F-2200 Series Vortex
Flow Meter Installation and
Operation Guide
12-15-08
1500 North Belcher Road • Clearwater, FL 33765 • Tel (727) 447-6140 • Fax (727) 442-5699
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F-2200 Series Vortex Flow Meter Installation and Operation Guide
Addendum
December 12, 2008
The drawing below illustrates the proper method for insulating the flow meter.
CAUTION
!
Insulating the entire neck of the flow meter will increase heat transfer to the electronics enclosure
and may in some cases cause premature failure of the electronics.
F-2000 SERIES STEAM FLOW METER WITH INSULATION DETAIL
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TABLE OF CONTENTS
1.0 INTRODUCTION .............................................................................................................. 7
1.1 Purpose of This Guide .............................................................................................. 7
1.2 Principal of Operation .............................................................................................. 7
1.3 Features and Specifications...................................................................................... 7
1.4 Additional Required Materials................................................................................. 9
1.5 Working Environment............................................................................................... 9
1.6 Serial Number ........................................................................................................... 9
2.0 UNPACKING.................................................................................................................... 10
2.1 Checking That You Have Received Everything ..................................................... 10
3.0 INSTALLATION INFORMATION................................................................................... 11
3.1 Site Selection........................................................................................................... 11
3.1.1 Flow direction and meter position.............................................................. 11
3.1.2 Maximum allowable difference between inside of meter body and
the connecting pipe...................................................................................... 12
3.1.3 Straight, unimpeded inlet and outlet runs.................................................. 13
3.1.4 Minimizing pipe vibration........................................................................... 14
3.1.5 Locating the meter in a pipeline that runs parallel to a wall ..................... 14
3.1.6 State of medium ........................................................................................... 14
3.1.6.1 Liquid Applications ..................................................................... 14
3.1.6.2 Steam or compressed gas applications........................................ 14
3.2 Mechanical Installation .......................................................................................... 15
3.2.1 Orient the display for convenient viewing ................................................. 15
3.2.1.1 Liquid applications ...................................................................... 15
3.2.1.2 Steam or compressed gas applications........................................ 16
3.2.2 Flanged type connections to ANSI B16.5 (Schedule 40)............................ 16
3.2.3 Temperature Measurements......................................................................... 17
3.3 Wiring Terminations ............................................................................................... 17
4.0 START-UP & TROUBLESHOOTING .............................................................................. 18
4.1 Start Up.................................................................................................................... 18
4.2 Measurement Mode................................................................................................. 18
4.3 Operating the Display ............................................................................................. 19
4.4 Error Handling......................................................................................................... 20
4.5 Troubleshooting Hints............................................................................................. 21
5.0 FLOW STRAIGHTENER CATALOG SHEET.................................................................. 22
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SECTION 1.0: INTRODUCTION
We, at ONICON INCORPORATED, would like to thank you for purchasing our F-2200 Series Vortex Flow
Meter. As our valued customer, our commitment to you is to provide fast reliable service and assistance,
while continuing to offer you new products to meet your growing flow measurement needs.
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 ONICON F-2200 Series Vortex Flow Meters.
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.
!
1.2 PRINCIPAL OF OPERATION
ONICON F-2000 series vortex flow meters utilize Karman’s vortex street principal to detect changes
in velocity in the medium flowing around the titanium shedder bar and through the meter body. A
volumetric flow rate is then derived by utilizing the known cross-sectional area of the meter body
and the average velocity of the medium. When provided with optional temperature and/or pressure
compensation the F-2000 series flow meters are capable of calculating the required density
corrections necessary to provide direct mass flow measurement of liquids, steam or gases.
1.3 FEATURES AND SPECIFICATIONS
CONSTRUCTION
Meter body:
Casting: 316 stainless steel for diameters up to 4”
304 stainless steel for 6” and 8” diameters
Shedder bar: Unalloyed titanium
Shedder bar seal: Ni plated Inconnel
Damper pin o-ring:
Viton for, non-steam, -4° to 356° F
Kalrez 4079 for, non-steam, -4° to 428° F
Parofluor for steam, -4° to 464° F
Electronics enclosure:
Enclosure material: Die-cast aluminum
Enclosure viewing window: Tempered glass,
UV blocking
CALIBRATION
Each meter undergoes a 5 point velocity calibration
from 0-250 ft/sec
PROGRAMMING
Each meter is programmed at the factory based on application specific data provided by the
customer. Field re-programmable via keypad, with coded access for security.
