Intek Rheotherm 210 User manual

TABLE OF CONTENTS
SECTION 1 !GENERAL INFORMATION ..................................... -1-
1.1 INTRODUCTION .............................................. -1-
1.2 DESCRIPTION OF OPERATION ................................. -2-
1.3 PRECAUTIONS ............................................... -2-
SECTION 2 !INSTALLATION .............................................. -4-
2.1 SENSOR ..................................................... -4-
2.2 TRANSMITTER ELECTRONICS ................................. -6-
2.3 ELECTRICAL CONNECTIONS .................................. -7-
SECTION 3 !OPERATION ................................................. -11-
3.1 START UP ................................................... -11-
3.2 GENERAL INFORMATION .................................... -11-
3.3 OPERATIONAL INTERFACES ................................. -11-
3.4 INSTRUMENT CONFIGURATION .............................. -12-
3.5 OUTPUT CURVE ............................................. -16-
SECTION 4 !MAINTENANCE ............................................. -17-
4.1 GENERAL MAINTENANCE .................................... -17-
4.2 FLOW CALIBRATION ADJUSTMENT ........................... -17-
4.3 SPARE PARTS ............................................... -17-
4.4 TROUBLESHOOTING ......................................... -17-
SECTION 5 !CUSTOMER SERVICE ........................................ -21-
5.1 QUESTIONS ON EXISTING HARDWARE ........................ -21-
5.2 TROUBLESHOOTING ......................................... -21-
5.3 FACTORY AND FIELD SERVICE ............................... -21-
5.4 DECONTAMINATION OF EQUIPMENT ......................... -21-
5.5 QUESTIONS ON NEW EQUIPMENT ............................ -21-
SECTION 6 !CUSTOM INFORMATION ..................................... -22-
6.1 UNIT IDENTIFICATION ....................................... -22-
6.2 CONFIGURATION ............................................ -22-
6.3 SPECIAL INSTRUCTIONS ..................................... -22-
TABLE OF ORIGINAL CALIBRATION DATA .......................... -23-
FLOW OUTPUT CURVE
MODEL 210 FLOW METER SENSOR INSTALLATION
Intek, Inc. 2010
Manual no. A2100606 Rev. B
MODEL 210FM RevB.wpd

WARRANTY
Intek, Inc. warrants each Rheotherm Model 210 product to be free
from defects in material and workmanship under normal use and
service; Intek's obligation under this warranty being limited to
making good any part or parts thereof which shall, within one (1)
year after delivery of such product to the original purchaser, be
returned to Intek with transportation charges prepaid and which
Intek's examination shall disclose to its satisfaction to have been thus
defective; this warranty being expressly in lieu of all other
warranties, express or implied and all other obligation or liabilities on
Intek's part. The purchaser willassume allresponsibility and expense
for removal, decontamination and reinstallation of equipment.
Rheotherm flow meters are manufactured under United States patent numbers 4,255,968; 4,942,763; 4,949,578;
5,485,754; 5,752,411 and 6,526,755. Intek, Rheotherm,RheoVac, Rheovec, Rheomax and RheoSmart areregistered
trademarks of Intek, Inc.
Intek, Inc.
751 Intek Way
Westerville, Ohio 43082-9057
TEL: [phone] FAX: [phone]
website: www.intekflow.com
e-mail: [e-mail]

