KEPCO ES749 User manual

ES749
Utility Metering Flow CoMpUter
99718 05/09/16

ES749 Flow Computer
SAFETY INSTRUCTIONS .............................................................................................................1
1. INTRODUCTION
1.1 Unit Description ............................................................................................................2
1.2 Specications ...............................................................................................................3
2. INSTALLATION
2.1 General Mounting Hints................................................................................................ 8
2.2 Mounting Diagrams ......................................................................................................8
3. APPLICATIONS
3.1 Steam Mass................................................................................................................ 13
3.2 Steam Heat................................................................................................................. 11
3.3 Steam Net Heat .......................................................................................................... 13
3.4 Steam Delta Heat .......................................................................................................14
3.5 Corrected Gas Volume ............................................................................................... 15
3.6 Gas Mass ...................................................................................................................16
3.7 Gas Combustion Heat ................................................................................................17
3.8 Corrected Liquid Volume ............................................................................................ 18
3.9 Liquid Mass ................................................................................................................19
3.10 Liquid Combustion Heat ...........................................................................................20
3.11 Liquid Sensible Heat................................................................................................. 21
3.12 Liquid Delta Heat...................................................................................................... 22
3.13 Steam – Condensate Heat ....................................................................................... 23
4. WIRING
4.1 Terminal Designations ................................................................................................ 24
4.2 Typical Wiring Connections ........................................................................................ 25
4.2.1 Flow Input ................................................................................................... 25
4.2.2 Stacked DP Input........................................................................................ 25
4.2.3 Pressure Input ............................................................................................ 25
4.2.4 Temperature Input ...................................................................................... 26
4.2.5 Temperature 2 Input ................................................................................... 26
4.3 Wiring In Hazardous Areas......................................................................................... 29
4.3.1 Flow Input ................................................................................................... 27
4.3.2 Pressure Input ............................................................................................ 27
4.3.3 Temperature Input ...................................................................................... 27
5. UNIT OPERATION
5.1 Front Panel Operation Concept for Operate Mode..................................................... 28
5.2 General Operation ...................................................................................................... 29
5.3 Password Protection................................................................................................... 29
5.4 Relay Operation.......................................................................................................... 29
5.5 Pulse Output ..............................................................................................................29
5.6 Analog Outputs ........................................................................................................... 29
5.7 Function Keys; Display Grouping ............................................................................... 29
5.8 RS-232 Serial Port Operation..................................................................................... 30
5.8.1 PC Communications................................................................................... 30
5.8.2 Operation of RS-232 Serial Port with Printers ............................................ 30
5.9 RS-485 Serial Port Operation..................................................................................... 30
5.10 Pause Computations Prompt.................................................................................... 30
6. PROGRAMMING
6.1 Front Panel Operation Concept for Program Mode.................................................... 31
6.2 EZ Setup .................................................................................................................... 32
6.3 Detailed Menu Descriptions........................................................................................ 34
6.4 System Parameters .................................................................................................... 35
6.5 Display........................................................................................................................40
6.6 System Units ..............................................................................................................42
6.7 Fluid Data ...................................................................................................................49
6.8 Flow Input ................................................................................................................... 54
6.9 Other Input.................................................................................................................. 66
6.10 Pulse Output.............................................................................................................69
6.11 Current Output .......................................................................................................... 70
6.12 Relays....................................................................................................................... 74
6.13 Communication......................................................................................................... 78
6.14 Network Card............................................................................................................ 85
6.15 Service & Analysis....................................................................................................86
CONTENTS

ES749 Flow Computer
CONTENTS
7. PRINCIPLE OF OPERATION
7.1 General.......................................................................................................................92
7.2 Square Law Flowmeter Considerations...................................................................... 92
7.3 Flow Equations ........................................................................................................... 92
7.3.1 Flow Input Computation.............................................................................. 92
7.3.2 Pressure Computation................................................................................ 93
7.3.3 Temperature Computation .......................................................................... 93
7.3.4 Density/Viscosity Computation ................................................................... 93
7.3.5 Corrected Volume Flow Computation......................................................... 94
7.3.6 Mass Flow Computation ............................................................................. 95
7.3.7 Combustion Heat Flow Computation.......................................................... 95
7.3.8 Heat Flow Computation .............................................................................. 96
7.3.9 Sensible Heat Flow Computation ............................................................... 96
7.3.10 Liquid Delta Heat Computation................................................................. 96
7.3.11 Expansion Factor Computation for Square Law Flowmeters ................... 96
7.3.12 Uncompensated Flow Computation ......................................................... 99
7.3.13 ILVA Flow Meter Equations..................................................................... 100
7.4 Computation of the D.P. Factor ................................................................................ 101
8. RS-232 SERIAL PORT
8.1 RS-232 Serial Port Description................................................................................. 102
8.2 Instrument Setup by PC Over Serial Port ................................................................ 102
8.3 Operation of Serial Communication Port with Printers ............................................. 102
8.4 SUPERtrol II RS-232 Port Pinout ............................................................................. 102
9. RS-485 SERIAL PORT
9.1 RS-485 Serial Port Description................................................................................. 103
9.2 General.....................................................................................................................103
9.3 Operation of Serial Communication Port with PC .................................................... 103
9.4 SUPERtrol II RS-485 Port Pinout ............................................................................. 103
10. FLOW COMPUTER SETUP SOFTWARE
10.1 System Requirements ............................................................................................104
10.2 Cable and Wiring Requirements............................................................................. 104
10.3 Installation for Windows™3.1 or 3.11 ..................................................................... 104
10.4 Using the Flow Computer Setup Software ............................................................. 104
10.5 File Tab ................................................................................................................... 105
10.6 Setup Tab ............................................................................................................... 105
10.7 View Tab ................................................................................................................. 106
10.8 Misc. Tab ................................................................................................................ 106
11. GLOSSARY OF TERMS
10 Glossary Of Terms..................................................................................................... 107
12. Diagnosis and Troubleshooting
12.1 Response of SUPERtrol II on Error or Alarm.......................................................... 110
12.2 Diagnosis Flowchart and Troubleshooting.............................................................. 110
12.3 Error Messages .......................................................................................................111
Appendix A
Fluid Properties Table..................................................................................................... 114
Appendix B - Setup Menus
Setup Menus with Operator Code Access...................................................................... 115
Setup Menus with Supervisor Code Access................................................................... 116
Appendix C - RS-485 Modbus Protocol
Description...................................................................................................................... 117
Wiring Pinout and Installation......................................................................................... 118
Register and Coil Usage................................................................................................. 120
Warranty .....................................................................................................................................123
Decoding Part Number................................................................................................................ 123

