ANALYTICAL FLOW TECHNOLOGIES DENSITRAK D625 User manual

DENSITRAK® D625 OPERATION
MANUAL
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INTRODUCTION
We sincerely THANK YOU for your purchase of an ANALYTICAL FLOW TECHNOLOGIES
DENSITRAK® D625 Density Meter (Henceforth, D625).
This manual is intended for the personnel responsible for the installation, operation and/or
maintenance of the ANALYTICAL FLOW TECHNOLOGIES D625 density meter.
This manual explains the following topics:
Safety and Precautions
Brief History of ANALYTICAL FLOW TECHNOLOGIES Principle of Operation
Specifications
Features and Benefits
Installation
Operation
Maintenance
Field Density Output Correction (Error offset) Troubleshooting
Carefully read this manual prior to installation and operation of this meter to ensure safe and
proper operation.
Do NOT discard this manual - Always keep it in a place where you can access it for quick reference.
If you lose or require additional copies of this manual refer to the ANALYTICAL FLOW
TECHNOLOGIES website (www.densitrak.nt-rt.ru)for a PDF version.
Carefully read ALL Safety Precautions and Important Notes prior to installation and operation of
this meter.
THE ANALYTICAL FLOW TECHNOLOGIES D625 MODEL DENSITY METER CAN BE UTILIZED IN
MANY VARIOUS FLUID DENSITY MONITORING APPLICATION, SUCH AS:
Water and Wastewater Treatment
Petroleum Refinery and Pipeline Applications
Fluid Product Blending & Interface Detection
Pulp & Paper Manufacturing
Chemical Processing
Power Generation
…and many more

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IMPORTANT SAFETY INFORMATION
SAFETY CAUTIONS
SYSTEM PRESSURE: Do NOT expose meter to pressure greater than the meter and/or
flange rating –whichever is lowest.
Do NOT pressure test meter above 1.5 x operating pressure.
MATERIAL COMPATIBILITY: Do NOT expose the meter wetted parts to fluids
(chemicals) that are NOT COMPATIBLE with the materials of construction.
Consult ANALYTICAL FLOW TECHNOLOGIES engineers with any questions regarding
material compatibility.
EXPLOSION HAZARD: The cables and fittings provided with this meter are not certified
for use in hazardous or explosive environments unless specifically noted on the meter
and electronics enclosure.
HEAVY OBJECT: Handle the meter with care and request assistance when lifting,
moving or installing.
Dropping the meter can cause injuries and/or equipment failure.
ELECTRICAL HAZARD: Remove power source prior to installation or maintenance of the
density meter.
Ensure that all electrical connections and or maintenance are performed by properly
qualified personnel.
ENVIRONMENT: DO NOT operate meter in situations where continuous line vibration is
greater than 0.5g.
IMPORTANT NOTES
INSTALLATION: Do not install the meter in situations where:
Meter is exposed to excessive vibration
Meter can become submerged in water or other fluids
Meter can come in contact with corrosive materials
Meter is hard to access for periodic maintenance
PROCESS FLUIDS: All process fluids must be compatible with the wetted parts of the
meter.
TRANSPORTATION: NEVER transport the meter with hazardous fluids still entrapped in
the meter or process connections.
Please notify ANALYTICAL FLOW TECHNOLOGIES of the process fluids utilized in the
meter prior to returning to the factory for repair or service.
A CLEANING FEE applies to ALL METERS returned to ANALYTICAL FLOW
TECHNOLOGIES that have not been thoroughly cleaned prior to return.

