Onicon F-5100 Inline Operating instructions

F-5100 Insertion
Thermal Mass Flow Meter
Installation and Operation Guide
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SAFETY INFORMATION
This meter was calibrated at the factory before shipment. To ensure correct use of the meter, please
read this manual thoroughly.
Regarding this Manual:
• This manual should be passed on to the end user.
• Before use, read this manual thoroughly to comprehend its contents.
• The contents of this manual may be changed without prior notice.
• All rights reserved. No part of this manual may be reproduced in any form without
ONICON’s written permission.
• ONICON makes no warranty of any kind with regard to this material, including, but not
limited to, implied warranties of merchantability and suitability for a particular purpose.
• All reasonable effort has been made to ensure the accuracy of the contents of this manual.
However, if any errors are found, please inform ONICON.
• ONICON assumes no responsibilities for this product except as stated in the warranty.
• If the customer or any third party is harmed by the use of this product, ONICON assumes
no responsibility for any such harm owing to any defects in the product which were not
predictable, or for any indirect damages.
Safety Precautions:
The following general safety precautions must be observed during all phases of installation,
operation, service, and repair of this product. Failure to comply with these precautions or
with specic WARNINGS given elsewhere in this manual violates safety standards of design,
manufacture, and intended use of the product. ONICON Incorporated assumes no liability for
the customer’s failure to comply with these requirements. If this product is used in a manner not
specied in this manual, the protection provided by this product may be impaired.
The following symbols are used in this manual:
!
!
WARNING
Messages identied as “Warning” contain information regarding the personal safety of individuals
involved in the installation, operation or service of this product.
CAUTION
Messages identied as “Caution” contain information regarding potential damage to the product or
other ancillary products.
IMPORTANT NOTE
Messages identied as “Important Note” contain information critical to the proper operation of the
product.
i
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TABLE OF CONTENTS
1.0 INTRODUCTION ..................................................................................................5
1.1 PURPOSE OF THIS GUIDE .......................................................................5
1.2 TYPICAL INSERTION THERMAL MASS FLOW METER .......................5
1.3 STANDARD FEATURES AND SPECIFICATIONS....................................6
1.4 ADDITIONAL REQUIRED HARDWARE...................................................7
1.5 ADDITIONAL HARDWARE THAT MAY BE REQUIRED.........................8
1.5.1 Flow Conditioners .......................................................................8
1.5.2 Additional Remote Mount Cable ................................................8
1.6 WORKING ENVIRONMENT .....................................................................9
1.7 WARRANTY & SERIAL NUMBER ............................................................9
2.0 UNPACKING ....................................................................................................10
2.1 CHECKING TO SEE THAT YOU RECEIVED EVERYTHING..................10
3.0 INSTALLATION, REMOVAL AND ADJUSTMENT ..........................................11
3.1 INSTALLATION SITE SELECTION ........................................................11
3.2 MECHANICAL INSTALLATION.............................................................13
3.2.1 Installation Kits..........................................................................13
3.2.2 Directions For Standard Installation (new construction) ........14
3.2.3 Directions For Hot Tap Installation (pressurized system)........14
3.3 INSTALLING THE FLOW METER ......................................................... 15
3.3.1 Determining the Insertion Depth, Inserting the Meter and
Tightening the Compression Fitting .........................................15
3.4 REMOVING THE FLOW METER ............................................................18
3.5 ELECTRICAL INSTALLATION ...............................................................19
3.5.1 Analog Output ...........................................................................19
3.5.2 Pulse Output ..............................................................................19
3.5.3 Integral Mount Wiring ...............................................................20
3.5.4 Using the Pulse Isolator Module...............................................21
3.5.5 Remote Mount Wiring ...............................................................22
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4.0 START-UP & COMMISSIONING FOR ONICON INSERTION THERMAL MASS
FLOW METERS ..................................................................................................23
4.1 DISPLAY ..................................................................................................23
4.2 POWERING THE METER ........................................................................23
4.3 HELPFUL HINTS FOR START-UP & COMMISSIONING ......................23
4.4 START-UP & COMMISSIONING.............................................................24
4.5 START-UP & COMMISSIONING WORKSHEET.....................................25
5.0 TROUBLESHOOTING GUIDE............................................................................26
APPENDIX
A-1 REMOTE MOUNT MECHANICAL HARDWARE
A-2 USE OF THE INSERTION DEPTH GAGE
A-3 - A-5 ZERO FLOW CALIBRATION TEST
A-6 CONDITIONS OF SALE
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SECTION 1.0: INTRODUCTION
We, at ONICON Incorporated, would like to thank you for purchasing our quality American made
F-5100 Series Thermal Mass Flow Meter. As our valued customer, our commitment to you is to
provide fast reliable service, while continuing to offer you quality products to meet your growing
ow measurement needs.