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ACCURACY
Volumetric flow
1% of reading accuracy ( 2% for ¾” & smaller sizes)
Mass flow
1.5% of reading accuracy ( 2.5% for ¾” & smaller sizes)
OPERATING TEMPERATURE RANGE
Media temperature
25° to 464° F
Ambient temperature
0° to 132° F
DISPLAY / USER INTERFACE
16x64 dot matrix LCD with 3 button keypad and magnetic pin programming
OUTPUT SIGNALS
Rate: 4-20mA, loop-powered
Supply voltage range: 14-36 VDC
Minimum load resistance: 100 ohms
Maximum load resistance is calculated as follows:
Max load = Vs – 12V
0.020A
Where Vs = supply voltage
Total: Scaled output pulse, programmable
Optically isolated open collector, 0.5 hz maximum
Rating: 5-36 VDC, 100mA maximum
SUPPLY VOLTAGE:
14-36 VDC
PROCESS CONNECTIONS:
Standard:
Optional:
ANSI #300 flanges
ANSI #600 flanges
APPROVALS
Safety:
Enclosure:
Conforms to CE mark as per LVD, PED and EMC Directive
Conforms to IP 65 and IP 67
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1.4 ADDITIONAL REQUIRED MATERIALS
Installer is responsible for providing suitable flanges and fasteners to connect the meter to the
process piping. In addition, most installations will also require one reducer, one expander, pipe
supports and a sufficient length of straight pipe (pipe diameter = meter size) to meet the installation
requirements outlined in this manual. Use of an optional flow rectifier may be required in cases
where the available space is not sufficient to allow for proper upstream straight pipe run.
1.5 WORKING ENVIRONMENT
ONICON F-2000 series vortex flow meters are designed for use in industrial environments that are
free of corrosive liquids, fumes and excessive vibration. Do not expose the flow meter electronics
enclosure to direct sunlight. Install a sunshade if necessary. Do not expose the flow meter to intense
vibration. If necessary, provide additional support to the pipeline, at the meter location, to minimize
vibration. The rotating design of the electronics enclosure makes it easier to connect the power and
signal cables to the terminals in the rear of the enclosure. Rotate the enclosures as necessary before
installing the meter.
The ambient operating temperature range is 0° to 132° F.
1.6 SERIAL NUMBER
The serial number for your F-2000 series vortex flow meter is located on the metal identification
plate mounted on the side of the electronics enclosure. Please have this number available whenever
you contact ONICON for assistance.
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SECTION 2.0: UNPACKING
F-2000 series vortex flow meters are shipped in one package. Additional items, if ordered, will be shipped
in separate packaging. All shipments are insured for damage in transit. Carefully inspect each package and
notify the freight carrier and ONICON immediately if any items arrive damaged.
2.1 ENSURING THAT YOU HAVE RECEIVED EVERYTHING
Standard Documentation
Each ONICON flow meter is serialized and supplied with a comprehensive documentation
package specifically prepared for this meter. It includes the following items. Please notify
ONICON immediately if any discrepancies are found.
•
•
•
•
Flow Meter
The F-2000 Vortex Flow Meter Installation and Operation Guide
The Flow Meter Calibration Data Sheet
Magnetic programming pin
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SECTION 3.0: INSTALLATION INFORMATION
The F-2000 series vortex flow meter must be installed by a technician qualified to work with pressurized
liquid, steam and/or gas flow and must conform to all federal, state and local building codes. ONICON will
be happy to assist with technical recommendations and to provide guidance via telephone or mail. On-site
engineering, installation and service are also available, at additional cost.
