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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. 

Series 220 In-Line Vortex Flow Meter................................... 1-3 

1-2. 

Measurement Principle of Vortex Flow Meters...................... 1-4 

1-3. 

Reynolds Number Range for the Innova-Flo.......................... 1-6 

2-1. 

Recommended Pipe Length Requirements............................. 2-2 

2-2. 

Flange Bolt Torquing Sequence ............................................. 2-3 

2-3. Wafer-Style 

Flow 

Meter Installation ...................................... 2-4 

2-4. Flange-Style 

Flow 

Meter Installation ..................................... 2-5 

2-5. 

Hot Tap Sequence................................................................... 2-8 

2-6. 

Insertion Calculation (Compression Type)........................... 2-10 

2-7. 

Flow Meter with Compression Type Fitting......................... 2-11 

2-8. 

Insertion Calculation (Meters with Insertion Tool) .............. 2-12 

2-9. 

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

 

Summary of Contents for Innova-Flo 220 Series

Page 1: ...anuary 2006 CORPORATE HEADQUARTERS 5 Harris Court Building L Monterey CA 93940 Phone 831 373 0200 800 866 0200 Fax 831 373 4402 www sierrainstruments com 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...

Page 2: ...translated into any human or computer language in any form or by any means electronic mechanical manual or otherwise or disclosed to third parties without the express written permission of Sierra Instruments The information contained in this manual is subject to change without notice TRADEMARKS Innova Flo is a trademark of Sierra Instruments Inc Other product and company names listed in this manua...

Page 3: ...ow 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 ...

Page 4: ...gth Requirements 2 2 2 2 Flange Bolt Torquing Sequence 2 3 2 3 Wafer Style Flow Meter Installation 2 4 2 4 Flange Style Flow Meter Installation 2 5 2 5 Hot Tap Sequence 2 8 2 6 Insertion Calculation Compression Type 2 10 2 7 Flow Meter with Compression Type Fitting 2 11 2 8 Insertion Calculation Meters with Insertion Tool 2 12 2 9 Flow Meter with Permanent Insertion Tool 2 13 2 10 Flow Meter with ...

Page 5: ...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...

Page 6: ...Table of Contents Series 220 221 Instruction Manual 0 6 IM 22 C ...

Page 7: ... 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 Inno...

Page 8: ...king 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 ...

Page 9: ...uency 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 b...

Page 10: ...x remains con stant as shown below By sensing the number of vortices passing by the velocity sensor the Innova Flo Vortex Flow Meter computes the total fluid volume Vortex shedder bar Flow Vortices Velocity sensor 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 frequ...

Page 11: ...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 ρ V D 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 Re µ Where Re Reynolds Number ρ mass density o...

Page 12: ...omati 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 0 3 0 2 0 1 0 0 3 4 10 Linear range Reynolds Number Re S...

Page 13: ...ss 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 Re...

Page 14: ...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...

Page 15: ...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 ent...

Page 16: ...mple 2 Two 90 elbows before meter in one plane C Flow meter A B C Flow conditioner if used Example 3 Two 90 elbows before meter out of plane if three 90 bends present double recommended length Flow meter A B Example 4 Reduction before meter C C Flow conditioner if used Flow meter A B C C Flow conditioner if used Example 5 Expansion before meter Example 6 Regulator or valve partially closed before ...

Page 17: ...s 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 Siz...

Page 18: ...oned 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 inst...

Page 19: ...e installing the flow meter 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 1 Turn o...

Page 20: ...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 of 1 875 inches is required and the valve s body size should be two inches Normally gate valves are used 2 Verify that the valve s body and flange rating are within the fl...

Page 21: ...urrs 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 Warning All flow meter connec tions isolation valves and fittings for cold tapping must have the same o...

Page 22: ...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 valv...

Page 23: ...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 Warning An insertion t...

Page 24: ...om 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 ...

Page 25: ...e 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 serio...

Page 26: ... 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 12 inches R 5 inches t 0 438 inches The example insertion length is 16 09 inches Example 2 N...

Page 27: ...ter 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 redu...

Page 28: ...em 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...

Page 29: ...d 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...