1.1 PURPOSE OF THIS GUIDE
We have written this guide to provide the persons responsible for the installation, operation and
maintenance of your ow meter with the product specic information they will need. This is
NOT an electrical or plumbing trade manual.
WARNING
Please do not permit persons to install, operate or maintain this equipment unless they have a
complete knowledge of their trade skills and are competent to work on combustible gas and/or
high pressure compressed air systems, according to their individual trades. Death or permanent
injury may result from accidents with these systems.
!
This guide is the basic reference tool for all ONICON F-5100 Thermal Mass Flow Meters.
If you have not purchased all of the options, there will be references in this manual which are not
applicable to your meter(s).
1.2 TYPICAL INSERTION THERMAL MASS FLOW METER
Each ONICON thermal mass meter has a single pair of encapsulated platinum sensors that are
in direct contact with the gas. The sensors consist of highly stable reference-grade platinum
windings. One sensor is self-heated and serves as the ow sensor. The other acts as a reference
sensor, and measures the gas temperature. Our proprietary sensor circuitry maintains a constant
temperature differential between the ow sensor and the reference sensor.
As gas ows by the heated sensor (ow sensor), the molecules of owing gas carry heat away
and the sensor cools. The sensor circuitry continuously compensates for this cooling effect and
maintains a constant temperature differential between the two sensors. The energy required to
maintain this temperature differential is directly proportional to the mass ow. There is no need
for additional temperature or pressure compensation.
Flow
F-5000 Series
www.onicon.com
Clearwater, FL USA
Output signal(s)
to control system Optional
ONICON
Display
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1.3 STANDARD FEATURES AND SPECIFICATIONS
CALIBRATION
Every ONICON thermal mass ow meter is wet calibrated in a ow laboratory against standards that are directly
traceable to N.I.S.T. A certicate of calibration accompanies every meter. Each meter is calibrated for use with a specic gas.
Standard Reference Conditions for Natural Gas: Standard Reference Conditions for Air:
Fluid: Methane Fluid: Air
Fluid Temperature: 60°F Fluid Temperature: 70° F
Fluid Pressure: 29.92” Hg (14.70 PSIA) Fluid Pressure: 29.92” Hg (14.70 PSIA)
Contact ONICON for reference conditions for other uid types.
ACCURACY
Natural Gas
± 1.0% of reading from 500 – 7000 SFPM
± 2.0 % of reading from 100 – 500 SFPM
Compressed Air & other high velocity calibrations
± 1.0 % of reading + 0.5% of scale over a
100:1 turndown
OVERALL FLOW RANGE
5 to 35,000 SFPM
SENSING METHOD
Thermal mass ow utilizing hybrid analog/digital sensing circuitry, no moving parts
INPUT POWER
Standard: 24 VDC ±10%, 100 mA maximum current
Optional: 90-265 VAC, 50/60 Hz
Optional: 12 VDC ±10%, 200 mA maximum current
FLUID TEMPERATURE RANGE
Standard: -40° to 200° F
Optional: 200° to 300° F
Optional: 300° to 450° F
Optional: 450° to 700° F
AMBIENT TEMPERATURE RANGE
-5° to 150° F
MAXIMUM OPERATING PRESSURE
Standard: 500 PSI
Optional: 1,000 PSI
MATERIALS OF CONSTRUCTION
Wetted metal components - 316L stainless steel
Sensor head - Platinum windings encapsulated in 316L stainless steel
Electronics enclosure - Powder coat painted cast aluminum
Remote mount enclosure - Cast aluminum
ENCLOSURE RATING
Weathertight, NEMA 4 (All versions)
APPROVALS
Integral and remote mount (24 VDC only) Class 1, Division 2, Groups B, C, & D,
(ATEX: Ex nA IIC T4X)
ELECTRICAL CONNECTIONS
Enclosed terminal blocks, cable access through two ½” NPT conduit ttings
PROGRAMMING / MEMORY
Factory programmed for specic application.