3.1
SITE SELECTION
Careful attention in locating the point in the piping system where the flow meter will be installed
will ensure accurate and reliable operation. When selecting an installation site, consider the criteria
contained in Section 1.5 WORKING ENVIRONMENT, as well as the following:
CAUTION
The installation guidelines presented below are minimum requirements for the proper operation of
this flow meter.
!
3.1.1 Flow Direction And Meter Position
The flow must always be in the direction of the arrow located on the meter body.
This will orient the bluff side of the vortex shedder bar so that it faces the incoming
flow (i.e. the upstream side).
For vertical pipe runs, flow must always be in the upward direction. Consult the
factory in the event that a downward flowing pipe is the only available location.
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The diagrams shown below illustrate the correct meter orientation for vertical and horizontal pipe.
3.1.2 Maximum Allowable Difference Between Inside Diameter Of Meter Body
And The Connecting Pipe
The table below provides the maximum allowable difference between the diameter of
the flow meter body and the connecting pipe.
Nominal Meter Size
(in.)
Meter Body
Diameter (in.)
Maximum Pipe ID
Difference (in.)
1”
1 1/2”
2”
1.05
1.61
2.07
3.07
4.03
6.07
7.98
0.016
0.016
0.024
0.024
0.024
0.031
0.039
3”
4”
6”
8”
Ensure that the bore of the locating pipes are smooth and without deposits,
scaling, or welding beads.
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3.1.3 Straight, Unimpeded Inlet And Outlet Runs
D = Meter Size (Nominal diameter in inches)
With a flow straightener, the inlet pipe length may be reduced by 50%. For example, with a
control valve upstream, the inlet length is 25D instead of 50D. The minimum inlet pipe length
including the flow straightener must always be at least 12D.
3.1.4 Minimizing Pipe Vibration
Pipe vibration caused, for example, by the action of pumps, valves, etc. will distort flow
measurements, particularly at low flow velocities. To minimize the effects of vibration,
support the pipeline on both sides of the meter in a direction perpendicular to both the
pipeline and the shedder bar axis.
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3.1.5 Locating The Meter In A Pipline That Runs Parallel To A Wall
Wherever possible, the distance between the pipe centerline and the wall should be greater
than 20”. This will allow for access to the electronics enclosure compartment where wire
terminations are made. If adequate space is not available, first connect all the cables to the
terminals in the connection compartment (power supply and outputs) and then run the wires
to an intermediate junction box (also see Section 3.2) before installing the meter.
3.1.6 State Of Medium
In all cases the meter requires a single-phase flow for proper operation. Liquid droplets in
the gas or vapor, solid particles in the gas or liquid and gas bubbles in the liquid are not
permitted.
3.1.6.1 Liquid Applications
When operating with liquids, the meter requires a minimum downstream pressure
to prevent cavitation. The formula used to determine the minimum downstream
pressure is as follows:
Pds(bar_g) > =(2.9*DP) + (1.3*Ps)-1.013
Where DP=pressure drop of the meter, in Bar, as determined by the ONICON sizing
program and Ps=saturation pressure, in Bar, at the operating temperature.
For any fluid, a filter or strainer may be used to remove the solid particles. This is
especially important for meter sizes below 1” where a filter or a strainer is required.
3.1.6.2 Steam Or Compressed Gas Applications
In case of steam or compressed gas, a moisture separator should be used 50D
upstream of the meter if the dryness fraction is less than 95%.
IMPORTANT NOTE
Steam quality will affect the accuracy of the measurement. It is strongly recommended that a moisture
separator be installed upstream of the inlet straight pipe run for anything less than 95% dry steam.
i
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3.2 MECHANICAL INSTALLATION
3.2.1 Orient The Display For Convenient Viewing
Both the electronics enclosure and the display itself can be rotated to four different
orientations to change the viewing angle for the display. If necessary, this should be done
before the meter is installed.
3.2.1.1 Rotating the electronics enclosure
The electronics enclosure is attached to the meter body with (4) 5mm Allen head
screws. To rotate the enclosure, you must first remove the screws and then carefully
rotate the enclosure as needed. The interconnecting stem assembly is a conduit for
wires that connect the sensors to the circuitry contained in the enclosure. Care must
be taken to prevent these wires from being damaged when rotating the enclosure.