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TABLE OF CONTENTS
Introduction................................................................................................................................................................................ 3
Important Safety Information ............................................................................................................................................ 4
Table of Figures................................................................................................................................................................... 7
Table of Equations.............................................................................................................................................................. 7
History of ANALYTICAL FLOW TECHNOLOGIES........................................................................................................ 8
Theory of Operation ............................................................................................................................................................... 8
Density Equations............................................................................................................................................................... 9
Product Specifications.........................................................................................................................................................10
Benefits and Features ..........................................................................................................................................................11
Unpacking.................................................................................................................................................................................11
Installation ...............................................................................................................................................................................12
Installation Planning .......................................................................................................................................................12
Installation Dimensions .................................................................................................................................................13
TOP-VIEW DIMENSIONS...........................................................................................................................................13
FRONT-VIEW DIMENSIONS.....................................................................................................................................13
SIDE-VIEW DIMENSIONS .........................................................................................................................................14
Meter Assembly.................................................................................................................................................................15
D625 Meter –Electrical Connections .......................................................................................................................16
Model D625 EX-PROOF ENCLOSURE ElectrICAL CONNECTIONS ...........................................................16
D625 Meter –Electrical Connections .......................................................................................................................20
Meter –Process Flow Installation..............................................................................................................................22
Inline Setup Installation............................................................................................................................................23
ANSI 15O#/300#/600# remote mount SCOOPED FLANGE INSTALLATION.....................................24
ANSI 15O#/300#/600# SCOOPED FLANGE INSTALLATION ...................................................................25
ORIFICE / BYPASS D625 Installation ..................................................................................................................26
Other Installation MEthods......................................................................................................................................27
Meter Maintenance ...............................................................................................................................................................28
Meter Cleaning Procedure ............................................................................................................................................28
Density Output –Field Calibration.................................................................................................................................30
When to field calibrate…................................................................................................................................................30
Field Calibration Example:............................................................................................................................................30
Field Calibration Work Table.......................................................................................................................................31
Meter Troubleshooting .......................................................................................................................................................32

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Contact Information .............................................................................................................................................................32
APPENDIX I: CONVERSION FACTORS..........................................................................................................................33
Density ..................................................................................................................................................................................33
Pressure................................................................................................................................................................................33
Flow Rate..............................................................................................................................................................................33
Temperature.......................................................................................................................................................................34
APPENDIX II –aft DENSITRAK DOCUMENTS ............................................................................................................35
AFT CUSTOMER INTERFACE BOARD PINOUT.....................................................................................................35
AFT DENSITRAK D625-XX-XX-01 ELECTRONICS EXPLODED VIEW ..........................................................36
AFT DENSITRAK D625-XX-XX-03 ELECTRONICS EXPLODED VIEW ..........................................................37
AFT DENSITRAK D625-00-00-04 ENCLOSURE EXPLODED VIEW...............................................................38

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TABLE OF FIGURES
Figure 1: CUTAWAY VIEW - DENSITRAK D625 Vibrating Tube DensitOMeter........................................... 8
Figure 2: DENSITRAK D625 –TOP VIEW - DIMENSIONS....................................................................................13
Figure 3: DENSITRAK D625 –FRONT VIEW - DIMENSIONS..............................................................................14
Figure 4: DENSITRAK D625 –SIDE VIEW - DIMENSIONS...................................................................................14
Figure 5: IN-LINE DENSITY METER INSTALLATION ............................................................................................23
Figure 6: DENSITRAK D625 REMOVAL.......................................................................................................................23
Figure 7: SCOOPED FLANGE ASSEMBLY .....................................................................................................................24
Figure 8: CUTAWAY VIEW OF SCOOP ORIENTATION INSIDE THE MAIN PIPELINE ..............................24
Figure 9: SCOOP FLANGE FLOW RATE VERSUS MAIN PIPELINE FLOW VELOCITY................................25
Figure 10: ANSI SCOOP FLANGE TO D625 MOUNTING ASSEMBLY................................................................25
Figure 11: TYPICAL DENSITRAK D625 “BYPASS INSTALLATION” SETUP..................................................26
Figure 12: customer interface circuit board pin-out ................................ Error! Bookmark not defined.
Figure 13: aft electronics exploded view........................................................ Error! Bookmark not defined.
TABLE OF EQUATIONS
Equation 1: Uncorrected (Periodic) Density Equation ........................................................................................... 9
Equation 2: Temperature Corrected Density Equation.......................................................................................... 9
Equation 3: Pressure Corrected Density Equation................................................................................................... 9
Equation 4: K0Density Offset Equation.......................................................................................................................30

