Hydreka HYDRINS 2 User manual

HydrINS 2 / HydrINS 2 Mini Flow Meter
Installation Manual
Page 1/73
HydrINS 2 and HydrINS 2 Mini
Electromagnetic Insertion Flow Meters
Installation Manual
Revision
Date
Author
Modifications
Signature
01
15/02/11
GSE
Approval
GSE
00
15/12/10
MRE
Updated

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Installation Manual
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CONTENTS
1INTRODUCTION .......................................................................................................... 6
1.1 Measurement Principle ...................................................................................................... 7
1.2 Environmental and safety conditions .................................................................................. 8
1.3 Conditions in the measurement environment ..................................................................... 8
1.4 Software environment ....................................................................................................... 9
1.5 Safety ................................................................................................................................ 9
1.6 Product transport............................................................................................................. 10
1.7 Product guarantee............................................................................................................ 12
1.8 Conditioning the product before use................................................................................. 12
2DESCRIPTION OF THE HYDRINS2/HYDRINS 2 MINI PRODUCT RANGE ......................... 13
2.1 Mechanical description: ................................................................................................... 13
2.2 Models in the HydrINS 2 / HydrINS 2 Mini flow meter range.............................................. 15
3INSTALLATION LOCATION OF THE HYDRINS 2 / HYDRINS 2 MINI FLOW METER .......... 17
3.1 Choice of installation location and installation and flow conditions ................................... 17
3.2 Velocity limits for measurement ....................................................................................... 18
3.3 Choice of position for the electromagnetic sensor............................................................. 19
3.4 Valve diagram for the installation of HydrINS 2 / HydrINS 2 Mini flow meters.................... 20
3.5 Inside diameter measurement gauges .............................................................................. 21
4INSTALLATION OF THE HYDRINS 2 / HYDRINS 2 MINI FLOW METER........................... 23
4.1 Method for installation at the centre:............................................................................... 23
4.1.1 Step 1/3: Measuring the inside diameter ID using the gauge............................................. 24
4.1.2 Step 2/3: Measurement of insertion length at the centre LI1/2 .......................................... 25

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Installation Manual
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4.1.3 Step 3/3: Insertion of the probe ......................................................................................... 26
4.2 Method for installation at 1/8 .......................................................................................... 27
4.3 Aligning the guide bar with the direction of flow............................................................... 28
5INSTALLING THE PRESSURE CHANNEL ON A DATA LOGGER ....................................... 29
6PROCESSING OF DATA MEASURED BY DISPLAY OR RECORDING ................................ 29
7INSTALLATION OF A DISPLAY A OR A DISPLAY C ........................................................ 31
7.1 Overview of Displays A and C............................................................................................ 31
7.2 Wall mounting of Display A or Display C............................................................................ 33
7.3 Mode change of the HydrINS 2 and HydrINS 2 Mini probes................................................ 34
7.3.1 Equipment........................................................................................................................... 34
7.3.2 Removal............................................................................................................................... 34
7.3.3 Mode change....................................................................................................................... 36
7.4 Electrical power supply of Display A.................................................................................. 36
7.4.1 Internal power supply using 3.6 VDC lithium batteries ...................................................... 37
7.4.2 External power supply using 3.6 VDC lithium batteries...................................................... 38
7.4.3 Internal power supply using alkaline batteries................................................................... 39
7.4.4 External 9 to 28 VDC power supply connected to the internal terminals. ......................... 39
7.4.5 External power supply by military connector ..................................................................... 40
7.5 Electrical power supply of Display C .................................................................................. 40
7.6 Wiring of the entities of the measurement chain............................................................... 42
7.7 Internal wiring ................................................................................................................. 45
7.7.1 Connections of the flow meter pulse output to the Display terminal block ...................... 45
7.7.2 Pulse output connections to the Display terminal block .................................................... 46
7.7.3 Wiring the 4-20 mA outputs to the terminal block of Display C ......................................... 47
7.8 Protecting the displays from lightning and surges.............................................................. 48