CAUTION
!
Make certain the sensor wires are not damaged when re-attaching the enclosure.
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3.2.1.2 Rotating the display
To rotate the display, first unscrew the cover using the special tool provided for this
purpose. Once the cover is removed, the (4) Philips head screws that secure the
display are exposed. To rotate the display, remove these screws and carefully move it
to the desired position making certain that the interconnecting cable is not damaged
in the process.
CAUTION
•
•
•
•
Do not remove enclosure covers in any wet environment
Keep dirt and debris out of electronics enclosure
Keep threads lubricated (silicone based lubricant)
Do not over tighten covers. Use special tool for removal only.
!
3.2.2 Flanged-Type Connection To Ansi B16.5 (Schedule 40)
Meter sizes
3/8”, 1/2”, 3/4”, 1”, 1 1/2”, 2”, 3”, 4”, 6”, 8”
Pipe flanges
To ANSI: #300 standard,
#600 optional
Gaskets are supplied with flanged units.
Center the flow meter by sight.
Check the flange connections for leak-tightness
after the flow meter installation.
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3.3.2 Temperature Measurements
ONICON F-2000 series vortex meters are supplied with an internal PT 1000 type RTD
temperature sensor located within the shedder bar. This sensor provides an accurate
temperature measurement at the point where the flow rate is being measured. Flow meters
supplied with this option will display the medium temperature and deliver an output signal
that is temperature compensated for mass and/or normalized flow.
3.3 WIRING TERMINATIONS
The standard F-2000 series vortex meter is a 2-wire loop powered device. Wiring connections are shown
below.
CAUTION
•
•
•
•
Do not remove enclosure covers in any wet environment
Keep dirt and debris out of electronics enclosure
Keep threads lubricated (silicone based lubricant)
Do not over tighten covers. Use special tool for removal only.
!
4-20 mA
100 ohms
minimum
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SECTION 4.0: START UP AND TROUBLESHOOTING
4.1 START UP
When the power is applied to the F-2000 series vortex meter, alphanumeric characters will appear
on the display. Initially, the meter will operate in a “TEST” mode where self diagnostic checks are
performed on the pre-amplifier and sensor circuits. Following this, configuration data is loaded
from the non-volatile memory and the program advances to the measurement mode.
IMPORTANT NOTE
The meter should be installed and powered for at least 15 minutes before media is allowed to flow
through the meter.
i
CAUTION
Flow velocity through the meter should be increased gradually until full flow is achieved.
!
4.2 MEASUREMENT MODE
In the measurement mode, the display
indicates real-time flow, temperature and/
or pressure data in the appropriate units.
The top line of the display indicates the
current measured value. The second line
of the display indicates the programmed
units of measurement.
There are two options for displaying data in
the measurement mode. The display may
be set to automatically scroll through each
menu page or it may be set to manually step
through the menu pages using the up arrow
key to advance each page. Displays operating
in the cyclic mode will advance through
each page every 6 seconds.
IMPORTANT NOTE
When measuring steam flow, condensate may form on the cool surfaces of the meter and piping
system when the system is started up for the first time (causing faulty measurement).
i
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4.3 OPERATING THE DISPLAY
Please read the entire procedure before proceeding. Wiring diagrams are located in the Appendix. A
worksheet for checking off the following steps and recording measured values is located on the next
page.
key Hall
Effect Switch
key Hall
Effect Switch
key Hall
Effect Switch
Display page scroll
(measurement mode)
IMPORTANT NOTE
Do not attempt to enter the program mode without first contacting ONICON service.
i
There are 3 user interface switches located immediately below the display. Each switch performs a
separate function. The table below describes the function of each switch. There are also 3
corresponding Hall Effect switches that perform the same functions. The Hall Effect switches may be
activated without removing the display cover, using the magnet provided with the meter. Place the
magnet against the cover in proximity to the Hall Effect switch to activate.
CAUTION
• Do not remove enclosure covers in any wet environment.
• Keep dirt and debris out of electronics enclosure.
• Keep threads lubricated (silicone based lubricant).
