Flo-Tronic Plus™ - United Process Controls
Contents
1. located on page 8 Adjustment of Output Signal This procedure requires the ability to move the float rod from 0 Zero flow to 100 Full Scale flow There are two methods to achieve this Method 1 Remove the Flo Tronic and float rod assembly from the Flo Meter and manually move the float rod assembly to the required position for calibration Refer to page 6 of this manual for removal and installation This is the preferred method of Calibration of the Flo Tronic CAUTION Make sure supply fluid to Flo Meter has been SHUT OFF before removing the Flo Tronic from the Flo Meter Failure to do so may result in accidental death or explosion Method 2 If the equipment and process allows this the float rod assembly can be moved to the required position for calibration by shutting off the fluid valve for zero flow and opening the fluid valve to full open for full flow WARNING Depleting or over gassing of equipment that the Flo Meter A is connected to may produce a hazardous condition check with all personnel before attempting this method of calibration Waukee is not responsible for any damages that may occur using this method To adjust the Zero 0 the float rod should be at the bottom or zero flow position Then adjust the Zero pot until the signal is correct for the selected analog output This will be 4mA for 4 20mA OmA for 0 20mA 2V for 2 10VDC and OV for 0 10VDC To adjust the Span Full Scale Flow the fl2. e Over Temperature Condition e Output Wiring Problem voltage may result in damage to unit and poses a potential fire risk WARNING An external relay must be used if connecting alarm contacts to a load over 0 5 Amps Use of alarm contact with loads over 0 5 Amps will result in relay failure and poses a potential risk of fire Y CAUTION Relay is for use with 30VDC or less ONLY Use of any other 7 CALIBRATION AND FIELD SERVICE The Flo Tronic Plus output signal is calibrated at the factory and should be received calibrated but in some cases the unit may require field calibration of the electronics If you find that the analog output signal is not correct in relation to the indicated flow you can recalibrate the output by the adjustment of the Zero and Span potentiometers located inside the sensor box 4h CAUTION Do not turn potentiometers excessively as these adjustments are sensitive Lead from DMM Copyright 2013 Waukee Engineering a member of United Process Controls All rights to copy reproduce and transmit are reserved Flo Tronic Plus Rev 03 Page 20 Measurement of Ouput Signal The best way to measure the output signal is to disconnect the unit from the field device and connect a multi meter across terminals 3 amp 4 Set the multi meter to measure the correct signal the unit is setup for Ah If you are unsure what the output signal is refer to Analog output configuration
3. a specially designed waveguide by the momentary interaction of two magnetic fields One field comes from a moving magnet which passes along the outside of the sensing tube the other field from a current pulse launched along a wire inside the waveguide The interaction between these two magnetic fields produces a strain pulse which travels at sonic speed along the waveguide until the pulse is detected at the head of the transducer The position of the moving magnet is precisely determined by measuring the elapsed time between the launching of the electronic pulse and the arrival of the strain pulse As a result accurate non contact sensing of the Flo Meter s indicator is achieved The indicator position is directly related to the Flo Meter s flow rate and is represented by a proportional analog electrical signal Model Explanation FT M17 Size S17 S Gas 3 Scale SF17 SF Liquid 3 Scale M17 M1 7 6 Scale M811 M8 11 Scale L13 L1 3 9 Scale L46 L4 6 9 Scale L79 L7 9 9 Scale L10 L10 9 Scale UG perencennc FLO TRONIC Plus Series POWER ON ALARM SENSOR www group upc com D ho O a D a OUTPUT Waukee a member of TEMP United PROCESS CONTROLS Copyright 2013 Waukee Engineering a member of United Process Controls All rights to copy reproduce and transmit are reserved Flo Tronic Plus Rev 03 Page 15 9 SPECIFICATIONS General Specifi
