Page 1
User’s Guide
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FMG-1000 SERIES
Municipal/Industrial Magmeter
Xxxxx Xxxxxxxx
XXXXXX
Page 2
OMEGAnet®Online Service Internet e-mail
U.S.A.:
ISO 9001 Certified
omega.com [email protected]
Servicing North America:
Omega Engineering, Inc., One Omega Drive, P.O. Box 4047
Stamford, CT 06907-0047 USA
Toll Free: 1-800-826-6342 TEL: (203) 359-1660
FAX: (203) 359-7700 e-mail: [email protected]
Canada:
976 Bergar
Laval (Quebec), Canada H7L 5A1
Toll-Free: 1-800-826-6342 TEL: (514) 856-6928
FAX: (514) 856-6886 e-mail: [email protected]
For immediate technical or application assistance:
U.S.A. and Canada: Sales Service: 1-800-826-6342/1-800-TC-OMEGA
Customer Service: 1-800-622-2378/1-800-622-BEST
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®
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733 01 Karviná, Czech Republic
Toll-Free: 0800-1-66342 TEL: +420-59-6311899
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France:
Managed by the United Kingdom Office
Toll-Free: 0800 466 342 TEL: +33 (0) 161 37 29 00
FAX: +33 (0) 130 57 54 27 e-mail: [email protected]
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D-75392 Deckenpfronn, Germany
Toll-Free: 0 800 6397678 TEL: +49 (0) 7059 9398-0
FAX: +49 (0) 7056 9398-29 e-mail: [email protected]
United Kingdom: OMEGA Engineering Ltd.
ISO 9001 Certified One Omega Drive, River Bend Technology Centre, Northbank
Irlam, Manchester M44 5BD England
Toll-Free: 0800-488-488 TEL: +44 (0)161 777-6611
FAX: +44 (0)161 777-6622 e-mail: [email protected]
It is the policy of OMEGA Engineering, Inc. to comply with all worldwide safety and EMC/EMI
regulations that apply. OMEGA is constantly pursuing certification of its products to the European New
Approach Directives. OMEGA will add the CE mark to every appropriate device upon certification.
The information contained in this document is believed to be correct, but OMEGA accepts no liability for any
errors it contains, and reserves the right to alter specifications without notice.
WARNING: These products are not designed for use in, and should not be used for, human applications.
Page 3
TABLE OF CONTENTS
General Information
General Information, Features ................................................................................................... Page 1
Specications
Specications, Flow Range ............................................................................................................ Page 3
Installation and Grounding
Positioning the Meter,
Calibration, Chemical Injection, Metal Pipe Installations, Plastic Pipe Installations....................... Page 4
Straight Pipe Recommendations ................................................................................................ Page 5
Full Pipe Recommendations ...................................................................................................... Page 6
Inputs/Outputs and Operation
Power, Pulse Output, High Frequency, K-Factor, Display Reading ................................................... Page 7
Connections Diagrams
FMG1000-MAW, FMG-1000-DL................................................................................................. Page 8
Straight Pipe Recommendations, Full Pipe Recommendations, Fittings,
Troubleshooting
Problem, Probable Cause, Things to Try .................................................................................... Page 9
TABLES, DIAGRAMS & CHARTS
Features ...................................................................................................................................Page 1
Specifications .......................................................................................................................... Page 3
Flow Range ............................................................................................................................. Page 3
Metal Pipe Installation, Plastic Pipe Installation ..................................................................... Page 4
Straight Pipe Recommendations ............................................................................................. Page 5
Full Pipe Recommendations .................................................................................................... Page 6
High Frequency Output ............................................................................................................. Page 7
Display Readings ..................................................................................................................... Page 7
Connections Diagrams ............................................................................................................. Page 8
Troubleshooting ......................................................................................................................... Page 9
Page 4
GENERAL INFORMATION
The FMG-1000 Series are anged electromagnetic owmeters
for use in 3” to 10” pipe in municipal or industrial water and
wastewater applications where propeller meters have typically
been used in the past. Because the FMG-1000 has no moving
parts and has electrodes designed to discourage fouling, this
magmeter performs well and requires much less frequent
maintenance in applications where debris would impede
propeller meters. There is no rotor to stop turning or bearings
to wear out. Minimal straight pipe requirements allow FMG1000 Series meters to be used in piping congurations where
there is little space between the meter and an elbow.
