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Omega FD-400 Series User Manual

Doppler ultrasonic flow meter
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MADE
1 YEAR
IN U.S.A.
WARRANTY

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Summary of Contents for Omega FD-400 Series

  • Page 1 MADE 1 YEAR IN U.S.A. WARRANTY...
  • Page 3 QUICK-START OPERATING INSTRUCTIONS This manual contains detailed operating instructions for all aspects of the FD-400 flow instrument. The following condensed instructions are provided to assist the operator in getting the instrument started up and running as quickly as possible. This pertains to basic operation of the clamp-on transducer only.
  • Page 4 QUICK-START OPERATING INSTRUCTIONS Cables point in the direction of flow Top View of Pipe Figure 1.2 Transducer Direction Connections 3. TRANSDUCER CONNECTIONS A. Mount FD-400 monitor within the length of the transducer cables. While transducer cable extension is not generally recommended, if additional transducer cable is required, utilize RG59 75 Ohm coaxial cable and 75 Ohm interconnections such as BNC.
  • Page 5 TABLE OF CONTENTS Page Quick-Start Operating Instructions Introduction General Applications Product Specifications Transducer Installation Transducer Mounting Locations Pipe Preparation Clamp-On Transducer Mounting Probe Transducer Mounting Transmitter Installation Mounting Location Dimensional Drawing Transducer Wiring Connections Power Supply Wiring Connections Wiring Diagram Multiple Meter Synchronization ISO Modules—General Information 4-20 mA Module...
  • Page 6 TABLE OF CONTENTS Page Control Relay Module 3.10 Rate Pulse Output Module 3.11 Instrument Programming Keypad Operation Totalizer Reset Measurement Units Selection Engineering Units Selection 4-20 mA Programming Rate Pulse Programming Dual Relay Configuration 4.10 Change Password 4.12 Advanced Set-up 4.12 Startup and Troubleshooting Startup Requirements...
  • Page 7 PART 1 - INTRODUCTION General The FD-400 ultrasonic flow meter is designed to measure volumetric flow of solids-bearing or aerated liquid within closed conduit. Trans- ducers are available as non-contacting (FD-400C) or insertion probe (FD-400I) types. FD-400C non-contacting transducers are strapped to the outside of a pipe and are suitable for most installations where the pipe material supports the transmission of ultrasound.
  • Page 8 The serial number and complete model number of each FD-400 is Product located on the inside of the monitor’s front cover. Should technical Identification assistance be required, please provide the Omega Customer Service Department with this information. Rev. 03/15 -1.6-...
  • Page 9 PART 1 - INTRODUCTION Rev. 03/15 -1.7- Series FD-400...
  • Page 10 PART 2 - TRANSDUCER INSTALLATION Unpacking After unpacking, it is recommended to save the shipping carton and packing materials in case the instrument is stored or re-shipped. Inspect the equipment and carton for damage. If there is evidence of shipping damage, notify the carrier immediately. The transducers that are utilized by the FD-400 contain piezoelectric Mounting crystals for transmitting and receiving ultrasonic sound energy...
  • Page 11 PART 2 - TRANSDUCER INSTALLATION flow readings will be realized over a very large range of flow. Since products like the FD-400 have software algorithms that assume a full-pipe of liquid, partially-filled pipes can lead to very large flow measurement errors and should be avoided. Select a transducer mounting location with adequate straight runs of pipe, both upstream and downstream, to achieve stable readings Examples of minimum upstream and downstream requirements are...
  • Page 12 PART 2 - TRANSDUCER INSTALLATION Pipe Preparation Before the transducer heads are mounted to the pipe surface, an area slightly larger than the flat surface of the transducer face must be prepared. If pipe insulation is present, it must be peeled back to expose the pipe surface.
  • Page 13 PART 2 - TRANSDUCER INSTALLATION Top View of Pipe Figure 2.3 Transducer Placement PROCEDURE: 1. Large pipe installations utilize stainless steel straps to secure the transducers to the outside of the pipe. The FD-400 system is shipped with four 36 inch (900 mm) straps, which are suitable for pipes up to 39 inches (1000 mm) diameter.