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HISTORY OF ANALYTICAL FLOW TECHNOLOGIES
The DENSITRAK® D625 liquid density meter was ORIGINALLY designed by Calibron Systems, Inc.
of Scottsdale, AZ. Calibron Systems, Inc. was eventually acquired by Honeywell Enraf. Honeywell
Enraf licensed the exclusive rights for manufacture and service of the DENSITRAK® meter to
Analytical Flow Technologies in March 2010.
Analytical Flow Technologies is owned and operated by Paul Heinritz, who has a long relationship
with the DENSITRAK® Densitometer in which he ran the DENSITRAK® product line for Calibron
Systems, Inc. and briefly for Honeywell Enraf prior to the DENSITRAK® production move to Pune,
India. Analytical Flow Technologies emphasizes American-Made products, along with high quality
customer service and support to differentiate itself from the large corporation alternatives.
THEORY OF OPERATION
The liquid density meter uses the spring mass principle for measuring the fluid density. A portion of
the measurement tube is energized (transmit sensor) to vibrate and to maintain its natural
resonant frequency by using an electrical feedback driving system. A change in the vibrating mass,
(as a result of change in the fluid density) shifts the resonant frequency which is interpreted by the
receive sensor. The signal is then output to the density processing unit via the rear mount electrical
connector.
An ANALYTICAL FLOW TECHNOLOGIES density processing unit uses algorithms that incorporate
temperature (integrated into the meter), pressure (via an external pressure transmitter 4-20mA
output) and the shift in frequency to determine the density of the measured fluid.
FIGURE 1: CUTAWAY VIEW - DENSITRAK D625 VIBRATING TUBE DENSITOMETER

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DENSITY EQUATIONS
A simple definition for Density (for a homogeneous object) is the mass of the object divided by the
volume of the object. Thus, common units of fluid density are grams per cubic centimeter,
kilograms per cubic meter, and pounds per cubic foot.
The hydrometer is probably the most common device used to measure fluid density in which it
measures the volume displaced by an object of known mass. The pycnometer is another
instrument used for measuring fluid density. However, these devices are mainly restricted for use
in laboratories. Another instrument used to determine the density of a liquid or a gas is the
oscillating U-tube digital density meter. The U-tube digital density meter is installed in a process
flow system where it continuously monitors “real-time” fluid density.
The oscillating U-tube is a method to determine the density of liquids based on an electronic
measurement of the frequency of oscillation. The density value is calculated by incorporating
frequency of oscillation, fluid temperature and pressure. The equations shown below are utilized
by the density processor or flow computer to determine the density of the fluid flowing through the
meter.
EQUATION 1: UNCORRECTED (PERIODIC) DENSITY EQUATION
  󰇛 󰇜  󰇛 󰇜
DU= Density of the fluid based on the periodic time (frequency of oscillation) of the meter. It is
UNCORRECTED for Temperature and Pressure. Unit = grams per cubic centimeter [gr/cm3]
T = Periodic Time (frequency of Oscillation) of the density meter. Unit = microseconds [µs]
K0, K1, K2= Density Coefficients. These coefficients vary for each meter and are determined at
the factory during the meter calibration process. Refer to the Calibration Certificate included
with your meter.
EQUATION 2: TEMPERATURE CORRECTED DENSITY EQUATION
    󰇟󰇛  󰇜󰇠 󰇛  󰇜    󰇛󰇜
DU= Uncorrected Density, [gr/cm3]
DT= Temperature Corrected Density , [gr/cm3]
KTv, KT0, KT1 = Temperature Correction Density Coefficients –included with Calibration
Certificate.
TF= Live fluid temperature in degrees Fahrenheit [°F]
TC= Reference temperature in degrees Fahrenheit [°F]
EQUATION 3: PRESSURE CORRECTED DENSITY EQUATION
               