Page 30: ...y to expose the packing gland nuts Loosen the two packing gland nuts 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 ...

Page 31: ... 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 t...

Page 32: ...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 ...

Page 33: ...a 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 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 loo...

Page 34: ...sistance 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 ta...

Page 35: ...e 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 m...

Page 36: ...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 posi...

Page 37: ...tons 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 ...

Page 38: ...st 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 Setup Menus Password ENTER Volume Flow...

Page 39: ...tup Menus Display Total Viscosity Vortek Coef Ck Low Flow Cutoff 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 des...

Page 40: ...ears 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 Vol...

Page 41: ...o smooth display 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 outp...

Page 42: ...etting 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 t...

Page 43: ...dard cubic meters scf standard cubic feet nm 3 normal cubic meters bbl barrels 42 US gallon Mass Flow Unit lb ton gram kg mton sm 3 scf nm 3 Volume Flow Unit gal bbl cm 3 lit m 3 ft 3 sec min hr day sec min hr day 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 ...

Page 44: ...st 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 ...

Page 45: ...Meter Factor for thermal expansion of meter body for Series 220 Density xxx Units are lb ft3 Ref Density xxx Units are lb ft3 Used for calculation of standard cubic meters standard cubic feet and normal cubic meters Viscosity xxx Units are centipoise Cp The Calibration Menu contains the calibration coefficients for the flow meter These values should by changed only by properly trained personnel Th...

Page 46: ...0 221 Instruction Manual 3 10 IM 22 C Password Menu Password ENTER Use keys to access menus Password Menu Set Password 1234 ENTER Run Mode Use the Password Menu to set or change the system password The factory set password is 1234 ...

Page 47: ...ain power before disassembling any part of the flow meter 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 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 setu...

Page 48: ...nits 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 Value...

Page 49: ...own 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 c...

Page 50: ...stics 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 frequenci...

Page 51: ...stack 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 l...

Page 52: ...A 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 temp...

Page 53: ...ximum Flow Rates scfm 1 Pressure inch inch 1 inch 1 5 inch 2 inch 3 inch 4 inch 6 inch 8 inch 0 psig 1 8 17 5 3 3 41 4 5 90 13 221 22 369 50 826 88 1438 198 3258 347 5708 100 psig 5 137 9 2 324 15 701 37 1728 62 2879 138 6447 240 11222 543 25421 952 44536 200 psig 6 8 257 12 6 608 20 1313 50 3234 83 5389 185 12067 322 21006 730 47585 1279 67122 300 psig 8 3 378 15 3 893 24 1924 59 4740 98 7900 220...

Page 54: ...fer 316L SS A105 Carbon Steel C276 Hastelloy 600 lb 221 Pressure Ratings Probe Seal Process Connection Material Rating Ordering Code Compression Fitting 2 inch MNPT 316L SS ANSI 600 lb CM 2 inch 150 lb flange 316L SS ANSI 150 lb CF 2 inch 300 lb flange 316L SS ANSI 300 lb CG 2 inch 600 lb flange 316L SS ANSI 600 lb CH Packing Gland 2 inch MNPT 316L SS 50 psig PM 2 inch 150 lb flange 316L SS 50 psi...

Page 55: ... 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 Two 3 4 inch female NPT ports Mounting Connections Series 220 Wafer or 150 300 600 lb ANSI flange Series 221 Permanent installation 2 inch MNPT 150 300 6...

Page 56: ...Appendix A Specifications Series 220 221 Instruction Manual A 4 IM 22 C ...

Page 57: ...hanges in Factor a fluid s density due to changes in temperature and or pressure CSA Canadian Standards Association d Width of a bluff body or shedder bar D Diameter of a flow channel E F G H f Frequency of vortices generated in a vortex flow meter usually in Hz Flow Channel A pipe duct stack or channel containing flowing fluid Flow Profile A map of the fluid velocity vector usually non uniform in...

Page 58: ... low viscosity P Permanent pressure loss P 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 unde...

Page 59: ...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 A dimensionless number equal to the frequency or St 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 nu...

Page 60: ...Appendix B Glossary Series 220 221 Instruction Manual B 4 IM 22 C ...

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