TECHNICAL DOCUMENTATION FOR ONICON SYSTEM-1 BTU METERS

Transcription

1 TECHNICAL DOCUMENTATION FOR ONICON SYSTEM-1 BTU METERS This file contains the following: 1. System-1 BTU Meter Order Form 2. System-1 BTU Meter Installation Guide Please note that Excel spreadsheet versions of our order forms are available on our web site: ONICON Incorporated is proud to be a partner in Johnson Controls Preferred Supplier Program Updated September 2001

2 ORDER FORM: System-1 BTU Measurement System Please provide ship to & bill to information on your purchase order Company Name: and location (city,st) Contact Name: Purchase Order #: Project Name: and location (city,st) Specified By: (Engineering firm, city, ST) FLOW METER MODEL: METER TAG INFORMATION: FLOW METER INFORMATION Note: Standard lead time for meters is two weeks, contact factory if shorter lead time is required. Requested Delivery Date: Ship Meters Via: Ship install kits in advance? Ship Kits Via: BTU METER MODEL: Model 100, 110, 120, 130 METER TAG INFORMATION: Ground, 3-day, 2-day, Overnight YES or NO Ground, 3-day, 2-day, Overnight BTU METER INFORMATION APPLICATION TYPE: (CHW, HW, make-up, boiler feed, etc.) LIQUID TYPE: (Be specific to ensure proper calibration of BTU Meter) A. Water B. x% Ethylene Glycol C. x% Propylene Glycol D. Other PIPE SIZE (nominal) : PIPE MATERIAL: (i.e:. Carbon steel, copper tube, pvc, etc.) PIPE SCHEDULE, TYPE, or I.D.: (i.e.: sch 40, standard, type L, etc.) MAX. OPERATING TEMPERATURE: * Required for hot water systems only TYPICAL FLOW RATE: Expected "typical" flow rate for the system DESIGN MAXIMUM FLOW RATE: Maximum flow per system design The following four selections pertain to output signals for flow rate. For flow meter models ending in "00", skip to available options. ANALOG FULL SCALE FLOW RATE: For Analog Output (i.e.: 20 ma = X gpm) ANALOG OUTPUT: For Analog Models Only Choose from: 4-20 ma, 0-10 V, 0-5 V MAXIMUM OUTPUT FREQUENCY: For Divided, or Scaled Output Models SCALE FACTOR: Scaled Output Models Only (1 Pulse = X gal, L, etc.) AVAILABLE OPTIONS: A. Standard (w/1 valve, for new constr.) B. Hot Tap (w/1.25 valve, for wet tap) C. Stainless Steel (select A or B also) D. No Kit - provide height of valve assy. Wetted Metal Components* Standard: Plated Brass Optional: 316 SS Signal Connections Std: 10' cable & 1/2" conduit adapter Option: Plenum cable w/ DIN connector Conduit Option 10' of 3/8" liquid tight conduit w/connectors Additional Signal Cable Standard: 10 ft. cable Optional: 25, 50 or 100' additional cable Electronics Enclosure* Standard: Weathertight enclosure Optional: Submersible enclosure These affect price, refer to price sheet for details. Installation Hardware: All kits allow insertion/removal without system shutdown. Choose kit # from price book, or select below: A B C D Standard Optional Standard Optional Provide Conduit Standard Optional: 25' 50' 100' Standard Optional PIPE SIZE & MATERIAL if different from flow meter pipe size or material SYSTEM TYPE: Single Mode: cooling or heating Dual Mode: 2-pipe heating/cooling DESIGN TEMPERATURES: TOTALIZER UNITS: BTU's (standard), Ton-Hrs., KW-Hrs. PULSE DURATION: 500 ms (standard), 250 ms, 50 ms AVAILABLE OPTIONS: LCD for Energy Rate Supply Temp. ( F) Return Temp. ( F) LCD for Liquid Flow Rate or Total LCD for Supply/Return Temperatures A. Standard Thermowells B. Hot Tap Thermowells C. Stainless Steel Thermowells D. Outdoor Thermowells Analog Outputs for Supply & Return Temperatures: Available temperature spans: 25, 50, 75, 100 F Select Signal: 4-20 ma or 0-10 V Select zero point: 4 ma or 0V = X F Select full scale: 20 ma or 10V= Y F Analog Output for Energy Rate: Select signal type: 4-20 ma or 0-10 V Select units: BTU/min, BTU/hr, Tons, KW Upgrade Temp. Sensor Cable to Plenum Rated Type Cable: Additional Sensor Cable: Standard: 10ft. cable per sensor Optional: 25, 50 or 100 ft. cables Electronics Enclosure Standard: NEMA 13, steel Optional: NEMA 4, steel, for wet areas Cooling Heating Dual Mode These affect price, refer to price sheet for details. NO NO NO Temperature Thermowells: Standard thermowells are included in BTU Meter price. Choose any combination of A, B, C, or D below: A B C D NO Standard Cable Plenum Rated Standard Optional: 25' 50' 100' Standard Optional YES YES YES YES 4-20 ma 0-10 V Zero Point: F Full Scale: F NO YES 4-20 ma 0-10 V Units: NOTES: Maximum operating pressure for flow meters is 400 PSI * 316 SS wetted parts required for HW systems operating over 250 F as well as for submersible applications Logan Street, Clearwater, FL Tel (727) Fax (727) sales@onicon.com

3 2161 Logan St., Clearwater, FL (727) FAX (727) SYSTEM-1 BTU METER Installation Guide BTU / MIN BTU x 1000 POWER SYSTEM-1 BTU METER 2058E July 10, 2001

4 DISCLAIMER The information in this manual has been carefully prepared and checked for completeness and accuracy. There is, however, the possibility of omission or error. In such an event, ONICON INCORPORATED does not assume liability for any damages resulting from the use of this manual. SERVICE REQUIREMENTS In the event of equipment malfunction, all repairs must be performed by ONICON INCORPORATED, an authorized agent or dealer of ONICON INCORPORATED, or any other organization authorized by your warranty agreement.

