Omega FD6003 User manual

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User’s Guide

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regulations that apply. OMEGA is constantly pursuing certification of its products to the European New
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WARNING: These products are not designed for use in, and should not be used for, human applications.

1-1
PART 1 - TABLE OF CONTENTS
Description Pages
Quick Start Installation 1.2-1.3
Operating Theory 1.4
Product Limitations 1.5
Model Number Matrix 1.6
Specifications 1.7
Transducer Installation 2.1-2.5
Pre-Installation Functional Test 3.1-3.2
Transmitter Installation 3.3-3.4
Power Source Jumper Settings 3.5
Electrical Connections 3.5-3.6
Power Up and Configuration 3.7
Keypad Operations 3.8-3.19
Trouble Shooting 3.20-3.21
Appendix
Fluid Sound Speed Conversions
Ductile Iron Pipe Data
Cast Iron Pipe Data
Steel, SS, PVC Pipe Data
FPS to GPM Conversion Chart

1-2
This manual contains detailed operating instructions for all
aspects of the FD6000 instruments. 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 only. If specific
instrument features 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. In general, select a mounting location on the piping
system with a minimum of 10 pipe diameters (10 X the
pipe inside diameter) of straight pipe upstream and 5
straight diameters downsteam. See Table 2.1 for
additional configurations.
B. On horizontal pipe, select a position that is between 2
and 4 o’clock on the pipe, with 12 o’clock representing
the top. Installations on vertical pipe should be made
in an area where the flow moves from bottom to top—
ensuring a full pipe of liquid.
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. Loosely wrap the appropriate length of strap around
the pipe at the location determined in Step 1. Refer to
Figure 1.1 for proper orientation of the transducer. For
greatest accuracy, point the cable of the transducer in
the primary flow direction.
C. Apply a liberal amount of couplant onto the transducer
face. Place the transducer onto the pipe ensuring
square and true placement. If an RTV type of
couplant (requiring curing time) was utilized, allow
sufficient time for curing before applying power to the
instrument or moving the cable.
PART 1 - QUICK START
General
FLOW
Figure 1.1
Top View of Pipe
Transducer Cable

1-3
3. TRANSDUCER/POWER CONNECTIONS
A. Do not attempt to add additional cable to the
transducers.
B. Refer to the DIAGRAMS in Figure 1.2 for proper power
and transducer connections. Verify proper jumper
selections are in place for the power source. See
Figure 3.4.
4. INITIAL SETTINGS AND POWER UP
A. Adjust the GAIN control [R13] to 1/4 turn from full
counter-clockwise rotation.
B. Apply power to the instrument.
C. If the pipe is full of a flowing liquid, the flow meter
signal strength will increase from a zero reading.(press
the 2nd FUNCT key, then press SIGNAL STR). If the
Signal Strength does not increase to a minimum of
000125 counts, gradually turn the GAIN control [R13]
clockwise until the indication is between 000125 and
000200. (Do not over adjust this setting as ambient
noise can influence readings.)
D. If possible, turn off the flow in the pipe. Verify that
SIGNAL STR. is lower than 000100. If SIGNAL STR.
is greater than 000100, verify that the sensor/
transmitter are not located near electrically noisy
components. (VFDs, inverters, motors, power relays,
etc) Verify that transducer connections are proper
and secure. If the SIGNAL STR. remains greater than
000100, consult the Dynasonics Factory for
assistance. It is possible that the GAIN control [R13] is
set too far clockwise and ambient noise is influencing
the readings. Turn the control counter-clockwise until
the signal strength decreases to below 000070 counts.
E. If the instrument passes steps 4C and 4D, the basic
setup of the instrument is complete.
PART 1 - QUICK START
IMPORTANT!
In order to successfully complete the configuration of
the FD6000 Series flow meter, the transducer must be
mounted on a pipe which is full of a flowing liquid. It
is normal to have a zero reading and no signal
strength indication with empty pipes or zero flow rate.
Figure 1.2
Transducer (top picture)
and Power (bottom picture)
Connections

