4. Model Number------------------------------------------------------------ 5
5. Principal of Operation--------------------------------------------------- 6
Signal Transmitter ------------------------------------------------------- 7
Material Selection and Construction ---------------------------------- 8
Flowmeter Calibrations ------------------------------------------------- 8
Analog Output: 4 to 20mA, 1 to 5V, (dip switch selectable)
24mA overflow condition
Load resistance: Max 650 Ω at 24 Vdc
Accuracy: ±0.02% of full scale
Temperature drift: 40 ppm °C
Pulse output: 0 to 5V
Recommended Minimum
Load Resistance: 50kΩ
Pulse Scaling: Divide by 1, 10, 100 per flow unit of measure
Hi/Lo Alarm (Optional): Relay (2A, 30 Vdc), 0 to 5V, Open
Collector (0.5A, 30 Vdc)
Communications RS232 port for configuration and diagnostics
Linearization: Up to 20 points
Operating temperature: -40 to 85
o
C (-40 to 185CoF)
Humidity: 0 to 90% non-condensing
Enclosure: Explosion-Proof
FM: Class I, Div. 1, Gr. ABCD
Class II/III, Div. 1, Gr. EFG
CSA: Class I, Div. 1, Gr. ABCD
Class II, Div 1, Gr. EFG, Class III
Type 4X
Ex d IIC, Class I, Zone 1, IP 66
ATEX: Ex II 2GD Ex d IIC
IEC: Ex d IIC IP68
For use with FTB liquid turbines 1" riser, to be phased in as replacements
for FLSC-18, FLSC-28, FLSC-34, FLSC-35 and FLSC-51 series.
Replacement signal conditioner ONLY for gas turbine system 3/4" riser.
Blade
Angle
0.05#/FT3
Range
ACFM
0.25#/FT
3 Range
ACFM
Drop
(PSID)
0.05#
/FT3
Press.
Drop
(PSID)
@
@
0.25#
/FT3
-5-
5. Principal of Operation
Omega Engineering Turbine Flowmeter includes integrally mounted
microprocessor-based signal transmitter. The transmitter is mounted in
an explosion proof enclosure.
Pickup Coil
Riser
(Threaded)
Flowmeter
Housing
Flow
Straightener
Deflector
Cones
The turbine flow sensor consists of a rotor assembly which is supported
on a shaft held in place by triple tube clusters and secured with locking
nuts within the flowmeter housing.
The rotor is free to spin on a self lubricated ceramic ball bearing. A
modulated carrier pickup coil (MCP) is attached on the exterior of the
flowmeter housing.
A low mass rotor design allows for rapid dynamic response. The
deflector cones eliminate downstream thrust on the rotor and allows for
dynamic positioning of the rotor between deflector cones.
The dynamic positioning of the low mass rotor provides wider
rangeability and longer bearing life than that of conventional turbine
flowmeters. Integral flow straightening tubes minimize the effects of
upstream flow turbulence.
As the gas flows through the flowmeter the rotor spins at rate
proportional to the volumetric gas flowrate.
Each rotor blade passing through the pickup coil generates an electrical
pulse. The frequency of the pulses is proportional to flowrate. The
summation of pulses represents total amount of gas volume passed
through the meter.
-6-
The number of pulses generated per cubic foot is called the calibration
factor or K-Factor. This calibration factor is programmed into the
electronic transmitter to calculate correct flowrate.
The MCP pickup is a type of coil which eliminates pickup drag and
requires a Modulated Carrier Signal Conditioner circuit. The MCP
works on a principle where the motion of the rotor modulates a high
frequency signal. The conditioner demodulates, filters, amplifies, and
shapes the resulting signal prior to sending it to the microcontroller.
Signal Transmitter
The transmitter is a DC or AC powered microprocessor-based unit,
which provides a 0 – 5 V, TTL/CMOS pulse output, a 4 to 20 mA
analog output and optional High/Low flow alarm output. Optional 20point linearization is available to correct for flowmeter non-linearities,
improving overall system accuracy.
An RS232 communications port is located under the top plate of the
transmitter. It allows unit to be configured using a Windows based
program included with the unit. Configuration and remote monitoring
may also be performed using any PC based communications program
(e.g., HyperTerminal) or ASCII terminal.