5 TABLE OF CONTENTS 1.0 INTRODUCTION Purpose of this Guide Typical SYSTEM-1 BTU Meter Standard Features and Specifications Additional Required Hardware Optional Features Working Environment Warranty and Serial Number UNPACKING Checking that You Have Received Everything INSTALLATION Site Selection Mechanical Installation Thermowell Installation Temperature Sensor Installation Flow Meter Installation Electrical Connections AC Power Input Signal Connections from Temperature & Flow Sensors Output Signal Connections SYSTEM-1 START-UP AND COMMISSIONING Start-up Electro-Mechanical Totalizer Diagnostics Diagnostic LEDs Temperature Signals Analog Outputs (Optional) Flow Signals Energy Rate Calculation System-1 BTU Meter Installation Guide - Rev. 7/10/01

6 TABLE OF CONTENTS (CONTINUED) APPENDIX A - DRAWINGS A-1 TYPICAL SYSTEM INSTALLATION A-2 STANDARD THERMOWELL ASSEMBLY A-2.1 THERMOWELL INSTALLATION A-3/A-4 HOT TAP THERMOWELL (2 PAGES) A-5 TEMPERATURE SENSOR ASSEMBLY A-6 MOTHER BOARD TEMPERATURE AND FLOW SENSOR INPUT CONNECTIONS A-7 MOTHER BOARD OUTPUT CONNECTIONS A-8 ISOLATED ANALOG FLOW METER OUTPUT A-9 NON-ISOLATED ANALOG FLOW METER OUTPUT A-10 SCALED FLOW METER OUTPUT A-11 MOTHER BOARD A-12 BTU COMPUTER BOARD A-13 POWER SUPPLY BOARD A-14 ANALOG TEMPERATURE OUTPUT BOARD A-15 ANALOG BTU RATE OUTPUT BOARD APPENDIX B - DOCUMENTS B-1 CONDITIONS OF SALE System-1 BTU Meter Installation Guide - Rev. 7/10/01

7 SECTION 1.0: INTRODUCTION We, at ONICON INCORPORATED, would like to thank you for purchasing our quality U.S. made SYSTEM-1 BTU Meter. As our valued customer, our commitment to you is to provide fast reliable service and assistance, while continuing to offer you new products to meet your growing flow measurement needs. 1.1 PURPOSE OF THIS GUIDE We have written this guide to provide the persons responsible for the installation, operation, and maintenance of your SYSTEM-1 BTU Meter with the specific equipment information they will need. This is NOT an electrical or plumbing trade manual. PLEASE DO NOT PERMIT ANY PERSONS TO INSTALL, OPERATE, OR MAIN- TAIN THIS EQUIPMENT UNLESS THEY HAVE A COMPLETE KNOWLEDGE OF THEIR TRADE SKILLS AND ARE COMPETENT TO WORK ON HIGH VOLTAGE POWER WIRING OR HIGH PRESSURE HOT AND COLD WATER AND STEAM SYSTEMS, ACCORDING TO THEIR INDIVIDUAL TRADES. DEATH OR PERMANENT INJURY MAY RESULT FROM ACCIDENTS WITH THESE SYSTEMS. This guide is the basic reference tool for everyone who purchases an ONICON SYSTEM-1 BTU Meter regardless of which of the many options they may have selected. If you have not purchased all of the options, there will be references in this manual which are not applicable to your system. 1.2 TYPICAL SYSTEM-1 BTU METER ONICON S System-1 is a true heat (BTU) computer which accepts data from several meters, performs a series of computations with that data, and displays and/or transmits the results as an indication of the amount of heat (BTU s) being transferred per unit time or as a totalized amount. See Typical SYSTEM-1 Installation Drawing, Appendix A-1. The typical SYSTEM-1 BTU Meter consists of the following components: Main Unit The heat computer, power supply, mother board, LED status indicators, and the local displays, are enclosed in a single NEMA 13 enclosure. Flow Meter This is an Insertion Turbine Flow Meter or an Inline Flow Meter, which is designed to measure the liquid flow rate in the system. System-1 BTU Meter Installation Guide - Rev. 7/10/01 1

8 Temperature Sensors Temperature sensors are matched and shipped in pairs: one for measuring the supply liquid temperature and one for measuring the return liquid temperature. Thermowells Two standard brass thermowells are provided with the required mechanical installation hardware. If your SYSTEM-1 was furnished with any additional items, they will be listed on the packing slip. 1.3 STANDARD FEATURES AND SPECIFICATIONS Model 100» Matched solid state temperature sensors, thermowells and mounting hardware.» 8 x10 x4 NEMA 13 enclosure with attached wall mounting bracket» Prepunched conduit holes with filler plugs» 120 VAC operation» 6 digit electromechanical totalizing register» Customer selection of totalizer units» Front panel POWER indicator light» Isolated solid state output switch (dry contacts)» Calibrated at the factory for the heating or cooling mode (as selected) Model 110 This model has all of the features of the Model 100 plus:» Automatic switching between the heating and cooling modes. BTU s transferred in either mode are totalized on the same register, and switch output (Mode 1 Output Contacts). Model 120 This model has all of the features of the Model 100 and Model 110 plus:» BTU s transferred in the heating mode and the cooling mode are totalized on separate registers and separate switch outputs. 2 System-1 BTU Meter Installation Guide - Rev. 7/10/01

9 Model 130 This model has all of the features of the Model 100 plus:» Dual registers and output switches like the model 120, except the mode switch is based on flow direction rather than heating vs. cooling. Any of ONICON s FB-1200 Series Bi-Directional Flow Meters can be used. This model is designed for stratified thermal storage tank monitoring and custody transfer applications. 1.4 ADDITIONAL REQUIRED HARDWARE Flow Meters ONICON offers a wide variety of flow meters with various output options to satisfy most heat metering applications. For 3 /4 and 1 pipe sizes, inline flow meters are usually the most practical and cost effective. For larger pipes, insertion flow meters greatly reduce the overall cost and make servicing easier. Please refer to the ONICON s flow meter literature, or consult the sales office for help in selecting the flow meter that will best fit your requirements. 1.5 OPTIONAL FEATURES Liquid Flow Rate Display Liquid Flow Totalizer Energy Rate Display LCD for Supply and Return Temperatures Hot Tap Thermowells This option allows installation of the temperature sensor thermowells in a system that is filled and pressurized, without a system shutdown. Two 1 full port isolation valves are included along with close nipples and 1 branch outlets. System-1 BTU Meter Installation Guide - Rev. 7/10/01 3

10 Analog Output for BTU Rate This option provides a 4-20 ma or 0-10 VDC analog output for instantaneous BTU rate, such as BTU/min, BTU/Hr, or TONS. See BTU Meter Calibration Sheet for Output Scaling information. Analog Temperature Outputs This option provides analog 4-20 ma or 0-10 VDC outputs for the supply and return temperatures. These outputs are factory calibrated for a specified temperature range. See BTU Meter Calibration Sheet. 230 VAC, 50 Hz or 24 VAC Input Power NEMA 4 Enclosure Plenum Rated and/or Longer Temperature Sensor Cables 1.6 WORKING ENVIRONMENT The SYSTEM-1 was designed for installation and use in typical industrial environments that are free of corrosive liquids and fumes, direct liquid exposure or heavy condensation, and temperature extremes and vibrations. The operating ambient air temperature range is 40º F to 120º F. The electrical power should be relatively clean, free of high frequency noise, large voltage transients, and protected from power surges and brown outs. 4 System-1 BTU Meter Installation Guide - Rev. 7/10/01