  • Page 14 PART 2 - TRANSDUCER INSTALLATION transducers are to be mounted. Leave the strap loose enough to allow the transducers to be placed underneath. If multiple straps are being used, it can be beneficial to wrap electrical tape around all but one strap connection to secure the strap worm screws in place.
  • Page 15 PART 2 - TRANSDUCER INSTALLATION FD-400I Probe The FD-400I insertion transducer that is utilized by the FD-400 contains piezoelectric crystals for transmitting and receiving Transducer ® ultrasonic sound energy. The black Ultem plastic tip of the FD-400I Mounting contains these crystals, which are designed to be inserted just into the path of the flowing liquid.
  • Page 16 PART 2 - TRANSDUCER INSTALLATION Figure 2.6 Hot Tap Installation Rev. 03/15 -2.7- Series FD-400...
  • Page 17 PART 2 - TRANSDUCER INSTALLATION Rev. 03/15 -2.8- Series FD-400...
  • Page 18 PART 2 - TRANSDUCER INSTALLATION Rev. 03/15 -2.9- Series FD-400...
  • Page 19 PART 2 - TRANSDUCER INSTALLATION TO CALCULATE INSERTION DEPTH Measure and record the following linear distances: E = PROBE LENGTH = _______ C = SEAL FITTING TO PIPE WALL = _______ B = PIPE WALL THICKNESS = _______ A = 0.125 × PIPE ID = _______ D = INSERTION DEPTH = _______...
  • Page 20 PART 2 - TRANSDUCER INSTALLATION Rev. 03/15 -2.11- Series FD-400...
  • Page 21 PART 2 - TRANSDUCER INSTALLATION Figure 2.8 Flow Direction Arrow Rev. 03/15 -2.12- Series FD-400...
  • Page 22 PART 3 - TRANSMITTER INSTALLATION After unpacking, it is recommended to save the shipping carton and packing materials in case the instrument is stored or re-shipped. Inspect the equipment and carton for damage. If there is evidence of shipping damage, notify the carrier immediately. The enclosure should be mounted in an area that is convenient for Mounting servicing, calibration and for observation of the LCD readout.
  • Page 23 PART 3 - TRANSMITTER INSTALLATION Figure 3.1 FD-400 Transmitter Installation Dimensions Rev. 03/15 -3.2- Series FD-400...
  • Page 24 PART 3 - TRANSMITTER INSTALLATION Transducer To access terminal strips for electronic connectors, loosen the two screws in the enclosure door and open the door. Wiring Connections 1. Guide the transducer terminations through the transmitter conduit hole located in the bottom-center of the enclosure. Secure the transducer cable with the supplied conduit nut (if flexible conduit was ordered with the transducer).
  • Page 25 PART 3 - TRANSMITTER INSTALLATION WIRING DIAGRAM CAUT IO N! To a void se rious injur y or pro du ct d am a ge , d isco n ne ct e lectrical p owe r b e for e se rvicing this m eter. JP 3 JP 3 Connections...
  • Page 26 PART 3 - TRANSMITTER INSTALLATION AC Power AC POWER CONNECTIONS Supply 1. Verify that the jumpers at JP3 are properly oriented for the power supply. See Figure 3.2 on page 3.4. Verify that the jumpers at JP1 and JP2 are not present. 2.
  • Page 27 PART 3 - TRANSMITTER INSTALLATION DC Power DC POWER CONNECTIONS Supply The FD-400 may be operated from a 12-28 VDC source, as long as the source is capable of supplying a minimum of 2.5 Watts. 12 VDC Supply @ 208 mA minimum 24 VDC Supply @ 104 mA minimum 1.
  • Page 28 PART 3 - TRANSMITTER INSTALLATION Multiple Meter Installations Multiple Meter Synchronization The FD-400 flow meter contains a provision for synchronizing multiple FD-400 flow meters together. Synchronization is required when more than one FD-400 flow meter is mounted on a common pipe or header system.