Non-volatile memory retains all program parameters and totalized values in the event of power loss.
OUTPUT SIGNAL(S)
Analog output: 4-20 mA
Scalable pulse output: Active 24 VDC pulse, 500ms duration
DISPLAY
Graphic OLED display indicates:
Bar graph indicating percentage of full scale ow
Flow rate: 7 digits
Flow total: 9 digits (Total rolls over to zero when maximum count is exceeded)
Fluid temperature: 3 digits
mWatts of energy used to heat ow sensor: 4 digits
Engineering units for rate and total
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1.4 ADDITIONAL REQUIRED HARDWARE
All ONICON insertion thermal mass meters can be installed and removed via a ¾” or larger full
port ball valve without disrupting ow. The terms “Standard” and “Hot Tap” refer to the
installation method only.
Standard Installation: Occurs during new construction or
scheduled shutdown. Once kit is installed, the ow meter can
be installed or removed without disrupting ow.
Hot Tap Installation: For applications which require the access
hole in the pipe to be drilled through the valve using a wet tap
drilling machine while the piping system is pressurized.
NOTE: Installation hardware materials vary based on pipe
material, pipe size, the maximum operating pressure and the
maximum operating temperature.
Contact ONICON when installation hardware is required for
different pipe materials or when higher pressure or temperature ratings are required.
Part # Kit Description Items Included with Kit
INSTL64
Installation kit for 1” and larger welded carbon
steel pipe
Maximum operating pressure, 50 PSIG
Maximum operating temperature, 200°F
¾” full port bronze ball valve
¾” galvanized close nipple
¾” to ½” brass reducer bushing
¾” carbon steel weld-on branch outlet
½” stainless steel compression tting with PTFE ferrules
INSTL69
Stainless steel installation kit for 1” and larger
welded carbon steel pipe
Maximum operating pressure, 50 PSIG
Maximum operating temperature, 200°F
¾” full port SS ball valve
¾” SS close nipple
¾” to ½” SS reducer bushing
¾” carbon steel weld-on branch outlet
½” stainless steel compression tting with PTFE ferrules
INSTL70
Installation kit for 1” and larger welded carbon
steel pipe
Maximum operating pressure, 500 PSIG
Maximum operating temperature, 140°F
¾” full port bronze ball valve
¾” galvanized close nipple (Qty 2)
¾” carbon steel weld-on branch outlet
¾” stainless steel weldment with steel cable and
retaining collars
½” stainless steel compression tting with PTFE ferrules
INSTL91 Insertion meter compression tting w/o
installation hardware, 125psig/140° F max ½” stainless steel compression tting with PTFE ferrules
INSTL82
Stainless steel installation kit for 1” and larger
welded stainless steel pipe
Maximum operating pressure, 500 PSIG
Maximum operating temperature, 140° F
¾” full port SS ball valve
¾” SS close nipple (Qty 2)
¾” stainless steel weld-on branch outlet
¾” stainless steel weldment with steel cable and
retaining collars
½” stainless steel compression tting with PTFE ferrules
Compression Fitting
Reducer Bushing
Ball Valve
Close Nipple
Weld-on Branch Outlet
(INSTL 64 Shown)
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1.5 ADDITIONAL HARDWARE THAT MAY BE REQUIRED
1.5.1 Flow Conditioners
Flow conditioners may be required when an insufcient straight run of pipe is available
upstream of the proposed meter location. ONICON provides ow conditioners as an
optional accessory.
ONICON ow conditioners are designed to be installed between two anges (provided
by installer) that are located a specic distance upstream of the ow meter. The use of
ow conditioners signicantly reduces the upstream straight pipe length requirement
for ow meter. See page 12 for straight run requirements. The size of the ow conditioner
must match the pipe size. Contact ONICON for Schedule 80 ow conditioners.