Pickup
Coil
Amplifier Microprocessor
RS232
Port
Signal Transmitter Block Diagram
-7-
Pulse
Output
Analog
Output
Material Selection and Construction
The housing is made of 316 stainless steel. The rotor is made of 17.4
pH stainless steel. Bearings are shielded, ceramic hybrid ball bearings
and are made of 440C stainless steel. Bearings are self lubricating type
and do not require any external lubrication.
Flowmeter Calibrations
The standard calibration provided with an Omega gas turbine
flowmeter consists of a 10-point water calibration that is traceable to
NIST. Based on this water calibration, we derive an average k-factor
for water for the flowmeter. The average k-factor for water is then
converted to ACF by using the following equation.
K-Factor / .134 = pulses/ACF
The uncertainty of this calibration methodology is +/-2%
The gas flowmeters are optionally available with actual gas calibrations
at an additional charge. The uncertainty of an actual gas calibration is
+/-0.5%. Actual gas calibrations are generally recommended for
custody transfer (billing) applications.
The k-factor on turbine flowmeters used on gas service is NOT density
dependent. The flowmeter “turndown” range is density dependent.
The higher the operating density; the better the flow turndown range is
on any Omega gas turbine flowmeter.
-8-
6. Installation
Inspect all packages for any indications of damage which may have
occurred during shipment.
Verify that all meter parts or auxiliary components have arrived with
the shipment. Refer to the packing list/invoice for a detailed list of
items included in the shipment.
The flowmeter should be installed horizontally for proper operation.
It is required to install meter with a minimum straight run of pipe
approximately 10 pipe diameters ahead of the inlet and 5 pipe
diameters following the outlet.
The meter housing is marked by a flow direction arrow and the inlet is
marked ‘IN’ and the outlet is marked ‘OUT’. The meter must be
installed in the piping in the correct orientation to ensure the most
accurate and reliable operation.
Install meter with adequate distance and isolation from electric motors,
transformers, welding equipment and solenoids to avoid any
electromagnetic interference from ambient electrical field.
-9-
A typical flowmeter installation is shown below:
BYPASS RUN
Bypass Valve
Flow Straighener
Turbine FlowmeterStrainer
METER RUN
Blocking ValveBlocking Valve
Figure 1: Typical Flowmeter Installation
Blocking and Bypass valves should be installed if it is necessary to do
preventive maintenance on the flowmeter without shutting down the
flow system. The Bypass valve can be opened before the Blocking
valves allowing the flow to continue while removing the turbine
flowmeter for service.
IMPORTANT: All flow lines should be purged prior to installing the meter. To prevent possible damage to the meter, install the meter ONLY in flow lines that are clean and free of debris.
Upon initial start-up of the system a spool piece should be installed in
place of the flowmeter so that purging of the system can be performed
to remove all particle debris which could cause damage to the meter
internals.
CAUTION: Avoid over-spinning the meter. Over-spinning the meter
may cause damage to the meter internals and lead to
needless meter failure.
-10-
N/CN
P
-
N/CA
S
SIG-+ DC+DC-- P
DC-
DC+SIG-
P
-
N/CN/CP
S
A
N
L1L
7. Transmitter Wiring
Shielded cables are recommended for all input and output signals. The
shield should be connected to the earth ground lug on the transmitter.
The shield on the opposite end of the cable should be left unconnected.
This wiring practice is required for electromagnetic compatibility, as per
EMC-Directive 89/336/EEC of the Council of European Community.
DC Power Supply (13-30 VDC)
IG+
DC
POWER
SUPPLY
AC Power Supply (100-240 VAC)
AC power for TRANSMITTER requires an optional circuit board, PCA182. The
Alarm option (PCA184) is not available when the AC Power option is equipped.
IG+
NLG
ULSE+
ULSE
/C
2
NLG
ULSE+
ULSE
/C
NEUTRAL
PLUG AC MALE
HOT
-11-
A
N/CP
-
N/CN/CS
A
SIG-
DC+
DC-
P
N/CP
-
N/CN/CS
A
SIG-
DC+DC-
P
Flowmeter Input
B
C
Modulated Carrier Pickup (RF)
IG+
NLG
ULSE+
ULSE
1
DIP switch settings for
MCP pickup coil
PCA180
SW1
The flowmeter input is wired at the factory and does not require user
wiring.
