Sierra Innova Flo 220 User Manual

Sierra Series 220 and 221  
Innova-FloVortex Flow Meters  
Instruction Manual  
Part Number IM-22  
05/03 Revision C  
IMPORTANT: This manual is for use with 220/221 Vortex Products  
purchased during 1997 through January 2006  
CORPORATE HEADQUARTERS  
5 Harris Court, Building L Monterey, CA 93940  
Phone (831) 373-0200 (800) 866-0200 Fax (831) 373-4402  
EUROPE HEADQUARTERS  
Bijlmansweid 2 1934RE Egmond a/d Hoef The Netherlands  
Phone +31 72 5071400 Fax +31 72 5071401  
ASIA HEADQUARTERS  
Tomson Centre, Rm. A618, 188 Zhang Yang Road  
Pu Dong New District, Shanghai, P.R.China  
Phone: + 8621 5879 8521 Fax: +8621 5879 8586  
Series 220/221 Instruction Manual  
Table of Contents  
Table of Contents  
Chapter 1 Introduction  
Innova-FloVortex Flow Meters........................................................1-1  
Using this Manual .........................................................................1-1  
Note and Safety Information.........................................................1-2  
Receipt of System Components ....................................................1-2  
Technical Assistance.....................................................................1-2  
How the Innova-Flo Vortex Flow Meter Operates..............................1-3  
Velocity Measurement/Pressure Drop...........................................1-3  
Flow Meter Configurations..................................................................1-7  
Chapter 2 Installation  
Installation Overview...........................................................................2-1  
Flow Meter Installation Requirements..........................................2-1  
Unobstructed Flow Requirements.................................................2-2  
Series 220 In-Line Flow Meter Installation.........................................2-3  
Wafer-Style Flow Meter Installation.............................................2-4  
Flange-Style Flow Meter Installation............................................2-5  
Series 221 Insertion Flow Meter Installation.......................................2-6  
Cold Tap Guidelines......................................................................2-7  
Hot Tap Guidelines .......................................................................2-8  
Flow Meter Insertion ...........................................................................2-9  
Installing Meters with a Compression Connection .....................2-10  
Installing Meters with a Packing Gland Connection...................2-12  
Installing Meters (Packing Gland), No Insertion Tool................2-15  
Adjusting Meter Orientation..............................................................2-17  
Display/Keypad Adjustment .......................................................2-17  
Enclosure Adjustment .................................................................2-18  
Wiring Connections...........................................................................2-19  
Input Power Connections ............................................................2-19  
Pulse Output Connections...........................................................2-21  
Remote Electronics Wiring .........................................................2-22  
Chapter 3 Operating Instructions  
Flow Meter Display/Keypad................................................................3-1  
Start Up................................................................................................3-2  
Using the Setup Menus........................................................................3-3  
Programming the Flow Meter .......................................................3-3  
Output Menu .................................................................................3-4  
Display Menu................................................................................3-5  
Totalizer Menu..............................................................................3-6  
Units Menu....................................................................................3-7  
Diagnostics Menu..........................................................................3-8  
Calibration Menu ..........................................................................3-9  
Password Menu ...........................................................................3-10  
IM-22-C  
0-3  
Table of Contents  
Series 220/221 Instruction Manual  
Chapter 4 Troubleshooting and Repair  
Hidden Diagnostics Menus..................................................................4-1  
Column One Hidden Diagnostics Values......................................4-2  
Column Two Hidden Diagnostics Values.....................................4-2  
Analog Output Calibration ..................................................................4-3  
Troubleshooting the Flow Meter .........................................................4-3  
Symptom: Output at no Flow........................................................4-3  
Symptom: Erratic Output ..............................................................4-3  
Symptom: No Output ....................................................................4-4  
Electronics Assembly Replacement.....................................................4-5  
Returning Equipment to the Factory....................................................4-6  
Appendix A Product Specifications  
Appendix B Glossary  
List of Figures  
1-1.  
1-2.  
1-3.  
2-1.  
2-2.  
2-3.  
2-4.  
2-5.  
2-6.  
2-7.  
2-8.  
2-9.  
Series 220 In-Line Vortex Flow Meter...................................1-3  
Measurement Principle of Vortex Flow Meters......................1-4  
Reynolds Number Range for the Innova-Flo..........................1-6  
Recommended Pipe Length Requirements.............................2-2  
Flange Bolt Torquing Sequence .............................................2-3  
Wafer-Style Flow Meter Installation ......................................2-4  
Flange-Style Flow Meter Installation .....................................2-5  
Hot Tap Sequence...................................................................2-8  
Insertion Calculation (Compression Type)...........................2-10  
Flow Meter with Compression Type Fitting.........................2-11  
Insertion Calculation (Meters with Insertion Tool) ..............2-12  
Flow Meter with Permanent Insertion Tool..........................2-13  
2-10. Flow Meter with Removable Insertion Tool.........................2-14  
2-11. Insertion Calculation (Meters without Insertion Tool).........2-15  
2-12. Display/Keypad Viewing Adjustment..................................2-17  
2-13. Enclosure Viewing Adjustment............................................2-18  
2-14. DC Power Connections.........................................................2-19  
2-15. Load Resistance Versus Input Voltage.................................2-20  
2-16. Pulse Output with External Power Supply ...........................2-21  
2-17. Junction Box Sensor Connections ........................................2-22  
3-1.  
Flow Meter Display/Keypad...................................................3-1  
List of Tables  
2-1.  
Minimum Stud Bolt Lengths for Wafer-Style Meters ............2-3  
0-4  
IM-22-C  
Series 220/221 Instruction Manual  
Table of Contents  
Warnings and Cautions  
Warning!  
Agency approval for hazardous location installations varies between flow meter models.  
Consult the factory for specific flow meter approvals before any hazardous location instal-  
lation. For explosion proof installations, you must use solid metal conduit and follow  
NFPA (or your local code) approved wiring methods.  
Hot tapping must be performed by a trained professional. U.S. regulations often require a  
hot tap permit. The manufacturer of the hot tap equipment and/or the contractor perform-  
ing the hot tap is responsible for providing proof of such a permit.  
All flow meter connections, isolation valves and fittings for cold/hot tapping must have the  
same or higher pressure rating as the main pipeline.  
For Series 221 insertion flow meter installations, an insertion tool must be used for any  
installation where a flow meter is inserted under pressure greater than 50 psig.  
To avoid serious injury, DO NOT loosen a compression fitting under pressure.  
All wiring procedures must be performed with the power Off.  
Before attempting any flow meter repair, verify that the line is de-pressurized.  
Always remove main power before disassembling any part of the mass flow meter.  
Caution!  
Calibration must be performed by qualified personnel. Sierra Instruments, Inc., strongly rec-  
ommends that you return your flow meter to the factory for calibration.  
In order to achieve accurate and repeatable performance, the flow meter must be in-  
stalled with the specified minimum length of straight pipe upstream and downstream of  
the flow meter’s sensor head.  
When using toxic or corrosive gases, purge the line with inert gas for a minimum of four  
hours at full gas flow before installing the flow meter.  
Wafer-style flow meter gaskets must be carefully aligned to ensure accurate flow meas-  
urement.  
For Series 221 insertion flow meter installations, the sensor alignment pointer must point  
downstream in the direction of flow.  
IM-22-C  
0-5  
Table of Contents  
Series 220/221 Instruction Manual  
0-6  
IM-22-C  
Series 220/221 Instruction Manual  
Chapter 1 Introduction  
Chapter 1 Introduction  
Innova-Flo™ Vortex Flow Meters  
The Sierra Instruments’ Series 220 In-Line and the Series 221 Insertion  
Innova-Flo™ Vortex Flow Meters provide a reliable solution for process  
flow measurement. From a single entry point in the pipeline, Innova-Flo  
meters offer precise measurements of mass or volumetric flow. The ve-  
locity sensor reduces the effects of pipeline vibration by incorporating a  
unique piezoelectric element that senses the vortex frequency. To extend  
rangeability at the low end of flow, the meter’s smart electronics calcu-  
lates the Reynolds number (Re) based on constant values of fluid density  
and viscosity stored in memory and automatically corrects for any non-  
linearity down to Re = 5,000.  
Innova-Flo digital electronics allows reconfiguration for most gases, liq-  
uids and steam. The instrument is loop powered (12 to 36 VDC) with  
two output signals. The pulse output signal is proportional to volumetric  
flow rate; the analog linear 4-20 mA signal offers your choice of volu-  
metric flow rate or mass flow rate. The mass flow rate is based on a con-  
stant value for fluid density stored in the instrument’s memory. The local  
keypad/display provides instantaneous flow rate in engineering units or  
totalized flow.  
The Sierra Series 220 and 221 Innova-Flo Meters simple installation  
combines with an easy-to-use interface that provides quick set up, long  
term reliability and accurate flow measurement over a wide range of  
flows and conditions.  
Using This Manual  
This manual provides the information needed to install and operate the  
Series 220 In-Line and Series 221 Insertion Innova-Flo Vortex Flow Me-  
ters. The four chapters of this manual cover these areas:  
Chapter 1 includes the introduction and product description  
Chapter 2 provides information needed for installation  
Chapter 3 describes system operation and programming  
Chapter 4 covers troubleshooting and repair  
The product specifications are found in Appendix A. Appendix B con-  
tains a glossary of terms.  
IM-22-C  
1-1  
Chapter 1 Introduction  
Series 220/221 Instruction Manual  
Note and Safety Information  
We use note, caution and warning statements throughout this book to  
draw your attention to important information.  
Caution!  
This statement appears with  
information that is important  
for protecting your equipment an important detail.  
and performance. Read and  
Note  
Warning!  
This statement appears with  
information that is important to  
protect people and equipment  
from damage. Pay very close  
attention to all warnings that  
apply to your application.  
This statement appears with a  
short message to alert you to  
follow all cautions that apply  
to your application.  
Receipt of System Components  
When receiving a Sierra flow meter, carefully check the outside packing  
carton for damage incurred in shipment. If the carton is damaged, notify  
the local carrier and submit a report to the factory or distributor. 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 con-  
tacting Sierra Customer Service.  
Technical Assistance  
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 4, Troubleshooting, for specific  
information and recommendations.  
If the problem persists after following the troubleshooting procedures  
outlined in Chapter 4, contact Sierra Instruments, Technical Support at  
(800) 866-0200 or (831) 373-0200 between 8:00 a.m. and 5:00 p.m. PST.  
When calling Technical Support, have the following information on  
hand:  
the flow range, serial number and Sierra order number (all  
marked on the meter nameplate)  
the problem you are encountering and any corrective action  
taken  
application information (gas, pressure, temperature and pip-  
ing configuration)  
1-2  
IM-22-C  
Series 220/221 Instruction Manual  
Chapter 1 Introduction  
How the Innova-Flo Vortex Flow Meter Operates  
Figure 1-1. Series 220 In-Line Vortex Flow Meter  
Sierra Series 220 and 221 Innova-FloVortex Flow Meters use a unique  
velocity sensor head to monitor volumetric flow rate. The built-in flow  
computer calculates mass flow rate based on a constant value of fluid  
density stored in the instrument’s memory. To measure fluid velocity,  
the flow meter incorporates a bluff body (shedder bar) in the flow  
stream, and the velocity sensor measures the frequency of vortices cre-  
ated by the shedder bar. The velocity sensor head is located downstream  
of the shedder bar within the flow body.  
