Omega Products FD-400C Installation Manual
MADE
IN U.S.A.
1 YEAR
WARRANTY
Location
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. If specific instrument features or an alternate
transducer style are to be used or if the installer is unfamiliar with this type
of instrument, refer to the appropriate section in the manual for complete
details.
1. TRANSDUCER LOCATION
A. Determine the appropriate mounting location for the transducers by
referring to Figure 1.1. Pipe must be filled with liquid to ensure
proper operation.
Top View of Pipe
Figure 1.1
Transducer Locations
Pipe Preparation
and Mounting
2. PIPE PREPARATION AND TRANSDUCER MOUNTING
A. The piping surface, where the transducers are to be mounted,
needs to be clean and dry. Remove loose scale, rust and paint to
ensure satisfactory acoustical bonds.
B. Connect the mounting straps around the pipe. Leave the strap
loose enough to slip the transducers underneath.
C. Apply a liberal amount of silicone grease onto the transducer
faces.
D. Place each transducer under the mounting strap, 180° apart on the
pipe. Ensure that the transducer cables are facing the same
direction on the downstream side of the flow. See Figure 1.2 on
page 1.2.
E. Route the transducer cable back to the FD-400 monitor, avoiding
conduits that contain high voltage AC supply wires.
Rev. 11/09 -1.1- Series FD-400
QUICK-START OPERATING INSTRUCTIONS
Cables point in the
direction of flow
Top View of Pipe
Figure 1.2
Transducer Direction
Connections
Startup
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.
B. Route the transducer cables through the center conduit hole in the
bottom of the FD-400 enclosure and connect to terminal block J4.
The terminal blocks are a pluggable type and can be removed to
simplify wiring access. A wiring diagram is located on the inner
door for reference.
4. INITIAL SETTINGS AND POWER UP
A. Verify that the FD-400 power supply jumper settings are properly
configured for the power supply that will be utilized. A wiring and
jumper selection diagram is located on the inner door for reference.
NOTE: Power supply selection is specified during order placement
and appropriate jumpers are placed at the factory. If power is
changed from AC to DC or vice versa, the fuse requirement will
change. Fuse ratings are listed on the transmitter’s door.
B. Route power connections through the conduit hole farthest to the
left and in the FD-400 enclosure. Then connect power to the J2
terminal block. See Figure 3.2 on page 3.4.
C. Apply power.
D. On initial power-up, the FD-400 conducts a series of self-diagnostic
tests and buffering operations that take approximately 30 seconds.
E. Enter pipe internal diameter (Pipe ID), measuring units and output
configuration.
Rev. 11/09 -1.2- Series FD-400
TABLE OF CONTENTS
Quick-Start Operating Instructions
Introduction
General
Applications
Product Specifications
Transducer Installation
Transducer Mounting Locations
Pipe Preparation
Page
1.1
1.5
1.5
1.7
2.1
2.3
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
2.3
2.6
3.1
3.2
3.3
3.3
3.4
3.7
3.8
3.9
Rev. 11/09 -1.3- Series FD-400
TABLE OF CONTENTS
Control Relay Module
Rate Pulse Output Module
Instrument Programming
Keypad Operation
Totalizer Reset
Measurement Units Selection
Engineering Units Selection
4-20 mA Programming
Rate Pulse Programming
Dual Relay Configuration
Change Password
Advanced Set-up
Page
3.10
3.11
4.1
4.3
4.3
4.4
4.7
4.9
4.10
4.12
4.12
Startup and Troubleshooting
Startup Requirements
Troubleshooting
Appendix
FD-400 Software Map—General Operations
FD-400 Software Map—Output Configurations
Specific Gravity / Fluid Sound Speed Chart
Pipe Dimension Chart: ST, SS, PVC / Cast Iron / Ductile Iron
FPS to GPM Conversion Chart
5.1
5.2
Rev. 11/09 -1.4- Series FD-400
PART 1 - INTRODUCTION
General
Application
Versatility
The FD-400 ultrasonic flow meter is designed to measure volumetric
flow of solids-bearing or aerated liquid within closed conduit. Transducers 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. Some
pipe materials, such as concrete pressure pipe and some plastic
lined pipes do not allow ultrasound to penetrate to the liquid inside.
