Onicon SYSTEM-30 Operating instructions

System-30 BTU Measurement System LON – Installation Guide – Revised 10/2006
1
SYSTEM-30 BTU MEASUREMENT SYSTEM
LON Version
Installation and Operation Guide
1500 North Belcher Road, Clearwater, Florida 33765 [phone] Fax [phone]
www.onicon.com E-mail: [email protected]
For Software Version 2.8B Higher

System-30 BTU Measurement System LON – Installation Guide – Revised 10/2006
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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 specific 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 specified in this manual,
the protection provided by this product may be impaired.
The following symbols are used in this manual:
IMPORTANT NOTE
Messages identified as “Important Note” contain information critical to the
proper operation of the product.
CAUTION
Messages identified as “Caution” contain information regarding potential
damage to the product or other ancillary products.
!
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WARNING
Messages identified as “Warning” contain information regarding the
personal safety of individuals involved in the installation, operation or
service of this product.
!

System-30 BTU Measurement System LON – Installation Guide – Revised 10/2006
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TABLE OF CONTENTS
1.0 INTRODUCTION ......................................................................................................................5
1.1 Purpose of this Guide ................................................................................................. 5
1.2 Typical SYSTEM-30 BTU MEASUREMENT SYSTEM .............................................5
1.3 Standard Features and Specifications ....................................................................... 6
1.4 Working Environment ................................................................................................7
1.5 Warranty and Serial Number .....................................................................................7
2.0 UNPACKING ............................................................................................................................ 8
2.1 Checking That You Have Received Everything......................................................... 8
3.0 INSTALLATION .......................................................................................................................9
3.1 Site Selection ..............................................................................................................9
3.2 Mechanical Installation ............................................................................................10
3.2.1 Main Unit Installation............................................................................10
3.2.2 Thermowell Installation ........................................................................11
3.2.3 Temperature Sensor Installation ..........................................................11
3.3 Electrical Installation ................................................................................................14
3.3.1 Single Mode vs. Dual Mode Operation .................................................14
3.3.2 Electrical Wiring ....................................................................................17
4.0 START UP & COMMISSIONING ...........................................................................................18
4.1 Display and User Interface........................................................................................18
4.2 Processor Start Up ....................................................................................................18
4.3 Units and Multipliers................................................................................................19
4.4 Network Device Address Entry ................................................................................20
4.5 LONWorks Files ........................................................................................................20
4.5.1 Ouput Network Variables ..........................................................................20
4.5.2 Input Network Variables............................................................................21
4.5.3 Node Object Network Variables ................................................................22
4.5.4 Sample System-30-LON Set Up Document ..............................................23
4.6 Diagnostics ................................................................................................................27
4.6.1 Diagnostic Lights........................................................................................27
4.7 Commissioning .........................................................................................................28
4.7.1 Commissioning Worksheet .......................................................................29
TROUBLESHOOTING GUIDE ......................................................................................................29

System-30 BTU Measurement System LON – Installation Guide – Revised 10/2006
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APPENDIX A – DRAWINGS
A-1 TYPICAL SYSTEM INSTALLATION
A-2 / A-3 THERMOWELL INSTALLATION
A-4 WIRING DIAGRAM
A-5 SIGNAL CONNECTION BOARD
A-6 WIRING DIAGRAM FOR DIN CONNECTOR

System-30 BTU Measurement System LON – Installation Guide – Revised 10/2006
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SECTION 1.0: INTRODUCTION
1.1 PURPOSE OF THIS GUIDE
The purpose of this guide is to provide installation and commissioning procedures and basic
operating and servicing instructions for the ONICON SYSTEM-30 BTU MEASUREMENT
SYSTEM.
1.2 TYPICAL SYSTEM-30 BTU MEASUREMENT SYSTEM
ONICON’S System-30 is a true heat (BTU) computer, which accepts data from several sensors,
performs a series of computations with that data, and transmits the results as an indication of
the amount of heat (BTU’s) being transferred or as a totalized amount.
WARNING
Only qualified service personnel should attempt to install or service this equipment.
Serious injury may result from the improper installation or use of this equipment.
!

