Intek Rheotherm 100CS Manuale utente

WARRANTY

Intek, Inc. warrants each Rheotherm product to be free from defects

in material and workmanship under normal use and service, Intek's

obligation under this warranty being limited to making good any part

or parts thereof which shall, within one (1) year after delivery of such

product to the original purchaser, be returned to Intek with

transportation charges prepaid and which Intek's examination shall

disclose to its satisfaction to have been thus defective; this warranty

being expressly in lieu of all other warranties, express or implied and

all other obligation or liabilities on Intek's part. The purchaser will

assume all responsibility and expense for removal, decontamination

and reinstallation of equipment.

Rheotherm flow meters are manufactured under United States patent numbers 4,255,968; 4,942,763; 4,949,578; 5,485,754, and 5,752,411

Intek, Rheotherm, RheoVac, Rheovec and Rheomax are registered trademarks of Intek, Inc.

Intek, Inc.

751 Intek Way

Westerville, Ohio 43082-9057

TEL: (614) 895-0301 FAX: (614) 895-0319

www.intekflow.com

Intek, Inc. 2010

Manual no. A100CS9606 REV B

I:\OFFICE\WPMANUAL\Rheotherm\Model 100CS\MOD100CS.RVB

TABLE OF CONTENTS

SECTION 1 !GENERAL INFORMATION ........................................ -1-

1.1 INTRODUCTION .................................................... -1-

1.2 DESCRIPTION OF OPERATION ....................................... -2-

1.3 PRECAUTIONS ..................................................... -2-

SECTION 2 !INSTALLATION ................................................. -4-

2.1 TRANSDUCER ...................................................... -4-

2.2 ELECTRICAL CONNECTIONS ........................................ -5-

SECTION 3 !OPERATION ..................................................... -6-

3.1 START UP .......................................................... -6-

3.2 GENERAL INFORMATION ........................................... -6-

3.3 ADJUSTING THE TRIP POINT ........................................ -6-

3.4 USE AS A LEVEL SWITCH (INSERTION PROBES ONLY) ................. -7-

SECTION 4 !MAINTENANCE ................................................. -8-

4.1 GENERAL MAINTENANCE ........................................... -8-

4.2 SPARE PARTS ...................................................... -8-

4.3 TROUBLE SHOOTING ............................................... -9-

TABLE I. TROUBLE SHOOTING GUIDE .................................... -9-

SECTION 5 !CUSTOMER SERVICE .......................................... -10-

5.1 QUESTION ON EXISTING HARDWARE ............................... -10-

5.2 TROUBLE SHOOTING .............................................. -10-

5.3 FACTORY AND FIELD SERVICE ..................................... -10-

5.4 DECONTAMINATION OF EQUIPMENT ............................... -10-

5.5 QUESTIONS ON NEW EQUIPMENT .................................. -10-

SECTION 6 !CUSTOM INFORMATION ....................................... -11-

6.1 UNIT IDENTIFICATION ............................................. -11-

6.2 CONFIGURATION .................................................. -11-

6.3 SPECIAL INSTRUCTIONS ........................................... -11-

Figure 1. Model 100CS Interconnect Diagram ...................................... -12-

Figure 2. Model 100CS PWB Layout Diagram ..................................... -12-

- 1 -

SECTION 1 !GENERAL INFORMATION

1.1 INTRODUCTION

Rheotherm flow switches offer reliable flow switch protection in liquids, gases and slurries. They can

be used for flow/no flow detection, or specific low and/or high level alarms over a given 10 to 1 flow.

They are manufactured exclusively by Intek, Inc. and employ a patented thermal technique used by

industry since 1978. The unique transducer designs have protected sensors, are easy to install and

require little or no maintenance.

Each model 100CS flow switch consists of an explosion-proof electronics enclosure mounted on a

sensor head. The enclosure houses the round P/C board on which the relay and electrical interface

connector are mounted. Intek also has other switch models where the sensor and electronics are separate

units, for high temperature fluids or other conditions. In addition, a two relay flow switch is available

for indicating high and low flow conditions.