In chemical injection applications, the chemical injection point
must be placed downstream of the magmeter OR far enough
upstream for complete mixing to occur before the uid
reaches the meter.
The submersible units, -SUB option, are rated IP68 (NEMA 6P)
for applications where the meter may be under water up to a
depth of 3 meters for prolonged periods of time.
Rate and total indication are standard on both models. Units
are customer-selected and factory-set. No set-up is required.
The FMG-1000 is externally powered with 8-32 Vdc at 30 mA
max (see NOTE in Specications).
The 20-foot power cable also provides pulse output for use
with a variety of displays and controls for remote reading,
data logging, pulse-to-analog conversion, and telemetry
applications. High frequency pulse rate (required for use with
4-20 mA converters) is standard; additional pulse rates are
available.
FEATURES
Rate and total indicator
Powder-coated diecast-aluminum electronics housing
Tamper-evident security seal &
cross-drilled screws (2) for tamper-evidence
Internal Data Logger (Optional)
Power/Output cable port access, tamper-sealed
(NOTE: FMG-1000 comes with standard 20’ cable installed)
Welded steel epoxy-coated ow tube
316SS electrodes
Dual durometer rubber liner
Flanges, ANSI 150 lb. drilling
Equalization lug
Page 1
FMG-1000 (Non-IP68)
Page 5
FEATURES Continued
Rate and total indicator
Tamper-evident security seal &
cross-drilled screws (2) for tamper-evidence
Internal Data Logger (Optional)
Power/Output cable port access, tamper-sealed
(NOTE: FMG-1000 comes with standard 20’ cable installed)
Powder-coated ductile cast iron body & electronics housing
316SS electrodes
Glass lled molded plastic liner
Flanges, ANSI 150 lb. drilling
Equalization
FMG-1000-sub
(IP68 housing standard for 3” model)
Rate and total indicator
Tamper-evident security seal &
cross-drilled screws (2) for tamper-evidence
Power/Output cable port, tamper-sealed
(NOTE: FMG-1000 comes with standard 20’ cable installed)
Internal Data Logger (Optional)
Powder-coated ductile cast iron electronics housing
Equalization lug
IP68 Housing Option (-sub)
(For 4”-10” meter;
standard for 3” model)
Page 2
Page 6
SPECIFICATIONS
SPECIFICATIONS*
Pipe Sizes
Fittings
Pressure
Temperature Operating
Accuracy
Materials Body (3” Only)
Body (4”-10”)
Liner (3” Only)
Liner (4”-10”)
Electronics Housing
Electrodes
O-ring (3” Only)
Display
Power
Pulse Output
High Frequency
(pulse/gal)
Conductivity
Empty Pipe Detection
Environmental
*Specications subject to change.