4. at www group upc com United Process Controls brings together leading brands to the heat treating industry including Waukee Engineering Furnace Control Marathon Monitors and Process Electronic We provide prime control solutions through our worldwide sales and services network with easy to access local support WAUKEE ENGINEERING COMPANY INC A member of United Process Controls 5600 West Florist Avenue Milwaukee WI 53218 U S A Phone 1 414 462 8200 Fax 1 414 462 7022 E mail sales waukeemeters com Page 25 United PROCESS CONTROLS f NNI ozs Uy
5. ESHOOTING Suit a ico 23 LO APPENDIX A DRAWINGS sinceron a a a a a a aa a E a aa a ai 24 Copyright 2013 Waukee Engineering a member of United Process Controls All rights to copy reproduce and transmit are reserved Flo Tronic Plus Rev 03 Page 13 3 MANUAL OVERVIEW The Purpose of this Manual Thank You for Purchasing a Flo Tronic Plus Flow Sensor This manual shows you how to install wire and maintain Waukee s Flo Tronic Plus It also helps you understand how to interface it to other devices in a control system This manual contains important information and should be read and understood by all individuals who install use or service this equipment Supplemental Manuals The Installation and Operation of Waukee Flo Meters manual contain technical information as well as precautions about Waukee Flo Meters Technical Support We strive to make our manuals the best in the industry We rely on your feedback to let us know if we are reaching our goal If you cannot find the solution to your particular application or if for any reason you need technical assistance please call us at 1 414 462 8200 Toll free North America 1 800 438 3347 Our technical support group will work with you to answer your questions They are available Monday through Friday from 8 00 A M to 4 30 P M Central Standard Time We also encourage you to visit our web site where you can find technical and non technical information about our products and c
6. PE Remove the Float Rod Assembly and store it in a safe location until Flo Meter body is installed and mounted Once the Flo Meter is installed remove the red tape from the float rod and insert the float rod assembly into the Flo Meter body Fill the sight glass tube with Waukee Flo Meter oil so that the level of oil is approximately one 1 inch from the top Then carefully install the Flo Tronic on to the FLO TRONIC SENSOR Flo Meter HHH Do not put oil in the sight glass tube of meters used for oxygen or methanol service Oxygen Flo Meters should be run dry or with distilled water Flo Meters for Methanol service will automatically fill the sight glass tube with Methanol when in service A WARNING Do not fill the sight glass tube with Flo Meter oil on meters used for oxygen service Use of oil may cause fire or explosion Serious personal injury may result from fire or explosion Copyright 2013 Waukee Engineering a member of United Process Controls All rights to copy reproduce and transmit are reserved Flo Tronic Plus Rev 03 Page 17 Wiring Guidelines Your company may have guidelines for wiring installation If so you should check those before you begin the installation Here are some general things to consider e Use the shortest wiring route whenever possible e Use shielded wiring for all signal wiring and ground the shield at the Field Device end DO NOT ground the shield at both the Flo Tronic Sensor and Fiel
7. WAUKEE WWW GROUP UPC COM ENGINEERING company ine Flo Tronic Plus User Manual Revision 03 Pnited AFFILIATED MEMBERS PROCESS CONTROLS Furnace Control Corp Marathon Monitors Inc Process Electronic Waukee Engineering Co Flo Tronic Plus Rev 03 Page 10 Manual 011 Initial Release 12 21 2010 Rev No 03 Date 4 15 2013 COPYRIGHT No part of this publication may be reproduced transmitted transcribed stored in a retrieval system or translated into any language or computer language in any form or by any means electronic mechanical magnetic optical chemical manual or otherwise without prior written permission of United Process Controls LN DISCLAIMER The Flo Tronic Plus is to be used by the industrial operator under his her direction Waukee Engineering is not responsible or liable for any product process damage or injury incurred while using the Flo Tronic Plus United Process Controls Inc makes no representations or warranties with respect to the contents hereof and specifically disclaim any implied warranties or merchantability or fitness for any particular purpose For assistance please United Process Controls Inc contacti TEL 1 414 462 8200 e FAX 1 414 462 7022 Toll free North America 1 800 438 3347 waukee support group upc com www group upc com Copyright 2013 Waukee Engineering a member of United Process Controls All rights to copy reproduce and transmit are
