User’s Guide
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FD6001, FD6002, FD6003
Ultrasonic Flowmeter
with Totalization
PART 1 - TABLE OF CONTENTS
Description
Pages
1.2-1.3
1.4
Quick Start Installation
Operating Theory
Product Limitations
Model Number Matrix
Specifications
1.5
1.6
1.7
Transducer Installation
2.1-2.5
Pre-Installation Functional Test
Transmitter Installation
3.1-3.2
3.3-3.4
3.5
Power Source Jumper Settings
Electrical Connections
3.5-3.6
Power Up and Configuration
Keypad Operations
3.7
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
1-1
PART 1 - QUICK START
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.
General
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
Transducer
Cable
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.
FLOW
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.
Figure 1.1
Top View of Pipe
1-2
PART 1 - QUICK START
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
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.
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
Figure 1.2
Transducer (top picture)
and Power (bottom picture)
Connections
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.
1-3
PART 1 - GENERAL
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
General
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
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.
Operating Theory
1-4
PART 1 - GENERAL
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
Measuring Limits
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.
1-5
PART 1 - GENERAL
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
Serial Number
Department with this information.
Email:
1-6
PART 1 - GENERAL
(Std) 115 or 230 VAC 50/60 Hz 10% and 12 VDC. (Opt)
Power consumption less than 12 VA.
1-7
NOTES
PART 2 - TRANSDUCER INSTALLATION
The following list outlines how to install the
transducer for optimal performance, highest reliability
and greatest accuracy:
Transducer Mounting
Locations
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
Table 2.11
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.
2-1
PART 2 - TRANSDUCER INSTALLATION
operating range of the meter. Down stream from
pump or orifices, etc., locate at least 20 diameters.
See Table 2.1
Transducer
Cable
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.)
FLOW
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.
Figure 2.2
Top View of Pipe
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
2-2
PART 2 - TRANSDUCER INSTALLATION
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:
Acoustic Couplant
Types
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.
Small Pipe
Transducers
2-3
PART 2 - TRANSDUCER INSTALLATION
Installations requiring intrinsic safety should refer to
the Appendix drawings covering these applications.
Intrinsic Safety
Installations
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
2-4
PART 2 - TRANSDUCER INSTALLATION
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.
2-5
NOTES
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.
Unpacking
The FD6000 Series flowmeter can be checked for basic
Functional Test
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.
Figure 3.1
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.
Figure 3.2
7. Rub the face of the transducer lengthwise back and
3-1
PART 3 - PRE-INSTALLATION CHECKOUT
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
3-2
PART 3 - TRANSMITTER INSTALLATION
1. Place the transmitter in a location that is:
♦ Where little vibration exist.
Transmitter
Installation
♦ 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.
3-3
PART 3 - TRANSMITTER INSTALLATION
1.45
[36.8]
3.88
[98.5]
FD-5000 Shown
FIGURE 3.3
NOTE: The transducer cable carries low level signals.
Do not attempt to add additional cable to the factory
supplied transducer cable.
Important !
3-4
PART 3 - TRANSMITTER INSTALLATION
The 4-20mA output is proportional to the flow rate
measuring scale and can drive a load of up to 1000 ohms.
The output is isolated from earth ground and circuit low.
Connect the load to the 4-20 mA connection terminals
located on the inside of the enclosure, matching polarity
as indicated.
4-20mA OUTPUT
Line power is connected by supplying power to the
appropriate terminals located inside of the enclosure
Use wiring practices that conform to local codes
(National Electric Code Hand book in the USA).
Use only the standard three wire connection. The ground
terminal grounds the instrument, which is mandatory for
safe operation.
Power Connections
CAUTION: Any other wiring method may be unsafe or
cause improper operation of the instrument.
It is recommended not to run line power with other signal
wires within the same wiring tray or conduit. Verify that
the power supply jumper connections are oriented cor-
rectly for the power source being wired. The electronics
can be damaged if improper power is connected or if
jumpers are not installed correctly. The DC input is not
fuse protected. It is recommended that an external fuse
be installed if DC power is selected. The fuse should be a
1A delay action type. See Figure 3.4
Jumpers
JP8, JP10, JP11
JP9, JP11
JP7
JP3, JP5
JP4, JP6
Power Source
115 VAC
230 VAC
100 VAC
12 VDC
Figure 3.4
Power Supply Jumper
Selection
24 VDC
NOTE: This instrument requires clean electrical line
power. Do not connect the meter on a circuit which oper-
ates lighting ballasts, motors, solenoids, etc.