Pulse Output (0-5V)
USER DCS
PULSE
INPUT
+
-
IG+
NLG
ULSE+
ULSE
1
Pulse Output option that is scaled according to the least significant digit
of the internal total amount. A scaling factor of 1, 10 or 100 is available
to reduce or increase the resolution of the pulse output. For example, if
the Total Decimal Point is set to 0000000.0, and the Pulse Scale is 1, then
1 pulse will be output for each tenth (0.1) of a unit of measure. Changing
the Pulse Scale to 10, would result in an output pulse for each 1.0 unit of
measure. The output must be scaled so that the pulse frequency does not
exceed the Pulse Frequency setting (100 Hz. Max) at the maximum flow
rate
DIP switch settings for
0-5V pulse output
PCA180
SW2
-12-
Analog Output
DC
POWER
+
DC+
DCSIG+
SIGANLG
PULSE+
+
PULSEN/C
N/C
N/C
SUPPLY
LOAD
1
PCA183, SW1
4–20 mA Output
Analog Output is proportional to the flow rate. Default settings are
4mA (1V) at zero flow and 20mA (5V) at max flow rate of the turbine.
1
PCA183, SW1
1-5 V Output
The following equations are used to compute the flow rate and analog
output current.
Where:
flowrate
frequency
Kfactor
Kfactor = Is dependent on the Flow Calculation Method setting and
is either the Average K-Factor or the Linearized K-Factor
from the Frequency / K-Factor table.
FM = Is the Flow rate Units setting of 0, 1, or 2. Where “0” is
For Seconds, “1” is for Minutes, and “2” is for Hours.
CF = Is the Correction Factor setting.
Where:
AF = Is the 20 mA maximum Flow rate value.
mAxmAcurrent164
FM
60
flowrate
xCFx
AF
-13-
If the calculated flowrate is greater than the AF setting, the current
will be set to 24mA to indicate an “Over-range” condition.
The analog output response time to reach steady state due to a change
in the flow rate is approximately 0.25 seconds. When flow stops, the
time for the analog output to return to 4 mA will be between 3 and 12
seconds, depending on the Maximum Sample Time (MST) setting.
MST is adjusted using the NB= (DATA) command, where NB is a
value between 1 and 80. The default MST setting is NB= 1. Adjusting
the MST is only recommended for low flow applications where the
minimum input frequency is below 1 Hz.
Alarm Output
Optional High/Low Flow Alarm feature requires an optional circuit
board, PCA184. The Alarm option is not available when the AC
Power option is equipped.
Hi/Lo Alarm (Relay)
DC+
DCSIG+
SIGANLG
PULSE+
PULSEN/C
N/C
N/C
NC1
COM1
NO1
High/Low-Nomally Closed
High/Low-COM
High/Low-Nomally Open
1
DIP switch settings
PCA184
SW1
for relay alarm
-14-
Hi/Lo Alarm (0-5V)
DC+
DCSIG+
SIGANLG
PULSE+
PULSEN/C
N/C
N/C
ALARM1
COM
USER DCS
+
Alarm
Indicator
-
1
DIP switch settings for 0-5V alarm
PCA184
SW1
Hi/Lo Alarm (Open Collector)
V+
USER DCS
2.7K
DC+
ALARM1
DCSIG+
SIGANLG
PULSE+
PULSEN/C
N/C
N/C
COM
+
-
Alarm
Indicator
1
PCA184
DIP switch settings
for open collector alarm
SW1
-15-
RS232 Communications Port
The RS232 serial port connector is located under the top plate of
transmitter and may be accessed by removing the two screws from the
top plate. A matching connector is provided with Communications
Cable supplied with transmitter.
Transmitter unit has to be powered from external supply in order to be
able to communicate. Additional power for TRANSMITTER
communication circuitry is supplied by the RS232 serial port of the
computer/terminal.
