Onicon SYSTEM-40 Operating instructions

11451 Belcher Road South, Largo, FL 33773 • USA • Tel +1 (727) 447-6140 • Fax +1 (727) 442-5699

www.onicon.com • [email protected]

SYSTEM-40 BTU MEASUREMENT SYSTEM

Installation and Operation Guide

06-16

2018 / 35870

FLOW

AND

ENERGY

MEASUREMENT

11451 Belcher Road South, Largo, FL 33773 • USA • Tel +1 (727) 447-6140 • Fax +1 (727) 442-5699 • [email protected]

System-40-BTU Meter Installation and Operation Guide 06/16 - 2018 / 35870 Page 2

SAFETY INFORMATION

This meter was calibrated at the factory prior to shipment. To ensure correct use of the meter, please

read this manual thoroughly.

Regarding this Manual:

• This manual should be passed on to the end user.

• Before use, read this manual thoroughly to comprehend its contents.

• The contents of this manual may be changed without prior notice.

ONICON’s written permission.

• ONICON makes no warranty of any kind with regard to this material, including, but not

limited to, implied warranties of merchantability and suitability for a particular purpose.

• All reasonable effort has been made to ensure the accuracy of the contents of this manual.

However, if any errors are found, please inform ONICON.

• ONICON assumes no responsibilities for this product except as stated in the warranty.

• If the customer or any third party is harmed by the use of this product, ONICON assumes

no responsibility for any such harm owing to any defects in the product which were not

predictable, or for any indirect damages.

Safety Precautions:

The following general safety precautions must be observed during all phases of installation,

operation, service, and repair of this product. Failure to comply with these precautions or with

specic WARNINGS given elsewhere in this manual violates safety standards of design,

manufacture, and intended use of the product. ONICON Incorporated assumes no liability for the

customer’s failure to comply with these requirements. If this product is used in a manner not

specied in this manual, the protection provided by this product may be impaired.

The following symbols are used in this manual:

!

WARNING

Messages identied as “Warning” contain information regarding the personal safety of individuals

involved in the installation, operation or service of this product.

CAUTION

Messages identied as “Caution” contain information regarding potential damage to the product or

other ancillary products.

IMPORTANT NOTE

Messages identied as “Important Note” contain information critical to the proper operation of the

product.

i

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System-40-BTU Meter Installation and Operation Guide 06/16 - 2018 / 35870 Page 3

TABLE OF CONTENTS

1.0 INTRODUCTION ...................................................................................................... 5

1.1 PURPOSE OF THIS GUIDE ........................................................................... 5

1.2 TYPICAL SYSTEM-40 BTU METER ............................................................. 5

1.3 STANDARD FEATURES AND SPECIFICATIONS ........................................ 5

1.4 ADDITIONAL REQUIRED HARDWARE ....................................................... 7

1.5 WORKING ENVIRONMENT ......................................................................... 7

1.6 WARRANTY & SERIAL NUMBER ................................................................ 7

2.0 UNPACKING ... .......................................................................................................... 7

2.1 CHECKING THAT YOU HAVE RECEIVED EVERYTHING .......................... 7

3.0 INSTALLATION ........................................................................................................ 8

3.1 SITE SELECTION ........................................................................................... 8

3.2 INSTALLING THE FLOW SENSOR .............................................................. 9

3.3 INSTALLING TEMPERATURE SENSORS & THERMOWELLS .................. 13

3.3.1 Direct Insertion Temperature Sensors............................................ 13

3.3.2 Thermowells ................................................................................... 14

3.4 REMOTE MOUNTING THE CALCULATOR ENCLOSURE ........................ 14

3.5 POWER & SIGNAL WIRING CONNECTIONS ............................................ 15

4.0 SYSTEM-40 START UP & COMMISSIONING ...................................................... 16

4.1 START UP ..................................................................................................... 16

4.1.1 Single and Dual Mode Display Pages ............................................ 17

4.1.2 Additional Display Pages ............................................................... 18

4.2 COMMISSIONING ....................................................................................... 19

4.2.1 Commissioning Following Initial Power-up.................................. 19

4.3 SEALING THE METER ................................................................................ 23

5.0 DIAGNOSTIC FUNCTIONS ................................................................................... 23

6.0 BACnet® MS/TP ...................................................................................................... 24

6.1 BACnet® OBJECT TYPES ............................................................................. 24

6.2 PROTOCOL IMPLEMENTATION STATEMENT ........................................ 24

6.3 DEVICE OBJECT .......................................................................................... 25

6.4 ANALOG INPUT(S) ..................................................................................... 26

6.5 ANALOG VALUE(S) .................................................................................... 27

6.6 BINARY VALUE(S) ...................................................................................... 28

6.7 MULTI STATE VALUE .................................................................................. 29

6.8 TREND LOG MULTIPLE .............................................................................. 30

7.0 MODBUS® ........................................................................................................ 31

7.1 MODBUS® MEMORY MAP ......................................................................... 32

7.2 DIAGNOSTIC FUNCTION CODE ................................................................. 39

7.3 REPORT SLAVE ID FUNCTION CODE ........................................................ 40

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System-40-BTU Meter Installation and Operation Guide 06/16 - 2018 / 35870 Page 4

