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VorTek FlowCalc Instruction Manual

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_____________________________________________________________________________________
FlowCalc™ Flow Computer
(303) 682-9999
_____________________________________________________________________________________
M-000-0110
VorTek Instruments
FlowCalc™ Flow Computer
Instruction Manual
M-000-0110
Rev 05/2024
8475 W I-25 Frontage Rd
Suite 300
Longmont, CO 80504
(888) 386-7835
http://www.vortekinst.com
Fax (303) 682-4368
Instruction Manual
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  • Page 1 _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual VorTek Instruments FlowCalc™ Flow Computer Instruction Manual M-000-0110 Rev 05/2024 8475 W I-25 Frontage Rd Suite 300 Longmont, CO 80504 (303) 682-9999 (888) 386-7835 Fax (303) 682-4368 http://www.vortekinst.com _____________________________________________________________________________________ M-000-0110...

  • Page 2: Specific Conditions Of Use

    Instruments. The information contained in this manual is subject to change without notice. TRADEMARKS FlowCalc™ is a trademark of VorTek Instruments, LLC. Other product and company names listed in this manual are trademarks or trade names of their respective manufacturers.

  • Page 3: Table Of Contents

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Table of Contents Chapter 1 Introduction ..........................9 Multi-Parameter Flow Computer ......................9 Using This Manual ..........................9 Note and Safety Information ....................... 10 Technical Assistance ........................... 10 Multivariable Options ......................... 11 Flow Computer Electronics ........................ 11 Chapter 2 Installation ..........................
  • Page 4 _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Energy Menu (For EMS Energy Meters Only) ................... 44 Fluid Menu ............................45 Units Menu ............................47 Time & Date Menu ..........................48 Diagnostics Menu ..........................49 Calibration Menu ..........................51 Password Menu ........................... 52 Chapter 4 Serial Communications ......................
  • Page 5 _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Chapter 5 Troubleshooting and Repair ..................... 116 Hidden Diagnostics Menus ........................116 Level One Hidden Diagnostics Values ..................... 118 Level Two Hidden Diagnostics Values .................... 119 Analog Output Calibration ........................121 Display Contrast Adjustment ........................ 121 Figures Figure 2.1 - AC Wiring Terminals ......................
  • Page 6 _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Figure 4.1 - DC Powered Meter Wiring (HART) ..................53 Figure 4.2 - AC Powered Meter Wiring (HART) ..................54 Figure 4.3 - RS-485 Wiring (MODBUS) ....................63 Figure 4.4 - RS-485 Wiring (BACnet) ......................73 Figure 4.5 –...

  • Page 7: Warnings And Cautions

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Warnings and Cautions Warning! Consult the flow meter nameplate for specific flow meter approvals before any hazardous location installation. To avoid potential electric shock, follow National Electric Code or your local code when wiring this unit to a power source.

  • Page 8: Revision History

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Revision History Rev. 05/2024 Page Change Description _____________________________________________________________________________________ M-000-0110...

  • Page 9: Chapter 1 Introduction

    VorTek Instruments’ FlowCalc™ flow computer is a field mounted flow computer which can be used for liquid and gas applications. FlowCalc™ is the most powerful flow computer of its kind and represents some of the latest advancements in operation, performance, and modularity.

  • Page 10: Note And Safety Information

    Verify that your settings and adjustments are consistent with factory recommendations. If the problems occur, contact VorTek Instruments, Technical Support Via Email at Sales@vortekinst.com or by phone at (888) 386-7835 or (303) 682-9999 between 8:00 a.m. and 5:00 p.m.

  • Page 11: Multivariable Options

    MODBUS, HART, BACnet, and IP version of MODBUS/BACnet communications are also available. FlowCalc™ Flow Computers include a local 2 x 16 character LCD display housed within the enclosure. Local operation and reconfiguration is accomplished using six pushbuttons operated via finger touch.

  • Page 12: Chapter 2 Installation

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Chapter 2 Installation High Power Meter Wiring Connections Warning! To avoid potential electric The NEMA 4X enclosure contains an integral wiring compartment with one terminal block shock, follow National (located in the smaller end of the enclosure). Two 3/4-inch female NPT conduit entries are...

  • Page 13: Figure 2.2 - Dc Wiring Terminals

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual OPTION 1 OPTION 2 1 2 3 FREQ PULSE ALARM ALARM ALARM 4-20 4-20 4-20 mA 1 mA 2 mA 3 Figure 2.2 - DC Wiring Terminals Figure 2.3 - POE Wiring Terminals _____________________________________________________________________________________...

  • Page 14: Input Power Connections

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Input Power Connections To access the wiring terminal blocks, locate and loosen the small set screw which locks the small enclosure cover in place. Unscrew the cover to expose the terminal block. AC Power Wiring The AC power wire size must be 20 to 10 AWG with the wire stripped 1/4 inch (7 mm).

  • Page 15: Figure 2.5 - Dc Power Connections

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual DC Power Wiring The DC power wire size must be 20 to 12 AWG with the wire stripped 1/4 inch (7 mm). Connect 12 to 36 VDC (300 mA, 9 W maximum) to the +DC Pwr and –DC Pwr terminals on Warning! the terminal block.