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SECTION 1 !GENERAL INFORMATION
1.1 INTRODUCTION
Rheotherm®precision flow meters are designed toprovide accurate representation of fluid flow rate.
Rheotherm instruments are manufactured exclusively by Intek, Inc. and employ a patented thermal
technique used by industry since 1978. The unique sensor designs have protected sensors, are easy
to install and require little or no maintenance. The Model 210 is a “smart” instrument; its unique
features and performance characteristics are described in SECTIONS 3, 4, and 6.
Each Rheotherm flow meter consists of two elements a sensor and a transmitter unit. The sensors
come in two basic designs, intrusive and nonintrusive (SECTION 2.1). Design selection is based
on application constraints or customer preference. The transmitter, for signal processing, is housed
in one of three enclosure styles (SECTION 2.2). Again, selection is based on application
requirement.
Key features of Rheotherm instruments are:
Nonintrusive flow measurement For pipe sizes from 0.030 to 2 inches, flow sensing can
be done from outside the flow tube.
No moving parts There are no rotating, translating, undulating or oscillating parts to
wear, stick, break or fatigue.
Chemical compatibility The wetted surface(s) can be any of a number of corrosion
resistant metals or alloys. Most TU or TUL type sensors can be made with no internal
joints or seals.
Flexibility Rheotherm meters can be ordered calibrated for mass or volumetric units
or in average velocity. Flow rate, totalization and fluid temperature displays or output
signals are available, as well as rangeability up to 100:1 or more.
Fluid pressure options to 10,000 psi (check sensor tag for rating on your unit).
Withstands over-ranging No damage or change in calibration will occur due to
excessive flow rates many times higher than calibration range.
Immunity to shock and vibration.
Optional nuclear radiation hardening.
Range of application includes measurements in capillary tubes to large diameter pipes or
ducts.

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1.2 DESCRIPTION OF OPERATION
Rheothermflow meters are available with various nonintrusive and intrusive sensor designs, but they
all use the same, patented, thermal sensing technique. Two temperature sensors are used one is
in thermal equilibrium with the fluid and provides a fluid temperature reference, while the second
temperature sensor is located near a heater so that its temperature is slightly above that of the fluid.
In a TU or TUL sensor, the temperature sensors and heater are attached to the outside of the flow
tube, whereas the probe sensors have the sensors and heater located in the probe(s) that are inserted
into the stream. The rate at which heat is removed from the heated sensor by the stream is related
to fluid velocity. Hence, the measured temperature differential between the reference sensor and
heated sensor is a function of flow rate. Intek, Inc. is licensed to use this patented and trademarked
flow measurement method.
Nonintrusive sensor Examples of insertion probe sensors
(TU or TUL) with thread or flange fittings
1.3 PRECAUTIONS
!! CAUTION: Throughout the manual this caution notation
indicates that failure to execute the
accompanying instructions may cause the
instrument or external equipment to malfunction.
!! WARNING: A warning indicates that failure to execute the
accompanying instructions may cause permanent
damage to the instrument or external equipment.
1. Use proper input power Check the label on the transmitter for the input power
requirements.
2. Use reasonable care in handling the sensor. Do not try to disassemble the sensors; there
are no removable parts.
TU or TUL Twisting or bending can damage the sensor. The flow tubes are thin-
walled tubing. Do not rotate the electronics box or try to disassemble the sensor body tube
fittings (at each end of the shell).

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Probes (NPT/2I, NPT/I, BF/2I, BF/I, etc.) Take care not to bend the probes or damage
the tips. Do not try to remove or turn the electronics box.
3. Check the sensor maximum temperature rating Do n ot operate a sensor at or subject
it to a temperature above its specified limit.
4. Keep moisture out of the electronic enclosure and sensor junction box. Once cable
connections are made in the junction box, make sure the lid is tightly closed. Seal conduit
lines if they can become wet inside.
5. Keep sensor wetted surfaces clean and free of permanent layer build-up.
6. Do not exceed pressure limits of the tube or fittings.
7. Maintain a thermally stable environment (short-term) for the sensor and adjacent line
(See SECTION 2 INSTALLATION).
These instructions cover installation, calibration and maintenance of Rheotherm meters in standard
configurations. Any special information pertaining to your unit is covered under CUSTOM
INFORMATION (SECTION 6). Time should be taken to carefully read these instructions prior to
installation of the equipment. Should any questions arise or problems occur, call Intek for
immediate assistance.