• Do not over tighten covers. Use special tool for removal only.
!
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4.4 ERROR HANDLING
The meter can detect errors in either the test or the measurement modes. When in the measurement
mode, a blinking vertical bar will appear in the top left corner of the display indicating an error has
been detected. If the error reporting function is enabled, error messages will be displayed as separate
menu pages. The first line of the error menu page indicates the total number of errors and the second
line displays the error message. Measurement mode error messages are listed below.
Error Message
(display second line)
Type Description
Corrective Action
Required
NO SIGNAL
No signal from the vortex
sensor
No flow. Also check for any other errors dur-
ing power-on diagnostics. If there is a sensor
problem, contact ONICON.
LOW FREQ.
HIGH FREQ.
LOW FLOW
Vortex frequency is too low
Check for flow rate lower than specified mini-
mum. Contact ONICON.
Vortex frequency is too high Check for flow rate higher than specified maxi-
mum. Contact ONICON.
Flow rate lower than speci-
fied range
Converter will continue to display actual flow
rate. However, accuracy of measurement may
suffer.
HIGH FLOW
Actual flow rate higher than
specified range
Corrective action depends on application pro-
cess. If the flow rate exceeds the maximum
value it may damage the sensor physically.
INV. CONFIG.
Configuration data in non-
Contact ONICON.
volatile memory is not valid
ISO FAIL
Checked Sensor isolation has failed
Contact ONICON.
Contact ONICON.
during
power-
on only
AMP FAIL
Pre-amplifier section has
failed
PIEZO FAIL
Piezo wires broken
Contact ONICON.
CHECK INST
Flow signal quality is bad
Check: 1) Flow rate, if OK; 2) Check for
excessive pipe vibration and upstream flow
disturbances; 3) Contact ONICON.
LOW SIGNAL
HIGH SIGNAL
Vortex signal amplitude too
low
Check: 1) Flow rate, if OK; 2) Contact ONI-
CON.
Vortex sensor signal
amplitude too high
This occurs in cases of high density medium.
Check 1) Flow rate, if OK 2) Contact ONI-
CON.
LOW.TEMP.PHY.
HIGH.TEMP.PHY.
Operating temperature is
lower than the physical limit cess.
Take corrective action depending on the pro-
Operating temperature is
Take corrective action immediately. This will
higher than the physical limit cause damage to the shedder bar as well as
to the electronics.
T.SENS.SHORT
T.SENS.OPEN
Temperature sensor/wires
short circuit
Indicates a fault in the temperature sensor.
Contact ONICON.
Temperature sensor open
circuit
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4.5 TROUBLESHOOTING HINTS
REPORTED
PROBLEM
POSSIBLE
SOLUTIONS
• Mains interference due to improper Earth ground connection. The protective
Earth PE terminal should be properly grounded (see page 17).
• Excessive mechanical vibration in the pipe. If so, support the pipeline near the
meter perpendicular to both the axis of the pipe and the axis of the shedder
bar.
A non-zero flow indi-
cated when no actual
flow is in the pipe.
• This problem may also be solved by reducing the factory set gain. (Contact
ONICON for assistance.)
NOTE: By reducing the gain, the minimum measurable flow rate will go up
by the factor which is approximately equal to the square root of the gains
(odd gains new gain). If the minimum flow with reduced gain is above the
minimum flow which is required to be measured, then reducing the gain is
not the permanent solution. Then the installaion should be corrected and
also the vibrations should be eliminated.
The display should normally indicate 0.0 flow rate, LOW FLOW or LOW SIGNAL
when there is no flow in the pipe. The additional CHECK INSTALL error (flow
rate = 0.0 or some steady or fluctuating value) is an indication of:
“CHECK INST.” error
is displayed when no
flow is in the pipe.
• Improper/inadequate earthing
• Excessive pipe vibration
• The vortex sensor cable is disconnected or is not properly connected.
• Flow sensor is faulty. Contact ONICON for assistance.
Flow rate inidcated is
0.0 even with flow in
the pipe.
• The meter is not properly centered on the pipeline. The axis of the meter bore
should be aligned with that of the pipe.