8. cations Operation Specification Accuracy 0 4 FS 1 6 Rd Measurement Repeatability lt 0 5 FS Turndown Ratio 1 40 25 100 _ Operating Voltage 24VDC 10 Electrical Power lA i Current 4 20mA or 0 20mA Ranges Selectable Voltage 0 10VDC or 2 10VDC Voltage Output Analog Output Short Circuit Current 0 875mA Min Load Impedance 1k Ohm Current Output Copyright 2013 Waukee Engineering a member of United Process Controls All rights to copy reproduce and transmit are reserved Flo Tronic Plus Rev 03 Page 16 6 INSTALLATION AND WIRING Flo Meter Installation The Installation and Operation of Waukee Flo Meters manual contains instructions on the proper installation of the Flo Meter Read all CAUTIONS and WARNINGS before proceeding The Flo Tronic Meter is shipped as a complete unit Before installing the Flo Meter carefully remove the Flo Tronic Sensor to achieve this lay the unit on its side on a work bench or table Then hold the Flo Tronic unit with one hand while unscrewing the union nut counters clockwise with the other hand to loosen it FLO METER BODY FLOAT STOP BODY O RING Fo a FLOAT ROD ASSEMBLY CAUTION Once the Flo Tronic is loose from the Flo Meter make sure to pull the Flo Tronic from the Flo Meter straight back off the float rod assembly Moving the Flo Tronic to one side or another during removal may result in damage to the float rod assembly RED TA
9. cerning the installation or operation of this equipment or if you need additional information please call us at 414 462 8200 WARNING This unit contains ESD Electrostatic Discharge sensitive parts and assemblies Static control precautions are required when installing testing servicing or repairing this assembly Component damage may result if ESD control procedures are not followed If you are not familiar with static control procedures refer to an applicable ESD protection handbook A WARNING Read this manual thoroughly before using Flo Tronic A WARNING Flo Meter must be earth grounded Ungrounded Flo Meters may become a source of Ignition Copyright 2013 Waukee Engineering a member of United Process Controls All rights to copy reproduce and transmit are reserved Flo Tronic Plus Rev 03 Page 12 2 TABLE OF CONTENTS ts E A O O 11 2 TABLEOFCONTEN Suu ici puetca eco 12 3 MANUAL OVERVIEW coi a e AAA di add 13 4 FLOW SENSOR INTRODUCTION siisssccsccncscauasistidcncsiswatasstesadaiweneansussedendendswauanpoaieubsceddnaspecsedcbndoadwalsesacussesedemsbsosardannes 14 Be SPECIFICATIONS brosirani tes snesiecacoasocarpenieanaaieneebeteasuateedscebuavesectneuadcasnoves o iento 15 6 INSTALLATION AND WIRING cos siani nicinia can picas 16 7 CALIBRATION AND FIELD SERVICE iz iicicccasswegenneivaecsases a Ra a EE a veedioneaesaedan sve senvGeacateenevocsseesesees 19 8 MAINTENANCE misiri cc din 21 9 AA O 22 10 TROUBL
10. d Device e Do not run the signal wiring next to large motors high current switches or transformers This may cause noise problems e Route the wiring through an approved cable housing to minimize the risk of accidental damage Check local and national codes to choose the correct method for your application e Be sure to leave enough slack in the cables to allow easy removal of the Flo Tronic from the Flo Meter for maintenance lf seal tight or similar conduit is used be sure to provide an adequate loop of conduit for maintenance access Wiring Connections All wiring connections are located inside the main box To access the wiring terminals remove the 4 four screws located on the front of the box and remove the cover Ad 1 WARNING Any electrical or mechanical modification to this equipment CAUTION To reduce the risk of electrical shock and also to prevent damage to the Flo Tronic and the Field Device It is advised to turn off the supply power to the Flo Tronic and Field Device before connecting or disconnecting any wires without prior written consent of United Process Controls will void all warranties may result in a safety hazard and may void the CE listing A Use 18 22AWG shielded cable for the signal wiring It is recommended to run all signal wires in a separate steel conduit The shield wire should only be connected at the Field Device end Do not connect shield wire on both ends Circuit Protection The Flo Tro