ES749 Flow Computer
1
!
SAFETY INSTRUCTIONS
The following instructions must be observed.
• This instrument was designed and is checked in accordance with
regulations in force EN 60950 (“Safety of information technology
equipment, including electrical business equipment”).
A hazardous situation may occur if this instrument is not used for
its intended purpose or is used incorrectly. Please note operating
instructions provided in this manual.
• The instrument must be installed, operated and maintained by
personnel who have been properly trained. Personnel must read
and understand this manual prior to installation and operation of the
instrument.
• The manufacturer assumes no liability for damage caused by incorrect
use of the instrument or for modications or changes made to the
instrument.
Technical Improvements
• The manufacturer reserves the right to modify technical data without
prior notice.

ES749 Flow Computer
2
1. Introduction
Peak Demand Option
There are applications where customer charges are determined
in part by the highest hourly averaged owrate observed during
a billing period.
The peak demand option for the ES749 is intended for applica-
tions where it is important to compute such an hourly average
owrate, to note the value of the peak occurrence and the cor-
responding time and date of that event.
The demand last hour rate is computed based on the current
total and the total 60 minutes prior. This value is recomputed
every 5 minutes.
The peak demand is the highest value observed in the demand
last hour.
The time and date stamp is the time and date at which the high-
est peak demand occurred.
The Demand Last Hour and/or Peak Demand can be directly
viewed on the display by pressing the RATE key and then
scrolling through the rates with the ^/v arrow key until the de-
sired item is viewed.
The Peak Time and Date stamp can be viewed on the display
by pressing the TIME and then scrolling through the time re-
lated parameters using the ^/v arrow keys until the desired item
is viewed.
All of these items can be included into the scrolling display list
along with the other process values and totalizers in a user
selectable list.
The peak demand may be cleared by pressing the CLEAR key
while viewing the PEAK DEMAND or by means of a command
on the serial port.
The Peak Time and Date stamp can be viewed on the display
by pressing the TIME and then scrolling through the time re-
lated parameters using the ^/v arrow keys until the desired item
is viewed.
The Demand Last Hour and Peak Demand can be assigned
to one of the analog outputs. The demand last hour or peak
demand could thusly be output on a recording device such as
a strip chart recorder or fed into a building energy automation
system.
The Demand Last Hour and Peak Demand can be assigned
to one of the relays. The customer can be notied that he is
approaching or exceeding a contract high limit by assigning the
demand last hour to one of the relays and setting the warn-
ing point into the set point. A warning message would also be
displayed.
The peak demand may be used in conjunction with the print list
and data logger to keep track of hourly customer usage proles.
The Demand Last Hour, Peak Demand, and Time and Date
Stamp information can be accessed over the serial ports. The
Peak Demand may also be reset over the serial ports.
The peak demand option may also be used as a condition to
call out in remote metering by modem.
EZ Setup
The unit has a special EZ setup feature where the user is guided
through a minimum number of steps to rapidly congure the
instrument for the intended use. The EZ setup prepares a series
of questions based on ow equation, uid, and owmeter type
desired in the application.
1.1 Unit Description:
The SUPERtrol II (ES749) Flow Computer satises the instrument
requirements for a variety of owmeter types in liquid, gas, steam
and heat applications. Multiple ow equations are available in a
single instrument with many advanced features.
The alphanumeric display offers measured parameters in easy to
understand format. Manual access to measurements and display
scrolling is supported.
The versatility of the Flow Computer permits a wide measure of
applications within the instrument package. The various hardware
inputs and outputs can be “soft” assigned to meet a variety of
common application needs. The user “soft selects” the usage of
each input/output while conguring the instrument.
The isolated analog output can be chosen to follow the volume
ow, corrected volume ow, mass ow, heat ow, temperature,
pressure, or density by means of a menu selection. Most hardware
features are assignable by this method.
The user can assign the standard RS-232 Serial Port for data
logging, or transaction printing, or for connection to a modem for
remote meter reading.
A PC Compatible software program is available which permits the
user to rapidly redene the instrument conguration.
Language translation option features also permit the user to dene
his own messages, labels, and operator prompts. These features
may be utilized at the OEM level to creatively customize the unit
for an application or alternately to provide for foreign language
translations. Both English and a second language reside within
the unit.
NX-19 option
Advanced orderingoptions areavailable forNatural Gas calculations
where the user requires compensation for compressibility effects.
Compensation for these compressibility effects are required at
medium to high pressure and are a function of the gas specic
gravity, % CO2, % Nitrogen, as well as temperature and pressure.
The compressibility algorithm used is that for NX-19.
Stacked differential pressure transmitter option
This option permits the use of a low range and high range DP
transmitter on a single primary element to improve ow transducer
and measurement accuracy.
Peak demand option
This option permits the determination of an hourly averaged ow
rate. Demand last hour, peak demand and time/date stamping for
applications involving premium billing.
Data logging option
This option provides data storage information in 64k of battery
backed RAM. Items to be logged, conditions to initiate the log and
a variety of utilities to clear and access the data via the RS-232
port are provided.