COM port settings must be set as follows:
Baud Rate: 2400
Data Bits: 8
Parity: None
Stop bits: 1
Handshaking: None
Communications Cable
CD 1
Rx 2
Tx 3
DTR 4
SIG COM 5
DB9
6 DSR
7 RTS
8 CTS
9 NC
VDC1
VDC2
-16-
Pin 1
Molex
0511100660
or
Equivalent
Pin 2
8. Maintenance and Troubleshooting
Pickup Coil Testing
Testing the MCP pickup coil requires measuring the resistance with an
ohmmeter.
1. Measure the resistance between pin A and pin B. The resistance
should be approximately 11.5 10% Ohms.
2. The resistance from any pin to the case should be greater than 1
mega Ohm.
If either resistance measurement fails, replace the pickup coil. When
installing a coil, make sure to firmly seat the coil in the flowmeter
housing.
Bearing Testing
It is recommended that the shielded, self lubricating ceramic ball
bearings be checked periodically for wear. The cleanliness of the gas
affects the life expectancy of the bearings.
It is recommended that the bearings be replaced if any signs of wear are
apparent. An unexplained shift in the output accuracy could be a sign of
worn bearings.
CAUTION: If bearings are allowed to operate without replacement at the recommended interval, the accuracy of the device may
drift from the original calibration and if left long enough
severe damage to the rotor and/or internals may occur.
The shielded, self lubricating 440c SS ball bearings may be changed in
the field.
Lock N ut
ConeShaft
Han ger/Flow Straightener
Bearing
Rotor
Figure 1 Exploded View - Flowmeter Internals
-17-
Bearing Replacement
1. Move the flowmeter to a clean stable work surface.
2. Using two “Spin-Tite” wrenches, remove one lock nut from the shaft.
3. Place a small head stove bolt in a vise. Guide the bolt head gently
through one of the hanger/flow straightener tubes and in a smooth
firm stroke remove the hanger from the housing.
4. With the shaft placed vertically downward, carefully remove a cone,
two bearings, and the rotor.
5. Remove the other hanger in a similar manner.
6. Examine the shaft and cones for scoring. If scoring is present,
replacement is necessary.
7. Obtain new bearings of the same type from stock or the manufacturer.
Discard old bearings.
8. Reassemble one hanger in the housing with the shaft, a cone, and lock
nut.
9. Place the bearings into the rotor. Guide the bearings and rotor onto
the shaft making sure to reassemble with the “IN” side of rotor facing
the “IN” side of the housing.
10. Place the remaining cone on the shaft. Gently “rattle” the flowmeter
to seat the internals on the shaft.
11. When properly seated, gently push the hanger onto the shaft. Be sure
to properly align the hanger on the shaft. The hangers seat against a
shoulder machined into the housing.
12. Gently tighten the self-locking lock nuts until they make contact with
the spring clip hanger. “Two Finger” tight on a “Spin-Tite” is more
than adequate.
13. Holding the meter horizontally, gently blow into it (DO NOT use
compressed air). The rotor should turn freely. With a magnetic coil
the rotor should gradually slow down and then “quiver” to a stop with
one of its blades aligning with the pickup coil. With a MCP (RF) coil
the rotor should “coast” smoothly to a stop.
14. Clean the flowmeter assembly with ISOPROPYL ALCOHOL or an
alternately approved cleaning solution.
-18-
9. Communication Protocols
Message Format and Timeout
Communication messages consist of a string of ASCII characters
terminated by a carriage return character. The maximum message length
coming to the unit is 20 characters, including the carriage return. The
unit will transmit no more than 35 characters before transmitting a
carriage return.
If a message longer than 20 characters sent, the instrument responds with
“Command Sequence is Too Long!<NL>”
If an unrecognized or invalid command is sent, the instrument responds
with
“Invalid Command! <NL>”
The
UNIT echoes all received messages and then transmits a response
string terminated with a carriage return. If the sending unit takes longer
than one minute to send a message,
the receive buffer.
If the sending unit (PC or other such device) wishes to change a setting
on the
sign (“=”) with the data following immediately after the equal sign. The
carriage return terminates the message.
UNIT, the sending unit shall follow the command with an equal
UNIT aborts the message by clearing
Any
UNIT response that sends data back to the sending unit shall have an
equal sign (“=”) followed by the data. Space is allowed between the
equal sign and the data on the return message, but the total message
length is limited to 35 characters.