1-4
The FD6000 Series flowmeter is designed to
measure the flow of liquids and slurries in full-pipe
closed systems. The transmitter is field configured to
measure flow on a variety of pipes and liquids. The
standard product is typically used on pipe sizes
ranging from 1 - 120 inch [ 25 - 1524 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: sewage,
sludges, concrete, mining slurries, dredging, etc.
Because the 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
300°F [149°C].
The basic principle of operation is the measurement
of the frequency shift “Doppler” of a reflected
ultrasonic signal from discontinuity in the flowing
liquid. In theory, these discontinuities can be virtually
any amount of suspended bubbles, solids, or
interfaces caused by turbulent flow. In practice the
degree to which this can be reliably accomplished is a
function of the sensitivity and frequency of the
transducer and associated transmitter. The design
requires greater than 100 PPM of suspended
solids or bubbles over 100 microns in size. The
PART 1 - GENERAL
General
Operating Theory
transducer which generates and receives the
ultrasonic signal supplies the data to the transmitter.
The transmitter processes the signal and provides an
analog and pulse output for velocity indicating and
volumetric totalizing. In addition, the transmitter
contains a signal strength indicator which determines
satisfactory operation.

1-5
The flowmeter is typically used as a unidirectional
meter and is most accurate when the transducer is
mounted in the orientation detailed in this manual.
But, the meter will measure flow in both directions —
although flow direction will not be indicated or
totalized properly. The flowmeter will operate from
signals returned from turbulence alone (such as
installation directly at pump discharges or
downstream from elbows and valves); however, it
should be noted that turbulence may vary with flow
rates and result in non-linear results. The
repeatability of the device is not dependent on most
process liquids.
The flowmeter is designed to measure the flow of
liquids and slurries, as long as a small, homogeneous
quantity of entrained air or suspended solids are
present. Without the presence of continuing supply of
air or solids, the transmitted pulses are not reflected
back to the transducer and the indicator will indicate
zero flow.
The signal strength value will indicate a value greater
than 100 counts when a minimum size and
concentration of suspended particles are available for
a reliable flow reading (100 micron and 100 PPM
minimum) and the liquid is moving at least 0.1 FPS
[0.03 MPS]. Most water-based liquids can be
measured from a factory calibrated flowmeter.
However, liquids with a heavy solids level (i.e. over
2% by volume), liquids with sound speeds that vary
from water (see Appendix - Liquid Sound Speed list)
or pipes with liners may have to be field calibrated.
This is done by adjusting the Calibration value on the
keypad to make the indicator agree with a known flow
velocity or a mathematically corrected fluid velocity.
All standard flow meters are calibrated to measure
the flow of a water-based liquid at 25 degrees C. If
the scale range or units need to changed, the process
to do so is covered in detail later in this manual.
PART 1 - GENERAL
Measuring Limits

1-6
The FD6000 Series employs modular construction
and provides electrical safety for the operator. The
display face contains voltages no greater than 9 Vdc
and any exposed metal work is electrically connected
to Earth Ground. The display face swings open to
allow access to user connections.
The serial number and complete model number of
your meter is located on the inside of the transmitter
front cover. Should technical assistance be required,
please provide OMEGA’s Customer Service
Department with this information. Email:
[email protected].
PART 1 - GENERAL
Serial Number

1-7
PART 1 - GENERAL
(Std) 115 or 230 VAC 50/60 Hz ±10% and 12 VDC. (Opt)
Power consumption less than 12 VA.

NOTES

2-1
The following list outlines how to install the
transducer for optimal performance, highest reliability
and greatest accuracy:
1. Select a transducer site at least 10 pipe diameters
downstream from bends, or fittings and 5 pipe
diameters upstream. A symmetrical flow pattern is
necessary for accuracy and repeatability over the
PART 2 - TRANSDUCER INSTALLATION
Table 2.1
1
1
The system will provide repeatable measurements on piping systems that do not meet these
requirements, but the accuracy of these readings may be influenced to various degrees.
Transducer Mounting
Locations