3-5
PART 3 - TRANSMITTER INSTALLATION
1. Guide the transducer terminations through the
Transducer
Connections
transmitter conduit hole located on the left side of the
enclosure. Secure the transducer cable with the
supplied conduit nut.
2. The terminals on the transducer cable are coded with
wire markings. Connect the appropriate wires to the
corresponding screw terminals in the transmitter.
NOTE: The transducer cable carries low level signals.
Do not attempt to add additional cable to the factory
supplied transducer cable.
If additional cable is required contact OMEGA Engineering
to order a transducer with the appropriate length of cable
Cables to 300 feet [90 meters] are available.
NOTE: An additional hole in the transmitter enclosure is
required for outputs. Drill the hole in the the enclosure
bottom taking care not to drive the drill bit into wiring or the
circuit boards with the transmitter.
The CTR pulse output is proportional to the flow rate
measuring scale. This output may be used one of two
ways:
CTR Output
♦
♦
To drive a 12V logic device or electromechanical total-
izers.
To drive a low impedance, 12V device. Minimum
resistance 50 ohms.
The pulse output pulses with totalizer increments. The
connections are located on the right side of the signal
processing PCB in the back of the enclosure. The pulse
width is fixed at 50 milli-seconds. CTR “ - ” represents
circuit low. CTR “ + “ represents 12 Vdc pulse output.
3-6
PART 3 - STARTUP AND CONFIGURATION
Note: The FD6000 Series flow meter system requires a
Before Starting the
Instrument
full pipe of flowing liquid before a successful startup can
be completed. Do not attempt to make adjustments or
change configurations until a full pipe is verified.
Procedure:
Instrument Startup
1. Verify that all wiring is properly connected and routed.
2. Apply power.
3. Adjust the GAIN control [R13] to 1/4 turn from full
counter-clockwise rotation.
4. Apply power to the instrument.
5. If the pipe is full of a flowing liquid that contains ade-
quate concentrations of suspended solids, the flow me-
ter 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 at between
000125 and 000200. (Do not over adjust this setting
as ambient noise can influence readings.)
6. 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 DT6 transducer connections are proper
and secure. If the SIGNAL STR. remains greater than
000100, consult OMEGA Engineering 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.
5. If the instrument passes steps 5 and 6, the basic setup
of the instrument is complete.
It is normal to have low/zero SIGNAL STRENGTH
indication at ZERO flow.
Important!
3-7
PART 3 - KEYPAD CONFIGURATION
After a successful flow meter installation and startup
(covered in the previous sections of this manual) the FD6000
can be keypad configured to provide select engineering
unit readings of flow and a scaled 4-20mA output.
Configuration inputs are made via the keypad and are
stored by the microprocessor. The entries are retained by
the flow meter’s E2PROM memory in the event of power
failure. If fluid velocity readings, FPS or MPS, are the
only required measurement keypad configuration is not
required.
UP/DOWN Arrows
Allow changing of the FD6000 Series configuration
constants. Use the UP arrow to increase constant values
and the DOWN arrow to decrease values. The
arrows can be momentarily pressed to change values
incrementally or held to advance continuously. Constants
outside of the valid range of the unit cannot be
displayed. The scrolling rate at which the values will change
is two tiered. Scrolling will be relatively slow during the first
five seconds of a continuous keypad press; the
scrolling rate will increase after that time to allow rapid
changes of large values.
2nd FUNCT
Controls access to the commands located on the lower
half of the keys. After pressing this key the word
SERVICE MODE will appear on the LCD indicator.
ENTER
Records and activates the configuration constant value
that is displayed on the LCD indicator. Can also be used
to return the meter to its run mode.
3-8
PART 3 - KEYPAD CONFIGURATION
F1 and F2
Not utilized.
RESET
Caution: Conducts a system reset. All configuration
constants will be lost and the FD6000 will load default values
for all constants.
I.D.
Allows entry of a pipes internal diameter.