READ Example:
To read the number of points that the
UNIT has in the K factor table, send
“NP<CR>”
The UNIT echoes the sent message, and responds with
“NUM PTS=2<CR>”
WRITE Example:
To change the number of points to 20 in the K factor table, the sending
unit shall send
“NP=20<CR>”
-19-
UNIT echoes the sent message and responds with
The
“NUM PTS=20<CR>”.
The UNIT checks the ranges for data and rejects writes that are not within
the allowed range. If the sending unit sends data that is not within the
allowed range, the
value that is currently stored in the
UNIT echoes the sent message and responds with the
UNIT.
Example:
If the sending unit wishes to change the max sample time to 2000 from
the previous setting of 10, the sending unit shall send
“NB=2000<CR>”
The UNIT echoes the sent message, and responds with
“MAX M TIME=10<CR>”.
-20-
Messages
Command Description/Allowed Data/Response
DN
FC
KD
AK
Tag Number
“0” to “99999999”
“TAG NUM = (DATA)”
The first three digits are the units code for total.
Changing these digits will change the TU settings.
Linearization
“0” = Average K factor
“1” = Linearization table
“F C METHOD = AVG” for Average K factor
or
“F C METHOD = LIN” for Linearization table
K Factor Decimal Point Location
“0” for 00000000.
“1” for 0000000.0 and all K Factors are less than
9999999.9, otherwise not allowed
“2” for 000000.00and all K Factors are less than
999999.99, otherwise not allowed
“3” for 00000.000 and all K Factors are less than
99999.999, otherwise not allowed
“K-FAC DECL=(DATA)”
Average K Factor
“0.001” to
“99999.999” if KD = 3
“999999.99” if KD = 2
“9999999.9” if KD = 1
“ 99999999” if KD = 0
“AVG KFAC =(DATA)”
NP
Number Points in the Table
“2” to “20”
“NUM PTS =(DATA)”
-21-
Command Description/Allowed Data/Response
F##
K##
CF
TU
Frequency 1-20
F01 has a range of “0.000” to the value of F02
minus 0.001; F20 has a range of the value from F19
plus 0.001 to “5000.000”; Frequencies F02 to F19
must be 0.001 greater than the previous frequency and
0.001 less than the next frequency.
“FREQ ## =(DATA)” for F01 through F20. Data
to fixed three decimal places.
K-Factor 1-20
“K-FACT # =(DATA)” for K01 through K09.
“K-FACT ## =(DATA)” for K10 through K20.
DATA to decimal places as per KD command.
Correction Factor
“0.001” to “9999999.999”
“CORR FACT =(DATA)”
Total Units
“100” for gallons
“140” for liters
“110” for cubic feet
“150” for cubic meters
“180” for barrels
All other integer values from 0 and less than 999 will
map to custom units
“TOT UNITS =(DATA)”
(DATA) shall be:
“GAL” for gallons
“LIT” for liters
“FT3” for cubic feet
“M3 ” for cubic meters
“BBL” for barrels
“CUS” for custom
These three numbers will be the same as the first three
digits of the tag number. Changes to this menu shall
cause the changes to the tag number.
-22-
Command Description/Allowed Data/Response
FM
NB
LF
AF
Rate Units
“0” for seconds
“1” for minutes
“2” for hours
“3” for days
“FLOW UNITS=(DATA)”
(DATA) shall be:
“SEC” for seconds
“MIN” for minutes
“HR ” for hours
“DAY” for days
Max Sample Time
“1” to “80”
“MAX M TIME=(DATA)”
Out Low
“0.000” to a maximum value of the Out High setting
“4mA FLOW =(DATA)”
Out High
Minimum is the Out Low Setting (LF) to a maximum of
the following:
“99999.999” if RD = 3
“999999.99” if RD = 2
“9999999.9” if RD = 1
“ 99999999” if RD = 0
“20mA FLOW =(DATA)”
-23-
Command Description/Allowed Data/Response
PS
FO
UA
Pulse Scale
“0” for OFF
“1” for 1
“10” for 10
“100” for 100
“PULS SCALE=(DATA)”
(DATA) shall be:
“OFF” for OFF
“1” for 1
“10” for 10
“100” for 100
Pulse Frequency
“1”
“2”
“4”
“8”
“PULS FREQ =(DATA)”
Alarm Function
“0” for OFF
“1” for RATE
“2” for TOTAL
“ALARM FUNC=(DATA)”
(DATA) shall be:
“OFF” for OFF
“RAT” for RATE
“TOT” for TOTAL
-24-
Command Description/Allowed Data/Response
AL
OC
PR
Alarm Out
“0.001” to a maximum defined as follows:
If UA is RATE:
“99999.999” if RD = 3
“999999.99” if RD = 2
“9999999.9” if RD = 1
“ 99999999” if RD = 0
If UA is Total or Off:
“99999.999” if TD = 3
“999999.99” if TD = 2
“9999999.9” if TD = 1
“ 99999999” if TD = 0
“ALARM OUT =(DATA)”
Current Out
“0” - Current output follows rate.