2-2
operating range of the meter. Down stream from
pump or orifices, etc., locate at least 20 diameters.
See Table 2.1
2. On horizontal pipe, select a position that is
between 2 and 4 o’clock on the pipe, with 12
o’clock representing the top. If the transducer is
to be mounted on a vertical pipe, select a section
of pipe where the flow is moving from bottom to
top (flow moving vertically down a pipe tends to
cavitate and provide unreliable operation.)
3. Mount the transducer in the orientation shown in
Figure 2.2. The flow meter will read flow in both
directions, but will be most accurate if the cable is
mounted in the orientation shown—pointing in the
primary flow direction.
4. If totalization of the measured fluid is required, the
pipe must remain full. The meter will read when
the liquid level is greater than the placement of the
transducer, but the volumetric measurement will
be based on a full pipe, so totalization will be
higher than actual.
5. The flowmeter will achieve proper Doppler signals
off of turbulence; however, it should be noted that
turbulence may not be linear with pump speed
changes, nor is the reading necessarily accurate
due to the non-uniformity of turbulence.
6. When a liquid has less than 100 PPM of 100
micron or larger particles, try mounting the
transducer within 12 inches of a pump discharge
or other source of flow turbulence or cavitation. A
reading obtained under these circumstances will
be repeatable, but not necessarily accurate or
linear.
7. It is a good practice to test the flow meter on the
piping system before permanently mounting the
transducer using RTV. Function can be verified
by applying a water soluble lubricant, such as KY-
Jelly, and holding the transducer by hand on the
pipe in the location where the transducer will be
PART 2 - TRANSDUCER INSTALLATION
FLOW
Figure 2.2
Top View of Pipe
Transducer Cable

2-3
permanently mounted. Under flowing liquid
conditions, adequate signal is indicated when the
Signal Strength indicates between 000125 and
000200 counts.
For proper operation, there cannot be air voids
between the traducer face and pipe. The space must
be filled with a material which is a good transmitter of
sound energy such as:
SILICONE GREASE: Dow Corning 111 R or
comparable (-100 to +450 F.) The material must be
suitable not to flow at temperature of pipe. Used for
temporary survey installations and portable flow
meters.
SILICONE RUBBER: Dow Corning 732-RTV R.
Excellent for permanent bonding. This adhesive is a
recommended bonding agent and easily removable.
INSTALLATION AND PIPE PREPARATION
The cable from the transducer is provided with
either dual-coaxial cables, flexible nylon conduit or
PVC coated steel conduit with a 1/2” NPT fitting. The
coaxial cable was ordered from the factory at a
specific length UNDER NO CIRCUMSTANCES
should the coaxial cable be lengthened as this
may de-tune the circuitry and influence
performance.
Installation of the small-pipe transducers follow the
same procedures as the standard pipe type. The only
difference is that the small pipe transducers utilize an
integral pipe clamping mechanism with two
opposing sensing heads and the standard pipe units
use a stainless steel strap.
PART 2 - TRANSDUCER INSTALLATION
Acoustic Couplant
Types
Small Pipe
Transducers

2-4
1. Pipe Preparation:
For permanent silicone adhesive mounting, after
determining the transducer location, some attention
must be given to the pipe condition. Before the
transducer head is bonded to the pipe surface, an
area slightly larger than the flat surface to the
transducer head (black rectangle) must be cleaned to
bare metal. This means the removal of all paint rust,
and scale. Some minor pipe pitting will not cause
problems, as the acoustic couplant will take up the
voids. In the case where plastic pipe is used, remove
all paint and grease so that a smooth, dry surface is
exposed.
2. Transducer Mounting:
The transducer center line is designed to mount
parallel to the pipe center line. The groove in the
transducer body will allow the 1/2” stainless steel
strap that was enclosed with the meter to align the
transducer properly on the pipe. DO NOT mount the
transducer on bends, elbows or fittings. Every effort
should be made to mount the transducer parallel to
the axis of the pipe as well as flat on the pipe. The
transducer cable should run in the “down-stream”
direction of liquid flow. See Figure 2.2.
In horizontal pipe runs, mount the transducer
between 2 and 4 o’clock from the top—12 o’clock
position; prepare the pipe surface as described.
Finish the surface with some emery paper and then
wipe the surface with trichlorenthylene to thoroughly
degrease the contact surface in a area slightly larger
than the flat surface of the transducer.
For permanent mounting, use a good silicone based
PART 2 - TRANSDUCER INSTALLATION
Intrinsic Safety
Installations
Installations requiring intrinsic safety should refer to
the Appendix drawings covering these applications.