8.0 AUXILIARY INPUTS AND OUTPUTS ................................................................... 41

8.1 DETERMINING AUXILIARY INPUT & OUTPUT CONFIGURATION ........ 41

8.2 AUXILIARY INPUTS .................................................................................... 41

8.3 AUXILIARY OUTPUTS ................................................................................ 42

8.3.1 Single Mode Operation Pulse Outputs .......................................... 42

8.3.2 Dual Mode Operation Pulse Outputs ............................................. 43

8.4 ANALOG OUTPUTS .................................................................................... 44

APPENDIX

A-1 SYSTEM-40 WIRING DIAGRAM

A-2 CHANGING RS-485 SETTINGS OR METER PROGRAMMING AFTER

COMMISSIONING

A-3 SELECTING THE RIGHT METER SIZE & CALCULATING PRESSURE LOSS

A-4 CONDITIONS OF SALE

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System-40-BTU Meter Installation and Operation Guide 06/16 - 2018 / 35870 Page 5

SECTION 1.0: INTRODUCTION

1.1 PURPOSE OF THIS GUIDE

The purpose of this guide is to provide installation and commissioning procedures, and basic

operating and servicing instructions for the ONICON SYSTEM-40 BTU Meter.

1.3 STANDARD FEATURES AND SPECIFICATIONS

• Single mode Btu calculations, in either the heating or cooling mode, are totalized and

displayed.

• Two-pipe dual mode Btu calculations in both the heating mode and the cooling modes are

totalized and displayed.

• Three 2-wire signal ports can be congured as pulse inputs or outputs. One of the ports can

be congured as an analog output.

!

WARNING

Only qualied service personnel should attempt to install or service this product. Serious injury

may result from the improper installation or use of this product.

1.2 TYPICAL SYSTEM-40 BTU METER

ONICON’S System-40 is a true heat (Btu) computer, which accepts data from several sensors,

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.

Integral mount shown

Bracket provided for remote mount within 5 ft.

CONTROL SYSTEM

BACnet® MS/TP OUTPUT

24 AC/DC POWER

FAN COIL UNIT

OR

AIR HANDLING UNIT

CHILLED WATER

RETURN

CHILLED WATER

SUPPLY

RETURN TEMP

WATER METER

GAS METER

ELECTRIC METER

ETC

UP TO THREE

PULSE INPUTS

OUTPUT / POWER

SYSTEM-40

BTU METER

Made in USA

KBTU



FLOW

AND

ENERGY

MEASUREMENT

POWER

24 V ac/dc Input Power

Input and Output

Signals and

BACnet / Modbus

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System-40-BTU Meter Installation and Operation Guide 06/16 - 2018 / 35870 Page 6

GENERAL SPECIFICATIONS*

CALIBRATION

Flow meter and temperature sensors are individually

calibrated to N.I.S.T. and or international metrological

standards, followed by a complete system calibration. Field

commissioning is also available.

ACCURACY

FLOW

Meets EN1434 Class 1 accuracy requirements

± 1% of reading over 25:1 turndown

± 2% of reading over 100:1 turndown

Overall turndown exceeds 500:1

Repeatability: ≤ ± 0.2%

TEMPERATURE

Field serviceable MID certied matched pair of 2-wire

1000Ω

platinum RTDs

Calibrated to a differential measurement uncertainty of

± 0.18° F

Meets EN1434/C900.1 accuracy requirements for 3K sensors

CALCULATOR

Computation error: ≤ 0.09% @ 30° F ∆t

Meets EN1434 Class 1 requirements with 3K minimum ∆t

ELECTRICAL

POWER SUPPLY REQUIREMENTS

12-36 VAC, 50/60 Hz, 5 VA maximum

12-42 VDC, 5 W maximum

CLOCK /CALENDAR

Real-time clock / calendar with lithium battery back-up

Estimated battery life ≥ 10 years

PROGRAMMING

Factory programmed for specic application. Field

programming available through the user interface.

MEMORY

Nonvolatile FLASH memory retains all program parameters

and totalized values in the event of power loss.

PULSE INPUTS, OUTPUTS, and ANALOG OUTPUT

The three 2-wire signal ports can be congured as pulse inputs

or outputs. One of the ports can be congured as an analog

output.

Isolated totalizing pulse inputs for use with sinking open

collector or dry contact outputs

Input rating: 30 VDC, 10 mA maximum

Pulse duration: 50 ms minimum

Isolated totalizing solid state contact closure pulse outputs may

be programmed for energy, volume, alarm indication or coil

indication (MODBUS RTU only)

Contact ratings: 50 mA, 30 V

Contact pulse duration: 50, 100, 500 or 1000 ms

(500 ms default)

Analog 4-20 mA, 0-5 V or 0-10 V output for ow rate or

temperature or ∆T

COMMUNICATION PROTOCOLS

BACnet® MS/TP per ASHRAE Standard 135.1: 2009

MODBUS® RTU

NETWORK CONFIGURATION & ADDRESSING

Baud Rates: 4800, 9600, 19200, 38400, 76800, or

115200

Device Address Range: 1 – 255 (1 - 247 MODBUS®)

Device Instance Range: 1 – 4,194,303 (BACnet® only)

Parity: None, Even, Odd (MODBUS RTU only)

NETWORK CONNECTION

Isolated RS485 serial interface

Unit load = ¼

Recommended devices per segment = 32

MECHANICAL

FLOW SENSOR

Individually wet calibrated inline ow sensor with

direct path wetted ultrasonic ow transducers.