11 1.7 WARRANTY AND SERIAL NUMBER Warranty ONICON s Limited Warranty is included in Appendix B of this manual as a part of the Conditions of Sale. Serial Number The serial number of your SYSTEM-1 is located outside and inside the main unit. All components of your SYSTEM-1 (flow meter, temperature sensors, and main unit) should bear identical serial numbers. The serial numbers are unique identifiers that you should use whenever you require assistance regarding your system. System-1 BTU Meter Installation Guide - Rev. 7/10/01 5

12 SECTION 2.0: UNPACKING The SYSTEM-1 is generally shipped in two packages unless optional hardware or equipment is ordered. One package contains the main unit with the temperature sensors. The second package contains the thermowells. Open these packages with caution to prevent damage to their contents. In the event that they are damaged, notify the shipping company (all products are shipped insured) and the ONICON Customer Service Department. NOTE: Flow meters are packed separately 2.1 CHECKING THAT YOU HAVE RECEIVED EVERYTHING The Documentation Enclosed with each SYSTEM-1 is a comprehensive documentation package which includes the following items:» A packing slip detailing all items shipped or back ordered.» The SYSTEM-1 BTU Meter Installation Guide» The BTU Meter Calibration Data Sheet If any of these documents is missing, please notify ONICON. The Main Unit Remove it from the shipping carton and inspect it for physical damage such as broken LED's or registers. Also, make sure that the front panel options and totalizer units are correct. Check the unit for any parts that may have loosened during transit, such as conduit hole filler plugs or strain relief fittings. When you complete the external inspection, open the SYSTEM-1 Main Unit and remove the plastic bag containing the temperature sensors. Inside the main unit there are at least three circuit boards (the number may vary according to the options purchased). The main connection board, or mother board, is located at the back of the unit. The power supply is plugged into the mother board at the bottom, and the BTU computer is plugged into the mother board on the left side of the unit (Appendix A-11). Ensure that the boards and connectors are securely plugged into the mother board. If you find any discrepancies, please notify the ONICON Customer Service Department immediately. 6 System-1 BTU Meter Installation Guide - Rev. 7/10/01

13 The Temperature Sensors Standard sensors with 18 inch cables are shipped inside the BTU meter panel. Inspect for external damage to either the sensors themselves or to their cables. Each sensor should have a label attached with a serial number identical to that found on the SYSTEM-1 main unit. Each sensor should also be identified by its tag as the HI or LO temperature sensor. If either tag is missing or damaged, please notify ONICON s Customer Service Department. The Flow Meter Remove the flow meter from its shipping carton and inspect it for physical damage. The inspection should include:» Testing the turbines to see that they rotate freely when you blow on them parallel to their shafts (they are turbines, not paddlewheels).» If your particular flow meter has any threaded parts, see that they have not been damaged.» If your meter is an insertion meter, inspect the long stem for bends or other damage. The stem forms the seal against liquid leakage as it slides through an O ring inside the Hot Tap Adapter. Deep scratches in the stem may cause leakage.» Confirm that any additional cable (10 is standard) which you ordered has been included. Make certain that the wire connection/calibration data tag is attached to the meter. This tag should remain attached to the meter after installation.» The serial and model numbers on the wire connection/calibration data tag should match the numbers on the tag mounted directly on the flow meter. Be sure that the unit was calibrated to the correct pipe size and flow rate for your installation by comparing the wire connection/calibration data tag with your specifications. If you find any discrepancies or damage, please notify ONICON s Customer Service Department at once System-1 BTU Meter Installation Guide - Rev. 7/10/01 7

14 SECTION 3.0: INSTALLATION A SYSTEM-1 BTU Meter should be installed by experienced plumbers, electricians, and others with related knowledge and experience in the heating, cooling, and fluid metering fields. ONICON will be happy to assist with technical recommendations and to provide guidance by telephone and/or mail. On-site field engineering, installation, and service is also available at an additional cost. The installer should use good trade practices and adhere to all state and local building or other applicable codes. Before you begin, clean the external surfaces of all pipes at the installation sites so that they are free of debris, foreign matter, solids, sticky liquids such as certain leak inhibitors, and chemically aggressive substances. Flush the entire system so that it is free of flux, solder, pipe and tube cuttings and any other free moving particles. Damage resulting from failure to maintain a clean system is not covered under the warranty. THE ONICON SYSTEM-1 BTU MEASUREMENT SYSTEM IS A CUSTOM CALIBRATED SYSTEM. ALL COMPONENTS (BTU METER, FLOW METER, & TEMPERATURE SENSORS) SHARE THE SAME SERIAL NUMBER AND MUST BE INSTALLED TOGETHER AS A SYSTEM. DO NOT MIX COMPONENTS FROM DIFFERENT SYSTEMS (i.e. DIFFERENT SERIAL NUMBERS) OR THE DATA WILL NOT BE CORRECT. 3.1 SITE SELECTION Careful attention to the site selection for the system components will help the installers with the initial installation, reduce start-up problems, and make future maintenance easier. For example, do not install the flow meter where it will be difficult for your personnel to perform the necessary periodic maintenance. When selecting a site for mounting the system components, you should consider the criteria under Section 1.6, WORKING ENVIRONMENT, as well as the following: The Main Unit» Find an easily accessible location so that wire connections and meter readings can be done from the floor level.» Minimize the need for additional wire by placing the main unit close to the temperature sensors and flow meters. 8 System-1 BTU Meter Installation Guide - Rev. 7/10/01

15 » Mount the main unit on a vibration-free surface. Avoid sites such as the plenum of a fan coil, heat exchanger, or other housing containing motors. The Temperature Sensors» The temperature sensors must be located in an easily accessible location. This location selection will facilitate any on-site calibration. Calibration personnel will need to work with test equipment and calibration instruments at this location.» Place the temperature sensors as close as possible to the beginning and end of the loop in which to measure the transfer of thermal energy. This will reduce the effects of heat gain or loss in long supply and return lines.» It is recommended that you place the temperature sensors as far as possible from any other heating or cooling lines or sources of direct heating or cooling, so that external sources of thermal energy will not influence their readings. This allows for accurate sensing of the temperature change (Delta-T) experienced by the liquid as it flows through the hydronic loop.» The sensor location should be free from harmonic motion and low or high frequency vibration.» Place the temperature sensors away from sources of electrical noise that the temperature sensor signal wire could pick up. It is also recommended to place the sensors close to the main unit thereby reducing or eliminating the need for additional cable. The Flow Meter» Refer to the Insertion Turbine Flow Meter Installation and Adjustment Guide. 3.2 MECHANICAL INSTALLATION 3.21 THERMOWELL INSTALLATION It is important that no dirt or other foreign material be allowed into the thermowells as this could affect the thermal response of the system. Standard Thermowells The drawings on pages A-2 and A-2.1 show the standard thermowell installation in various pipe materials. Do not overtighten threaded thermowells as it could cause the opening to narrow. System-1 BTU Meter Installation Guide - Rev. 7/10/01 9