Key features of Rheotherm flow switches are:

Nonintrusive flow monitoring For pipe sizes from .030 to ¾ inch, flow sensing is done

from outside the flow tube.

No moving parts There are no rotating, translating, undulating or oscillating parts to wear,

stick, break or fatigue.

Chemicalcompatibility The wetted surface(s) can be any of a number of corrosion resistant

metals or alloys. There are no internal seals in a TU type transducer. Most sensors are 316

SS or 316 SS and nickel braze.

Fluid pressure options to several thousand psi.

Withstands over ranging No damage or change in operation will occur due to excessive

flow rates many times higher than originally specified.

Immunity to shock and vibration.

Range of application includes flow monitoring in capillary tubes to large diameter pipes or

ducts.

The model 100CS is the simplest Rheotherm flow instrument, meant for low temperature applications.

Intek, Inc. also has flow switches (Model 100FS) for high temperature liquids and gases and other

extraordinary process conditions.

- 2 -

Example of dual probe

with flange fitting

Example of single probe

with NPT fitting

Nonintrusive transducer

(TU)

1.2 DESCRIPTION OF OPERATION

Rheotherm flow switches are available with various nonintrusive and intrusive transducer designs, but

they all use the same thermal sensing technique. Two temperature sensors are used one is in thermal

equilibrium with the fluid and provides a fluid temperature reference, while the second temperature

sensor is located near a heater so that its temperature is slightly above that of the fluid. In a TU

transducer, the temperature sensors and heater are attached to the outside of the flow tube, whereas the

dual and single probe transducers have the sensors and heater located in the probe(s) that are inserted

into the stream. The amount of heat removed from the heated sensor by the stream is related to fluid

velocity. Hence, the measured temperature differential between the reference sensor and heated sensor

is a function of flow rate. Only Intek, Inc. is licensed to use this patented and trademarked method for

precision flow measurement.

1.3 PRECAUTIONS

1. Use proper input power Check the label on the unit for the input power requirements.

2. Use reasonable care in handling the flow switch. Do not try to disassemble the transducers;

there are no removable parts.

TU excessive twisting or bending can damage the sensor. The flow tubes are thin-walled

tubing.

Probes (NPT/2I, NPT/I, BF/2I, BF/I, etc.) take care not to bend the probes or damage the

tips. Do not try to remove or turn the electronics box.

3. Check the flow switch maximum temperature rating do not operate a transducer at or

subject it to a temperature above its specified limit.

4. Keep moisture out of the electronic enclosure. Once cable connections are made in the

electronic box, make sure the lid is tightly closed. Seal conduit lines if they can become wet

inside.

5. Keep transducer wetted surfaces clean and free of permanent layer build-up.

- 3 -

6. Do not exceed pressure limits of the tube or fittings.

7. Maintain a thermally stable environment (short-term) for the transducer and adjacent line.

(See SECTION 2 INSTALLATION.)

These instructions cover installation,operation and maintenance of Rheotherm flow switchesin standard

configurations. Any special information pertaining to your unit is covered under CUSTOM

INFORMATION (SECTION 6). Time should be taken to carefully read these instructions prior to

installation of the equipment. Should any questions arise or problems occur, call Intek for immediate

assistance.

- 4 -

SECTION 2 !INSTALLATION

2.1 TRANSDUCER

!! IMPORTANT: All transducers have a directional arrow on the tag

and/or etched into a metal part. Before installing a sensor, please note

proper flow direction. This is critical to sensor operation.

The transducer style supplied with your meter is listed in the model code number in SECTION 6.

Proper installation of the sensor is necessary for achieving accuracy and repeatability. Installation

suggestions for each type of standard transducer are given here. For custom transducer installations,

refer to CUSTOM INFORMATION SECTION 6.