IP65 inline ow body with male BSPP (straight) threads

Wetted components:

Brass (Lead free, corrosion resistant)

PEEK

EPDM (FKM optional)

METER COUPLINGS

½” - 2" Meters: Brass couplings with BSPP nut and

male NPT threads

2½” Meters: ANSI class 150 - anges standard optional

PN16, ANSI class 300

Wetted components:

Brass (Lead free)

EPDM (FKM optional)

TEMPERATURE SENSOR PAIR

½” – 1” meter sizes

2-wire platinum RTDs with 1.5m (4.9 ft.) cables

Screw in direct insertion RTDs with M10 (straight)

threads

Wetted components:

RTD – Stainless steel

NPT x M10 reducer bushing – Brass (Lead free)

1¼” – 2 ½” meter sizes

2-wire platinum RTDs with 3.0m (9.8 ft) cables

Push in insertion RTDs for use with thermowells

Wetted components: None

THERMOWELLS

Brass thermowells with ½” male NPT threads

Wetted components:

Thermowells – Brass (Lead free)

NPT reducer bushings – Brass (Lead free)

Sweat x NPT reducer bushings – Brass (Lead free)

CALCULATOR

Detachable enclosure with user interface and backlit

display includes a 5 ft. extension cable and remote

mounting bracket

IP65 polycarbonate plastic enclosure

Wetted components: None

APPROVALS

FCC: Part 15, Subpart B

CE

Conforms to ANSI/NSF 61 & 372 (certication pending)

BTL Certied to ASHRAE 135:2009

*Specications subject to change without notice

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System-40-BTU Meter Installation and Operation Guide 06/16 - 2018 / 35870 Page 7

1.4 ADDITIONAL REQUIRED HARDWARE

For ½” – 1” meter sizes, a customer supplied line size threaded tee is required. The tee is used

with the line size NPT (or copper sweat) x M10 bushing ordered with the meter when installing the

remote temperature sensor.

For 1¼” – 2½” meter sizes, two customer supplied tees are required. The tees are used with the two

½” NPT thermowells ordered with the meter.

2½” meters are provided with raised face anges. Mating anges, ange gaskets and mounting

hardware are required to complete the installation.

1.5 WORKING ENVIRONMENT

The SYSTEM-40 was designed for installation and use indoors in residential, commercial and

light industrial environments that are free of corrosive liquids and fumes, temperature extremes

and excess vibration.

The System-40 may be installed outdoors in protected spaces away from direct sunlight and rain,

sleet or snow.

The operating ambient air temperature range is -13° F to 131° F. Electrical power should be

relatively clean, free of excess high frequency noise and large voltage transients.

1.6 WARRANTY & SERIAL NUMBER

Warranty

ONICON’s 2-year “No-fault” warranty reduces start-up costs by extending coverage for

incidental damage during installation. Certain exclusions apply. Please refer to ONICON’s

Conditions of Sale for details.

Serial Number

The serial number of your SYSTEM-40 is located on the side of the enclosure. The serial number is

a unique identier for the product. Please have this number available when contacting ONICON for

assistance.

SECTION 2.0: UNPACKING

The SYSTEM-40 is generally shipped in one package unless optional hardware or equipment is

ordered. Notify the freight carrier and ONICON if any items are damaged in transit.

2.1 CHECKING THAT YOU HAVE RECEIVED EVERYTHING

• The following items are normally provided with the SYSTEM-40 BTU Meter:

Two line size process connection meter couplings with male NPT threads and sealing

gaskets (shipped attached to meter)

One line size NPT (or copper sweat) x M10 bushing for the remote temperature sensor

OR two thermowells with ½” male NPT threads

One SYSTEM-40 BTU Meter Installation and Operation Guide

One SYSTEM-40 BTU Meter Certicate of Calibration

Please notify ONICON if any of these items are missing.

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System-40-BTU Meter Installation and Operation Guide 06/16 - 2018 / 35870 Page 8

SECTION 3.0: INSTALLATION

The SYSTEM-40 BTU Meter should be installed by experienced plumbers, electricians, and others

with related knowledge and experience in the heating, cooling, and uid metering elds. ONICON

technical support personnel are available via telephone or e-mail to provide technical assistance

before, during and after installation. On-site eld engineering, installation, and service are also

available at an additional cost. Installers should use good trade practices and must adhere to all

applicable state and local building 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, leak inhibitors, and chemically aggressive substances. Flush the entire

system so that it is free of ux, solder, pipe and tube cuttings and any other free moving debris.

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 ow sensor where it will be difcult for personnel to perform periodic

maintenance. When selecting a site for mounting the system components, consider the criteria

under Section 1.5: WORKING ENVIRONMENT, as well as the following.

The following limitations apply to the installation of the meter:

• The ow sensor body must be correctly oriented with respect to the direction of ow in the

pipe. Meters installed with reversed ow will not function.

• The System-40 is provided with xed cable lengths for the ow sensor and temperature

sensors. Do not alter the cable lengths. Doing so will void the calibration and may invalidate

the warranty.

• The maximum operating pressure for the ow sensor body, the direct insertion temperature

sensors, the temperature sensor adapter bushings and the thermowells is 400 psi.

• At uid temperatures above 212° F the calculator enclosure should be remote mounted.

• Do not install the meter in close proximity to strong sources of electromagnetic interference

(e.g. electric motors, VFD’s, etc.)

i

IMPORTANT NOTE

Proper site selection is critical to the performance of this Btu meter. Both the ow sensor and the

remote temperature sensor must be properly located within the piping system in order to ensure

an accurate energy measurement.

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3.2 INSTALLING THE FLOW SENSOR

When properly installed, the ow sensor will only measure ow associated with that portion of the

piping system for which the energy measurement is being made. The ow sensor may be installed

in either the supply or return pipe of the heat exchange circuit. Before you install the sensor, the

entire piping system should be ushed and free of debris. Please refer to the table and diagrams

below when selecting the installation location. Upstream straight unobstructed pipe requirements

vary considerably based on nature of the upstream obstructions. As a general rule, ONICON always

recommends that the sensor be located with as much straight pipe upstream as possible.