ES749 Flow Computer
3
1.2 Specications:
Environmental
Operating Temperature: 0 to +50 C
Storage Temperature: -40 to +85 C
Humidity : 0-95% Non-condensing
Materials: UL, CSA, VDE approved
Approvals: CE Approved Light Industrial, UL/CSA Pending
Display
Type: 2 lines of 20 characters
Types: Backlit LCD, OLED and VFD ordering options
Character Size: 0.3" nominal
User selectable label descriptors and units of measure
Keypad
Keypad Type: Membrane Keypad
Keypad Rating: Sealed to Nema 4
Number of keys: 16
Raised Key Embossing
Enclosure
Enclosure Options: Panel, Wall, Explosion Proof
Size: See Chapter 2; Installation
Depth behind panel: 6.5" including mating connector
Type: DIN
Materials: Plastic, UL94V-0, Flame retardant
Bezel: Textured per matt nish
Equipment Labels: Model, safety, and user wiring
NX-19 Compressibility Calculations
Temperature -40 to 240 F
Pressure 0 to 5000 psi
Specic Gravity 0.554 to 1.0
Mole % CO2 0 to 15%
Mole % Nitrogen 0 to 15%
Power Input
The factory equipped power options are internally fused.
An internal line to line lter capacitor is provided for added
transient suppression. MOV protection for surge transient is
also supported
Universal AC Power Option:
85 to 276 Vrms, 50/60 Hz
Fuse: Time Delay Fuse, 250V, 500mA
DC Power Option:
24 VDC (16 to 48 VDC)
Fuse: Time Delay Fuse, 250V, 1.5A
Transient Suppression: 1000 V
Flow Inputs:
Flowmeter Types Supported:
Linear:
Vortex, Turbine, Positive Displacement, Magnetic,
GilFlo, GilFlo 16 point, ILVA 16 Point, Mass Flow
and others
Square Law:
Orice, Venturi, Nozzle, V-Cone, Wedge, Averaging
Pitot, Target, Verabar, Accelabar and others
Multi-Point Linearization:
May be used with all owmeter types. Including: 16
point, UVC and dynamic compensation.
Analog Input:
Ranges
Voltage: 0-10 VDC, 0-5 VDC, 1-5 VDC
Current: 4-20 mA, 0-20 mA
Basic Measurement Resolution: 16 bit
Update Rate: 2 updates/sec minimum
Accuracy: 0.02% FS
Automatic Fault detection: Signal over/under-range,
Current Loop Broken
Calibration: Operator assisted learn mode. Learns Zero
and Full Scale of each range
Fault Protection:
Fast Transient: 1000 V Protection (capacitive clamp)
Reverse Polarity: No ill effects
Over-Voltage Limit: 5 0 V D C O v e r v o l t a g e
protection
Over-Current Protection: Internally current limited
protected to 24 VDC
Optional: Stacked DP transmitter 0-20 mA or 4-20 mA
Pulse Inputs:
Number of Flow Inputs: one
Input Impedance: 10 kΩnominal
Trigger Level: (menu selectable)
High Level Input
Logic On: 2 to 30 VDC
Logic Off: 0 to .9 VDC
Low Level Input (mag pickup)
Selectable sensitivity: 10 mV and 100 mV
Minimum Count Speed: 0.25 Hz
Maximum Count Speed: Selectable: 0 to 40 kHz
Overvoltage Protection: 50 VDC
Fast Transient: Protected to 1000 VDC (capacitive clamp)
Temperature, Pressure, Density Inputs
The compensation inputs usage are menu selectable for
temperature, temperature 2, pressure, density, steam trap
monitor or not used.
Calibration: Operator assisted learn mode
Operation: Ratiometric
Accuracy: 0.02% FS
Thermal Drift: Less than 100 ppm/C
Basic Measurement Resolution: 16 bit
Update Rate: 2 updates/sec minimum
Automatic Fault detection:
Signal Over-range/under-range
Current Loop Broken
RTD short
RTD open
Transient Protection: 1000 V (capacitive clamp)
Reverse Polarity: No ill effects
Over-Voltage Limit (Voltage Input): 50 VDC
Over-Current Limit (Internally limited to protect input to
24 VDC)
Available Input Ranges
(Temperature / Pressure / Density / Trap Monitor)
Current: 4-20 mA, 0-20 mA
Resistance: 100 Ohms DIN RTD
100 Ohm DIN RTD (DIN 43-760, BS 1904):
Three Wire Lead Compensation
Internal RTD linearization learns ice point resistance
1 mA Excitation current with reverse polarity protection
Temperature Resolution: 0.1°C
Temperature Accuracy: 0.5°C

