VorTek M22 Series User manual

 
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VorTek Series M22 and M23
Pro-V™ Vortex Volumetric and Mass Flow Meters
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Document Number M-000-00010
Rev 07/2011
8475 W I-25 Frontage Rd
Suite 300
Longmont, CO 80504
[phone] [phone] Fax [phone]
http://www.vortekinst.com

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
Unless you have specifically ordered VorTek’s optional O
2
cleaning, this flow me-
ter may not be fit for oxygen service. Some models can only be properly cleaned
during the manufacturing process. VorTek Instruments, LLC., is not liable for any
damage or personal injury, whatsoever, resulting from the use of VorTek Instru-
ments standard mass flow meters for oxygen gas.
© COPYRIGHT VORTEK INSTRUMENTS 2011
No part of this publication may be copied or distributed, transmitted, transcribed, stored in
a retrieval system, or translated into any human or computer language, in any form or by
any means, electronic, mechanical, manual, or otherwise, or disclosed to third parties
without the express written permission of VorTek Instruments. The information contained
in this manual is subject to change without notice.
TRADEMARKS
Pro-V™ is a trademark of VorTek Instruments, LLC. Other product and company names
listed in this manual are trademarks or trade names of their respective manufacturers.

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Pro-V™ Vortex Mass Flow Meters..................................................... 1-1
Using this Manual ......................................................................... 1-1
NoteandSafetyInformation......................................................... 1-2
ReceiptofSystemComponents.................................................... 1-2
Technical Assistance ..................................................................... 1-2
How the Pro-V Vortex Meter Operates............................................... 1-3
Velocity Measurement .................................................................. 1-3
Vortex Shedding Frequency .......................................................... 1-4
Vortex Frequency Sensing ............................................................ 1-4
Flow Velocity Range ..................................................................... 1-5
Temperature Measurement ............................................................ 1-6
Pressure Measurement ................................................................... 1-6
Flow Meter Configurations.................................................................. 1-7
Multivariable Options ................................................................... 1-7
LineSize/ProcessConditions/Materials.................................... 1-8
Flow Meter Electronics ................................................................. 1-8
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Installation Overview........................................................................... 2-1
FlowMeterInstallationRequirements.......................................... 2-1
UnobstructedFlowRequirements................................................. 2-2
Series M22 In-Line Flow Meter Installation ....................................... 2-3
Wafer-StyleFlowMeterInstallation............................................. 2-4
Flange-StyleFlowMeterInstallation............................................ 2-5
Series M23 Insertion Flow Meter Installation..................................... 2-6
Cold Tap Guidelines...................................................................... 2-7
Hot Tap Guidelines ....................................................................... 2-8
Flow Meter Insertion ......................................................................... 2-10
InstallingMeterswithaCompressionConnection..................... 2-11
InstallingMeterswithaPackingGlandConnection................... 2-13
InstallingMeters(PackingGland),NoInsertionTool................ 2-16
Adjusting Meter Orientation.............................................................. 2-18
Display/Keypad Adjustment ....................................................... 2-18
Enclosure Adjustment ................................................................. 2-19
Loop Power Flow Meter Wiring Connections................................... 2-20
Input Power Connections ............................................................ 2-20
4-20 mA Output Connections ..................................................... 2-21
Pulse Output Connections ........................................................... 2-22
Frequency Output Connections ................................................... 2-23
OptionalBacklightConnections................................................. 2-23
Remote Electronics Wiring ......................................................... 2-24
High Power Flow Meter Wiring Connections................................... 2-26
Input Power Connections ............................................................ 2-26
4-20 mA Output Connections ..................................................... 2-28
Frequency Output Connections ................................................... 2-29
Pulse Output Connections ........................................................... 2-30