16 Hot Tap Thermowells The drawings on pages A-3 and A-4 show a Hot Tap Thermowell installation in welded steel pipe. Install the valve assembly as shown, then drill a 7/8 hole using a wet-tap drilling machine. Once the valve assembly has been installed, the thermowell assembly can be inserted into the flow stream without a system shutdown. WARNING: Hot Tap Thermowells are designed to be inserted and removed under pressure. Read instructions carefully before proceeding further. Failure to follow these instructions could result in serious injury. Insertion of the Hot Tap Thermowell 1) First, calculate the insertion force (lbs.) required by multiplying the system pressure (psi) by The person inserting well should ensure adequate footing for the force required, prior to opening the valve. 2) Thread the hot tap adapter into the valve. Firmly grasp the wiring enclosure, loosen the position clamping nut, open the valve, and carefully push the thermowell into the flow stream. NOTE: If strong vibration is felt, withdraw the thermowell until the vibration stops. 3) Carefully tighten the position clamping nut which is located at the top of the 1" NPT hot tap adapter fitting. Do not release the wiring enclosure until the position clamping nut has been tightened. DO NOT OVER TIGHTEN. If fluid leaks, do not attempt to correct by tightening this nut further. Fluid is sealed by an internal o-ring. Contact the factory for assistance in the event of a leak. Removal of the Hot Tap Thermowell 1) System pressure will push the thermowell out of the flow stream when the clamping nut is released. Be sure to establish safe footing prior to loosening the clamping nut. The force pushing out against the thermowell is the same as the insertion force calculated above. 2) Grasp the wiring enclosure firmly, holding the thermowell in the pipe then loosen the position clamping nut. After the thermowell is completely withdrawn, carefully close the isolation valve. NOTE: Rotate the well back and forth as you slowly close the valve to ensure that the lower tip is completely free of the valve! If resistance is felt, open valve and rotate the well as you pull it out of the pipe further, then try again. DO NOT let go of the wiring enclosure until the thermowell is completely withdrawn and the valve is closed. 10 System-1 BTU Meter Installation Guide - Rev. 7/10/01

17 3.22 TEMPERATURE SENSOR INSTALLATION The temperature sensors are factory matched and tagged by serial number and labeled as HI and LO temperature sensors. Sensors from different pairs cannot be used and must be returned to the factory for recalibration. If the HI and LO tags are accidently removed, please contact the factory for simple instructions to determine which is the HI and which is the LO sensor. NOTE: Placement of the HI and LO sensors depends on the model/application. Please refer to page 12 for further details. Apply a thin coat of thermally conductive grease to the temperature sensor, and gently insert the temperature sensor all the way into the thermowell until it contacts the bottom of the cavity. Gently tighten the retainer nut. DO NOT OVERTIGHTEN. The thermowell completely seals the plumbing system without the retainer cap. The only purpose for the nut is to keep the sensor from losing contact with the bottom of the thermowell cavity. Finger-tight is adequate. NOTE: Cable length is specified at time of order. Cable provided for temperature sensors is #22 gauge twisted shielded pair. Additional cable can be added in the field if necessary, but must be twisted shielded pair #22 gauge minimum and #18 gauge maximum FLOW METER INSTALLATION Determine which pipe (supply or return) has the longer unobstructed straight run. Install the flow meter in the longest straight pipe run available. One temperature sensor should be installed downstream of the flow meter. Also refer to the Installation manual and/or other documentation that is provided with your ONICON Flow Meter. System-1 BTU Meter Installation Guide - Rev. 7/10/01 11

18 PLACEMENT OF HI AND LO TEMPERATURE SENSORS 1) System-1 Model 100 A) Heating Mode Hi Temperature Sensor in supply pipe Lo Temperature Sensor in return pipe B) Cooling Mode Hi Temperature Sensor in return pipe Lo Temperature Sensor in supply pipe 2) System-1 Model 110 and Model 120 HI Temperature Sensor always in supply pipe regardless of actual temperature LO Temperature Sensor always in return pipe regardless of actual temperature 3) System-1 Model Stratified Thermal Storage System HI Temperature Sensor in (upper) tank return line. (This line should always have a higher temperature than the other line.) LO Temperature Sensor in (lower) tank charge line. (This line should always have a lower temperature than the other line.) 12 System-1 BTU Meter Installation Guide - Rev. 7/10/01

19 3.3 ELECTRICAL INSTALLATION All user supplied conduit fittings, junction boxes, etc. are to be installed at this time as required by legal codes AC POWER Utilize an electrically clean power line, free of electrical noise and protected from high voltage spikes, power surges, and brown-outs. The power source should be a separate line with its own circuit breaker or circuit protection device. Use a three wire service in which one wire is a protective ground. CAUTION: BE SURE AC POWER IS TURNED OFF AT THIS POINT Connect the power source to the main unit through the conduit or strain relief hole located on the bottom left hand side of the main unit. Fasten the power line wires under the appropriate screw terminals (Appendix A-13, Power Supply Board). Now that you have connected the AC Power, turn on the power to verify the operation of the power lights. Neither the main power light on the front power panel or the red LED located on the power supply should flash. If there is any problem, turn the power off immediately and check your wire connections. Call ONICON s Customer Service Department with questions. TURN AC POWER OFF AT THIS POINT 3.32 INPUT SIGNAL CONNECTIONS FROM TEMPERATURE SENSORS AND FLOW SENSOR Make connections on the mother board, located in the main unit, at terminal strip TB2. Refer to page A-6 for details. Note that the number of wires from the flow meter and color code is dependent on which model you are using. Refer to the documentation provided with the flow meter for specific flow meter wiring details. System-1 BTU Meter Installation Guide - Rev. 7/10/01 13

20 3.33 OUTPUT SIGNAL CONNECTIONS Refer to page A-7 for: Refer to page A-8 for: - Contact Closure Outputs for BTU Total - Mode Relay Output - Analog Temperature Outputs - Analog BTU Rate Outputs - Analog Liquid Flow Rate Outputs. ONLY QUALIFIED SERVICE PERSONNEL SHOULD MAKE CONNECTIONS BETWEEN THE SYSTEM-1 AND THE USER S EXTERNAL EQUIPMENT. ANY MISAPPLICATION OF POWER AND/OR GROUND CAN RESULT IN IMPROP- ER OPERATION OF THE UNIT OR DAMAGE TO THE SYSTEM-1, THE FLOW METER CIRCUITRY, AND TO EXTERNALLY CONNECTED EQUIPMENT. ANY DAMAGE TO THE SYSTEM-1 BTU METER, THE FLOW METER, OR ANY OTHER CUSTOMER CONNECTED EQUIPMENT WHICH OCCURS THROUGH MISAPPLICATION OF THE EXTERNAL CONNECTION CAPABILITY OF THE SYSTEM-1, IS THE SOLE RESPONSIBILITY AND LIABILITY OF THE CUS- TOMER AND IS NOT COVERED UNDER ANY ONICON INCORPORATED WARRANTY, EITHER WRITTEN OR IMPLIED. 14 System-1 BTU Meter Installation Guide - Rev. 7/10/01