A

B

C

D

E & F

G

Flow Direction

A. This is a recommended position for the ow sensor.

B. This is a recommended position for the ow sensor.

C. Avoid installation locations where air can become trapped in the piping system.

D. This is an acceptable installation location for closed loop pressurized systems.

E. Do not install the sensor downstream of modulating valves or partially open valves. Fully open

isolation valves (e.g. ball valves) are OK.

F. Do not install the ow sensor at the inlet of a pump. To prevent cavitation, the minimum

operating pressure at the inlet of the meter must always exceed the pressure drop across the

sensor. Refer to Appendix A-3 for calculating pressure the drop at different ow rates.

G. Avoid installing the sensor downstream of multiple bends out of plane with each other where

there are less than 10 diameters of straight unobstructed pipe between bends.

STRAIGHT RUN REQUIREMENTS

Upstream Obstruction

Minimum Upstream Straight Run Required (Pipe Diameters)

Meter Size

0.5" - 1.0" 1.25" - 2.5"

Single Elbow 0 0

Expander / Reducer 0 0

Coil, Upstream 3 3

Isolation Valve, 2 Position 3 5

Control Valve 10 15

Notes:

1 Straight run is based on use of manufacturer provided couplings

2 Avoid the following obstructions where possible: Modulating valves, pump discharge, multiple

elbows out of plane.

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IMPORTANT NOTE

The ow sensor body must be correctly oriented with respect to the direction of ow in the pipe.

Meters installed with ow in the reverse direction will not function.

i

For ½” – 1” meter sizes the calculator enclosure may be rotated around the axis of the ow

sensor into three different positions. To rotate, temporarily slide the enclosure off the ow sensor

mounting brackets. Remove the two retaining screws and reposition the mounting brackets as

required. Reinstall the enclosure with the display properly oriented for viewing. Mounting tracks

on the back of the enclosure allow for mounting in any orientation.

Flow Direction The sensor port is always on

the downstream end of meter.

Retaining Nut SealCoupling

Slide calculator

enclosure to

remove from

sensor mounting

brackets

Slide Enclosure

Mounting Tracks

Retaining

Screw

Retaining

Screw

IMPORTANT NOTE

When installing the meter in a vertical pipe with upward ow you must rotate the enclosure back

plate 180° when rotating the display 90°. To accomplish this, temporarily remove the 4 cover

screws and rotate the backing plate.

i

The ow sensor is installed with threaded meter couplings and at sealing gaskets as shown

below. Orient the sensor body by aligning the ow direction arrow with the direction of ow

in the pipe.

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System-40-BTU Meter Installation and Operation Guide 06/16 - 2018 / 35870 Page 11

Orient the ½” - 1” meters as shown below. The meter may be installed with upward or downward

ow in vertical pipes in closed loop pressurized systems. Avoid any installation locations where

the pipe may not be completely full.

Back View Side View

Back View

Side View

Do not orient meter as shown above

Preferred Orientation for Horizontal Housing

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System-40-BTU Meter Installation and Operation Guide 06/16 - 2018 / 35870 Page 12

Orient the 1¼" - 2½" meters as shown below. The meter may be installed with upward or

downward ow in vertical pipes in closed loop pressurized systems. Avoid any installation

locations where the pipe may not be completely full.

The ow sensor is installed with threaded meter couplings and at sealing gaskets as shown

below. Orient the sensor body by aligning the ow direction arrow with the direction of ow in

the pipe.

Side View

Preferred Orientation for Horizontal Housing

Side View

Do not orient meter as shown below

The sensor port is

always on the

downstream

end of meter.

Flow Direction

SealCoupling

Retaining Nut

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System-40-BTU Meter Installation and Operation Guide 06/16 - 2018 / 35870 Page 13

3.3 INSTALLING TEMPERATURE SENSORS & THERMOWELLS

When properly installed, the temperature sensors will only measure the inlet and outlet

temperatures of the heat exchange circuit where the energy measurement is being made. Before

you install thermowells or direct insertion sensors, the entire piping system should be ushed

and free of debris.

3.3.1 Direct Insertion Temperature Sensors

SYSTEM-40 BTU Meters congured with direct insertion temperature sensors are

provided with one sensor pre-installed in the ow sensor body. The second sensor must

be installed in the pipe opposite that of the ow sensor as shown below. The tapered

sensors are provided with an M10 threaded tting and a at sealing gasket. For standard

installations, an M10 x NPT (or copper sweat) bushing is provided for use with a customer

supplied line size tee. The torque required to properly install the temperature sensors is

4lb-ft.

FAN COIL UNIT

OR

AIR HANDLING UNIT

SUPPLY

RETURN TEMP

SYSTEM-40

BTU METER

Made in USA

KBTU



FLOW

AND

ENERGY

MEASUREMENT

Customer

supplied line

size tee

M10 x NPT

bushing provided

Sealing gasket

Temperature

sensor

!

CAUTION

The platinum RTD sensors provided with the System-40 are calibrated with the attached cables.

Altering these cable lengths will result in signicant measurement errors and void the meter

calibration.

Customer

supplied line

size tee

Flush bushing

provided

RTD &

Gasket

Copper Installation

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System-40-BTU Meter Installation and Operation Guide 06/16 - 2018 / 35870 Page 14

Slot for Pipe

Clamps

0.219”

Slide Tracks

3.3.2 Thermowells

Standard versions of the 1¼” - 2½” System-40 BTU Meters are provided with two thermowells

with ½” NPT Process Connections for use with customer supplied threaded tees. The

temperature sensors are installed in the thermowells and held in place with a set screw on the

thermowell.