ES749 Flow Computer
4
Datalogger (optional)
Type: Battery Backed RAM
Size: 64k
Initiate: Key, Interval or Time of Day
Items Included: Selectable List
Data Format: Printer or CSV Access via RS-232 command
Stored Information (ROM)
Steam Tables (saturated & superheated), General Fluid
Properties, Properties of Water, Properties of Air, Natural
Gas
User Entered Stored Information (EEPROM / Nonvolatile
RAM)
Transmitter Ranges, Signal Types
Fluid Properties
(specific gravity, expansion factor, specific heat,
viscosity,
isentropic exponent, combustion heating value, Z factor,
Relative Humidity)
Units Selections (English/Metric)
RS-232 Communication
Uses: Printing, Setup, Modem, Datalogging
Baud Rates: 300, 1200, 2400, 9600
Parity: None, Odd, Even
Device ID: 0 to 99
Protocol: Proprietary, Contact factory for more information
Chassis Connector Style: DB 9 Female connector
Power Output: 8V (150 mA max.) provided to Modem
RS-485 Communication (optional)
Uses: Network Communications
Baud Rates: 300, 600, 1200, 2400, 4800, 9600, 19200
Parity: None, Odd, Even
Device ID: 1 to 247
Protocol: ModBus RTU
Chassis Connector Style: DB 9 Female connector (standard)
Excitation Voltage
24 VDC @ 100 mA overcurrent protected
Relay Outputs
The relay outputs usage is menu assignable to (Individually
for each relay) Hi/Lo Flow Rate Alarm, Hi/Lo Temperature
Alarm, Hi/Lo Pressure Alarm, Pulse Output (pulse options),
Wet Steam or General purpose warning (security).
(Peak demand and demand last hour optional)
Number of relays: 2 (3 optional)
Contact Style: Form C contacts (Form A with 3 relay option)
Contact Ratings: 240 V, 1 amp
Fast Transient Threshold: 2000 V
Analog Outputs
The analog output usage is menu assignable to correspond
to the Heat Rate, Uncompensated Volume Rate, Corrected
Volume Rate, Mass Rate, Temperature, Density, or
Pressure.
(Peak demand and demand last hour optional)
Number of Outputs: 2
Type: Isolated Current Sourcing (shared common)
Isolated I/P/C: 500 V
Available Ranges: 0-20 mA, 4-20 mA (menu selectable)
Resolution: 16 bit
Accuracy: 0.05% FS at 20 Degrees C
Update Rate: 5 updates/sec
Temperature Drift: Less than 200 ppm/C
Maximum Load: 1000 ohms
Compliance Effect: Less than .05% Span
60 Hz rejection: 40 dB minimum
EMI: No effect at 10 V/M
Calibration: Operator assisted Learn Mode
Averaging: User entry of DSP Averaging constant to
cause an smooth control action
Isolated Pulse output
The isolated pulse output is menu assignable to Uncompensated
Volume Total, Compensated Volume Total, Heat Total or Mass
Total.
Isolation I/O/P: 500 V
Pulse Output Form (menu selectable): Open Collector NPN or
24 VDC voltage pulse
Nominal On Voltage: 24 VDC
Maximum Sink Current: 25 mA
Maximum Source Current: 25 mA
Maximum Off Voltage: 30 VDC
Saturation Voltage: 0.4 VDC
Pulse Duration: User selectable
Pulse output buffer: 8 bit
Real Time Clock
The Flow Computer is equipped with either a super cap or a
battery backed real time clock with display of time and date.
Format:
24 hour format for time
Day, Month, Year format for date
Daylight Savings Time (optional)
Measurement
The Flow Computer can be thought of as making a series
of measurements of ow, temperature/density and pressure
sensors and then performing calculations to arrive at a
result(s) which is then updated periodically on the display. The
analog outputs, the pulse output, and the alarm relays are also
updated. The cycle then repeats itself.
Step 1: Update the measurements of input signals-
Raw Input Measurements are made at each input using
equations based on input signal type selected. The system
notes the “out of range” input signal as an alarm condition.
Step 2: Compute the Flowing Fluid Parameters-
The temperature, pressure, viscosity and density equations
are computed as needed based on the ow equation and input
usage selected by the user.

ES749 Flow Computer
5
Step 3 : Compute the Volumetric Flow-
Volumetric ow is the term given to the ow in volume units.
The value is computed based on the owmeter input type
selected and augmented by any performance enhancing
linearization that has been specied by the user.
Step 4: Compute the Corrected Volume Flow at Reference
Conditions-
In the case of a corrected liquid or gas volume ow calculation,
the corrected volume ow is computed as required by the
selected compensation equation.
Step 5 : Compute the Mass Flow-
All required information is now available to compute the mass
ow rate as volume ow times density. A heat ow computation
is also made if required.
Step 6: Check Flow Alarms-
The ow alarm functions have been assigned to one of
the above ow rates during the setup of the instrument. A
comparison is now made by comparing the current ow rates
against the specied hi and low limits.
Step 7: Compute the Analog Output-
This designated ow rate value is now used to compute the
analog output.
Step 8: Compute the Flow Totals by Summation-
A ow total increment is computed for each ow rate. This
increment is computed by multiplying the respective ow rate
by a time base scaler and then summing. The totalizer format
also includes provisions for total rollover.
Step 9: Pulse Output Service-
The pulse output is next updated by scaling the total increment
which has just been determined by the pulse output scaler and
summing it to any residual pulse output amount.
Step 10: Update Display and Printer Output-
The instrument nally runs a task to update the various table
entries associated with the front panel display and serial
outputs.
Instrument Setup
The setup is password protected by means of a numeric lock
out code established by the user. The help line and units of
measure prompts assure easy entry of parameters.
An EZ Setup function is supported to rapidly congure the
instrument for rst time use. A software program is also
available which runs on a PC using a RS-232 Serial for
connection to the Flow Computer. Illustrative examples may
be down loaded in this manner.
The standard setup menu has numerous subgrouping of
parameters needed for ow calculations. There is a well
conceived hierarchy to the setup parameter list. Selections
made at the beginning of the setup automatically affect
offerings further down in the lists, minimizing the number of
questions asked of the user.
In the setup menu, the ow computer activates the correct
setup variables based on the instrument conguration, the
ow equation, and the hardware selections made for the
compensation transmitter type, the ow transmitter type,
and meter enhancements (linearization) options selected. All
required setup parameters are enabled. All setup parameters
not required are suppressed.
Also note that in the menu are parameter selections which have
preassigned industry standard values. The unit will assume
these values unless they are modied by the user.
Most of the process input variables have available a “default”
or emergency value which must be entered. These are the
values that the unit assumes when a malfunction is determined
to have occurred on the corresponding input.
It is possible to enter in a nominal constant value for
temperature or density, or pressure inputs by placing the
desired nominal value into the default values and selecting
"manual". This is also a convenience when performing bench
top tests without simulators.
The system also provides a minimum implementation of an
“audit trail” which tracks signicant setup changes to the unit.
This feature is increasingly being found of benet to users
or simply required by Weights and Measurement Ofcials
in systems used in commerce, trade, or “custody transfer”
applications.
Simulation and Self Checking:
This mode provides a number of specialized utilities required
for factory calibration, instrument checkout on start-up, and
periodic calibration documentation.
A service password is required to gain access to this
specialized mode of operation. Normally quality, calibration,
and maintenance personnel will nd this mode of operation
very useful.
Many of these tests may be used during start-up of a new
system. Output signals may be exercised to verify the electrical
interconnects before the entire system is put on line.
The following action items may be performed in the Diagnostic
Mode:
Print Calibration/Maintenance Report
View Signal Input (Voltage, Current, Resistance, Frequency)
Examine Audit Trail
Perform a Self Test
Perform a Service Test
View Error History
Perform Pulse Output Checkout / Simulation
Perform Relay Output Checkout / Simulation
Perform Analog Output Checkout / Simulation
Calibrate Analog Inputs using the Learn Feature
Calibrate Analog Output using the Learn Feature
Schedule Next Maintenance Date
Note that a calibration of the analog input/output will advance
the audit trail counters since it effects the accuracy of the
system.