Part # Description
17381 1” Flow Conditioner, Sch40
17382 1¼” Flow Conditioner, Sch 40
17383 1½” Flow Conditioner, Sch40
17384 2” Flow Conditioner, Sch40
17385 2½” Flow Conditioner, Sch40
17386 3” Flow Conditioner, Sch40
17387 4” Flow Conditioner, Sch 40
17388 6” Flow Conditioner, Sch40
17389 8” Flow Conditioner, Sch40
1.5.2 Additional Remote Mount Cable
ONICON remote mount meters are provided with 25 ft of cable. Additional cable lengths
of up to 1000 ft may be added without affecting the calibration of the meter.
Part # Description
17350 25 ft of additional mount remote cable
17351 50 ft of additional remote mount cable
17352 100 ft of additional remote mount cable
Largest of the
two perforated
plates
Gaskets
FLOW
ANSI class flanges
(user supplied)
2 pipe
diameters
Flow conditioning
assembly is
inserted here
Flow meter
inserts here
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1.6 WORKING ENVIRONMENT
F-5000 series meters are designed for installation and use in typical industrial environments that
are free of corrosive liquids and fumes, direct liquid exposure, heavy condensation, temperature
extremes and vibrations. Do not install the meter in direct sunlight.
The operating ambient air temperature range is -5° to 150° F.
The electrical power should be relatively clean, free of high frequency noise, large voltage
transients, and protected from power surges and brown outs.
1.7 WARRANTY & SERIAL NUMBER
Warranty
ONICON provides a 2-year warranty for this product. Certain exclusions apply. Please
refer to Appendix A-6, ONICON’s Conditions of Sale for details.
Serial Number
The serial number of your F-5100 series ow meter is located on the nameplate attached to
the top of the enclosure. This serial number will also be located on the remote sensor for
remote mount meters.
IMPORTANT NOTE
ONICON F-5000 series ow meters are individually calibrated. Remote mount electronics
enclosures and sensors must share the same serial number and must be installed together as a
system. Mixing components from different meters will result in signicant errors in calibration.
i
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SECTION 2.0: UNPACKING
ONICON Insertion Thermal Mass Flow Meters are packed and shipped in individual cartons.
An optional installation hardware kit, if ordered, will be packaged with each meter. All other
installation hardware and peripheral devices, including ow conditioners, will be packaged and
shipped separately.
Please open all packages with care to prevent damage to their contents. Carefully inspect each
item for signs of damage in transit. The ow meter stem should be straight and free of blemishes or
abrasions.
All ONICON products are shipped insured unless the customer specically requests otherwise. Please
notify the shipping company and ONICON immediately if any items are damaged in transit. Save all
packing material for inspection by the shipper.
2.1 CHECKING THAT YOU RECEIVED EVERYTHING
Standard Documentation
Enclosed with each meter is a comprehensive documentation package that includes the
following items:
• Installation and Operation Guide
• Flow Meter Calibration Certicate
• Product Data Sheet
• Scaled Pulse Isolator Module
Please notify the ONICON customer service department if any of these documents are
missing.
Product
• F-5100 Insertion Thermal Mass Flow Meter
• Optional Installation Hardware Kit, if ordered
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SECTION 3.0: INSTALLATION, REMOVAL AND ADJUSTMENT
WARNING
Insertion ow meters may be installed in pipes which are under high pressure or pipes lled with
combustible gases. Accidents with these systems can cause serious injury or death. Only persons
experienced with high pressure and/or combustible gas distribution systems and uid metering
should attempt to install, adjust, or remove the ow meter. Please read all instructions carefully
before attempting to install, remove or service a ow meter.
ONICON will be happy to assist with technical recommendations and to provide guidance by phone
or e-mail. On-site eld engineering, installation and service are also available at an additional cost.
3.1 INSTALLATION SITE SELECTION
Install the ow meter where it will be accessible for personnel to perform necessary periodic
maintenance. The clearance required for installation is typically 30-36” from the pipe wall
to the nearest obstruction above the valve assembly. This clearance dimension will increase
with larger diameter pipes. Refer to Section 1.6 WORKING ENVIRONMENT for additional
considerations.