  • Page 29 PART 3 - TRANSMITTER INSTALLATION ISO Modules The FD-400 utilizes ISO-MODs for input and output functions. ISO- MODs are epoxy encapsulated electronic input/output modules that are simple to install and replace in the field. See Figure 3.6. All modules are 2,500 V optically isolated from FD-400 power and earth grounds.
  • Page 30 PART 3 - TRANSMITTER INSTALLATION 4-20 mA Output The 4-20 mA Output Module interfaces with most recording and logging systems by transmitting an analog current signal that is Module proportional to system flow rate. The 4-20 mA ISO-MOD may be configured via jumper selections for either an internally powered (Figure 3.7A) or externally powered (Figure 3.7B) mode.
  • Page 31 PART 3 - TRANSMITTER INSTALLATION Control Relay Two independent SPDT (single-pole, double-throw, Form C) relays are contained in this module. The relay operations are user Output Module configured via the front panel to act in either a flow rate alarm, error alarm or totalizing pulse.
  • Page 32 PART 3 - TRANSMITTER INSTALLATION Rate Pulse The Rate Pulse Output Module is utilized to transmit information to external counters and PID systems via a frequency output that is Output Module proportional to system flow rate. The frequency output range of the Rate Pulse Module is 0-2,500 Hz.
  • Page 33 PART 4 - INSTRUMENT PROGRAMMING General The FD-400 is configured through the keypad interface. All entries are saved in non-volatile FLASH memory and will be retained indefinitely in the event of power loss. Keypad The FD-400 contains a four-key tactile feedback keypad interface that allows the user to view and change configuration parameters Operation used by the FD-400 operating system.
  • Page 34 PART 4 - INSTRUMENT PROGRAMMING 6. To exit programming mode, press the MENU key. Depending on your position in the programming mode, up to three MENU key presses may be required to exit. The display will change to RUN mode. NOTE: The FD-400 firmware revision can be displayed by pressing both arrow keys simultaneously.
  • Page 35 PART 4 - INSTRUMENT PROGRAMMING Menu The FD-400 software is structured using menus. A menu map of the user interface is included in the Appendix of this manual. The Structure map provides a visual path to the configuration parameters that users can access.
  • Page 36 PART 4 - INSTRUMENT PROGRAMMING To display only the Flow Rate, select RATE. To display only the Flow Total, select TOTAL. To alternately display the Flow Rate and the Total, select BOTH. By selecting BOTH, the display will switch between RATE and TOTAL every 7 seconds. The DIAG selection places the display in the diagnostics mode.
  • Page 37 PART 4 - INSTRUMENT PROGRAMMING Engineering TOTL UNT – Engineering Units for Flow Totalizer Units GALLONS - U.S. Gallons TOTALIZER LITERS - Metric Liters MGAL - Millions of U.S. Gallons CUBIC FT - Cubic Feet M CU FT - Millions of Cubic Feet CUBIC ME - Cubic Meters MEGLTRS - Millions of Metric Liters ACRE FT - Acre Feet...
  • Page 38 PART 4 - INSTRUMENT PROGRAMMING Fluid Specific SP GRAV – Fluid Specific Gravity Entry Gravity unitless Allows adjustments to be made to the specific gravity (density) of the liquid. If Pounds (LBS) or Kilograms (KGS) is selected for either the RATE UNT or the TOTL UNT, a specific gravity must be entered for the correct mass flow to be calculated.
  • Page 39 PART 4 - INSTRUMENT PROGRAMMING System DAMPING – System Damping Damping Relative Percent Entry: 0-99% Flow Filter Damping establishes a maximum adaptive filter value. Under stable flow conditions (flow varies less than 10% of reading), this adaptive filter will increase the number of successive flow readings that are averaged together up to this maximum value.
  • Page 40 PART 4 - INSTRUMENT PROGRAMMING Configured via jumper selections for either a passive (current sinking) or active (current sourcing) transmission mode (see Part 3 for details), the 4-20 mA Output Module interfaces with virtually all recording and logging systems by transmitting an analog current signal that is proportional to system flow rate.
