Dwyer | Series IEF | Instruction manual | Dwyer Series IEF Instruction Manual

Dwyer Series IEF Instruction Manual
F-IEFS
Series IEFS
INSERTION MAGNETIC
FLOW METER instructions
IEFS-0XX
IEFS-1XX
Table of Contents
General Information­­­­
General Information, Features, Specifications.................................................................................................. Page 1
Installation
Piping, Distorted Flows, Immersion, Positioning the Meter............................................................................. Page 2
Fitting Installation, Meter Installation................................................................................................................ Page 3
Proper Depth Setting.......................................................................................................................................... Page 4
Dimension “C”, Pipe Wall Thickness.................................................................................................................. Page 5
Straight Pipe Recommendations....................................................................................................................... Page 6
Full Pipe Recommendations............................................................................................................................... Page 7
Electrical Connections
General Electrical Guidelines, Power, Forward (and Reverse) Flow Output,
Grounding Guidelines, Grounding Diagram...................................................................................................... Page 8
Connections Diagrams
Counter or PLC, Series BAT 4 to 20 mA Output................................................................................................................
Page 9
RTI Display and Proportional Feed, RTI & 4 to 20 mA Output, Dual RTI Displays.......................................... Page 10
Operation & Maintenance
Zero Adjustment, Minimum Flow, Presence of Flow Indication, Filtering,
Electrode Coating................................................................................................................................................Page 11
Calibration (“K-Factor”), Flow Rates in Gallons Per Minute............................................................................. Page 12
Troubleshooting
Problems, Probable Causes and Things to Try.................................................................................................. Page 13
GENERAL INFORMATION, FEATURES and SPECIFICATIONS
The complete lack of moving parts in the Series IEFS insertion flow
sensor is the source of its reliability. Brass and stainless steel models
withstand a variety of temperature, pressure, and chemical conditions.
The IEFS Series has no rotor to stop turning in dirty water and there
are no bearings to wear out.
A rapidly reversing magnetic field is produced in the lower housing.
As the fluid moves through this field, a voltage is generated that is
measured and translated into a frequency signal proportional to flow
rate. This square wave signal can be sent directly to a PLC or other
control, or can be converted using any of the Dwyer Instruments Inc.
family of indicators and converters.
A modular system of electronics can be attached directly to the flow
Reverse flow output and immersibility are optional.
Housing Screw (connect ground to one)
FEATURES
Cover or Electronics Module
Cable Strain Relief
Lower Housing
Brass or 316 Stainless Shaft
Compression Nut
Adapter Fitting
1 1/2” Male NPT threads
IEFS-0XX
IEFS-1XX
Sensor Housing
Valve assembly for
hot tap installation
Electrodes and Cap
SPECIFICATIONS*
3” to 48” (up to 60” when ordered with 12” extension option)
Pipe Sizes
Materials
TableS, DIAGRAMS & Charts
Shaft/Fitting
316 SS or Brass
Electrodes
Hastelloy®
Electrode Cap
PVDF
Housing
Features............................................................................................................................................................... Page 1
Distorted Flows, Positioning the Meter.............................................................................................................. Page 2
Meter Installation, Sensor Removal................................................................................................................... Page 3
Proper Depth Setting.......................................................................................................................................... Page 4
Dimension “C”, Pipe Wall Thickness.................................................................................................................. Page 5
Straight Pipe Recommendations....................................................................................................................... Page 6
Full Pipe Recommendations............................................................................................................................... Page 7
Grounding Diagram............................................................................................................................................. Page 8
Connection Diagrams: Counter or PLC, Series BAT 4 to 20 mA Output.......................................................... Page 9
Connection Diagrams: Series RTI Display and Proportional Feed, RTI & 4-20 mA Output,
Dual Series RTI Displays..................................................................................................................................... Page 10
Zero Adjustment, Flow Rates in Gallons Per Minute......................................................................................... Page 11
IEFS K-factors (in Pulses/Gallon) for various pipe sizes.................................................................................. Page 12
Troubleshooting Problems, Probable Causes and Things to Try...................................................................... Page 13
sensor or remotely mounted. The Dwyer Instruments Inc. Series RTI
provides full indication of rate and total, plus 4 to 20 mA output and
the Series BAT provides blind 4 to 20 mA output.