For these applications, the FD-400I insertion probe will be needed.
The flow meter operates by transmitting an ultrasonic sound from its
transmitting transducer through the pipe wall or from the probe tip
into the moving liquid. The sound will be reflected by useful sonic
reflectors1 suspended within the liquid and recorded by the receiving
transducer. If the sonic reflectors are moving within the sound
transmission path, sound waves will be reflected at a frequency
shifted (Doppler frequency) from the transmitted frequency. The
shift in frequency will be directly related to the speed of the moving
particle or bubble. This shift in frequency is interpreted by the
instrument and converted to various user defined measuring units.
1
What makes a good Doppler reflector? The four criteria are:
The scattering material must have a sonic impedance (sound
speed difference) at least 10% different from the fluid.
There must be some particles large enough to cause longitudinal
reflection – particles larger than 35 micron.
For a given pipe size, the longitudinal reflection must have suffi-
cient energy to overcome the Rayleigh (energy wasting) scattering caused by smaller particles.
The reflecting material must travel at the same velocity as the
fluid for good accuracy.
The FD-400 flow meter can be successfully applied on a wide range
of metering applications. The easy to program transmitter allows
the standard product to be used on pipe sizes ranging from 1 - 120
inch (25 - 3050 mm) pipe I.D. With the small pipe transducer option,
the pipe size range is 0.25 - 1 inch (6 - 25 mm). A variety of liquid
applications can be accommodated: raw sewage, river water, plant
effluent, mining slurries, sludge, etc. Because the clamp-on
transducers are non-contacting and have no moving parts, the flow
meter is not affected by system pressure, fouling or wear. Standard
transducers are rated to 250 °F (121 °C). Optional high temperature
transducers are rated to operate to 400 °F (204 °C).
Rev. 11/09 -1.5- Series FD-400
PART 1 - INTRODUCTION
User Safety
Data Storage
Product
Identification
The FD-400 employs modular construction and provides electrical
safety for the operator. The enclosure is constructed from rugged
polycarbonate plastic with UV inhibitors. The enclosure does not
contain any conductive materials that can become energized while
the door is closed. The keypad is also manufactured from
polycarbonate and is designed for outdoor use. The AC power
transformer provides 4,000 Volts of isolation from the power supply
mains. The display face contains voltages no greater than 24 Vdc.
Output modules are optically isolated from external power supplies
and provide a great degree of immunity to ground loops.
The FD-400 product retains all user configuration data and totalizer
accumulations in non-volatile FLASH memory indefinitely.
The serial number and complete model number of each FD-400 is
located on the inside of the monitor’s front cover. Should technical
assistance be required, please provide the Omega Customer
Service Department with this information.
Rev. 11/09 -1.6- Series FD-400
PART 1 - INTRODUCTION
Rev. 11/09 -1.7- Series FD-400
PART 2 - TRANSDUCER INSTALLATION
Unpacking
Mounting
Locations
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
crystals for transmitting and receiving ultrasonic sound energy
through the pipe wall in the case of the Series FD-400C transducer
and from the probe tip of the Series FD-400I. Placement of the
ultrasonic transducer is the most critical step in achieving an accurate and reliable flow reading. All flow meters of this type rely on a
full-pipe of fluid that is flowing symmetrically (evenly) in the pipe.
Flow in partially filled pipes and immediately downstream of elbows,
valves and pumps is unstable and will lead to unstable readings and
non-linearity.