2-5
adhesive (Dow-732). Spread a bead of the adhesive
on the flat surface of the transducer face, covering
well. Now spread a bead to the prepared pipe
surface and press the head lightly to the pipe. Let the
adhesive flow enough to fill in all the area beneath the
head. At the same time, clamp (clamp supplied) into
place until the silicone has set up. Taping along the
edges of the head will hold the adhesive in place. A
pad of adhesive must be formed between the
transducer face and the pipe. Ensure that no relative
movement between the transducer and the pipe takes
place during the setup time (about 24 hours). Clamp
transducer only tight enough to hold it in place while
the adhesive is curing. Tighten for mechanical
strength only after 24 hours. Secure the conduit as
well.
3. Temporary Mounting and Spot Checks:
For temporary mounting, clean pipe as described and
use silicone grease as the acoustical coupling
material, holding by hand for spot readings or with a
strap clamp for indefinite periods.
PART 2 - TRANSDUCER INSTALLATION

NOTES

3-1
PART 3 - PRE-INSTALLATION CHECKOUT
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 FD6000 Series flowmeter can be checked for basic
functionality using the following Bench Test procedure.
It is recommended that this operation be performed
before permanently installing the system.
Procedure:
1. Open the transmitter cover.
2. Connect the transducer cable connector to the
terminal locations on the lower left corner of the
FD6000 Series main circuit card. See Figure 3.1.
3. Connect supply power to the appropriate terminal
locations on the upper right corner of the main circuit
card. See Figure 3.2. Verify that the power supply
selection jumpers are configured properly—See
Figure 3.4.
4. Apply power.
5. Verify that the display indicates 0.00 FPS (or 0.0 flow
rate of any other unit). If the display does not register
0.0, then press the 2nd FUNCT key, then press
SIGNAL STR. Verify that SIGNAL STR. is lower than
000100. If SIGNAL STR. is greater than 000100,
verify that the sensor/transmitter are not located near
electrically noisy components. (VFDs, inverters,
motors, power relays, etc) Verify that transducer
connections are proper and secure. If the SIGNAL
STR. remains greater than 000100, consult the
Dynasonics Factory for assistance.
6. Press the 2nd FUNCT key to enter SERVICE MODE.
Press the SIGNAL STR key to display SIGNAL STR.
XXXXXX.
7. Rub the face of the transducer lengthwise back and
Unpacking
Functional Test
Figure 3.2
Figure 3.1

3-2
forth with your thumb using moderate pressure. The
cycle time should be 1-2 times per second.
8. Verify that signal strength increases with frequency of
the rubbing. Typical increases will range from 20-30
counts.
9. Verify that signal strength decreases when rubbing
ceases.
Bench Test is Complete
PART 3 - PRE-INSTALLATION CHECKOUT

3-3
1. Place the transmitter in a location that is:
♦Where little vibration exist.
♦Protected from falling corrosive fluids.
♦Within ambient temperature limits - 22 to 122°F [-30 to
50°C]
♦Out of direct sunlight. Direct sunlight may increase
temperatures within the transmitter to above maximum
limit.
2. Mounting: Refer to Figure 3.3 for enclosure and
mounting dimension details. Ensure that enough room
is available to allow for door swing, maintenance and
conduit entrances. Secure the enclosure to a flat
surface with four appropriate fasteners.
3. Conduit holes. Conduit hubs should be used where
cables enter the enclosure. Holes not used for cable
entry should be sealed with plugs.
NOTE: Use NEMA 4 [ IP65 ] rated fittings and plugs to
maintain the water tight integrity of the enclosure.
Generally, the right conduit hole (viewed from front) is
used for line power; the left conduit hole for transducer
connections.
4. If additional holes are required, (analog outputs, etc.)
drill the appropriate size hole in the enclosure’s
bottom. Use extreme care not to run the drill bit into
the wiring or circuits cards.
To access terminal strips for electronic connectors, loosen
the two screws in the enclosure door and open the door.
PART 2 - ELECTRICAL CONNECTIONS
PART 3 - TRANSMITTER INSTALLATION
Transmitter
Installation

3-4
NOTE: The transducer cable carries low level signals.
Do not attempt to add additional cable to the factory
supplied transducer cable.
PART 2 - SERVICE AND MAINTENANCE
PART 3 - TRANSMITTER INSTALLATION
FIGURE 3.3
Important !
FD-5000 Shown
1.45
[36.8]
3.88
[98.5]