The adapter fitting of the sensor is standard male NPT, and can be
directly threaded into ordinary saddles or threaded weld fittings. The
IEFS-1 includes an isolation valve, allowing hot-tap installation, or
installation and removal under pressure; a bronze ball valve is standard,
with a 316 stainless steel valve option if needed.
Power
Valve Assembly
(IEFS-1 Only)
Bronze (stainless optional) with bronze ball valve
O-Ring
(IEFS-1 Only)
EPDM
Full Power
12 to 25 VDC, 250 mA
Low Power
12 to 25 VDC, 40 mA average with 250 mA peaks
0.28 to 20 ft/sec (0.08 - 6.09 m/sec)
Flow Range
IEFS-0XX
1-1/2” Male NPT
Fitting Size
Temperature
Cast powder-coated aluminum
Ambient
0 to 160˚F (-17 to 72˚C)
Fluid
32 to 200˚F (0 to 93˚C)
IEFS-1XX
2” Male NPT
Pressure
200 psi (13.8 bar)
Minimum Conductivity
20 microSiemens/cm
Calibration Accuracy
+/- 1% of full-scale
Output
Square wave pulse, opto isolated, 550 Hz @ 20 ft/sec
6 mA max, 30 Vdc forward flow standard; reverse flow optional
Empty Pipe Detection
Software, defaults to zero flow
*Specifications subject to change
Hastelloy® is a trademark of Hanes International, Inc.
Page 1
INSTALLATION
INSTALLATION
Piping. For best results, the IEFS sensor should be
installed with at least ten diameters of straight pipe
upstream and five downstream. Certain extreme situations
such as partially-opened valves are particularly difficult and
may require more straight diameters upstream (see page 6
for straight pipe recommendations).
IEFS-0XX INSTALLATION
POSITIONING THE METER
Fitting Installation. IEFS-0XX sensors come with a 1-1/2” male NPT pipe
thread adapter fitting. Any fitting that provides the matching NPT female
thread may be used. Installation procedure compensates for fitting height
differences. Cut a minimum 1-3/4” hole in the pipe. If possible, measure
the wall thickness and write it down for use in depth setting. Then install
the threaded fitting (saddle, weldolet, etc.) on the pipe.
Fair
(Unacceptable position
if air is present)
DISTORTED FLOWS
Distorted
Flow Profile
Faster Flow
Causes Meter
To Read High
Best
Position
FLOW
10X
5X
Fair
(Unacceptable position if fluid
contains sediment)
Meter Installation. Loosen the compression nut so that the adapter slides
freely. Pull the meter fully upward and finger-tighten the compression
nut. Using a thread sealant, install the adapter in the pipe fitting. Do
not overtighten. Loosen the compression nut, and lower the meter to
the appropriate depth setting (see diagram and instructions that follow).
Be sure flow is in the direction of the arrow on the housing. Tighten
compression nut fully.
Chemical Injection or Fertigation. When any magmeter, by
any manufacturer, is used in a chemical injection application (including fertigation), the chemical line must be placed
downstream of the magmeter OR far enough upstream for
complete mixing to occur before the fluid reaches the meter.
When unmixed chemical or fertilizer alternates with water
passing through the meter, the rapid changes in conductivity
may cause sudden spikes and drops in the meter’s reading,
resulting in inaccurate measurement. The magmeter will
restabilize, however, with a steady flow of fluid of uniform
conductivity.
Caution: In chemical injection or fertigation applications, install chemical line
downstream of magmeter, or far enough
upstream to allow complete mixing of
fluids before the meter.
Page 2
Vertical flow in upward direction is the preferred installation
orientation, since it improves low-flow performance and avoids
problems with trapped air and sediment. Bottom, top, and
vertical pipe installations are all acceptable if required by
the piping layout.
Caution: These flow sensors are not recommended for installation downstream
of a boiler feedwater pump where installation fault may expose the flow sensor
to boiler pressure and temperature. Maximum
recommended temperature is 200°F.
