145810 in Europe.
When contacting Customer Service, be sure to have the meter serial number and model code.
When requesting further troubleshooting guidance, record the following values first:
f, fi, G, and A at no flow and during flow if possible. Pressure, temperature, and flow rate
IM-22 5-7
Page 59
Chapter 5 Troubleshooting & Repair Series 220/221 Instruction Manual
5-8 IM-22
Page 60
Series 220/221 Instruction Manual Appendix A Specifications
Appendix A Product Specifications
Accuracy
Process 220 Series In-Line Meters 221 Series Insertion Meters Variables Liquids Gas & Steam Liquids Gas & Steam Volumetric
Flow Rate
±0.7% of rate
over a
30:1 range
(2)
±1% of rate
over a
30:1 range
(2)
±1.2% of
rate over a
30:1 range
±1.5% of rate
(2)
30:1 range
Notes: (1) Accuracies stated are for the total volumetric flow through the
pipe.
(2) Nominal rangeability is stated. Precise rangeability depends on
fluid
Repeatability 0.1% of rate. Response Time Adjustable from 1 to 100 seconds.
and pipe size.
Material Compatibility Series 220 In-Line Flow Meter: Any gas, liquid or steam compatible with 316L stainless steel, C276
hastelloy or A105 carbon steel. Not recommended for multi-phase flu­ids.
Series 221 Insertion Flow Meter: Any gas, liquid or steam compatible with 316L stainless steel. Not
recommended for multi-phase fluids.
Flow rates Typical volumetric flow ranges are given in the following tables. Precise
flow range depends on the fluid and pipe size. 221 insertion meters are applicable to pipe sizes from 2 inch and above. Consult factory for siz­ing program.
Air Minimum and Maximum Flow Rates (scfm) (1) Pressure ½-inch ¾-inch 1-inch 1.5-inch 2-inch 3-inch 4-inch 6-inch 8-inch 0 psig 1.8
17.5
100 psig 5
137
200 psig 6.8
257
300 psig 8.3
378
400 psig 9.5
500
500 psig 10.6
620
3.3
41.4
9.2
324
12.6 608
15.3 893
17.5
1178
19.5
1464
5
90 15
701
20
1313
24
1924
27
2535
29
3147
13
221
37
1728
50
3234
59
4740
66
6246
72
7752
22
369
62
2879
83
5389
98
7900
110
10410
120
12920
50
826 138
6447
185
12067
220
17687
247
23308
270
22592
88
1438
240
11222
322
21006
382
30789
430
31141
469
29834
198
3258
543
25421
730
47585
866
48821
975
46884
1063
44915
Note: (1) Standard conditions are 70° F and 1 atmosphere.
Steam Minimum and Maximum Flow Rates (lb/hr) Pressure ½-inch ¾-inch 1-inch 1.5-inch 2-inch 3-inch 4-inch 6-inch 8-inch 5 psig 6.5
51.7
100 psig 14.8
270
200 psig 20
493
300 psig 24
716
400 psig 27.7
940
500 psig 30.8
1170
12
122
27.4 639
37
1164
44.5
1689
51
2220
57
2761
20
265
46
1385
61
2524
74
3662
85
4814
95
5986
49
652 112
3413
151
6217
182
9021
209
11859
233
14745
82
1087
187
5688
252
10362
304
15035
349
19764
389
24575
183
2434
419
12735
565
23200
681
33664
781
44253
870
55025
319
4237
729
22168
984
40385
1185
58601
1359
77033
1515
95784
722
9598 1651
50219
2229
91485
2685
132750
3078
174505
3433
216983
over a
5708
44536
1279
67122
1518
64552
1708
61990
1862
59387
1265
16815
2893
87980
3905
160275
4707
232570
5393
305721
6014
331080
(1)
(2)
347
952
IM-22 A-1
Page 61
Appendix A Specifications Series 220/221 Instruction Manual
Water Minimum and Maximum Flow Rates ½-inch ¾-inch 1-inch 1.5-inch 2-inch 3-inch 4-inch 6-inch 8-inch gpm 1
22
m3/hr .23 5 .3
Linear Range Smart electronics corrects for lower flow down to a Reynolds num-
Liquids 30:1 1 foot per second velocity minimum 30 feet per second velocity maximum Gases 30:1 10 feet per second velocity minimum 300 feet per second velocity maximum
Process Fluid Pressure
Process Fluid and Ambient Temperature Standard temperature sensor: –40° to 400° F (–40° to 205° C). Medium temperature sensor: 250° to 500° F (120° to 260° C). High temperature sensor: 250° to 750° F (120° to 400° C).