System-30 BTU Measurement System LON – Installation Guide – Revised 10/2006
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1.3 STANDARD FEATURES AND SPECIFICATIONS
•Single mode BTU calculations, in either the heating or cooling mode, are totalized
and reported.
•Two-pipe dual mode BTU calculations in both the heating mode and the cooling
mode are totalized and reported separately.
CALIBRATION
Flow sensor and temperature sensors are
individually calibrated, followed by a
complete system calibration.
Field commissioning is also available.
ACCURACY
Differential temperature accuracy ±0.15° F
over calibrated range
Computing non-linearity within ±0.05%
Flow sensor accuracy:
±0.5% OF READING at calibrated velocity
±1% OF READING from 3 to 30 ft/s (10:1 range)
±2% OF READING from 0.4 to 20 ft/s (50:1 range)
TEMPERATURE SENSORS
Solid state sensors are custom calibrated using
N.I.S.T. traceable temperature standards.
PROGRAMMING
Factory programmed for each specific application
MEMORY
Nonvolatile EEPROM memory retains all
program parameters and totalized values in the
event of power loss.
OUTPUT SIGNALS
Isolated solid state dry contacts for mode 1 and
mode 2 energy total
Contact rating: 100 mA, 50V
Contact duration: 0.5, 1, 2 or 6 sec selectable
OPTIONAL OUTPUT SIGNALS
(1) Isolated analog output, factory selectable for
flow rate, energy rate or delta-T
(Available as 4-20 mA, 0-10 V or 0-5 V signal)
OR
Serial connection for: Johnson Controls N2,
Siemens LON or LONWORKS® networks
OPTIONAL LOCAL DISPLAY:
Alphanumeric LCD displays total energy, total
Flow, energy rate, flow rate, supply temperature
and Return temperature
Alpha: 16 characters, 0.2” high
Numeric: 6 digit, 0.4” high
MAINTENANCE:
ONICON recommends periodic inspection and
recalibration. No other periodic maintenance is
required.
TEMPERATURE RANGE:
Liquid temperature range: 32° to 200°F
Ambient temperature range: 40° to 120°F
MECHANICAL
OVERALL DIMENSION:
9.25” L x 5” W x 6.5” H
TEMPERATURE THERMOWELL:
Brass thermowell (½” sweat or ¼” NPT)
ELECTRICAL
This equipment is intended for INSTALLATION
CATEGORY (OVERVOLTAGE CATEGORY) II
applications
INPUT VOLTAGE: 24 V ±10% AC 50/60 Hz or
24 V ±4 DC
INPUT CURRENT: 200 mA maximum
TERMINALS CONNECTIONS: Use 18-22 ga. Copper
wire. Do not exceed 4.5 in-lb (0.5 Nm) of torque
when tightening.
WIRING:
CONDUIT: Use PVC jacketed copper cable with a
wire gauge suitable for the length of run and
required maximum current carrying capacity. The
installation must comply with all local, state and
federal codes.
PLENUM AREA: (without conduit) Use plenum
rated copper cable with a wire gauge suitable for
the length of run and required maximum current
carrying capacity. The installation must comply
with all local, state and federal building codes.
Note: Specifications are subject to change without
notice.

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1.4 WORKING ENVIRONMENT
The SYSTEM-30 was designed for installation and use in typical commercial and residential
environments that are free of corrosive liquids and fumes, direct liquid exposure, heavy
condensation, and temperature extremes and vibrations.
The operating ambient air temperature range is 40° F to 120° F.
The electrical power should be relatively clean, free of high frequency noise, large voltage transients,
and protected from power surges and brown outs.
1.5 WARRANTY & SERIAL NUMBER
•Warranty
ONICON’s 2-year “No-fault” warranty reduces start-up costs with extended coverage that
includes coverage for incidental damage during installation. Certain exclusions apply. See
our complete warranty statement for details.
•Serial Number
The serial number of your SYSTEM-30 is located on the side of the enclosure. Serial
numbers are unique identifiers that you should have available when contacting the factory for
assistance regarding your system.