  • Page 16: 4-20 Ma Output Connections

    Plug Ethernet drop off cable from your Local Area Network (LAN) switch to LAN connector of Vortek meter. You should see a blinking orange LED and a solid green on the front of the LAN connector of the meter henCAT5 Ethernet cable is plugged in and communicating.

  • Page 17: Figure 2.9 - Isolated 4-20Ma Output Using External Power Supply

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Figure 2.9 - Isolated 4-20mA Output Using External Power Supply Figure 2.10 – Non-Isolated 4-20 mA Output Using Meter Input Power Supply _____________________________________________________________________________________ M-000-0110...

  • Page 18: Figure 2.11 - Isolated 4-20 Ma Output Using External Power Supply

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Figure 2.11 - Isolated 4-20 mA Output Using External Power Supply Figure 2.12 – Isolated 4-20 mA Output Using Meter Provided Power Supply _____________________________________________________________________________________ M-000-0110...

  • Page 19: Pulse Output Connections

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Pulse Output Connections The pulse output is used for a remote counter. When the preset volume or mass (defined in the totalizer settings, see page 38) has passed the meter, the output provides a 50 millisecond square pulse.

  • Page 20: Figure 2.14 - Non-Isolated Pulse Output Using Input Power Supply

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Figure 2.14 – Non-Isolated Pulse Output Using Input Power Supply Figure 2.15 - Isolated Pulse Output Using External Power Supply _____________________________________________________________________________________ M-000-0110...

  • Page 21: Frequency Output Connections

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Figure 2.16 – Isolated Pulse Output Using Meter Provided Power Supply Frequency Output Connections The frequency output is used for a remote counter. It can be scaled to output a 1 to 10 kHz signal proportional to mass or volume flow, temperature, pressure, or density.

  • Page 22: Figure 2.17 - Isolated Frequency Output Using External Power Supply

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Figure 2.17 - Isolated Frequency Output Using External Power Supply Figure 2.18 – Non-Isolated Frequency Output Using Input Power Supply _____________________________________________________________________________________ M-000-0110...

  • Page 23: Figure 2.19 - Isolated Frequency Output Using External Power Supply

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Figure 2.19 - Isolated Frequency Output Using External Power Supply Figure 2.20 – Non-Isolated Frequency Output Using Meter Provided Power Supply _____________________________________________________________________________________ M-000-0110...

  • Page 24: Alarm Output Connections

    Instruction Manual Alarm Output Connections One alarm output (Alarm 1) is included on the standard FlowCalc™ Flow Computer. Two or more alarms (Alarm 2 and Alarm 3) are included on the optional communication board. The alarm output requires a separate 5 to 36 VDC power supply. The alarm output optical relay is a normally-open single-pole relay.

  • Page 25: Figure 2.22 - Non-Isolated Alarm Output Using Internal Power Supply

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Figure 2.22 – Non-Isolated Alarm Output Using Internal Power Supply Figure 2.23 - Isolated Alarm Output Using External Power Supply _____________________________________________________________________________________ M-000-0110...

  • Page 26: Figure 2.24 - Non-Isolated Alarm Output Using Meter Provided Power Supply

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Figure 2.24 – Non-Isolated Alarm Output Using Meter Provided Power Supply _____________________________________________________________________________________ M-000-0110...

  • Page 27: Optional Input Electronics Wiring

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Optional Input Electronics Wiring The meter has two optional input wiring terminals, maximum wire size is 16 AWG. These can be used to input a Remote or Second RTD input in the case of an Energy Monitoring meter, for the input of a Remote Pressure Transducer, to pass a Contact Closure or for a Remote Density measurement to name a few.

  • Page 28: Figure 2.27 - External 4-20 Ma Input Wiring - External Power Supply

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Option 1 Option 2 External Power Ext. 4-20 mA Input Device Figure 2.27 - External 4-20 mA Input Wiring - External Power Supply Follow the above diagram to wire the external 4-20 mA input into the flow meter using an external power supply.

  • Page 29: Optional External 4-20 Ma Input And Rtd Wiring

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Option 1 Option 2 AC units only. Meter provided DC power. + 24 VDC OUT - 24 VDC OUT Ext. 4-20 mA Input Device Figure 2.29 - External 4-20 mA Input Wiring - AC Powered Meter Follow the above diagram to wire the external 4-20 mA input into the flow meter using power from the 24 VDC output of an AC powered meter.

  • Page 30: Optional Energy Ems External 4-20 Ma Input And Rtd Wiring

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Optional Energy EMS External 4-20 mA Input and RTD Wiring Option 1 Option 2 Red Red Black Black Red Black R = 1000 ohm R = 1000 ohm External Power Ext. 4-20 mA Input Device Figure 2.31 - Energy EMS External 4-20 mA Input and RTD Wiring - High Power...