Internal
diameters must be entered if volumetric flow rates are to
be displayed.
n If a UNITS code for U.S. measurements was made the
I.D. value will be entered in inches. Valid ranges for
this entry are 0.25 to 120.00 inches.
n If a UNITS code for metric measurement was made
the I.D. value will be entered in millimeters. Valid
ranges for this entry are 6 to 3050 millimeters.
The appendices in the back of this manual contain tables
of common pipe sizes and schedules. If the pipe size
does not appear in the table, consult the pipe manufacture
or conduct a physical measurement of the pipe internal
diameter. Errors in the entry of this value can result in
large inaccuracies.
FULL SCALE
Allows entry of the maximum fluid velocity anticipated
within the pipe. This value does not have any bearing on
displayed flow rates or values, but is used to scale the
span value of the 4-20mA analog output. If the analog
output is not going to be utilized set this value to 30.00 if
measuring in U.S. units or 10.00 if measuring in metric
units.
n If a UNITS code for U.S. measurements was made the
FULL SCALE value will be entered in FPS (feet per
3-9
PART 3 - KEYPAD CONFIGURATION
second). Valid ranges for this entry are 0.00 to 30.00
FPS. Two useful equations that relate liquid velocity to
volume:
GPM = 2.45 X I.D.2 X FPS
FPS = ( GPM X 0.408) / I.D.2
I.D. in inches
n If a UNITS code for metric measurement was made
the I.D. value will be entered in MPS (meters per
second). Valid ranges for this entry are 0 to 10.00
MPS. Two equations that relate liquid velocity to
volume are
LPM = 0.047 X I.D.2
X MPS
MPS = ( LPM X 21.28) / I.D.2
I.D. in inches
Note: Attempting to set a FULL SCALE value of less than
0.5 FPS [0.15 MPS] may result in an unstable transmitted
output. If flows are typically lower than this range, the
LOW FLOW FILTERS and higher DAMPing values may
be required.
UNITS
Utilized to set engineering units of measure. There are
twelve different selections possible. The Table 3.1 lists
the entry code number, flow rate unit of measure and
totalizer unit of measure.
Note:
After changing the UNITS value, it may be
necessary to change other configuration values
accordingly. For example, FULL SCALE, I.D., HIGH/LOW
ALARM are influenced by the UNITS entry.
Note: Flow already accumulated will not be correctly
compensated for if the UNITS of measure changes.
3-10
PART 3 - KEYPAD CONFIGURATION
Table 3.1
UNITS Code Flow Rate
Totalizer
FPS (feet per sec)
N/A
0
1
2
3
GPM (gallons per min) GALLONS
GPH (gallons per hr) GALLONS
MGD (millions of gal GALLONS
pre day)
CFM (ft.3 per min)
CF
4
5
6
7
8
MPS (meters per sec) N/A
CMH (m3 per hr)
m3
LPM (liters per min)
Liters
MLD (millions of liters Liters
per day)
BPM (barrels per min) BARRELS
9
BPH (barrels per hr)
BARRELS
10
11
BPD (barrels per day) BARRELS
3-11
PART 3 - KEYPAD CONFIGURATION
HIGH ALARM (Labeled RELAY-1 on the Main PCB)
Controls the set-point of the SPDT relay labeled RELAY-1
on the Main PCB. Enter a liquid velocity at which a relay-
contact action is desired. Relay contacts are utilized for
signaling flow rate conditions that are higher of lower than
a desired set point. If a relay setting is made very close to
a nominal liquid velocity, relay “chatter” ( rapid opening
and closing of the relay ) may result.
n If a UNITS code for U.S. measurements was made the
HIGH ALARM value will be entered in FPS. Valid
ranges for this entry are 0.00 to 30.00 FPS.
n If a UNITS code for metric measurements was made
the HIGH ALARM value will be entered in MPS. Valid
ranges for this entry are 0.00 to 10.00 MPS.
LOW ALARM (Labeled RELAY-2 on the Main PCB)
Controls the set-point of the SPDT relay labeled RELAY-2
on the Main PCB. Enter a liquid velocity at which a relay-
contact action is desired. Relay contacts are utilized for
signaling flow rate conditions that are higher of lower than
a desired set point. If a relay setting is made very close to
a nominal liquid velocity, relay “chatter” ( rapid opening
and closing of the relay ) may result.
n If a UNITS code for U.S. measurements was made the
HIGH ALARM value will be entered in FPS. Valid
ranges for this entry are 0.00 to 30.00 FPS.
n If a UNITS code for metric measurements was made
the HIGH ALARM value will be entered in MPS. Valid
ranges for this entry are 0.00 to 10.00 MPS.
