Omega FMA 4000 User manual

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User’s Guide
FMA 4000
Digital Mass Flow Meters
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TABLE OF CONTENTS
1. UNPACKING THE FMA 4000 MASS FLOW METER...................................
1.1 Inspect Package for External Damage.................................................
1.2 Unpack the Mass Flow Meter...............................................................
1.3 Returning Merchandise for Repair.......................................................
2. INSTALLATION........................................................................................
2.1 Primary Gas Connections.................................................................
2.2 Electrical Connections......................................................................
2.2.1 Power Supply Connections..............................................................
2.2.2 Output Signals Connections..............................................................
2.2.3 Communication Parameters and Connections...................................
3. PRINCIPLE OF OPERATION...................................................................
4. SPECIFICATIONS...................................................................................
5. OPERATING INSTRUCTIONS..................................................................
5.1 Preparation and Warm Up..................................................................
5.2 Swamping Condition.......................................................................
5.3 FMA 4000 Parameters Settings...........................................................
5.3.1 Engineering Units Settings...............................................................
5.3.2 Gas Table Settings..............................................................................
5.3.3 Totalizer Settings.............................................................................
5.3.4 Flow Alarm Settings........................................................................
5.3.5 Relay Assignment Settings..............................................................
5.3.6 K Factors Settings...........................................................................
5.3.7 Zero Calibration...............................................................................
5.3.8 Self Diagnostic Alarm.......................................................................
5.4 Analog output Signals configuration...................................................
6. MAINTENANCE.........................................................................................
6.1 Introduction......................................................................................
6.2 Flow Path Cleaning...........................................................................
6.2.1 Restrictor Flow Element (RFE)........................................................
6.2.2 FMA 4000 model.............................................................................
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7. CALIBRATION PROCEDURES.................................................................
7.1 Flow Calibration...............................................................................
7.2 Gas Calibration of FMA 4000 Mass Flow Meter................................
7.2.1 Connections and Initial Warm Up.....................................................
7.2.2 ZERO Check/Adjustment Adjustment.................................................
7.2.3 Gas Linearization Table Adjustment.................................................
7.3 Analog output Calibration of FMA 4000 Mass Flow Meter..............
7.3.1 Initial Setup.......................................................................................
7.3.2 Gas flow 0-5 Vdc analog output calibration....................................
7.3.3 Gas flow 4-20 mA analog output calibration...................................
8. RS485 / RS232 SOFTWARE INTERFACE COMMANDS.........................
8.1 General............................................................................................
8.2 Commands Structure.........................................................................
8.3 ASCII Commands Set.........................................................................
9. TROUBLESHOOTING................................................................................
9.1 Common Conditions........................................................................
9.2 Troubleshooting Guide.....................................................................
9.3 Technical Assistance.......................................................................
10. CALIBRATION CONVERSIONS FROM REFERENCE GASES...................
APPENDIX I OMEGA FMA 4000 EEPROM Variables..............................
APPENDIX II INTERNAL USER SELECTABLE GAS FACTOR TABLE
(INTERNAL “K” FACTORS)........................................................
APPENDIX III GAS FACTOR TABLE (“K” FACTORS)....................................
APPENDIX IV COMPONENT DIAGRAM......................................................
APPENDIX V DIMENSIONAL DRAWINGS.................................................
APPENDIX VI WARRANTY...........................................................................
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TRADEMARKS
Buna-N®-is a registered trademark of DuPont Dow Elastomers.
Kalrez®-is a registered trademark of DuPont Dow Elastomers.
Neoprene®-is a registered trademark of DuPont.
Omega®-is a registered trademark of Omega Engineering Inc.

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1. UNPACKING THE FMA 4000 MASS FLOW METER
1.1 Inspect Package for External Damage
Your FMA 4000 Mass Flow Meter was carefully packed in a sturdy cardboard car-
ton, with anti-static cushioning materials to withstand shipping shock. Upon
receipt, inspect the package for possible external damage. In case of external
damage to the package contact the shipping company immediately.
1.2 Unpack the Mass Flow Meter
Open the carton carefully from the top and inspect for any sign of concealed ship-
ping damage. In addition to contacting the shipping carrier please forward a copy
of any damage report to Omega7directly.
When unpacking the instrument please make sure that you have all the items
indicated on the Packing List. Please report any shortages promptly.
1.3 Returning Merchandise for Repair
Please contact an OMEGA7customer service representative and request a
Return Authorization Number (AR).
It is mandatory that any equipment returned for servicing be purged and neutral-
ized of any dangerous contents including but not limited to toxic, bacterially infec-
tious, corrosive or radioactive substances. No work shall be performed on a
returned product unless the customer submits a fully executed, signed SAFETY
CERTIFICATE. Please request form from the Service Manager.
