Onicon SYSTEM-1000 Operating instructions
ON
I
CON
Flow and Energy Measurement
SYSTEM-1000SYSTEM-1000
FLOW AND ENERGY MEASUREMENT SYSTEMFLOW AND ENERGY MEASUREMENT SYSTEM
Installation and Operation GuideInstallation and Operation Guide
DOC-0005327 Rev.A
SYSTEM-1000 FLOW AND ENERGY MEASUREMENT SYSTEM
ONICON Incorporated 727.447.6140 Page 2 onicon.com
SAFETY INFORMATION
The System-1000 BTU Meter was calibrated at the factory before shipment. To ensure correct use of the system, 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 Incorporated’s written
permission.
• ONICON Incorporated 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.
•
found, please inform ONICON Incorporated.
• ONICON Incorporated 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 Incorporated 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
violates safety standards of design, manufacture, and intended use of the product. ONICON Incorporated assumes no
this manual, the protection provided by this product may be impaired.
The following messages are used in this manual:
WARNING
Messages identied as “WARNING” contain information regarding the personal safety of individuals involved in
the installation, operation or service of this product.
CAUTION
Messages identied as “CAUTION” contain information regarding potential damage to the product or other
ancillary products.
IMPORTANT NOTE
Messages identied as “IMPORTANT NOTE” contain information critical to the proper operation of the product.
SYSTEM-1000 FLOW AND ENERGY MEASUREMENT SYSTEM
ONICON Incorporated 727.447.6140 Page 3 onicon.com
TABLE OF CONTENTS
SECTION 1.0 GENERAL INFORMATION ................................................................................................................. 4
......................................................................................................................................................4
-.......................................................................................................4
1.3 STANDARD FEATURES AND SPECIFICATIONS ..................................................................................................................5
..................................................................................................................................................6
...................................................................................................................................7
.........................................................................................................................................................7
..............................................................................................................................................................................7
SECTION 2.0 UNPACKING ....................................................................................................................................... 8
..................................................................................................8
SECTION 3.0 INSTALLATION.................................................................................................................................... 9
...............................................................................................................................................................................9
3.1.1 The System-1000 BTU Meter ............................................................................................................................................9
3.1.2 The Flow Meter.......................................................................................................................................................................9
3.1.3 The Temperature Sensors...................................................................................................................................................9
................................................................................................................................................10
3.2.1 Thermowell Installation....................................................................................................................................................11
3.2.1.1 Dry Tap Thermowells (ONICON/Analog).....................................................................................................11
....................................................................................................11
3.2.1.3 Clamp-on Thermowell (ONICON/Analog)..................................................................................................13
3.2.1.4 5mm Diameter Thermowell (4-wire RTDs)..................................................................................................14
3.2.1.5 6mm Diameter Thermowell (4-wire RTDs)..................................................................................................14
3.2.2 Temperature Sensor Installation...................................................................................................................................15
3.2.3 Flow Meter Installation.....................................................................................................................................................15
....................................................................................................................................................16
3.3.1 Input Power Requirements .............................................................................................................................................16
3.3.2 Input Signal Connections ................................................................................................................................................17
3.3.2.1 Input Signal Connections from Flow Meters .............................................................................................18
..................................................................................................................19
3.3.2.3 Input Signal Connections for Temperature Sensors ...............................................................................20
3.3.2.4 Peripheral Devices: Flow Meters .....................................................................................................................21
3.3.2.5 Output Signal Connections...............................................................................................................................22
SECTION 4.0 START-UP AND COMMISSIONING ............................................................................................... 23
............................................................................................................................................23
4.2 UNITS........ .........................................................................................................................................................................................23
........................................................................................................................................................................24
.................................................................................................................................................26
SECTION 5.0 MENU TREE ....................................................................................................................................... 34
SECTION 6.0 DIAGNOSTICS................................................................................................................................... 40
......................................................................................................................................................................41
APPENDIX A –DRAWINGS .................................................................................................................................... 44
................................................................................................A-1
............................ A-2&3
SYSTEM-1000 FLOW AND ENERGY MEASUREMENT SYSTEM
ONICON Incorporated 727.447.6140 Page 4 onicon.com
SECTION 1.0 GENERAL INFORMATION
1.1 PURPOSE OF THIS MANUAL
1.2 TYPICAL SYSTEM-1000 BTU METER INSTALLATION
The purpose of this guide is to provide installation and commissioning procedures and basic operating and servicing
instructions for the ONICON System-1000 BTU Meter.