TOTAL MULT
Utilized for setting the flow totalizer exponent and
changing the External Counter output. This feature is
useful for accommodating a very large accumulated flow.
The exponent is a “ X 10n
” multiplier, were “n” can be from
0 (100, X 1 multiplier) to 4 (104, X 10,000 multiplier).
3-12
PART 3 - KEYPAD CONFIGURATION
The External Counter output, available at the two
terminals labeled CTR on the Main PCB, is influenced by
the TOTAL MULT value. Since the output is designed to
operate electromechanical accumulators, large flow rates
will require that the TOTAL MULT be set to a value usable
by these types of counters (typically speeds no faster than
3 cps). The following chart tabulates suggested settings
vs. flow ranges:
Exponent
Multiplier
Useable CTR
Range:
GPM or LPM
X1
30-600
0
1
2
3
4
X10
300-6,000
X100
X1,000
X10,000
3,000-60,000
30,000-600,000
300,000-6,000,000
TOTAL ON/OFF
This key has three functions:
Key press number
First press
Operation
Stops the internal totalizer/
external CTR and displays
the last value
Second press
Resets the internal totalizer
to zero
(continued)
3-13
PART 3 - KEYPAD CONFIGURATION
(continued)
Third press
Restarts the internal
totalizer/external CTR
(The internal totalizer starts
from zero.)
If inhibiting (pausing) the totalizer is necessary, there are
two methods suggested:
1. Connect and external totalizer to the CTR terminals.
See the section of this manual related to CTR
electrical connections for connection parameters.
2. To inhibit the internal totalizer without resetting the
accumulation, press the TEST key to pause the
accumulation. Press the ENTER key to resume
accumulation.
LOCK ON
To ensure security of the configuration and accumulated
flow, the keypad can be locked. To enable the keyboard
lock out, press LOCK ON key, the display will show
LOCK ON. Press ENTER to return to Run mode. To
turn the lock off, press the LOCK ON key. Use the arrow
keys to set a value of 125. Press the ENTER key. The
display will show LOCK OFF to acknowledge that all
keypad entries can now be made.
CAL
A few factors can influence the readings of a FD6000
flow meter. The CAL entry allows the user to compensate
for flow discrepancies without affecting the factory
calibration. Examples of situations that can cause
reading discrepancies are:
n Operations on liquids with sonic velocity carrying
properties that are different from water. See the table
3-14
PART 3 - KEYPAD CONFIGURATION
of correction factors located in the Appendix of this
manual for Liquid Sound Speed and their associated
correction factors.
n Transducer mounted in non-recommended locations.
By applying a CAL value other than 100%, the factory-
calibrated readings will be altered by the percentage
entered. This CAL value will be reflected in the display,
4-20mA and CTR outputs and relay settings.
For example, if a reading of 175 GPM is displayed and the
known flow rate is 160 GPM, a CAL value of
160 GPM
175 GPM
x 100 = 91.4%
The FD6000 will not allow decimal values to be entered as
a CAL constant, so round to the nearest whole number; in
this case 91%.
Acceptable input ranges for the CAL constant are 0-255%.
DAMP
In installations where very turbulent or erratic flow is
encountered, increasing the Damping setting can increase
display and output stability. The DAMP setting increases
and decreases the response time of the flow meter display
and outputs. To set the damping time constant, press the
DAMP key. Set a value between 1 and 10, 1 having the
fastest response and 10 having the slowest response.
Press ENTER to complete the configuration.
TEST
The meter contains a test function for verification of the 4-
20mA analog and CTR external counter outputs. To
activate the test function, press the TEST key. Verify that
20mA is flowing in the 4-20mA output and verify that the
CTR output is supplying 50mS pulses. Press ENTER to
exit the test function.
3-15
PART 3 - KEYPAD CONFIGURATION
2nd FUNCT - SERVICE MODE
{2nd FUNCT} SIGNAL STR
Displays the raw Doppler signal strength value. This
value will increase as the velocity of the liquid increases.
Typically, a liquid flowing at a velocity greater than 0.2
FPS [0.06 MPS], with adequate suspended solids (100
ppm or 100 micron or larger solids) or aeration, will
produce SIGNAL STR readings of at least 000125 counts.