Velocity Measurement  
The Innova-Flo vortex velocity sensor is a patented mechanical design  
that minimizes the effects of pipeline vibration and pump noise, both of  
which are common error sources in flow measurement with vortex flow  
meters. The velocity measurement is based on the well-known Von Kar-  
man vortex shedding phenomenon. Vortices are shed from a shedder bar,  
and the vortex velocity sensor located downstream of the shedder bar  
senses the passage of these vortices. This method of velocity measurement  
has many advantages including inherent linearity, high turndown, reliabil-  
ity and simplicity.  
IM-22-C  
1-3  
Chapter 1 Introduction  
Series 220/221 Instruction Manual  
Vortex Shedding Frequency  
Von Karman vortices form downstream of a shedder bar into two distinct  
wakes. The vortices of one wake rotate clockwise while those of the  
other wake rotate counterclockwise. Vortices generate one at a time, al-  
ternating from the left side to the right side of the shedder bar. Vortices  
interact with their surrounding space by over-powering every other  
nearby swirl on the verge of development. Close to the shedder bar, the  
distance (or wave length) between vortices is always constant and meas-  
urable. Therefore, the volume encompassed by each vortex remains con-  
stant, as shown below. By sensing the number of vortices passing by the  
velocity sensor, the Innova-FloVortex Flow Meter computes the total  
fluid volume.  
Velocity sensor  
Vortex shedder bar  
Flow  
Vortices  
Constant  
wave length  
Figure 1-2. Measurement Principle of Vortex Flow Meters  
Vortex Frequency Sensing  
The velocity sensor incorporates a piezoelectric element that senses the  
vortex frequency. This element detects the alternating lift forces pro-  
duced by the Von Karman vortices flowing downstream of the vortex  
shedder bar. The alternating electric charge generated by the piezoelec-  
tric element is processed by the transmitter’s electronic circuit to obtain  
the vortex shedding frequency. The piezoelectric element is highly sensi-  
tive and operates over a wide range of flows, pressures and temperatures.  
1-4  
IM-22-C  
Series 220/221 Instruction Manual  
Chapter 1 Introduction  
Flow Velocity Range  
To ensure trouble-free operation, vortex flow meters must be correctly  
sized so that the flow velocity range through the meter lies within the  
measurable velocity range (with acceptable pressure drop) and the linear  
range.  
The measurable range is defined by the minimum and maximum velocity  
using the following table.  
Gas  
Liquid  
25  
ft/s  
English ρ (lb/ft3)  
ρ
Vmin  
1 ft/s  
Vmax  
300 ft/s  
30 ft/s  
37  
m/s  
Metric ρ (kg/m3)  
ρ
Vmin  
Vmax  
0.3 m/s  
9.1 m/s  
91 m/s  
The pressure drop for series 221 insertion meters is negligible. The pres-  
sure drop for series 220 in-line meters is defined as:  
P = .00024 ρ V2 English units (P in psi, ρ in lb/ft3, V in ft/sec)  
P = .000011 ρ V2 Metric units (P in bar, ρ in kg/m3, V in m/sec)  
The linear range is defined by the Reynolds number. The Reynolds num-  
ber is the ratio of the inertial forces to the viscous forces in a flowing  
fluid and is defined as:  
ρ V D  
Re =  
µ
Where  
Re = Reynolds Number  
ρ
=
mass density of the fluid being measured  
V = velocity of the fluid being measured  
D = internal diameter of the flow channel  
µ
=
viscosity of the fluid being measured  
The Strouhal number is the other dimensionless number that quantifies the  
vortex phenomenon. The Strouhal number is defined as:  
f d  
St =  
Where  
V
St = Strouhal Number  
f
=
frequency of vortex shedding  
d = shedder bar width  
V = fluid velocity  
IM-22-C  
1-5  
Chapter 1 Introduction  
Series 220/221 Instruction Manual  
As shown below, Innova-FloVortex Flow Meters exhibit a constant  
Strouhal number across a large range of Reynolds numbers, indicating a  
consistent linear output over a wide range of flows and fluid types. Be-  
low this linear range, the intelligent electronics in Innova-Flo automati-  
cally corrects for the variation in the Strouhal number. Innova-Flo’s  
smart electronics correct for this non-linearity by calculating the Rey-  
nolds number based on constant values of the fluid’s density and viscos-  
ity stored in the instrument’s memory. Innova-Flo Vortex Flow Meters  
automatically correct down to a Reynolds number of 5,000.  
Corrected range  
0.3  
Linear range  
0.2  
0.1  
0.0  
103  
104  
10 5  
106  
107  
108  
5000  
Reynolds Number, Re  
Figure 1-3. Reynolds Number Range for the Innova-Flo Meter  
1-6  
IM-22-C  
Series 220/221 Instruction Manual  
Chapter 1 Introduction  
Flow Meter Configurations  
Innova-Flo™ Vortex Flow Meters are available in two configurations:  
Series 220 in-line flow meter (replaces a section of the pipeline)  
Series 221 insertion flow meter (requires a “cold” tap or a “hot” tap  
into an existing pipeline)  
Both the in-line and insertion configurations are similar in that they both  
use identical electronics and have similar sensor heads. Besides installa-  
tion differences, the main difference between an in-line flow meter and  
an insertion flow meter is their method of measurement.  
For an in-line vortex flow meter, the shedder bar is located across the en-  
tire diameter of the flow body. Thus, the entire pipeline flow is included  
in the vortex formation and measurement. The sensing head, which di-  
rectly measures velocity is located just downstream of the shedder bar.  
An insertion vortex flow meter has its sensing head at the end of a 0.750  
inch diameter tubular stem. The stem is inserted into the pipe until the  
sensing head is properly located in the pipe’s cross section. The sensing  
head fits through any entry port with an 1.875 inch minimum internal di-  
ameter.  
The sensing head of an insertion vortex flow meter directly monitors the  
velocity at a point in the cross-sectional area of a pipe, duct, or stack (re-  
ferred to as “channels”). The velocity at a point in the pipe varies as a func-  
tion of the Reynolds number. The insertion vortex flow meter computes the  
Reynolds number based on constant values of the fluid’s density and vis-  
cosity stored in its memory and then computes the total flow rate in the  
channel. The output signal of insertion meters is the total flow rate in the  
channel. The accuracy of the total flow rate computation depends on ad-  
herence to the piping installation requirements given in Chapter 2. If ad-  
herence to those guidelines cannot be met, contact the factory for specific  
installation advice.  
Flow Meter Electronics  
Innova-Flo electronics are available mounted directly to the flow body,  
or remotely mounted. The electronics housing may be used indoors or  
outdoors, including wet environments. The instrument requires 4-20 mA  
loop power (12 to 36 VDC). One analog output signal is available for  
your choice of volumetric flow rate or mass flow rate. A pulse output is  
available for totalization.  
IM-22-C  
1-7  
Chapter 1 Introduction  
Series 220/221 Instruction Manual  
The meter includes a local 2 x 16 character LCD display housed within  
the enclosure. Local operation and reconfiguration is accomplished using  
six push buttons. For hazardous locations, the six push buttons can be  
operated through the sealed enclosure using a hand-held magnet, thereby  
not compromising the integrity of the hazardous location certification.  
The electronics include nonvolatile memory that stores all configuration  
information. The memory allows the flow meter to function immediately  
upon power up, or after an interruption in power.  
1-8  
IM-22-C  
Series 220/221 Instruction Manual  
Chapter 2 Installation  
Chapter 2 Installation  
Installation Overview  
Innova-Flo™ meter installations are simple and straightforward. Both the Se-  
ries 220 In-Line and Series 221 Insertion type flow meter installations are  
covered in this chapter. After reviewing the installation requirements given  
below, see page 2-3 for Series 220 installation instructions. See page 2-6 for  
Series 221 installation instructions. Wiring instructions begin on page 2-19.  
Flow Meter Installation Requirements  
Before installing the flow meter, verify the installation site allows for these  
considerations:  
Warning!  
Consult the flow meter name-  
plate for specific flow meter  
approvals before any hazard-  
ous location installation.  
1. Line pressure and temperature will not exceed the flow meter  
rating.  
2. The location meets the required minimum number of pipe di-  
ameters upstream and downstream of the sensor head as illus-  
trated Figure 2-1.  
3. Safe and convenient access with adequate overhead clearance  
for maintenance purposes.  
4. Verify that the cable entry into the instrument meets the specific  
standard required for hazardous area installations.  
5. For remote installations, verify the supplied cable length is suf-  
ficient to connect the flow meter sensor to the remote electron-  
ics.  
Also, before installation check your flow system for anomalies such as:  
leaks  
valves or restrictions in the flow path that could create disturbances in  
the flow profile that might cause unexpected flow rate indications  
IM-22-C  
2-1  
Chapter 2 Installation  
Series 220/221 Instruction Manual  
Unobstructed Flow Requirements  
Select an installation site that will minimize possible distortion in the flow  
profile. Valves, elbows, control valves and other piping components may  
cause flow disturbances. Check your specific piping condition against the ex-  
amples shown below. In order to achieve accurate and repeatable perform-  
ance install the flow meter using the recommended number of straight run  
pipe diameters upstream and downstream of the sensor.  
Note: For liquid applications in vertical pipes, avoid installing with flow in  
the downward direction because the pipe may not be full at all points.  
Choose to install the meter with flow in the upward direction if possible.  
A
B
A
B
C'  
C
Flow meter  
Flow meter  
Flow conditioner  
(if used)  
Example 1.  
One 90° elbow before meter  
Example 4.  
Reduction before meter  
A
B
A
B
C'  
C
Flow meter  
C'  
C
Flow meter  
Flow conditioner  
(if used)  
Example 2.  
Two 90° elbows before meter in one plane  
Example 5.  
Expansion before meter  
Flow conditioner  
(if used)  
A
B
A
B
C'  
C
Flow meter  
C'  
C
Flow meter  
Flow conditioner  
(if used)  
Flow conditioner (if used)  
Example 3.  
Example 6.  
Two 90° elbows before meter out of plane (if three  
90° bends present, double recommended length)  
Regulator or valve partially closed before meter  
(If valve is always wide open, base length  
requirements on fitting directly preceding it)  
Minimum Required  
Upstream Diameters  
No Flow  
Minimum Required  
Downstream Diameters  
No Flow  
Conditioner  
B
With Flow  
Conditioner  
Conditioner  
A
With Flow Conditioner  
Example  
A
C
C´  
B
1
2
3
4
5
6
10 D  
15 D  
25 D  
10 D  
20 D  
25 D  
N/A  
N/A  
5 D  
5 D  
5 D  
5 D  
5 D  
N/A  
5 D  
5 D  
5 D  
5 D  
5 D  
5 D  
5 D  
10 D  
5 D  
5 D  
5 D  
5 D  
5 D  
5 D  
5 D  
5 D  
10 D  
10 D  
10 D  
10 D  
10 D  
10 D  
D = Internal diameter of channel. N/A = Not applicable  
Figure 2-1. Recommended Pipe Length Requirements for Installation, Series 220 and 221  
2-2  
IM-22-C  
Series 220/221 Instruction Manual  
Chapter 2 Installation  
Series 220 In-Line Flow Meter Installation  
Install the Series 220 In-Line Flow Meter between two conventional pipe  
flanges as shown in Figures 2-3 and 2-4. Table 2-1 provides the recom-  
mended minimum stud bolt lengths for wafer-style meter body size and dif-  
ferent flange ratings.  