WARNING
Only qualied service personnel should attempt to install or service this product. Serious injury may result from the
improper Installation or use of this product.
1. ONICON Flow Meters and Temperature Sensors are provided separately
2.
3.
4. Flow Meter and Temperature sensors used for thermal energy calculations
5.
6.
7. Digital Outputs are available for Energy Totals, Flow Totals, Operating Modes, and Alarms
8.
9. RS485 or IP for BACnet MSTP or BACnet UDP/IP
SYSTEM-1000 FLOW AND ENERGY MEASUREMENT SYSTEM
ONICON Incorporated 727.447.6140 Page 5 onicon.com
*SPECIFICATIONS subject to change without notice.
1.3 STANDARD FEATURES AND SPECIFICATIONS*
PERFORMANCE
Computing nonlinearity within ±0.05%
applications.
TEMPERATURE
ACCURACY /
Precision solid state current based sensors.
(ordered separately)
DIMENSIONS
ADC12 Die Cast Aluminum
NEMA 13
Frequency Inputs Two (2) Active Frequency Inputs
Analog Inputs Two (2) Active Analog Inputs
Digital Inputs Two (2) Open Collector / Isolated Dry
Temperature
Sensor Inputs
Two (2) Passive Analog Inputs or
Analog Outputs Four (4) Active Analog Outputs
Digital Outputs Four (4) Isolated Dry Contact Inputs for
Frequency Inputs Four (4) Active Frequency Inputs
Analog Inputs Four (4) Active Analog Inputs
Digital Inputs Four (4) Open Collector / Isolated Dry
Temperture Sensor
Inputs
Four (4) Passive Analog Inputs or (4) 1000
Analog Outputs Eight (8) Active Analog Outputs
Digital Outputs Eight (8) Isolated Dry Contact Inputs for
SYSTEM-1000 FLOW AND ENERGY MEASUREMENT SYSTEM
ONICON Incorporated 727.447.6140 Page 6 onicon.com
1.3 STANDARD FEATURES AND SPECIFICATIONS (CONTINUED)*
*SPECIFICATIONS subject to change without notice.
** The default address is set to slave to prevent bus contention. The user will have to program the master address they
desire for MS/TP communication with the SYSTEM-1000 to proceed.
Isolated RS485 serial interface or IP ethernet port connection
COMMUNICATION
BACnet MS/TP or BACnet UDP/IP
BACnet MS/TP
Baud Rates 9600, 19200, 38400, 57600, or 76800
(Default: 38400)
Device Address
Range
0 – 127 (Master) 128 - 254 (Slave)
(Default: 128**)
Device Instance
Range
1 – 4,194,302 (Default:57017)
Max master 1-127
BACnet UDP/IP (IPv4)
Default Address 192.168.1.24
Instance Number 1 – 4,194,302 (Default:57017)
Subnet Mask Programmable (Default:255.255.255.0)
Programmable
UDP port: Programmable (Default:47808)
FCC Part 15, Subpart B
CE
Meter Model Number Coding = SYS-1X00-ABC
X = System Conguration
1 = Single Channel System
2 = Dual Channel System
A = Electronics Enclosure
B = Input Power
C = Network Communications
0 = No communications
1 = RS485 or IP (BACnet MS/TP or UDP/IP)
1.4 MODEL NUMBERING SYSTEM
SYSTEM-1000 FLOW AND ENERGY MEASUREMENT SYSTEM
ONICON Incorporated 727.447.6140 Page 7 onicon.com
1.5 ADDITIONAL REQUIRED HARDWARE
1.6 WORKING ENVIRONMENT
The System-1000 was designed for installation and use in typical industrial environments that are free of corrosive liquids
and fumes, direct liquid exposure, temperature extremes and vibrations. Do not expose the meter to direct sunlight.
frequency noise, large voltage transients, and protected from power surges and brown outs.