  • Page 31: Chapter 3 Operating Instructions

    Instruction Manual Chapter 3 Operating Instructions After installing the FlowCalc™ Flow Computer, you are ready to begin operation. The sections in this chapter explain the display/keypad commands, meter start-up and programming. The meter is ready to operate at start up without any special programming. To...

  • Page 32: Display Contrast Adjustment

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Display Contrast Adjustment The flow computer display contrast is set at the factory but if the display characters appear too dark or too light proceed as follows: 1. Hold down the “Exit” button on the front panel for 5 to 10 seconds. “Setting Contrast”...

  • Page 33: Run Mode Screens

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Run Mode Screens ENTER Mass Flow Password Rate ENTER Volume Flow Rate Press Exit to return Setup Menus to Run Mode Temperature Pressure Energy EMS Energy Meters Only Density Total keys to access Alarm...

  • Page 34: Using The Setup Menus

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Using the Setup Menus • • _____________________________________________________________________________________ M-000-0110...

  • Page 35: Programming The Flow Computer

    3. Use the Setup Menus described on the following pages to customize the multi-parameter features of your FlowCalc™ Flow Computer. (The entire lower display line is available for entering parameters.) Some items depicted in the graphic on the preceding page may not be displayed based on flow computer configuration settings.

  • Page 36: Output Menu

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Output Menu ENTER Run Mode Password ENTER Output Menu keys to acce ss me nus < Measur e > None Mass Volume 4-20 mA Output 1 < 4 mA = xxxx > < 20mA = xxxx >...
  • Page 37 _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Example for Setting an Output The following shows how to set Output 1 to measure mass flow with 4 mA = 0 lb/hr and 20 mA = 100 lb/hr with a time constant of 5 seconds. (All outputs are disabled while using the Setup Menus.) First, set the desired units of measurement: 1.
  • Page 38 _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Example for Setting a Scaled Frequency The following shows how to set Scaled Frequency to measure temperature with Max. Frequency = 5000 Hz, 0 Hz = 0 °F, and MaxHz = 300°F with a time constant of 5 seconds. (All outputs are disabled while using the Setup Menus.)

  • Page 39: Display Menu

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Display Menu ENTER Run Mode Password ENTER Display Menu keys to acce ss me nus Cycle Tim e (sec) If Cyc le Time is set to zero, m anual advance is required Num ber of Digits...

  • Page 40: Alarms Menu

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Alarms Menu ENTER Run Mode Password ENTER Alar ms * see below keys to acce ss me nus Menu <M easure> None Mass <M ode> Volume Relay Ala rm 1 None <M easure> units ** Energy More >...
  • Page 41 _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Example for Setting an Alarm The following shows how to set Relay Alarm 1 to activate if the mass flow rate is greater than 100 lb/hr. You can check the alarm configuration in the Run Mode by pressing the  keys until Alarm [1] appears.

  • Page 42: Totalizer #1 Menu

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Totalizer #1 Menu ENTER Run Mode Password ENTER Totalize r * Ene rgy EMS Meters Only Menu keys to acce ss me nus Totaling Inactive Exa mple: Mass Volume Maximum flow rate = 600 gallons per m inute...

  • Page 43: Totalizer #2 Menu

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Totalizer #2 Menu ENTER Run Mode Password ENTER Totalize r Menu keys to acce ss me nus Totaling Inactive * Ene rgy EMS Meters Only Mass Volume * Ene rgy Note: (unit) / Pulse will m atc h...

  • Page 44: Energy Menu (For Ems Energy Meters Only)

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Energy Menu (For EMS Energy Meters Only) ENTER Run Mode Password ENTER Ene rgy Menu keys to acce ss me nus Loc in S ent Flow Ene rgy EMS Meters Only Yes or No...

  • Page 45: Fluid Menu

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Fluid Menu ENTER Run Mode Password keys to acce ss me nus ENTER < Liquid Water Fluid Ammonia Menu Chlorine < Density > < AL > < BL xxxx xxxx xxxx Flowing F luid <...
  • Page 46 _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Use the Fluid Menu to configure the flow meter for use with common gases, liquids and steam. Your flow meter is pre-programmed at the factory for your application’s process fluid. Reference Richard W. Miller, Flow Measurement Engineering Handbook (Third Edition, 1996), page 2-75 for definition and use of the Goyal-Doraiswamy equation and page 2-76 for the definition and use of the API 2540 equation.

  • Page 47: Units Menu

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Units Menu ENTER Run Mode Password ENTER Units keys to acce ss me nus Menu Mass Flow Unit Ston = Short Ton = 2000 lb lb, Ston, Lton, gram Lton = Long Ton = 2240 lb...

  • Page 48: Time & Date Menu

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Use the Units Menu to configure the flow meter with the desired units of measurement. (These are global settings and determine what appears on all screens. Time & Date Menu ENTER Run Mode Password ENTER Tim e &...

  • Page 49: Diagnostics Menu

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Diagnostics Menu ENTER Run Mode Password ENTER Diagnositcs Menu keys to acce ss me nus Simulate Vortex Sim Vor Fr eq Frequency (Hz) * The unit of measure of the displayed value is the same...
  • Page 50 _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Use the Diagnostics Menu to simulate operation and review the system files. The system log files contain time/date stamped messages including: power on, power off, programming time outs, parameter faults, incorrect password entry and other various information relative to system operation and programming.