11. e front panel of the unit PWR The Power LED indicates when power is applied Quine FLO TR ONIC ai SEN The Sensor LED indicates when Sensor POWER MODEL Signal is Lost Cor ESTU ALARM OUT The Output LED indicates when there is a gon ii ia es dd problem with the output signal PTEMA gprs Current mode Output Open No Load TEMP United or load resistance too high Voltage mode Output shorted or input resistance too low TEMP The TEMP LED indicates when unit electronics IC temperature is in excess of 185 F unit will not function until temperature is below 185 F Diagnostics Description Corrective Actions 1 Check for 24VDC power at terminals 1 and 2 PWR LED not Illuminated 2 Make sure power supply is not over loaded l 1 Check wiring at terminals 1 2 3 of sensor TB SENSOR LED Illuminated 2 Check for cut or damaged sensor cable 1 Check wiring at terminals 3 amp 4 OUTPUT LED Illuminated 2 Check wiring at Field device Ensure unit is configured for correct output signal TEMP LED Illuminated 1 Shield device from sources of heat Copyright 2013 Waukee Engineering a member of United Process Controls All rights to copy reproduce and transmit are reserved Flo Tronic Plus Rev 03 Page 24 10 APPENDIX A DRAWINGS On Demand Copyright 2013 Waukee Engineering a member of United Process Controls All rights to copy reproduce and transmit are reserved Flo Tronic Plus Rev 03 Reach us
12. nic is equipped with built in over voltage and short circuit protection The unit may require recycling of power to reset once the fault condition is removed Copyright 2013 Waukee Engineering a member of United Process Controls All rights to copy reproduce and transmit are reserved Flo Tronic Plus Rev 03 Page 18 Wiring Terminals 0 Power Analog Output Wiring 4 Pin Terminal Block a of Wire Description Color 1 fac Red LN SS d a Alarm Relay Wirin y g amp 3 Pin Terminal Block Wire Description ne nen OE ae E Analog Output Configuration Use the table below to configure the unit to the desired analog output DIP Switch Settings oF on f 2towc Sensor Wiring 3 Pin Terminal Block e Wire Description Color on or oom on o ooe Basic Wiring Diagram 24VDC RED DC COMMON BLK ANALOG WHT 4 2 4 Conductor ANALOG GRN 1 Es aha SHIELD y PROTHERM 400 M 242VDC Process er Controller Supl or Data Logger A Copyright O 2013 Waukee Engineering a member of United Process Controls All rights to copy reproduce and transmit are reserved Flo Tronic Plus Rev 03 Page 19 Alarm Relay Wiring The Flo Tronic Plus includes an alarm relay on power up the relay is energized to indicate that the unit has power The relay will de energize under the following alarm conditions e Loss of Power e Loss of Sensor Signal
13. oat rod will now need to be adjusted to Full scale 100 Then adjust the Span pot until the signal is correct for the selected analog output This will be 20mA for a current output or 10VDC for a voltage output Copyright O 2013 Waukee Engineering a member of United Process Controls All rights to copy reproduce and transmit are reserved Flo Tronic Plus Rev 03 Page 21 8 MAINTENANCE The Flo Tronic is a magnetic based sensor which is unaffected by dirt The dampening oil can be soiled to the point that it is not possible to visually read the flow on the Flo Meter and the unit will still accurately determine the position of the float rod assembly The Flo Meter is a mechanical device that requires regular maintenance in order to maintain accuracy All Flow Meters are susceptible to dirt affecting its accuracy Although not all manufactures have a means to gauge when the Flo Meter requires maintenance Waukee Flo Meters on the other hand have a built in indication when the Flo Meter requires maintenance which is the dampening oil When the oil becomes soiled it is indication maintenance on the Flo Meter is needed The frequency of maintenance intervals will vary depending on the cleanliness of the gas being used To replace the oil will require the removal of the Flo Tronic refer to the installation section of this manual for instructions Also during these maintenance intervals it is recommended that all gaskets and o rings are ins