NOTE: If the liquid is not flowing a low SIGNAL STR
reading is non-conclusive. If a high SIGNAL STR is
indicated at zero flow rate, it indicates that a source of
interference (another ultrasonic instrument, VFD, or poor
electrical ground) may be present. Verify that SIGNAL
STR increases when the flow starts. If it does, increase
the SS CUTOFF setting (see SS CUTOFF).
If SIGNAL STR is lower than 100 counts in a flowing
liquid, one or more of the following steps may need to be
invoked:
1. If the liquid velocity is less than 1 FPS (0.3 MPS) turn
SW-1 “LOW FLOW” switch ON. (This dual DIP switch
is located near the center of the Main PCB.)
2. If SW-1 did not cause an increase in SIGNAL STR to a
level above 100, turn ON SW-2.
3. There may not be adequate reflectors for the Doppler
principle to operate. The transducer can be relocated
to a source of liquid degasification, such as would be
found a 1-3 diameters down stream of a 90-degree
elbow. A surrogate source of aeration can also be
introduced by bleeding a small amount of compressed
air into the line several diameters upstream of
the transducer.
3-16
PART 3 - KEYPAD CONFIGURATION
{2nd FUNCT} 4 mA
The 4-20mA output on standard FD6000 Series flow meters
is scaled at zero flow equals 4mA and 20 FPS (6.08 MPS)
equals 20mA. The 4mA key allows fine adjustments to be
made to the “zero” of the 4-20mA output or allows offset to
be placed on the 4-20mA output. To adjust the 4mA
output, an ammeter or reliable reference connection to the
4-20mA output must be present.
Procedure:
1. Either break the present current loop and connect the
ammeter in series (disconnect either wire at the
terminal block labeled 4-20mA on the Main PCB of the
FD6000) or, if this output is not being utilized, connect
the ammeter + to the + terminal and – to the – terminal
of the 4-20mA output.
2. Press the 4mA key.
3. With no flow moving through the pipe, adjust the
setting count using the arrow keys until 4.00mA is
indicated on the ammeter. The typical count value
range for this setting is between 3350 and 3850.
4. Press ENTER to store the value.
5. Re connect the 4-20mA output circuitry as required.
{2nd
FUNCT} VEL ADC
Press VEL ADC to display the raw analog to digital
converter counts that are being processed by the
microprocessor. This count value will vary linearly with
flow rate from 0000 at zero flow rate to 1024 at maximum
full-scale flow rate. No modifications of this count can be
made, this display is for diagnostic purposes only.
{2nd
FUNCT} BLANKING
This key is unused.
3-17
PART 3 - KEYPAD CONFIGURATION
{2nd FUNCT} 20mA
The 4-20mA output on standard FD6000 flow meters is
scaled at zero flow equals 4mA and 20 FPS (6.08 MPS)
equals 20mA. The 20mA key allows fine adjustments to
be made to the “span” of the 4-20mA output. To adjust
the 20mA output, an ammeter or reliable reference
connection to the 4-20mA output must be present.
Procedure:
1. Either break the present current loop and connect the
ammeter in series (disconnect either wire at the
terminal block labeled 4-20mA on the Main PCB of the
FD6000) or, if this output is not being utilized, connect
the ammeter + to the + terminal and – to the – terminal
of the 4-20mA output.
2. Press the 20mA key.
3. With maximum flow moving through the pipe, adjust
the setting count using the arrow keys until 20.00mA is
indicated on the ammeter. The typical count value
range for this setting is between 1450 and 1950.
4. Press ENTER to store the value.
5. Re connect the 4-20mA output circuitry as required.
{2nd
FUNCT} SS CUTOFF
This entry represents the signal strength cutoff level (low
velocity cutoff). At flow rates below 0.2 FPS [0.06 MPS]
the readings displayed by the FD6000 are unreliable. By
utilizing the default SS CUTOFF of 100 counts, small
unstable readings at low flow rates will be avoided.
Note: If SS CUTOFF is set to a level higher than the
SIGNAL STR value the meter will not show flow or output
any values.
3-18
PART 3 - KEYPAD CONFIGURATION
{2nd FUNCT} INPUT F.S.
This key is used to select a maximum velocity that the
instrument will operate. Choices are 10, 20 and 30 FPS.