ES749 Flow Computer
6
Operation of Steam Trap Monitor
In applications on Saturated Steam, the otherwise unused
Compensation Input may be connected to a steam trap monitor
that offers the following compatible output signal levels:
4mA = trap cold
12 mA = trap warm and open (blowing)
20 mA = trap warm and closed
In normal operation a steam trap is warm and periodically opens
and closes in response to the accumulation of condensate. A
cold trap is indication that it is not purging the condensate, a
trap that is constantly blowing is an indication that it is stuck
open. To avoid a false alarm, the ES749 permits the user to
program a delay, or time period, which should be considered
normal for the trap to be either cold, or open. An alarm will
only be activated if the trap is detected as continuously being
in the abnormal states for a time period greater than this TRAP
ERROR DELAY time.
The user selects to use the Compensation Input for Trap
Monitoring by selecting “4-20mA TRAP STATUS as the INPUT
SIGNAL for OTHER INPUT1.
The user can program the ERROR DELAY time in HH:MM
format into both the TRAP ERROR DELAY (cold trap error)
menu and the TRAP BLOWING DELAY (trap stuck open)
menu.
The ES749 will warn the operator of a TRAP ERROR
when an abnormal condition is detected. The error can be
acknowledged by pressing the ENTER key. However, the
problem may reassert itself if there is a continued problem
with the steam trap.
In addition, the event is noted in the ERROR LOG.
It is also possible for the user to program a trap malfunction
as one of the conditions worthy of a CALL OUT of a problem
by selecting this error in the ERROR MASK.
The Data-Logging option of the ES749 can also be used to log
the performance of the trap by storing the % of time the trap
has been cold, and/or blowing open during the datalog interval.
Datalogging Option
The Datalogging Option for the ES749 permits the user to
automatically store sets of data items as a record on a periodic
basis. A datalog record may be stored as the result of either a
PRINT key depression, or an INTERVAL, or a TIME OF DAY
request for a datalog.
The user denes the list of items to be included in each datalog
by selecting these in the PRINT LIST menu located within the
COMMUNICATIONS SUBMENU.
The user selects what will trigger a datalog record being stored
in the PRINT INITIATE menu. The choices are PRINT KEY,
INTERVAL, and TIME OF DAY.
The user can select the datalog store interval in a HH:MM
format in the PRINT INTERVAL menu.
The user can also select the store time of day in a 24 hr HH:
MM format in the PRINT TIME menu.
The user can also dene whether he just wants the data stored
into the datalogger, or if he wants the data both stored in the
datalogger and sent out over the RS232 port in the DATALOG
ONLY menu.
The user can dene the format he wishes the data to be output
in using the DATALOG FORMAT menu. Choices are PRINTER
and DATABASE. PRINTER format will output the data records
in a form suitable to dump to a printer. DATABASE format will
output the values in a CSV, or Comma Separated Variable with
Carriage return delimiting of each record.
A number of serial commands are also included to access and
manipulate information stored with in the datalogger. Among
these RS232 command capabilities are the following actions:
Clear Data Logger
Send all Data in Datalogger
Send Only New Data since Datalogger was last Read
Send Data for the date included in the request
Send the column heading text for the CSV data elds
Send the column units of measure text for the CSV data
elds
Store one new record into datalogger now
Read Number of New Records in the datalogger
Read number of records currently in the datalogger
Read the maximum number of records capacity of the
datalogger
Move Pointer Back N records
Dump Record at Pointer
Dump records newer than pointer
Dump data from N records back
The datalogger option is used in conjunction with the RS-232
port in remote metering applications.
The technical details associated with the serial commands
are listed in Universal Serial Protocol Manual available upon
request.
RS-232 Serial Port
The Flow Computer has a general purpose RS-232 Port
which may be used for any one of the following purposes:
Transaction Printing
Data Logging
Remote Metering by Modem
Computer Communication Link
Conguration by Computer
Print System Setup
Print Calibration/Malfunction History
Instrument Setup by PC’s over Serial Port
A Diskette program is provided with the Flow Computer that
enables the user to rapidly congure the Flow Computer
using an Personnel Computer. Included on the diskette are
common instrument applications which may be used as a
starting point for your application. This permits the user to
have an excellent starting point and helps speed the user
through the instrument setup.