1.7 SERIAL NUMBER
the meter data screens. Please have this number available when contacting ONICON for assistance.
Type of Meter Flow Meter Model Line Sizes Installation Type
Chilled Water,
Hot Water,
Water/Glycol
Solutions
F-1100 Single Turbine Flow Meter 1¼” and larger Insertion
F-1200 Dual Turbine Flow Meter 2½” and larger Insertion
F-11XX Turbine Flow Meter ¾” and 1” Inline
F-3500 Insertion Mag Flow Meter 1¼” and larger Insertion
FT-3000 Series Electromagnetic Flow Meter ¼” and larger Inline
F-4300 Ultrasonic Flow Meter Clamp-on
F-4600 Ultrasonic Flow Meter Inline
Steam
F-2600 Vortex Flow Meter Inline
F-2700 Vortex Flow Meter Insertion
F-1500 Turbine Flow Meter Insertion
Gas F-5400/F-5500 Thermal Mass Flow Meters ¾” - 24” Inline/Insertion
requirements.
1.UPDATE WITH OTHER METER TYPES? STEAM/GAS/ETC
SYSTEM-1000 FLOW AND ENERGY MEASUREMENT SYSTEM
ONICON Incorporated 727.447.6140 Page 8 onicon.com
SECTION 2.0 UNPACKING
CHECK THAT YOU HAVE RECEIVED EVERYTHING
Each box comes with a label identifying the ONICON job number, Model Number, Serial Number, and
Tag Information. (Use tags to identify the meter location.)
SYSTEM-1000
UNPACKING INSTRUCTIONS
!
CAUTION
Please open the package with caution to avoid damaging its contents. If any item
is damaged upon receipt, notify the shipping company immediately and alert the
ONICON customer service department. Most products are shipped insured unless the
customer specically requests otherwise.
SIGN A L ( RED )
REFERENCE ( B L A CK )
SUPPLY
S/N 123456
1
1
1
23
4 5
DOC-0005048 Rev. A
Flow Meter Box
Comes Separately
(Check Job Number Label)
Install Kits Box
(Check Job Number Label)
STEP 1
Typical order includes:
System-1000 with
temperature sensors
located inside of the
enclosure
Flow Meters
(from 1-8 Boxes) Installation Kits
(may have been
shipped in advance)
4 Quick Start Guides
(Mechanical, Electrical,
Network, Commissioning)
Conguration Sheet /
Calibration Certicate
i
IMPORTANT NOTICE
Flow and BTU meters will be congured and programmed for use together as a system.
The ow meter serial number will be shown on the System-1000 conguration sheet.
SIGN A L ( RED )
REFERENCE ( B L A CK )
SUPPLY
S/N 123456
2.1 CHECKING THAT YOU HAVE RECEIVED EVERYTHING
i
IMPORTANT NOTICE
SYSTEM-1000 FLOW AND ENERGY MEASUREMENT SYSTEM
ONICON Incorporated 727.447.6140 Page 9 onicon.com
SECTION 3.0 INSTALLATION
The System-1000 BTU Meter should be installed by experienced contractors with related knowledge and experience
assistance.
The installer should use good trade practices and must adhere to all state and local building or other applicable codes.
3.1 SITE SELECTION
3.1.1 The System-1000 BTU Meter
3.1.2 The Flow Meter
Careful attention to the site selection for the system components will help the installers with the initial installation, reduce
start-up problems, and make future maintenance easier.
following.
IMPORTANT NOTE
Proper site selection is critical to the performance of this BTU meter. Both the ow meter and the two temperature
sensors must be properly located within the piping system in order to ensure an accurate energy measurement.
Mount the System-1000 enclosure on a vibration free surface. Avoid locations such as the plenum of a fan coil, heat
exchanger or any housing that may contain electric motors or other strong sources of electrical interference.