ONICON insertion style ow meters must also be correctly oriented in the pipe with respect
to the direction of ow and the UPSTREAM mark on the stem. On meters with an integrally
mounted display, this will affect the orientation of the display.
F-5000 Series
ONICON
Flow Direction
Flow Direction
Flow Direction
The drawings above illustrate the relationship between
flow direction and display orientation for standard meters.
F-5000 Series
ONICON
F-5000 Series
ONICON
The drawings above illustrate the relationship between the integral display, the ow direction
and the orientation of the meter when installed in the pipe. Contact ONICON for assistance if
this relationship does not allow for viewing the display.
GENERAL PRACTICES:
1. For best results, install the ow meter in a straight run of pipe, free of bends, tees,
valves, transitions and obstructions.
2. Straight run requirements vary based on the nature of the upstream obstruction.
See the table on page 13 for guidelines in determining upstream straight run
requirements. Depending upon specic location details, more or less straight run
may be required to produce a satisfactory ow prole.
3. If there is insufcient straight run, allow 80% of the run upstream and 20% of
the run downstream. If the total length of straight run is less than 75% of the
recommended distance, performance may seriously degrade, and consideration
should be given to installing a ow conditioner.
!
F-5000 Series
F-5000 Series
F-5000 Series
ONICON ONICON
ONICON
Flow Direction
Flow Direction
Flow Direction
The drawings above illustrate the relationship between
flow direction and display orientation for standard meters.
UPSTREAM
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In addition to the information provided above and on the previous page, the following diagram
and table should be used as a guide to the proper location for installing the meter.
Upstream obstruction Minimum straight run required upstream of meter location
(A) Without Flow Conditioner (B) Upstream of Flow Conditioner
Single bend preceded by ≥ 9 diameters of
straight pipe 15 Diameters 3 Diameters
Pipe size reduction in straight pipe run 15 Diameters 3 Diameters
Multiple bends in plane with < 9 diameters
of straight pipe between them 20 Diameters 9 Diameters
Pipe size expansion in straight pipe run 20 Diameters 10 Diameters
Tees 30 Diameters 10 Diameters
Multiple bends out of plane 30 Diameters 9 Diameters
Modulating or regulating valve 40 Diameters 10 Diameters
Diaphram or roots type utility meter 40 Diameters 10 Diameters
IMPORTANT NOTICE
Always use the maximum available straight run. When more than the minimum required straight
run is available place the meter such that the excess straight run is upstream of the meter location.
The ow meter must be properly installed with respect to the direction of ow. Installing the
meter with the UPSTREAM label facing downstream will result in signicant errors in the ow
measurement.
i
How to Determine the Available Straight Pipe Diameters:
For each application, locate the longest straight, unobstructed section of pipe (no bends,
tees, valves, other insertion probes, size transitions).The longest straight pipe run in
inches divided by nominal pipe size in inches equals “diameters of straight pipe.”
2 X Diameter
• For 1” and larger diameter pipes
• Install in vertical or horizontal pipe
• For horizontal pipe position meter
anywhere in upper 180°
CLEARANCE
REQUIRED
FOR INSTALLATION
30” - 36”
Depending on
pipe size
Vertical pipe position
2 Dia.
B*
A* 5 Dia.
Clearwater, FL USA
F-5000 Series
www.onicon.com
ᴫ
COMM
PWR
FLOW
2 Dia.
B*
A* 5 Dia.
Clearwater, FL USA
F-5000 Series
www.onicon.com
ᴫ COMM PWR
FLOW
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3.2 MECHANICAL INSTALLATION
ONICON Insertion Thermal Mass Flow Meters are designed to allow for insertion and removal,
when necessary, without interrupting ow in the pipe. To take advantage of this feature, the ow
meter must be installed through an isolation valve. The installation must allow for sufcient
overhead clearance to fully extract the meter, and a full 5/8” opening in the pipe wall is required
to clear the sensor head and allow for insertion. Make sure that your valves and ttings are full
port and at least ¾” in actual internal diameter.
Flow
F-5000 Series
www.onicon.com
Clearwater, FL USA
Output signal(s)
to control system Optional
ONICON
Display
CAUTION
ONICON insertion style ow meters must be installed through a valve assembly. Failure to do so
negates the ability to remove the meter without disrupting ow. It will also result in an excessive
amount of stem protruding from the pipe. Excessive stem lengths unnecessarily expose the meter
to incidental damage.