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Installation Manual
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8MAINTENANCE ......................................................................................................... 49
9MAINTENANCE ......................................................................................................... 50
9.1 Calibration ....................................................................................................................... 50
9.2 Replacing the batteries of the HydrINS 2 / HydrINS 2 Mini flow meter ............................... 51
9.3 Replacing the batteries in Display A .................................................................................. 51
10 PRODUCT DISPOSAL .............................................................................................. 52
APPENDIX 1: SELECTION GUIDE - THE RIGHT HYDRINS 2 MODEL FOR YOUR MEASUREMENT
SITE ACCORDING TO YOUR PIPE ...................................................................................... 53
APPENDIX 2: INSIDE DIAMETER GAUGES ......................................................................... 62
APPENDIX 3: CATALOGUE NUMBERS ASSOCIATED WITH THE RANGE OF HYDRINS 2 /
HYDRINS 2 MINI PRODUCTS............................................................................................ 63
APPENDIX 4: TEMPLATE FOR HYDREKA CALIBRATION CERTIFICATE FOR THE HYDRINS 2 /
HYDRINS 2 MINI FLOW METER ........................................................................................ 67
TABLE OF ILLUSTRATIONS ............................................................................................... 68
LIST OF TABLES ............................................................................................................... 70

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Installation Manual
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This document is the user manual for the following electromagnetic insertion flow meter: HydrINS
2/HydrINS 2 Mini in the configuration with Displays A and C
For acquisition programming, refer to the HydrINS 2 / HydrINS 2 Mini flow meter programming
manual, the programming manual for the data logger used, and the programming manual for an
internal pressure channel
For additional information, please contact us:
HYDREKA
34, route de Saint Romain –69450 ST CYR AU MONT D’OR – France
Tel.: [phone] –Fax: [phone]
E-mail: [e-mail] or [e-mail]
Customer Service: [e-mail]
Rentals: [e-mail]
Sales: [e-mail]
Export: expo[email protected]

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Installation Manual
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1Introduction
The HydrINS 2/ HydrINS 2 Mini electromagnetic insertion flow meter is intended to measure flow in
pipes carrying drinking water or raw water. The probe performs a velocity measurement and
calculates the flow rate by integrating the velocity over the flow cross-section.
The measurement scale is from 2 cm/s to 5 cm/s and the relative measurement accuracy is +/-2% or
+/-2 mm/s, where the error applied is the larger of the two.
The HYDREKA range of electromagnetic insertion flow meters comprises the HydrINS 2, which comes
in five standard lengths (300, 500, 700, and 1000 mm) and the HydrINS2 Mini, covering diameters
from 70 mm to more than 2000 mm.
Flow meters are installed using a 1" BSP or NPT insert collar equipped with a ball valve (also possible
using a 3/4" BSP or NPT collar, but only for the HydrINS 2 Mini).
HydrINS 2 and HydrINS 2 Mini electromagnetic insertion flow meters can operate in several different
configurations:
Connected to a standalone data logger with a digital input channel
(records data on site): Lolog, Vista +
Connected to a standalone data logger with a digital input channel
with communications capability (records data remotely): Octopus LX
Connected to a Display A, blue (possibility of a Pulse output to a
remote management system)
Connected to a Display C, green (possibility of a Pulse or 4-20 mA
output to a remote management system)
Two measurement positions are used for continuous flow measurement:
The position at the centre of the pipe, position representing the maximum speed
The position at one eighth of the diameter, a position representing the average speed
The velocity sensor of the HydrINS 2/HydrINS 2 Mini flow meter can be inserted in different positions
across the cross-section of the pipe. This allows a flow velocity profile to be created in order to refine
the mean speed calculation and therefore also the flow measurement. A set of default parameters is
available in the Winfluid software (refer to the HydrINS 2 / HydrINS 2 Mini Flow Meter
Programming Manual).
All Catalogue Numbers for the products presented in this manual are listed in Appendix 3.