21 SECTION 4.0: SYSTEM-1 START-UP AND COMMISSIONING For systems with two-wire (current based) temperature sensors 4.1 START-UP Approximately seconds after main power is activated, the unit will begin to calculate energy. The following sections describe how to verify operation of the System-1 and for systems without optional LCD readouts to compare flow and temperature readings to expected values ELECTRO-MECHANICAL TOTALIZER The totalizer will increment along with the output signal contact closure each time the amount of thermal energy representing the scale factor has been calculated (refer to the calibration data sheet for the unit s scale factor). The electro-mechanical register is non-resetable, and will roll over at 999,999 counts. The scale factor is also printed on the front panel. Example: If the scale factor is BTU x 1,000 and the totalizer reading is 2,423, then the amount of thermal energy recorded is 2,423 x 1,000 = 2,423,000 BTUs 4.2 DIAGNOSTICS IMPORTANT: Each BTU Meter is calibrated at the factory for a specific flow meter. Be sure to connect the flow meter and temperature sensors with the same serial number as the BTU meter. NOTE: Also refer to page A-11, System-1 Mother Board diagram DIAGNOSTIC LEDs Liquid Flow LED located on Mother PCB, right side, just below terminal block 2. The flash rate is proportional to the liquid flow rate. Non-flashing LED indicates no flow signal. Energy LED located on Heat computer PCB, upper left corner as you face the System-1 with access door open. The flash rate is proportional to the calculated energy rate. Non-flashing LED indicates no energy transfer. If liquid flow LED is flashing check the wiring and placement of the HI and LO temperature sensors. If they are reversed, the unit will not calculate energy. Model 110 and 120 will calculate energy regardless of temperature sensor placement, however, the logic for the mode switch is dependent on proper placement of the sensors. System-1 BTU Meter Installation Guide - Rev. 7/10/01 15

22 4.22 TEMPERATURE SIGNALS TEST POINTS Near the middle of the Mother PCB are three test points configured in an inverted triangle. Use these test points to measure low temperature, high temperature and delta-t. The scaling is 10 mv per F, therefore, a reading of VDC = 54.5 F. If temperature readings are unusually high or low, verify that both sensors are inserted completely into their thermowells. Also verify that the thermowells are installed correctly and are inserted into the flowing stream. Note for Model 100, if the temperature sensors are reversed, as evidenced by a negative delta-t, the unit will not calculate energy ANALOG OUTPUTS (OPTIONAL) OPTIONAL analog output signals for supply and return temperatures are located towards the lower end of TB1 near the middle of the Mother PCB. The scaling and signal type is listed on the calibration data sheet and is custom calibrated for each meter. Consult the factory if you cannot locate the calibration data sheet FLOW SIGNALS ONICON Turbine Flow Meters provide multiple electronic outputs to facilitate commissioning during the start-up phase of a project and during subsequent operation throughout the life of the meter. By calculating and comparing the volumetric flow rate in GPM from each of the outputs, various installation deficiencies can be uncovered and corrected. The following readings should be taken while holding the flow rate constant. If holding a constant flow rate is not possible, take the various output readings a quickly as possible to lessen the possibility of a change in flow rate between readings affecting the results. (Please note that the electronic sensing system will not work in air, therefore, blowing on the turbine(s) will not produce a signal.) Verify that 24 V is present at the flow meter. (serial # and later allow 24V AC or DC, earlier meters required 24 VDC). Confirm that the meter is tagged for the pipe size it is installed in (measure the circumference of the pipe to verify the size). Verify the insertion depth and meter orientation as described in the flow meter Frequency Output. 16 System-1 BTU Meter Installation Guide - Rev. 7/10/01

23 NOTE: For the following tests, refer to the right side of the System-1 Mother PCB in the area labeled FLOW METER CONNECTIONS. If diagnostic signals were not brought back to the BTU meter, they can be measured at the flow meter. The System-1 calculates energy based on the frequency output from the flow meter. Any additional flow signals such as analog (4-20 ma) or contact closures are not used by the System-1. Those additional signals are for connection to the user s control system or other monitoring device. The frequency output signal is available on the green wire (frequency output) and is referenced to the black wire (common ground) of the flow meter cable. All output signals are also available from within the electronics enclosure of the flow meter (see manual). The average frequency output signal is a 0-15 VDC pulsed output ranging up to 200 Hz and must be measured with a frequency counter or oscilloscope. Measure the frequency between the average frequency output (green wire) and the common ground (black wire). The relationship between frequency and flow rate is as follows: Flow Rate (GPM) = 60 x Frequency (Hz Meter Factor (pulses per gallon)* *The meter factor is tagged on the flow meter and is also listed on the calibration data sheets shipped with each flow meter. Please contact the factory if you cannot locate the meter factor. Also measure these signals in DC volts. A normal square wave will generate a 6 to 7 VDC signal as read by a typical handheld multimeter. A voltage close to zero or 15 VDC indicates a turbine that is not spinning. In this case, remove the meter and check the turbines. A low voltage in the 1-3 VDC range indicates potential electronic damage which should be evaluated further. F-1200 Series Dual Turbine Additional diagnostic information is available from the F-1200 Series Dual Turbine Flow Meter. The individual upper turbine and lower turbine frequencies are available and can be used to verify the operation of the flow meter. Measure the frequency between the upper and lower turbine frequency output (white or orange wire, respectively) and the common ground (black wire). The frequencies should be within 20% of each other, depending upon the installation location, and the average frequency should be the average of the top and bottom turbine frequencies. System-1 BTU Meter Installation Guide - Rev. 7/10/01 17

24 If either the upper turbine or lower turbine frequencies are substantially different than the other, the meter should be removed for visual inspection for turbine damage or clogging with debris. Also measure the DC voltage for these outputs as described above ENERGY RATE CALCULATION The BTU rate in BTU s per minute may be calculated with the following* formula: BTU Rate (BTU/min) = x Delta T (F) x Flow Rate (GPM) Where Delta T = difference between supply and return temperatures *This equation is for straight water systems. Glycol solutions require a different multiplier. The BTU Rate may be used to verify the operation of the BTU Meter by timing the pulses of the BTU mechanical totalizer. Compare the actual measured time between an increment in the mechanical register to the value calculated below. This is an approximate comparison due to the possible changes in flow rate and Delta T during the test period. The amount of time (in seconds) between pulses can be calculated as follows: Time Between Pulses (sec) = 60 x BTU Multiplier BTU Rate (BTU/min) where the BTU multiplier is found on the front panel BTU totalization display (Example: BTU x 1,000). For units calibrated in Ton-Hours use a BTU multiplier of 12, System-1 BTU Meter Installation Guide - Rev. 7/10/01