System-30 BTU Measurement System LON – Installation Guide – Revised 10/2006
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SECTION 2.0: UNPACKING
The SYSTEM-30 generally ships in one package unless optional hardware or equipment is ordered. If
any items are damaged, notify the shipping company (all products are shipped insured) and the
ONICON Customer Service Department.
2.1 CHECKING THAT YOU HAVE RECEIVED EVERYTHING
•Standard Documentation
Enclosed with each SYSTEM-30 is a comprehensive documentation package that includes the
following items:
oThe SYSTEM-30 BTU MEASUREMENT SYSTEM Installation and Operation Guide
oThe System-30 Calibration Data Sheet
oTypical Installation Drawing
oWiring Diagram
Please notify ONICON immediately if any items are missing.
•The Main Unit
Remove the System-30 from the shipping carton and inspect it for physical damage.
•Temperature Sensors
One temperature sensor is built-in to the body of the meter and the other is connected to the
main unit via a permanently attached cable. Inspect the free sensor and cable for external
damage.
•Temperature Thermowell
A standard thermowell with installation hardware is packed with the main unit.
•Mounting Hardware
The System-30 is supplied with two tail pieces to facilitate connection to the piping system.
A compression fitting with retaining nut makes up one end of each tail piece. The other end
will either be a sweat fitting for copper or a threaded nipple with NPT threads.

System-30 BTU Measurement System LON – Installation Guide – Revised 10/2006
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SECTION 3.0: INSTALLATION
The SYSTEM-30 BTU MEASUREMENT SYSTEM should be installed by experienced plumbers and
others with related knowledge and experience in the heating, cooling, and fluid metering fields.
ONICON will be happy to assist with technical recommendations and to provide guidance by
telephone and/or mail. On-site field engineering, installation, and/or service is also available at an
additional cost.
The installer should use good trade practices and adhere to all state and local building or other
applicable codes.
3.1 SITE SELECTION
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. For example, do
not install the System-30 or its temperature sensor where it will be difficult for personnel to perform
periodic maintenance and calibration. When selecting a site for mounting the system components,
consider the criteria under Section 1.4, WORKING ENVIRONMENT, as well as the following:
•The Main Unit
¾Choose the location (supply or return) with the longest straight, unobstructed run. Ideally,
the location chosen should allow for at least 20 diameters of unobstructed straight run
upstream of the meter and at least 10 diameters of unobstructed straight run downstream.
If both the supply and return have adequate straight run conditions, locate the meter in
the supply.
¾The location must be accessible to facilitate service and recalibration.
•The Temperature Sensor
¾The temperature sensor should be located in an accessible location. This will facilitate
any on-site service.
¾Place the temperature sensor away from sources of electrical noise that might interfere
with the temperature sensor signal.
CAUTION
ONICON strongly recommends the use of a valved bypass and strainer in
conjunction with the installation of the System-30 to facilitate servicing and to
protect the turbine assembly during start-up.
!

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3.2 MECHANICAL INSTALLATION
3.2.1 MAIN UNIT INSTALLATION
Find an easily accessible location where wire connections can be made and the diagnostic LED’s can
be viewed from floor level. The location where the main unit is mounted should be free from
vibration. Clean the external surface of the pipe at the installation site so that it is free of debris,
foreign matter, solids, leak inhibitors, and chemically aggressive substances. Next, locate the tail
pieces that were shipped with the main unit and install these on the pipe making certain that the
compression nuts are correctly oriented. Wherever appropriate, use pipe dope on threaded
connections to ensure a leak free seal. DO NOT USE TEFLON TAPE.
Insert the main unit between the two open ends of the pipe and secure in place using the
compression fittings. MAKE CERTAIN THAT THE FLOW DIRECTION ARROW ON THE BODY OF
THE MAIN UNIT IS POINTING IN THE DIRECTION OF FLOW.
TYPICAL S
Y
STEM-30 INSTALLATION
CAUTION
Before you attempt to use the BTU MEASUREMENT SYSTEM, isolate the main
unit, open the bypass and flush the entire system so that it is free of flux, solder,
pipe and tube cuttings and any other free moving particles.
!