  • Page 41 PART 4 - INSTRUMENT PROGRAMMING 2. Using the arrow keys, increase the numerical value to increase the current in the loop to 4 mA. Decrease the value to decrease the current in the loop to 4 mA. Typical values range between 40-80 counts.
  • Page 42 PART 4 - INSTRUMENT PROGRAMMING collector”. The turbine meter simulation sources a non-ground referenced saw-tooth waveform with a maximum peak amplitude of approximately 500 mV p-p. The open-collector output utilizes a 0.21 Ohm MOSFET output that is rated to operate at 100 V and 1 A maximum.
  • Page 43 PART 4 - INSTRUMENT PROGRAMMING Two independent SPDT (single-pole, double-throw, Form C) relays are contained in this module. The relay operations are user configured via the keypad to act in either a total pulse output, flow rate alarm or error alarm mode. The relays are rated for 200 VAC maximum and a have current rating of 0.5A resistive load (175 VDC @ 0.25A resistive).
  • Page 44 PART 4 - INSTRUMENT PROGRAMMING Configure CFG MOD2 – Configure I/O Module 2 I/O Module 2 The I/O configurations for CFG MOD2 are identical to those detailed in CFG MOD1. Change PASSWORD – Change the Security Password Password 0-9999 By changing the Security Password from 0000 to some other value (any value between 0001-9999), configuration parameters will not be accessible without first entering that value when prompted.
  • Page 45 PART 4 - INSTRUMENT PROGRAMMING When the unit is powered up, there is a delay before the unit begins transmitting sound into the pipe. During this time, the signal strength is measured and a base signal level is obtained. Typically this is a value of about 20.
  • Page 46 PART 4 - INSTRUMENT PROGRAMMING Gain Control GAIN POT – Digital Gain Pot 0-64 Using the arrow keys, increase or decrease the numerical value to set the signal gain level. Typically, optimum flow measurement is made when this value is between 10 and 50. Use the lowest value that provides an accurate and stable flow reading.
  • Page 47 PART 4 - INSTRUMENT PROGRAMMING Linearization LINEAR – Entry of Linearization Data The Linearization feature allows for correction of flow readings caused by non-linear flow measurement. This typically occurs when there is insufficient straight piping before or after the location where the transducers are mounted.
  • Page 48 PART 5 - STARTUP AND TROUBLESHOOTING FD-400 Startup NOTE: The FD-400 flow meter system requires a full pipe of flowing liquid before a successful startup evaluation can be Requirements completed. Do not attempt to make adjustments or make Manual configuration changes until a full pipe of flowing liquid is verified. NOTE: If an RTV sealant was utilized to couple the transducers to the pipe, the sealant must fully cure before power is applied to the instrument.
  • Page 49 PART 5 - STARTUP AND TROUBLESHOOTING Troubleshooting Symptom Resolution Display does not light up 1. Insufficient power to FD-400 monitor – measure voltage at J2 2. Power supply not properly wired to J2 – See Part 3 3. Fuse F1 is open or not installed 4.
  • Page 50 PART 5 - STARTUP AND TROUBLESHOOTING Troubleshooting Symptom Resolution Analog output does not match 1. Verify 4-20 mA calibration data collection system 2. Verify 4 mA and 20 mA flow settings 3. Verify that the loop load is within the supply voltage range 4.
  • Page 51 A P P E N D I X...
  • Page 52 SERIES SOFTWARE MAP - General Operations VER 1.04-1.05 ID UNIT (Pipe Measurement Units) TOTL UNT (Flow Totalizer Units) PASSWORD (Locks Keypad) INCH (Inches) GALLONS XXXX (Other than 0000—Locks Keypad) MM (Millimeters) LITERS 0000 (Keypad Unlocked) MGAL (Million Gallons) CUBIC FT (Cubic Feet) ID (Pipe Internal Diameter) AD SETUP (Advanced Setup) M CU FT (Million Cubic Feet)
  • Page 53 SERIES SOFTWARE - Output Configuration Map VER 1.04-1.05 4-20MA From “General Operations” Software Map FLOW 4MA (Flow Rate at 4 mA output) Configuration of Output 1 and 2 are essentially identical, so FLOW20MA (Flow Rate at 20 mA output) only Output 1 configuration is detailed. 4-20CAL? CFG MOD1 (Configure Output Module #1) 4MA OUT (~40 Counts typical)
  • Page 54 Fluid Properties Original Date: 7/30/1999 Revision: Revision Date: 9/10/2003 Fluid Specific Gravity Sound Speed delta-v/degree C Kinematic Viscosity Absolute Viscosity 20 degrees C ft/s m/s/degree C Centistokes Centipoise Acetate, Butyl 1270 4163.9 Acetate, Ethyl 0.901 1085 3559.7 0.489 0.441 Acetate, Methyl 0.934 1211 3973.1...