  • Page 51: Calibration Menu

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Calibration Menu ENTER Run Mode Password ENTER Calibration Menu keys to acce ss me nus Inline style meter – meter size Meter Siz e Inse rtion style m ete r – pipe inter nal diameter (inche s)

  • Page 52: Password Menu

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Password Menu ENTER Run Mode Password ENTER Password Menu keys to acce ss me nus Set Pa ssword 1234 Use the Password Menu to set or change the system password. The factory-set password is 1234.

  • Page 53: Chapter 4 Serial Communications

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Chapter 4 Serial Communications HART Communications The HART Communications Protocol (Highway Addressable Remote Transducer Protocol) is a bidirectional digital serial communications protocol. The HART signal is based on the Bell 202 standard and is superimposed on 4-20 mA Output 1. Peer-to-peer (analog / digital) and multi- drop (digital only) modes are supported.

  • Page 54: Figure 4.2 - Ac Powered Meter Wiring (Hart)

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual AC Powered Meter Wiring Vortex Meter RS485 RS485 RS485 GND R load, Current 250 ohm Meter minimum NEUT / L2 HOT / L1 Field Connection Remote Connection for Communicator for Communicator Figure 4.2 - AC Powered Meter Wiring (HART)

  • Page 55: Hart Commands With The Dd Menu

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual HART Commands with the DD Menu Online Menu 1 Process Variables 1 Mass Flo 2 Vol **If you require DD or 3 Temp 4 Temp 2 DTM files, please reach 5 Delta Temp. 6 Energy flo out to the factory for a link.

  • Page 56: Analog Output Menu

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Analog Output Menu 1 Fix Analog Output 2 Tr im Analog Output From Online Menu 1 PV is 3 Configure AO1 2 PV Loop cur rent 4 PV is 3 PV 5 PV AO 1 Out...

  • Page 57: Maintenance Menu

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Fluid Menu From Online Menu 1 Fluid Liquid Water 2 Fluid Type Other Liquid Ammonia Goyal-Dor ais Chlor ine API-2540 Nat Gas AGA8 Real Gas Other Liquid Density Other Gas Viscosity Coef AL Liquified Gas...
  • Page 58 _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Maintenance Menu _____________________________________________________________________________________ M-000-0110...
  • Page 59 _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Diagnostics Menu 1 Vel 1 Vtx Freq From Online Menu 2 Pres 2 Sim Vtx Freq 3 Temp 3 Vtx AtoD 4 Temp 2 4 Filter Set 5 Inter nal Temp 5 Change Filter Set 6 Vor tex Diag.
  • Page 60 _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Review Menu _____________________________________________________________________________________ M-000-0110...

  • Page 61: Sensor Cal Menu

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Sensor Cal Menu * If insertion vortex 1 K Factor 2 Base Reynolds * 1 Calibr ation Review From Online Menu 3 SR Coefficient * 1 Unit 1 Vtx Freq 2 Vor tex Sensor...

  • Page 62: Hart Commands With Generic Dd Menu

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual HART Commands with Generic DD Menu Online Menu From Device setup / Review 1 Device setup 1 Process Variables 1 PV 1 Model 1 4 mA 2 PV 2 PV % Rnge 2 Distributor...

  • Page 63: Modbus Communications

    This document describes the preliminary implementation of the Modbus communication protocol vortex meter. for use in monitoring common process variables in the VorTek FlowCalc™ Flow Computer. The physical layer utilizes the half-duplex RS-485 port, and the Modbus protocol. Reference Documents The following documents are available online from www.modbus.org.

  • Page 64: Menu Items

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Menu Items The following menu items are in the Output Menu and allow selection and control of the Modbus communication protocol. Address When the Modbus protocol is selected, the Modbus address is equal to the user programmable device address if it is in the range 1…247, in accordance with the Modbus...
  • Page 65 _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Modbus Protocol The Modbus RTU protocol is supported in this implementation. Supported baud rates are 1200, 2400, 4800, 9600, 19200, 38400, 57600, and 115200. The default baud rate is 19200 baud. Depending upon the Modbus protocol selected, data are transmitted in 8-bit data frames with even or odd parity and 1 stop bit, or no parity and 2 or 1 (non-standard) stop bits.
  • Page 66 _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual The flow rate, temperature, pressure, and density variables may be accessed as either the flow meter internal base units or in the user-programmed display units, which is determined by the programming Output Menu’s “Modbus Units” item. The display units strings may be examined by accessing their associated registers.
  • Page 67 _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Simulated Vortex 03, 04 33001-33002 float — 3000-3001 Frequency Simulated 03, 04 33003-33004 float — 3002-3003 Temperature 0 Simulated 03, 04 33005-33006 float — 3004-3005 Temperature 1 33007-33008 Simulated Pressure float — 03, 04...
  • Page 68 _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual The following registers contain the display units strings: Registers Variable Data type Units Function code Addresses 32007-32012 Volume Flow Units string — 03, 04 2006-2011 32001-32006 Mass Flow Units string — 03, 04 2000-2005...
  • Page 69 _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Control Register Definitions The only writeable registers in this implementation are the Reset Exception Status, Reset Meter and Reset Totalizer functions, which are implemented as ”coils” which may be written with the Write Single Coil command (function code 05) to address 0 through 9, respectively, (register #00001 through #00010).
  • Page 70 _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Command Message Format The start address is equal to the desired first register number minus one. The addresses derived from the start address and the number of registers must all be mapped to valid defined registers, or an invalid data address exception will occur.
  • Page 71 _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Request the first 12 registers from device with address 1: 01 04 00 00 00 0C F0 0F 01 Device address 04 Function code, 04 = read input register 00 00 Starting address 00 0C Number of registers = 12...
  • Page 72 _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Request the state all three alarms: 01 02 00 00 00 03 38 0B 01 Device address 02 Function code 2 = read discrete inputs 00 00 Starting address 00 03 Number of inputs = 3...