ES749 Flow Computer
7
Operation of Serial Communication Port with Printers
The Flow Computer’s RS-232 channel supports a number
of operating modes. One of these modes is intended to
support operation with a printer in metering applications
requiring transaction printing, data logging and/or printing
of calibration and maintenance reports.
For transaction printing, the user denes the items to be
included in the printed document. The user can also select
what initiates the transaction print generated as part of the
setup of the instrument. The transaction document may be
initiated via a front panel key depression.
In data logging, the user denes the items to be included in
each data log as a print list. The user can also select when
or how often he wishes a data log to be made. This is done
during the setup of the instrument as either a time of day or
as a time interval between logging.
The system setup and maintenance report list all the
instrument setup parameters and usage for the current
instrument configuration. In addition, the Audit trail
information is presented as well as a status report listing any
observed malfunctions which have not been corrected.
The user initiates the printing of this report at a designated
point in the menu by pressing the print key on the front
panel.
Operating Serial Communication Port with Modems
The ES749 offers a number of capabilities that facilitate its use
with modems. The ES749’s RS232 port can be connected to
a modem in order to implement a remote metering system
that uses either the phone companies standard phone lines
or cellular telephone system. In addition to remote meter
readings, the serial commands may also be used to examine
and/or make setup changes to the unit, and to check for proper
operation or investigate problems. Several hundred commands
are supported. A compatible industrial modem accessory and
interconnecting cabling is offered in the MPP2400N specically
designed for use with the ES749.
The ES749 and Modem can be used together to create systems
with one or more of the following capabilities:
1. Poll the ES749 unit for information from a remote PC.
2. Call Out from the ES749 unit to a remote PC on a
scheduled reading time and/or crisis basis
3. Some combination of the above two descriptions where
the unit is polled by one PC and calls into to a different PC
if a problem is detected.
In fact, up to ve ES749 units can share the same modem. Each
ES749 must have a unique DEVICE ID. This multidropping of
ow computers on a single modem is popular when there are
several ow computers mounted near each other.
In most applications using modem communications, the
ES749’s RS232 USAGE is rst set equal to MODEM. Each
ES749 on a shared modem cable is given a unique serial
device address or DEVICE ID. The BAUD RATE is commonly
set to 2400, the PARITY set to NONE, and the HANSHAKING
set to NONE to complete the basic setup. The remote PC’s
communication settings are chosen to match these.
The level of complexity of the ES749 to Modem connection can
range from simple to more complex.
In a simple system a remote PC will call into the telephone
number of the modem. The modem will answer the call, and
establish a connection between the ES749 and the remote
PC. An exchange of information can now occur. The ES749
will act as a slave and respond to commands and requests for
information from the remote MASTER PC. The MASTER PC
will end the exchange by handing up.
However, it is more common that the ES749 will be used
to control the modem. In these applications the following
communication menu settings would be used:
RS232 USAGE = MODEM
DEVICE ID, BAUD RATE, PARITY, and HANDSHAKING
are set
MODEM CONTROL = YES
DEVICE MASTER = YES (When multidropping several
ES749's, only one unit will be the DEVICE MASTER)
MODEM AUTO ANSWER = YES (This instructs the unit
to answer incoming calls)
HANG UP IF INACTIVE = YES (This instructs the unit
to hang up the line if no activities occur within several
minutes).
A more complex form of a remote metering system can be
implemented where the ES749 will initiate a call to contact
the remote PC at a scheduled time and/or in the event of a
problem that has been detected. In these applications the
ES749 has additional setup capabilities including:
The ES749 must have a unique identier assigned to
it (using the TAG NUMBER)
Call Out Telephone number must be entered in the
CALL OUT NUMBER
The scheduled call out time for the daily reading must
be entered in CALL OUT TIME
A decision must be made whether the unit will be used
to call on error(s) in CALL ON ERROR
The particular error conditions to call out on must be
dened in the ERROR MASK
The NUMBER OF REDIALS to be attempted if line is
busy must be entered in that cell
HANG UP IF INACTIVE= YES will disconnect the call
if remote computer does not respond.
Consult the Universal Serial Commands User Manual for
details on the individual commands supported by the ES749.
Contact the Flow Applications Group for a discussion on the
remote metering system capabilities you are considering.
NOTE: Some modems can be congured in advance to
answer incoming calls, terminate phone connections if
communications is lost. In such applications there may be no
need for the ES749 to be functioning to “control” the modem.
Setting the RS233 USAGE = COMPUTER will likely work.
RS-485 Serial Port (optional)
The RS-485 serial port can be used for accessing ow
rate, total, pressure, temperature, density and alarm status
information. The port can also be used for changing presets
and acknowledging alarms.

ES749 Flow Computer
8
2. Installation
2.1 General Mounting Hints:
The ES749 Flow Computer should be located in an area with a clean, dry atmosphere
which is relatively free of shock and vibration. The unit is installed in a 5.43" (138mm)
wide by 2.68" (68mm) high panel cutout. (see Mounting Dimensions) To mount the
Flow Computer, proceed as follows:
a. Prepare the panel opening.
b. Slide the unit through the panel cutout until the it touches the panel.
c. Install the screws (provided) in the mounting bracket and slip the bracket over the
rear of the case until it snaps in place.
d. Tighten the screws rmly to attach the bezel to the panel. 3 in. lb. of torque must
be applied and the bezel must be parallel to the panel.
NOTE: To seal to NEMA4X / IP65 specications, supplied bezel kit must be used
and panel cannot ex more than .010".
When the optional bezel kit is used, the bezel adaptor must be sealed to
the case using an RTV type sealer to maintain NEMA4X / IP65 rating.
General Mounting Hints
Mounting Procedure
NEMA4X / IP65 Specications
ES749 ES749
Bezel Adaptor
Gasket
Mounting Bracket
Mounting Bracket
Standard Mounting Bezel Kit Mounting
Dimensions
Dotted Line Shows Optional Bezel Kit
Panel
Cutout
5.43
(138)
2.68
(68)
Dimensions are in inches (mm)
5.67 (144)
2.83
(72)
3.43
(87)
6.18
6.15
(156) 0.5
(13)
0.28 (7.2)
0.4 (10)
2.2 Mounting Diagrams:

ES749 Flow Computer
9
1.10
(28)
1.10
(28)
7.8 (198)
4.72 (120)
0.59
(15)
0.75” Conduit Knockouts
(5 places)
1.06
(27)
9.4 (238)
7.3 (184)
2.34 (59.5)
8.4 (213.4)
4.13 (105)
2.33 (59)
0.385
(9.8)
Security Tag
Provisions
0.625”ø 0.75”ø 5 places
1.10
(28)
1.10
(28)
1.10
(28)
1.10
(28)
1.10
(28)
1.10
(28)
Wall Mount (mounting option W)
2.2 Mounting Diagrams:
(continued)
NEMA4 Wall Mount (mounting option N)

ES749 Flow Computer
10
2.2 Mounting Diagrams:
(continued) Explosion Proof Mount (mounting option E)