The meter inside diameter is equal to the same size nominal pipe ID in  
schedule 80. For example, a 2” meter has an ID of 1.939” (2” schedule 80).  
Do not install the meter in a pipe with an inside diameter smaller than  
the inside diameter of the meter. For schedule 160 and higher pipe, a spe-  
cial meter is required. Consult the factory before purchasing the meter.  
Series 220 Meters require customer-supplied gaskets. When selecting gasket  
material make sure that it is compatible with the process fluid and pressure  
ratings of the specific installation. Verify that the inside diameter of the gas-  
ket is larger than the inside diameter of the flow meter and adjacent piping. If  
the gasket material extends into the flow stream, it will disturb the flow and  
cause inaccurate measurements.  
Flange Bolt Specifications  
Stud Bolt Lengths for Each Flange Rating (inches)  
Line Size  
Class 150  
Class 300  
Class 600  
1 inch  
1.5 inch  
2 inch  
3 inch  
4 inch  
6.00  
6.25  
8.50  
9.00  
9.50  
7.00  
8.50  
8.75  
10.00  
10.75  
7.50  
9.00  
9.50  
10.50  
12.25  
Table 2-1. Minimum Recommended Stud Bolt Lengths for Wafer Meters  
The required bolt load for sealing the gasket joint is affected by several ap-  
plication-dependent factors, therefore the required torque for each application  
may be different. Refer to the ASME Pressure Vessel Code guidelines for  
bolt tightening standards.  
1
1
1
12  
5
5
7
8
6
8
9
4
3
4
3
4
3
10  
7
11  
6
2
2
2
4-bolt  
8-bolt  
12-bolt  
Figure 2-2. Flange Bolt Torquing Sequence  
IM-22-C  
2-3  
Chapter 2 Installation  
Series 220/221 Instruction Manual  
Wafer-Style Flow Meter Installation  
Install the wafer-style meter between two conventional pipe flanges of the  
same nominal size as the flow meter. If the process fluid is a liquid, make  
sure the meter is located where the pipe is always full. This may require lo-  
cating the meter at a low point in the piping system. Note: Vortex flow me-  
ters are not suitable for two-phase flows (i.e., liquid and gas mixtures). For  
horizontal pipelines having a process temperature above 300° F, mount the  
meter at a 45 or 90-degree angle to avoid overheating the electronics enclo-  
sure. To adjust the viewing angle of the enclosure or display/keypad, see  
page 2-17.  
Caution!  
When using toxic or cor-  
Figure 2-3. Wafer-Style Flow Meter Installation  
rosive gases, purge the  
line with inert gas for a  
minimum of four hours  
at full gas flow before  
installing the flow meter.  
When installing the meter make sure the section marked “inlet” is positioned up-  
stream of the outlet, facing the flow. This ensures that the sensor head is posi-  
tioned downstream of the vortex shedder bar and is correctly aligned to the flow.  
Installing the meter opposite this direction will result in completely inaccurate  
flow measurement. To install the meter:  
1. Turn off the flow of process gas, liquid or steam. Verify that the line is  
not pressurized. Confirm that the installation site meets the required  
minimum upstream and downstream pipe diameters.  
2. Insert the studs for the bottom side of the meter body between the pipe  
flanges. Place the wafer-style meter body between the flanges with the end  
stamped “inlet” facing flow. Center the meter body inside the diameter  
with respect to the inside diameter of the adjoining piping.  
3. Position the gasket material between the mating surfaces. Make sure both  
gaskets are smooth and even with no gasket material extending into the  
flow profile. Obstructions in the pipeline will disturb the flow and cause  
inaccurate measurements.  
4. Place the remaining studs between the pipe flanges. Tighten the nuts in the  
sequence shown in Figure 2-2. Check for leaks after tightening the flange  
bolts.  
2-4  
IM-22-C  
Series 220/221 Instruction Manual  
Chapter 2 Installation  
Flange-Style Flow Meter Installation  
Install the flange-style meter between two conventional pipe flanges of the  
same nominal size as the flow meter. If the process fluid is a liquid, make  
sure the meter is located where the pipe is always full. This may require lo-  
cating the meter at a low point in the piping system. Note: Vortex flow me-  
ters are not suitable for two-phase flows (i.e., liquid and gas mixtures). For  
horizontal pipelines having a process temperature above 300° F, mount the  
meter at a 45 or 90-degree angle to avoid overheating the electronics enclo-  
sure. To adjust the viewing angle of the enclosure or display/keypad, see  
page 2-17.  
Figure 2-4. Flange-Style Flow Meter Installation  
When installing the meter make sure the flange marked “inlet” is positioned up-  
stream of the outlet flange, facing the flow. This ensures that the sensor head is  
positioned downstream of the vortex shedder bar and is correctly aligned to the  
flow. Installing the meter opposite this direction will result in completely inaccu-  
rate flow measurement. To install the meter:  
Caution!  
When using toxic or cor-  
rosive gases, purge the  
line with inert gas for a  
minimum of four hours  
at full gas flow before  
installing the flow meter.  
1. Turn off the flow of process gas, liquid or steam. Verify that the line is  
not pressurized. Confirm that the installation site meets the required  
minimum upstream and downstream pipe diameters.  
2. Seat the meter level and square on the mating connections with the flange  
marked “inlet” facing the flow. Position a gasket in place for each side. Make  
sure both gaskets are smooth and even with no gasket material extending into  
the flow profile. Obstructions in the pipeline will disturb the flow and cause  
inaccurate measurements.  
3. Install bolts in both process connections. Tighten the nuts in the sequence  
shown in Figure 2-2. Check for leaks after tightening the flange bolts.  
IM-22-C  
2-5  
Chapter 2 Installation  
Series 220/221 Instruction Manual  
Series 221 Insertion Flow Meter Installation  
Prepare the pipeline for installation using either a cold tap or hot tap method  
described on the following pages. Refer to a standard code for all pipe tap-  
ping operations. The following tapping instructions are general in nature and  
intended for guideline purposes only. Before installing the meter, review the  
mounting position and isolation value requirements given below.  
Mounting Position  
Allow clearance between the electronics enclosure top and any other obstruc-  
tion when the meter is fully retracted.  
Isolation Valve Selection  
An isolation valve is available as an option with Series 221 meters. If you  
supply the isolation valve, it must meet the following requirements:  
1. A minimum valve bore diameter  
1.875-inch min.  
of 1.875 inches is required, and  
valve bore  
the valve’s body size should be  
2-inch min.  
two inches. Normally, gate  
valves are used.  
2-inch  
valve size  
2. Verify that the valve’s body and  
flange rating are within the flow  
meter’s maximum operating  
pressure and temperature.  
Isolation Valve Requirements  
3. Choose an isolation valve with  
at least two inches existing between the flange face and the gate portion  
of the valve. This ensures that the flow meter’s sensor head will not in-  
terfere with the operation of the isolation valve.  
2-6  
IM-22-C  
Series 220/221 Instruction Manual  
Chapter 2 Installation  
Cold Tap Guidelines  
Refer to a standard code for all pipe tapping operations. The following tap-  
ping instructions are general in nature and intended for guideline purposes  
only.  
Caution!  
When using toxic or  
corrosive gases, purge  
the line with inert gas  
for a minimum of four  
hours at full gas flow  
before installing the  
flow meter.  
1. Turn off the flow of process gas, liquid or steam. Verify that the line is  
not pressurized.  
2. Confirm that the installation site meets the minimum upstream and  
downstream pipe diameter requirements. See Figure 2-1.  
3. Use a cutting torch or sharp cutting tool to tap into the pipe. The pipe  
opening must be at least 1.875 inches in diameter. (Do not attempt to in-  
sert the sensor probe through a smaller hole.)  
4. Remove all burrs from the tap. Rough edges may cause flow profile dis-  
tortions that could affect flow meter accuracy. Also, obstructions could  
damage the sensor assembly when inserting into the pipe.  
5. After cutting, measure the thickness of the cut-out and record this num-  
ber for calculating the insertion depth.  
6. Weld the flow meter pipe connec-  
tion on the pipe. Make sure this  
connection is within ± 5° perpen-  
dicular to the pipe centerline.  
Warning!  
All flow meter connec-  
tions, isolation valves and  
fittings for cold tapping  
must have the same or  
higher pressure rating as  
the main pipeline.  
7. Install the isolation valve (if  
used).  
8. When welding is complete and all fittings are installed, close the isola-  
tion valve or cap the line. Run a static pressure check on the welds. If  
pressure loss or leaks are detected, repair the joint and re-test.  
9. Connect the meter to the pipe process connection.  
10. Calculate the sensor probe insertion depth as described on the following  
pages. Insert the sensor probe into the pipe.  
IM-22-C  
2-7  
Chapter 2 Installation  
Series 220/221 Instruction Manual  
Hot Tap Guidelines  
Refer to a standard code for all pipe tapping operations. The following tap-  
ping instructions are general in nature and intended for guideline purposes  
only.  
Warning!  
Hot tapping must be  
performed by a trained  
professional. US. regula-  
tions often require a hot  
tap permit. The manufac-  
turer of the hot tap  
equipment and/or the  
contractor performing the  
hot tap is responsible for  
providing proof of such a  
permit.  
1. Confirm that the installation site meets the minimum upstream and  
downstream pipe diameter requirements.  
2. Weld a two inch mounting adapter on the pipe. Make sure the mounting  
adapter is within ± 5° perpendicular to the pipe centerline (see previous  
page). The pipe opening must be at least 1.875 inches in diameter.  
3. Connect a two inch process connection on the mounting adapter.  
4. Connect an isolation valve on the process connection. The valve’s full  
open bore must be at least 1.875 inches in diameter.  
Warning!  
All flow meter connec-  
tions, isolation valves and  
fittings for hot tapping  
must have the same or  
higher pressure rating as  
the main pipeline.  
5. Hot tap the pipe.  
6. Close the isolation valve. Run a static pressure check on the welds. If  
pressure loss or leaks are detected, repair the joint and re-test.  
7. Connect the flow meter to the isolation valve.  
8. Calculate the sensor probe insertion depth as described on the following  
pages. Insert the sensor probe assembly into the pipe.  
Check upstream and  
downstream piping  
requirements  
Weld mounting  
adapter  
Connect process  
connection  
(flange or NPT)  
Connect  
isolation valve  
Hot tap pipe  
Test for leaks,  
purge pipe  
FLOW  
Connect meter to  
valve, calculate  
insertion depth,  
install flow meter  
Figure 2-5. Hot Tap Sequence  
2-8  
IM-22-C  
Series 220/221 Instruction Manual  
Chapter 2 Installation  
Flow Meter Insertion  
The sensor head must be properly positioned in the pipe. For this reason, it is  
important that insertion length calculations are carefully followed. A sensor  
probe inserted at the wrong depth in the pipe will result in inaccurate readings.  
Insertion flow meters are applicable to pipes 2 inch and larger. For pipe sizes  
ten inches and smaller, the centerline of the meter’s sensing head is located at  
the pipe’s centerline. For pipe sizes larger than ten inches, the centerline of the  
sensing head is located in the pipe’s cross section five inches from the inner  
wall of the pipe; i.e., its “wetted” depth from the wall to the centerline of the  
sensing head is five inches.  
Insertion flow meters are available in three probe lengths:  
Standard Probe configuration is used with most flow meter process connec-  
tions. The length, S, of the stem is 29.47 inches.  
Compact Probe configuration is used with compression fitting process con-  
nections. The length, S, of the stem is 13.1 inches.  
