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TABLE OF CONTENTS 1. UNPACKING THE FMA 4000 MASS FLOW METER...................................1 1 1.1 Inspect Package for External Damage................................................. 1 1.2 Unpack the Mass Flow Meter............................................................... 1 1.3 Returning Merchandise for Repair....................................................... 2. INSTALLATION........................................................................................ 1 2.1 Primary Gas Connections..
7. CALIBRATION PROCEDURES................................................................. 20 7.1 Flow Calibration...............................................................................20 7.2 Gas Calibration of FMA 4000 Mass Flow Meter................................21 7.2.1 Connections and Initial Warm Up.....................................................21 7.2.2 ZERO Check/Adjustment Adjustment................................................. 21 7.2.3 Gas Linearization Table Adjustment..........
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 carton, 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 shipping damage.
CAUTION: FMA 4000 TRANSDUCERS SHOULD NOT BE USED FOR MONITORING OXYGEN GAS UNLESS SPECIFICALLY CLEANED AND PREPARED FOR SUCH APPLICATION. For more information, contact Omega7. Attitude limit of the Mass Flow Meter is ±15F from 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 accuracy.
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.
2.2.3 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, totalizer and alarm settings, gas table, conversion factors and engineering units selection, dynamic response compensation and linearization table adjustment. Communication Settings for RS485 / RS232 communication interface: Baud rate: Stop bit: Data bits: Parity: Flow Control: ...................... ...
Figure b.1 - FMA 4000 15 PIN “D” CONNECTOR CONFIGURATION PIN FMA 4000 FUNCTION 1 Common, Signal Ground For Pin 2 (4-20 mA return). 2 0-5 Vdc or 4-20mA Flow Signal Output. 3 Relay No. 2 - Normally Open Contact. 4 Relay No. 2 - Common Contact. 5 Common, Power Supply (- DC power for 11 to 26 Vdc). 6 Relay No. 1 - Common Contact. 7 Plus Power Supply (+ DC power for 11 to 26 Vdc). 8 RS485 (-) (Optional RS232 TX). 9 RS232 Signal GND (RS485 GND Optional). 10 Do not connect (Test/Maintenance terminal).
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 conduit 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.
4. SPECIFICATIONS FLOW MEDIUM: Please note that FMA 4000 Mass Flow Meters are designed to work only with clean gases. Never try to measure flow rates of liquids with any FMA 4000. CALIBRATIONS: Performed at standard conditions [14.7 psia (101.4 kPa) and 70FF (21.1FC)] unless otherwise requested or stated. ENVIRONMENTAL (PER IEC 664): Installation Level II; Pollution Degree II. FLOW ACCURACY (INCLUDING LINEARITY): ±1% of FS at calibration temperature and pressure. REPEATABILITY: ±0.15% of full scale.
CAUTION: Omega makes no expressed or implied guarantees of corrosion resistance of mass flow meters as pertains to different flow media reacting with components of meters. It is the customers' sole responsibility to select the model suitable for a particular gas based on the fluid contacting (wetted) materials offered in the different models. INLET AND OUTLET CONNECTIONS: Model FMA 4000 standard 1/4" compression fittings. Optional 1/8" or 3/8" compression fittings and 1/4" VCR fittings are available.
5. OPERATING INSTRUCTIONS 5.1 Preparation and Warm Up It is assumed that the Mass Flow Meter has been correctly installed and thoroughly leak tested as described in section 2. Make sure the flow source is OFF. When applying power to a flow meter within the first two seconds, you will see on the LCD display: the product name, the software version, and revision of the EEPROM table (applicable for LCD option only). OMEGA FMA 4000 485 S: Ver1.4 Rev.
Note: Allow the Digital Mass Flow Meter to warm-up for a MINIMUM of 6 minutes. During initial powering of the FMA 4000 transducer, the flow output signal will be indicating a higher than usual output. This is an indication that the FMA 4000 transducer has not yet attained its minimum operating temperature. This condition will automatically cancel within a few minutes and the transducer should eventually indicate zero.