DPT = Pressure & Temperature corrected Density, [gr/cm3]
DT= Temperature Corrected Density , [gr/cm3]
KPv, KP0, KP1 = Pressure Correction Density Coefficients –included with Calibration Certificate.
P = Live pressure in Pounds per square inch [PSIG]

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PRODUCT SPECIFICATIONS
ANALYTICAL FLOW TECHNOLOGIES D625 Product Specifications Chart
Density Operating Range
0.40 –2.00 grams/cubic centimeter [gr/cm3]
Maximum Density Span
0.70 gr/cm3(range can be extended with reduction in accuracy)
Density Resolution
0.0001 gr/cm3
Meter Accuracy
0.0001 gr/cm3
Repeatability
Better than 0.01%
Operating Temperature
Standard: 50°F to 140°F [10°C - 60°C]
Optional: 32°F to 203°F [0°C - 95°C]
MAX Temp. Differential
ΔTmax = 90°F [50°C]
Operating Pressure
Range: 0 to 2,220 PSI [0 –149 bar]
ANSI Flanged same as flange rating at 100°F
Hydrostatic Test: 1.5 times line pressure
Flow Rate
MIN: .25 Gallons per Minute (GPM)
MAX: 30 GPM
Frequency Signal Output
Nominal 0.30 kHz to 3.0 kHz
Temperature Sensor
3 Wire 100Ω Pt RTD
Power Requirement
VOLTAGE: 24 VDC
CURRENT: 30 –50 mA nom.
Materials of Construction
Standard Wetted Parts: 316/316L Stainless Steel,
HASTELLOY® C276
Non-Wetted Parts: 304 Stainless Steel
Electrical Classification
Designed to meet NEC/CSA Class 1, Div. 1, Group C & D, CE Mark
Housing Approved: CSA, FM, EExd, UL
RoHS Compliant
Physical Dimensions
SEE APPENDIX DRAWING
Shipping Weight: Approx. 16 pounds

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BENEFITS AND FEATURES
The ANALYTICAL FLOW TECHNOLOGIES D625 density meter offers a multitude of design features
which greatly benefit the customer while also maintaining an affordable price.
BENEFITS
FEATURES
Small, compact design
Free draining/lower pressure
drop
Safe design integrity.
Temperature compensated
density.
Detects small density changes.
No radioactive source.
Quick connect can be installed
or moved easily.
Suitable for narrow range
applications.
Made & Assembled in the USA
Small, compact design.
No moving parts.
Dynamic calibration.
Outer shell pressure rated
above operating pressure.
Integral 3 wire RTD.
High resolution.
Non-nuclear.
RoHS Compliant.
UNPACKING
Please verify that ALL of the STANDARD items listed below were included in the meter package.
Use check box to verify.
Item
Qty

D625 Density Meter Housing
1

Density Processor (DP) Electrical Housing
1

Process Connection Flange(s)
1

VITON® O-Rings
2

Flange Bolts (3/8”-16 x 2)
4

Anti-seize Compound (tube)
1

Laminated Calibration Certificate (w/ Calibration
Coefficients)
1

Certificate of Conformance
1

USER MANUAL / SOFTWARE1
1

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INSTALLATION
Proper installation is crucial to the overall performance of the D625 Density Meter. The accuracy of
the meter can be adversely affected by improper installation.
To ensure meter accuracy it is imperative that the items listed below be considered prior to
installation of the meter into the system.
Also note that there must be some scheme present in the process flow system to induce sufficient
flow through the meter. Refer to the Process Connections section for more detail.
INSTALLATION PLANNING
Prior installation planning is critical for the best metering results. The table below outlines a
“checklist” of important items for proper installation planning.
PERFORMANCE - Installation Planning Checklist

All joints and couplings are airtight –GAS Bubbles in process fluid must be avoided

Meter is connected at a sufficient (> 5ft) distance from fluid pump

Pump (if applicable) is oriented so that it pushes fluid through the meter –NOT Pulls

Avoid vibration from surrounding equipment

Fluid should be at sufficient flow rate (> 1 GPM) with little or no cavitations as it enters the
meter

Avoid installing in an environment with quick and extreme temperature changes. ALWAYS
consider the use of an insulation jacket for OUTDOOR Installations.