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3.2.2 THERMOWELL INSTALLATION
IMPORTANT NOTE
It is important that no dirt or other foreign material be allowed into the thermowell as this
could affect the thermal response of the system.
Standard Thermowell
The most common installation methods are shown below. Consult the factory for special
applications.
3.2.3 TEMPERATURE SENSOR INSTALLATION
The temperature sensor is factory matched and permanently attached to the BTU
MEASUREMENT SYSTEM. Sensors from different BTU meters cannot be used without being
returned to the factory for recalibration.
Apply a thin coat of thermally conductive grease to the temperature sensor, and gently insert
the temperature sensor all the way into the thermowell until it contacts the bottom of the
cavity. Gently tighten the retainer cap. DO NOT OVER TIGHTEN. The thermowell
completely seals the plumbing system without the retainer cap. The only purpose of the cap
is to keep the sensor from losing contact with the bottom of the thermowell cavity.
IMPORTANT NOTE
Cable length is specified at time of order. This is three wire shielded plenum rated
cable. Altering the cable length may affect calibration. Do not change the cable length
without consulting ONICON.
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System-30 BTU Measurement System LON – Installation Guide – Revised 10/2006
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THERMOWELL INSTALLATION IN THREADED PIPE TEES
THERMOWELL INSTALLATION IN COPPER TEE

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THERMOWELL INSTALLATION IN WELDED PIPE

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3.3 ELECTRICAL INSTALLATION
All user supplied conduit fittings, junction boxes, etc. are to be installed as required by legal codes.
3.3.1 SINGLE MODE (4 PIPE) vs. DUAL MODE (2 PIPE) OPERATION
ONICON System 30 BTU meters may be configured for single or dual mode applications. Single and
dual mode is a reference to the piping system and not the meter itself. Single mode (4 pipes)
applications are those that always have the same relationship between the supply and return pipe
temperatures. In dual mode (2 pipes) applications the polarity of the temperature differential (Delta t)
reverses; often on a seasonal basis.
It is often desirable to totalize the amount of energy transferred in each mode in separate registers.
For these applications, ONICON BTU meters may be configured for dual mode operation. In this
configuration, the meter will measure and totalize energy in separate registers based on the polarity of
the Delta t.
The drawings and tables below illustrate the relationship between meter location, temperature sensor
and mode of operation.
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IMPORTANT NOTE
The System-30-LON BTU meter is designed with one internal (TemLON) and one
remote (Temp 2) temperature sensor. If the meter body is located in the supply pipe
then the internal temperature sensor will indicate the supply temperature and the
remote sensor will indicate the return temperature. This relationship will reverse if
the meter body is located in the return pipe. The location of the meter will also affect
the logic used to determine mode 1 and mode 2 operations for dual mode
applications. Single mode energy measurements are absolute measurements and are
not effected by polarity of the Delta t.

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Temperature Sensor/ Mode of Operation Relationship with Meter in Supply Line
Supply Temp Temperature 1 Sensor (Internal Sensor)
Return Temp Temperature 2 Sensor (External Sensor)
Mode 1 Total Heating (Supply Temp > Return Temp)
Mode 2 Total Cooling (Supply Temp < Return Temp)
(External Sensor)

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Temperature Sensor/ Mode of Operation Relationship with Meter in Return Line
Supply Temp Temperature 2 (External Sensor)
Return Temp Temperature 1 (Internal Sensor)
Mode 1 Total Cooling (Supply Temp < Return Temp)
Mode 2 Total Heating (Supply Temp > Return Temp)