5.3 FMA 4000 Parameters Settings 5.3.1 Engineering Units Settings The FMA 4000 Mass Flow Meter is capable of displaying flow rate with 23 different Engineering Units. Digital interface commands (see paragraph 8.3 ASCII Command Set “FMA 4000 SOFTWARE INTERFACE COMMANDS”) are provided to: - get currently active Engineering Units set desired Engineering Units.
Note: Once Flow Unit of Measure is changed, the Totalizer’s Volume/Mass based Unit of Measure will be changed automatically. 5.3.2 Gas Table Settings The FMA 4000 Mass Flow Meter is capable of storing calibration data for up to 10 different gases. Digital interface commands are provided to: - get currently active Gas Table number and Gas name set desired Gas Table.
Local maintenance push button is available for manual Totalizer reset on the field. The maintenance push button is located on the right side of the flow meter inside the maintenance window above the 15 pin D-connector (see Figure c-1 “FMA 4000 configuration jumpers”). Note: In order to locally Reset Totalizer, the reset push button must be pressed during power up sequence. The following sequence is recommended: 1. 2. 3. 4. Disconnect FMA 4000 from the power.
Latch Mode- 0123- Controls Latch feature when Relays are assigned to Alarm event. Following settings are available: Latch feature is disabled for both relays Latch feature is enabled for Relay#1 and disabled for Relay#2 Latch feature is enabled for Relay#2 and disabled for Relay#1 Latch feature is enabled for both relays. Note: If the alarm condition is detected, and the Relay is assigned to Alarm event, the corresponding Relay will be energized. Note: By default, flow alarm is non-latching.
The available K Factor settings are: • • • Disabled (K = 1). Internal Index The index [0-35] from internal K factor table (see APPENDIX II). User Defined User defined conversion factor. Note: The conversion factors will not be applied for % F.S. engineering unit. 5.3.7 Zero Calibration The FMA 4000 includes an auto zero function that, when activated, automatically adjusts the mass flow sensor to read zero. The initial zero adjustment for your FMA 4000 was performed at the factory.
AUTOZERO IS ON! Figure b-6: FMA 4000 Screen in the beginning of Auto Zero procedure. The Auto Zero procedure normally takes 1 - 2 minutes during which time the DP Zero counts and the Sensor reading changes approximately every 3 to 6 seconds. AUTOZERO IS ON! S: 405 DP: 512 Figure b-7: FMA 4000 during the Auto Zero procedure. The nominal value for a fully balanced sensor is 120 Counts.
5.3.8 Self Diagnostic Alarm FMA 4000 series Mass Flow Meters are equipped with a self-diagnostic alarm which is available via multicolor LED, digital interface and on screen indication (for devices with optional LCD).
Analog output signals of 0-5 Vdc and 4-20 mA are attained at the appropriate pins of the 15-pin “D” connector (see Figure b-1) on the side of the FMA 4000 transducer. Table VI Analog Output Jumper Configuration ANALOG SIGNAL OUTPUT Flow Rate Output Jumper Header J7 0-5 Vdc J7.A J7.B J7.C 4-20 mA 5-9 6-10 7-11 J7.A J7.B J7.C 1-5 2-6 3-7 See APPENDIX IV for actual jumpers layout on the PCB. Note: Digital output (communication) is simultaneously available with analog output. 6. MAINTENANCE 6.
6.2 Flow Path Cleaning Before attempting any disassembly of the unit for cleaning, try inspecting the flow paths by looking into the inlet and outlet ends of the meter for any debris that may be clogging the flow through the meter. Remove debris as necessary. If the flow path is clogged, proceed with steps below. Do not attempt to disassemble the sensor. If blockage of the sensor tube is not alleviated by flushing through with cleaning fluids, please return meter for servicing. 6.2.