Be sure wetted surfaces are clean before installing. If cleaning is needed, use non-residue solvent and

wipe dry. Keep moisture out of the electronics box. Make sure the lid is tightly sealed and, if supplied,

the gasket is in place. Seal conduit lines at the electronics box if conduit lines can become wet.

1. TU Transducers

!! CAUTION: TU transducers are made with thin-walled tubing use

care when installing. TU1'16 and TUctransducers require particularly

careful handling.

!! CAUTION: The electronics box should never be rotated for any

reason.

Straight run for a flow switch is not a requirement, particularly for flow/no flow indications,

but for best repeatability some straight run is useful, such as 10 to 20 pipe diameters on the

inlet and 6 to 10 diameters on the outlet. If installed vertically, the flow should be going up

through the sensor. Connection in the line is via compression fittings, hose with clamp,

threaded fittings or flanges, whichever is appropriate. Care must be taken not to transmit a

twisting force through the transducer's midsection. The TU transducer, whether flanged or

not, must not be used to pull other piping together or to make up angular mismatch of fittings.

Typically, TU1'16" O.D. flow tubes are sleeved with a c" tube for added support. Fluid

connections should always be made to the 1'16 " tube, as there is no assured seal between the

1'16" tube and the sleeves.

Fluid temperatures other than ambient require special attention. Thermal gradients from one

end of the transducer to the other, as well as along the radius of the connection pipe, are

undesirable. Therefore, effective insulation should be installed around the inlet and outlet

straight line runs. Gradients which may exist in the line further up stream can be removed if

an insulated elbow is installed in the line prior to entering the straight line portion of the

plumbing.

- 5 -

The ideal installation will provide the sensor with well established smooth flow, uniform

system temperature and consistent fluid media.

2. Intrusive Probes

Straight run is not critical, but if trying to hold a precise set point, some straight run is

useful, such as 10 to 20 pipe diameters on the inlet and at least 6 diameters on the outlet.

The various probe transducers are mounted through a threaded collar (NPT/2I and NPT/I) or

flanged tee (BF/2I or BF/I). Other fittings and sensor designs are also available and are

discussed on the Custom Information page. Generally the probes are sized so the tips extend

½ to 1 inch beyond the pipe center line when properly installed. However, for larger pipes,

the probes may extend in 1/8of a diameter from the wall.

Proper alignment of the sensor with flow is important; the flow direction is indicated on the

transducer tag and/or etched into the transducer. All dual probe transducers (NPT/2I, BF/2I)

are installed so that the two probes are side-by-side across the fluid stream. Never rotate the

electronics box. If this occurs the flow switch could be damaged and/or installed misaligned

with the flow direction.

For high temperature applications, the sensor and surrounding line should be well insulated.

Leave a portion of the transducer neck un-insulated to allow heat dissipation before reaching

the junction box.

2.2 ELECTRICAL CONNECTIONS (See Figure 1 on page 12)

The input power requirement is listed on the tag on the electronics enclosure; make sure the input power

source is compatible. The standard power requirement is 120 Vac, 60 Hz, single phase (220 Vac, 50

Hz and 24 Vdc are options).

Wire sizes no smaller than 24 gauge can be used for power. The electronics power ground is common

to the transducer casing. 14 gauge stranded wire is recommended for the relay contacts (10A resistive

at 120 Vac, 5 Amps resistive at 240 Vac).

The input power and relay connections are made as shown in Figure 1. Note the connector is removable

for easier insertion of the wires. Once all connections are made, firmly push the connector back onto

its base. Be sure the wires are stress relieved sufficiently to prevent an inadvertent disconnect.

The typical housing for a 100CS flow switch is a round explosion-proof enclosure. When ready for use,

the housing lid should be tightly screwed on. A gasket is included when rain tightness is required. Here

again, the lid should be on tight to make a good seal against the gasket.

- 6 -

SECTION 3 !OPERATION

3.1 START UP

Typically, Rheotherm flow switches come from the factory set up for a 10 to 1 flow rate range, and with

the trip level set approximately as requested by the customer. The trip level can be adjusted using the

instructions in SECTION 3.3.