It is not recommended to deviate alter this value from
factory settings, as certain spans have been set that
correlate to the set maximum velocity. Consult OMEGA
Engineering for adjustment procedures.
{2nd
FUNCT} DAC 3
This key is not used.
{2nd FUNCT} BACK LIGHT
Toggles the electro-luminescent LCD back lighting ON
and OFF. This type of back lighting has an illumination
half-life of approximately one year. If the instrument is left
unattended for long periods of time, turning the back
lighting OFF can preserve the electro-luminescent panel
and save a small amount of power.
{2nd
FUNCT} CONTRAST
This setting allows the adjustment of the LCD contrast.
An LCD’s viewing quality is affected by temperature,
ambient lighting, back lighting and viewing angle. Adjust
the contrast level to provide the best contrast possible.
Default count is 50.
3-19
PART 3 - TROUBLE SHOOTING
CONDITION
POSSIBLE CAUSE
Unit does not turn “ON” when power is
applied
•
•
•
Verify that AC power source is live.
Test the fuse
Verify that proper power supply jumpers
are in place.
FAULT CONDITION is indicated on LCD
indicator
•
Fault conditions can arise from several
causes: electrical surges, short circuits,
open circuits, etc. To clear a “Fault Condi-
tion”, press 2nd Function then press Re-
set. Use the arrow keys to change the
Fault code number to “0”. Press Enter. If
the meter resumes measuring flow, no
permanent damage was incurred.
•
•
•
•
Ensure that the transducer is properly
mounted to the pipe.
Verify that transducer connections are
correct
Ensure that the pipe is full of moving
liquid.
If SIGNAL STR is less than 000100 counts
and flow rate is greater than 1 FPS [0.3
MPS], adjust GAIN control (R13 on the
Main PCB) till SIGNAL STR reaches at
least 000125 counts.
•
•
On cleaner liquids, move the transducers
closer to a 90o pipe elbow.
If GND connection and pipe are at
different potentials, ground FD6000 to
pipe potential.
•
If Variable Frequency Drives are being
utilized, verify that the FD6000 obtains a
flow indication when the pump turns OFF.
If it does, contact OMEGA Engineering.
3-20
PART 3 - TROUBLE SHOOTING
Stability of flow readings are
unsatisfactory
• Increase the DAMP constant from keypad.
• Move transducers to a location further
from piping tees, elbows, valves, filters,
Erroneous Reading
• Transducer mounted incorrectly or not
true to the pipe.
• Another local ultrasonic instrument is
operating at about the same frequency
[consult OMEGA Engineering].
• Presence of large amounts of suspended
solids or aeration. Use CAL constant to
compensate.
• Sources of radiated interference are
present. Apply appropriate shielding.
• An electrically noisy power supply is
powering the FD6000. Power the meter
with a circuit that does not power motors.
• Verify that residual leakage and flow is not
The display indicates flow, when
true fluid velocity is zero.
present. [I.e. leaking check valves]
• Verify that GAIN control (R13 on the Main
PCB) is not adjusted too high. With
nominal flow running through the pipe,
adjust GAIN control till the display zeros
with no flow.