25 APPENDIX A - DRAWINGS A-1 TYPICAL SYSTEM INSTALLATION A-2 STANDARD THERMOWELL ASSEMBLY A-2.1 A-3/A-4 THERMOWELL INSTALLATION HOT TAP THERMOWELL (2 PAGES) A-5 TEMPERATURE SENSOR ASSEMBLY A-6 MOTHER BOARD TEMPERATURE AND FLOW SENSOR INPUT CONNECTIONS A-7 MOTHER BOARD OUTPUT CONNECTIONS A-8 ISOLATED ANALOG FLOW METER OUTPUT A-9 NON-ISOLATED ANALOG FLOW METER OUTPUT A-10 SCALED FLOW METER OUTPUT A-11 MOTHER BOARD A-12 BTU COMPUTER BOARD A-13 POWER SUPPLY BOARD A-14 ANALOG TEMPERATURE OUTPUT BOARD A-15 ANALOG BTU RATE OUTPUT BOARD System-1 BTU Meter Installation Guide - Rev. 7/10/01

26 10¾" POWER 120 VAC Return Supply BTU X 1,000 6" TYPICAL SYSTEM-1 INSTALLATION ONICON insertion flow meter Output signal(s) to control system SYSTEM-1 BTU METER HI. TEM. High "T" Sensor Heat Exchanger LO. TEM. Low "T" Sensor 2161 Logan St., Clearwater, Florida Tel (727) Fax (727) sales@onicon.com A-1

27 STANDARD THERMOWELL ASSEMBLY FOR SYSTEM-1 BTU METER SHOWN WITH TEMPERATURE SENSOR PLACE ELECTRONICS MODULE IN BOX AFTER CONNECTING WIRES. HI-TEMP SIGNAL (RED) COMMON (BLACK) S/N /8" MINIMUM HOLE SIZE PROVIDE #18 TWISTED SHIELDED PAIR. COIL ONE FOOT OF EXTRA CABLE IN CONDUIT BOX. 1/2" HOLE FOR CONDUIT OR STRAIN RELIEF FITTING. 1/2" NPT WELDED BRANCH OUTLET NOTES: 1. If additional couplings are required, ensure that tip of thermowell remains in flow stream. A /

28 Thermowell Installation Copper Tees Threaded Tee Welded Pipe ONICON furnished Junction Box (With System-1 only) ONICON furnished Junction Box (With System-1 Only) ONICON furnished Junction Box (With System-1 only) ONICON furnished bushing with 1/2" NPT outlet 1/2" NPT ONICON Furnished 1/2" NPT Welded Branch Outlet ONICON Furnished 1" Sweat x 1/2" NPT Flush Bushing 5/8" Minimum Hole Size ONICON Furnished Copper Tee With 1" Outlet Customer supplied threaded tee (outlet size = line size) IMPORTANT Use no additional bushings to ensure that tip of thermowell is inserted into flow stream. NOTES: 1. If additional fittings are required, ensure that tip of thermowell remains in flow stream. 2. Thermowell length varies with pipe size Logan St., Clearwater, Florida Tel (727) Fax (727) sales@onicon.com A

29 HOT TAP INSTALLATION DETAIL FOR THERMOWELL IN WELDED PIPE ***CAUTION*** SYSTEM MAY BE UNDER HIGH PRESSURE. When adjusting the thermowell position or removing it, be sure to hold the conduit box firmly by hand before SLOWLY loosening the positioning clamping nut. Failure to do this will allow the pressure to suddenly and rapidly force the thermowell from the pipe and someone could be seriously injured if struck by the thermowell. The thermowell could also be damaged or break apart causing a break in the water seal with the resultant loss of large amounts of water. HOT TAP ADAPTER INSTALLATION KIT COMPONENTS "O" RING SEAL 1" CLOSE 1" FULL PORT NIPPLE BALL VALVE 1" NPT WELDED BRANCH OUTLET POSITION CLAMPING NUT DO NOT OVER TIGHTEN HOLE SIZE 7/8" DIA MIN 5-1/2" WITHDRAWAL STOP NON-REMOVABLE CONDUIT BOX STRAIN RELIEF CONNECTOR THERMOWELL SHOWN WITHDRAWN INTO HOT TAP ADAPTER 2072 / Logan St., Clearwater, Florida Tel (727) Fax (727) A-3

30 HOT TAP THERMOWELL ASSEMBLY FOR SYSTEM-1 BTU METERS TIGHTEN CAP WITH FINGERS TO PRESS TEMPERATURE SENSOR TO BOTTOM OF WELL. ONICON TEMPERATURE SENSOR ASSEMBLY ATTACH ELECTRONICS MODULE TO VELCRO PATCH IN BOX AFTER CONNECTING WIRES. COIL TWO FEET OF EXTRA CABLE IN CONDUIT BOX SENSOR PLASTIC END PIECE SPACER SLEEVE (Length varies with Thermowell length) THREADED RETAINER CAP ELECTRONICS MODULE HI-TEMP TEMPERATURE SIGNAL (RED) COMMON (BLACK) S/N / Logan St., Clearwater, Florida Tel (727) Fax (727) A-4

31 SYSTEM-1 BTU METER STANDARD TEMPERATURE SENSOR ASSEMBLY HI-TEMP TEMPERATURE SIGNAL (RED) COMMON (BLACK) ELECTRONICS MODULE SPACER SLEEVE (Length varies with thermowell length) PLASTIC END PIECE SENSOR S/N A-5

32 SYSTEM-1 BTU METER MOTHER BOARD TEMPERATURE AND FLOW SENSOR INPUT CONNECTIONS TEMPERATURE CONNECTIONS FLOW METER CONNECTIONS * * * * * * * A A B B C C D SIGNAL (RED) COMMON (BLK) SIGNAL (RED) COMMON (BLK) 24 VDC (RED) FREQUENCY (GREEN) GROUND (BLACK) TOP TURBINE (WHITE) BOTTOM TURBINE (ORANGE) 0-10 VDC or CONTACT (BROWN) 4-20mA or CONTACT (BLUE) DIRECTION CONTACT (GREY) DIRECTION CONTACT (VIOLET) ISOLATED GROUND (YELLOW) HIGH TEMPERATURE SENSOR PROBE LOW TEMPERATURE SENSOR PROBE FLOW METER SOME FLOW METER OUTPUTS ARE OPTIONAL AND THE WIRES SHOWN HERE WILL NOT BE PRESENT ON EVERY FLOW METER. Wire connections and colors are the same for all flow meters in the ONICON product line. Flow meters are selected separately and shipped with their own installation manuals and wiring diagrams. 2058C TB2 * BASIC CONNECTIONS REQUIRED BY ALL INSTALLATIONS A OPTIONAL CONNECTIONS FOR DUAL TURBINE DIAGNOSTICS IF DESIRED NOT NECESSARY FOR OPERATION OF THE BTU METER B ADDITIONAL CONNECTIONS FOR ANALOG OUTPUT FLOW METERS AND DIVIDED or SCALED OUTPUT FLOW METERS C D ADDITIONAL CONNECTIONS FOR BIDIRECTIONAL FLOW METERS ADDITIONAL CONNECTIONS FOR ISOLATED ANALOG OUTPUT FLOW METERS A