12-Inch Extended Probe configuration is used with exceptionally lengthy flow  
meter process connections. The length, S, of the stem is 41.47 inches.  
Use the Correct Insertion Formula  
Depending on your flow meter’s process connection, use the applicable in-  
sertion length formula and installation procedure as follows:  
Warning!  
An insertion tool must be  
used for any installation  
where a flow meter is  
inserted under pressure  
greater than 50 psig.  
Flow meters with a compression type connection (NPT or flanged) fol-  
low the instructions beginning on page 2-10.  
Flow meters with a packing gland type connection (NPT or flanged) con-  
figured with an insertion tool, follow the instructions beginning on page  
2-12.  
Flow meters with a packing gland type connection (NPT or flanged)  
without an insertion tool, follow the instructions beginning on page 2-  
15.  
IM-22-C  
2-9  
Chapter 2 Installation  
Series 220/221 Instruction Manual  
Installing Flow Meters with a Compression Connection*  
Use the following formula to determine insertion length for flow meters  
(NPT and flanged) with a compression process connection. The installation  
procedure is given on the next page.  
Insertion Length Formula  
I = S – F – R – t  
Where:  
I = Insertion length.  
S = Stem length – the distance from the center of the sensor head to the base of the  
enclosure adapter (S = 29.47 inches for standard probes; S = 13.1 inches for  
compact; S = 41.47 inches for 12-inch extended).  
F = Distance from the raised face of the flange or top of NPT stem housing to the  
outside of the pipe wall.  
R = Pipe inside diameter ÷ 2 for pipes ten inches and smaller.  
R = Five inches for pipe diameters larger than ten inches.  
t = Thickness of the pipe wall. (Measure the disk cut-out from the tapping proce-  
dure or check a piping handbook for thickness.)  
Figure 2-6. Insertion Calculation (Compression Type)  
Example:  
To install a Series 221 meter with a standard probe (S = 29.47 inches) into a 14  
inch schedule 40 pipe, the following measurements are taken:  
F
R
t
= 3 inches  
= 5 inches  
= 0.438 inches  
The insertion length for this example is 21.03 inches. Insert the stem through the fit-  
ting until an insertion length of 21.03 inches is measured with a ruler.  
*All dimensions are in inches  
2-10  
IM-22-C  
Series 220/221 Instruction Manual  
Chapter 2 Installation  
Insertion Procedure for Meters with a Compression Connection  
Figure 2-7. Flow Meter with Compression Type Fitting  
1. Calculate the required sensor probe insertion length.  
2. Fully retract the stem until the sensor head is touching the bottom of the  
stem housing. Slightly tighten the compression nut to prevent slippage.  
Caution!  
The sensor alignment  
pointer must point  
downstream, in the  
direction of flow.  
3. Bolt or screw the flow meter assembly into the process connection. Use  
Teflon tape or pipe sealant to improve the seal and prevent seizing on NPT  
styles.  
4. Hold the meter securely while loosening the compression fitting. Insert  
the sensor into the pipe until the calculated insertion length, I, is meas-  
ured between the base of the enclosure adapter and the top of the stem  
housing, or to the raised face of the flanged version. Do not force the  
stem into the pipe.  
Warning!  
To avoid serious injury,  
DO NOT loosen the  
compression fitting  
under pressure.  
5. Align the sensor head using the sensor alignment pointer. Adjust the  
alignment pointer parallel to the pipe and pointing downstream.  
6. Tighten the compression fitting to lock the stem in position. When the  
compression fitting is tightened, the position is permanent.  
IM-22-C  
2-11  
Chapter 2 Installation  
Series 220/221 Instruction Manual  
Installing Flow Meters with a Packing Gland Connection*  
Use the formula below to determine the insertion depth for flow meters (NPT  
and flanged) equipped with an insertion tool. To install, see the next page for  
instructions for meters with a permanent insertion tool. For meters with a re-  
movable insertion tool, see page 2-14.  
Insertion Length Formula  
I = F + R + t – 1.35  
Where:  
I = Insertion length.  
F = Distance from the raised face of the flange or top of the  
process connection for NPT style meters to the top out-  
side of the process pipe.  
R = Pipe inside diameter ÷ 2 for pipes ten inches & smaller.  
R = Five inches for pipe diameters larger than ten inches.  
t = Thickness of the pipe wall. (Measure the disk cut-out  
from the tapping procedure or check a piping handbook  
for thickness.)  
Figure 2-8. Insertion Calculation (Meters with Insertion Tool)  
Example 1: Flange Style Meters:  
To install a Series 221 Flow Meter into a 14 inch schedule 40 pipe, the fol-  
lowing measurements are taken:  
F
R
t
=
=
=
12 inches  
5 inches  
0.438 inches  
The example insertion length is 16.09 inches.  
Example 2: NPT Style Meters:  
The length of thread engagement on the NPT style meters is also subtracted  
in the equation. The length of the threaded portion of the NPT meter is 1.18  
inches. Measure the thread portion still showing after the installation and  
subtract that amount from 1.18 inches. This gives you the thread engagement  
length. If this cannot be measured use .55 inch for this amount.  
F
R
t
=
=
=
12 inches  
5 inches  
0.438 inches  
The example insertion length is 15.54 inches.  
*All dimensions are in inches.  
2-12  
IM-22-C  
Series 220/221 Instruction Manual  
Chapter 2 Installation  
Insertion Procedure for Flow Meters with Permanent Insertion Tool  
Figure 2-9. Flow Meter with Permanent Insertion Tool  
1. Calculate the required sensor probe insertion length (see previous page).  
Measure from the depth marker arrow down the stanchion and scribe a  
mark at the calculated insertion depth.  
2. Fully retract the flow meter until the sensor head is touching the bottom  
of the stem housing. Attach the meter assembly to the two inch full-port  
isolation valve, if used. Use Teflon tape or pipe sealant to improve seal  
and prevent seizing on NPT style.  
3. Loosen the two packing gland nuts on the stem housing of the meter.  
Loosen the stem lock bolt adjacent to the sensor alignment pointer. Align  
the sensor head using the sensor alignment pointer. Adjust the alignment  
pointer parallel to the pipe and pointing downstream. Tighten the stem lock  
bolt to secure the sensor position.  
Caution!  
The sensor alignment  
pointer must point  
downstream, in the  
direction of flow.  
4. Slowly open the isolation valve to the full open position. If necessary,  
slightly tighten the two packing gland nuts to reduce the leakage around  
the stem.  
Note  
If line pressure is above  
500 psig, it could require  
up to 25 ft lb of torque to  
insert the flow meter.  
Do not confuse this with  
possible interference  
in the pipe.  
5. Turn the insertion tool handle clockwise to insert the sensor head into the  
pipe. Continue until the top of the upper retractor bracket aligns with the  
insertion length position scribed on the stanchion. Do not force the stem  
into the pipe.  
6. Tighten the packing gland nuts to stop leakage around the stem. Do not  
torque over 20 ft-lb.  
IM-22-C  
2-13  
Chapter 2 Installation  
Series 220/221 Instruction Manual  
Insertion Procedure for Flow Meters with Removable Insertion Tool  
Figure 2-10. Flow Meter with Removable Insertion Tool  
1. Calculate the required sensor probe insertion length. Measure from the  
depth marker arrow down the stanchion and scribe a mark at the calcu-  
lated insertion depth.  
2. Fully retract the flow meter until the sensor head is touching the bottom  
of the stem housing. Attach the meter assembly to the two inch full-port  
isolation valve, if used. Use Teflon tape or pipe sealant to improve seal  
and prevent seizing on NPT style.  
Caution!  
The sensor alignment  
pointer must point  
downstream, in the  
direction of flow.  
3. Remove the two top stem clamp nuts and loosen two stem clamp bolts.  
Slide the stem clamp away to expose the packing gland nuts.  
4. Loosen the two packing gland nuts. Loosen the stem lock bolt adjacent to  
the sensor alignment pointer. Align the sensor head using the sensor  
alignment pointer. Adjust the alignment pointer parallel to the pipe and  
pointing downstream. Tighten the stem lock bolt to secure the sensor po-  
sition.  
Note  
If line pressure is above  
500 psig, it could require  
up to 25 ft lb of torque to  
insert the flow meter.  
Do not confuse this with  
possible interference  
in the pipe.  
5. Slowly open the isolation valve to the full open position. If necessary,  
slightly tighten the two packing gland nuts to reduce the leakage around  
the stem.  
6. Turn the insertion tool handle clockwise to insert the stem into the pipe.  
Continue until the top of the upper retractor bracket lines up with the in-  
sertion length mark scribed on the stanchion. Do not force the stem into  
the pipe.  
2-14  
IM-22-C  
Series 220/221 Instruction Manual  
Chapter 2 Installation  
7. Tighten the packing gland nuts to stop leakage around the stem. Do not  
torque over 20 ft-lbs.  
8. Slide the stem clamp back into position. Torque stem clamp bolts to 15  
ft-lbs. Replace the stem clamp nuts and torque to 10-15 ft-lbs.  
9. Attach the safety chain from the stem clamp to the hook on the enclosure  
adapter at the nearest link. To separate the insertion tool from the flow  
meter, remove four socket head cap bolts securing the upper and lower re-  
tractor brackets. Remove the insertion tool.  
Installation of Meters with Packing Gland Connection (No Insertion Tool)*  
Use the following formula to determine insertion depth for meters with a  
packing gland connection (NPT and flanged) without an insertion tool.  
Insertion Length Formula  
I = S – F – R – t  
Where:  
I = Insertion length.  
S = Stem length – the distance from the center  
of the sensor head to the base of the enclo-  
sure adapter (S = 29.47 inches for standard  
probes; S = 41.47 inches for 12 inch ex-  
tended probes).  
F = Distance from the raised face of the flange  
or top of NPT stem housing to the outside  
of the pipe wall.  
R = Pipe inside diameter ÷ 2 for pipes ten  
inches & smaller.  
R = Five inches for pipe diameters larger than  
ten inches.  
t = Thickness of the pipe wall. (Measure the  
disk cut-out from the tapping procedure or  
check a piping handbook for thickness.)  
Figure 2-11. Insertion Calculation (Meters without Insertion Tool)  
Example:  
To install a Series 221 Flow Meter with a standard probe (S = 29.47) into a  
14 inch schedule 40 pipe, the following measurements are taken:  
F
R
t
= 3 inches  
= 5 inches  
= 0.438 inches  
The example insertion length is 21.03 inches.  
*All dimensions are in inches.  
IM-22-C  
2-15  
Chapter 2 Installation  
Series 220/221 Instruction Manual  
Insertion Procedure for Flow Meters with No Insertion Tool  
(Packing Gland Connection)  
1. Calculate the required sensor probe insertion length.  
2. Fully retract the stem until the sensor head is touching the bottom of the  
stem housing. Remove the two top stem clamp nuts and loosen two stem  
clamp bolts. Slide the stem clamp away to expose the packing gland nuts.  
Loosen the two packing gland nuts.  
Warning!  
The line must be  
less than 50 psig  
for installation.  
3. Align the sensor head using the sensor alignment pointer. Adjust the  
alignment pointer parallel to the pipe and pointing downstream.  
Caution!  
The sensor alignment  
pointer must point  
downstream, in the  
direction of flow.  
4. Insert the sensor head into the pipe until insertion length, I, is achieved.  
Do not force the stem into the pipe.  
5. Tighten the packing gland nuts to stop leakage around the stem. Do not  
torque over 20 ft-lbs.  
