ProAir FGP Series User manual

Manual

Hardware and Software

FGP_e // V1.0 // technical data are subject to change //350125

Thermal

Mass flow meter

for COMPRESSED AIR and GASES

Model FGP

FGP-3

flowguardPRO - flex

FGP-4

flowguardPRO - 4...20

FGP-1 and FGP-2

flowguardPRO - compact

We doesn't accept warranty and liability claims neither upon this pub-

lication nor in case of improper treatment of the described products.

The document may contain technical inaccuracies and typographical

errors. The content will be revised on a regular basis. These changes

will be implemented in later versions. The described products can be

improved and changed at any time without prior notice.

USA

FCC notice:

This equipment has been tested and found to comply with the limits for a Class B

digital device, pursuant to part 15 of the FCC Rules. These limits are designed to

provide reasonable protection against harmful interference in a residential installa-

tion. This equipment generates, uses and can radiate radio frequency energy and,

if not installed and used in accordance with the installation manual, may cause

harmful interference to radio communications. However, there is no guarantee that

interference will not occur in a particular installation. If this equipment does cause

harmful interference to radio or television reception, which can be determined by

turning the equipment off and on, the user is encouraged to try to correct the

interference by one or more of the following measures:

- Reorient or relocate the receiving antenna.

- Increase the separation between the equipment and receiver.

- Connect the equipment into an outlet on a circuit different from that to which the

receiver is connected.

- Consult the dealer or an experienced radio/TV technician for help.

Caution:

Any changes or modifications not expressly approved by the party responsible for

compliance could void the user's authority to operate this device.

CANADIAN

ICES-003 notification:

This Device B digital apparatus complies with Canadian ICES-003.

Cet appareil numérique de la classe B est conforme à la norme NMB-003 du

Canada.

1. GENERAL ............................................................................................................ 4

1.1.Symbol Clarification ................................................................................................. 4

1.2.Safety Instructions .................................................................................................. 4

1.2.1. Intended Use ................................................................................................... 4

1.2.2. Installation, start up and control .................................................................................. 5

1.3.Environmental aspects.............................................................................................. 5

2. PRODUCT DESCRIPTION....................................................................................... 6

3. INSTALLATION...................................................................................................... 7

3.1.Mounting dimensions ............................................................................................... 7

3.1.1. FGP-1, FGP-2 and FGP-3 ....................................................................................... 7

3.1.2. FGP-4 ......................................................................................................... 8

3.2.Determining installation site......................................................................................... 8

3.2.1. Process pressure ............................................................................................... 8

3.3.Installation position.................................................................................................. 9

3.4.Required length of straight pipe..................................................................................... 10

3.5.Installation FGP-1, FGP-2 and FGP-3 .............................................................................. 11

3.5.1. Mounting valve - ball valve....................................................................................... 11

3.5.2. Assembly without flowmeter, but with screw cap instead (blind cap) ................................................. 11

3.5.3. Shut off the ball valve ........................................................................................... 11

3.5.4. Installation of the flowmeter sensing probe ........................................................................ 12

3.5.5. Removal of the sensing probe of the flowmeter.................................................................... 12

3.6.Installation FGP-4 in the pipe line .................................................................................. 13

3.7.Setting the pipe diameter ........................................................................................... 15

4. ELECTRICAL CONNECTIONS ................................................................................. 16

4.1.Connection diagram................................................................................................. 16

4.1.1. Relay and pulse output, internal switching ........................................................................ 16

5. CONTROL COMPONENTS ...................................................................................... 17

5.1.Jumper J1 and J2 ................................................................................................... 17

5.2.Digital interface USB ( for configuration)............................................................................ 17

5.3.Display / Indicator with keypad (optional)........................................................................... 18

5.3.1. Indication of the analogue and pulse output ....................................................................... 18

5.3.2. Indication of the switch output.................................................................................... 18

5.3.3. Indication of the MIN / MAX values ............................................................................... 19

5.3.4. Reset of the consumption counter or the MIN / MAX value ......................................................... 19

6. ERROR MESSAGES .............................................................................................. 20

7. MAINTENANCE ..................................................................................................... 20

7.1.Cleaning of the sensor of the flowmeter ............................................................................ 20

8. REPLACEMENT PARTS / ACCESSORIES ................................................................. 20

8.1.Order Code Replacement Sensor .................................................................................. 20

8.2.Order Code Replacement sensor cable (only for FGP-3 and FGP-4) ...................................... 21

8.3.Order Code Replacement mounting valve for FGP-1, FGP-2 und FGP-3 ......................................... 21