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3.3.2 ELECTRICAL WIRING
Connect all BTU Meter signal outputs to terminal strip TB1 and/or TB4 (optional communication
output) as shown below.
Then connect the 24 V AC/DC input power to terminal strip TB1. The standard SYSTEM-30 is
configured for 24 V AC 60 Hz operation or 24 V DC operation. Do not connect the 24 V AC/DC source
until all other signal connections have been made and verified.
View of Signal Connection Board
Wiring Diagram

System-30 BTU Measurement System LON – Installation Guide – Revised 10/2006
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SECTION 4.0: START UP AND COMMISSIONING
4.1 DISPLAY AND USER INTERFACE (If display ordered)
The System 30 may be ordered from the factory with an optional display and user interface.
The display consists of 2 lines of alphanumeric characters. Line 1 indicates the current value while
the bottom line identifies the engineering units and multiplier values that apply to the current value
displayed on line 1. In the example shown the current value is 3864, the engineering units are BTU’s
and the multiplier is 10,000. This would be read as 38,640,000 BTU’s.
The user interface consists of 3 pushbutton switches. These 3 switches allow the user to operate the
display and program the meter.
When operating in the run mode, the scroll button
advances the display from one parameter to the next. A total
of up to 8 different operating parameters may be
available for display depending on whether the meter is
being used in a single mode or dual mode application.
When operating in the run mode, the reset button (if
enabled) allows the user to reset volume and energy
totals.
The program button is not functional in the run mode.
4.2 PROCESSOR START-UP
When power is applied to the BTU Meter alphanumeric characters appear on the two lines of the
display, indicating the meter is operating. Press and release the SCROLL button on the front panel.
Observe the display cycle to the next display page.
Select the SUPPLY TEMP Page. Note the displayed temperature. Confirm that it is in the expected
range. Now select the RETURN TEMP page. Again note the displayed temperature. Confirm that it
is also in the correct range.
Select the FLOW RATE page. Note the displayed flow rate. Confirm that the flow rate value is in the
correct range.
Successively pressing the SCROLL button will cycle the display through the run mode pages
summarized in the tables below.

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Single Mode Operation
SINGLE MODE BTU METERS – RUN MODE DISPLAY PAGES
PAGE
No.
DISPLAY
NAME
SELECTABLE
UNITS
1 ENERGY TOTAL BTU, TONHR or KWHR
2 VOLUME TOTAL GAL, LITER, METERS3
3 ENERGY RATE BTU / HR, TONS, KW
4 VOLUME RATE GPM, GPH, MGD, L/SEC, L/MIN, L/HR,
METERS3/HR
5 INTRN TEMP DEG F, DEG C
6 EXTRN TEMP DEG F, DEG C
Dual Mode BTU Meters
DUAL MODE BTU METERS – RUN MODE DISPLAY PAGES
PAGE
No.
DISPLAY
NAME
SELECTABLE
UNITS
1 MODE 1 ENERGY TOTAL BTU, TONHR or KWHR
3 MODE 1 VOLUME TOTAL GAL, LITER, METERS3
2 MODE 2 ENERGY TOTAL BTU or TONHR
4 MODE 2 VOLUME TOTAL GAL, LITER, METERS3
5 ENERGY RATE BTU / HR, TONS or KW
6 VOLUME RATE GPM, GPH, MGD, L/SEC, L/MIN, L/HR,
METERS3/HR
7 INTRN TEMP DEG F, DEG C
8 EXTRN TEMP DEG F, DEG C
The operating mode, measurement units and multipliers are programmed into the BTU meter at the
factory. These settings may be re-programmed in the field. Please contact ONICON technical support
personnel for assistance, if changes are required.
4.3 UNITS AND MULTIPLIERS
The units and multipliers are programmed prior to delivery. Contact ONICON’s technical support
personnel for assistance in changing units or multipliers.