Non-Operating
Digits
Units
Signal
Pulse Rates
3”,4”, 6”, 8”, 10”
ANSI 150 lb. drilling
150 psi (10.3 bar) working pressure
10˚ to 130˚ F (-12˚ to 54˚ C)
-40˚ to 158˚ F (-40˚ to 60˚ C)
+/- 1% of reading for ow between 10% to 100% of max ow
+/- 2% of reading for ow from cutoff to 10% of max ow
Ductile cast iron, powder coated w/NSF61 listed epoxy powder
Welded steel, epoxy-coated
PPO/PPS Blend
Dual durometer rubber
Diecast aluminum, powder-coated (non-IP68) Ductile Cast Iron (IP68)
316 stainless steel
EPDM
Rate Total
5 8
Gallon/Minute, Liter/Minute, Liter/Second, Gallon, Gallon x 1000, Liter, Liter x 1000, Mega Liter,
Cubic Feet/Minute, Cubic Meter/Hour, Cubic Meters, Cubic Meter x 1000, Cubic Feet,
Million Gallon/Day, Mega Liter/Day Cubic Feet x 1000
8-32 Vdc at 30 mA max
NOTE: Using an unregulated power supply >18 Vdc may damage the meter due to AC line input voltage uctuation
Current sinking pulse, opto-isolated, 30 Vdc at 10 mA max
High Frequency (default); 10 units/pulse; 100 units/pulse; 1000 units/pulse
3” 4” 6” 8” 10”
25.228 16.362 6.307 3.344 2.150
>20 microSiemens/cm
Hardware/software, conductivity-based
NEMA 4X Standard (IP68/NEMA 6P Option)
FLOW RANGE (3” - 10”)
Meter
Size
Gal/Min Liter/Sec Gal/Min Liter/Sec Gal/Min Liter/Sec Gal/Min Liter/Sec Gal/Min Liter/Sec
3” 4” 6” 8” 10”
Minimum 7.5 . 47 12 .75 32 2 60 3.8 95 6
Maximum 700 44.2 1,000 63 2,400 151 .4 4,400 27 7. 6 7,000 4 41 . 6
Page 3
Page 7
INSTALLATION and GROUNDING
INSTALLATION
Caution: These ow sensors are not recommended
where installation fault may expose the ow sensor
to boiler pressure and temperature. Maximum
recommended temperature is 130˚ F.
Positioning the Meter. These meters can be installed
horizontally, vertically, and in any radial position. Using a
check valve on the upstream side of the meter, and/or an air
vent (vacuum relief valve) in the same unobstructed run of pipe
as the meter, is required any time reverse suction is present.
Reverse suction can cause damage to the liner. Liner damage
caused by reverse suction, without the use of a check valve
and/or air vent, may void the warranty.
Straight Pipe Recommendations. As with most ow meters,
the FMG-1000 requires some straight pipe before and
after the meter for best accuracy. However, the ability of
electromagnetic meters to average the ow across the entire
pipe allows for shorter straight pipe recommendations than
most mechanical meters (see page 4).
Full Pipe Recommendations. All magmeters require a
method for determining that the pipe is empty, to prevent false
reading. This meter is designed to go to zero reading if one
or more electrodes is exposed. For highest accuracy, install
the meter so that the pipe will be full when there is ow. If air
bubbles may be present in the pipe or sludge accumulation
is an issue, rotate the meter by one ange hole to position
the control housing at a 45˚ angle (see diagrams on page 5).
Fittings. The anges have standard ANSI 150 lb. drilling and
mate with any other ANSI 150 lb. ange.
Calibration. The FMG-1000 is factory-calibrated and will not
require any form of eld calibration.
Chemical Injection. When any magmeter, by any manufacturer, is used in a chemical injection application, the chemical
injection point must be placed downstream of the magmeter OR far enough upstream for complete mixing to occur
before the uid reaches the meter. When unmixed chemical
alternates with water passing through the meter, the rapid
changes in conductivity may cause sudden spikes and drops
in the meter’s reading, resulting in inaccurate measurement.
The magmeter will restabilize, however, with a steady ow of
uid of uniform conductivity.
Caution: In chemical injection applications, install
chemical injection point downstream of magmeter,
or far enough upstream to allow complete mixing
of uids before the meter.
EQUALIZATION AND GROUNDING
Metal Pipe Installations. To equalize the electrical potential
of the uid, the FMG-1000 meter, and the surrounding pipe,
secure the ange plates (factory-installed on the equalization
lug) to both pipe anges at one of the bolt holes, as shown
below. Be sure the lockwasher ts between the pipe ange
and the ange plate.
