Onicon SYSTEM-40 Operating instructions
ON
I
CON
Flow and Energy Measurement
SYSTEM-40
BTU Measurement System
Installation and Operation Guide
ONICON Incorporated 727-447-6140 Page 2 www.onicon.com
SYSTEM-40 BTU MEASUREMENT SYSTEM
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.
•
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
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
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.
ONICON Incorporated 727-447-6140 Page 3 www.onicon.com
SYSTEM-40 BTU MEASUREMENT SYSTEM
TABLE OF CONTENTS
SECTION 1.0 INTRODUCTION ................................................................................................. 6
1.1 PURPOSE OF THIS GUIDE ........................................................................................................................ 6
1.2 TYPICAL SYSTEM-40 BTU METER INSTALLATION .............................................................................. 6
1.3 STANDARD FEATURES AND SPECIFICATIONS..................................................................................... 7
1.4 MODEL NUMBERING CODIFICATION.................................................................................................... 8
1.5 ADDITIONAL HARDWARE REQUIRED................................................................................................... 9
1.6 WORKING ENVIRONMENT...................................................................................................................... 9
1.7 SERIAL NUMBER........................................................................................................................................ 9
SECTION 2.0 UNPACKING ......................................................................................................... 9
2.1 CHECKING THAT YOU HAVE RECEIVED EVERYTHING ....................................................................... 9
SECTION 3.0 INSTALLATION................................................................................................... 10
3.1 SITE SELECTION....................................................................................................................................... 10
3.2 MECHANICAL INSTALLATION .............................................................................................................. 11
3.3 INSTALLING THE FLOW SENSOR.......................................................................................................... 12
.............................................................................................................................................12
3.3.2 Installing the Flow Meter.................................................................................................................................................13
3.3.3 Installing Meter Couplings..............................................................................................................................................14
3.3.4 Adjustment and Rotation ................................................................................................................................................15
3.3.5 Orientation............................................................................................................................................................................16
3.4 INSTALLING THE TEMPERATURE SENSORS ....................................................................................... 17
..........................................................................17
..........................................................................18
..................................................................................19
3.5 REMOTE MOUNTING THE ENCLOSURE............................................................................................... 19
3.6 POWER AND SIGNAL WIRING CONNECTIONS ................................................................................. 20
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SYSTEM-40 BTU MEASUREMENT SYSTEM
SECTION 4.0 START-UP AND COMMISSIONING ................................................................ 21
4.1 START-UP.................................................................................................................................................. 21
4.2 COMMISSIONING.................................................................................................................................... 21
.......................................................................................................................................................22
......................................................................................................................22
..................................................................................................................23
.....................................................................................................................................................24
4.2.2 Long Commissioning ........................................................................................................................................................24
................................................................................................................................25
........................................................................................................................................................25
..............................................................................................26
4.3 USER SCREENS ......................................................................................................................................... 28
........................................................................................................................................................................28
...........................................................................................................................................................................30
4.4 SEALING THE METER .............................................................................................................................. 30
SECTION 5.0 AUXILIARY INPUTS AND OUTPUTS .............................................................. 31
5.1 DETERMINING AUXILIARY INPUTS AND OUTPUTS CONFIGURATIONS...................................... 31
5.2 AUXILIARY INPUTS ................................................................................................................................. 31
5.3 AUXILIARY OUTPUTS ............................................................................................................................. 31
......................................................................................................................31
.........................................................................................................................32
5.4 ANALOG OUTPUT.................................................................................................................................... 33
5.5 JUMPER LOCATIONS AND DETAILS..................................................................................................... 34
SECTION 6.0 TROUBLESHOOTING & OTHER INFORMATION .......................................... 35
6.1 ALARM ................................................................................................................................................... 35
6.2 DIAGNOSTICS .......................................................................................................................................... 37
6.3 MORE TOTALS .......................................................................................................................................... 38
6.4 METER DATA............................................................................................................................................. 39
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SYSTEM-40 BTU MEASUREMENT SYSTEM
SECTION 7.0 BACNET MS/TP.................................................................................................. 40
7.1 BACNET OBJECT TYPES.......................................................................................................................... 40
7.2 PROTOCOL IMPLEMENTATION STATEMENT...................................................................................... 40
7.3 DEVICE OBJECT........................................................................................................................................ 41
7.4 ANALOG INPUT(S).................................................................................................................................. 42
7.5 ANALOG VALUES..................................................................................................................................... 43
7.6 BINARY VALUE(S).................................................................................................................................... 44
7.7 MULTI-STATE VALUE............................................................................................................................... 45
7.8 TREND LOG MULTIPLE............................................................................................................................ 46
SECTION 8.0 MODBUS ............................................................................................................. 47
8.1 MODBUS MEMORY MAP ....................................................................................................................... 48
8.2 DIAGNOSTIC FUNCTION CODE ............................................................................................................ 55
8.3 REPORT SLAVE ID FUNCTION CODE.................................................................................................... 57
ONICON Incorporated 727-447-6140 Page 6 www.onicon.com
SYSTEM-40 BTU MEASUREMENT SYSTEM
SECTION 1.0
INTRODUCTION
The purpose of this guide is to provide installation and commissioning
procedures, and basic operating and servicing instructions for the ONICON
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.