8.4.Order Code Accessories for FGP-4................................................................................. 21

9. TECHNICAL DATA FGP-1, FGP-2 and FGP-3............................................................. 22

10.TECHNICAL DATA FGP-4....................................................................................... 24

Table of contents - HARDWARE

Table of contents - SOFTWARE

1. General ................................................................................................................ 26

2. Installation ........................................................................................................... 26

2.1.Configuration of the USB Interface (VirtualCOM)................................................................... 27

3. User Interface ....................................................................................................... 28

4. Menu toolbar ........................................................................................................ 28

4.1.File .................................................................................................................. 28

4.2.Transmitter .......................................................................................................... 29

4.3.Extras ............................................................................................................... 29

5. Input Screen......................................................................................................... 29

5.1.Output 1, Output 2 .................................................................................................. 29

5.1.1. Output mode ................................................................................................... 29

5.1.2. Measurand ..................................................................................................... 29

5.1.3. Units........................................................................................................... 29

5.1.4. Output mode – analogue ........................................................................................ 29

5.1.5. Output mode – switch (relay) .................................................................................... 30

5.1.6. Output mode – pulse ............................................................................................ 31

5.2.Display .............................................................................................................. 31

5.3.Adjustment .......................................................................................................... 32

5.3.1. 1-point adjustment .............................................................................................. 32

5.3.2. 2-point adjustment .............................................................................................. 33

5.3.3. Reset to factory settings ......................................................................................... 33

5.4.Measuring values overview ......................................................................................... 34

5.4.1. Reset of the MIN / MAX values .................................................................................. 34

5.4.2. Reset of the consumption counter (totalizer)....................................................................... 34

5.5.Setting up Process Parameters..................................................................................... 34

5.5.1. Change the Process Gas ........................................................................................ 34

5.5.2. Pressure compensation ......................................................................................... 35

5.5.3. Setting the pipe diameter ........................................................................................ 35

5.6.External pressure transmitter for pressure compensation .......................................................... 35

1. GENERAL

This manual is a part of the scope of supply and serves to ensure optimal operation and functioning of the

equipment.

For this reason, the manual must be read before start-up.

Therefore, it is necessary that this manual is read and understood by those responsible for the handling,

installation, and maintenance of the equipment.

This manual may not be used for competitive purposes or passed on to third parties

without the written consent.

It is permitted to make copies for personal use.

All information, technical data and illustrations contained in these instructions are based on

information available at the time of publication.

1.1. Symbol Clarification

This symbol indicates safety instructions.

The safety instructions have to be carried out unconditionally. If disregarded loss, injury, or damage may be

inflicted to people and property. In any case we cannot be hold responsible.

This symbol indicates attention.

The note should be observed to achieve an optimal functioning of the equipment.

1.2. Safety Instructions

1.2.1. Intended Use

The flowmeter is intended to be used for the measurement of air and other non-corrosive gasses in pipelines

only. Consult the factory first before the measurement of wet or filthy gasses.

The design of the flowmeter allows for the FGP to be installed in a pressurized system up to PN16 – is

16 bar (230 psi).

For FGP-1, FGP-2 and FGP-3:

Prior to the start of the installation, the system has to be depressurized. Before the installation or

removal of the sensing probe or the screw cap, the ball valve should be closed.

Mounting, electrical installation, putting in operation and maintenance should only be done by qualified

personnel.

The use of the flowmeter in any other way than described in this manual bears a safety risk for people and

the entire measurement installation and is therefore not allowed.

The manufacturer cannot be hold responsible for damages as a result of incorrect handling, installation, and

maintenance of the equipment.

To avoid health risks or damage to the equipment, the installation should not be operated on with tools, which

are not specifically mentioned or described in this manual.

Excessive mechanical stress and inappropriate handling must be avoided.

For FGP-1, FGP-2 and FGP-3:

A short interruption of the flow using the ball valve cannot be avoided when exchanging the sensing probe.

The flowmeter can only be utilized in accordance with the conditions defined in the technical data. Otherwise,

inaccuracies of the measurement will occur and equipment failures cannot be ruled out.

For the safety of the user and for the functionality of the equipment the recommended steps by the

manufacturer to put into operation, to test and to maintain should be taken and completed.

1.2.2. Installation, start up and control

The flowmeter is designed and built in accordance with the latest state in technology, tested adequately and

has been shipped from the factory in good order and condition.

As the user, you are responsible to comply with all applicable safety regulations amongst others:

• Instruction for the installation

• Local standards and codes

The manufacturer has taken all measures to assure safe operation. The user has to make sure that the

equipment is positioned and installed in such a way that safe operation is not impaired.