RETURN

SUPPLY

FAN COIL UNIT

OR

AIR HANDLING UNIT

KBTU



Thermowell &

Temperature

Sensor

Line Size x ½"

Bushing **

Customer

Supplied Line

Size Tee

1" Solder x ½"

NPT bushing**

Thermowell &

Temperature

Sensor

Customer

supplied line

size tee with

1" outlet

Copper Installation

3.4 REMOTE MOUNTING THE CALCULATOR ENCLOSURE

The System-40 is provided with a mounting bracket and the cables required for remote mounting

the calculator. The cable lengths must not be altered. The remote mounting bracket is shown

below. It has two mounting holes designed for #10 screws. It also has parallel slots that allow for

the use of pipe clamps when mounting the enclosure on a stanchion or pipe. The bracket may

be used as a template for marking hole locations. Also shown is the back of the calculator. The

mounting bracket slides on to tracks on this back plate.

3"

RED

BLUE*

* Sensor with blue tag is

always installed downstream

from the ow body.

Standard NPT Installation Optional NPT Installation

Thermowell &

Temperature

Sensor

Customer

supplied line

size tee with

½" outlet

** Bushings provided by customer or ordered from ONICON

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System-40-BTU Meter Installation and Operation Guide 06/16 - 2018 / 35870 Page 15

3.5 POWER AND SIGNAL WIRING CONNECTIONS

The System-40 is provided with 4 glands on the right hand side of the enclosure for power and

signal cables. Each includes a strain relief for securing the cabling and a sealing cap. The power

cable should enter the enclosure through the bottom gland. Do not remove the sealing caps from

unused cable glands. To access the wiring connections, remove the 4 cover screws shown below.

Cover Screws

Install power

cable here

Cover Screws

1 2 3 4 5 6 7 8 1 2 3

10

9

H5 SERIAL

TB3 TB2

H3

4321 4321

1 2 1 2 1 2 1 2

TB8 TB7 TB6 TB5 SW6 SW7 SW2 SW1

C34

C33

R6

DS3

R8 H2 SERIAL

2

1

GRD

DS2

R60

3

JMP5

1

CAUTION

INSTALL + SIDE UP

CR2032 BATTERY

BAT1

Internal RTD

(Flow)

External RTD

24V AC/DC (+)

24V COMMON (-)

AUX 1 (+)

AUX 1 (-)

AUX 2 (+)

AUX 2 (-)

AUX 3 (+)

AUX 3 (-)

RS485 (+)

RS485 (-)

RS485 COMMON

TB1 TB4

COMMISSIONING MICROPROCESSOR

RESET

RS485 Termination

1 - 2 = 120 Ω

2 - 3 = None

System-40-BAC Enclosure Label

1048 / 33354 02-15

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www.onicon.com • [email protected]

Actual Size - 4.125” x 2.875”

Cutline

Remote (external) Temperature Sensor

Name Terminal # Description

1000 ohm TB2-1 RTD signal wire

Not used TB2-2 No Connection

Not used TB2-3 No Connection

1000 ohm RTD TB2-4 RTD signal wire

Flow (internal) Temperature Sensor*

Name Terminal # Description

1000 ohm TB3-1 RTD signal wire

Not used TB3-2 No Connection

Not used TB3-3 No Connection

1000 ohm RTD TB3-4 RTD signal wire

Power and Signal Inputs (18 - 22 AWG wire)

Name Terminal # Description

24V ac/dc (+) TB1-1 12 - 36Vac, 50/60Hz, 5 VA max.

12-42Vdc, 5W max.

24V ac/dc Common (-) TB1-2

Aux I/O # 1 (+) TB1-3 Congured as either input or output at factory.

Output rating

Pulse Output:

Pulse duration: Selectable 50, 100, 500, or 1,000 ms

Contact ratings: 50mA, 30VDC max.

*Analog Output (AUX I/O # 3 only):

Selectable: 4-20mA, 0-10VDC, 0-5VDC

Input rating

For use with open collector sinking and dry contact

outputs only.

Pulse duration: 50ms min.

Sinking Current: 1mA max.

Aux I/O # 1 (-) TB1-4

Aux I/O # 2 (+) TB1-5

Aux I/O # 2 (-) TB1-6

Aux I/O # 3 (+) TB1-7

Aux I/O # 3 (-) TB1-8

RS485 (20 - 24 AWG wire)

Name TB4 Description

RS485 B (+) TB4-1

RS485 Unit Load = 1/4

Recommended Devices

per Segment = 32

RS485 A (-) TB4-2

RS485 Common TB4-3

RS485 Termination Resistor

Name JMP5 Description

120 ohm Position 1 Jumper Position 1 & 2

= 120 ohms

120 ohm Position 2

None Position 3 Jumper Position 2 & 3

= No Termination

* This sensor must be in the same

pipe as the ow sensor.

i

IMPORTANT NOTE

Open isolation valves, leak test and purge the piping system of air prior to wiring the meter.

11451 Belcher Road South, Largo, FL 33773 • USA • Tel +1 (727) 447-6140 • Fax +1 (727) 442-5699 • [email protected]

System-40-BTU Meter Installation and Operation Guide 06/16 - 2018 / 35870 Page 16

SECTION 4.0: SYSTEM-40 START-UP AND COMMISSIONING

4.1 START-UP

When power is rst applied to the meter the display will be illuminated and the following start

screen will appear. Momentarily press SEL (select) to access the operating mode (User Screens)

display pages.