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SECTION 2 !INSTALLATION
2.1 SENSOR
!! WARNING: If the instrument has been selected for use in
hazardous environments the model number shall end with the suffix
-FM. The -FM notation designates that the instrument has been
designed, manufactured for use, and reviewed by Factory Mutual
(FM) as suitable for use in Class I, Division 1, Groups B, C, D, (Class
I, Zone 1, IIB+H2 for US Only), Class II, Division 1, Groups E, F, G,
Class III, Division 1, type NEMA 4X, T6 Ta=60/C, Hazardous
Locations. This instrument is not recommended for use in acetylene
environments.
!! WARNING: TO PREVENT IGNITION OF HAZARDOUS
ATMOSPHERES, DO NOT REMOVE COVER WHILE CIRCUITS
ARE ALIVE and SEAL ALL CONDUITS WITHIN 18".
!! WARNING: The sensors have no user serviceable parts, so do not
try to disassemble. Permanent damage may result.
!! CAUTION: All sensors have a directional arrow on the tag and/or
etched into a metal part. Before installing a sensor, please note proper
flow direction. This is critical to instrument performance.
The sensor style supplied with your meter is listed in the model code number in SECTION 6. Proper
installation of the sensor is necessary for achieving accuracy and repeatability. Installation
suggestions for each type of standard sensor are given here and instrument detail drawings may be
included in the appendix. For custom sensor installations, refer to CUSTOM INFORMATION
SECTION 6.
Be sure wetted surfaces are clean before installing. If cleaning is needed, use non-residue solvent
and wipe dry. Some sensor terminations are enclosed in an aluminum housing and if it is not sealed
properly can easily be damaged by moisture and corrosion. Make sure the lid is tightly sealed and
the gasket, if supplied, is in place.
1. TU or TUL (nonintrusive) capillary (C), 1'16 and cTU or TUL sensors particularly
require special care in handling and installing to avoid damage to sensor tube and tube stubs.
!! WARNING: TU and TUL sensors are made with thin-walled
tubing use care when installing.
All TU and TUL sensors larger than cinch should have straight line input and output
sections, typically 20 pipe diameters on the inlet and 6 to 10 diameters on the outlet. If
installed vertically, the direction of flow should be up through the sensor. Connection in

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the line is via compression fittings, hose with clamp, threaded fittings or flanges,
whichever is appropriate. Care must be taken not to transmit a twisting force through the
sensor’s midsection. The TU and TUL sensors, whether flanged or not, must not be used
to pull other piping together or to make up angular mismatch of fittings. The sensor
mounted enclosure should never be rotated for any reason.
TU and TUL sensors 1
'16 or smaller may be sleeved with a c" tube for added support.
Connection should always be made to the flow tube, as there is no assured seal between
the flow tube and the sleeve.
Fluid temperatures other than ambient require special attention. Thermal gradients from
one end of the sensor to the other, as well as along the radius of the connection pipe, are
undesirable. Therefore, effective insulation should be installed around the inlet and outlet
straight line runs. Gradients which may exist in the line further up stream can be removed
if an insulated elbow is installed in the line prior to entering the straight line portion of the
plumbing. Metallic support braces for the sensor or adjoining plumbing can act as a heat
sink and cause indication errors in high temperature applications. The support braces
should be thermally isolated from the line to avoid heat loss effects.
If the sensor is for use above 212°F, it will have a stainless steel side arm to get the
electronics box away from the heat. Free air should be allowed to flow around the side
arm and electronics enclosure to keep the electronics cool. The side arm can be insulated
up to one third of its length from the sensor body.
In these applications, proper thermal control is vital to accurate meter performance. Non-
uniformheat tracing, relay on/off temperature controllers and oscillating proportional type
control should always be avoided. Steam trace lines with good pressure regulation or
properly tuned proportional temperature control systems are effective in maintaining
uniform fluid temperature. A box around the sensor and inlet tubing is highly
recommended for operating temperatures higher than room ambient. Allow enough
inlet tubing inside the box to allow the fluid temperature to become the same
temperature as the surrounding air. Separately control the box air temperature at the
same temperature as the incoming fluid temperature to minimize thermally induced
indication errors.
Flow stream conditioning must also be considered to maximize meter performance. Avoid
upstream protrusions and short distance straight runs, particularly for insertion probes and
TU/TUL sensors ¼" and larger. Flow pulsations, such as those created by metering
pumps, may cause the instrument to differ from the factory calibration. Furthermore, if the
flow is varied by stroke and by pump speed adjustment, the indication will most likely be
non-repeatable. If you are using a pump of this type, it is recommended that a pulsation
dampening device be used to provide smooth continuous flow. Otherwise a readjustment
of the instrument calibration after installation would be required (See SECTION 4.2).
For liquid measurement systems using high pressure gas to force flow, the effects of the
absorbed gas must be considered. In these cases, sudden pressure drops up stream of the
sensor such as line size expansions, control valves, and pressure dropping regulators must