“1” - Current output set to 4mA.
“2” - Current output set to 12mA.
“3” - Current output set to 20mA.
For “0”, response = “ Output equal to
input.”
For “1”, response = “ Output is 4mA.”
For “2”, response = “ Output is 12mA.”
For “3”, response = “ Output is 20mA.”
Pulse Output Controlled By PS and FO
“ Pulse Output Released ”
The PS and FO menus shall control the pulse output.
Used to terminate the TP command.
-25-
Command Description/Allowed Data/Response
TP
RA
AS
OI
MO
OM
OF
Output 1Hz Test Frequency for Pulse Output
“ Test Pulse Output ”
Sets output to 1Hz, 50% duty cycle signal. This mode is
for factory test.
Release Alarm Output for Control According to Menu
Settings
“ Alarm Released ”
Releases alarm output for control by the alarm output
settings.
Alarm Output Test
“0” – Alarm output is set low.
“1” - Alarm output is set high.
For “0”, response = “ Alarm Active ”
For “1”, response = “ Alarm Released ”
After using the “AS” command, you must initiate a RA
command to allow HIT-2A to return to normal operation.
Output 4mA
“ Output is 4mA.”
Current output set to 4mA.
Output 12mA
“ Output is 12mA.”
Current output set to 12mA.
Output 20mA
“ Output is 20mA.”
Current output set to 20mA.
Output = Rate (Input)
“ Output equal to input.”
Current output follows rate.
-26-
Command Description/Allowed Data/Response
AA
DA
UI
RR
Auto Data
“F (DATA) R (DATA) T (DATA)”
The response, not the echo, is sent every two seconds
until it receives another message from the master. The
(DATA) following the F denotes the frequency of the
pulses to a precision of three places past the decimal, the
(DATA) following the R denotes the rate to a precision
of three places past the decimal, and the (DATA)
following the T denotes the total to a precision of three
places past the decimal.
Dump All
All of the responses in previous table.
The
UNIT gives all responses except for the CL
command.
Unit Identification
“UNIT MODEL= XX YY.ZZ”
Model and software number for the unit. XX is the
hardware revision number, YY.ZZ is the software
revision where YY is the major software revision and ZZ
is the minor software revision.
Read Rate
“FLOW = (DATA)”
(DATA) = “0” to the following maximums:
“99999.999” if RD = 3
“999999.99” if RD = 2
“9999999.9” if RD = 1
“ 99999999” if RD = 0
-27-
Command Description/Allowed Data/Response
CN
CM
SA
Adjust 4mA output point
“CN=#(DATA)”
(DATA) is the integer value that the unit sends to the 4-
20mA converter to output 4mA
This parameter is passed to the unit to adjust the 4mA
output point of the device. This value is used in
production at the test step to calibrate the 4mA output
point. “CN” will cause an Invalid Command response
and absence of the # symbol will cause the unit to ignore
the data.
Adjust 20mA output point
“CM=#(DATA)”
(DATA) is the integer value that the unit sends to the 4-
20mA converter to output 20mA
This parameter is passed to the unit to adjust the 20mA
output point of the device. This value is used in
production at the test step to calibrate the 20mA output
point. “CM” will cause an Invalid Command response
and absence of the # symbol will cause the unit to ignore
the data.
Set Alarm Output On
“ Alarm Active ”
Sets the alarm output active regardless of the settings.
-28-
-29- -30-
M5116/0312
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