3.1.3 The Temperature Sensors
The two or four temperature sensors must be located in such a manner as to accurately measure only the temperature of
the supply line entering and the return line leaving the portion of the piping system for which the energy measurement is
two independent energy measurements.
performance of the sensors.
other sensor.
Two types of thermowells might be provided with the unit and depending on the condition of the system. For empty
allows for the insertion and removal of the thermowell without a system shutdown.
sensor length. Matching the thermowell to the pipe diameter ensures that the thermowell will be fully immersed in the
the well and provide accurate, responsive temperature measurement.
SYSTEM-1000 FLOW AND ENERGY MEASUREMENT SYSTEM
ONICON Incorporated 727.447.6140 Page 10 onicon.com
CAUTION
DO NOT drill holes in the enclosure. Use only the openings that are provided.
3.2 MECHANICAL INSTALLATION
10.90"
11.25"
CENTERLINE
USE FOR LEVELING
SYSTEM-1000
MOUNTING TEMPLATE AND INSTRUCTIONS
STEP 2
THE MOUNTING SURFACE MUST BE STRUCTURALLY SOUND AND CAPABLE OF WITHSTANDING
A MINIMUM WEIGHT OF 60LBS (27KG). USE THE FOLLOWING HARDWARE FOR MOUNTING.
CONCRETE, BLOCK & BRICK
(4) 1/4” X 1-1/2” HEX HEAD CONCRETE SCREWS THAT SUPPORTS A MINIMUM OF 60LBS
DIN 3 RAIL
(4) SINGLE CLIP MOUNTING ADAPTER FOR DIN 3 RAIL
WOOD:
(4) 1/4” X 1-1/2” HEX HEAD LAG SCREWS THAT SUPPORTS A MINIMUM OF 60LBS
DRYWALL:
(4) #12 X 1-1/2” HEX HEAD SCREW
(4) #12 WASHERS
(4) DRYWALL ANCHORS THAT SUPPORT A MINIMUM OF 60 LBS
Image not to scale
SYSTEM-1000 FLOW AND ENERGY MEASUREMENT SYSTEM
ONICON Incorporated 727.447.6140 Page 11 onicon.com
3.2.1 Thermowell Installation
Sections 3.2.1.1 - 3.2.1.3 are thermowell kits for ONICON solid state temperature sensors and high temperature RTDs with
matching transmitters. See sections 3.2.1.4 - 3.2.1.5 for thermowells for 4-wire RTDs
IMPORTANT NOTE
It is important that no dirt or other foreign material be allowed into the thermowells as this could aect the
thermal response of the system.
Dry tap thermowells are for new construction or scheduled shutdown. The most common installation methods are
thermowell installations. Consult ONICON for special applications.
prior to installation. The thermowell is installed through a 1” full port ball valve as shown in the drawing on the next page.
A hot tap drilling machine equipped with a 7/8” drill is required to perform this type of installation.
Install the valve assembly as shown in the drawing and then drill the 7/8” hole using the hot tap drilling machine. Once
without a system shutdown.
NOTES
1.
2.
3.2.1.1 Dry Tap Thermowells
3.2.1.2 Hot Tap Thermowells
SYSTEM-1000 FLOW AND ENERGY MEASUREMENT SYSTEM
ONICON Incorporated 727.447.6140 Page 12 onicon.com
WARNING
SYSTEM MAY BE UNDER HIGH PRESSURE. Be sure to hold the conduit box rmly by hand before slowly loosening
the position clamping nut when installing, adjusting or removing the thermowell. Failure to do this will allow
the pressure to suddenly and rapidly force the thermowell from the pipe, potentially causing serious injury. The
thermowell could also be damaged or break apart causing a break in the water seal with the resultant loss of
large amounts of water.
Insertion of the Hot Tap Thermowell
1. Calculate the insertion force (lbs) required by multiplying the system pressure (psig) by 0.11. The person inserting the
thermowell should ensure adequate footing for the force required prior to opening the valve.