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be avoided. Sudden pressure drops can cause the absorbed gas to release into the liquid,
making the flow sporadic and difficult to measure. Control valves should be placed down
stream of the sensor.
The ideal installation will provide the sensor with well established smooth flow,
uniform system temperature and consistent fluid media.
2. Intrusive Probes
!! IMPORTANT: Recommended straight run for best accuracy is
aminimum 20 diameters upstream and 10 diameters downstream.
The various probe sensors are mounted through a threaded collar (NPT/2I and NPT/I) or
flanged tee (BF/2I or BF/I). Other fittings and sensor designs are also available and are
discussed on the Custom Information page. Generally the probes are sized so the tips
extend ½ to 1 inch beyond the pipe center line when properly installed. There are
exceptions to this in certain applications; see CUSTOM INFORMATION (SECTION 6)
as it applies.
Proper alignment of the sensor with flow is important; the flow direction is indicated on
the sensor tag and/or etched into the sensor. All dual probe sensors (NPT/2I, BF/2I) are
installed so that the two probes are side-by-side across the fluid stream. Never rotate the
integral box. If this occurs the sensor could be damaged and/or installed misaligned with
the direction of flow.
For high temperature applications, the sensor and surrounding line should be well
insulated. Leave a portion of the sensor neck un-insulated to allow heat dissipation before
reaching the junction box.
2.2 TRANSMITTER ELECTRONICS
Three transmitter configurations are available. The base model contains a round box integrally
mounted on the sensor, and provides a linear 4-20 mA output (the “blind” option). When a local
display is needed, the transmitter is enclosed in an explosion-proof box that contains a windowed
electronics package for process variable display, IR communication, and IR proximity sensor user
adjustment (the “display” option). A remote user interface option allows the sensor and the
electronics to be separated by up to 200 feet with the use of a shielded instrument cable (Model
210R option). Consider the operational needs when selecting an installation site. Review the
operation section of this manual and provide access to the features that may need to be used during
normal or maintenance operations.
Each configuration is designed such that the instrument is watertight (non-submersible) when the
covers are properly seated. The housing(s) should be mounted such that wire/cable ports are located
at the back, bottom, or sides of the housing(s) to reduce risks associated with water spray,
condensation and settling of dust and dirt. All exposed parts are stainless steel (unless a special
alloy has been specified), painted cast aluminum or steel, polycarbonate, or quartz glass (display
window). These materials tolerate most corrosive environments.