7. 7.1 CALIBRATION PROCEDURES NOTE: REMOVAL OF THE FACTORY INSTALLED CALIBRATION SEALS AND/OR ANY ADJUSTMENTS MADE TO THE METER, AS DESCRIBED IN THIS SECTION, WILL VOID ANY CALIBRATION WARRANTY APPLICABLE. Flow Calibration Omega® Engineerings' Flow Calibration Laboratory offers professional calibration support for Mass Flow Meters using precision calibrators under strictly controlled conditions. NIST traceable calibrations are available.
7.2 Gas Flow Calibration of FMA 4000 Mass Flow Meter All adjustments in this section are made from the outside of the meter via digital communication interface between a PC (terminal) and FMA 4000. There is no need to disassemble any part of the instrument or perform internal PCB component (potentiometers) adjustment. FMA 4000 Mass Flow Meters may be field recalibrated/checked for the same range they were originally factory calibrated for.
Gas flow calibration parameters are separately stored in the Gas Dependent portion of the EEPROM memory for each of 10 calibration tables. See APPENDIX I for complete list of gas dependent variables. Note: Make sure the correct gas number and name selected are current. All adjustments made to the gas linearization table will be applied to the currently selected gas. Use Gas Select command via digital communication interface (see paragraph 8.
If a simple communication terminal is used for communication with the FMA 4000, then “MW” (Memory Write) command from the software interface commands set may be used to adjust sensor value in the linearization table (see section 8.3 for complete software interface commands list). Memory Read “MR” command can be used to read the current value of the index.
The FMA 4000 analog output calibration involves calculation and storing of the offset and span variables in the EEPROM for each available output. The 0-5 Vdc output has only scale variable and 20 mA output has offset and scale variables. The following is a list of the Gas independent variables used for analog output computation: 7.3.
Enter Backdoor mode by typing: Unit will respond with: Disable DAC update by typing: Unit will respond with: !11,MW,1000,1[CR] !11,BackDoorEnabled: Y !11,WRITE,4,D[CR] !11,DisableUpdate: D 7.3.2 Gas flow 0-5 Vdc analog output calibration 1. 2. 3. 4. Install jumpers J7A, J7B and J7C on the PC board for 0-5 Vdc output (see Table VI). Connect a certified high sensitivity multi meter set for the voltage measurement to the pins 2 (+) and 1 (-) of the 15 pins D connector.
Enable DAC update by typing: Unit will respond with: !11,WRITE,4,N[CR] !11,DisableUpdate: N Close BackDoor access by typing: Unit will respond with: !11,MW,1000,0[CR] !11,BackDoorEnabled: N 8. RS485 / RS232 SOFTWARE INTERFACE COMMANDS 8.1 General The standard FMA 4000 comes with an RS485 interface. For the optional RS232 interface, the start character (!) and two hexadecimal characters for the address must be omitted.
Note: Address 00 is reserved for global addressing. Do not assign, the global address for any device. When command with global address is sent, all devices on the RS485 bus execute the command but do not reply with an acknowledge message. The global address can be used to change RS485 address for a particular device with unknown address: 1. 2. Make sure only one device (which address must be changed) is connected to the RS485 network.
28 Selects one of the ten primary gas calibration tables to use. Tables are entered via the MEM commands at time of calibration.
29 Alarm conditions: Flow > High Limit = H Flow < Low Limit = L Low < Flow < High = N Sets / reads the status of the gas flow alarms. Note: High and Low limits have to be entered in the %F.S. High alarm value has to be more than Low alarm value. Flow Alarms 6 5 Starts /reads the status of the auto zero feature (Note: The Z,N command can be used only when absolutely no flow thru the meter and no earlier then 6 minutes after power up. It can take several minutes to complete.
30 Totalizer Relay Action NOTE: If Warm Up Delay option is set to E (enabled) the Totalizer will not totalize the flow during first 6 minutes after power up. Sets and controls action of the flow totalizer. Assigns action of the two SPDT relays. The coil is energized when the condition specified by an Argument 2 becomes true.
31 9 K Factors See list of the internal K-factors in the operating manual. (NOTE: does not work with % F.S. engineering unit.) Applies a gas correction factor to the currently selected primary gas calibration table. No.