Adapter fitting
with
standard NPT
threads
IEFS-1 INSTALLATION
‘Hot-tap’ IEFS-1XX meters are designed so they can be installed and
serviced without depressurizing the pipe.
Immersion. The IEFS Series sensors are not designed for
underwater operation. Even occasional immersion can
cause damage. If occasional immersion is possible, such
as when a vault floods, then the -IMM option, (immersion)
is recomended.
Compression nut
Fitting Installation. The IEFS-1XX sensors have a 2” NPT thread for
compatibility with the 2” isolation valve. Any fitting that provides matching
NPT female thread may be used. The installation procedure compensates
for differences in fitting height.
If initial installation is performed on an unpressurized pipe, cut a
minimum 1-3/4” hole in the pipe. If possible, measure the wall thickness
and write it down for use in depth setting. Then install the threaded fitting
(saddle, weldolet, etc.) on the pipe.
If it is necessary to do the initial installation under pressure, any standard
hot tap drilling machine with 2” NPT adapter, such as a Transmate or a
Mueller, can be used. Ordinarily, it is not necessary to use an installation
tool, due to the small diameter tube the meter can be installed by hand
in exception for applications with higher pipe pressures.
Meter Installation. Remove the sensor unit from the valve assembly.
Using a thread sealant, install the valve assembly on the pipe fitting. If
the initial installation is a pressure (“hot-tap”), remove the 1-1/2” x 2”
adapter bushing at the back of the valve. Thread the tapping machine
on, open the valve, and tap using a minimum of 1-3/4” or maximum
1-7/8” cutter. After retracting the machine and closing the valve, reinstall
the flow sensor. When the sensor is secure, open the valve and adjust
depth setting (see diagram and instructions that follow). Be sure flow is
in the direction of the arrow on the housing. Tighten locking collar and
compression nut fully.
Compression nut
Locking collar
2” adapter removes
to mount hot-tap
machine
Full-port 2” ball
valve allows sensor
removal
Standard 2”
NPT threads
IEFS-1XX Sensor
Removal
Page 3
INSTALLATION
INSTALLATION
PROPER DEPTH SETTING
Depth Setting. It is important for accuracy that the sensor
be inserted to the correct depth into the pipe.
1. In Table 1, find Dimension C for your sensor model
and pipe size. Subtract wall thickness of your pipe
(Table 2) to find Dimension D.
2. Measuring from the outside of the pipe to the joint in
the housing, as shown in the diagram, adjust the
sensor to Dimension D and hand-tighten compression
nut.
3. Align the conduit housing with the centerline of the
pipe, as shown. Be sure the arrow on the housing
points in the direction of flow.
Table 1: Dimension “C”
Nominal Pipe Size
3”
4”
6”
8”
10”
12”
14”
16”
18”
20”
24”
30”
36”
IEFS-0SX
10.04
9.93
9.69
9.46
9.22
8.99
8.75
8.52
8.28
8.05
7.58
6.87
6.17
IEFS-0LX
15.04
14.93
14.69
14.46
14.22
13.99 13.75
13.52 13.28 13.05
12.58
11.87
11.17
IEFS-1SX
17.04
16.93
16.69
16.46
16.22
15.99 15.75
15.52
15.28 15.05
14.58
13.87
13.17
IEFS-1LX
21.04
20.93
20.69
20.46
20.22
19.99 19.75
19.52
19.28 19.05
18.58
17.87
17.17
Table 2: Pipe Wall Thickness
NOMINAL Pipe Size
3”
Caution! Never attempt to remove a flow
sensor when there is pressure in the pipe
unless it is specifically designed for hot
tap installation and removal. Loosen the
compression nut slowly to release any trapped pressure. If fluid sprays out when removing the sensor,
stop turning and depressurize the pipe. Failure to
do so could result in the sensor being thrown from
the pipe, resulting in damage or serious injury.