6. Slide the stem clamp back into position. Torque stem clamp bolts to 15  
ft-lbs. Replace the stem clamp nuts and torque to 10-15 ft-lbs.  
2-16  
IM-22-C  
Series 220/221 Instruction Manual  
Chapter 2 Installation  
Adjusting Meter Orientation  
Depending on installation requirements, you may need to adjust the meter  
orientation. There are two adjustments available. The first rotates the position  
of the LCD display/keypad and is available on both in-line and insertion me-  
ters. The second is to rotate the enclosure position. This adjustment is only  
allowed on Series 220 In-Line meters.  
Display/Keypad Adjustment (All Meters)  
Figure 2-12. Display/Keypad Viewing Adjustment  
The electronics boards are electrostatically sensitive. Wear a grounding wrist  
strap and make sure to observe proper handling precautions required for  
static-sensitive components. To adjust the display:  
1. Disconnect power to the flow meter.  
2. Loosen the small set screw which secures the electronics enclosure. Un-  
screw and remove the cover.  
3. Loosen the 4 captive screws.  
4. Carefully pull the display/microprocessor board away from the meter  
standoffs. Make sure not to damage the connected ribbon cable.  
5. Rotate the display/microprocessor board to the desired position. Maxi-  
mum turn, two positions left or two positions right (180-degrees).  
6. Align the board with the captive screws. Check that the ribbon cable is  
folded neatly behind the board with no twists or crimps.  
7. Tighten the screws. Replace the cover and set screw. Restore power to  
the meter.  
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2-17  
Chapter 2 Installation  
Series 220/221 Instruction Manual  
Enclosure Adjustment (Series 220 Only)  
Figure 2-13. Enclosure Viewing Adjustment  
To avoid damage to the sensor wires, do not rotate the enclosure beyond 180-  
degrees from the original position. To adjust the enclosure:  
1. Remove power to the flow meter.  
2. Loosen the three set screws shown above. Rotate the display to the de-  
sired position (maximum 180-degrees).  
3. Tighten the three set screws. Restore power to the meter.  
2-18  
IM-22-C  
Series 220/221 Instruction Manual  
Chapter 2 Installation  
Wiring Connections  
The NEMA 4X enclosure contains an integral wiring compartment with one  
dual strip terminal block (located in the smaller end of the enclosure). Two  
3/4-inch female NPT conduit entries are available for separate power and  
signal wiring. For all hazardous area installations, make sure to use an  
agency-approved fitting at each conduit entry. If conduit seals are used, they  
must be installed within 18 inches (457 mm) of the enclosure.  
Warning!  
To avoid potential electric  
shock, follow National Electric  
Code safety practices or your  
local code when wiring this  
unit to a power source and to  
peripheral devices. Failure to  
do so could result in injury or  
death. All wiring procedures  
must be performed with the  
power off.  
Input Power Connections  
To access the wiring terminal blocks, locate and loosen the small set screw  
which locks the small enclosure cover in place. Unscrew the cover to expose  
the terminal block.  
DC Power Wiring  
Connect 4-20 mA loop power (12 to 36 VDC) to the +Pwr and –Pwr termi-  
nals on the terminal block. Torque all connections to 4.43 to 5.31 in-lbs (0.5  
to 0.6 Nm). The DC power wire size must be 20 to 10 AWG with the wire  
stripped 1/2 inch (14 mm). The nominal voltage required to operate the 4-20  
mA loop is 12 volts at the meter. The 4-20 mA loop is optically isolated from  
the flow meter electronics.  
Figure 2-14. DC Power Connections  
IM-22-C  
2-19  
Chapter 2 Installation  
Series 220/221 Instruction Manual  
4-20 mA Output Connections  
The Innova-Flo meter has a single 4-20 mA loop. The 4-20 mA loop current  
is controlled by the meter electronics. The electronics must be wired in series  
with the sense resistor or current meter. The current control electronics re-  
quire 12 volts at the input terminals to operate correctly.  
The maximum loop resistance (load) for the current loop output is depend-  
ent upon the supply voltage and is given in Figure 2-16. The 4-20 mA loop  
is optically isolated from the flow meter electronics.  
Rload is the total resistance in the loop, including the wiring resistance (Rload  
Rwire + Rsense ). To calculate Rmax, the maximum Rload for the loop, use the  
maximum loop current, 20 mA. The voltage drop in the loop due to resis-  
=
tance is 20 mA times Rload and this drop is subtracted from the input voltage.  
Thus:  
The maximum resistance Rload = Rmax = 50 (Vsupply – 12V).  
*
Figure 2-15. Load Resistance Versus Input Voltage  
2-20  
IM-22-C  
Series 220/221 Instruction Manual  
Chapter 2 Installation  
Pulse Output Connections  
The pulse output is used for a remote counter. When the preset volume or  
mass (defined in the totalizer settings, see page 3-6) has passed the meter, the  
output provides a 50 millisecond square pulse.  
The pulse output requires a separate 5 to 36 VDC power supply. The pulse  
output optical relay is a normally-open single-pole relay. The relay has a  
nominal 200 volt/160 ohm rating. This means that it has a nominal on-  
resistance of 160 ohms, and the largest voltage that it can withstand across  
the output terminals is 200 volts. However, there are current and power  
specifications that must be observed. The relay can conduct a current up to  
40 mA and can dissipate up to 320 mW. The relay output is isolated from the  
meter electronics and power supply.  
Figure 2-16. Isolated Pulse Output with External Power Supply  
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2-21  
Chapter 2 Installation  
Series 220/221 Instruction Manual  
Remote Electronics Wiring  
The remote electronics enclosure should be mounted in a convenient, easy to  
reach location. For hazardous location installations, make sure to observe  
agency requirements for installation. Allow some slack in the interface cable  
between the junction box and the remote electronics enclosure. To prevent  
damage to the wiring connections, do not put stress on the terminations at  
any time.  
The meter is shipped with temporary strain relief glands at each end of the  
cable. Disconnect the cable from the meter’s terminal block inside the junc-  
tion box–not at the remote electronics enclosure. Remove both glands and in-  
stall appropriate conduit entry glands and conduit. When installation is com-  
plete, re-connect each labeled wire to the corresponding terminal position on  
the junction box terminal block. Make sure to connect each wire pair’s  
shield. Note: incorrect connection will cause the meter to malfunction.  
Figure 2-17. Junction Box Sensor Connections  
Note: Numeric code in junction box label matches wire labels.  
2-22  
IM-22-C  
Series 220/221 Instruction Manual  
Chapter 3 Operation  
Chapter 3 Operating Instructions  
After installing the Innova-Flo Vortex Meter, you are ready to begin op-  
eration. The sections in this chapter explain the display/keypad com-  
mands, meter start-up and programming. The meter is ready to operate at  
start up without any special programming. To enter parameters and sys-  
tem settings unique to your operation, see the following pages for in-  
structions on using the setup menus.  
Flow Meter Display/Keypad  
The flow meter’s digital electronics allow you to set, adjust and monitor  
system parameters and performance. A full range of commands are avail-  
able through the display/keypad. The LCD display gives 2 x 16 characters  
for flow monitoring and programming. The six push buttons are operable  
either directly on the display panel or with a hand-held magnet through  
the explosion-proof enclosure.  
From the Run Mode, theENTER key allows  
access to the Setup Menus (through a  
password screen). Within the Setup Menus,  
pressing ENTER activates the current field.  
To set new parameters, press the ENTER key  
until an underline cursor appears. Use the  
×ØÕÖ keys to select new parameters.  
Press ENTER to continue. (If change is not  
alllowed, ENTER has no effect.) All outputs  
are disabled when using the Setup Menus.  
Display/Keypad  
Commands  
×
EXIT  
ENTER  
INNOVA FLO™  
SIERRA  
INSTRUMENTS  
The EXIT key is active within the Setup Menus.  
When using a Setup Menu,EXIT returns you to the  
Run Mode. If you are changing a parameter and  
make a mistake, EXIT allows you to start over.  
Õ
Ö
Ø
The ×ØÕÖ keys advance through each screen  
of the current menu. When changing a system  
parameter, all ×ØÕÖ keys are available to enter  
new parameters.  
Figure 3-1. Flow Meter Display/Keypad  
IM-22-C  
3-1  
Chapter 3 Operation  
Series 220/221 Instruction Manual  
Start-Up  
To begin flow meter operation:  
1. Verify the flow meter is installed and wired as described in Chapter  
2.  
Note  
Starting the flow meter  
or pressing EXIT will  
always display the Run  
Mode screens.  
2. Apply power to the meter. At start up, the unit runs a series of self-  
tests that check the program configuration and all flow sensing com-  
ponents. After completing the self-test sequence, the Run Mode  
screens appear.  
3. The Run Mode displays flow information as determined by settings en-  
tered in the Display Menu (page 3-5). Press the ×Ø arrow keys to  
view the Run Mode screens.  
Press the ENTER key from any Run Mode screen to access the Setup  
Menus. Use the Setup Menus to configure the meter’s multi-parameter  
features to fit your application.  
Run Mode  
Screens  
ENTER  
Volume  
Flow Rate  
Password  
ENTER  
Mass Flow  
Rate  
Setup  
Menus  
Press EXIT to return  
to Run Mode  
Total  
Use  
keys to access  
each item  
To operate the six push buttons through the  
display enclosure, use the hand held magnet  
as shown at right.  
3-2  
IM-22-C  
Series 220/221 Instruction Manual  
Chapter 3 Operation  
Using the Setup Menus  
Run Mode  
Screens  
ENTER  
Volume  
Password  
ENTER  
Flow Rate  
Setup Menus  
Mass Flow  
Rate  
Output  
Menu  
Display  
Menu  
Totalizer  
Menu  
Units  
Diagnostics  
Calibration  
Menu  
Password  
Menu  
Menu  
Menu  
Total  
4-20 mA  
Output 1  
Cycle Time  
(sec)  
Volume  
Flow Unit  
Sim Vor  
Freq  
Meter Size  
or Pipe ID  
Set  
Password  
Totaling  
Number of  
Digits  
Unit per  
Pulse  
Mass Flow  
Unit  
Highest  
Velocity  
Meter Factor  
Display TC  
(sec)  
Process  
Temp (F)  
Reset Total  
Display  
VFlow?  
Density  
Ref Density  
Viscosity  
Display  
MFlow?  
Display  
Total?  
Vortek Coef  
Ck  
Low Flow  
Cutoff  
Serial  
Number  
Programming the Flow Meter  
1. Enter the Setup Menu by pressing the ENTER key until prompted for a password. (All  
outputs are disabled while using the Setup Menus.)  
2. Use the ×ØÕÖ keys to select the password characters (1234 is the factory-set  
password). When the password is correctly displayed, press ENTER to continue.  
3. Use the Setup Menus described on the following pages to customize the multi-  
parameter features of your Innova-Flo Vortex Meter. (The entire lower display line is  
available for entering parameters.)  
4. To activate a parameter, press ENTER. Use the ×ØÕÖ keys to make selections. Press  
ENTER to continue. Press EXIT to save or discard changes and return to Run Mode.  
IM-22-C  
3-3  
Chapter 3 Operation  
Series 220/221 Instruction Manual  
Output Menu  
ENTER  
Run Mode  
Password  
ENTER  
Output  
Menu  
Use  
keys to access menus  
< Measure >  
None  
Volume  
Mass  
4-20mA Output 1  
More >  
< 4mA = xxxx >  
xxxx  
< 20mA = xxxx >  
xxxx  
< TimeConst(SEC)  
xxxx  
Example for Setting an Output  
The following shows how to set Output 1 to measure volumetric flow with 4 mA = 0 gal/min and 20 mA = 100  
gal/min with a time constant of 5 seconds. (All outputs are disabled while using the Setup Menus.)  