14. ompany http www waukeemeters com http www group upc com If you have a comment question or suggestion about any of our products services or manuals please e mail or contact us by phone Conventions Used When you see the exclamation point icon in the left hand margin the A paragraph to its immediate right will be a warning This information could prevent injury loss of property or even death in extreme cases Any warning in this manual should be regarded as critical information that should be read in its entirety The word WARNING or CAUTION in boldface will mark the beginning of the text HHHH When you see the notepad icon in the left hand margin the paragraph to its immediate right will be a special note Ea Copyright 2013 Waukee Engineering a member of United Process Controls All rights to copy reproduce and transmit are reserved Flo Tronic Plus Rev 03 Page 14 4 FLOW SENSOR INTRODUCTION The Waukee Flo Tronic utilizes a sensor to read the position of the float rod indicator on a Waukee Flo Meter The unit provides both electrical and mechanical indication of flow The unit is factory calibrated to provide linear and accurate flow measurement If necessary the Flo Tronic may be field calibrated How it works Magnet assembly attached to float rod of the Waukee Flo Meter interacts with a magnetostrictive linear position sensor installed in Flo Meter sensing head A strain pulse is induced in
15. pected for signs of wear or damage Replace worn or damaged seals Gasket kit sets are available from Waukee if needed Copyright 2013 Waukee Engineering a member of United Process Controls All rights to copy reproduce and transmit are reserved Flo Tronic Plus Rev 03 9 CALCULATIONS Determine output for a given flow rate 1 First determine the of scale represented by Full Scale Flow cfh 2 Then the Output is calculated by For 4 20mA mA of Scale x 16 4 For 0 20mA mA of Scale x 20 For 2 10VDC VDC of Scale x 8 2 For 0 10VDC VDC of Scale x 10 Determine the flow rate from the output 1 First determine of Full Scale 4 20mA Range MA 4 16 0 20mA Range mA 20 0 10VDC Range VDC 10 2 10VDC Range VDC 2 8 2 Then Actual Flow is calculated by Actual Flow of Full Scale x Full Scale Flow Copyright 2013 Waukee Engineering a member of United Process Controls Page 22 Example 1 Scale Plate is 750CFH Indicated Flow is 5 00CFH Output range 4 20mA 900 6666 750 6666 x 16 4 14 65mA Example 2 Find the flow rate for a 4 20mA signal of 12 00mA and a Flow Meter Scale of 1000CFH 12 4 5or 50 9 x 1000 SOOCFH All rights to copy reproduce and transmit are reserved Flo Tronic Plus Rev 03 Page 23 10 TROUBLESHOOTING Diagnostic Lights The Flo Tronic has a comprehensive diagnostic system The diagnostic lights are displayed on th
16. reserved Flo Tronic Plus Rev 03 Page 11 1 WARNING Thank you for purchasing control equipment from Waukee Engineering a member of United Process Controls We want your new control equipment to operate safely Anyone who uses this equipment should read this publication and any other relevant publications before installing or operating the equipment To minimize the risk of potential safety problems you should follow all applicable local and national codes that regulate the installation and operation of your equipment These codes vary from area to area and usually change with time It is your responsibility to determine which codes should be followed and to verify that the equipment installation and operation are in compliance with the latest version of these codes At a minimum you should follow all applicable sections of the National Fire Code National Electrical Code and codes of the National Electrical Manufacture s Association NEMA There may be local regulatory or government offices that can also help determine which codes and standards are necessary for safe installation and operation Equipment damage or serious injury to personnel can result from failure to follow all applicable codes and standards We do not guarantee the products described in this publication are suitable for your particular application nor do we assume any responsibility for you product design installation or operation lf you have any questions con
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