33 SYSTEM-1 BTU METER MOTHER BOARD OUTPUT CONNECTIONS MODEL 100 MODEL MODE RELAY NOT AVALIABLE ON MODEL MODE RELAY OPEN: BTU TRANSFR IN MODE 1 CLOSED:BTU TRANSFER IN MODE MODE 1 OUTPUT CALIBRATED CONTACT CLOSURE OUTPUT FOR HEATING OR COOLING SYSTEMS 3 4 MODE 1 OUTPUT CALIBRATED CONTACT CLOSURE OUTPUT FOR MODE 1 AND 2 ON THE SAME CHANNEL 5 6 MODE 2 OUTPUT NOT AVAILABLE ON MODEL MODE 2 OUTPUT NOT AVAILABLE ON MODEL ANALOG OUTPUT 0-10 VDC OR 4-20 ma OUTPUT FOR TEMPERATURE OF HIGH TEMP SENSOR ANALOG OUTPUT 0-10 VDC OR 4-20 ma OUTPUT FOR TEMPERATURE OF HIGH TEMP SENSOR. OPTIONAL ANALOG OUTPUT 0-10 VDC OR 4-20 ma OUTPUT FOR TEMPERATURE OF LOW TEMP SENSOR. OPTIONAL ANALOG OUTPUT 0-10 VDC OR 4-20 ma OUTPUT FOR TEMPERATURE OF LOW TEMP SENSOR ANALOG OUTPUT 0-10 VDC OR 4-20 ma OUTPUT FOR BTU TRANSFER RATE ANALOG OUTPUT 0-10 VDC OR 4-20 ma OUTPUT FOR BTU TRANSFER RATE. TB1 TB1 MODEL 120 MODEL 130 FOR USE WITH BI-DIRECTIONAL FLOW METERS 1 2 MODE RELAY OPEN: BTU TRANSFER IN MODE 1 CLOSED: BTU TRANSFER IN MODE MODE RELAY OPEN: BTU TRANSFER IN MODE 2 CLOSED: BTU TRANSFER IN MODE 1 * 3 4 MODE 1 OUTPUT CALIBRATED CONTACT CLOSURE OUTPUT FOR MODE MODE 1 OUTPUT CALIBRATED CONTACT CLOSURE OUTPUT FOR MODE 1 * 5 6 MODE 2 OUTPUT CALIBRATED CONTACT CLOSURE OUTPUT FOR MODE MODE 2 OUTPUT CALIBRATED CONTACT CLOSURE OUTPUT FOR MODE ANALOG OUTPUT 0-10 VDC OR 4-20 ma OUTPUT FOR TEMPERATURE OF HIGH TEMP SENSOR ANALOG OUTPUT 0-10 VDC OR 4-20 ma OUTPUT FOR TEMPERATURE OF HIGH TEMP SENSOR. OPTIONAL ANALOG OUTPUT 0-10 VDC OR 4-20 ma OUTPUT FOR TEMPERATURE OF LOW TEMP SENSOR. OPTIONAL ANALOG OUTPUT 0-10 VDC OR 4-20 ma OUTPUT FOR TEMPERATURE OF LOW TEMP SENSOR ANALOG OUTPUT 0-10 VDC OR 4-20 ma OUTPUT FOR BTU TRANSFER RATE ANALOG OUTPUT 0-10 VDC OR 4-20 ma OUTPUT FOR BTU TRANSFER RATE. TB1 TB1 * MODE RELAY IS CLOSED WHEN WATER FLOW IS IN THE DIRECTION OF THE ARROW ON THE FLOW METER. 2058C A

34 SYSTEM-1 BTU METER MOTHER BOARD ISOLATED ANALOG FLOW METER OUTPUT ISOLATED 4-20 ma FLOW RATE OUTPUT SIGNAL GND FREQUENCY (GREEN) GROUND (BLACK) TOP TURBINE (WHITE) BOTTOM TURBINE (ORANGE) 0-10 VDC or CONTACT (BROWN) 4-20mA or CONTACT (BLUE) DIRECTION CONTACT (GREY) DIRECTION CONTACT (VIOLET) ISOLATED GROUND (YELLOW) FLOW METER SOME FLOW METER OUTPUTS ARE OPTIONAL AND THE WIRES SHOWN HERE WILL NOT BE PRESENT ON EVERY FLOW METER. Wire connections and colors are the same for all flow meters in the ONICON product line. Flow meters are selected separately and shipped with their own installation manuals and wiring diagrams. TB2 A

35 SYSTEM-1 BTU METER MOTHER BOARD NON-ISOLATED ANALOG FLOW METER OUTPUT COMMON GND NON-ISOLATED 4-20 ma FLOW RATE OUTPUT SIGNAL FREQUENCY (GREEN) GROUND (BLACK) TOP TURBINE (WHITE) BOTTOM TURBINE (ORANGE) 0-10 VDC or CONTACT (BROWN) FLOW METER SOME FLOW METER OUTPUTS ARE OPTIONAL AND THE WIRES SHOWN HERE WILL NOT BE PRESENT ON EVERY FLOW METER. SIGNAL 4-20mA or CONTACT (BLUE) DIRECTION CONTACT (GREY) Wire connections and colors are the same for all flow meters in the ONICON product line. DIRECTION CONTACT (VIOLET) ISOLATED GROUND (YELLOW) Flow meters are selected separately and shipped with their own installation manuals and wiring diagrams. TB2 2058C A

36 SYSTEM-1 BTU METER MOTHER BOARD SCALED FLOW METER OUTPUT SCALED OUTPUT CONTACTS FREQUENCY (GREEN) GROUND (BLACK) TOP TURBINE (WHITE) BOTTOM TURBINE (ORANGE) CONTACT (BROWN) FLOW METER SOME FLOW METER OUTPUTS ARE OPTIONAL AND THE WIRES SHOWN HERE WILL NOT BE PRESENT ON EVERY FLOW METER. CONTACT (BLUE) DIRECTION CONTACT (GREY) DIRECTION CONTACT (VIOLET) ISOLATED GROUND (YELLOW) Wire connections and colors are the same for all flow meters in the ONICON product line. Flow meters are selected separately and shipped with their own installation manuals and wiring diagrams. TB2 2058C A