strain
relief
4. Check Dimension D one more time.
5. Tighten the compression nut fully.
Page 4
FLOW
4”
6”
8”
10”
12”
14”
16”
18”
20”
24”
30”
36”
PVC/Steel
Sch. 40
0.216
0.237 0.280
0.322
0.365
0.406 0.438
0.500
0.562
0.593
0.687
PVC/Steel
Sch. 80
0.300
0.337 0.432
0.500
0.593
0.687 0.750
0.843
0.937
1.031
1.218
Stainless
Steel (10S)
0.120
0.120 0.134
0.148
0.165
0.180
0.188
0.188
0.188
0.218
0.250 0.312
0.312
Stainless
Steel (40S)
0.216
0.237 0.280
0.322
0.365
0.375
0.375
0.375
0.375
0.375
0.375
0.375
Copper Tubing
(Type L)
0.090
0.110
0.140
0.200
0.250
0.280
Copper Tubing
(Type K)
0.109
0.134
0.192
0.271
0.338
0.405
Brass Pipe
0.219
0.250 0.250
0.312
0.365
0.375
Duct. Iron
(Class 52)
0.280
0.290
0.330
0.350
0.370 0.390
0.400
0.410
0.420
0.440 0.470 0.530
0.310
0.375
Page 5
INSTALLATION
INSTALLATION
STRAIGHT PIPE RECOMMENDATIONS
FULL PIPE RECOMMENDATIONS
(X = diameter)
10X
5X
Possible Problem
Better Installation
Reduced Pipe
IEFS
Ensures full pipe
10X
Two Elbows In Plane
5X
Allows air pockets to form at sensor
IEFS
Possible Problem
Two Elbows, Out Of Plane
20X
Better Installation
5X
IEFS
Post-valve cavitation can create air pocket
20X
Keeps pipe full at sensor
5X
Possible Problem
Expanded Pipe
Better Installation
IEFS
30X
Spiral Flow
IEFS
Propeller Meter
Swirling Flow
Page 6
Allows air to bleed off
Caution: These flow sensors are not recommended for installation downstream of a boiler feedwater pump where installation fault may expose the
flow sensor to boiler pressure and temperature. Maximum recommended
temperature is 200°F.
50X
Partially Open
Butterfly Valve
Air can be trapped
IEFS
Page 7
CONNECTIONS DIAGRAMS
ELECTRICAL CONNECTIONS
General Electrical Guidelines:
•
•
Whenever possible, avoid running control cables in
the same conduit with or bundled with AC power.
Using shielded cable, be sure to connect shield to
ground at power supply end of the cable. Do not
connect other end of shield.
•
Avoid routing flow sensor cables in close proximity to
a variable frequency drive.
•
Recommended power and output wiring is shielded
twisted pair 18 to 22 AWG control cable.
•
Recommended voltage is 12 to 24 VDC. Note that
unregulated power supplies can vary from nameplate
voltage by a considerable amount, especially with AC
line voltage fluctuation. Therefore 24V power supplies
must be regulated.
See the Connections diagrams on the following pages for the
appropriate terminals.
Power: A 12 to 24 Vdc power supply capable of at least 250
mA current output is needed.
Output: The standard output is pulses with flow in the forward
direction (Reverse flow output is optional (-RFO ). Electrically
it is an open collector opto isolated switch. The output is not
internally powered.
Counter or PLC
Grounding Guidelines:
For best results, use a good quality earth ground, such as
metallic water piping or a driven ground, to ensure a good
connection to earth ground and good noise suppression.
For Metallic Pipe: For optimum connection, clamp wire to the
piping a short distance to one side of the flow sensor using an
electrical grounding clamp. Connect the wire to the earth ground
and to one of the housing screws, as shown in “Grounding
Diagram” below.
For Non-Metallic Pipe: Connect a wire from the housing screws
to a good earth ground, such as metalic water piping or a rod
driven into the ground.
• Clamp a ferrite bead (Steward 28A2029-OAO or
equivalent) on meter signal/power wire within 3/4”
of the meter strain relief (tape or tie wrap in place if
necessary). See diagram below.
• IMPORTANT - Connect the cable shield ground
wire to ground, ONLY at power supply end of cable.