1.1 PURPOSE OF THIS GUIDE
1.2 TYPICAL SYSTEM-40 BTU
METER INSTALLATION
Return
Supply
Supply
Return
BTU METER
SYSTEM-40
Made in USA
BTU/HR
49.50
BTU METER
SYSTEM-40
Made in USA
BTU/HR
49.50
Fan Coil
Unit or
Air
Handling
Unit
2
1
Figure 1: Installation Detail for Pipe Size Range from ½ - 1"
Figure 2: Installation Detail for Pipe Size Range from 1¼- 2½"
3
Supply Temp
2
1
3
4
Fan Coil
Unit or
Air
Handling
Unit
1. Input Power
2. Input and output signals
an analog output
3.
4.
Meter may be installed in either supply or return line.
ONICON Incorporated 727-447-6140 Page 7 www.onicon.com
SYSTEM-40 BTU MEASUREMENT SYSTEM
1.3 STANDARD FEATURES AND SPECIFICATIONS*
SYSTEM-40 TRANSMITTER
PERFORMANCE
• Two (2) aux pulsed inputs & one (1) aux pulsed output
• One (1) aux pulsed input, one (1) aux pulsed output & one (1)
analog output
May be programmed for energy, volume, alarm indication, mode
Contact Rating: 50 mA, 30 V
For use with devices providing sinking open collector or dry contact
outputs
IP65 polycarbonate with display
Lead-free brass, PEEK
•
•
4800, 9600, 19200, 38400, 76800, or 115200
FCC
BTL
SYSTEM-40 FLOW SENSOR
PERFORMANCE Inline wetted ultrasonic sensing (no moving parts)
Overall turndown exceeds 500:1
Meets EN1434 Class 1 accuracy requirements
Meets EN1434/C900.1 Class A requirements
400 psi
Less than 1 psi at 4 ft/s, decreasing at lower velocities
*
ONICON Incorporated 727-447-6140 Page 8 www.onicon.com
SYSTEM-40 BTU MEASUREMENT SYSTEM
1.3 STANDARD FEATURES AND SPECIFICATIONS (CONTINUED)*
1.4 MODEL NUMBERING CODIFICATION
SYS-40 = Integral BTU Meter
AAA = Nominal Meter Size in Inches E = Serial Communications
050 = ½” 130 = 1¼”
340 = ¾” 150 = 1½”
341 = ¾” High Flow 020 = 2” 2 = Two (2) Aux Pulse Inputs and One (1) Aux Pulse Output2
010 = 1” 250 = 2½” 6 = One (1) Aux Pulse Input, One (1) Aux Pulse Output, and
011 = 1” High Flow One (1) Analog Output
B = Process Connection Type G = Temperature Sensor Type
0 = NPT Threads 3
14
C = Display/Interface 5
D = Input Power
[1] Required for 2½” meter, NOT available on ½” to 2” meters
[2]
[3]
[4]
[5]
Meter Model Number Coding = SYS-40-AAA-BCD-EFG
Meets EN1434/C900.1 accuracy requirements for 3K sensors
½ - 2½” nominal diameter
• Male NPT threads
61
372
*
ONICON Incorporated 727-447-6140 Page 9 www.onicon.com
SYSTEM-40 BTU MEASUREMENT SYSTEM
1.7 SERIAL NUMBER
SECTION 2.0
UNPACKING
2.1 CHECKING THAT YOU HAVE
RECEIVED EVERYTHING
1.5 ADDITIONAL HARDWARE
REQUIRED
several sensors, performs a series of computations with that data, and displays
required. The kit is ordered with the meter to install the remote temperature
sensor.
For remote style meters, two tees are required. The tees are used with the two ½”
NPT thermowells ordered with the meter. 2½” meters are provided with raised
to complete the installation.
1.6 WORKING
ENVIRONMENT
commercial and light industrial environments that are free of corrosive liquids
and fumes, temperature extremes and excess vibration. It may be installed
outdoors in protected spaces away from direct sunlight and rain, sleet or snow.
should be clean, free of excess high frequency noise and large voltage transients.
the enclosure. Please have this number available when contacting ONICON for
assistance.
hardware or equipment is ordered. Notify the freight carrier and ONICON if any
items are damaged in transit.