Operating: –5° to 140° F (–20° to 60° C). Storage: –40° to 150° F (–40° to 65° C). 0-98% relative humidity, non-condensing conditions.
1.3 40
9.1
Connection
Probe Seal Process
Compression Fitting
Packing Gland 2-inch MNPT 316L SS 50 psig PM
Packing Gland with Removable Retractor
Packing Gland with Permanent Retractor
2.2 67
0.5 15
Process
Flanged 316L SS, A105 Carbon Steel, C276 Hastelloy 150, 300, 600 lb
Wafer 316L SS, A105 Carbon Steel, C276 Hastelloy 600 lb
2-inch 150 lb flange 316L SS ANSI 150 lb CF 2-inch 300 lb flange 316L SS ANSI 300 lb CG 2-inch 600 lb flange 316L SS ANSI 600 lb CH
2-inch 150 lb flange 316L SS 50 psig PF 2-inch 300 lb flange 316L SS 50 psig PG
2-inch 150 lb flange 316L SS ANSI 150 lb PF, RR 2-inch 300 lb flange 316L SS ANSI 300 lb PG, RR
2-inch 150 lb flange 316L SS ANSI 150 lb PFR 2-inch 300 lb flange 316L SS ANSI 300 lb PGR 2-inch 600 lb flange 316L SS ANSI 600 lb PHR
5.5
166
1.3 38
ber of 5,000. The Reynolds number is calculated using the fluid density and viscosity entered into the memory. Rangeability de­pends on the fluid, process conditions and pipe size. Consult factory for your application. Velocity rangeability under ideal conditions is as follows:
Process Fluid:
Ambient:
9.2
276
2.1 63
220 Pressure Ratings
Material Rating
221 Pressure Ratings
Connection
2-inch MNPT
2-inch MNPT
2-inch MNPT
21
618
4.7
140
Material Rating Ordering
316L SS ANSI 600 lb
316L SS ANSI 300 lb PM, RR
316L SS ANSI 600 lb PMR
36
1076
8.1
244
81
2437
18
554
142
4270
32
970
Code
CM
A-2 IM-22
Page 62
Series 220/221 Instruction Manual Appendix A Specifications
Power Requirements Loop powered, 12 to 36 VDC. Output Signals Analog: field rangeable linear, 4-20 mA output signal, 1000 ohms
Pulse: field rangeable volume/pulse output for totalization is a 50-
Display Alphanumeric 2 x 16 LCD digital display. Six push buttons (up, down, right, left, enter, exit) operable either di-
Viewing at 90° mounting intervals.
Totalizer Based on user-determined flow units, six significant figures in scien-
Wetted Materials Series 220 In-Line Flow Meter: 316L stainless steel standard. C276 hastelloy or A105 carbon steel optional.
Series 221 Insertion Flow Meter: 316L stainless steel standard. Teflon Graphite packing gland above 500° F (205° C).
Enclosure NEMA 4X cast enclosure. Electrical Ports Two 3/4-inch female NPT ports. Mounting Connections Series 220: Wafer or 150, 300, 600 lb ANSI flange.
Series 221 Permanent installation: 2-inch MNPT; 150, 300, 600 lb Series 221 Hot Tap Note: (1) Removable under line pressure. Mounting Position
Series 221 Insertion Flow Meter: Meter must be perpendicular Note: (1) For liquid applications, pipeline must remain full at all
Certifications Construction Inspection ( ANSI/ASME B31.3). Materials (NACE MR-01-75[90]). CE and FM approved. CSA, CENELEC approval pending.
FM approvals: Class I, Division 1, Groups B, C, & D, T6 at Tamb = 60°C Class II/III, Division 1, Groups E, F, & G IP66, NEMA 4X
(1)
Series 220 In-Line Flow Meter: No effect.
maximum loop resistance, selected by user for volumetric flow rate or mass flow rate.
millisecond duration pulse operating a solid-state relay capable of switching 40 VDC, 40 mA maximum.
rectly on the display panel or with a hand-held magnet through the display glass of the explosion-proof enclosure.
tific notation. Total stored in non-volatile memory.
®
packing gland below 500° F (205° C).