!
3.2.1 Installation Kits
ONICON offers installation hardware kits for commonly used pipe materials. The kits are
specically designed for ONICON ow meters, and their use is strongly recommended.
The installation instructions contained in this manual assume that the pipe material is
welded steel. Contact ONICON for assistance, if necessary, if the installation involves a
different pipe material.
ONICON offers different types of kits based on the maximum operating pressure and
the maximum uid temperature. This information is detailed in section 1.4 of this manual.
Contact ONICON for assistance before installing the kit if it does not meet the pressure or
temperature requirements of your application.
IMPORTANT NOTICE
This manual includes detailed installation instructions for welded steel pipe Contact ONICON if
installation hardware instructions are needed for other pipe materials.
i
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INSTALLATION KIT COMPONENTS
¾” WELD-ON ¾” CLOSE ¾” FULL PORT ¾” CLOSE ½” COMPRESSION WELDMENT WITH
BRANCH OUTLET NIPPLE BALL VALVE NIPPLE FITTING CABLE & COLLARS
5/8” MINIMUM DIA
ACCESS HOLE
3.2.2 Directions For Standard Installation (During New Construction)
1. Identify an appropriate location for the ow meter.
2. Weld the branch outlet onto the pipe.
3. Drill a 5/8 inch (minimum) access hole, centered in the branch outlet.
4. Install the close nipple, ball valve, reducer bushing (or close nipple and
weldment) and compression tting as shown above; use a paste type thread
sealant or Teon® tape as needed.
5. Flush and pressurize the system.
3.2.3 Directions For Hot Tap Installation (A Pressurized System)
1. Identify an appropriate location for the ow meter.
2. Weld the branch outlet onto the pipe.
3. Install the close nipple and ball valve as shown below; use a paste type thread
sealant or use Teon® tape.
4. Use a hot tap drilling machine to create the 5/8” access hole.
5. Remove the drill and clear all debris from the valve.
6. Install the reducer bushing and compression tting (or weldment and
compression tting) using paste type thread sealant or Teon tape as needed.
50 PSIG Maximum Pressure
500 PSIG Maximum Pressure
G
G
L
L
¾” NPT BRANCH ¾” CLOSE ¾” FULL PORT ¾” TO ½” REDUCER ½” COMPRESSION
OUTLET NIPPLE BALL VALVE BUSHING FITTING
INSTALLATION KIT COMPONENTS
⅝” MINIMUM DIA
ACCESS HOLE
(Exploded view)
Compression
Fitting
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3.3 INSTALLING THE FLOW METER
Begin by calculating the effort that will be required to hold the meter. Establish adequate footing
for this task, taking extra care when working from a ladder or platform. Use the following
formula:
E=0.2 x P Where: E = effort in pounds
P = system pressure in pounds per square inch
Example: In a 50 PSI system, 10 pounds of force is required to insert the meter into
the pipe.
WARNING
SYSTEM MAY BE UNDER HIGH PRESSURE. When inserting, removing or adjusting the meter
position, be sure to hold the enclosure rmly by hand before SLOWLY loosening the
compression tting. Failure to do this will allow the pressure to suddenly and rapidly force the
meter from the pipe causing serious injury. The hand effort required to hold the meter will be 0.2
times the pipe pressure.
!
WARNING
Remove all sources of ignition (i.e. open ame, welding equipment, a lit cigarette, etc.) from the
area prior to installing, removing or adjusting the ow meter when working with combustible
gases.
!
3.3.1 Determining the Insertion Depth, Inserting the Meter and Tightening the
Compression Fitting
WARNING
The following instructions assume that the pipe is pressurized. Whenever the ball valve is open;
a rm grip must be maintained on the meter at all times until the insertion depth is set and the
compression tting is properly tightened.
!
WARNING
Do not attempt to insert the meter into a pipe pressurized to greater than 200 PSIG. For pipes
pressurized above 200 PSIG isolate ow and relieve pressure in the pipe before attempting to
install the meter.
!
The insertion depth is based on the inside diameter of the pipe into which the meter is
installed. When the meter is properly installed, the ow sensor is positioned in the center
of the pipe.