ES749 Flow Computer
11
3.1 Steam Mass
Measurements:
A owmeter measures the actual volume ow in a steam line. A temperature and/or
pressure sensor is installed to measure temperature and/or pressure.
Calculations:
• Density and mass ow are calculated using the steam tables stored in the ow
computer.
• With square law device measurement the actual volume is calculated from the
differential pressure, taking into account temperature and pressure compensation.
• Saturated steam requires either a pressure or temperature measurement with the other
variable calculated using the saturated steam curve.
• Optional steam trap monitoring using Compensation Input 1.
Input Variables:
Superheated Steam: Flow, temperature and pressure
Saturated Steam: Flow, temperature or pressure
Output Results:
• Display Results
Mass or Volume Flow Rate, Resettable Total, Non-Resettable Total, Temperature,
Pressure, Density (optional: peak demand, demand last hour, time/date stamp)
• Analog Output
Mass or Volume Flow Rate, Temperature, Pressure Density, Peak Demand,
Demand Last Hour
• Pulse Output
Mass or Volume Total
• Relay Outputs
Mass or Volume Flow Rate , Total, Pressure, Temperature, Alarms, Peak
Demand, Demand Last Hour
Applications:
Monitoring mass ow and total of steam. Flow alarms are provided via relays and
datalogging is available via analog (4-20mA) and serial outputs.
STEAM MASS
Steam Mass
Illustration
3. Applications
FlowmeterTemperature
Transmitter
PRINT
5
0–
TIME
CLEAR
•
MENU
ENTER
HELP
TEMP
4
PRE 1
3
RATE
2
TOTAL
1
GRAND
6
SCROLL
7
PRE 2
8
DENS
9
Pressure
Transmitter
Mass Flow
Mass Flow = volume ow • density (T, p)
Calculations
*
* or Steam Trap Monitor
*
* or Steam Trap Monitor

ES749 Flow Computer
12
3.2 Steam Heat
Measurements:
A owmeter measures the actual volume ow in a steam line. A temperature and/or
pressure sensor is installed to measure temperature and/or pressure.
Calculations:
• Density, mass ow and heat ow are calculated using the steam tables stored in the
ow computer. The heat is dened as the enthalpy of steam under actual conditions
with reference to the enthalpy of water at T=0°C.
• With square law device measurement the actual volume is calculated from the
differential pressure, taking into account temperature and pressure compensation.
• Saturated steam requires either a pressure or temperature measurement with the other
variable calculated using the saturated steam curve.
• Optional steam trap monitoring using compensation input.
Input Variables:
Superheated Steam: Flow, temperature and pressure
Saturated Steam: Flow, temperature or pressure
Output Results:
• Display Results
Heat, Mass or Volume Flow Rate, Resettable Total, Non-Resettable Total,
Temperature, Pressure, Density (optional: peak demand, demand last hour,
time/date stamp)
• Analog Output
Heat, Mass or Volume Flow Rate, Temperature, Pressure, Density, Peak
Demand, Demand Last Hour
• Pulse Output
Heat, Mass or Volume Total
• Relay Outputs
Heat, Mass or Volume Flow Rate , Total, Pressure, Temperature Alarms, Peak
Demand, Demand Last Hour
Applications:
Monitoring heat ow and total heat of steam. Flow alarms are provided via relays and
datalogging is available via analog (4-20mA) and serial outputs.
STEAM HEAT
Heat Flow
Heat Flow = Volume ow • density (T, p) • Sp. Enthalpy of steam (T, p)
Calculations
Steam Heat
Illustration
Temperature
Transmitter
PRINT
5
0–
TIME
CLEAR
•
MENU
ENTER
HELP
TEMP
4
PRE 1
3
RATE
2
TOTAL
1
GRAND
6
SCROLL
7
PRE 2
8
DENS
9
Pressure
Transmitter
Orifice Plate
with DP Transmitter
FlowmeterTemperature
Transmitter
PRINT
5
0–
TIME
CLEAR
•
MENU
ENTER
HELP
TEMP
4
PRE 1
3
RATE
2
TOTAL
1
GRAND
6
SCROLL
7
PRE 2
8
DENS
9
Pressure
Transmitter
*
* or Steam Trap Monitor
*
* or Steam Trap Monitor

ES749 Flow Computer
13
3.3 Steam Net Heat
Measurements:
A owmeter measures the actual volume ow in a steam line. A temperature and a
pressure sensor are installed to measure temperature and/or pressure. All measurement
are made on the steam side of a heat exchanger.
Calculations:
• Density, mass ow and net heat ow are calculated using the steam tables stored in the
ow computer. The net heat is dened as the difference between the heat of the steam
and the heat of the condensate. For simplication it is assumed that the condensate
(water) has a temperature which corresponds to the temperature of saturated steam
at the pressure measured upstream of the heat exchanger.
• With square law device measurement the actual volume is calculated from the
differential pressure, taking into account temperature and pressure compensation.
• Saturated steam requires either a pressure or temperature measurement with the other
variable calculated using the saturated steam curve.
• Optional steam trap monitoring using compensation input.
Input Variables:
Superheated Steam: Flow, temperature and pressure
Saturated Steam: Flow, temperature or pressure
Output Results:
• Display Results
Heat, Mass or Volume Flow Rate, Resettable Total, Non-Resettable Total,
Temperature, Pressure, Density, (optional: peak demand, demand last hour,
time/date stamp)
• Analog Output
Heat, Mass or Volume Flow Rate, Temperature, Pressure, Density, Peak
Demand, Demand Last Hour
• Pulse Output
Heat, Mass or Volume Total
• Relay Outputs
Heat, Mass or Volume Flow Rate , Total, Pressure, Temperature Alarms, Peak
Demand, Demand Last Hour
Applications:
Monitoring the thermal energy which can be extracted by a heat exchanger taking into
account the thermal energy remaining in the returned condensate. For simplication
it is assumed that the condensate (water) has a temperature which corresponds to
the temperature of saturated steam at the pressure measured upstream of the heat
exchanger.
STEAM NET HEAT
Net Heat Flow
Net Heat Flow = Volume ow • density (T, p) • [ED(T, p)– EW(TS(p))]
ED = Specic enthalpy of steam
Ew = Specic enthalpy of water
TS(p) = Calculated condensation temperature
(= saturated steam temperature for supply pressure)
Calculations
Steam Net Heat
Illustration
FlowmeterTemperature
Transmitter
PRINT
5
0–
TIME
CLEAR
•
MENU
ENTER
HELP
TEMP
4
PRE 1
3
RATE
2
TOTAL
1
GRAND
6
SCROLL
7
PRE 2
8
DENS
9
Pressure
Transmitter
Water
Steam
*
* or Steam Trap Monitor