Verify that the meter is functional by stepping through the display pages and conrming the ow

rate and temperature data is within expected norms. Momentarily press NEXT or BACK to change

the displayed page. A complete list of the display pages is provided on the following page.

Alarm Indication

Unit of Measure

When reviewing the displayed data, note the factory programmed engineering units on each

display page (e.g. kBtu, gallons, kBtu/h, gpm, ° F, etc.). Note any changes that may be necessary.

These will need to be made during commissioning.

When reviewing the Supply and Return temperature display pages, note which one has the word

“FLOW” in the lower left corner of the page. This is an indication of the ow sensor location in the

piping system. Verify the actual location of the ow sensor in the piping system. It is critical that

the correct location (supply or return) be programmed into the meter.

!

CAUTION

During start-up and commissioning, the FLOW location must be properly identied as being

in the supply or return pipe of the heat exchange circuit. The sensor’s position must then be

programmed into the meter. Failure to do so will result in signicant errors in both the ow

and energy measurements.

To return to the commissioning mode from the user screens, momentarily press MENU. The

following page will appear. Momentarily press EXIT to return to the start screen.

11451 Belcher Road South, Largo, FL 33773 • USA • Tel +1 (727) 447-6140 • Fax +1 (727) 442-5699 • [email protected]

System-40-BTU Meter Installation and Operation Guide 06/16 - 2018 / 35870 Page 17

4.1.1 Single and Dual Mode Display Pages

*

* Will only appear if Aux I/O was congured at factory for pulse input.

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System-40-BTU Meter Installation and Operation Guide 06/16 - 2018 / 35870 Page 18

4.1.2 Additional Display Pages

More Totals

Diagnostic

! Alarms

EXIT

YTD Energy

EXIT

YTD Volume

EXIT

Prev. Yr Energy

EXIT

Prev. Yr Volume

0

kBtu

0

kBtu

0

gallons

0

gallons

EXIT

Signal Strength

0

EXIT

Speed of Sound

0 = Empty Pipe

0

ft/s

Diagnostics

Alarms

Empty Pipe

Low Supply Temp

EXIT

MORE

High Return Temp

Alarms Alarm Messages

Low Supply Temp

High Supply Temp

Low Return Temp

High Return Temp

Δ t < Minimum

High Energy Rate

Empty Pipe

Comm error

System Fault

High Flow

EXIT

Manufacturing Date

EXIT

Calibration Date

EXIT

Firmware Rev

EXIT

MeterConfig

Meter Data

0000/00

Boot: 0.0.0

App: 0.0.0

DA: 0.0.0

DB: 0.0.0

0

EXIT

00.00000 Up

00.00000 Dn

Transit Time

EXIT

YTD Energy

EXIT

YTD Volume

EXIT

Prev. Yr Energy

EXIT

Prev. Yr Volume

0

kBtu

0

kBtu

0

gallons

0

gallons

More Totals

EXIT

User Energy Total

0

kBtu

EXIT

YTD Energy

0

kBtu

M1

M2

EXIT

YTD Volume

0

gallons

M2

M1

EXIT

Prev. Yr Energy

0

kBtu

M2

M1

EXIT

Prev. Yr Volume

0

gallons

M2

M1

EXIT

User Energy Total

0

kBtu

M2

YTD Energy & Volume Totals reset at

12:01 AM on targetdate

Prev. Yr Energy & Volume Totals update at

12:01 AM on targetdate

More Totals

Single ModeDual Mode

Meter Data

EXIT

Serial Number

0

Year/Month

0000/00

Year/Month

Pre: 0.0.0

YTD Energy & Volume Totals reset at

12:01 AM on January 1st

Prev. Yr. Energy & Volume Totals update at

12:01 AM on January 1st

User Energy Totals reset via MODBUS

EXIT

Signal Strength

0

EXIT

Speed of Sound

0 = Empty Pipe

0

ft/s

EXIT

00.00000 Up

00.00000 Dn

Transit Time

EXIT

Modbus Diagnostics 1

Modbus Diagnostics 2

00000 Event Counter

00000 Message Count

00000 Comm Errors

00000 Exceptions

00000 Serv. Messages

00000 Serv. No Respond

00000 Serv. Busy

00000 Char. Overrun

11451 Belcher Road South, Largo, FL 33773 • USA • Tel +1 (727) 447-6140 • Fax +1 (727) 442-5699 • [email protected]

System-40-BTU Meter Installation and Operation Guide 06/16 - 2018 / 35870 Page 19

4.2 COMMISSIONING

The last step in the installation process is commissioning the meter. Commissioning is a 2 step

process. The rst step is to review the mechanical installation to conrm that the ow sensor and

temperature sensor(s) are properly located in the piping system. The second step is a review of

the meter program settings. Both steps must be completed in order to nish the installation. A

simple commissioning checklist is shown below. A copy of this may be found online at

www.onicon.com/system40.html.

Commissioning Checklist

Part 1 Mechanical installation

Conrm that the ow sensor is properly located in the piping system (Sec. 3.1 & 3.2).

Conrm that the ow sensor is properly oriented with respect to ow direction (Sec. 3.2).

Conrm that the temperature sensor(s) is properly located in the piping system (Sec. 3.3).

Part 2 Programming

Conrm that the ow sensor location in the piping system (supply or return) is programmed into the

meter (Sec. 4.1 & 4.2.1).