  • Page 73: Bacnet Ms/Tp Communications

    MS/TP bus communicate at the same baud rate. The baud rate setting determines the rate at which devices communicate data over the bus. The baud rate settings available on FlowCalc™ Flow Computers are 9600, 19200 and 38400. _____________________________________________________________________________________...

  • Page 74: Supported Bacnet Objects

    MAC address range is 0-127 Supported BACnet Objects A BACnet object represents physical or virtual equipment information, as a digital input or parameters. The FlowCalc™ Flow Computer presents the following object types: 1) Device Object 2) Analog Input 3) Binary Input...
  • Page 75 _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Properties Object Types Device Analog Input Binary Input Binary Value Object_Identifier     Object_Name     Object_Type     System_Status  Vendor_Name  Vendor_Identifier  Model_Name  Firmware_Revision ...
  • Page 76 {T,F,F,T,F,T,F,F,T,F,F,F,F,F,F,F,F,F,F,F,F,F,F,F,F} supported object-list {(analog-input,1),(analog-input,2),(analog-input,3),(analog-input,4), (analog- input,5), (analog-input,6),(analog-input,7),(analog-input,8) (analog- input,9),(analog-input,10), (analog-input,11), (analog-input,12), (analog- input,13),(analog-input,14), (analog-input,15),(analog-input,16),(analog- input,17), (analog-input,18),(analog-input,19),(binary-input,1),(binary- input,2),(binary-input,3),(binary-input,4), (binary-value,1), (device,7) } max-apdu-length-accepted segmentation-supported no-segmentation apdu-timeout 3000 number-of-APDU-retries max-master max-info-frames device-address-binding database-revision Note - Device Communication Control: Password – “vortek” _____________________________________________________________________________________ M-000-0110...
  • Page 77 _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Analog Input Object Vortex Mass Flow Meters Analog Input type objects are described below: Object Instance Object Name Unit Description Volume Flow cubic-feet-per-second, This AI object is used to cubic-feet-per-minute, measure volume flow. us-gallons-per-minute,...
  • Page 78 _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual kilograms-per-minute, kilograms-per-hour, pounds-mass-per-minute, pounds-mass-per-hour, tons-per-hour, grams-per-second, grams-per-minute If Totalizer selection for Volume measure – cubic-feet-per-second, cubic-feet-per-minute, us-gallons-per-minute, imperial-gallons-per-minute, liters-per-minute, liters-per-second, liters-per-hour, cubic-meters-per-second, cubic-meters-per-minute, cubic-meters-per-hour If Totalizer selection for Energy measure – Kilowatts, Horsepower, btus-per-hour,...
  • Page 79 _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Binary Input Object Vortex Mass Flow Meters Binary Input type objects are described below: Object Object Description Instance Name Alarm1 The status of the three alarms may be monitored via the Modbus command. The value returned indicates the state of the alarm and will be 1 only if the Alarm2 alarm is enabled and active.

  • Page 80: Annex - Bacnet Protocol Implementation Conformance Statement

    FlowCalc™ Flow Computer Instruction Manual ANNEX – BACnet Protocol Implementation Conformance Statement Date: 19-April-2012 Vendor Name: VorTek Instruments Product Name: FlowCalc™ Flow Computer Product Model Number: M22/M23/M24 VT/VTP Applications Software Version: 1.07 Firmware Revision: N/A BACnet Protocol Revision: 4 Product Description: VorTek multivariable flow-meter Annex L –...
  • Page 81 _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Annex K – All BACnet Interoperability Building Blocks Supported BIBBs DS-RP-B DS-WP-B DM-DDB-B DM-DOB-B DM-DCC-B DS-RPM-B DS-WPM-B Services Supported Read Property Execute Write Property Execute Read Property Multiple Execute Write Property Multiple Execute Who-Is...
  • Page 82 _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Standard Object Types Supported Standard Object Types Supported Dynamically Dynamically Additional Range Object Type Creatable Delete-able Writable Properties Restrictions Analog Input (AI) None None Binary Input (BV) None None Binary Value None None Device...
  • Page 83 _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Object List Properties of Analog Input/Value Objects Type Present Status Event Out of Name Units Value Flags State Service Volume Flow F,F,F,F Normal False Mass Flow F,F,F,F Normal False Temperature 1 F,F,F,F Normal False...
  • Page 84 _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Properties of Analog Input/Value Objects Type Polarity Present Status Event Out of Name Value Flags State Service F,F,F,F Normal False Alarm1 Normal Alarm2 F,F,F,F Normal False Normal F,F,F,F Normal False Alarm3 Normal External F,F,F,F...
  • Page 85 _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Device Address Binding Is static device binding supported? (This is currently necessary for two-way communication with MS/TP slaves and certain other devices.): Yes No Networking Options  Router, Clause 6 - List all routing configurations, e.g., ARCNET-Ethernet, Ethernet-MS/TP, etc.