First, set the desired units of measurement:  
1. Use ÕÖ keys to move to the Units Menu (see page 3-8).  
2. Press Ø key until Volume Flow Unit appears. Press ENTER.  
3. Press Ø key until gal appears in the numerator. Press Ö key to move the underline cursor to the  
denominator. Press the Ø key until min appears in the denominator. Press ENTER to select.  
4. Press × key until Units Menu appears.  
Second, set the analog output:  
1. Use ÕÖ keys to move to the Output Menu.  
2. Press the Ø key until 4-20mA Output 1 appears.  
3. Press Ö key to access Measure selections. Press ENTER and press the Ø key to select Volume. Press ENTER.  
4. Press Ö key to set the 4 mA point in the units you have selected for volume of gal/min. Press ENTER  
and use ×ØÕÖ keys to set 0 or 0.0. Press ENTER.  
5. Press Ö key to set the 20 mA point. Press ENTER and use ×ØÕÖ keys to set 100 or 100.0. Press ENTER.  
6. Press Ö key to select the Time Constant. Press ENTER and use ×ØÕÖ keys to select 5. Press ENTER.  
7. Press the EXIT key and answer YES to permanently save your changes.  
3-4  
IM-22-C  
Series 220/221 Instruction Manual  
Chapter 3 Operation  
Display Menu  
ENTER  
Run Mode  
Password  
ENTER  
Display  
Menu  
Use  
keys to access menus  
Cycle Time(Sec)  
0
If Cycle Time is set to zero, manual advance is required  
Number of Digits  
2
Used to set the number of digits displayed after  
decimal point  
Display TC(sec)  
1
TC = Display Time Constant, used to smooth display  
Display VFlow?  
YES or NO  
For each parameter:  
Select Yes to view parameter in Run Mode  
Select No to hide parameter in Run Mode  
Display MFlow?  
YES or NO  
Display Total?  
YES or NO  
Use the Display Menu to set the cycle time for automatic screen sequencing used in the Run Mode,  
change the precision of displayed values, smooth the values or enable or disable each item displayed  
in the Run Mode screens.  
Example for Changing a Run Mode Display Item  
The following shows how to remove the mass flow screen from the Run Mode screens. Note: all outputs are  
disabled while using the Setup Menus.  
1. Use ÕÖ keys to move to the Display Menu.  
2. Press Ø key until Display MFlow? appears.  
3. Press ENTER to select.  
4. Press Ø key until N appears. Press ENTER to select.  
5. Press EXIT and then ENTER to save changes and return to the Run Mode.  
IM-22-C  
3-5  
Chapter 3 Operation  
Series 220/221 Instruction Manual  
Totalizer Menu  
ENTER  
Run Mode  
Password  
ENTER  
Totalizer  
Menu  
Use  
keys to access menus  
Totaling  
Inactive  
Volume  
Mass  
Example:  
Maximum flowrate = 600 gallons per minute  
(600 gallons per minute = 10 gallons per second)  
(unit)/Pulse  
xxxx  
If unit per pulse is set to 600 gallons per pulse,  
the totalizer will pulse once every minute.  
Reset Total?  
YES or NO  
If unit per pulse is set to 10 gallons per pulse,  
the totalizer will pulse once every second.  
Use the Totalizer Menu to configure and monitor the totalizer. The totalizer output is a 50  
millisecond (.05 second) positive pulse (relay closed for 50 milliseconds). The totalizer  
cannot operate faster than one pulse every 100 millisecond (.1 second). A good rule to follow  
is to set the unit per pulse value equal to the maximum flow in the same units per second.  
This will limit the pulse to no faster than one pulse every second.  
Example for Setting the Totalizer  
The following shows how to set the totalizer to track volumetric total gallons. (All outputs are disabled  
while using the Setup Menus.)  
First, set the desired units of measurement:  
1. Use ÕÖ keys to move to the Units Menu (see to page 3-8).  
2. Press Ø key until Volume Flow Unit appears. Press ENTER.  
3. Press Ø key until gal appears in the numerator. Press Ö key to move the underline cursor to the  
denominator. Press the Ø key until min appears in the denominator. Press ENTER to select.  
4. Press × key until Units Menu appears.  
Second, set the pulse output:  
1. Use ÕÖ keys to move to the Totalizer Menu.  
2. Press the Ø key until Totaling appears.  
3. Press ENTER and press the Ø key to select Volume. Press ENTER.  
4. Press Ø key to set the gallons per pulse. Press ENTER and use ×ØÕÖ keys to set the pulse  
value equal to the maximum flow in the same units per second. This will limit the frequency to  
1 Hz. Press ENTER.  
5. To reset the totalizer, press Ø key until Reset Total? appears. Press ENTER and the Ø key to reset  
the totalizer if desired. Press ENTER.  
6. Press the EXIT key and answer YES to permanently save your changes.  
3-6  
IM-22-C  
Series 220/221 Instruction Manual  
Chapter 3 Operation  
Units Menu  
ENTER  
Run Mode  
Password  
ENTER  
Units  
Use  
Menu  
keys to access menus  
Volume Flow Unit  
gal  
sec  
bbl  
min  
c
m^3 /  
bbl = barrels = 42 US gallon  
hr  
day  
lit  
m^3  
ft^3  
Mass Flow Unit  
lb  
ton  
ton = 2000 lb  
sec  
min  
hr  
mton = Metric Ton = 1000 kg  
sm^3 = standard cubic meters  
scf = standard cubic feet  
nm^3 = normal cubic meters  
gram  
kg  
mton  
sm^3  
scf  
/
day  
nm^3  
Use the Units Menu to configure the flow meter with the desired units of measurement.  
(These are global settings and determine what appears on all screens.)  
IM-22-C  
3-7  
Chapter 3 Operation  
Series 220/221 Instruction Manual  
Diagnostics Menu  
ENTER  
Run Mode  
Password  
ENTER  
Diagnositcs  
Menu  
Use  
keys to access menus  
Sim Vor Freq  
xxx  
Simulate Vortex  
Frequency (Hz)  
Highest Velocity  
xxx  
Highest Recorded  
Velocity (ft/sec)  
Use the Diagnostics Menu to simulate flow and review the highest recorded veloc-  
ity in ft/sec.  
The simulated vortex frequency is used for testing the meter to verify that the  
programming is correct. Enter any value for the sensor input in Hz. The meter  
will calculate a flow rate based on the corresponding value and update the analog  
output (the totalizer display and output is not affected by a simulated fre-  
quency). Note: when your diagnostic work is complete, make sure to return the  
simulated frequency to zero to allow the electronics to use the actual value.  
3-8  
IM-22-C  
Series 220/221 Instruction Manual  
Chapter 3 Operation  
Calibration Menu  
ENTER  
Run Mode  
Password  
ENTER  
Calibration  
Menu  
Use  
keys to access menus  
Meter Size  
or Pipe ID  
Series 220 - meter size  
Series 221 - pipe internal diameter (inches)  
Meter calibration constant  
Series 220 - pulses/ft3  
Series 221 - pulses/ft  
Meter Factor  
xxxx  
Process Temp(F)  
xxx  
Used to correct Meter Factor for thermal  
expansion of meter body for Series 220  
Density  
xxx  
Units are lb/ft3  
Units are lb/ft3. Used for calculation of  
standard cubic meters, standard cubic feet,  
and normal cubic meters.  
Ref Density  
xxx  
Viscosity  
xxx  
Units are centipoise (Cp)  
Adaptive filter setting  
Vortex Coef Ck  
xx  
Low Flow Cutoff  
xx  
Low signal threshold for vortex signal,  
dimensionless (A to D counts / gain)  
Serial Number  
xxxxxxxxx  
The Calibration Menu contains the calibration coefficients for the flow meter. These  
values should by changed only by properly trained personnel. The Vortex Coef Ck and  
Low Flow Cutoff are set at the factory. Consult the factory for help with these settings if  
the meter is showing erratic flow rate. The units of measurement used in the Calibration  
Menu are preset and are as follows: Density = lbm/ft3, Reference Density = lbm/ft3,  
Viscosity = centipoise.  
IM-22-C  
3-9  
Chapter 3 Operation  
Series 220/221 Instruction Manual  
Password Menu  
ENTER  
Run Mode  
Password  
ENTER  
Password  
Menu  
Use  
keys to access menus  
Set Password  
1234  
Use the Password Menu to set or change the system password.  
The factory-set password is 1234.  
3-10  
IM-22-C  
Series 220/221 Instruction Manual  
Chapter 4 Troubleshooting & Repair  
Chapter 4 Troubleshooting and Repair  
f
G
fi  
A
4-20, Zero  
xxxx  
Vper  
Vcyc  
4-20, FScale  
xxxx  
P
V
Re  
Vor Freq  
Direct?  
Tot  
wt  
Disable  
Recorct  
it  
Kc  
Kb  
It  
b
Gain Control  
Filter Control  
*
*
Not Present on  
220 models  
Pre-Filt  
Water?  
Total in  
EEprom  
Config Code  
Factory  
Defaults  
Test Pulse  
Out  
Hidden Diagnostics Menus  
The menus shown above can be accessed using the password 16363, then moving  
to the display that reads “Diagnostics Menu” and pressing ENTER (rather than  
one of the arrow keys).  
Warning!  
Before attempting any flow  
meter repair, verify that the  
line is not pressurized.  
Always remove main power  
before disassembling any  
part of the flow meter.  
Use the right arrow key to move to the second column. Press EXIT to move  
from the second column back to the first, press EXIT while in the first column to  
return to the setup menus.  
Caution: password 16363 will allow full access to the configuration and should  
be used carefully to avoid changes that can adversely alter the function of the me-  
ter.  
Each of the menus above will first be defined followed by specific troubleshoot-  
ing steps.  
IM-22-C  
4-1  
Chapter 4 Troubleshooting & Repair  
Series 220/221 Instruction Manual  
Column One Hidden Diagnostics Values  
f = vortex shedding frequency (Hz).  
fi = adaptive filter – should be approximately 25% higher than  
the vortex shedding frequency, this is a low-pass filter.  
G = gain (applied to vortex signal amplitude). Gain changes  
from 333.3 (at a weak signal) to 100.0, then 33.3, then 10.0,  
then 3.3, then 1.0 as the flow rate increases.  
A = A to D counts (vortex signal amplitude). This value  
ranges from about 200 to 4000. It also increases as the flow  
rate increases, but will shift when the gain steps to a different  
level.  
Vper = vortex period (for factory use only).  
Vcyc = vortex cycle (for factory use only).  
V = calculated average pipe velocity (ft/sec).  
Re = calculated Reynolds number.  
Tot = totalizer value in the same units as the display.  
wt = totalizer fraction, in lb. Counts up until the next round  
number is reached in terms of the displayed units, then the to-  
talizer increments, and the wt value starts again at zero.  
it = totalizer iteration. Counts the total, in lb, and rolls over to  
zero at 1000 lb.  
Kc = profile equation (factory use only). Series 221 only.  
It = profile equation (factory use only). Series 221 only.  
Kb = profile equation (factory use only). Series 221 only.  
b = profile equation (factory use only). Series 221 only.  