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4.4 NETWORK ADDRESS
The BTU meter contains two processors – the computational processor and the LONTalk
Neuron processor. The two processors communicate using a serial channel with the device
address set at 017. The device address of 017 must not be changed.
4.5 LONWORKS FILES
Each System-30-LON BTU meter is shipped with a diskette containing an .xif file. The diskette also
contains the Neuron executable in various formats and a document describing the LONTalk network
variables in detail.
4.5.1 OUTPUT NETWORK VARIABLES
The System-30 LON BTU meter outputs 4-byte, 2-byte and single-byte network variables (SNVTs).
The network variables are described in the tables below. Column 1 contains a brief description of the
network variables. Column 2 contains the network variable names. Column 3 contains the Standard
Network Variable Type (SNVT) for each variable. Column 4 contains the LONMark SNVT numbers.
Column 5 contains the units and column 6, the numerical range for each variable.
FOUR-BYTE (FLOATING POINT) OUTPUT LON NETWORK VARIABLES
Four-byte, floating-point network variables are preferred for those systems that can handle them. They are not as
susceptible to overflow as the two-byte network variables..
Description Variable Name SNVT Name No Units Range
Flow (Volume Rate) nvoVolRateLf SNVT_flow_f 53 Liters / Sec 0 TO 1012
Volume-1 Accumulator nvoVol1Lf SNVT_vol_f 65 Liters 0 TO +1012
Volume-2 Accumulator nvoVol2Lf SNVT_vol_f 65 Liters 0 TO +1012
Supply Temperature nvoSupplyTempf SNVT_temp_f 63 DegC -17.778 TO 148.889
Return Temperature nvoReturnTempf SNVT_temp_f 63 Deg C -17.778 TO 148.889
Energy Rate (Power) nvoEnrRateWf SNVT_power_f 57 Watts 0 TO 1012
LCD Energy Rate nvoDispEnrRatef SNVT_count_f 51 Various 0 TO 1012
Energy-1 Accumulator nvoBTU1f SNVT_btu_f 67 BTU 0 TO 1012
LCD Energy-1 Accumulator nvoDispEnergy1f SNVT_count_f 51 Various 0 TO 1012
Energy-2 Accumulator nvoBTU2f SNVT_btu_f 67 BTU 0 TO 1012
LCD Energy-2 Accumulator nvoDispEnergy2f SNVT_count_f 51 Various 0 TO 1012
Auxiliary Input* nvoAuxIn1 SNVT_count_f 51 None 0 TO 1012
Note 1 - LON Network Values nvoDispEnrRatef, nvoDispEnergy1f, nvoDispEnergy2f are the values displayed on the Sytem-10 Front-Panel
LCD.
Note 2 - nvoDispEnrRatef, nvoDispEnergy1f, nvoDispEnergy2f have the units and multipliers shown on the System-30 Front-Panel LCD.
Note 3 – Meter Operating Mode (S-Single, D-Dual or B-Bidirectional) is a user selectable feature.
Note 4 - In S(SINGLE) Operation, Energy-1 and Volume-1 values ARE computed and output.
Note 5 – In S(SINGLE) Operation, Energy-2 and Volume-2 values are NOT computed nor output.
Note 6 – In D(DUAL) Operation, when Temperature > 0 (HEATING-H), Energy-1 and Volume-1 values are computed and output.
Note 7 – In D(DUAL) Operation, when Temperature < 0 (COOLING-C), Energy-2 and Volume-2 values are computed and output.
Note 8 – In B (BIDIRECTIONAL) Operation, when flow is in the SAME direction as the arrow depicted on the body of the flow meter,
Energy-1 and Volume-1 values are computed and output . The direction is defined as F (FORWARD).
Note 9 - In B (BIDIRECTIONAL) Operation, when flow is OPPOSITE the direction of the arrow depicted on the body of the flow meter,
Energy-2 and Volume-2 values are computed and output. The direction is defined as R (REVERSE).
Note 10 – Volume-1 and Energy-1 are called Mode-1 Energy and Mode-1Volume Totals elsewhere; Volume-2 and Energy-2 are described
as Mode-2 Volume and Mode-2 Energy Totals elsewhere.
Im
p
ortant Note
LON network variables relating to the auxiliary input function are not used on the
System-30.
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