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Installation Manual
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1.1 Measurement Principle
The velocity measurement principle is based on the application of Faraday's Law, which states that a
voltage is generated by the movement of a conductor through a magnetic field.
In the case of HydrINS 2/HydrINS 2 Mini, the magnetic field is generated by a coil at the end of the
probe, and the water passing through the pipe, whose conductivity must be at least 20 µS/cm,
represents the conductor.
The electromotive force generated by the passage of the water through the magnetic field,
comparable to a voltage, is measured by the two electrodes, which are visible on both sides of the
stem. Because this electromotive force is proportional to the velocity, the HydrINS 2/ HydrINS 2 Mini
probe carries out a velocity measurement derived from the electromotive force of the water. The
flow rate is then deduced from this velocity measurement.
The electromagnetic sensor is located at the tip of the insertion rod. It has an exciter coil and two
electrodes, seen on the side of the sensor.
Figure 1: Location of sensor on the HydrINS2/HydrINS 2 Mini flow meter
Probe head and guide bar
Insertion stem
Electrodes
Sensor

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Installation Manual
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The flow value is obtained via the following processing chain:
Figure 2: HydrINS 2/HydrINS 2 Mini data processing system
1.2 Environmental and safety conditions
Optimum use of the HydrINS 2 flow meter requires a suitable measurement environment in order to
avoid as far as possible any environmental disturbances that could affect the measurement.
Hydreka shall not be held liable for the quality of the measurements performed using the HydrINS
2/HydrINS 2 Mini flow meter if the recommendations given below are not observed.
1.3 Conditions in the measurement environment
Protection: IP 68 (NEMA 6): resistance to submersion within the limits of the
standard
Operating temperature range: -20°C to +60°C
Storage temperature range: -20°C to +70℃
Measured velocity Vm
= A × Fi × Fp × Vm
Where:
Q: flow rate
A: internal cross-section (calculated by Winfluid software from the inside diameter,
ID)
Fi: insertion factor (calculated by the Winfluid software)
Fp: profile factor (calculated by the Winfluid software)
Vm: measured velocity

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Installation Manual
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1.4 Software environment
The HydrINS 2 and HydrINS 2 Mini and Displays A and C are configurable using Winfluid and Winfluid
Mobile software, developed by Hydreka.
1.5 Safety
THE CONDUCTIVITY OF THE WATER PASSING THROUGH THE PIPE
MUST BE GREATER THAN 20µS/cm.
Minimum software version: Winfluid 2.98 or Winfluid Mobile 1.98
: The physical installation of the HydrINS 2/HydrINS 2 Mini
probe is a potentially hazardous operation. Because of the intrusive
nature of the procedure, the probe can be ejected if there is excessive
pressure inside the pipe. The probe is supplied with a safety chain,
which must be used. Ensure compliance with the installation
conditions (pumps shut off, wait for night-time conditions before
installing, etc.).
ENSURE THAT THE CHAIN IS OPERATIONAL BEFORE OPENING THE
INSERT VALVE
WARNING: It is essential to avoid sites where the pipes vibrate. If the
probe vibrates excessively after installation, the measurement will
not be correct. In this case, remove the probe.

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Installation Manual
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Figure 3: Safety chain
The safety chain is also used to ensure that the probe is fully raised when the flow meter is
withdrawn. It is connected to a hook that can pivot around the probe.
1.6 Product transport
The HydrINS 2 / HydrINS 2 Mini flow meters are delivered in an appropriate box with polystyrene
blocks to protect them during transport.
Figure 4: Typical packaging of the HydrINS2/HydrINS 2 Mini
Safety chain

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Installation Manual
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Reinforced cases, called PELICASE, are also available for the transport of HydrINS 2/HydrINS 2 Mini
300 to 700 models and their accessories:
Figure 5: Pelicase transport case
Your package, whether a box or a case, must contain:
The HydrINS 2 / HydrINS 2 Mini flow meter with plug
Guide bar, attached or bonded to the flow meter
This installation manual
The programming manual
: ENSURE THAT THE GUIDE BAR IS PRESENT IN THE PACKAGE. IT
IS ESSENTIAL FOR THE OPERATION OF THE HYDRINS 2 / HYDRINS 2
MINI. IT IS CONNECTED TO THE FLOW METER