  • Page 86: Acronyms And Definitions

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Acronyms and Definitions Item Description APDU Application Protocol Data Unit BACnet Building Automation and Control Network- Data communication protocol MS/TP Master-Slave Token passing (a twisted pair RS485 network created by BACnet) BIBB BACnet Interoperability Building Block (Specific individual function blocks for data exchange between interoperable devices).

  • Page 87: Poe Communications

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual POE Communications Direct Connection Options The unit must be powered by DC power or ethernet cable (see page 15-16). If using DC powering option, connect a standard ethernet cable to your PC and the unit. If using POE, ensure the switch is connected to your PC.

  • Page 88: Network Configuration

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Network Configuration Vortek/TCP meter needs to be configured in order to be “visible” on your local network. There are two methods of configuration: • Static IP address Dynamically assigned IP address via DHCP (Dynamic Host Configuration Protocol) •...
  • Page 89 _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual 2. Right click on “Wireless Network Connection” and then click “Disable.” 3. Right click on “Ethernet” and then select “Properties.” _____________________________________________________________________________________ M-000-0110...
  • Page 90 _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual 4. Click on “Internet Protocol Version 4 (TCP/IPv4)” and select “Properties.” _____________________________________________________________________________________ M-000-0110...
  • Page 91 _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual 5. The below window will be displayed. Fill in the following information and then click “OK.” a. Select “Use the following IP address.” b. Enter the IP address you wish to use. The IP address cannot be the same as the device IP address you are connecting to.
  • Page 92 Instruction Manual IPSetup Network Configuration Tool IPSetup is used to configure network settings on your Vortek/TCP device such as IP Address, Mask, Gateway, and DNS Server. If enabled in your device, IPSetup uses a User Datagram Protocol (UDP) broadcast on port 20034 to identify Vortek/TCP network devices. UDP broadcasts are not forwarded by routers, so IPSetup can only be used on a LAN or direct connection.

  • Page 93: Figure 4.5 - Ipsetup Displaying The Current Ip Address

    A firewall on your PC is blocking network port number 20034. Try temporarily disabling your firewall and try again. If you are trying to talk to a device on the other side of a router. Check to see if the PC • and Vortek/TCP devices are on the same LAN. _____________________________________________________________________________________ M-000-0110...

  • Page 94: Meter Web Pages

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual IPSetup FAQ • If DHCP serve can't assign an address to the meter, it will switch to AutoIP. AutoIPs are special addresses in the range 169.254.XXX.XXX. The XXX.XXX values are randomly selected with an attempt to avoid duplication. AutoIP is used for DIRECT CONNECTION to a PC.

  • Page 95: Figure 4.7 - Main/Home Page

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual 2023 Figure 4.7 - Main/Home Page Above is a Figure of the main page of the webpage with the menu selections on the left side. When the meter is initially powered up, it scans for connected meters. This version is intended for master/slave configuration with multiple meters connected to a single gateway.

  • Page 96: Figure 4.9 - Meter Menu

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual The above figure displays what values are available on the Flow Menu. Figure 4.9 - Meter Menu The above figure displays what values are available in the Meter Menu. _____________________________________________________________________________________ M-000-0110...

  • Page 97: Figure 4.10 - Fluid Menu

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Figure 4.10 - Fluid Menu The above figure displays the values of the Fluid Menu. Figure 4.11 - Diagnostic Menu The above figure shows the values of the Diagnostics Menu. _____________________________________________________________________________________ M-000-0110...

  • Page 98: Figure 4.12 - Configure Menu

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Figure 4.12 - Configure Menu The above figure shows the Configure page options. You may see the following screen if this is the first time accessing the WEB page for the meter. The Username is “creator” and the Password is 16363.

  • Page 99: Figure 4.14 - Data Log Menu

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Figure 4.14 - Data log Menu The above figure shows the Data Log options. Figure 4.15 - Startup Log Menu The figure above shows the Startup Log page. _____________________________________________________________________________________ M-000-0110...

  • Page 100: Web Configuration Interface

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual WEB Configuration Interface When access tabs in the Configure Page, you will need to enter the Username and Password. Figure 4.16 - Output Tab Figure 4.17 – External Input Tab _____________________________________________________________________________________ M-000-0110...