Column Two Hidden Diagnostics Values  
4-20, Zero = Analog counts to calibrate zero on analog output.  
4-20, FScale = Analog counts to calibrate full scale on analog out-  
put.  
Vor Freq Direct? = Frequency output setting, used by factory dur-  
ing calibration. Set to NO if totalizer is used.  
Disable ReCorct = Disable Reynolds number correction. Set to  
YES for series 220 in-line and set to NO for series 221 insertion.  
Gain Control = Manual gain control (factory use only). Leave set at  
255 to activate automatic gain control.  
Filter control = Manual filter control. This value can be changed to  
any number to force the fi value to a constant. A value of zero acti-  
vates the automatic filter control which sets fi at a level that floats  
above the f value.  
4-2  
IM-22-C  
Series 220/221 Instruction Manual  
Chapter 4 Troubleshooting & Repair  
Pre-Filt Water? = Pre-filter for liquid applications. YES for all liq-  
uid applications and NO for all gas or steam applications. Always  
set to NO for ½” and ¾” meters due to the high vortex shedding fre-  
quency.  
Total in EEprom = totalizer value in the same units as the dis-  
play.  
Config Code = Configuration Code (unused).  
Factory Defaults = Reset to factory defaults. If you change this to  
YES and press ENTER, all factory configuration is lost and you  
must reconfigure the entire program. Consult the factory before per-  
forming this process, it is required only in very rare cases.  
Test Pulse Out = Force totalizer pulse. Set to YES and press  
ENTER to send one pulse. Very useful to test totalizer counting  
equipment.  
Analog Output Calibration  
To check the 4–20 mA circuit, connect a DVM in series with the output  
loop. Select zero or full scale (from the second column of the hidden di-  
agnostics) and then actuate the enter key twice. This action will cause the  
meter to output its 4 mA or 20 mA condition. If the DVM indicates a  
current greater than ± 0.006 mA from 4 or 20, adjust the setting up or  
down until the output is calibrated. Note: these settings are not for adjust-  
ing the output zero and span to match a flow range, that function is lo-  
cated in the Output Menu.  
Troubleshooting the Flow Meter  
Symptom: Output at no Flow  
1. The low flow cutoff is set too low. At no flow, go to the first column  
of the hidden diagnostics menu and record the G and A values.  
Calculate the value of A/G. The low flow cutoff must be set above  
this value.  
Example: at no flow, G = 100 and A = 2500. A/G = 25. Set the low  
flow cutoff in the Calibration Menu to approximately 28 and the me-  
ter will no longer read a flow rate at no flow.  
Symptom: Erratic Output  
1. The flow rate may be too low, just at the cutoff of the meter range,  
and the flow cycles above and below the cutoff making an erratic  
output. The meter range is stamped on the label on the outside of the  
electronics enclosure cover (based on application conditions when  
the meter was ordered). Consult the factory if necessary to confirm  
the meter range based on current operating conditions. It may be  
possible to lower the low flow cutoff to increase the meter range.  
See the example above for output at no flow, only this time the low  
flow cutoff is set too high. You can lower this value to increase the  
meter range as long as you do not create the output at no flow condi-  
tion previously described.  
IM-22-C  
4-3  
Chapter 4 Troubleshooting & Repair  
Series 220/221 Instruction Manual  
2. Mechanical installation may be incorrect. Verify the straight run is  
adequate as described in Chapter 2. For in-line meters, make sure  
the meter is not installed backwards and there are no gaskets protrud-  
ing into the flow stream. For insertion meters, verify the insertion  
depth and flow direction.  
3. The meter may be reacting to actual changes in the flow stream. The  
output can be smoothed using a time constant. The displayed values  
can be smoothed using the time constant in the Display Menu. The  
analog outputs can be smoothed using the time constant in the Out-  
put Menu. A time constant of 1 will result in the change in value  
reaching 63% of its final value in one second. A time constant of 4  
is 22%, 10 is 9.5% and 50 is 1.9% of the final value in one second.  
The time constant equation is shown below (TC = Time Constant).  
% change to final value  
in one second  
= 100 (1 – e(-1/TC)  
)
4. The vortex coefficient Ck may be incorrectly set. The Ck is a value  
in the equation used to determine if a frequency represents a valid  
vortex signal given the fluid density and signal amplitude. In prac-  
tice, the Ck value controls the adaptive filter, fi, setting. During  
flow, view the f and fi values in the first column of the hidden diag-  
nostics. The fi value should be approximately 10-20 % higher than  
the f value. If you raise the Ck setting in the Calibration Menu, then  
the fi value will increase. The fi is a low pass filter, so by increasing  
it or lowering it, you can alter the range of frequencies that the meter  
will accept. If the vortex signal is strong, the fi value will increase to  
a large number – this is correct. Note: at high frequencies, the dis-  
play may not be able to display all the digits of the fi value (for ex-  
ample, 114 may be displayed and the actual value is 1140).  
Symptom: No Output  
1. For remote mounted electronics, carefully check all the wiring con-  
nections in the remote mount junction box. There are 6 connections  
that must be correct, verify each color (black and red), shield, and  
wire number.  
2. Check the density value in the Calibration Menu to see if it is correct  
for the current operating conditions.  
3. Using ESD precautions and hazardous area precautions, remove the  
electronics enclosure window cover. Disconnect the vortex sensor  
from the analog board (the analog board is the first board below the  
microprocessor (display) board. Measure the resistance from each  
outside pin to the meter ground - each should be open. Measure the  
resistance from the center pin to the meter ground – this should be  
grounded to the meter. With the sensor still disconnected, go the  
first column of the hidden diagnostics and display the vortex shed-  
ding frequency, f. Hold a finger on the three exposed pins on the  
4-4  
IM-22-C  
Series 220/221 Instruction Manual  
Chapter 4 Troubleshooting & Repair  
analog board. The meter should read electrical noise, 60 Hz for ex-  
ample. If all readings are correct, re-install vortex sensor wires.  
4. Verify all meter configuration and troubleshooting steps previously  
described. There are many possible causes of this problem, consult  
factory if necessary.  
Electronics Assembly Replacement (All Meters)  
The electronics boards are electrostatically sensitive. Wear a grounding  
wrist strap and make sure to observe proper handling precautions re-  
quired for static-sensitive components.  
1. Turn off power to the unit.  
2. Locate and loosen the small set screw which locks the larger enclo-  
sure cover in place. Unscrew the cover to expose the electronics  
stack.  
Warning!  
Before attempting any flow  
meter repair, verify that the  
line is not pressurized.  
Always remove main power  
before disassembling any  
part of the mass flow meter.  
3. Locate the sensor connector that comes up from the neck of the flow  
meter and attaches to the circuit board. Use small pliers to pull the  
connector off of the circuit board.  
4. Locate and loosen the small set screw which locks the smaller enclo-  
sure cover in place. Unscrew the cover to expose the field wiring  
strip. Tag and remove the field wires.  
5. Remove the screws that hold the black wiring label in place, remove  
the label.  
6. Locate the 4 Phillips head screws which are spaced at 90-degrees  
around the terminal board. These screws hold the electronics stack in  
the enclosure. Loosen these screws (Note: that these are captive  
screws, they will stay inside the enclosure).  
7. Carefully remove the electronics stack from the opposite side of the  
enclosure. If the electronics stack will not come out, gently tap the  
terminal strip with the screw driver handle. This will loosen the rub-  
ber sealing gasket on the other side of the enclosure wall. Be careful  
that the stack does not hang up on the loose sensor harnesses.  
8. Repeat steps 1 through 6 in reverse order to install the new electron-  
ics stack.  
IM-22-C  
4-5  
Chapter 4 Troubleshooting & Repair  
Series 220/221 Instruction Manual  
Returning Equipment to the Factory  
Before returning any Innova-Flo meter to the factory, you must re-  
quest a Return Material Authorization (RMA) number. To obtain an  
RMA number and the correct shipping address, contact Customer Ser-  
vice at:  
(800) 866-0200 or (831) 373-0200 in the USA,  
or +31(0)20-6145810 in Europe.  
When contacting Customer Service, be sure to have the meter serial  
number and model code.  
When requesting further troubleshooting guidance, record the following  
values first:  
f, fi, G, and A at no flow and during flow if possible.  
Pressure, temperature, and flow rate  
4-6  
IM-22-C  
Series 220/221 Instruction Manual  
Appendix A Specifications  
Appendix A Product Specifications  
Accuracy  
Process  
220 Series In-Line Meters  
221 Series Insertion Meters(1)  
Variables  
Liquids  
Gas & Steam  
Liquids  
Gas & Steam  
Volumetric  
Flow Rate  
±0.7% of rate  
over a  
±1% of rate  
over a  
±1.2% of  
rate over a  
30:1 range(2)  
±1.5% of rate  
over a  
30:1 range(2)  
30:1 range(2)  
30:1 range(2)  
Notes: (1) Accuracies stated are for the total volumetric flow through the  
pipe.  
(2) Nominal rangeability is stated. Precise rangeability depends on  
fluid  
and pipe size.  
Repeatability  
0.1% of rate.  
Response Time  
Material Compatibility  
Adjustable from 1 to 100 seconds.  
Series 220 In-Line Flow Meter:  
Any gas, liquid or steam compatible with 316L stainless steel, C276  
hastelloy or A105 carbon steel. Not recommended for multi-phase flu-  
ids.  
Series 221 Insertion Flow Meter:  
Any gas, liquid or steam compatible with 316L stainless steel. Not  
recommended for multi-phase fluids.  
Flow rates  
Typical volumetric flow ranges are given in the following tables. Precise  
flow range depends on the fluid and pipe size. 221 insertion meters are  
applicable to pipe sizes from 2 inch and above. Consult factory for siz-  
ing program.  
Air Minimum and Maximum Flow Rates (scfm) (1)  
Pressure  
0 psig  
½-inch  
¾-inch  
1-inch  
1.5-inch  
2-inch  
3-inch  
4-inch  
6-inch  
8-inch  
1.8  
3.3  
5
13  
22  
50  
88  
198  
347  
17.5  
41.4  
90  
221  
369  
826  
1438  
3258  
5708  
100 psig  
5
9.2  
15  
37  
62  
138  
240  
543  
952  
137  
324  
2879  
6447  
11222  
25421  
44536  
701  
1728  
200 psig  
300 psig  
400 psig  
500 psig  
6.8  
257  
12.6  
608  
20  
1313  
50  
3234  
83  
5389  
185  
12067  
322  
21006  
730  
47585  
1279  
67122  
8.3  
378  
15.3  
893  
24  
1924  
59  
4740  
98  
7900  
220  
17687  
382  
30789  
866  
48821  
1518  
64552  
9.5  
500  
17.5  
1178  
27  
2535  
66  
6246  
110  
10410  
247  
23308  
430  
31141  
975  
46884  
1708  
61990  
10.6  
620  
19.5  
1464  
29  
3147  
72  
7752  
120  
12920  
270  
22592  
469  
29834  
1063  
44915  
1862  
59387  
Note: (1) Standard conditions are 70° F and 1 atmosphere.  