2. INSTALLATION
2.1 Primary Gas Connections
Please note that the FMA 4000 Mass Flow Meter will not operate with liquids. Only
clean gases are allowed to be introduced into the instrument. If gases are con-
taminated they must be filtered to prevent the introduction of impediments into the
sensor.

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CAUTION: FMA 4000 TRANSDUCERS SHOULD NOT BE USED FOR
MONITORING OXYGEN GAS UNLESS SPECIFICALLY CLEANED AND
PREPARED FOR SUCH APPLICATION.
For more information, contact Omega 7 .
Attitude limit of the Mass Flow Meter is ±15Ffrom calibration position (standard
calibration is in horizontal position). This means that the gas flow path of the Flow
Meter must be within this limit in order to maintain the original calibration accura-
cy. Should there be need for a different orientation of the meter, re-calibration may
be necessary. It is also preferable to install the FMA 4000 transducer in a stable
environment, free of frequent and sudden temperature changes, high moisture,
and drafts.
Prior to connecting gas lines inspect all parts of the piping system including fer-
rules and fittings for dust or other contaminant’s.
When connecting the gas system to be monitored, be sure to observe the direc-
tion of gas flow as indicated by the arrow on the front of the meter.
Insert tubing into the compression fittings until the ends of the properly sized tub-
ing home flush against the shoulders of the fittings. Compression fittings are to be
tightened to one and one quarter turns according to the manufacturer's instruc-
tions. Avoid over tightening which will seriously damage the Restrictor Flow
Elements (RFE's)!
CAUTION: For FMA 4000 model, the maximum pressure in the
gas line should not exceed 500 PSIA (34.47 bars). Applying pressure above
500 PSIA (34.47 bars) will seriously damage the flow sensor.
FMA 4000 transducers are supplied with either standard 1/4 inch, or optional 1/8
inch inlet and outlet compression fittings which should NOT be removed unless
the meter is being cleaned or calibrated for a new flow range.
Using a Helium Leak Detector or other equivalent method, perform a thorough
leak test of the entire system. (All FMA 4000's are checked prior to shipment for
leakage within stated limits. See specifications in this manual.)
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2.2 Electrical Connections
FMA 4000 is supplied with a 15 pin “D” connector. Pin diagram is presented in
Figure b-1.
2.2.1 Power Supply Connections
The power supply requirements for FMA 4000 transducers are: 11 to 26 Vdc,
(unipolar power supply)
DC Power (+) --------------- pin 7 of the 15 pin “D” connector
DC Power (-) --------------- pin 5 of the 15 pin “D” connector
CAUTION: Do not apply power voltage above 26Vdc.
Doing so will cause FMA 4000 damage or faulty operation.
2.2.2 Output Signals Connections
CAUTION: When connecting the load to the output terminals, do not exceed
the rated values shown in the specifications. Failure to do so might cause
damage to this device. Be sure to check if the wiring and the polarity of the
power supply is correct before turning the power ON. Wiring error may cause
damage or faulty operation.
FMA 4000 Mass Flow Meters are equipped with either calibrated 0-5 or calibrat-
ed 4-20 mA output signals (jumper selectable). This linear output signal repre-
sents 0-100% of the flow meter’s full scale range.
WARNING: The 4-20 mA current loop output is self-powered (non-isolated).
Do NOT connect an external voltage source to the output signals.
Flow 0-5 VDC or 4-20 mA output signal connection:
Plus (+) -------------------------- pin 2 of the 15 pin “D” connector
Minus (-) -------------------------- pin 1 of the 15 pin “D” connector
To eliminate the possibility of noise interference, use a separate cable entry for
the DC power and signal lines.
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2.2.3 Communication Parameters and Connections
The digital interface operates via RS485 (optional RS232) and provides access to
applicable internal data including: flow, CPU temperature reading, auto zero, total-
izer and alarm settings, gas table, conversion factors and engineering units selec-
tion, dynamic response compensation and linearization table adjustment.
Communication Settings for RS485 / RS232 communication interface:
Baud rate: ...................... 9600 baud
Stop bit: ...................... 1
Data bits: ...................... 8
Parity: ...................... None
Flow Control: ...................... None
RS485 communication interface connection:
The RS485 converter/adapter must be configured for: multidrop, 2 wire, half
duplex mode. The transmitter circuit must be enabled by TD or RTS (depending
on which is available on the converter/adapter). Settings for the receiver circuit
should follow the selection made for the transmitter circuit in order to eliminate
echo.