Figure 2.1 illustrates five possible pipe configurations and recommends installation only in locations where it can be guaranteed that
the pipe will be filled at all times when flow measurements are
required. The two locations illustrated in the top two drawings may
allow the meter to operate, but it is unlikely that stable and accurate
Figure 2.1
Pipe Configurations and Installation Recommendations
Rev. 11/09 -2.1- Series FD-400
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 readings1.
Examples of minimum upstream and downstream requirements are
included in Figure 2.2.
1
2
3
4
5
Example
1 24 5
2 14 5
3 10 5
4 10 5
5 10 5
6 24 5
* Upstream
Pipe Diameters
** Downstream
Pipe Diameters
6
Figure 2.2
Upstream/Downstream Pipe Requirements
1
The FD-400 system will provide repeatable measurements on
piping systems that do not meet these requirements, but the
accuracy
Rev. 11/09 -2.2- Series FD-400
may be influenced to various degrees.
PART 2 - TRANSDUCER INSTALLATION
Pipe Preparation
Couplant
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. Typical preparation involves wire brush
removal of loose paint, rust, scale or dirt. Paint, if bonded well to
the pipe surface, does not need to be removed. The bumps present
on ductile iron pipe do not need to be removed. Thoroughly dry the
mounting surfaces so that the couplant grease will properly bond to
the surface.
NOTE: Small pits in the piping surface typically do not significantly
impact ultrasonic transmission or signal reception.
To assure an acoustically conductive path between the transducer
face and the prepared piping surface, a coupling compound is
employed. Clamp-on ultrasonic meters will not operate without
coupling compound mounted between the pipe wall and the transducer face. Enclosed with the FD-400 system is a tube of coupling
compound that is adequate for general purpose applications.
Omega prefers silicone-based valve grease or RTV (Room Temperature Vulcanizing) products or grease for Doppler installations as
they operate over a very wide temperature range. In some installations, such as automotive, silicone is not permitted. Alternate petroleum-based products can be utilized, but verify that the grease is
rated not to flow at the maximum surface temperature anticipated on
the pipe.
In general, utilize the following couplants with these transducers:
FD-400C Dow 732 or Dow 111 (or equivalent)
FD-400C-HT Dow 112 or Pyrogel Grade 100
FD-400I Not applicable
FD-400C
Clamp-On
Transducer
Mounting
Rev. 11/09 -2.3- Series FD-400
Clamp-on transducers should be mounted on the pipe 180° apart
and facing each other on the pipe, with the cables on the downstream side of the transducers. If the pipe is horizontal, the
preferred mounting orientation is 3 and 9 o’clock, with 12 o’clock
being the top of the pipe. See Figure 2.3 on page 2.4. Orientation
on vertical pipes does not matter. FD-400I insertion probe transducer installation starts on page 2.6.
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. Select the proper
number of transducer straps to allow a complete strap to go
around the circumference of the pipe. If a pipe is larger than 39
inches (1000 mm), it is recommended that a single strap/buckle
arrangement be utilized to reduce the number of strap connections. See Figure 2.4. The straps can be connected together to
make a continuous length. Small pipe installations do not utilize
straps, but use an integral clamping mechanism built into the
transducer.
2. Wrap the strap around the pipe in the area where the
Pipe Sizes Straps Required
1" to 9" 25 to 225 mm 1
10" to 19" 250 to 480 mm 2
20" to 29" 500 to 740 mm 3
30" to 39" 760 to 1000 mm 4
Figure 2.4
Straps Required vs. Pipe Size
Rev. 11/09 -2.4- Series FD-400
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
screws in place.
3. Spread an even layer of coupling compound, approximately
⅛ inch (3mm) thick, to the prepared transducer mounting areas
of the pipe.
4. Spread an even layer of coupling compound, approximately
⅛ inch (3mm) thick, to the flat face of the two transducers.