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!! WARNING: When used in hazardous environments, the model
number will include the -FM suffix. Using the shaft of a screwdriver
placed between the lid’s center bosses, the sensor mounted box lid
shall be tightened enough to assure it cannot be removed without the
use of a tool. All enclosure covers should be in place, with all
supplied gaskets, and tightened before power is applied to the unit.
Conduit seals are required for Class I, Division 1 and Class I, Zone 1
applications if the field wiring passes through a conduit length 18" or
longer. Applicable code requirements should be observed when
connecting the conduit to the enclosure.
For the Model 210R option, the sensor and transmitter housing(s) should be installed keeping in
mind the length and routing of the field wiring cable(s). Field wiring consisting of individually
shielded pairs, one pair for power and one pair for the flow signal, is recommended. EMC
compliance testing has been successfully completed using a single field wiring cable length of ten
feet per CE marking guidelines. Additional lengths have been factory tested up to 200 feet. Lengths
beyond ten feet require attention from the system installer with consideration given to potential RF
interference of the 4-20 mA signal and to assure adequate power DC voltage levels are delivered to
the instrument, given resistive voltage loss in longer DC power wire lengths. Sensor cable, for use
in Model 210R, is typically supplied by the factory. Conduit or other suitable protection is also
recommended for this cable between the sensor and the transmitter electronics.
Unless otherwise specified, normal ambient environment for the transmitter is 0-120°F. Maximum
environment temperature for the transmitter and transmitter enclosure contents is 135°F.
2.3 ELECTRICAL CONNECTIONS
1. Verify/configure the input power. The input power requirement is listed on the tag on the
transmitter enclosure. Be sure the input power source to be used is properly selected in
the unit. Unless specifically ordered otherwise, the input power requirements are
24±2Vdc @ 0.25A typical. Do not apply power to the instrument until all connections
are made and all enclosure covers are in place.
!! CAUTION: Use supply wires suitable for 10/C above ambient.
!! CAUTION: The output signal is isolated from the power ground.
If you are connecting the 4-20 mA output to an isolated input device,
it may be advisable to ground the incoming signal at the input device.
Refer to the input device manufacturer’s recommendations.
For CE compliance when using an input power source above 70 volts, it is required to
employ a switch or circuit-breaker as a means for disconnection. For all other cases this
is also recommended but may not be required by your local wiring code consult your
plant’s safety engineer.
2. Check the analog output configuration of the transmitter and your input device. Typically
the 4-20 mA output is configured to actively supply the loop current. If another output

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type has been ordered it will be listed in SECTION 6.3 - SPECIAL INSTRUCTIONS.
(Active: current to the loop is sourced by transmitter. Passive: output receiver sources the
current.)
3. Pull wires through the conduit. Wire for the power connection must be no smaller than 22
gauge or as required by applicable local or company wiring codes. After pulling the wire,
pot the conduit or wires near the enclosure if there is any possibility of water from
condensation or spray entering the enclosure through the conduit. With the “blind”
option, a single cable that contains two internal twisted-shielded pairs is included and is
used for both the input power and the output signal. For the 210R option, a shielded
sensor cable is supplied. Conduit or other suitable protection is also recommended for this
cable between the sensor and the transmitter electronics. Separate wire pairs are
recommended for power and signal conductor for use in hazardous locations where the -
FM option is required. (See Figures 1 and 2).
!! WARNING: The transmitter unit is not protected against
condensed liquid water inside the enclosure. Be sure conduit
interfaces are dry or sealed at the instrument to prevent condensation
that may be present in conduit lines from entering the enclosure.
4. Make wiring connections. Power should be off at this time. Refer to Figures 1 and 2 for
system wiring detail.
!! WARNING: Verify the wiring. The equipment can be
permanently damaged if not wired as instructed in this manual.
Conduit seals are required for Class I, Division 1 and Class I, Zone
1 applications if the field wiring passes through 18" or greater length
of conduit. Applicable code requirements should also be met when
connecting the conduit to the enclosure.
5. Secure the enclosure cover(s). Make sure it is tight enough to make a good seal against
the gasket if supplied, and ensure all other enclosure openings are completely watertight.
For the -XDT option, use the shaft of a screwdriver placed between the lid center bosses
(-X or -XDT options), tighten the sensor mounted box lid enough to assure that the lid
cannot be removed without the use of a tool. Tighten the lid and lock it by tightening the
1/16" hex headed set screw. All enclosure covers should be in place and tightened before
the unit is powered up. Conduit seals are required for Class I, Division 1 and Class I,
Zone 1 applications if the field wiring passes through 18" or greater of conduit.
Applicable code requirements should also be met when connecting the conduit to the
enclosure.
6. Connect functional ground. To assure EMC compliance, ground the sensor and the
windowed enclosure (if applicable) to earth ground using 3/8" wide ground straps or
equivalent. EMC compliance testing has been successfully completed using these straps
and ungrounded tubing. However, if the flow tubing and electrical conduits are reliably
grounded by other means, these straps may not be necessary. These straps may also be
required to supply a reliable or redundant ground path for operation in hazardous
locations. Consult your plant’s safety engineer.