3-21
APPENDIX
Appendix
Fluid Sound Speed Conversions
Pipe Dimension Chart: Ductile Iron
Pipe Dimension Chart: Cast Iron
Pipe Dimension Chart: Steel, SS, PVC
Velocity to Volumetric Conversion Chart
Fluid Sound Speeds
Original Date:
10/19/99
Revision:
Revision Date:
none
none
120.0176921
Doppler
Fluid
Specific Gravity
20 degrees C
Sound Speed
Calibration Entry
relative to 25C water
m/s
ft/s
Acetate, Butyl (n)
Acetate, Ethyl
Acetate, Methyl
Acetate, Propyl
Acetone
1270
1085
1211
1280
1174
1207
1270
1180
1120
1170
1222
1729
1639
1306
1338
889
4163.9
3559.7
3973.1
4196.7
3851.7
3960.0
4163.9
3868.9
3672.1
3836.1
4009.2
5672.6
5377.3
4284.8
4389.8
2916.7
3559.7
3836.1
2752.6
3038.1
4176.5
3211.9
3231.6
4295.1
5203.4
3960.0
3960.0
3231.6
3231.6
5439.6
2540
85
72
81
85
78
81
85
79
75
78
82
115
109
87
89
59
72
78
56
62
85
65
66
87
106
81
81
66
66
111
52
83
127
111
81
81
65
78
78
88
93
0.901
0.934
0.79
0.79
0.83
0.83
0.791
Alcohol
Alcohol, Butyl (n)
Alcohol, Ethyl
Alcohol, Methyl
Alcohol, Propyl (I)
Alcohol, Propyl (n)
Ammonia (35)
Anlline (41)
Benzene (29,40,41)
Benzol, Ethyl
Bromine (21)
n-Butane (2)
Butyrate, Ethyl
Carbon dioxide (26)
Carbon tetrachloride
Chloro-benezene
Chloroform (47)
Diethyl ether
Diethyl Ketone
Diethylene glycol
Ethanol
Ethyl alcohol
Ether
Ethyl ether
Ethylene glycol
Freon R12
Gasoline
Glycerin
Glycol
Isobutanol
Iso-Butane
0.78
0.77
1.02
0.88
0.867
2.93
0.60
1085
1170
839
926
1273
979
1.10
1.60
1.11
1.49
0.71
985
1310
1586
1207
1207
985
1.12
0.79
0.79
0.71
0.71
1.11
985
1658
774.2
1250
1904
1658
1212
1219.8
980
1170
1170
1324
1400
0.7
4098.4
6246.7
5439.6
3976.4
4002
3215.2
3838.6
3838.6
4343.8
4590.2
1.26
1.11
0.81
Isopentane (36)
Isopropanol (46)
Isopropyl alcohol (46)
Kerosene
0.62
0.79
0.79
0.81
Linalool
Linseed Oil
.925-.939
0.79
1770
1076
1076
1070
1210
1487
1172
1477
1250
1530
1431
1458
1420
1020
1290
1222
828.3
774.1
875.24
891
5803.3
3530.2
3530.2
3510.5
3967.2
4875.4
3845.1
4845.8
4101
118
72
72
71
81
99
78
99
83
102
96
97
95
68
86
82
55
52
58
59
60
52
44
44
38
66
89
93
70
66
84
100
94
99
102
103
104
103
101
99
96
93
89
93
102
72
90
89
89
Methanol (40,41)
Methyl alcohol (40,44)
Methylene chloride (3)
Methylethyl Ketone
Motor Oil (SAE 20/30)
Octane (23)
0.79
1.33
.88-.935
0.70
Oil, Castor
0.97
Oil, Diesel
0.80
Oil (Lubricating X200)
Oil (Olive)
Oil (Peanut)
Paraffin Oil
Pentane
5019.9
4694.9
4783.5
4655.7
3346.5
4229.5
4009.2
2717.5
2539.7
2871.5
2923.2
2932.7
2571.2
2182.7
2153.5
1883.2
3248
0.91
0.94
0.626
0.876
0.78
1.49
1.52
1.75
1.43
1.49
1.56
1.46
Petroleum
1-Propanol (46)
Refrigerant 11 (3,4)
Refrigerant 12 (3)
Refrigerant 14 (14)
Refrigerant 21 (3)
Refrigerant 22 (3)
Refrigerant 113 (3)
Refrigerant 114 (3)
Refrigerant 115 (3)
Refrigerant C318 (3)
Silicone (30 cp)
Toluene (16,52)
Transformer Oil
Trichlorethylene
1,1,1-Trichloro-ethane
Turpentine
893.9
783.7
665.3
656.4
574
1.62
0.99
0.87
990
1328
1390
1050
985
4357
4557.4
3442.6
3231.6
4117.5
4914.7
4596.7
4859.0
5013.1
5085.2
5095.1
5059.0
4980.3
4868.9
4721.3
4557.4
4370.5
4593
1.33
0.88
0.996
1255
1498
1402
1482
1529
1551
1554
1543
1519
1485
1440
1390
1333
1400
1531
1076
1343
1331.5
1334
(49,50)
Water, distilled
Water 0 degrees C
Water 20 degrees C
Water 40 degrees C
Water 60 degrees C
Water 80 degrees C
Water 100 degrees C
Water 120 degrees C
Water 140 degrees C
Water 160 degrees C
Water 180 degrees C
Water 200 degrees C
Water, heavy
Water, sea
Wood Alcohol (40,41)
m-Xylene (46)
o-Xylene (29,46)
p-Xylene (46)
1
1.025
0.791
0.868
0.897
5023
3530.2
4406.2
4368.4
4376.8
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. OMEGA’s Customer Service
Department will issue an Authorized Return (AR) number immediately upon phone or written request.