• Gaskets at the meter are protruding into the pipe bore. The gaskets must not
project into the effective cross-section of the pipe.
• Irregularities on the surface of the pipe bore. The pipe bore should be free from
irregularities at the welded joints, dirt, deposits and excessive surface rough-
ness.
• The Vortex signal is distorted due to a bi-phase medium. Bi-phase media are
not permitted. Use a moisture separator for wet steam applications to remove
the moisture droplets from the steam. Use suitable filters in gas applications to
remove solid particles from the flowing gas. • Incorrect angular position of the
meter. Refer to Section 3.1.1 for the allowable mounting positions.
• Insufficient upstream/downstream pipe lengths. Check that the upstream/
downstream pipe lengths are of the correct minimum length as given in
Section 3.1.3.
The flow indicated
responds to changes
in the flow but the
indicated value does
not correspond to the
actual flow rate. Also
“CHECK INST.” Error
may appear intermit-
tently.
• Error in meter factor K-Factor programming. Contact ONICON for assistance.
• Check that the flow direction and the direction arrow on the meter body agree.
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SECTION 5.0: FLOW STRAIGHTENER FOR VORTEX FLOW METERS
DESCRIPTION
The optional flow straightener accessory for
ONICON F-2000 Series Vortex Flow Meters is a
wafer-style flow conditioner that is designed to be
installed between two recessed flanges (provided
by installer) that are located a specified distance
upstream of the flow meter.
Use of a flow straightener significantly reduces the
upstream straight pipe length requirement for
ONICON Vortex Flow Meters.
The size of the straightener should always match
the meter size (as opposed to the original pipe size).
The flow straightener is made of 304/A 351 CF8
stainless steel.
TABLE 1 - ALL DIMENSIONS SHOWN IN INCHES
SIZE
DIM A
DIM B
DIM C
DIM D
NUMBER OF
HOLES
2”
3”
4”
6”
8”
3.93
5.31
6.26
8.50
10.62
1.0625
1.0625
1.0625
1.0625
1.0625
.28
.43
2.14
3.24
4.22
6.07
7.98
35
35
35
35
35
.55
.78
1.02
0.125
SERRATIONS SHOWN LOCATED UNDER GASKET, IF PROVIDED
NOTE: DIMENSION D INDICATES I.D. FOR SERRATIONS
GASKET THICKNESS, NOMINAL
DIM C
DIM D
DIM A
DIM B
0497
8-06
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ONICON F-2000 SERIES STEAM METER, NOTE 1
FLOW STRAIGHTENER, NOTE 3
300# ANSI FLANGE
(600# ANSI FLANGE OPTNL)
ECCENTRIC REDUCER, NOTE 2
UPSTREAM
OBSTRUCTION
SEE TABLE 1
2 DIAMETERS
DIMENSION B
5 DIAMETERS
MINIMUM DOWNSTREAM PIPE RUN
MINIMUM UPSTREAM PIPE RUN
DIMENSION A
REQUIRED DIMENSIONS FOR INSTALLATIONS WITH FLOW STRAIGHTENER
DIMENSION A
DIMENSION B
UPSTREAM
OBSTRUCTION
TOTAL UPSTREAM
PIPE RUN
DISTANCE BETWEEN
FLOW METER AND
STRAIGHTENER
SINGLE 90
TEE
12 DIA
12 DIA
12 DIA
17 DIA
17 DIA
10 DIA
10 DIA
10 DIA
15 DIA
15 DIA
RDCR/EXPNDR
TWO 90’S SAME PLANE
BALL/GATE VALVE FULLY
OPEN
TWO 90’S OUT OF PLANE
CONTROL VALVE
PRV
22 DIA
27 DIA
27 DIA
20 DIA
25 DIA
25 DIA
NOTES
1. Consult ONICON for meter size and applicable meter pipe run for each application. Install
according to manufacturer’s recommendations.
2. Provide eccentric reducer and expander when required.
3. Provide flow straightener when required to meet recommended minimum upstream pipe run
requirements.
4. Flanges provided by contractor. Recessed flanges are required for wafer flow straightener
installation.
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