Avoid mounting in direct sunlight or near surfaces with extremely high temperatures.

Refer to the meter dimensions prior to choosing a suitable location
SAFETY - Installation Planning Checklist

Ensure SAFE & PROPER handling of the meter during installation

Do NOT drop the meter or expose to extreme impacts

Adhere to all LOCAL electrical safety regulations

Only trained personnel should be allowed to install or maintain the meter

Verify that the process fluid is compatible with the wetted material of the density meter

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MAINTENANCE - Installation Planning Checklist

Mount meter in an area that provides sufficient space for proper piping and process
connections

Installation of a BYPASS and Valves should be considered between the meter and process
connections to facilitate easy removal for periodic maintenance

Plan an adequate location for the REMOTE ELECTRONICS (if applicable) enclosure.
Once you’ve fully planned your installation, the next step is to unpack and assemble your D625
meter.
INSTALLATION DIMENSIONS
The diagrams below outline the overall mounting dimensions for the D625 Density Meter. Please
take these dimensions into consideration. All dimensions shown are in INCHES. Weight is
approximately 16 pounds empty of fluids. ALL DIMENSIONS ARE SUBJECT TO CHANGE
TOP-VIEW DIMENSIONS
All dimensions shown are in INCHES.
FIGURE 2: DENSITRAK D625 –TOP VIEW - DIMENSIONS
FRONT-VIEW DIMENSIONS
All dimensions shown are in INCHES.

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FIGURE 3: DENSITRAK D625 –FRONT VIEW - DIMENSIONS
SIDE-VIEW DIMENSIONS
All dimensions shown are in INCHES.
FIGURE 4: DENSITRAK D625 –SIDE VIEW - DIMENSIONS

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METER ASSEMBLY
The D625 is shipped to the customer essentially fully assembled. The customer must simply attach
the INLET and OUTLET flow connections and the electrical cable gland and make the proper
electrical connections.
ANTI-SEIZE LUBRICANT: Each DENSITRAK D625 ships with a small tube of anti-seize
lubricant. Ensure that all threaded connections are coated with a layer of anti-seize
lubricant unless the threaded connection already utilizes Teflon tape.
The following table will guide you through the initial meter assembly and installation.
Unpack the D625 meter from the shipping
container.
Determine a suitable mounting location for the
meter and density processor housing before
beginning assembly.
Remove the two protective PLUGS from the
flange 0.5FNPT Fittings.
Ensure the internal NPT ports are free of
debris.
Install the meter into your Fluid Processing System:
Ensure that your piping configuration maintains a consistent flow rate
Try to minimize ambient vibration from the system and flow pumps –excessive
vibration can adversely affect meter performance
KEEP THE PACKAGING OR PROTECTIVE CAPS IN THE EVENT THE METER NEEDS
TO BE RETURNED FOR SERVICE
DO NOT DISCARD THE LAMINATED CALIBRATION CERTIFICATE
Once the meter is securely mounted in an appropriate location the next step is to connect the
electronics.

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D625 METER –ELECTRICAL CONNECTIONS
Electrical connections to the D625 meter are very simple –you simply supply DC power (+24 VDC)
to the Electronics Package and connect the 4-20mA output (or Frequency output if no processor is
selected) of the electronics package to your controls.
MODEL D625 EX-PROOF ENCLOSURE ELECTRICAL CONNECTIONS
Remove the ELECTRICAL ENCLOSURE COVER, and
the ¾ “NPT PLUG from the electronics assembly.
Connect your electronic cabling to the meter
via cable gland to either of the ¾ “ FNPT
ports located on either side of the enclosure.
The customer interface board terminal block
wiring locations are shown above. Each interface
will be discribed in detail in the following steps.
To power the meter, connect ground to
terminal block 3 pin 1 (black) and +24 VDC to
terminal block 3 pin 2 (red).