32 10 Units Note: The units of the totalizer output are not per unit time. Set the units of measure for gas flow and totalizer reading. No. COMMAND DESCRIPTION NAME U Command No Argument Returns current EU.
33 1 2 3 4 - Not Supported Command or Back Door is not enabled. Wrong # of Arguments. Address is Out of Range (MR or MW commands). Wrong # of the characters in the Argument. UART Error Codes: MW Writes the specified value to the 15 specified memory location. Use Carefully, can cause unit to malfunction. (Note: Some addresses are write protected!) Write EEPROM Memory B MR 13 LCD Back Light control (0-100.
9. TROUBLESHOOTING 9.1 Common Conditions Your FMA 4000 Digital Mass Flow Meter was thoroughly checked at numerous quality control points during and after manufacturing and assembly operations. It was calibrated according to your desired flow and pressure conditions for a given gas or a mixture of gases. It was carefully packed to prevent damage during shipment.
9.2 Troubleshooting Guide NO. INDICATION LIKELY REASON SOLUTION 1 No zero reading after 15 min. warm up time and no flow condition. Embedded temperature has been changed. Perform Auto Zero Procedure (see section 5.3.6 “Zero Calibration”). 2 Status LED indicator Power supply is bad or and LCD Display polarity is reversed. remains blank when unit is powered up. No response when flow is introduced from analog outputs 0-5 Vdc or 4-20 mA. Measure voltage on pins 7 and 5 of the 15 pin D-connector.
NO. INDICATION 8 Gas flows through the FMA 4000, but LCD Display reading and the output voltage 0-5 Vdc signal do not respond to flow. 9 Gas does not flow through the FMA 4000 with inlet pressure applied to the inlet fitting. LCD Display reading and output voltage 0-5 Vdc signal show zero flow. LIKELY REASON SOLUTION The gas flow is too low Check maximum flow range on transducer’s for particular model of front panel and make required flow FMA 4000. adjustment.
9.3 Technical Assistance OMEGA7 Engineering will provide technical assistance over the phone to qualified repair personnel. Please call our Flow Department at 800-872-9436 Ext. 2298. Please have your Serial Number and Model Number ready when you call. 10. CALIBRATION CONVERSIONS FROM REFERENCE GASES The calibration conversion incorporates the K factor. The K factor is derived from gas density and coefficient of specific heat.
APPENDIX I OMEGA7 FMA 4000 EEPROM Variables Rev.A0 [10/2/2007] Gas Independent Variables INDEX NAME DATA TYPE NOTES 0 BlankEEPROM char[10] Do not modify. Table Revision [PROTECTED] 1 SerialNumber char[20] Serial Number [PROTECTED] 2 ModelNumber char[20] Model Number [PROTECTED] 3 SoftwareVer char[10] Firmware Version [PROTECTED] 4 TimeSinceCalHr float Time since last calibration in hours. 5 Options1 uint Misc.
INDEX NAME DATA TYPE NOTES 35 Klag [5] float DRC Lag Constant [Do Not Alter] 36 Kgain[0] float Gain for DRC Lag Constant [Do Not Alter] 37 Kgain[1] float Gain for DRC Lag Constant [Do Not Alter] 38 Kgain[2] float Gain for DRC Lag Constant [Do Not Alter] 39 Kgain[3] float Gain for DRC Lag Constant [Do Not Alter] 40 Kgain[4] float Gain for DRC Lag Constant [Do Not Alter] 41 Kgain[5] float Gain for DRC Lag Constant [Do Not Alter] 42 Zero_T float Resistance when last AutoZero
Calibration Table: Gas Dependent Variables.
APPENDIX II INTERNAL “K” FACTORS CAUTION: K-Factors at best are only an approximation. K factors should not be used in applications that require accuracy better than +/- 5 to 10%. INDEX ACTUAL GAS K Factor Relative to N2 Cp [Cal/g] 0.5829 1.000 0.4346 .4036 0.24 0.352 DENSITY [g/I] 0 1 2 Acetylene C2H2 Air Allene (Propadiene) C3H4 3 Ammonia NH3 .7310 .492 4 Argon Ar 1.4573 .1244 1.782 5 Arsine AsH3 0.6735 0.1167 3.478 6 Boron Trichloride BCl3 0.4089 0.1279 5.