Upon examination by OMEGA, if the unit is found to be defective, it will be repaired or replaced at no
charge. OMEGA’s WARRANTY does not apply to defects resulting from any action of the purchaser,
including but not limited to mishandling, improper interfacing, operation outside of design limits,
improper repair, or unauthorized modification. This WARRANTY is VOID if the unit shows evidence of
having been tampered with or shows evidence of having been damaged as a result of excessive corrosion;
or current, heat, moisture or vibration; improper specification; misapplication; misuse or other operating
conditions outside of OMEGA’s control. Components in which wear is not warranted, include but are not
limited to contact points, fuses, and triacs.
OMEGA is pleased to offer suggestions on the use of its various products. However,
OMEGA neither assumes responsibility for any omissions or errors nor assumes liability for any
damages that result from the use of its products in accordance with information provided by
OMEGA, either verbal or written. OMEGA warrants only that the parts manufactured by the
company will be as specified and free of defects. OMEGA MAKES NO OTHER WARRANTIES OR
REPRESENTATIONS OF ANY KIND WHATSOEVER, EXPRESSED OR IMPLIED, EXCEPT THAT OF
TITLE, AND ALL IMPLIED WARRANTIES INCLUDING ANY WARRANTY OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY DISCLAIMED. LIMITATION OF
LIABILITY: The remedies of purchaser set forth herein are exclusive, and the total liability of
OMEGA with respect to this order, whether based on contract, warranty, negligence,
indemnification, strict liability or otherwise, shall not exceed the purchase price of the
component upon which liability is based. In no event shall OMEGA be liable for
consequential, incidental or special damages.
CONDITIONS: Equipment sold by OMEGA is not intended to be used, nor shall it be used: (1) as a “Basic
Component” under 10 CFR 21 (NRC), used in or with any nuclear installation or activity; or (2) in medical
applications or used on humans. Should any Product(s) be used in or with any nuclear installation or
activity, medical application, used on humans, or misused in any way, OMEGA assumes no responsibility
as set forth in our basic WARRANTY/DISCLAIMER language, and, additionally, purchaser will indemnify
OMEGA and hold OMEGA harmless from any liability or damage whatsoever arising out of the use of the
Product(s) in such a manner.
RETURN REQUESTS/INQUIRIES
Direct all warranty and repair requests/inquiries to the OMEGA Customer Service Department. BEFORE
RETURNING ANY PRODUCT(S) TO OMEGA, PURCHASER MUST OBTAIN AN AUTHORIZED RETURN
(AR) NUMBER FROM OMEGA’S CUSTOMER SERVICE DEPARTMENT (IN ORDER TO AVOID
PROCESSING DELAYS). The assigned AR number should then be marked on the outside of the return
package and on any correspondence.
The purchaser is responsible for shipping charges, freight, insurance and proper packaging to prevent
breakage in transit.
FOR WARRANTY RETURNS, please have the
following information available BEFORE
contacting OMEGA:
FOR NON-WARRANTY REPAIRS, consult OMEGA
for current repair charges. Have the following
information available BEFORE contacting OMEGA:
1. Purchase Order number under which the product
was PURCHASED,
1. Purchase Order number to cover the COST
of the repair,
2. Model and serial number of the product under
warranty, and
3. Repair instructions and/or specific problems
relative to the product.
2. Model and serial number of the product, and
3. Repair instructions and/or specific problems
relative to the product.
OMEGA’s policy is to make running changes, not model changes, whenever an improvement is possible. This affords
our customers the latest in technology and engineering.
OMEGA is a registered trademark of OMEGA ENGINEERING, INC.
© Copyright 2005 OMEGA ENGINEERING, INC. All rights reserved. This document may not be copied, photocopied,
reproduced, translated, or reduced to any electronic medium or machine-readable form, in whole or in part, without the
prior written consent of OMEGA ENGINEERING, INC.
Where Do I Find Everything I Need for
Process Measurement and Control?
OMEGA…Of Course!
Shop online at omega.com
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