Meter Flange
Pipe Flange
Lockwasher
Flange Plate
Equalization Lug
Metal
Pipe
Meter
Flange
Bolt
Pipe
Flange
Metal
Pipe
Equalization Diagram
Run wire from equalization lug to both pipe anges;
secure ange plates under bolt heads as shown.
WARNING: ELECTRICAL SHOCK HAZARD When
the meter is externally AC powered, the piping system must be grounded to meet national and local
electrical safety codes. Failure to do so can result
in electrocution.
Plastic Pipe Installations. When the FMG-1000 is installed
in a plastic piping system, it is not necessary to use the
equalization straps, but very important to ground the meter
to avoid electrical shock hazard and electrostatic interference with meter function.
Meter Equalization Lug
Plastic Pipe Plastic Pipe
Exothermically weld when
corrosion is a concern
#6 AWG Stranded
Copper Ground Wire
Ground Clamp
Earth
8’ Ground Rod
Page 4
Page 8
STRAIGHT PIPE RECOMMENDATIONS
(X = diameter)
Reduced Pipe
Two Elbows In Plane
Two Elbows, Out Of Plane
1X
2X
FMG-1000
1X
2X
FMG-1000
1X
2X
Expanded Pipe
Swirling Flow
Propeller Meter
Swirling Flow
Partially Open
Buttery Valve
5X
FMG-1000
FMG-1000
5X
5X
1X
1X
FMG-1000
1X
FMG-1000
Page 5
Page 9
FULL PIPE RECOMMENDATIONS
Recommended:
Keep pipe full at meter for accuracy
FMG-1000
FMG-1000
FMG-1000 FMG-1000
Recommended:
Keeps pipe full at meter for accuracy
FMG-1000
Not Ideal:
Allows air pockets to form at meter
Not Ideal:
Post-valve cavitation can create air pocket
FMG-1000
Recommended:
Allows air to bleed off
Electrode
moved from
top by rotating
meter
FMG-1000
Recommended:
Improved accuracy results from
unimpeded electrodes
Intermittent air
bubbles
miss electrode
Electrodes free
from sediment
build-up
Not Ideal:
Air can be trapped
Intermittent air
bubbles
pass over
electrode
Possible
sediment
build-up
FMG-1000
Not Ideal:
Air bubbles and sediment on the
electrodes can affect accuracy
Page 6
Page 10
INPUTS/OUTPUTS and OPERATION
INPUTS/OUTPUTS
Power. The FMG-1000 operates on 7-26 Vdc at 30 mA max
external power (see WARNING in wiring diagrams). The display
reads “P” when external power is in use (see illustration below).
Pulse Output. The cable also provides pulse output that
can be used for remote reading, 4-20 mA signal conversion,
datalogging, and telemetry applications. See page 7 for
connection diagrams to Omega controls and displays.
Pulse rates are selected by the customer at time of order,
factory-set, and can only be changed in the field by an
authorized Omega dealer. Three pulse rates are possible:
One pulse per ten gallons (or liters), one pulse per thousand
gallons (or liters), or High Frequency (required for use with
4-20 mA converters; see below):
High Frequency Output/K-Factor
Meter Size Pulses per Gallon Pulses per Liter
3”
4” 16.362 4.323
6” 6.307 1.666
8” 3.344 0.883
10” 2.150 0.568
OPERATION
Caution: There are no user-adjustable
connections or settings inside the display
housing. Use caution when opening the
housing for a battery change, to avoid
damage to internal components.
Display Reading. The FMG-1000 display has two lines, the
bottom line for ow rate and the top line for accumulated total.
Measurement units are pre-ordered and factory-set and can
be changed in the eld only by an authorized individual.
Refer to the diagrams below to read your display.