APPENDIX III GAS FACTOR TABLE (“K FACTORS”) CAUTION: K-Factors at best are only an approximation. K factors should not be used in applications that require accuracy better than +/- 5 to 10%. ACTUAL GAS K FACTOR Relative to N2 Cp [Cal/g] Density [g/I] .5829 1.0000 .4346 .7310 1.4573 1.205 .6735 .4089 .5082 .8083 .38 .26 .3855 .3697 .3224 .2631 .2994 .324 .291 .7382 .658 .4036 .240 .352 .492 .1244 .1244 .1167 .1279 .1778 .0539 .0647 .1369 .1161 .1113 .3514 .4007 .3648 .336 .374 .2016 .2016 1.162 1.
ACTUAL GAS K FACTOR Relative to N2 Cp [Cal/g] Density [g/I] Deuterium D2 Diborane B2H6 Dibromodifluoromethane CBr2F2 Dichlorodifluoromethane (Freon-12) CCl2F2 Dichlofluoromethane (Freon-21) CHCl2F Dichloromethylsilane (CH3)2SiCl2 Dichlorosilane SiH2Cl2 Dichlorotetrafluoroethane (Freon-114) C2Cl2F4 1,1-Difluoroethylene (Freon-1132A) C2H2F2 Dimethylamine (CH3)2NH Dimethyl Ether (CH3)2O 2,2-Dimethylpropane C3H12 Ethane C2H6 Ethanol C2H6O Ethyl Acetylene C4H6 Ethyl Chloride C2H5Cl Ethylene C2H4 Ethylene Oxi
ACTUAL GAS K FACTOR Relative to N2 Cp [Cal/g] Density [g/I] 1.000 1.000 .764 .9998 .9987 .7893 .80 .2492 .27 .2951 1.453 .7175 .75 .0861 .1912 .3171 .3479 .0545 .1025 .2397 .1108 .3872 .3701 .0593 .5328 .5328 3.610 1.627 1.206 .893 5.707 3.613 1.520 9.90 3.593 2.503 3.739 .7175 .7175 .5843 .4313 .5835 .6299 .68 .5180 .2499 .2126 .3512 .51 1.46 .990 1.000 .737 .4802 .6134 .7128 .176 .9926 .6337 .446 .2554 .2134 .3950 .174 .4438 .759 .3274 .3547 .1106 .1926 .3221 .2459 .164 .1373 .387 .4343 .246 .
ACTUAL GAS K FACTOR Relative to N2 Cp [Cal/g] Density [g/I] .36 .3021 .30 .35 .40 .5982 .284 .3482 .69 .2635 .3883 .5096 .3237 .3287 .3278 .1324 .1610 .1250 .399 .366 .3189 .1270 .1691 .1488 .1592 .1543 .127 .182 .1357 .1380 6.843 5.620 6.127 1.967 1.877 1.433 7.580 4.643 2.858 6.516 4.562 4.224 4.64 6.129 6.043 .2031 .161 8.
APPENDIX IV COMPONENT DIAGRAM TOP COMPONENT SIDE Aug.
BOTTOM COMPONENT SIDE Aug 09, 2007 47
APPENDIX V DIMENSIONAL DRAWINGS FMA 4000 WITHOUT READOUT 48
FMA 4000 WITH READOUT OPTION 49
WARRANTY/DISCLAIMER OMEGA ENGINEERING, INC. warrants this unit to be free of defects in materials and workmanship for a period of 13 months from date of purchase. OMEGA’s Warranty adds an additional one (1) month grace period to the normal one (1) year product warranty to cover handling and shipping time. This ensures that OMEGA’s customers receive maximum coverage on each product. If the unit malfunctions, it must be returned to the factory for evaluation.
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