ES749 Flow Computer
14
3.4 Steam Delta Heat
Measurements:
Measures actual volume ow and pressure of the saturated steam in the supply piping
as well as the temperature of the condensate in the downstream piping of a heat
exchanger.
Calculations:
• Calculates density, mass ow as well as the delta heat between the saturated steam
(supply) and condensation (return) using physical characteristic tables of steam and
water stored in the ow computer.
• With square law device measurement the actual volume is calculated from the
differential pressure, taking into account temperature and pressure compensation.
• The saturated steam temperature in the supply line is calculated from the pressure
measured there.
Input Variables:
Supply: Flow and pressure (saturated steam)
Return: Temperature (condensate)
Output Results:
• Display Results
Heat, Mass or Volume Flow Rate, Resettable Total, Non-Resettable Total,
Temperature, Pressure, Density (optional: peak demand, demand last hour,
time/date stamp)
• Analog Output
Heat, Mass or Volume Flow Rate, Temperature, Pressure, Density, Peak
Demand, Demand Last Hour
• Pulse Output
Heat, Mass or Volume Total
• Relay Outputs
Heat, Mass or Volume Flow Rate , Total, Pressure, Temperature Alarms, Peak
Demand, Demand Last Hour
Applications:
Calculate the saturated steam mass ow and the heat extracted by a heat exchanger
taking into account the thermal energy remaining in the condensate.
STEAM DELTA HEAT
Delta Heat Flow
Net Heat Flow = Volume ow • density (p) • [ED(p)– EW(T)]
ED = Specic enthalpy of steam
Ew = Specic enthalpy of water
Note: Assumes a closed system.
Calculations
Steam Delta Heat
Illustration
Pressure
Transmitter Flowmeter
Temperature
Transmitter
PRINT
5
0–
TIME
CLEAR
•
MENU
ENTER
HELP
TEMP
4
PRE 1
3
RATE
2
TOTAL
1
GRAND
6
SCROLL
7
PRE 2
8
DENS
9
Water
Saturated
Steam

ES749 Flow Computer
15
3.5 Corrected Gas Volume
Measurements:
A owmeter measures the actual volume ow in a gas line. Temperature and pressure
sensors are installed to correct for gas expansion effects.
Calculations:
• Corrected Volume is calculated using the ow, temperature and pressure inputs as well
as the gas characteristics stored in the ow computer (see "FLUID DATA" submenu).
Use the "OTHER INPUT" submenu to dene reference temperature and reference
pressure values for standard conditions.
Output Results:
• Display Results
Corrected Volume or Actual Volume Flow Rate, Resettable Total, Non-Resettable
Total, Temperature, Pressure, Density (optional: peak demand, demand last hour,
time/date stamp)
• Analog Output
Corrected Volume or Actual Volume Flow Rate, Temperature, Pressure, Density,
Peak Demand, Demand Last Hour
• Pulse Output
Corrected Volume or Actual Volume Total
• Relay Outputs
Corrected Volume or Actual Volume Flow Rate, Total, pressure, Temperature
Alarms, Peak Demand, Demand Last Hour
Applications:
Monitoring corrected volume ow and total of any gas. Flow alarms are provided via relays
and datalogging is available via analog (4-20mA) and serial outputs.
CORRECTED
GAS VOLUME
Volume Flow
Pulse Input; Average K-Factor
input frequency • time scale factor
Volume Flow =
K-Factor
Analog Input; Linear
Volume Flow = % input • Full Scale Flow
Corrected Volume Flow
P Tref Zref
Corrected Volume Flow = Volume Flow • • •
Pref T Z
Calculations
Corrected
Gas Volume
Illustration
FlowmeterTemperature
Transmitter
PRINT
5
0–
TIME
CLEAR
•
MENU
ENTER
HELP
TEMP
4
PRE 1
3
RATE
2
TOTAL
1
GRAND
6
SCROLL
7
PRE 2
8
DENS
9
Pressure
Transmitter

ES749 Flow Computer
16
Temperature
Transmitter
PRINT
5
0–
TIME
CLEAR
•
MENU
ENTER
HELP
TEMP
4
PRE 1
3
RATE
2
TOTAL
1
GRAND
6
SCROLL
7
PRE 2
8
DENS
9
Pressure
Transmitter
Orifice Plate
with DP Transmitter
FlowmeterTemperature
Transmitter
PRINT
5
0–
TIME
CLEAR
•
MENU
ENTER
HELP
TEMP
4
PRE 1
3
RATE
2
TOTAL
1
GRAND
6
SCROLL
7
PRE 2
8
DENS
9
Pressure
Transmitter
3.6 Gas Mass
Measurements:
A owmeter measures the actual volume ow in a gas line. Temperature and pressure
sensors are installed to measure temperature and pressure.
Calculations:
• Density and mass ow are calculated using gas characteristics stored in the ow
computer.
• With square law device measurement the actual volume is calculated from the
differential pressure, taking into account temperature and pressure compensation.
Output Results:
• Display Results
Mass or Volume Flow Rate, Resettable Total, Non-Resettable Total, Temperature,
Pressure, Density (optional: peak demand, demand last hour, time/date stamp)
• Analog Output
Mass or Volume Flow Rate, Temperature, Pressure, Density, Peak Demand,
Demand Last Hour
• Pulse Output
Mass or Volume Total
• Relay Outputs
Mass or Volume Flow Rate, Total, Pressure, Temperature, Density Alarms, Peak
Demand, Demand Last Hour
Applications:
Monitoring mass ow and total of gas. Flow alarms are provided via relays and datalogging
is available via analog (4-20mA) and serial outputs.
GAS MASS
Mass Flow
P Tref Zref
Mass Flow = Actual Volume Flow • ρref • • •
Pref T Z
ρref = Reference density
Tref = Reference temperature
Pref = Reference pressure
Zref = Reference Z-factor
Calculations
Gas Mass
Illustration