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MODEL D625 EX-PROOF ENCLOSURE ELECTRICAL CONNECTIONS
COMMUNICATE WITH AND CONNECTING TO METER OUTPUTS
To collect data from the meter make the
following connections (to change ouput 1 and 2 refer to
sofware manual);
1. Frequency (4-20mA) to terminal block 1 pin
12 (blue)
2. Output 1 (Density 4-20mA) to terminal block
1 pin 6 (purple)
3. Output 2 (Fluid Temp 4-20mA) to terminal
block 1 pin 9 (purple)
4. Ground to terminal block 1 pin 10 (green)
To communicate with the meter thruough
RS232 make the following connections;
1. RS232RX to terminal block 3 pin 11 (blue)
2. RS232TX to terminal block 3 pin 10 (yellow)
3. Ground to terminal block 3 pin 12 (green)
To communicate with the meter thruough
RE485 make the following connections;
1. RS485_L to terminal block 2 pin 4 (blue)
2. RS485_H to terminal block 2 pin 5 (yellow)
3. Ground to terminal block 2 pin 3 (green)
To communicate with the meter thruough USB
connections, connect directly to the mini USB
connector in the center of the customer
interface board.
Mini USB connector

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MODEL D625 EX-PROOF ENCLOSURE ELECTRICAL CONNECTIONS
CONNECTING TO METER INPUTS
To input external temerature (4-20mA) into the
meter make the following connections;
1. External TEMP(+) to terminal block 1 pin 8
(yellow).
2. Ground to terminal block 1 pin 7 (green).
To input external temerature Loop Type (4-
20mA) into the meter make the following
connections;
1. External temp(-) to terminal block 1 pin 6
(yellow).
2. External temp(+) to terminal block 3 pin 3
(red).
To input external pressure (4-20mA) into the meter
make the following connections;
1. External PRES(+) to terminal block 1 pin 2
(blue).
2. Ground to terminal block 1 pin 3 (green).
To input external pressure Loop Type (4-20mA) into
the meter make the following connections;
1. External pres(-) to terminal block 1 pin 2
(yellow).
2. External pres(+) to terminal block 3 pin 3
(red).

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MODEL D625 EX-PROOF ENCLOSURE ELECTRICAL CONNECTIONS
CLOSING THE METER ENCLOSURE
When all desired connections have been made;
1. Ensure the meter is grounded.
2. Replace the Electrical Enclosure Cover prior to
supplying the meter with 16 –32 VDC.
NOTE: PIPING SYSTEM NOT SHOWN ON THIS GRAPHIC

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D625 METER –ELECTRICAL CONNECTIONS
The D625 Meter display cycles through three screens, one every three seconds. Display
information can also be collected from the meter using the outputs on the customer interface board,
refer to DENSI-Trax Software User Manual for more detail.
The D625 display can be seen through the
enclosure’s display lenses. Units shown here are
the default settings, they can be changed in the
provided DENSI-Trax software.
Screen 1;
1. Line 1; Period, displayed to three decimal places,
units (seconds).
2. Line 2; Frequency, displayed to whole number, units
(1/seconds).
Screen 2;
1. Line 1; D (U) (uncompensated density),
displayed to five decimal places, units (g/cm3).
2. Line 2; Pressure, displayed to one decimal,
units (psi).
Screen 3;
1. Line 1; DENS (fully compensated density), displayed
to five decimal places, units (g/cm3).
2. Line 2; Fluid Temperature, displayed to one decimal,
units (ᵒF).
D625 Meter Display