37 SYSTEM-1 BTU METER MOTHER BOARD CONNECTIONS (2-wire Temperature Sensors) TEST_HIGH MODE RELAY SIGNAL (RED) J1 1 R5B 4B 10R0 R5A 10R0 R7 R6 TEST_LOW TEMP_LCD 1 1 OUTPUT CONTACTS MODE 1 - BTU OUTPUT CONTACTS MODE 2 - BTU OUTPUT CONTACTS HIGH TEMP COMMON (BLK) SIGNAL (RED) LOW TEMP COMMON (BLK) 24 VDC (RED) FREQUENCY (GREEN) TEMPERATURE INPUTS J2 1 5 J J3 LED_IND FREQ F_GPM 1 BTU_LCD 1 1 TP1 TP2 - - LOW TEMP ANALOG OUTPUT HIGH TEMP ANALOG OUTPUT GROUND (BLACK) TOP TURBINE (WHITE) BOTTOM TURBINE (ORANGE) 0-10 VDC / CONTACT (BROWN) 4-20mA / CONTACT (BLUE) (GREY) FLOW METER CONNECTIONS FACTORY TEST BTU BTU_REG J6 TB1 - BTU RATE ANALOG OUTPUT DIAGNOSTICS & CALIBRATION TB DIRECTION CONTACTS (VIOLET) ISOLATED GROUND (YELLOW) 10 R1 R3 9 TEMPERATURE FLOW SIGNAL SOURCE T C1 TEST RUN FLOW U HZ LOW T HIGH T METER CAUTION: LED1 5 - RATE 4 C2 3 DISCONNECT BTU SCALING = 10mV/ F - OUTPUT BEFORE TESTING WITH 60Hz INPUT - EXTERNAL SOURCE 15V PULSE Q1 FLASH RATE INDICATIVE OF FLOW D1 1N4004 1N4004 D G G -5 G 60HZ T1 D2 1N4004 1N4004 D4 J2-12 J REV. H ONICON INC. CLEARWATER,F COPYRIGHT 2000 VAR1 103 R7 C N N4744 1N /4 AMP TB1 F1 27 OHM 5% 3W C5 C1 U1 D7 D6 D5 R5 R3 R2 R4 471 LED2 LED1 C4 R6-5VDC 5VDC 120V NEUTRAL GROUND R1 J REV. E Logan St., Clearwater, Florida Tel (727) Fax (727) sales@onicon.com A

38 Q9 C19 C14 R49 D12 D15 R48 R33 D9 D11 C10 R7 SHUNT TP4 LED1 C13 R37 TP3 U Q Q3 R64 SWITCH 1 8 MODE R59 Q5 R61 Q4 R66 1 J1 U12 R65 R63 C9 105 D10 D8 C11 MODE 1 U14 C2 TEMP R5 R31 R6 R4 R38 D13 R60 SP5 R35 R34 SP4 C12 R62 U5 OUTPUT 1 8 MODE OUTPUT MODE 1 /- U10 SP D1 D20 D21 D16 D17 LM258 SP1 DIR C15 C3 106 C4 D7 R32 U U1 MODE 2 LM258 R U15 R2 R R B 100R B K D D5 R12 R52 C5 R3 R11 R9 R10 LM D3 36 D2 SP3 U11 LBA ZERO ADJUST 3006P R16 R15 R53 3 R SHUNT1 1 SHUNT4 R U9 8 1 U13 R20 U LM393 D4 U R29 R28 MODE 1 MODE 2 RN1 C25 U16 LMC6062 C7 D22 SAW TP2 R21 D19 R14 R18 R17 R50 C6 Q2 C23 C22 C D R27 C21 R30 SPAN ADJUST C16 R25 C20 Q R U2 106 LM258 R K100M R26 C1 C24 U6 COPYRIGHT 1999 CLEARWATER, FL ONICON INC. D18 D14 R39 R55 R56 R57 R58 R REV.H U15 50ms 3006P ms 2.5s 2 ZERO ADJUST R51 TP D SYSTEM-1 BTU METER BTU COMPUTER BOARD A-12

39 SYSTEM-1 BTU METER POWER SUPPLY BOARD D1 1N4004 1N4004 D G G -5 G 60HZ T1 D2 1N4004 1N4004 D4 J2-12 J VAR1 R7 C N N4744 1N F1 1/4 AMP TB1 27 OHM 5% 3W C5 C1 U1 D7 D6 D5 R5 R3 R2 471 C4 LED2 R6-5VDC R4 LED1 5VDC R1 J1 120V NEUTRAL GROUND REV. E 120 VAC CONNECTION A D

40 SYSTEM-1 BTU METER ANALOG TEMPERATURE OUTPUT BOARD T1B Q1B 3 2 HY C6B 822 U3B R13B D4B VR1B R14B C13B 1N5231 C11B R31B VR2B C14B 1 C23B C15B - 1N5242 R24B R30B C19B R15B TP2B C17B 104 R32B SHUNT2B 0-10V C12B C22B D7B D8B D5B 510 D6B R25B C21B 4-20mA LM258 R26B 4992 R28B Ispan Izero 104 U5B C18B Q2B 31R6 4 5 XTR110KP U7B T1A Q1A 3 2 HY R13A D4A R14A C13A VR1A U5A R31A C11A N C14A VR2A 1 C23A C15A R32A - TP2A R24A R30A C18A R15A C19A C17A 1N R29B R27B R23B R22B R21B ANALOG TEMP. OUTPUT REV. C 1 ONICON INC. CLEARWATER, FL 0-10V SHUNT2A C22A D7A D8A R29A 510 R25A D5A D6A C21A 4-20mA LM258 R26A 4992 R28A Ispan Izero 104 Q2A 31R6 XTR110KP U7A R27A R23A R22A R21A P1 COPYRIGHT 1999 C12A C4B R12B C5B U4B ISO U6B R16B C9B 1002 D3B D2B Vspan C3B C10B R11B R6B 332 R10B R9B C16B SHUNT1B R7B R5B C7B 1002 U2B CHANNEL B C8B R4B R8B 1002 LM258 C20B U1 R1 C2 D1 681 C6A U3A C R3 TP R12A C5A U4A ISO U6A R16A D3A C9A D2A 1002 Vspan R11A C10A R6A 332 R10A R9A C4A C3A R20B R17B R18B SUPPRESSED ZERO SHUNT1A R7A R5A C7A U2A CHANNEL A C8A R4A R8A LM258 R2 202 R20A R17A R18A SUPPRESSED ZERO C16A R19B R19A C20A REV. C 555 A-14