Counter or PLC Digital
Input
Max. 6 mA, 30 VDC
Forward Output
(open collector)
Max. 6 mA 30 VDC
Reverse Output
( -RFO only)
Series IEFS
*See Dual RTI Diagram for an
example of bidirectional connections.
BAT 4 to 20 mA Output
Series IEFS & EFS2 meters are usually unaffected by moderate
levels of electrical noise. In some applications performance
may be improved by taking the following steps:
• Use shielded twisted pair cable (Belden 8723 or
equivalent above ground or Alpha 35482 or
equivalent burial).
12 to 24 VDC
Power
24 VDC Power
Series IEFS
Frequency
24 VDC Power
Sensor
Power
Forward Output
Reverse Output +
(-RFO only) –
4 to 20 mA
4 to 20 mA
Series BAT
*See Dual RTI Diagram for an
example of bidirectional connections.
Note: This output is limited to 6 mA at 30 Vdc maximum.
GROUNDING DIAGRAM
PLACE FERRITE BEAD HERE
Earth
Ground
Housing Screw
Metallic Pipe
Grounding Clamp
Page 8
Page 9
CONNECTIONS DIAGRAMS
OPERATION & MAINTENANCE
SERIES RTI Display and Proportional Feed
Zero Adjustment. When the Series IEFS meter is powered up
and there is no flow, there should be no output pulses (or, if
connected to the RTI, flow rate should read “0”). If there are
pulses, it may be necessary to adjust the flow meter under noflow conditions after it has been installed. This should only be
done if the indicated flow is low, near the lower cutoff.
SERIeS RTI
24 VDC Power
Sensor
Input
Power
Pulse
Scaled
To
Proportional
Feed
Metering
Pump
Forward Output
Reverse Output
(-RFO only)
Zero
Adjust
Pins
Pulse
Pass-Thru
Series IEFS
Power
4 to 20mA
*See Dual RTI Diagram for an
example of bidirectional connections.
series RTI Display and 4 to 20 mA Output
Pulse
Scaled
Sensor
Input
Forward Output
24 VDCPower
Reverse Output
(-RFO only)
Pulse
Pass-Thru
Series IEFS
*See Dual RTI Diagram for an
example of bidirectional connections.
Power
4 to 20mA
To perform the adjustment, after determining that there is a
full pipe with no flow, short between the two pins marked “Zero
Adjust”. A red LED light will come on for approximately 50
seconds and then go out. The zero adjustment is completed.
Electrode Coating. Grease or other adhering, non-conductive
materials can stop flow detection if the electrodes become
heavily coated. To clean the electrodes, remove the sensor
from the pipe and gently scrub the electrodes (three silver
bumps) on the reading face of the flow sensor. A mild soap
(dishwashing liquid for example) can be used to aid the
cleaning process.
flow rates (in gallons per minute)
Feet Per
Second
4 to 20 mA Device
(e.g. pump, PLC)
Presence of Flow Indication. To assist in troubleshooting, the
“Status LED” has two blinking modes in normal operation.
When there is no flow detectable by the meter (below
minimum threshold), the LED blinks every 8.0 seconds. When
there is detectable flow, the same indicator blinks every 3.0
seconds (Pulses are being output when indicator is blinking
every 3 seconds).
Filtering. The software of the IEFS Series filters out electrical
noise and averages sudden variations in the flow to smooth
the output. It takes a matter of seconds for the flow sensor to
get up to full output when it is powered up or when flow begins.
Series RTI
24 VDC
Power
Power
Status
LED
Minimum Flow. As with any other flow sensor, there is a
rate below which the IEFS Series sensor cannot read. Check
the table below for the minimum flow rate detectable by the
sensor for a given pipe size.