For meters installed in pipes with a nominal diameter ≤ 6 inches, the reference point for
the insertion depth measurement is the inside wall of the pipe directly opposite from the
insertion point. For meters installed in pipes with a nominal diameter > 6 inches, a depth
gage is provided. See Appendix A-2 for instructions on the use of the insertion depth gage.
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Determining the Insertion Depth
The dimension used to set the insertion depth is the “X” dimension. This dimension is
printed on the laminated tag attached to the meter and can be found in the tables below.
Schedule 40 Pipe
Nominal
Diameter O.D. I.D. X Y
1” 1.315 1.049 Bottom N/A
1.25” 1.660 1.380 Bottom N/A
1.5” 1.900 1.610 0.20” 1.56”
2” 2.375 2.067 0.40” 1.82”
2.5” 2.875 2.469 0.60” 2.07”
3” 3.500 3.068 0.90” 2.38”
4” 4.500 4.026 1.40” 2.86”
6” 6.625 6.065 2.40” 3.95”
Schedule 80 Pipe
Nominal
Diameter O.D. I.D. X Y
1” 1.315 0.957 Bottom N/A
1.25” 1.660 1.278 Bottom N/A
1.5” 1.900 1.500 0.15” 1.56”
2” 2.375 1.939 0.35” 1.82”
2.5” 2.875 2.323 0.55” 2.07”
3” 3.500 2.900 0.80” 2.38”
4” 4.500 3.826 1.30” 2.86”
6” 6.625 5.761 2.25” 3.95”
Inserting the Meter
1. Insert the ow meter stem into the
compression tting.
2. Open the ball valve and carefully
insert the ow meter until the end
of the stem just contacts the opposite
wall of the pipe.
3. Mark the position of the stem where it
exits the top of the compression tting.
4. Withdraw the stem “X” distance as
measured from the top of the compression
tting. At the same time position the
electronics enclosure parallel to the pipe in the correct orientation relative to the
ow direction as shown. This will position the sensor with its axis in line
with the ow and in the correct direction.
Center Line
of Pipe
X
Y
FLOW
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Tightening the Compression Fitting
1. Insert the meter as described above.
2. Tighten the nut until the stem will not turn by hand or
move axially in the tting.
3. Mark the nut at the 6 o’clock position.
4. While holding the tting body steady, tighten the nut one
and one quarter (1¼) turns to the 9 o’clock position.
CAUTION
The compression tting must be tightened as described in the following procedure. Failure to do
will likely result in uid leaks and/or permanent damage to the ow meter stem.
!
Collar
Collar
For high pressure kits, position upper collar as shown and
then tighten both collars to complete the installation.
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3.4 REMOVING THE FLOW METER
WARNING
SYSTEM MAY BE UNDER HIGH PRESSURE. When removing the ow meter, be sure to grasp
the electronics enclosure rmly by hand before slowly loosening the compression tting. Failure
to do this will allow the pressure in the pipe to suddenly and rapidly force the meter from the
pipe causing serious injury. The hand effort required to hold the meter will be 0.2 times the pipe
pressure.
!
WARNING
Do not attempt to remove the meter from a pipe pressurized to greater than 200 PSIG. For pipes
pressurized above 200 PSIG isolate ow and relieve pressure in the pipe before attempting to
remove the meter.
!
Removal instructions for standard meter installations.
1. While rmly grasping the enclosure,
loosen the compression tting.
2. Slowly withdraw the stem until the
ats located on the sensor are exposed.
3. Close the ball valve and fully withdraw
the ow meter.
Stop here at the
flats on the sensor
Removal instructions for meter installed with safety cable and retaining collars.
1. Conrm that upper retaining collar is installed at the top of the ow meter stem. If it is
not reposition the collar as shown in the drawing on the preceding page. Make certain
this collar is tightly connected to the stem.
2. Loosen the lower retaining collar.
3. While rmly grasping the enclosure, loosen the compression tting.
4. Slowly withdraw the stem until safety cable is taut.
5. Close the ball valve, loosen the upper retaining collar and remove the ow meter.
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3.5.1 Analog Output
The F-5100 is provided with a single 4-20 mA output for instantaneous rate. This output is
electrically isolated from earth, but shares common with the scaled pulse output and, on
DC versions of the meter, with input power.