  • Page 55 Oil, Castor 0.97 1477 4845.8 0.670 0.649 Oil, Diesel 0.80 1250 4101 Oil (Lubricating X200) 1530 5019.9 Oil (Olive) 0.91 1431 4694.9 2.75 100.000 91.200 Oil (Peanut) 0.94 1458 4783.5 Paraffin Oil 1420 4655.7 Pentane 0.626 1020 3346.5 0.363 0.227 Petroleum 0.876 1290...
  • Page 56 Steel, Stainless Steel, P.V.C. Standard Schedules SCH. SCH. 10 SCH. 20 SCH. 30 STD. SCH. 40 SCH. 60 X STG. SCH. 80 SCH. 100 SCH. 120 SCH. 140 SCH. 180 Nominal (LTWALL) OUTSIDE Pipe Size DIAMETER Inches Wall Wall Wall Wall Wall Wall...
  • Page 57 Cast Iron Pipe Standard Classes CLASS A CLASS B CLASS C CLASS D CLASS E CLASS F CLASS G CLASS H Size O.D. I.D. O.D. I.D. O.D. I.D. O.D. I.D. O.D. I.D. O.D. I.D. O.D. I.D. O.D. I.D. Wall Wall Wall Wall Wall...
  • Page 58 Ductile Iron Pipe Standard Classes Cement Lining Pipe Outside Std./Double Class 50 Class 51 Class 52 Class 53 Class 54 Class 55 Class 56 Size Diameter Thickness (inches) (inches) Wall Wall Wall Wall Wall Wall Wall 3.96 3.46 0.25 3.40 0.28 3.34 0.31 3.28 0.34 3.22 0.37 3.14 0.41 4.80 4.28 0.26 4.22 0.29 4.16 0.32 4.10 0.35 4.04 0.38 3.93 0.44 6.90...
  • Page 59 FPS TO GPM CROSS - REFERENCE (Schedule 40) Nominal I.D. Pipe INCH (Inches) 1.05 2.6989 4.0484 5.3978 6.7473 8.097 9.4462 10.796 12.145 13.490 14.844 16.190 17.540 18.890 20.240 21.590 22.941 24.290 1.25 1.38 4.6620 6.9929 9.3239 11.655 13.99 16.317 18.648 20.979 23.310 25.641 27.970 30.300 32.630 34.960 37.300 39.627 41.958 1.61 6.3454 9.5182 12.691 15.864 19.04 22.209 25.382 28.555 31.730 34.900 38.070 41.250 44.420 47.590 50.760 53.936 57.109...
  • Page 60 FPS TO GPM CROSS - REFERENCE (Schedule 40) Nominal I.D. Pipe INCH (Inches) 16.88 697.52 1046.3 1395.0 1743.8 2093.0 2441.3 2790.1 3138.8 3488.0 3836.3 4185.0 4534.0 4883.0 5231.0 5580.0 5928.9 6277.7 18.81 866.14 1299.0 1732.0 2165.3 2598.4 3031.5 3464.6 3897.6 4330.7 4763.8 5196.8 5629.9 6063.0 6496.0 6929.1 7362.2 7795.3 22.63 1253.7 1880.0 2507.0 3134.1 3761.0 4387.8 5014.6 5641.5 6268.3 6895.1 7522.0 8148.8 8775.6 9402.4 10029 10656...