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Alarm Output Connections ..........................................................2-32
Remote Electronics Wiring .........................................................2-33
OptionalInputElectronicsWiring.............................................. 2-34
Optional Energy EMS RTD Input Wiring .................................. 2-34
OptionalExternal4-20mAInputWiring...................................2-35
Optional Contact Closure Input Wiring ......................................2-36
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Flow Meter Display/Keypad................................................................3-1
Start Up................................................................................................ 3-2
Using the Setup Menus........................................................................3-4
Programming the Flow Meter ....................................................... 3-5
Output Menu .................................................................................3-6
Display Menu ................................................................................3-8
Alarms Menu ................................................................................. 3-9
Totalizer #1 Menu .......................................................................3-10
Totalizer #2 Menu.......................................................................3-11
Energy Menu .......................................................................3-12
Fluid Menu.................................................................................. 3-13
Units Menu ..................................................................................3-14
Time and Date Menu ...................................................................3-15
Diagnostics Menu ........................................................................ 3-16
Calibration Menu .........................................................................3-17
Password Menu ...........................................................................3-18
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HART Communications......................................................................4-1
Wiring ...........................................................................................4-2
HARTCommandswiththeDDMenu.......................................... 4-3
HARTCommandswithGenericDDMenu..................................4-4
MODBUS Communications................................................................ 4-7
Wiring ...........................................................................................4-7
Menu Items .................................................................................... 4-8
Register Definitions .....................................................................4-10
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Hidden Diagnostics Menus..................................................................5-1
LevelOneHiddenDiagnosticsValues......................................... 5-3
LevelTwoHiddenDiagnosticsValues.........................................5-4
Analog Output Calibration ..................................................................5-7
Troubleshooting the Flow Meter .........................................................5-8
First Check Items................................................................................. 5-8
Record Values......................................................................................5-8
Determine the Fault .............................................................................5-9
Symptom: Output at no Flow ........................................................5-9
Symptom: Erratic Output ..............................................................5-9
Symptom: No Output ..................................................................5-11
Symptom:MeterDisplaysTemperatureFault............................ 5-12
Symptom:MeterDisplaysPressureFault...................................5-13

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Electronics Assembly Replacement................................................... 5-14
Pressure Sensor Replacement (Series M22 Only) ............................ 5-15
Returning Equipment to the Factory.................................................. 5-15
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1-1. In-Line Vortex Multi-Parameter Mass Flow Meter................ 1-3
1-2. Measurement Principle of Vortex Flow Meters...................... 1-4
1-3. Reynolds Number Range of the Pro-V................................... 1-6
2-1. Recommended Pipe Length Required for Installation............ 2-2
2-2. Flange Bolt Torquing Sequence ............................................. 2-3
2-3. Wafer-Style Flow Meter Installation...................................... 2-4
2-4. Flange-Style Flow Meter Installation..................................... 2-5
2-5. Hot Tap Sequence................................................................... 2-9
2-6. Insertion Calculation (Compression Type)........................... 2-11
2-7. Flow Meter with Compression Type Fitting......................... 2-12
2-8. Insertion Calculation (Meters with Insertion Tool) .............. 2-13
2-9. Flow Meter with Permanent Insertion Tool.......................... 2-14
2-10. Flow Meter with Removable Insertion Tool......................... 2-15
2-11. Insertion Calculation (Meters without Insertion Tool)......... 2-16
2-12. Display/Keypad Viewing Adjustment.................................. 2-18
2-13. Enclosure Viewing Adjustment............................................ 2-19
2-14. Loop Power Wiring Terminals............................................. 2-20
2-15. DC Power Connections......................................................... 2-20
2-16. Load Resistance Versus Input Voltage................................. 2-21
2-17. Isolated Pulse Output Using External Power Supply ........... 2-22
2-18. Non-Isolated Pulse Output Using External Power Supply... 2-22
2-19. Isolated Frequency Output Using External Power Supply...2-23
2-20. Non-Isolated Freq. Out. Using External Power Supply........ 2-23
2-21. Backlight Using External Power Supply.............................. 2-23
2-22. Loop Power Volumetric Flowmeter Junction Box............... 2-24
2-23. Loop Power Mass Flowmeter Junction Box......................... 2-25
2-24. AC Wiring Terminals........................................................... 2-26
2-25. AC Power Connections......................................................... 2-26
2-26. DC Wiring Terminals........................................................... 2-27
2-27. DC Power Connections......................................................... 2-27
2-28. Load Resistance Versus Input Voltage................................. 2-28
2-29. Isolated 4-20 Output Using External Power Supply............. 2-28
2-30. Non-Isolated 4-20 Output Using Input Power Supply..........2-29