The output is programmed at the factory. Refer to the attached laminated tag or the
certicate of calibration for information regarding the programmed full scale ow.
Contact ONICON for assistance if the full scale ow rate requires reprogramming.
3.5.2 Pulse Output
The F-5100 is provided with a single scaled pulse output for totalizing . This is an active
pulse output with a nominal pulse amplitude of 24 VDC (12 VDC for 12 V versions of the
meter). In all versions, the pulse duration is 500ms.
This DC pulse output is electrically isolated from earth, but shares common with the
analog output and, on DC versions of the meter, with input power. This output is
programmed at the factory. Refer to the attached laminated tag or the certicate of
calibration for information regarding the programmed pulse value.
Contact ONICON for assistance if the scaled pulse output requires reprogramming.
CAUTION
Cable glands shipped with the meter are for shipping purposes only. Remove and replace with
approved glands when installing the meter.
!
WARNING
If the meter is being installed in a Class 1 hazardous location, the installation must comply with all
appropriate electrical codes.
!
WARNING
The meter must be connected to a protective earth wire at the transmitter and at the sensor for
remote mount meters as per electrical codes.
!
3.5 ELECTRICAL INSTALLATION
The electrical installation of this product must comply with all federal, state and local building
codes. Connect and re-verify all output signal and safety earth wiring connections prior to
connecting power.
All connections must be made through the (2) ½’ NPT cable glands located on the enclosure.
To access the terminal wiring connections, remove the rear cover from the enclosure.
IMPORTANT NOTICE
The nominal pulse output voltage from this meter is 24 VDC. A pulse isolator module has been
provided with this meter that will convert this active pulse into an isolated dry contact output.
Refer to section 3.5.4 Using the Pulse Isolator Module for details.
i
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INSIDE BODY VIEW
1RED AC1 COM 1
2S1 AC2 B + 2
3RED NU A – 3
4WHITE NU 4
5S2 4-20mA 5
6WHITE SIG GND6
A B C
24 VDC
PULSE
VDC IN
+
VDC GND
–
INTEGRAL
1
2
3
4
5
6
1
2
3
4
5
6
A B C
NO CUSTOMER ACCESS
DO NOT OPEN THIS SIDE
INSIDE REAR
COVER LABEL
A1 - RED - VELOCITY SENSOR WIRE (HEATED ELEMENT)
A2 - NO WIRE
A3 - RED - VELOCITY SENSOR WIRE (HEATED ELEMENT)
A4 - WHITE - TEMPERATURE SENSOR WIRE
A5 - NO WIRE
A6 - WHITE - TEMPERATURE SENSOR WIRE
B1 - AC1 - AC VOLTAGE
B2 - AC2 - AC VOLTAGE
B3 - NU - NOT USED
B4 - 4 - 20 mA POWER
B5 - VDC IN - VOLTAGE DC - POSITIVE (+)
B6 - VDC GND - VOLTAGE DC - GROUND (-)
C1 - NOT USED
C2 - RS 485 (+)
C3 - RS 485 (-)
C4 - 24 VDC PULSE - 0 TO 24 DC PULSE OUTPUT
C5 - 4 - 20 mA - 4 TO 20 mA ANALOG OUTPUT
C6 - VDC GND - VOLTAGE DC - GROUND (-)
TERMINAL BLOCK SIDE
½” NPT
USER ENTRY
FOR WIRING
(ONE ON EACH SIDE)
DISPLAY SIDE
FLOW
½” NPT
USER ENTRY
FOR WIRING
*
*Factory installed jumper and resistor.
Do not remove.
*
3.5.3 Integral Mount Wiring
A B C
A B C
1
2
3
4
5
6
1
2
3
4
5
6
Control System
DC Pulse +
4-20mA +
+24 VDC
VDC Common
F-5100 Terminals
IMPORTANT NOTICE
The nominal pulse output voltage from this meter is 24 VDC. A pulse isolator module has been
provided with this meter that will convert this active pulse into an isolated dry contact output.
Refer to section 3.5.4 Using the Pulse Isolator Module for details.
i
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