5. Place each transducer under the strap with the flat face – amber
plastic window – positioned towards the pipe. The notch on the
back of the transducer will provide a mounting surface for the
strap. The transducer cables must be facing in the same
direction and downstream of the transducers for proper
operation.
strap connection to secure the strap worm
NOTE: Large pipes may require two people for this procedure.
6. Tighten the strap strong enough to hold the transducers in place,
but not so tight that all of the couplant squeezes out of the gap
between the transducer face and pipe. Ensure that the
transducers are squarely aligned on the pipe and 180° apart. If
RTV is utilized, avoid moving the transducers during the curing
time – typically 24 hours – as bubbles may form between the
transducer and pipe that can reduce ultrasonic signal transmission to unsatisfactory levels.
7. Route the transducer cables back to the area where the
transmitter will be mounted, avoiding high voltage cable trays
and conduits. 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 terminations. Failure to use proper cables can lead to
improper operation of the FD-400 flow meter. Excess cable may
be coiled to take up extra length or cutoff.
8. If the transducers are to be permanently mounted using Dow
732, the RTV must be completely cured before proceeding to
Instrument Start-up. Ensure that no relative motion between the
transducer and pipe occurs during the 24 hour curing process. If
Dow 111 grease was used for temporary operation of the FD400 system, proceed with the Instrument Start-up procedures.
Rev. 11/09 -2.5- Series FD-400
PART 2 - TRANSDUCER INSTALLATION
A
FD-400I Probe
Transducer
Mounting
The FD-400I insertion transducer that is utilized by the FD-400
contains piezoelectric crystals for transmitting and receiving
ultrasonic sound energy. The black Ultem® plastic tip of the FD-400I
contains these crystals, which are designed to be inserted just into
the path of the flowing liquid.
Select a transducer mounting location that will be completely filled
with liquid when flow measurements are to be made – See Figure
2.1 on page 2.1 – and with adequate straight runs (without
disturbances) of pipe, both upstream and downstream, to achieve
stable and accurate readings. Examples of minimum upstream and
downstream requirements are included in Figure 2.2 on page 2.2.
Note that if adequate straight piping cannot be provided, the FD400 system will operate repeatably, but will probably not achieve
ideal accuracy.
When installing the FD-400I transducer in a horizontal pipe, the
preferred orientation is at least 20 degrees from the top or bottom of
the pipe – See Figure 2.5. Ensure that the mounting location allows
for adequate clearance to install and retract the probe fully from the
pipe.
TOP V IEW
OF PIPE
20°
I
N
S
T
A
L
L
Figure 2.5
Acceptable
Installation Locations
20°
Install Doppler Probe between 1 o’clock
INSTALL MAGPROBE
BETWEEN 1 O’CLOC K
and 5 o’clock on the pipe
ND 5 O’CLOCK ON THE PIPE
A
T
I
O
N
R
A
N
G
E
The instructions cover hot tapped installations (installations where
it is required to install or remove the transducer probe without
shutting down the process pressure). If the product is being
installed without an isolation valve, ignore the steps that pertain to
its installation. Figure 2.6 on page 2.7 illustrates an exploded view
of an isolation valve assembly and names the various components.
Rev. 11/09 -2.6- Series FD-400
PART 2 - TRANSDUCER INSTALLATION
Figure 2.6
Hot Tap Installation
If FD-400I-BV or FD-400-SSV accessory kits were ordered with the
FD-400I probe, a hot tapped installation can be completed. The kits
include an isolation valve assembly and are designed for installation
in pipes under pressure, up to 700 psi (48 bar) at 70 F (21º C).
All items required for installation are provided with the kit, except for
the 1-½" NPT weld coupling or service saddle and the drilling and
welding equipment. These instructions call for the use of a drilling
machine designed for operations under pressure (for example,
Muller Co., Decatur, Illinois).
Procedures are as follows:
1. Verify that the pipe’s line pressure is within the rated limits of
the pressure drilling machine to be used.