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2-31. Isolated 4-20 Output Using Meter Power Supply (AC only)2-29
2-32. Isolated Frequency Output Using External Power Supply...2-30
2-33. Non-Isolated Frequency Output Using Input Power Supply 2-30
2-34. Isolated Freq. Out. Using Meter Power Sup. (AC only)....... 2-30
2-35. Isolated Pulse Output Using External Power Supply ...........2-31
2-36. Non-Isolated Pulse Output Using Input Power Supply ........2-31
2-37. Isolated Pulse Output Using Meter Power Sup. (AC only) ..2-31
2-38. Isolated Alarm Output Using External Power Supply..........2-32
2-39 Non-Isolated Alarm Output Using Meter Power Supply...... 2-32
2-40 Isolated Alarm Output Using Meter Power Sup. (AC only) 2-33
2-41 High Power Flow Meter Junction Box ................................2-33
2-42. Optional Energy EMS RTD Input Wiring............................ 2-34
2-43. External 4-20 mA Input Wiring – External Power Supply...2-35
2-44. External 4-20 mA Input Wiring – DC Powered Meter.........2-35
2-45. External 4-20 mA Input Wiring – AC Powered Meter.........2-36
2-46. Optional External Contact Closure Input Wiring .................2-36
3-1. Flow Meter Display/Keypad...................................................3-1
4-1. Loop Powered Meter Wiring (HART).................................... 4-1
4-2. DC Powered Meter Wiring (HART) ......................................4-2
4-3. AC Powered Meter Wiring (HART) ......................................4-2
4-4. RS-485 Wiring (MODBUS)...................................................4-7
5-1. Electronics Stack Sensor Connections..................................5-11
5-2. Remote Feed Through Board Sensor Connections...............5-11
5-3. Vortex Sensor Connector......................................................5-12
5-4. Temperature Sensor Connector ............................................5-13
5-5. Pressure Sensor Connector ...................................................5-13
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2-1. Minimum Recommended Stud Bolt Lengths .........................2-3
4-1. Byte Order (MODBUS)..........................................................4-9
4-2. Register Definitions (MODBUS) .........................................4-11
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
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
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


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
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
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
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 
 
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 
 


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
The VorTek Instruments’ Series M22 In-Line and the Series M23 Inser-
tion Pro-V™ Vortex Flow Meters provide a reliable solution for process
flow measurement. From a single entry point in the pipeline, Pro-V me-
ters offer precise measurements of mass or volumetric flow rates.

Mass flow meters utilize three primary sensing elements: a vortex shed-
ding velocity sensor, an RTD temperature sensor, and a solid state pres-
sure sensor to measure the mass flow rate of gases, liquids, and steam.
Meters are available as loop powered devices or with up to three 4-20
mA analog output signals for monitoring your choice of the five process
variables (mass flow, volumetric flow, temperature, pressure and fluid
density). The Energy Monitoring option permits real-time calculation of
energy consumption for a facility or process.

The primary sensing element of a volumetric flow meter is a vortex
shedding velocity sensor. Meters are loop powered. The analog 4-20
mA output signal offers your choice of volumetric or mass flow rate.
Mass flow rate is based on a constant value for fluid density stored in the
instrument’s memory.

Both the mass and volumetric flow meters can be ordered with a local
keypad/display which provides instantaneous flow rate, total, and process
parameters in engineering units. A pulse output signal for remote totali-
zation and MODBUS or HART communications are also available. Pro-
V digital electronics allows for easy reconfiguration for most gases, liq-
uids and steam. The VorTek Series M22 and M23 Pro-V Meters’ simple
installation combines with an easy-to-use interface that provides quick
set up, long term reliability and accurate mass flow measurement over a
wide range of flows, pressures and temperatures.

This manual provides information needed to install and operate both the
Series M22 In-Line and Series M23 Insertion Pro-V Flow Meters.
•Chapter 1 includes the introduction and product description
•Chapter 2 provides information needed for installation
•Chapter 3 describes system operation and programming
•Chapter 4 provides information on HART and MODBUS protocols
•Chapter 5 covers troubleshooting and repair
Appendix A - Product Specifications, Appendix B – Approvals,
Appendix C – Flow Meter Calculations, Appendix D – Glossary of
Terms

 
 

We use note, caution and warning statements throughout this book to
draw your attention to important information.
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
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  
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

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
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
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






When receiving a VorTek mass flow meter, carefully check the outside
packing carton for damage incurred in shipment. If the carton is dam-
aged, notify the local carrier and submit a report to the factory or distrib-
utor. Remove the packing slip and check that all ordered components are
present. Make sure any spare parts or accessories are not discarded with
the packing material. Do not return any equipment to the factory without
first contacting VorTek Customer Service.

If you encounter a problem with your flow meter, review the configura-
tion information for each step of the installation, operation and set up pro-
cedures. Verify that your settings and adjustments are consistent with fac-
tory recommendations. Refer to Chapter 5, Troubleshooting, for specific
information and recommendations.
If the problem persists after following the troubleshooting procedures
outlined in Chapter 5, contact VorTek Instruments, Technical Support at
[phone] or [phone] between 8:00 a.m. and 5:00 p.m.
MST. When calling Technical Support, have the following information
on hand:
•the serial number and VorTek order number (all marked on
the meter nameplate)
•the problem you are encountering and any corrective action
taken
•application information (fluid, pressure, temperature and
piping configuration)