The equipment is tested in the factory and shipped in good order and condition.

This manual contains information and notes of caution, which have to be adhered to by the user to assure a

safe operation.

• Mounting, electrical installation, putting into operation and maintenance should only be done by

qualified personnel. The plant operator should authorize qualified personnel to operate on the

installation.

• It is necessary that this manual is read and understood by these professionals and that they follow

the instructions as detailed in this manual.

• Check all connections of the entire installation thoroughly, before putting the system into operation.

• Do not put a damaged product into operation and make sure that that does not happen inadvert-

ently.

• A malfunction of the equipment should only be handled and fixed by authorized and qualified

personnel

• If it is not possible to repair the malfunction, put the equipment out of operation and make sure that

it cannot be put back into operation again.

• Repairs not described in this manual may only be carried out by the manufacturer or by the

respective service organization.

Disclaimer of Liability

The manufacturer or their delegated representative is only liable in case of intend or gross negligence. The

accountability is limited to the value of the order issued at the time to the manufacturer.

The manufacturer is not liable for damages, originated from disregarding the safety instructions or violating

the instructions of the manual or operating conditions.

Consequential damages are excluded from the any liability.

1.3. Environmental aspects

The products are developed and designed in due consideration to the importance of the protection of the

environment. Therefore, disposal of the product also should not lead to pollution of the

environment.

The single-variety components must be separated before the transmitter is disposed of. The electronic

components must be collected and as electronic scrap properly be disposed of.

2. PRODUCT DESCRIPTION

The flowmeter of the series FGP, based on the measurement principle of thermal mass flow, is suited for the

measurement of flow of air and gasses in pipelines. Measurement of for instance the consumption of com-

pressed air, nitrogen, helium, CO2, oxygen or other non-corrosive and non-flammable gasses.

The FGP measures the volume flow at standard conditions according to DIN 1343 (P0 = 1023.25 mbar; t0 =

273.15 K or 0 °C (32 °F). In addition to the standard volume flow, the measurand mass flow, norm flow and

temperature are available.

The FGP has an integrated consumption counter. The consumption quantity is indicated in the display and is

not lost after a power failure. Two signal outputs are available. Depending on the application, the outputs can

be configured as analogue (current or voltage), switch output or as pulse output for the measurement of the

consumption.

Mounting valve - Ball valve

The mounting valve assembly allows for the easy and reliable instal-

lation within the pipeline. During installation in the pipeline, observe

the required inlet and outlet paths (see page 10). The nominal size of

the ball valve assembly must match the nominal size of the pipe.

The ball valve allows for the instalment and removal of the sensing

probe with only interrupting the process flow for a short moment. The

ball valve assembly is suitable for pressures up to 16 bar (PN16) and

available for pipe diameters DN15 (1/2”) to DN50 (2”).

Signal conditioning with optional display

The enclosure with the signal conditioning is mounted either on the

measurement probe (model 1 or 2 compact) or is remote with a plu-

gable sensor cable up to 10 meter (33 feet) – (model 3 with remote

probe).

Sensing probe with measurement electronics

The interchangeable sensing probe contains the sensor element and

the measurement electronics, in which the data of the factory calibra-

tion is stored. The sensing probe is easy and quickly interchangeable

intheeld,independentoftheelectronicsforthesignalconditioning.

Aftertheexchange,thecongurationoftheoutputsisunchanged.

Screw cap

The screw cap, with female thread, is screwed in place if the flowm-

eter is not installed and the pipeline has to be used.

Sensor cable (only by model 3 with remote sensing probe)

The sensor cable allows for the remote installation, up to 10 meter (33

feet), of the sensing probe from the housing with the signal condition-

ing.

FGP-1, FGP-2 and FGP-3

FGP-4

236

3. INSTALLATION

3.1. Mounting dimensions

3.1.1. FGP-1, FGP-2 and FGP-3

115 145

129

183

173

cable gland

M16x1.5

cable gland

M16x1.5

Cross-section

bore hole:

Drilling Plan:

The bottom part of the housing is mounted with

4 screws (not in the scope of supply)

Max. screw diameter: 4.5 mm (0.17 inch).

e.g. 4.2 x 38 mm DIN 7938H Screws

Ball valve Threat A B

DN15 Rp1/2" 83,7 35

DN20 Rp3/4" 72,7 35

DN25 Rp1" 88 47.5

DN32 Rp1 1/4" 100 120

DN40 Rp1 1/2" 110 120

DN50 Rp2" 131 120

Female thread:

BSP thread acc. EN 10226

(old DIN 2999)

Mounting valve - Ball valve

Dimensions in mm

Non-return protection for secure mounting

The patented non-return protection combines three functions in one device:

• Non-return protection

The sensor can only be pushed in one direction during installation. The sensor cannot return at all,

even if it is released.