Nominal Pipe Size
3”
4”
6”
8”
10”
12”
14”
16”
18”
20”
24”
30”
36”
48”
274
395
617
888
1580
Min 0.28
6
11
25
44
69
99
134
175
222
Max 20.0
440
783
1,762
3,133
4,895
7,050
9,596
12,533
15,863
19,584 28,200 44,064 63,452
112,804
DUAL series RTI DisplayS
(Example of Bidirectional Connection)
series RTI
Power
Power 4 to 20mA
24 VC
Power
SERIES RTI
Sensor
Input
Pulse
Scaled
Pulse
Pass-Thru
Forward Output
Pulse
Scaled
Page 10
Sensor
Input
Reverse Output
(-RFO only)
IEFS Series
Pulse
Pass-Thru
Power 4 to 20mA
Page 11
TROUBLESHOOTING
OPERATION & MAINTENANCE
Calibration (“K-Factor”). In order to properly process pulses
from the flow sensor, a number must be entered into the
control to which the sensor is connected. This number, called
the K-factor, is the number of pulses the sensor puts out per
unit of fluid passing through the pipe. It is normally provided
for Dwyer Instruments Inc. sensors in pulses per gallon, and
is given on the chart “K-factors for Various Pipe Sizes” below.
These numbers are based on extensive testing, which has
shown close agreement between different IEFS sensors in
the same installation. Typically, most K-factor errors can be
attributed to installation variables, such as depth setting and
fitting configuration.
Problem
Probable Cause
Try...
No pulse output
Unit not grounded
Connect to earth ground
Below minimum flow cutoff
Check the Presence of Flow LED (see p. 12)
Flow reversed
Note flow direction arrow,
reverse direction to meter
Output connections reversed
Change output connections
Pipe not full
Check plumbing
Excessive electrical noise
Check for proper electrical wiring
No power
Check for power across power input terminals
Power reversed
Reverse connections
IEFS K-factors (in Pulses/Gallon) for various pipe sizes
Nominal Pipe Size
3”
4”
6”
8”
10”
12”
14”
16”
18”
20”
24”
70.397
40.985
18.130
10.497
6.674
4.709
3.900
2.989
2.364
1.904
1.319
78.748
45.360
20.084
11.495
7.322
5.184
4.297
3.281
2.588
2.094
1.451
62.385
36.626
16.510
9.642
6.173
4.373
3.620
2.756
2.169
1.762
1.223
0.784
0.576
70.397
40.985
18.130
10.497
6.674
4.661
3.827
2.893
2.263
1.819
1.249
0.791
0.580
76.371
43.552
19.513
11.201
7.230
5.016
78.371
44.638
20.223
11.622
7.500
5.239
Fluid conductivity <20 microSiemens/cm Select another flow meter
Brass Pipe
70.672
41.517
17.778
10.445
6.674
4.661
Empty pipe
Duct Iron
(Class 52)
57.376
37.320
16.915
9.503
6.197
4.325
PVC/Steel
Sch. 40
PVC/Steel
Sch. 40
Stainless Steel
(10S)
Stainless Steel
(40S)
Copper Tubing
(Type K)
Copper Tubing
(Type L)
3.189
2.443
1.931
1.565
1.088
30”
36”
Fluid conductivity <20 microSiemens/cm Select another flow meter
0.747
Output pulses incorrect
0.520
Missing or incorrect ground wire
Check for proper ground
Incorrect depth setting
Check depth setting from
Dimension “C” table (page 4)
Not enough straight pipe
Excessive electrical noise
Jumpy reading
Page 12
Check for full pipe or install meter in the vertical
position
Check for air pockets or turbulence. Refer to
installation, page 6
Check for proper electrical wiring
Rapidly changing conductivity (in chemi- Install chemical injection line downstream of
magmeter (or far enough upstream to allow
cal injection or fertigation applications)
complete mixing of fluids before meter)
Page 13
WARRANTY/RETURN
Refer to "Terms and Conditions of Sale" in
our catalog or on our website. Contact customer
service to receive a Returns Goods Authorization number before shipping your product back
for repair. Be sure to include a brief description
of the problem plus any relevant applciation
notes.
D w ye r I nstru m e nts, I n c. • 1 0 2 I n d i a n a H ighway 212 • M i c higan Ci t y, IN 46360 • U SA
( P ) 219 . 8 7 9 . 8 8 6 8 • ( F ) 2 1 9 . 8 7 2 . 9 0 5 7 • 1.800.872.9141 • www.dw yer- inst.c o m
PL-OM-65200387-090412
9/04/12
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