•
and sealing gaskets (shipped attached to meter)
•
temperature sensor OR two (2) thermowells with ½” male NPT threads
•
•
Please notify ONICON if any of these items are missing.
ONICON Incorporated 727-447-6140 Page 10 www.onicon.com
SYSTEM-40 BTU MEASUREMENT SYSTEM
SECTION 3.0
INSTALLATION
with related knowledge and experience in hydronic heating and cooling
installation assistance.
The installer should use good trade practices and must adhere to all state
and local building or other applicable codes.
Before you begin, clean the external surfaces of all pipes at the installation
sites so that they are free of debris, foreign matter, solids, leak inhibitors, and
chemically aggressive substances. Flush the entire system so that it is free of
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.
limitations that apply to the installation of the meter:
•
function.
•
void the calibration and may invalidate the warranty.
•
insertion temperature sensors, the temperature sensor adapter bushings
and the thermowells is 400 psi.
IMPORTANT NOTE
Proper site selection is critical to the performance of this BTU meter. Both
the ow sensor and the remote temperature sensor must be properly
located within the piping system in order to ensure an accurate energy
measurement.
3.1 SITE SELECTION
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SYSTEM-40 BTU MEASUREMENT SYSTEM
3.2 MECHANICAL
INSTALLATION
W
L
H
Size L Total LWH
½"11.2" 7.48" 5.75" 4.50"
¾"11.7" 7.48" 5.75" 4.50"
¾" high flow 11.7" 7.48" 5.75" 4.50"
1" 12.3" 10.23" 5.75" 4.50"
1" high flow 15.00" 10.23" 5.75" 4.50"
L Total
½ - 1" METER DIMENSIONS
BTU METER
SYSTEM-40
Made in USA
BTU/HR
49.50
BTU METER
SYSTEM-40
Made in USA
BTU/HR
49.50
W
L
H
Size L Total LWH
1¼"15.25" 10.20" 5.75" 4.50"
1½"17.00" 11.80" 6.25" 5.00"
2" 17.60" 11.80" 6.50" 5.50"
2½" * 11.81" 10.23"
L Total
1¼ - 2½" METER DIMENSIONS *
8.75" 7.00"
BTU METER
SYSTEM-40
Made in USA
BTU/HR
49.50
BTU METER
SYSTEM-40
Made in USA
BTU/HR
49.50
*2½" meter provided with flanged connections
ONICON Incorporated 727-447-6140 Page 12 www.onicon.com
SYSTEM-40 BTU MEASUREMENT SYSTEM
with that portion of the piping system for which the energy measurement
return pipe of the heat exchange circuit. Please refer to the table below
pipe requirements vary considerably based on the nature of the upstream
obstructions. ONICON always recommends that the sensor be located with as
much straight pipe upstream as possible.
3.3 INSTALLING THE
FLOW SENSOR
3.3.1 Straight Run Requirements
½ - 1" 1¼ - 2½"
0 0
Expander/Reducer 0 0
3 3
Isolation Valve, 2 Position 3 5
Control Valve 10 15
Notes:
1
2Avoid the following obstructions where possible: Modulating
valves, pump discharge, multiple elbows out of plane.
ONICON Incorporated 727-447-6140 Page 13 www.onicon.com
SYSTEM-40 BTU MEASUREMENT SYSTEM
A
CA
B
F
D & E
B. Avoid installation locations where air can become trapped in the piping system.
valves. Fully open isolation valves (e.g. ball valves) are acceptable.
minimum operating pressure at the inlet of the meter must always exceed the
pressure drop across the sensor.
F. Avoid installing the sensor downstream of multiple bends out of plane where
there are less than 10 diameters of straight unobstructed pipe between bends.
3.3.2 Installing the Flow Meter
FLOW
FLOW
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SYSTEM-40 BTU MEASUREMENT SYSTEM
3.3.3 Installing Meter Couplings
INSTRUCTIONS
• Inspect seating surfaces on the meter’s body and tail pieces prior to
• Install gasket in tail piece. Thread union onto meter’s body by hand until
piece.
• Place a corresponding mark on the coupling nut, # of degrees (based on
table on the following page) counter clockwise. Hold meter body while
•
NOTE: Torque setting is not an accurate means of gaging compression
on gasket due to the lack of resilience in the gasket material.
•
tighten. Relieve pressure and loosen coupling nuts. Remove and inspect the
gasket for damage. Repeat installation process.
Retaining
Nut
Coupling
Tail piece
Meter Sizes ½" To 1"
Flow
The sensor port
is always on the
downstream side of
the meter.