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Installation Manual
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Figure 6: HydrINS 2 / HydrINS 2 Mini guide bar connected to the flow meter in the packaging
The HydrINS 2 / HydrINS 2 Mini flow meter is delivered with a protective plug. Please remove it
before installing the HydrINS 2 in the pipe.
Figure 7: Flow meter protection plug
1.7 Product guarantee
The HydrINS 2 / HydrINS 2 Mini has a two-year guarantee when used in accordance with the
conditions of use. Contact Hydreka Customer Service to invoke this guarantee if necessary.
1.8 Conditioning the product before use
The sensor of the HydrINS 2/HydrINS 2 Mini flow meter must be soaked for one day before use in
order to obtain stable measurements.

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Installation Manual
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2Description of the HydrINS2/HydrINS 2 Mini product range
2.1 Mechanical description:
Figure 8: Mechanical description of the HydrINS 2 / HydrINS 2 Mini flow meter
Probe head with
orientation arrow
Alignment stem
Communication
port and pulse
output
Insertion marking
Clamp ring
Pressure output
Sensor

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Installation Manual
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*A: dimension A is 689 for Cat. No.:SI_HYDA2P-30 / 869 for Cat. No. SI_HYDA2P-50 / 1109 for SI_HYDA2P-70 /
1409 for SI_HYDA2P-100 / 500 for Cat. No. SI_HYDE2-15
Figure 9: Drawing of the HydrINS 2 and HydrINS 2 Mini probes
A*
100
29
55
215
120
Alignment stem
Watertight military
connector
Insertion marking
Clamp ring
Adapter
1 " BSP/NPT
Chain mounting ring
Chain attachment and
adjustment hook
Safety chain
Reinforced ABS
housing
100
50
22
50
145
120
HydrINS 2
HydrINS 2 Mini
3/4 " BSP/NPT
300
300
15
21
234
(B)
165
(B)
A*

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Installation Manual
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2.2 Models in the HydrINS 2 / HydrINS 2 Mini flow meter range
The following table is a selection guide to identify the most appropriate HydrINS 2 model according
to the pipe diameter and dimensions as shown in the diagram above:
A: Total stem length (see the above diagram)
B: Stacking length of HydrINS 2/HydrINS 2 Mini accessories (see dimensions on the diagram
above)
C: Stacking height at insertion level (theoretical value, must be checked on site).
HYDREKA
Catalogue
Number
Model
Hydrins
Dimension
A
Dimension
B
Dimension
C*
Available
insertion
length
= A-(B+C)
Usable on pipe
diameters
Profile
Centre
SI_HYDA2P-30
300
689
234
200
255
< 250
mm
< 500 mm
SI_HYDA2P-50
500
869
234
200
400
< 400
mm
< 800 mm
SI_HYDA2P-70
700
1109
234
200
675
< 650
mm
< 1300 mm
SI_HYDA2P-100
1000
1409
234
200
975
< 950
mm
< 1900 mm
SI_HYDE2-15
Min
(300)
500
165
200
175
< 180
mm
< 300 mm
Table 7: Flow meter selection table according to the flow range to be measured
*Warning: This is a theoretical value. It is provided as an indication, but must be checked on site
The model is also chosen according to the space available in the port. Allow sufficient distance above
the insertion point for installation in a port or valve chamber, known as the clearance height.