  • Page 101: Figure 4.18 - Display Tab

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Figure 4.18 - Display Tab 2023 Figure 4.19 - Alarms Tab _____________________________________________________________________________________ M-000-0110...

  • Page 102: Figure 4.20 - Totalizer Tab

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Figure 4.20 - Totalizer Tab Figure 4.21 - Units Tab Figure 4.22 - Fluid Tab _____________________________________________________________________________________ M-000-0110...

  • Page 103: Figure 4.23 - Diagnostics Tab

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Figure 4.23 - Diagnostics Tab 2023 Figure 4.24 - Calibration Tab _____________________________________________________________________________________ M-000-0110...

  • Page 104: Figure 4.25 - Sd Log Config. Tab

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Figure 4.25 - SD Log Config. Tab Figure 4.26 - HART Tab _____________________________________________________________________________________ M-000-0110...

  • Page 105: Figure 4.27 - System Tab

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Figure 4.27 - System Tab Figure 4.28 - Diagnostic Level 1 Troubleshooting Values 1 Tab _____________________________________________________________________________________ M-000-0110...

  • Page 106: Figure 4.29 - Diagnostics Level 1 Troubleshooting Values 2 Tab

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Figure 4.29 - Diagnostics Level 1 Troubleshooting Values 2 Tab Figure 4.30 - Diagnostics Level 2 4-20 mA Configuration Tab _____________________________________________________________________________________ M-000-0110...

  • Page 107: Internet Connection To The Meter - Security Issues

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Figure 4.31 - Diagnostic Level 2 Factory Configuration Tab Internet Connection to the Meter – Security Issues Typically the meter is connected to the Local Area Network (LAN) with non-routable Private Network Address (192.168.xx.xx, 10.xx.xx.xx, 172.16-31.xx.xx). There are two options to setup...
  • Page 108 _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Example of Port Forwarding → → External IP 50.202.79.132 Port 8080 mapped to 10.10.10.75 Port 80 → → External IP 50.202.79.132 Port 10502 mapped to 10.10.10.75 Port 502 → → External IP 50.202.79.132 Port 10443 mapped to 10.10.10.75 Port 443...

  • Page 109: Modbus/Tcp Interface

    General information about Port Forwarding and instructions how to set up it in simple home routers available everywhere. E.g. here: http://www.howtogeek.com/66214/how-to-forward- ports-on-your- router/ Modbus/TCP Interface VorTek’s TCP meter supports industry standard automation protocol Modbus/TCP. Once connected to Modbus/TCP, the addresses will be the same as our standard options. General specifications: Protocol...

  • Page 110: Bacnet/Tcp Interface

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Figure 4.32 - EXE Folder BACnet/TCP Interface All meters are configured for Modbus communications when shipped. If you are communicating with BACnet TCP/IP, make sure “BACnet (0x10000)” is selected in the “Config Options” section of the Calibration tab and the setting are saved (see below).

  • Page 111: Data Logging

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Data Logging VRTX/TCP meter has internal logging capability. The data is logged to micro SD card inside unit. The capacity of SD card may vary from 4 to 32 GB. The size of card and free space are shown on StartUp Log page.
  • Page 112 _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual To download file to your PC, right click on the file and select “save”. You may also open it immediately by clicking on the file. It will be opened as text file or in EXCEL depending on your settings of used browser.

  • Page 113: Figure 4.35 - Excel Example

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Figure 4.35 - EXCEL Example The SD Log Config tab has the following variables available to log. Just select desired items and click SET button at the bottom of the page. _____________________________________________________________________________________ M-000-0110...

  • Page 114: Figure 4.36 - Sd Log Configuration Tab

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Figure 4.36 - SD Log Configuration Tab _____________________________________________________________________________________ M-000-0110...

  • Page 115: Updating The Firmware

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Updating the Firmware VORTEX meter firmware can be updated on-line. For that there are two applications: • AutoUpdate – Standard update utility using UDP protocol. Local network only. • TcpUpdate – Update utility using TCP protocol allowing access from other networks.

  • Page 116: Chapter 5 Troubleshooting And Repair

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Chapter 5 Troubleshooting and Repair Hidden Diagnostics Menus The menus shown on the following page can be accessed using the password 16363, then moving to the display that reads “Diagnostics Menu” and pressing ENTER (rather than one of the arrow Warning! keys).
  • Page 117 _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual { ----- ------- Level One Values ----- ------- } { ----- --------- ---------- ------ Level Two Values ----- --------- ---------- ------ } Iso. Power 4-20(1), Zero Output Type Alar m(1) Test Volts xxxx None x.x vdc...

  • Page 118: Level One Hidden Diagnostics Values

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Level One Hidden Diagnostics Values f = Vortex shedding frequency (Hz). • fi = Adaptive filter – should be approximately 25% higher than the vortex shedding • frequency, this is a low-pass filter. If the meter is using the Filter Control (see below) in the manual mode, fi will be displayed as fm.