Steam Minimum and Maximum Flow Rates (lb/hr)  
Pressure  
5 psig  
½-inch  
¾-inch  
1-inch  
1.5-inch  
2-inch  
3-inch  
4-inch  
6-inch  
8-inch  
6.5  
12  
20  
49  
82  
183  
319  
722  
1265  
51.7  
122  
265  
652  
1087  
2434  
4237  
9598  
16815  
100 psig  
200 psig  
300 psig  
400 psig  
500 psig  
14.8  
270  
27.4  
639  
46  
1385  
112  
3413  
187  
5688  
419  
12735  
729  
22168  
1651  
50219  
2893  
87980  
20  
493  
37  
1164  
61  
2524  
151  
6217  
252  
10362  
565  
23200  
984  
40385  
2229  
91485  
3905  
160275  
24  
716  
44.5  
1689  
74  
3662  
182  
9021  
304  
15035  
681  
33664  
1185  
58601  
2685  
132750  
4707  
232570  
27.7  
940  
51  
2220  
85  
4814  
209  
11859  
349  
19764  
781  
44253  
1359  
77033  
3078  
174505  
5393  
305721  
30.8  
57  
95  
233  
389  
870  
1515  
3433  
6014  
1170  
2761  
5986  
14745  
24575  
55025  
95784  
216983  
331080  
IM-22-C  
A-1  
Appendix A Specifications  
Series 220/221 Instruction Manual  
Water Minimum and Maximum Flow Rates  
½-inch  
¾-inch  
1-inch  
1.5-inch  
2-inch  
3-inch  
4-inch  
6-inch  
8-inch  
gpm  
1
22  
1.3  
40  
2.2  
67  
5.5  
166  
9.2  
276  
21  
618  
36  
1076  
81  
2437  
142  
4270  
m3/hr  
.23  
5
.3  
9.1  
0.5  
15  
1.3  
38  
2.1  
63  
4.7  
140  
8.1  
244  
18  
554  
32  
970  
Linear Range  
Smart electronics corrects for lower flow down to a Reynolds num-  
ber of 5,000. The Reynolds number is calculated using the fluid  
density and viscosity entered into the memory. Rangeability de-  
pends on the fluid, process conditions and pipe size. Consult factory  
for your application. Velocity rangeability under ideal conditions is as  
follows:  
Liquids 30:1  
Gases 30:1  
1 foot per second velocity minimum  
30 feet per second velocity maximum  
10 feet per second velocity minimum  
300 feet per second velocity maximum  
Process Fluid Pressure  
220 Pressure Ratings  
Material  
Process  
Rating  
Connection  
Flanged  
Wafer  
316L SS, A105 Carbon Steel, C276 Hastelloy  
316L SS, A105 Carbon Steel, C276 Hastelloy  
150, 300, 600 lb  
600 lb  
221 Pressure Ratings  
Probe Seal  
Process  
Connection  
Material  
Rating  
Ordering  
Code  
Compression  
Fitting  
2-inch MNPT  
316L SS  
316L SS  
316L SS  
316L SS  
316L SS  
316L SS  
316L SS  
ANSI 600 lb  
ANSI 150 lb  
ANSI 300 lb  
ANSI 600 lb  
50 psig  
CM  
CF  
CG  
CH  
PM  
PF  
2-inch 150 lb flange  
2-inch 300 lb flange  
2-inch 600 lb flange  
2-inch MNPT  
Packing Gland  
2-inch 150 lb flange  
2-inch 300 lb flange  
50 psig  
50 psig  
PG  
Packing Gland with  
Removable Retractor  
2-inch MNPT  
316L SS  
316L SS  
316L SS  
ANSI 300 lb  
ANSI 150 lb  
ANSI 300 lb  
PM, RR  
PF, RR  
PG, RR  
2-inch 150 lb flange  
2-inch 300 lb flange  
Packing Gland with  
Permanent Retractor  
2-inch MNPT  
316L SS  
316L SS  
316L SS  
316L SS  
ANSI 600 lb  
ANSI 150 lb  
ANSI 300 lb  
ANSI 600 lb  
PMR  
PFR  
PGR  
PHR  
2-inch 150 lb flange  
2-inch 300 lb flange  
2-inch 600 lb flange  
Process Fluid and  
Ambient Temperature  
Process Fluid:  
Standard temperature sensor: –40° to 400° F (–40° to 205° C).  
Medium temperature sensor: 250° to 500° F (120° to 260° C).  
High temperature sensor: 250° to 750° F (120° to 400° C).  
Ambient:  
Operating: –5° to 140° F (–20° to 60° C).  
Storage: –40° to 150° F (–40° to 65° C).  
0-98% relative humidity, non-condensing conditions.  
A-2  
IM-22-C  
Series 220/221 Instruction Manual  
Appendix A Specifications  
Power Requirements  
Output Signals  
Loop powered, 12 to 36 VDC.  
Analog: field rangeable linear, 4-20 mA output signal, 1000 ohms  
maximum loop resistance, selected by user for volumetric flow rate  
or mass flow rate.  
Pulse: field rangeable volume/pulse output for totalization is a 50-  
millisecond duration pulse operating a solid-state relay capable of  
switching 40 VDC, 40 mA maximum.  
Display  
Alphanumeric 2 x 16 LCD digital display.  
Six push buttons (up, down, right, left, enter, exit) operable either di-  
rectly on the display panel or with a hand-held magnet through the  
display glass of the explosion-proof enclosure.  
Viewing at 90° mounting intervals.  
Totalizer  
Based on user-determined flow units, six significant figures in scien-  
tific notation. Total stored in non-volatile memory.  
Wetted Materials  
Series 220 In-Line Flow Meter:  
316L stainless steel standard.  
C276 hastelloy or A105 carbon steel optional.  
Series 221 Insertion Flow Meter:  
316L stainless steel standard.  
Teflon® packing gland below 500° F (205° C).  
Graphite packing gland above 500° F (205° C).  
Enclosure  
NEMA 4X cast enclosure.  
Electrical Ports  
Mounting Connections  
Two 3/4-inch female NPT ports.  
Series 220: Wafer or 150, 300, 600 lb ANSI flange.  
Series 221 Permanent installation: 2-inch MNPT; 150, 300, 600 lb  
ANSI flange with compression fitting probe seal.  
Series 221 Hot Tap(1) Installation: 2-inch MNPT; 150, 300, 600 lb  
ANSI flange and optional retractor with packing gland probe seal.  
Note: (1) Removable under line pressure.  
Mounting Position(1)  
Certifications  
Series 220 In-Line Flow Meter: No effect.  
Series 221 Insertion Flow Meter: Meter must be perpendicular  
within ± 5° of the pipe centerline.  
Note: (1) For liquid applications, pipeline must remain full at all  
times.  
Construction Inspection ( ANSI/ASME B31.3).  
Materials (NACE MR-01-75[90]).  
CE and FM approved.  
CSA, CENELEC approval pending.  
FM approvals:  
Class I, Division 1, Groups B, C, & D, T6 at Tamb = 60°C  
Class II/III, Division 1, Groups E, F, & G  
IP66, NEMA 4X  
IM-22-C  
A-3  
Appendix A Specifications  
Series 220/221 Instruction Manual  
A-4  
IM-22-C  
Series 220/221 Instruction Manual  
Appendix B Glossary  
Appendix B Glossary  
A B C D  
A
Cross sectional area.  
acfm  
Actual cubic feet per minute (volumetric flow rate).  
American Society of Mechanical Engineers.  
ASME  
Bluff Body  
A non-streamlined body placed into a flow stream to  
create vortices. Also called a Shedder Bar.  
BTU  
British Thermal Unit, an energy measurement.  
European Electrical Code.  
Cenelec  
Compressibility  
Factor  
A factor used to correct for the non-ideal changes in  
a fluid’s density due to changes in temperature  
and/or pressure.  
CSA  
d
Canadian Standards Association.  
Width of a bluff body or shedder bar.  
Diameter of a flow channel.  
D
E F G H  
f
Frequency of vortices generated in a vortex flow  
meter, usually in Hz.  
Flow Channel  
Flow Profile  
A pipe, duct, stack, or channel containing flowing fluid.  
A map of the fluid velocity vector (usually non-  
uniform) in a cross-sectional plane of a flow channel  
(usually along a diameter).  
FM  
Ft  
Factory Mutual.  
Foot, 12 inches, a measure of length.  
Square feet, measure of area.  
Cubic feet, measure of volume.  
Gallons per minute.  
Ft^2  
Ft^3  
gpm  
Hz  
Hertz, cycles per second.  
IM-22-C  
B-1  
Appendix B Glossary  
Series 220/221 Instruction Manual  
I J K L  
In-Line Flow Meter  
A flow meter which includes a short section of piping  
which is put in-line with the user’s piping.  
Insertion Flow Meter  
A flow meter which is inserted into a hole in the  
user’s pipeline.  
Joule  
LCD  
A unit of energy equal to one watt for one second.  
Also equal to a Newton-meter.  
Liquid crystal display.  
M N O P  
m
Mass flow rate.  
mA  
Milli-amp, one thousandth of an ampere of current.  
µ
Viscosity, a measure of a fluid’s resistance to shear stress.  
Honey has high viscosity, alcohol has low viscosity.  
P  
P
Permanent pressure loss.  
Line pressure (psia or bar absolute).  
ρ act  
The density of a fluid at the actual temperature and  
pressure operating conditions.  
ρ std  
The density of a fluid at standard conditions (usually  
14.7 psia and 20° C).  
Permanent  
Unrecoverable drop in pressure.  
Pressure Loss  
Piezoelectric Crystal  
A material which generates an electrical charge  
when the material is put under stress.  
PRTD  
psia  
An resistance temperature detector (RTD) with plati-  
num as its element. Used because of high stability.  
Pounds per square inch absolute  
(equals psig + atmospheric pressure). Atmospheric  
pressure is typically 14.696 psi at sea level.  
psig  
PV  
Pounds per square inch gauge.  
Liquid vapor pressure at flowing conditions (psia or  
bar absolute).  
B-2  
IM-22-C  
Series 220/221 Instruction Manual  
Appendix B Glossary  
Q R S T  
Q
Flow rate, usually volumetric.  
Rangeability  
Highest measurable flow rate divided by the lowest  
measurable flow rate.  
Reynolds Number  
or Re  
A dimensionless number equal to the density of a fluid  
times the velocity of the fluid times the diameter of the  
fluid channel, divided by the fluid viscosity (i.e., Re =  
ρVD/µ). The Reynolds number is an important num-  
ber for vortex flow meters because it is used to deter-  
mine the minimum measurable flow rate. It is the ratio  
of the inertial forces to the viscous forces in a flowing  
fluid.  
RTD  
Resistance temperature detector, a sensor whose  
resistance increases as the temperature rises.  
scfm  
Standard cubic feet per minute (flow rate converted  
to standard conditions, usually 14.7 psia and 20° C).  
Shedder Bar  
A non-streamlined body placed into a flow stream to  
create vortices. Also called a Bluff Body.  
Strouhal Number  
or St  
A dimensionless number equal to the frequency  
of vortices created by a bluff body times the width of  
the bluff body divided by the velocity of the flowing  
fluid (i.e., St = fd/V). This is an important number for  
vortex flow meters because it relates the vortex fre-  
quency to the fluid velocity.  
Totalizer  
Traverse  
An electronic counter which records the total accu-  
mulated flow over a certain range of time.  
The act of moving a measuring point across the  
width of a flow channel.  
U V W X Y Z  
Uncertainty  
The closeness of agreement between the result of a  
measurement and the true value of the measurement.  
V
Velocity or voltage.  
Volts, alternating current.  
Volts, direct current.  
An eddy of fluid.  
VAC  
VDC  
VORTEX  
IM-22-C  
B-3  
Appendix B Glossary  
Series 220/221 Instruction Manual  
B-4  
IM-22-C  

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