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Installation Manual
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The clearance heights are presented in the table below:
Model
Clearance height (mm)
300
800
500
980
700
1220
1000
1520
Min.
610
Table 7: Clearance heights above the insertion point required for installation of a HydrINS 2 / HydrINS 2 Mini flow meter.
Appendix 1 presents the HydrINS 2 / HydrINS 2 Mini flow meter models that can be used for several
standardised diameters.
Clearance height

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Installation Manual
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Q
3Installation location of the HydrINS 2 / HydrINS 2 Mini flow meter
3.1 Choice of installation location and installation and flow conditions
For accurate measurement of the flow, the pipe must be continuously carrying a flow, and
disturbance-free upstream and downstream distances ('straight lengths') must be observed. The
table below summarises the upstream distances to be observed according to the disturbing element
Figure 10: Flow conditions to be observed
UPSTREAM STRAIGHT LENGTH: See Table 1
DOWNSTREAM
STRAIGHT LENGTH:
5×ID
DIRECTION OF FLOW
*ID: inside diameter of pipe

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Installation Manual
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Disturbances
Upstream straight length to be observed (multiple of
the internal diameter ID)
Measurement to the
centre
Measurement to 1/8th
90° connection or elbow
25
50
Convergent cone (18 to 36°)
10
30
Divergent cone (14 to 28°)
25
55
Open gate valve
15
30
Open butterfly valve
25
45
Table 1: Upstream disturbance-free straight lengths to be observed
3.2 Velocity limits for measurement
Maximum velocities must be observed in order to prevent irreversible damage to the sensor. The
following charts show the maximum velocity applicable to the probe according to the chosen sensor
diameter and position. These values are provided as an indication. They are used when programming
the flow meter in Winfluid in the form of the maximum flow rate tolerated by the probe (refer to
the HydrINS 2/HydrINS 2 Mini flow meter acquisition programming manual)
The flow rate is calculated based on a perfectly developed flow profile. Refer to the ISO 7145-1982
standard.
0
1
2
3
4
5
6
Vitesse (m/s)
Diamètre (mm)
Vitesses maximum en mesure permanente
Centre
1/8 du diamètre
Figure 11: Maximum velocity for different pipe internal diameters
The creation of a velocity profile is used to refine the insertion factor and profile factor values (refer
to the HydrINS 2 / HydrINS 2 Mini flow meter acquisition programming manual). The order of
magnitude of the maximum velocities to be observed are indicated on the chart below.
1/8th of diameter
Diameter (mm)
Maximum velocities in permanent measurement
Velocity (m/s)

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Installation Manual
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0
1
2
3
4
5
6
100
200
300
400
500
600
700
800
900
1000
Vitesse (m/s)
Diamètre de conduite (mm)
Ordre de grandeur de vitesse à ne pas dépasser
pour réaliser un profil de vitesse
Figure 12: Orders of magnitude of maximum velocities not to be exceeded to create a velocity profile
3.3 Choice of position for the electromagnetic sensor
Two precise positions are chosen for the electrodes in order to take a flow measurement:
At the centre of the pipe
At 1/8th of the pipe diameter
Figure 13: Valid positions of the HydrINS2/HydrINS 2 Mini flow meter sensor for flow measurement
Position at 1/8 diameter, mean velocity
Position at 1/2 diameter, mean velocity
Orders of magnitude of maximum velocities not to be
exceeded to create a velocity profile
Velocity (m/s)
Pipe diameter (mm)

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Installation Manual
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3.4 Valve diagram for the installation of HydrINS 2 / HydrINS 2 Mini flow
meters
Figure 14: Diagram for the adaptation of different threads for the installation of the HydrINS 2/HydrINS 2 Mini flow
meter
1
4
5
6
7
HydrINS 2 PROBE
BALL VALVE
PIPE TO BE
EQUIPPED WITH
INSTRUMENTATION
3
1B
2
HydrINS 2 Mini PROBE
4B
3B
5
INSERT COLLAR
KEY
1 - 1 " BSP (NPT) thread
1B - 3/4" BSP (NPT) thread
2 - 3/4"-1" BSP (NPT) adapter (Not
supplied)
3- 1 " BSP (NPT) tapping
3B - 3/4" BSP (NPT) tapping
4 - Full bore 25 mm min.
4B - Full bore 19 mm min.
5 - M40 ×3 or M16 thread
6 - M40 ×3 or M16 tapping
7 - ф 25 mm or ф 19 mm (HydrINS 2
Mini) pipe drilling