  • Page 119: Level Two Hidden Diagnostics Values

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Adj. Filter = Adjustable filter. Displays the filtering in decibels. Normally reads zero. If • this value is consistently -5 or -10, for example, the Ck or density setting may be wrong. Iso. Power Volts = Nominally 2.7 VDC, if less than this check the flow meter input power.
  • Page 120 _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual Alarm (1) Test = Used as a test to verify that the alarm circuit is functioning. When low is • selected the alarm will initiate a low alarm on the output. When High is selected it will give a high alarm on the output.

  • Page 121: Analog Output Calibration

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Instruction Manual ft3/sec (1 through 10)  %Dev. (1 through 10)  Roughness = Factory use only. • Force Recal? = Factory use only. • Min. Delta H – Energy EMS meters only. Sets the deadband for totalization to begin. Must •...

  • Page 122: Appendix A Specifications

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Appendix A Specifications Appendix A Product Specifications Power Requirements 12 to 36 VDC, 25 mA, 1 W max., Loop Powered Volumetric or Mass 12 to 36 VDC, 300 mA, 9 W max. Multiparameter Mass options 100 to 240 VAC, 50/60 Hz, 5 W max. Multiparameter Mass...
  • Page 123 _____________________________________________________________________________________ FlowCalc™ Flow Computer Appendix A Specifications Multiparameter Meter: up to three field rangeable linear 4-20 mA output signals (1200 Ohms maximum loop resistance) selected from the five parameters–mass flow rate, volumetric flow rate, temperature, pressure and density. Pulse: Pulse output for totalization is a 50-millisecond duration pulse operating a solid-state relay capable of switching 40 VDC, 40 mA maximum.
  • Page 124 _____________________________________________________________________________________ FlowCalc™ Flow Computer Appendix A Specifications _____________________________________________________________________________________ M-000-0110...

  • Page 125: Appendix B Approvals

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Appendix B Approvals Appendix B Approvals FlowCalc Label Technical assistance may be obtained by contacting Customer Service at: (888) 386-7835 or (303) 682-9999 in the USA _____________________________________________________________________________________ M-000-0110...

  • Page 126: Appendix C Flow Computer Calculations

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Appendix C Flow Computer Calculations Appendix C Flow Computer Calculations In-Line Flow Meter Calculations Volume Flow Rate  Flowing Velocity  Mass Flow Rate  Q  Where: A = Cross sectional area of the pipe (ft^2)

  • Page 127: Insertion Flow Meter Calculations

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Appendix C Flow Computer Calculations Insertion Flow Meter Calculations Flowing Velocity V  Volume Flow Rate  Mass Flow Rate   Where: A = Cross sectional area of the pipe (ft^2) f = Vortex shedding frequency (pulses / sec)
  • Page 128 _____________________________________________________________________________________ FlowCalc™ Flow Computer Appendix C Flow Computer Calculations Energy Flow Calculations Energy is calculated for a steam supply/condensate return or hot/chilled water system. For steam/water, the meter must be located in the supply line; otherwise, the meter may be located in either the supply line or in the return line.

  • Page 129: Fluid Calculations

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Appendix C Flow Computer Calculations Fluid Calculations Calculations for Steam T & P When “Steam T & P” is selected in the “Real Gas” selection of the Fluid Menu, the calculations are based on the equations below.

  • Page 130: Calculations For Gas ("Real Gas" And "Other Gas")

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Appendix C Flow Computer Calculations Calculations for Gas (“Real Gas” and “Other Gas”) Use this formula to determine the settings for “Real Gas; Gas” selections and “Other Gas” selections entered in the Fluid Menu. The calculations for gas were taken from Richard W. Miller, Flow Measurement Engineering Handbook (Third Edition, 1996).

  • Page 131: Calculations For Liquid

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Appendix C Flow Computer Calculations Calculations for Liquid Use this formula to determine the settings for “Goyal-Dorais” selections and “Other Liquid” selections entered in the Fluid Menu. The liquid calculations were taken from Richard W. Miller, Flow Measurement Engineering Handbook (Third Edition, 1996).

  • Page 132: Appendix D Glossary

    _____________________________________________________________________________________ FlowCalc™ Flow Computer Appendix D Glossary Appendix D Glossary A B C D Cross sectional area. ACFM Actual Cubic Feet Per Minute (volumetric flow rate). ASME American Society of Mechanical Engineers. Bluff Body A non-streamlined body placed into a flow stream to create vortices. Also called a Shedder Bar.
  • Page 133 _____________________________________________________________________________________ FlowCalc™ Flow Computer Appendix D Glossary I J K L In-Line Flow Meter A flow meter which includes a short section of piping which is put in-line with the user’s piping. A flow meter which is inserted into a hole in the user’s pipeline.
  • Page 134 _____________________________________________________________________________________ FlowCalc™ Flow Computer Appendix D Glossary Q R S T Flow rate, usually volumetric. Rangeability Highest measurable flow rate divided by the lowest measurable flow rate. Reynolds Number A dimensionless number equal to the density of a fluid or Re times the velocity of the fluid times the diameter of the fluid channel, divided by the fluid viscosity (i.e., Re = VD/).

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