2. Grind off paint or other coatings from the pipe in the area where
the FD-400I Probe Assembly is to be installed.
3. Tack weld a 1-½" NPT weld coupling to the pipe or install a
service saddle according to the supplier’s instructions. The
coupling or saddle must be aligned perpendicular to the pipe
axis and square to its plane.
Rev. 11/09 -2.7- Series FD-400
PART 2 - TRANSDUCER INSTALLATION
4. Complete welding. A water tight, 0.25" minimum weld bead is
recommended.
5. Install the close nipple (supplied with assembly) into the weld
coupling. Use appropriate pipe sealants.
6. Install the isolating ball valve on the close nipple. Verify that the
valve is in fully open position.
7. Install drill bit and adapter into the pressure drilling machine.
Then attach the machine to the isolation valve.
8. Drill through the pipe wall in accordance with the instructions
supplied with the drilling machine.
9. Withdraw the drill bit through the isolating valve. Close the
valve and remove the drilling machine. Check for leakage at
valve and connections.
10. Place pipe sealant on the 1-½" NPT threads of the insertion
fitting assembly. Screw the assembly into the isolation valve
and tighten with a 2-½" pump wrench.
PROBE INSERTION
Before inserting the FD-400I probe into the piping system, it is
necessary to calculate the probe insertion depth that will place the
measuring electrodes at the proper position in the pipe. In order to
complete this calculation, some knowledge of the piping system
must be known. Refer to the paragraphs that follow and Figure 2.7
on page 2.10 for information regarding this process. The variables
required are:
The overall probe length
Pipe internal diameter (I.D.)
Pipe wall thickness
The length of the valve stack
Amount of straight pipe diameters in the system
Using this information and referring to Figure 2.7, proper insertion
depth can be determined.
Rev. 11/09 -2.8- Series FD-400
PART 2 - TRANSDUCER INSTALLATION
Measurement A — The typical depth that the FD-400I probe tip is
inserted into the piping system is ⅛ (12.5%) of the pipe internal
diameter.
Measurement B — Pipe wall thickness. This information can be
obtained from standard pipe wall charts (See the Appendix of this
manual) or ideally can be measured using an ultrasonic wall thickness gauge.
Measurement C — Measure the distance that is going to be taken
up by the pipe tap, nipple, full-flow ball valve and the insertion fitting.
FD-400I probes utilize 1-½" NPT hardware and the insertion fitting is
approximately 2.5 inches in height.
Measurement E — This is the overall length of the probe measured
from the black measurement tip to the top flange on the probe.
Measurement D — This is the length of FD-400I probe that will be
protruding from the insertion fitting after it is inserted to the proper
depth in the fluid stream.
1. Lubricate the O-rings located within the FD-400I probe seal
fitting so that the seals are not damaged during probe insertion.
2. Run the lower jam nuts down to a point that approximates the
final insertion position or at least far enough to allow insertion
into the insertion fitting. Using the threaded rods as a guide,
position the probe in the insertion fitting. Continue to insert the
probe as far into the isolation assembly as possible. The probe
tip will come in contact with the closed “ball” in the isolation
valve.
CAUTION: Do Not Force the Probe Tip Against the “Ball”, as
damage to the probe tip may result.
3. Replace the upper jam nuts (2 on each rod) and the cotter pins.
The nuts should be run down to the top side of the retaining
collar and the cotter pins replaced. Orient the probe in the
direction of flow as indicated by the FLOW direction arrow
located on the top of the probe flange. See Figure 2.8 on page
2.12. Lock the probe in position with the enclosed allen wrench.
CAUTION: The nuts on both ends of the retaining rods must
always be in place as a safety measure to prevent possible probe
blow out. Inserting cotter pins is a further safety measure.
Rev. 11/09 -2.9- Series FD-400
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 = _______
D = E - C - B - A
Figure 2.7
Installation Measurements
Rev. 11/09 -2.10- Series FD-400
Loading...