Verify that the Units of Measure Settings in the meter are correct (Sec. 4.1 & 4.2.1).

Conrm that there are no alarm indications and the meter is functional (Sec. 4.1.2 & 5.0).

4.2.1 Commissioning following initial power-up

During initial power-up, the following display pages will appear the commissioning

option is selected. The settings shown below allow the installer to set MODBUS® or

BACnet® parameters, the ow sensor location (supply or return pipe) and the date and

time. If the factory pre-programmed engineering units for ow, energy and temperature are

correct, press SAVE to exit commissioning once the correct date has been set. Momentarily

press NEXT if you wish access the remaining commissioning mode display pages shown

on the next page.

Initial Power-up

Next to complete Install

or adjust

settings.

EXIT

DONE

Protocol

Modbus

DONE

Protocol

BACnet

EXIT

BACnet Address

1

0 - 255

DONE

Modbus Address

017

0 - 247

DONE

Baud Rate

9600

EXIT

Instance Number

57017

0 - 4194303

EXIT

Baud Rate

38400

Parity

DONE

None

Odd Even None

EXIT

Meter Location

EXIT

Set Time

EXIT

Set Date

BACK

Set Meter

Supply

YYYY:MM:DD

HH:MM:SS

NEXT edits units of

measure

SAVE completes install

with current settings

EXIT

Medium

EXIT

Flow

EXIT

Volume

Water

gpm

gallons

EXIT

Energy

EXIT

Energy Rate

EXIT

Temperature

kBtu

F

Btu/hr

Select Units

EXIT

Mode

Single

Single or Dual

Short Commissioning Units of Measure & Aux I/O

Configuration Settings

EXIT

Aux Input 1

BACK

Set Meter

Counts

NEXT edits units of

measure

SAVE completes install

with current settings

EXIT

Num Aux Inputs

3

EXIT

Aux Input 2

Counts

EXIT

Aux Input 3

Counts

BACK

Set Meter

NEXT edits units of

measure

SAVE completes install

with current settings

EXIT

Pulse Timing

Pulse 500 ms

EXIT

Pulsed Output 1

Energy Total

Select Type

EXIT

Pulsed Output 2

Volume Total

Select Type

EXIT

Pulsed Output 3

Alarm

Select Type

EXIT

Pulse 1 Scaling

x1

Select Multiplier

EXIT

Pulse 2 Scaling

x1

Select Multiplier

EXIT

Pulse 3 Scaling

x1

Select Multiplier

EXIT

Aux Input 1

Counts

EXIT

Num Aux Inputs

2

EXIT

Aux Input 2

Counts

EXIT

Pulse Timing

Pulse 500 ms

EXIT

Pulsed Output 1

Energy Total

Select Type

EXIT

Pulse 1 Scaling

x1

Select Multiplier

BACK

Set Meter

NEXT edits units of

measure

SAVE completes install

with current settings

EXIT

Aux Input 1

Counts

EXIT

Num Aux Inputs

1

EXIT

Pulsed Output 1

Energy Total

Select Type

EXIT

Pulsed Output 2

Volume Total

Select Type

EXIT

Pulse Timing

Pulse 500 ms

EXIT

Pulse 1 Scaling

x1

Select Multiplier

EXIT

Pulse 2 Scaling

x1

Select Multiplier

BACK

Set Meter

NEXT edits units of

measure

SAVE completes install

with current settings

EXIT

Aux Input 1

Counts

EXIT

Num Aux Inputs

2

EXIT

Aux Input 2

Counts

BACK

Set Meter

NEXT edits units of

measure

SAVE completes install

with current settings

EXIT

Analog Signal

4-20 mA

EXIT

Analog Output

Energy Rate

EXIT

Analog Output Max

500.000

Analog Output Units

Select Signal

Select Type

EXIT

Analog Output Min

000.000

Analog Output Units

EXIT

Pulsed Output 1

Energy Total

Select Type

EXIT

Pulsed Output 2

Volume Total

Select Type

EXIT

Pulse Timing

Pulse 500 ms

EXIT

Pulse 1 Scaling

x1

Select Multiplier

EXIT

Pulse 2 Scaling

x1

Select Multiplier

BACK

Set Meter

NEXT edits units of

measure

SAVE completes install

with current settings

EXIT

Analog Signal

4-20 mA

EXIT

Analog Output

Energy Rate

EXIT

Analog Output Max

500.000

Analog Output Units

Select Signal

Select Type

EXIT

Analog Output Min

000.000

Analog Output Units

EXIT

Aux Input 1

Counts

EXIT

Num Aux Inputs

1

EXIT

Pulsed Output 1

Energy Total

Select Type

EXIT

Pulse Timing

Pulse 500 ms

EXIT

Pulse 1 Scaling

x1

Select Multiplier

BACK

Set Meter

NEXT edits units of

measure

SAVE completes install

with current settings

EXIT

Analog Signal

4-20 mA

EXIT

Analog Output

Energy Rate

EXIT

Analog Output Max

500.000

Analog Output Units

Select Signal

Select Type

EXIT

Analog Output Min

000.000

Analog Output Units

Next to complete Install

or adjust

settings.