2. Thread the hot tap adapter into the valve. Firmly grasp the wiring enclosure, loosen the position clamping nut, open
3.
release the wiring enclosure until the position clamping nut has been tightened.
CAUTION
Excessive vibration can damage the thermowell. Insert the thermowell to the proper depth using gauge supplied as
shown. Reduce the insertion depth as necessary if strong vibrations are felt during insertion, making certain that the
tip of the thermowell remains fully in the ow stream.
CAUTION
DO NOT OVER TIGHTEN THE POSITION CLAMPING NUT. If uid leaks, do not attempt to correct by tightening this
nut further. An internal o-ring seals the uid. Contact ONICON for assistance in the event of a leak.
3.2.1.2 Hot Tap Thermowells (CONTINUED)
Hot Tap Installation Detail For Thermowell In Welded Pipe
SYSTEM-1000 FLOW AND ENERGY MEASUREMENT SYSTEM
ONICON Incorporated 727.447.6140 Page 13 onicon.com
Removal Of The Hot Tap Thermowell
WARNING
Maintain a rm hold on the wiring enclosure until the thermowell is completely withdrawn and the valve is closed.
IMPORTANT NOTE
Rotating the thermowell as you slowly withdraw it through the valve will ensure that the lower tip is fully withdrawn
and completely free of the valve. If resistance is felt when closing the valve, open valve fully and rotate the well as
you pull it further out of the pipe.
1.
establish safe footing prior to loosening the clamping nut. The force pushing out against the thermowell is the same as
the insertion force calculated above.
2.
withdraw the thermowell from the pipe. After the thermowell is completely withdrawn, carefully close the isolation
valve.
3.2.1.3 Clamp-On Thermowell
is also very important to properly insulate over them. The insulation thickness (or R value) required is proportional to the
SYSTEM-1000 FLOW AND ENERGY MEASUREMENT SYSTEM
ONICON Incorporated 727.447.6140 Page 14 onicon.com
3.2.1.4 5mm Diameter Thermowell
5 mm RTDs are provided with thermowells with ½” male NPT process connections. They are designed for use in ½” to 2½”
the pipe material, the kit may include a copper sweat bushing or a threaded reducer bushing.
1. RTD temperature sensor – provided by ONICON.
2. 5 mm diameter thermowell – provided by ONICON.
3.
4.
1
2
3
4
6mm RTDs are provided with matching length thermowells with ½” male NPT process connections. They are designed for
use in 3” and larger diameter pipes. The RTDs are push-in type and are held in place with a set screw. The kit includes two
(2) weld-on branch outlets with ½” NPT threads.
1. 6 mm diameter thermowell - provided by ONICON.
2.
3.
2
1
3
3.2.1.5 6mm Diameter Thermowell
Thermowells for 4-wire RTDs
SYSTEM-1000 FLOW AND ENERGY MEASUREMENT SYSTEM
ONICON Incorporated 727.447.6140 Page 15 onicon.com
sensor.
• Apply a thin coat of thermal compound to the temperature sensor, and gently insert the temperature sensor all the way
into the thermowell until it contacts the bottom of the cavity.
•
• The thermowell completely seals the plumbing system without the retainer nut. The only purpose for the nut is to keep
the sensor from losing contact with the bottom of the thermowell cavity.
IMPORTANT NOTE
Cable length is specied at time of order. Cable provided for temperature sensors is #22 gauge twisted shielded pair.
Additional cable may be added in the eld if necessary, but must be of twisted shielded pair construction.
(#22 gauge minimum and #18 gauge maximum)
SIGNAL (RED)
REFERENCE
(BLACK)
SUPPLY
S/N 123456
5/8" MINIMUM
HOLE SIZE
1/2" HOLE FOR
CONDUIT OR
STRAIN RELIEF
FITTING.
PROVIDE 18-22 GA TWISTED
SHIELDED PAIR.
COIL ONE FOOT OF EXTRA
CABLE IN CONDUIT BOX.
1/2” NPT WELDED
BRANCH OUTLET
PLACE ELECTRONICS
MODULE IN BOX AFTER
CONNECTING WIRES.