• Seal

By means of an encapsulated O-ring, no compressed air can escape under pressure during assem-

bly.

• Precise positioning

The precise positioning with respect to immersion depth and orientation is easy to perform, guaran-

teeing accurate measurement results.

Mounting grip

With the mounting grip, the sensing probe is inserted and correctly positioned into the pipe line.

3.2. Determining installation site

• The installation site should be easy accessible and free of vibrations and shocks

• Observe enough clearance above the mounting position, in order to be able to install and remove

the sensing probe:

at least 120 mm (4.72) for FGP-1, FGP-2 and FGP-3

at least 450 mm (17.7”) for FGP-4 probe length 285 mm (11.22”) DN65 (2 1/2”) up to DN100 (4”)

at least 600 mm (23.6”) for FGP-4 probe length 435 mm (17.13”) DN125 (5”) up to DN300 (12”)

• The ambient temperature should not exceed the value as stated in the specifications (see page

22) – consider heating by radiation.

• The fluid should not condense at the installation site. Condensation on the tip of the sensing probe

must be avoided.

• In compressed air systems, the installation should be downstream of the dryer.

• Observe the direction of the flow by the installation (see page 11).

• Observe the required straight pipe lengths up and downstream, in order to warrant the specified

measurement accuracy.

• The flowmeter should be installed as far as possible from any flow disturbance. Valves or check-

valves should be installed in a respective distance from the flowmeter.

3.2.1. Process pressure

Because of the measuring principle the thermal mass flowmeter FGP is largely independent of the process

pressure and is factory calibrated at a pressure of 7 bar (100 psi) (FGP-1, FGP-2 and FGP-3) or 9 bar (130.5

psi) (FGP-4).

In order to achieve the highest measurement accuracy, the slight dependence on process pressure can be

compensated for in two ways:

• if the process pressure is stable, by programming the pressure value in the configuration software

(see page 35).

• in case of strong fluctuations of the process pressure (e.g. 3 to 10 bar (40 to 150 psi)) an external

pressure transmitter can be installed and connected to the pressure-compensation input

(see page 35).

R 1/2“ thread

M12x1 Connector

for probe cable

285 (11.22“) or 435 (17.13“)

variable insertion depth

max. 165 (6.5“) or 315 (12.4“)

45 (1.77“)

38 (1.5“)

20 (0.79“)

(0.59“)

(0.47“)

120 (4.72“)

180 (7.09“)

Ø 40 (1.57“)

Ø 13 (0.51“)

Ø 14 (0.55“)

Ø 40 (1.57“)

SW 36 (1.42“)

see accessories for NPT adapter

3.1.2. FGP-4

Model

Vertical Mounting Compact Remote

+ ++

Horizontal Mounting, sensor upwards

++ ++

Horizontal Mounting, sensor downwards

- -

Horizontal Mounting, sensor across

+ ++

3.3. Installation position

Make sure that the arrow on the tip of the sensing probe is pointing in the direction of the flow.

++ ... recommended installation position

+ ..... not recommended if there is vibration on the pipeline

-....... not recommended

Type

(DN = Nominal Pipe Size)

Straight inlet pipe Straight outlet pipe

Extension 15 x DN 5 x DN

Reduction 15 x DN 5 x DN

90° - elbow 20 x DN 5 x DN

Two 90° - elbows,

in one level 25 x DN 5 x DN

Two 90° - elbows,

in two levels 30 x DN 5 x DN

Valve, gate valve 50 x DN 5 x DN

3.4. Required length of straight pipe

The flowmeter should be installed as far as possible from disturbances of the flow. The causes for disturbance

of the flow are for instance, reducers, elbows, T-pieces, valves, gate valves, etc. The specified measurement

accuracy can be achieved only when the following straight inlet and outlet pipe lengths are installed:

• The stated values are as a minimum. If possible, allow for greater distances.

• Valves or gate valves should be installed downstream of the flowmeter.

• With lighter gasses the inlet straight pipe should be longer.

• Only for FGP-1, FGP-2 and FGP-3: The wall thickness of the inlet and outlet pipe should be 2,6 mm

owdirection

straight inlet pipe

nominal pipe size (DN)

straight outlet pipe

This manual suits for next models

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