EXIT

DONE

Protocol

Modbus

DONE

Protocol

BACnet

EXIT

BACnet Address

1

0 - 255

DONE

Modbus Address

017

0 - 247

DONE

Baud Rate

9600

EXIT

Instance Number

57017

0 - 4194303

EXIT

Baud Rate

38400

Parity

DONE

None

Odd Even None

EXIT

Meter Location

EXIT

Set Time

EXIT

Set Date

BACK

Set Meter

Supply

YYYY:MM:DD

HH:MM:SS

NEXT edits units of

measure

SAVE completes install

with current settings

Short Commissioning

11451 Belcher Road South, Largo, FL 33773 • USA • Tel +1 (727) 447-6140 • Fax +1 (727) 442-5699 • [email protected]

System-40-BTU Meter Installation and Operation Guide 06/16 - 2018 / 35870 Page 20

Commissioning

Next to complete Install

or adjust

settings.

EXIT

DONE

Protocol

Modbus

DONE

Protocol

BACnet

EXIT

BACnet Address

1

0 - 255

DONE

Modbus Address

017

0 - 247

DONE

Baud Rate

9600

EXIT

Instance Number

57017

0 - 4194303

EXIT

Baud Rate

38400

Parity

DONE

None

Odd Even None

EXIT

Meter Location

EXIT

Set Time

EXIT

Set Date

BACK

Set Meter

Supply

YYYY:MM:DD

HH:MM:SS

NEXT edits units of

measure

SAVE completes install

with current settings

EXIT

Medium

EXIT

Flow

EXIT

Volume

Water

gpm

gallons

EXIT

Energy

EXIT

Energy Rate

EXIT

Temperature

kBtu

F

Btu/hr

Select Units

EXIT

Mode

Single

Single or Dual

Short Commissioning Units of Measure & Aux I/O

Configuration Settings

EXIT

Aux Input 1

BACK

Set Meter

Counts

NEXT edits units of

measure

SAVE completes install

with current settings

EXIT

Num Aux Inputs

3

EXIT

Aux Input 2

Counts

EXIT

Aux Input 3

Counts

BACK

Set Meter

NEXT edits units of

measure

SAVE completes install

with current settings

EXIT

Pulse Timing

Pulse 500 ms

EXIT

Pulsed Output 1

Energy Total

Select Type

EXIT

Pulsed Output 2

Volume Total

Select Type

EXIT

Pulsed Output 3

Alarm

Select Type

EXIT

Pulse 1 Scaling

x1

Select Multiplier

EXIT

Pulse 2 Scaling

x1

Select Multiplier

EXIT

Pulse 3 Scaling

x1

Select Multiplier

EXIT

Aux Input 1

Counts

EXIT

Num Aux Inputs

2

EXIT

Aux Input 2

Counts

EXIT

Pulse Timing

Pulse 500 ms

EXIT

Pulsed Output 1

Energy Total

Select Type

EXIT

Pulse 1 Scaling

x1

Select Multiplier

BACK

Set Meter

NEXT edits units of

measure

SAVE completes install

with current settings

EXIT

Aux Input 1

Counts

EXIT

Num Aux Inputs

1

EXIT

Pulsed Output 1

Energy Total

Select Type

EXIT

Pulsed Output 2

Volume Total

Select Type

EXIT

Pulse Timing

Pulse 500 ms

EXIT

Pulse 1 Scaling

x1

Select Multiplier

EXIT

Pulse 2 Scaling

x1

Select Multiplier

BACK

Set Meter

NEXT edits units of

measure

SAVE completes install

with current settings

EXIT

Aux Input 1

Counts

EXIT

Num Aux Inputs

2

EXIT

Aux Input 2

Counts

BACK

Set Meter

NEXT edits units of

measure

SAVE completes install

with current settings

EXIT

Analog Signal

4-20 mA

EXIT

Analog Output

Energy Rate

EXIT

Analog Output Max

500.000

Analog Output Units

Select Signal

Select Type

EXIT

Analog Output Min

000.000

Analog Output Units

EXIT

Pulsed Output 1

Energy Total

Select Type

EXIT

Pulsed Output 2

Volume Total

Select Type

EXIT

Pulse Timing

Pulse 500 ms

EXIT

Pulse 1 Scaling

x1

Select Multiplier

EXIT

Pulse 2 Scaling

x1

Select Multiplier

BACK

Set Meter

NEXT edits units of

measure

SAVE completes install

with current settings

EXIT

Analog Signal

4-20 mA

EXIT

Analog Output

Energy Rate

EXIT

Analog Output Max

500.000

Analog Output Units

Select Signal

Select Type

EXIT

Analog Output Min

000.000

Analog Output Units

EXIT

Aux Input 1

Counts

EXIT

Num Aux Inputs

1

EXIT

Pulsed Output 1

Energy Total

Select Type

EXIT

Pulse Timing

Pulse 500 ms

EXIT

Pulse 1 Scaling

x1

Select Multiplier

BACK

Set Meter

NEXT edits units of

measure

SAVE completes install

with current settings

EXIT

Analog Signal

4-20 mA

EXIT

Analog Output

Energy Rate

EXIT

Analog Output Max

500.000

Analog Output Units

Select Signal

Select Type

EXIT

Analog Output Min

000.000

Analog Output Units

Next to complete Install

or adjust

settings.

EXIT

DONE

Protocol

Modbus

DONE

Protocol

BACnet

EXIT

BACnet Address

1

0 - 255

DONE

Modbus Address

017

0 - 247

DONE

Baud Rate

9600

EXIT

Instance Number

57017

0 - 4194303

EXIT

Baud Rate

38400

Parity

DONE

None

Odd Even None

EXIT

Meter Location

EXIT

Set Time

EXIT

Set Date

BACK

Set Meter

Supply

YYYY:MM:DD

HH:MM:SS

NEXT edits units of

measure

SAVE completes install

with current settings

Short Commissioning

Remaining parameters

branch depending on

model number. See

following pages.

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