External Power Indicator
No Power
Page 7
Meter Installed Backwards
Empty Pipe
Page 11
CONNECTIONS DIAGRAMS
The FMG-1000 requires a power source of 7 to 26 Vdc at
30 mA max (see WARNING). The power cable also serves as
a pulse output if needed for remote reading, data logging,
signal conversion, or telemetry.
FMG-1000-MAW
Blue
Do
Not
{
Orange
Use
4-20 mA
Power
5
6
4
3
2
1
0
Frequency
5
6
4
4
7
8
9
7
3
3
8
2
2
9
1
0
S
Sensor
Not
Used
5
5
6
6
4
7
7
3
8
8
2
9
9
1
1
0
0
Pulse-to-Analog Converter
Power Supply
at 30 mA max
(see WARNING)
White (-)
Green (+)
Black
Red
(-) (+)
7-26 Vdc
FMG1000 Cable Color Codes
Orange and Blue: Serial Output (Do Not Use)
Green (+) and White (-): Isolated solid-state contact closure pulse
output, 30 Vdc max, 10 mA max
Red (+) and Black (-): External Power, 7-26 Vdc at 30 mA max
Drain: Connect to earth ground (see WARNING)
Cable
Shielded
Drain Wire
Direct Burial Cable
22 AWG Stranded
WARNING: Using an unregulated power
supply >18 Vdc may damage the meter
due to AC line input voltage uctuation.
FMG-1000
FMG-1000-DL
Battery
Data Logger
Blue
Do
Not
{
Orange
Use
-
S
+
Not
Used
Power Supply
at 30 mA max
(see WARNING)
(-) (+)
7-26 Vdc
Green (+)
Black
Red
Drain Wire
White (-)
Shielded
Direct Burial Cable
22 AWG Stranded
Cable
FMG-1000
WARNING: Using an unregulated power
supply >18 Vdc may damage the meter
due to AC line input voltage uctuation.
Page 8
Page 12
TROUBLESHOOTING
Problem
Blank Display
Flow rate steadily reads
zero when there is ow
Flow rate intermittently
drops when there is ow
Probable Cause Try...
No power
Flow is below cutoff (very low)
Pipe not full
Meter is installed backwards
(display reads [ - ] )
Power connections reversed
Fluid conductivity <20mSiemens/cm
Pipe not full
Check power connections
Reading will resume when ow increases
Reposition meter for full pipe (see page 4)
Note ow direction arrow, reverse meter
Change power connections
Select another ow meter
Reposition meter for full pipe (see page 4)
Jumpy reading
Meter reads, but no
pulse output
Output pulses missing
Missing or incorrect ground wire
Rapidly changing conductivity
(in chemical injection applications)
External device needs pull-up resistor
Reversed leads (polarity sensitive)
Meter not reading
Check for proper ground
Install chemical injection line downstream
of meter (or far enough upstream to allow
complete mixing of uids before meter)
Add pull-up resistor
Change output connections
Check display
Page 9
Page 13
Page 14
WARRANTY/DISCLAIMER
FOR NON-WARRANTY REPAIRS,
OMEGA ENGINEERING, INC. warrants this unit to be free of defects in materials and workmanship for a
period of 13 months f rom date of purchase. OMEGA’s WARRANTY adds an additional one (1) month
grace period to the normal one (1) year product warranty to cover handling and shipping time. This
ensures that OMEGA’s customers receive maximum coverage on each product.
If the unit malfunctions, it must be re t u rned to the factory for evaluation. O M E G A ’s Customer Serv i c e
D e p a rtm ent will issue an Authorized Return (AR) number immediately upon phone or written re q u e s t .
Upon examination by OMEGA, if the unit is found to be defective, it will be re p a i red or replaced at no
c h a rge. O M E G A ’s WARRANTY does not apply to defects resulting from any action of the purc h a s e r ,
including but not limited to mishandling, improper interfacing, operation outside of desi
i m p roper re p a i r, or unauthorized modification. This WARRANTY is VOID if the unit shows evidence of
having been tampered with or shows evidence of having been damaged as a result of excessive corro s i o n ;
or current, heat, moisture or vibration; improper specification; misapplication; misuse or other operating
conditions outside of OMEGA’s c o n t r ol. Components in which wear is not warranted, include but are not
limited to contact points, fuses, and triacs.