RS485 T(-) or R(-) ...................... pin 8 of the 15 pin “D” connector (TX-)
RS485 T(+) or R(+) ...................... pin 15 of the 15 pin “D” connector (RX+)
RS485 GND (if available) ...................... pin 9 of the 15 pin “D” connector (GND)
RS232 communication interface connection:
Crossover connection has to be established:
RS232 RX (pin 2 on the DB9 connector) ..... pin 8 of the 15 pin “D” connector (TX)
RS232 TX (pin 3 on the DB9 connector) ..... pin 15 of the 15 pin “D” connector (RX)
RS232 GND (pin 5 on the DB9 connector) ..... pin 9 of the 15 pin “D” connector (GND)
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PIN FMA 4000 FUNCTION
1Common, Signal Ground For Pin 2
(4-20 mA return).
20-5 Vdc or 4-20mA Flow Signal Output.
3Relay No. 2 - Normally Open Contact.
4Relay No. 2 - Common Contact.
5Common, Power Supply
(- DC power for 11 to 26 Vdc).
6Relay No. 1 - Common Contact.
7Plus Power Supply
(+ DC power for 11 to 26 Vdc).
8RS485 (-) (Optional RS232 TX).
9RS232 Signal GND (RS485 GND Optional).
10 Do not connect (Test/Maintenance terminal).
11 Relay No. 2 - Normally Closed Contact.
12 Relay No. 1 - Normally Open Contact.
13 Relay No. 1 - Normally Closed Contact.
14 Do not connect (Test/Maintenance terminal).
15 RS485 (+) (Optional RS232 RX).
Shield Chassis Ground.
Figure b.1 - FMA 4000 15 PIN “D” CONNECTOR CONFIGURATION
IMPORTANT NOTES:
Generally, “D” Connector numbering patterns are standardized. There are, how-
ever, some connectors with nonconforming patterns and the numbering
sequence on your mating connector may or may not coincide with the numbering
sequence shown in our pin configuration table above. It is imperative that you
match the appropriate wires in accordance with the correct sequence regardless
of the particular numbers displayed on the mating connector.
Make sure power is OFF when connecting or disconnecting any cables in
the system.
The (+) and (-) power inputs are each protected by a 300mA M (medium time-lag)
resettable fuse. If a shorting condition or polarity reversal occurs, the fuse will cut
power to the flow transducer circuit. Disconnect the power to the unit, remove the
faulty condition, and reconnect the power. The fuse will reset once the faulty con-
dition has been removed. DC Power cable length may not exceed 9.5 feet (3
meters). Use of the FMA 4000 flow transducer in a manner other than that spec-
ified in this manual or in writing from Omega, may impair the protection provided
by the equipment.
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3. PRINCIPLE OF OPERATION
The stream of gas entering the Mass Flow transducer is split by shunting a small
portion of the flow through a capillary stainless steel sensor tube. The remainder of
the gas flows through the primary flow conduit. The geometry of the primary con-
duit and the sensor tube are designed to ensure laminar flow in each branch.
According to principles of fluid dynamics the flow rates of a gas in the two laminar
flow conduits are proportional to one another. Therefore, the flow rates measured
in the sensor tube are directly proportional to the total flow through the transducer.
In order to sense the flow in the sensor tube, heat flux is introduced at two sec-
tions of the sensor tube by means of precision wound heater-sensor coils. Heat is
transferred through the thin wall of the sensor tube to the gas flowing inside. As
gas flow takes place heat is carried by the gas stream from the upstream coil to
the downstream coil windings. The resultant temperature dependent resistance
differential is detected by the electronic control circuit. The measured temperature
gradient at the sensor windings is linearly proportional to the instantaneous rate
of flow taking place.
An output signal is generated that is a function of the amount of heat carried by
the gases to indicate mass-molecular based flow rates.
Additionally, the FMA 4000 Mass Flow Meter incorporates a Precision Analog
Microcontroller (ARM7TDMI7MCU) and non-volatile memory that stores all hard-
ware specific variables and up to 10 different calibration tables. The flow rate can
be displayed in 23 different volumetric or mass flow engineering units. Flow meter
parameters and functions can be programmed remotely via the RS485/RS232
(optional) interface. FMA 4000 flow meters support various functions including:
programmable flow totalizer, low, high or range flow alarm, automatic zero adjust-
ment (activated via local button or communication interface), 2 programmable
SPDT relays output, 0-5 Vdc / 4-20 mA analog outputs (jumper selectable), self
diagnostic alarm, 36 internal and user defined K-factor. Optional local 2x16 LCD
readout with adjustable back light provides flow rate and total volume reading in
currently selected engineering units and diagnostic events indication.
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