When power is first turned on, the flow switch may indicate a high flow rate, even if there is no flow

occurring. Correct indication of flow level will result after an initial period, which can extend to about

forty (40) seconds and depends on where the trip adjust is set.

For standard flow switches, the relay operates as stated below. For nonstandard units, the operation is

described in SPECIAL INSTRUCTIONS (SECTION 6).

A. Low Flow Switch The relay is energized (N.O. contact is closed) and the LED is green

when the flow rate is above the trip level. Therefore, the alarm condition (relay de-energizes)

occurs when the flow rate drops below the trip level or there is a loss of power to the sensor

(N.O. contact is open and LED color becomes red).

B. High Flow Switch The relay operation is exactly as described above. When used as a high

flow switch, the alarm condition is considered to be when the relay is energized (N.O. contact

is closed and LED color becomes green).

3.2 GENERAL INFORMATION

The Rheotherm instrument is compensated for a wide range of both ambient and flowing media

temperatures. However, abrupt changes in the temperature of the flowing material can cause the

instrument to read the flow rate improperly, which could lead to an inappropriate tripping of the relay

or a delay in reading loss of flow. A proper reading is obtained only when the transducer is in thermal

equilibrium with the material. Typically, a 20°F abrupt change in temperature may require 40 seconds

to stabilize.

In general, the heater used in the transducer does not develop enough power to cause damage to the

system in the absence of flow. This includes those used in liquids even if the line becomes empty and

filled with air. Special cases will be discussed in the section entitled SPECIAL INSTRUCTIONS

(SECTION 6).

- 7 -

3.3 ADJUSTING THE TRIP POINT

Adjust the flow switch trip point as follows (see Figure 2, page 12, for trip potentiometer location):

1. Establish a flow rate at the desired trip level. (This should be done with flow in the line, not

at zero flow. Select a flow rate below your normal usage. One example would be to use 50%

of your lowest normal flow rate as the set point.)

2. If the LED is green, adjust "Trip" potentiometer clockwise until the relay de-energizes (LED

turns red). This is the alarm condition.

3. If LED is red, adjust "Trip" potentiometer slowly counterclockwise just until the relay

energizes (LED turns green).

4. If the relay cannot be made to drop out over the full range of the "Trip" potentiometer, see

TABLE I.

3.4 USE AS A LEVEL SWITCH (Insertion Probes Only)

The probe switch design can be used to provide one point level switch indication. When the probe tips

are submerged in liquid, the relay is energized and the LED is green. When the liquid level drops below

the probes and they are surrounded by air or vapor, the relay de-energizes and the LED turns red.

- 8 -

SECTION 4 !MAINTENANCE

4.1 GENERAL MAINTENANCE

Certain precautions should be taken to insure proper performance of all models of flow instruments.

Since the measurement technique involves a signal resulting from heat transfer to the flowing medium,

care should be exercised to prevent build-up of varying layers on the walls of the transducer. Layers

such as bacterial growth, dried paints, gas bubbles and non-solubles can result in measurement below

actual flow rates. Periodic checks and cleaning should be performed to insure a clean pipe or probe

surface.

It should be part of normal maintenance procedure to check the system for proper functioning.

Experience and other observable conditions should be utilized to determine the frequency of inspection.

To test the flow switch action. the flow rate should be reduced below (for low flow switch) or raised

above (for high flow switch) the switching level. Then check and insure relay action and continuity of

the shut down or warning circuits which it operates.

The joints of all intrusive probes tips should be inspected for wear and corrosion.

4.2 SPARE PARTS

There are no normally recommended spare parts to stock. Should a spare be needed, a complete unit

should be ordered and stocked.

If fuse replacement is ever needed, for AC powered units , use a Wickman part no. 3730500041 (½A,

fast acting fuse) or equivalent. For units powered by 24 Vdc, the fuse is a 1A, slow blow fuse and may

be replaced with Wickman part no. 3741100041 or equivalent.

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