3.2.2 Temperature Sensor Installation (ONICON Solid State Sensors)
enough clearance to remove either sensor from the pipe without interference from the other sensor.
3.2.3 Flow Meter Installation
SYSTEM-1000 FLOW AND ENERGY MEASUREMENT SYSTEM
ONICON Incorporated 727.447.6140 Page 16 onicon.com
WARNING
Disconnect main power before proceeding.
CAUTION
This product must be connected to earth ground for proper operation. Failure to do so may result in erratic operation.
Connect the protective earth wire to the right top terminal connection of the motherboard..
Connect the power source to the main unit through the conduit opening located on the side of the main unit. DO NOT
drill holes in the enclosure. Fasten the power wires to the appropriate screw terminals as shown.
Main Menu screen. If this does not occur, disconnect power immediately and re-verify all wiring connections. If the
problem persists, contact ONICON.
3.3 ELECTRICAL INSTALLATION
1. Input voltages should be within he following ranges:
•
•
IMPORTANT NOTE:
This option is not eld selectable. Contact ONICON prior to installation if needed to change the input voltage rating.
WARNING
Conduit openings in the System-1000 enclosure must be closed with UL listed ttings applicable to NEMA 13
enclosures.
3.3.1 Input Power Requirements
24V
120-240V
SYSTEM-1000 FLOW AND ENERGY MEASUREMENT SYSTEM
ONICON Incorporated 727.447.6140 Page 17 onicon.com
3.3.2 Input Signal Connections
SYS-1000 comes with a custom-made wiring diagram to facilitate its installation. The schematics include the meter tag,
model number, serial number, and terminal connection location on the board. Please contact the factory if a copy of the
wiring diagram is needed.
SAMPLE
SYSTEM-1000 FLOW AND ENERGY MEASUREMENT SYSTEM
ONICON Incorporated 727.447.6140 Page 18 onicon.com
3.3.2.1 Input Signal Connections From Flow Meters
SYSTEM-1000 FLOW AND ENERGY MEASUREMENT SYSTEM
ONICON Incorporated 727.447.6140 Page 19 onicon.com
3.3.2.2 Temperature Input Wiring Details
ONICON FIXED RANGE or LOOP POWERED 4-20mA SCALABLE RANGE
TEMPERATURE INPUTS
TERMINAL BLOCK TB5
4. (+) RETURN TEMP
3. SHIELD
2. (-) SUPPLY TEMP
1. (+) SUPPLY TEMP
5. (-) RETURN TEMP
(+) Signal
(-) Reference Return Temperature Sensor
Shield
(+) Signal
(-) Reference Supply Temperature Sensor
1000 OHMS 4-WIRE PLATINUM RTD TEMPERATURE INPUTS
w/ ATTACHED PIGTAILS CABLE
TERMINAL BLOCK TB6 (SUP)
& TB7 (RET)
4. (B) COMPENSATION LEAD
3. (B) RTD SIGNAL LEAD
2. (A) COMPENSATION LEAD
1. (A) RTD SIGNAL LEAD Brown*
Yellow*
White*
Green*
1000 OHMS 4-WIRE PLATINUM TEMPERATURE INPUTS
w/ INTEGRAL CONDUIT READY JUNCTION BOX
TERMINAL BLOCK
* Cable color coding to DIN 47100
4. (B) COMPENSATION LEAD
3.
2. (B) RTD SIGNAL LEAD
1. (A) RTD SIGNAL LEAD
(A) COMPENSATION LEAD
Refer to Temperature Sensor Connection on next page for additional details on
the terminal location.
SYSTEM-1000 FLOW AND ENERGY MEASUREMENT SYSTEM
ONICON Incorporated 727.447.6140 Page 20 onicon.com
Do not exceed 4.5 in-lb (0.5 Nm) of torque when tightening.
CAUTION
Shield connections are required for proper operation. Failure to use shielded cable may result in erratic operation.
3.3.2.3 Input Signal Connections for Temperature Sensors
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