Flow
Tail piece
Retaining
Nut
Coupling
Flow
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SYSTEM-40 BTU MEASUREMENT SYSTEM
3.3.4 Adjustment and Rotation
sensor mounting brackets, remove the two retaining screws and reposition the
mounting brackets as required. Reinstall the enclosure with the display properly
oriented for viewing. Mounting tracks on the back of the enclosure allow for
mounting in any orientation.
IMPORTANT NOTE
When installing the meter in a vertical pipe with upward ow, you must
rotate the enclosure back plate 180° when rotating the display 90°. To
accomplish this, temporarily remove the four cover screws and rotate the
backing plate.
mounting
bracket
mounting
bracket
Retaining
Retaining
Mounting
tracks
Model Meter Size Min. Compression Min. Turn Past
Initial Contact
Degrees of Rotation
½” 1/2
¾” 1/3
1/3
1” 2/5
2/5
1¼” 2/5
1½” 4/9
2” 1/2
3.3.3 Installing Meter Couplings (continued)
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SYSTEM-40 BTU MEASUREMENT SYSTEM
Back View
Front view
Front view
3.3.5 Orientation
Orient the ½” - 1” meters as shown below. The meter may be installed with
Avoid any installation locations where the pipe may not be completely full.
Orient the 1¼" - 2½" meters as shown below. The meter may be installed with
Avoid any installation locations where the pipe may not be completely full.
IMPORTANT NOTE
Do not orient meters as shown above where air can become trapped in
the piping system.
ONICON Incorporated 727-447-6140 Page 17 www.onicon.com
SYSTEM-40 BTU MEASUREMENT SYSTEM
outlet temperatures of the heat exchange circuit where the energy measurement
is being made. Before you install thermowells or direct insertion sensors, the
3.4.1 Integral Mount Temperature Sensors - Direct Insertion Style
sensors is 4 lb/ft.
3.4 INSTALLING THE
TEMPERATURE SENSORS
BTU METER
SYSTEM-40
Made in USA
BTU/HR
49.50
1
2
3
4
5
6
7
8
CAUTION
The platinum RTD sensors provided with the System-40 are calibrated with
the attached cables. Altering these cable lengths will result in signicant
measurement errors and void the meter calibration.
1. Return pipe
2.
3. Temperature sensor installation kit
4. Fan coil unit or air handling unit
5.
6.
7.
8.
ONICON Incorporated 727-447-6140 Page 18 www.onicon.com
SYSTEM-40 BTU MEASUREMENT SYSTEM
1. Return pipe
2.
3. Temperature sensor installation kit
4. Fan coil unit or air handling unit
5.
6.
7. Threaded thermowell OR copper sweat thermowell - provided by ONICON
8.
BTU METER
SYSTEM-40
Made in USA
BTU/HR
49.50
1
2
3
4
5
6
7
8
3.4.2 Remote Mount Temperature Sensors - Direct Insertion Style
two threaded thermowells (or copper sweat thermowells) for use with customer
CAUTION
The platinum RTD sensors provided with the System-40 are calibrated with
the attached cables. Altering these cable lengths will result in signicant
measurement errors and void the meter calibration.
ONICON Incorporated 727-447-6140 Page 19 www.onicon.com
SYSTEM-40 BTU MEASUREMENT SYSTEM
3.4.3 Remote Mount Temperature Sensors - Thermowell Style
NPT process connections. The temperature sensors are installed in the threaded
thermowells, for push-in style. They are held in placed with a set screw.
1. Return pipe
2.
3. Remote temperature sensor installation kit
4. Fan coil unit or air handling unit
5.
6. Thermowell - provided by ONICON
7.
(Provided by customer or ordered from ONICON)
8.
5
6
7
8
BTU METER
SYSTEM-40
Made in USA
BTU/HR
49.50
3
1
2
4
CAUTION
The platinum RTD sensors provided with the System-40 are calibrated with
the attached cables. Altering these cable lengths will result in signicant
measurement errors and void the meter calibration.
ONICON Incorporated 727-447-6140 Page 20 www.onicon.com
SYSTEM-40 BTU MEASUREMENT SYSTEM
remote mounting the enclosure. The cable lengths must not be altered. It has two
mounting holes designed for #10 screws. The remote mounting bracket also has
parallel slots that allow for the use of pipe clamps when mounting the enclosure
on a stanchion or pipe. The bracket may be used as a template for marking hole
locations. Also shown is the back of the enclosure. The mounting bracket slides
onto tracks on this back plate.
3.5 REMOTE MOUNTING THE
ENCLOSURE
Clamps
0.129"
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