OMEGA is pleased to offer suggestions on the use of its various product s. However,
OMEGA neither assumes responsibility for any omissions or e
damages that result from the use of its products in accordance with information provided by
OMEGA, either verbal or written. OMEGA warrants only that the parts manufactured by the
company will be as specified and free of defects. OMEGA MAKES NO OTHER WARRANTIES OR
R E P R E S E N T ATIONS OF ANY KIND WHATSOEVER, EXPRESSED OR IMPLIED, EXCEPT THAT OF
TITLE, AND ALL IMPLIED WARRANTIES INCLUDING ANY W
AND FITNESS FOR A PA R TICULAR PURPOSE ARE HEREBY DISCLAIMED. LIMITATION OF
L I A B I L I T Y: The remedies of purchaser set forth herein are exclusive, and the total liability of
OMEGA with respect to this ord e r , whether based on contract, warr a n t y, negligence,
indemnification, strict liability or otherwise, shall not exceed the purchase price of the
componen t upon whi ch liabi lity is based. In no even t shall OME GA be liab l e for
co
nsequential, incidental or special damages.
CONDITIONS: Equipment sold by OMEGA is not intended to be used, nor shall it be used: (1) as a “Basic
Component” under 10 CFR 21 (NRC), used in or with any nuclear installation or activity; or (2) in medical
applications or used on humans. Should any Product(s) be used in or with any nuclear installation or
a c t i v i t y , medical application, used on humans, or misused in any way, OMEGA assumes no re s p o n s i b i l i t y
as set forth in our basic WA R R A N T Y/ D ISCLAIMER language, and, additionally, purchaser will indemnify
OMEGA and hold OMEGA h a rmless from any liability or damage whatsoever arising out of the use of the
P roduct(s) in such a manner.
rrors nor assumes liability for any
ARRANTY OF MERCHANTA B I L I T Y
gn limits,
RETURN REQUESTS/INQUIRIES
Direct all warranty and repair requests/inquiries to the OMEGA Customer Service Department. BEFORE
RETURNING ANY PRODUCT(S) TO OMEGA, PURCHASER MUST OBTAIN AN AUTHORIZED RETURN
(AR
) NUMBER FRO M O M E G A’S C U S TO MER SERV I CE DEPA R TMENT (IN ORD E R TO AV O I D
PROCESSING DELAYS). The assigned AR number should then be marked on the outside of the return
package and on any correspondence.
The purchaser is responsible for shipping charges, freight, insurance and proper packaging to prevent
breakage in transit.
WARRANTY RETURNS, please have the
FOR
following information available BEFORE
contacting OMEGA:
1 . P u r chase Order number under which the pro d u c t
was PURCHASED,
2. Model and serial number of the product under
warranty, and
3. Repair instructions and/or specific problems
relative to the product.
OMEGA’s policy is to make running changes, not model changes, whenever an improvement is possible. This affords
our customers the latest in technology and engineering.
OMEGA is a registered trademark of OMEGA ENGINEERING, INC.
© Copyright 2005 OMEGA ENGINEERING, INC. All rights reserved. This document may not be copied, photocopied,
reproduced, translated, or reduced to any electronic medium or machine-readable form, in whole or in part, without the
prior written consent of OMEGA ENGINEERING, INC.
for current repair charges. Have the following
information available BEFORE contacting OMEGA:
1. Purchase Order number to cover the COST
of the repair,
2. Model and serial number of the product, and
3. Repair instructions and/or specific problems
relative to the product.
consult OMEGA
Page 15
Notes
Page 16
W h e r e Do I Find Eve rything I Need for
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