ANSI flange with compression fitting probe seal. ANSI flange and optional retractor with packing gland probe seal.
within ± 5° of the pipe centerline. times.
(1)
Installation: 2-inch MNPT; 150, 300, 600 lb
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Appendix A Specifications Series 220/221 Instruction Manual
A-4 IM-22
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Series 220/221 Instruction Manual Appendix B Glossary
Appendix B Glossary A B C D
A Cross sectional area. acfm Actual cubic feet per minute (volumetric flow rate). ASME American Society of Mechanical Engineers. Bluff Body A non-streamlined body placed into a flow stream to
create vortices. Also called a Shedder Bar. BTU British Thermal Unit, an energy measurement. Cenelec European Electrical Code. Compressibility A factor used to correct for the non-ideal changes in
Factor a fluid’s density due to changes in temperature
and/or pressure. CSA Canadian Standards Association. d Width of a bluff body or shedder bar. D Diameter of a flow channel.
E F G H
f Frequency of vortices generated in a vortex flow meter, usually in Hz.
Flow Channel A pipe, duct, stack, or channel containing flowing fluid. Flow Profile A map of the fluid velocity vector (usually non-
uniform) in a cross-sectional plane of a flow channel
(usually along a diameter). FM Factory Mutual. Ft Foot, 12 inches, a measure of length. Ft^2 Square feet, measure of area. Ft^3 Cubic feet, measure of volume. gpm Gallons per minute. Hz Hertz, cycles per second.
IM-22 B-1
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Appendix B Glossary Series 220/221 Instruction Manual
I J K L
In-Line Flow Meter A flow meter which includes a short section of piping
which is put in-line with the user’s piping.
Insertion Flow Meter A flow meter which is inserted into a hole in the
user’s pipeline.
Joule A unit of energy equal to one watt for one second.
Also equal to a Newton-meter.
LCD Liquid crystal display.
M N O P
m Mass flow rate.
mA Milli-amp, one thousandth of an ampere of current. µ Viscosity, a measure of a fluid’s resistance to shear stress.
Honey has high viscosity, alcohol has low viscosity.
P Permanent pressure loss.
P Line pressure (psia or bar absolute).
ρ
The density of a fluid at the actual temperature and
act
pressure operating conditions.
ρ
The density of a fluid at standard conditions (usually
std
14.7 psia and 20° C).
Permanent Unrecoverable drop in pressure. Pressure Loss
Piezoelectric Crystal A material which generates an electrical charge
when the material is put under stress.
PRTD An resistance temperature detector (RTD) with plati-
num as its element. Used because of high stability.
psia Pounds per square inch absolute (equals psig + atmospheric pressure). Atmospheric
pressure is typically 14.696 psi at sea level.
psig Pounds per square inch gauge.
Liquid vapor pressure at flowing conditions (psia or
P
V
bar absolute).
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Series 220/221 Instruction Manual Appendix B Glossary
Q R S T
Q Flow rate, usually volumetric. Rangeability Highest measurable flow rate divided by the lowest
measurable flow rate. Reynolds Number A dimensionless number equal to the density of a fluid
or Re times the velocity of the fluid times the diameter of the
fluid channel, divided by the fluid viscosity (i.e., Re =
ρVD/µ). The Reynolds number is an important num-
ber for vortex flow meters because it is used to deter-
mine the minimum measurable flow rate. It is the ratio
of the inertial forces to the viscous forces in a flowing
fluid. RTD Resistance temperature detector, a sensor whose
resistance increases as the temperature rises. scfm Standard cubic feet per minute (flow rate converted
to standard conditions, usually 14.7 psia and 20° C). Shedder Bar A non-streamlined body placed into a flow stream to
create vortices. Also called a Bluff Body. Strouhal Number A dimensionless number equal to the frequency
or St of vortices created by a bluff body times the width of
the bluff body divided by the velocity of the flowing
fluid (i.e., St = fd/V). This is an important number for
vortex flow meters because it relates the vortex fre-
quency to the fluid velocity. Totalizer An electronic counter which records the total accu-
mulated flow over a certain range of time. Traverse The act of moving a measuring point across the
width of a flow channel.
U V W X Y Z
Uncertainty The closeness of agreement between the result of a
measurement and the true value of the measurement. V Velocity or voltage. VAC Volts, alternating current. VDC Volts, direct current. VORTEX An eddy of fluid.
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Appendix B Glossary Series 220/221 Instruction Manual
B-4 IM-22
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