Product Summary

The Flow Controller FC500-FC is an airflow test measurement and flowrate control solution which:

• combines the flow measurement, flow control, and logging functionality of the FC500 with a multiple sonic nozzle array
• can measure flowrates and control flowrates through the included sonic nozzle arrays
• operates as a stand-alone devices or connects to a PC for remote logging and monitoring

Key Features

• High mass flow accuracy (ranges from ±0.54% to ±0.17%)
• 2 analog and 2 configurable digital outputs
• Self-contained package including instrumentation

How does this flow controller work?

The embedded software in the FC500 takes the measurements received from its on-board instrumentation and performs the necessary calculations to compute a flow rate. In mass flow controller mode it is also capable of controlling flow rate to a setpoint sent via analog signal or digital control. The software also contains all of the calibration and configuration information needed to perform its required test. The controller software on a customer-provided PC is used to setup a given test and input the calibration coefficients for a given set of hardware. This data can then be transferred to the FC500 hardware. The software can also be used as a data monitor to view current conditions and flow rate.

In addition, this configuration requires that the customer provide both compressed air and 24vdc power to actuate the solenoid valves, which are supplied by Flow Systems.
This unique functionality allows the FC500-FC to act as a stand-alone Flow Controller. Users configure the setpoint (flow) range and the response characteristics and then the FC500-FC will adjust the flow to match the setpoint value. Optionally, Automated Pressure Regulation is available to increase resolution and minimize the effect of upstream pressure fluctuations.

Flow Computer & Flow Controller Comparison

For information on related flow computers and flow controllers, refer to the Flow Computer and Flow Controller Product Comparison.

System Specifications

The Flow Controller FC500-FC is available with the configuration options listed below.

Model Code	Meter Type Supported
FC500-CFV	Sonic Nozzle
FC500-VEN	Venturi
FC500-MSNM	Multiple Sonic Nozzle Manifold

Additional Specifications

Specification	Value(s)
Analog Outputs	Two independent analog output (4 to 20ma dc) channels which may be configured for remote monitoring of flow rate or other variables such as pressure or temperature by another device or data logger
Digital Outputs	Two independent digital outputs (24vdc, <400 ma each) may be configured to indicate specific conditions that can be sensed by another device
Analog Inputs	16-bit data acquisition system
Number of Sonic Nozzles	Up to 15 Sonic Nozzles, offering a 32768:1 range in throat area
Data Storage	3MB internal; 11MB additional available
Dimensions	5.25″ H x 17″ W x 13″ D

Accuracy

The FC500-FC uses a 16-bit data acquisition system to measure all analog inputs. The following tables state, percent of reading, mass flow accuracy for both available meter types and corresponding instrumentation configurations:

Configuration	Mass Flow Accuracy	Comments
Level 1	±6.45% of Reading	Assumes: diameter 0.031″ uncalibrated nozzle, 6:1 pressure range (±0.1% full scale) & 40° to 100°F gas temperature.
Level 1	±0.88% of Reading	Assumes: diameter 0.500″ uncalibrated nozzle, 6:1 pressure range (±0.1% full scale) & 40° to 100°F gas temperature.
Level 2	±0.56% of Reading	Assumes: ±0.5% CEESI calibration, 6:1 pressure range (±0.04% full scale) & 40° to 100°F gas temperature.
Level 3	±0.29% of Reading	Assumes: ±0.25% CEESI calibration, 6:1 pressure range (±0.02% full scale) & 40° to 100°F gas temperature.
Level 4	±0.14% of Reading	Assumes: ±0.1% CEESI calibration, 6:1 pressure range (±0.01% full scale) & 40° to 100°F gas temperature.
Optional Humidity sensor for moist air applications.

Uncertainty Analysis

For information on uncertainty analysis for this equipment refer to Uncertainty Analysis in Gas Flow Measurement When Using Sonic Nozzles.

Estimated Performance of FC500-FC 2×2(3-8)

Assumptions:

Gas Temperature = 70 F
Barometric Pressure = 14.696 psia

Maximum Back Pressure: (Maximum Back Pressure is due to the Choking Pressure Ratio of the smallest Sonic Nozzle in the Array)

50 psia
35.304 psig

Values For Air
Sonic Nozzle	Throat Diameter	Inlet Pressure	Inlet Temperature	Mass Flow					Actual Volume Flow
#	inches	psia	degree F	lbm / sec	SCFM*	SLPM**	kg / hr	g / sec	ACFM	ALPM
8	0.088	100	70	0.01	11.25	296.41	23.00	6.39	3.31	93.80
7	0.063	100	70	0.01	5.64	148.11	11.49	3.19	1.66	46.87
6	0.044	100	70	0.00	2.81	73.92	5.74	1.59	0.83	29.39
5	0.031	100	70	0.00	1.40	36.89	2.86	0.80	0.41	11.67
4	0.022	100	70	0.00	0.70	18.41	1.43	0.40	0.21	5.82
3	0.016	100	70	0.00	0.35	9.18	0.71	0.20	0.10	2.90
Maximum	0.124	100	70	0.03	22.22	583.87	45.30	12.58	6.52	184.76
Minimum	0.016	100	70	0.00	0.35	9.18	0.71	0.20	0.10	2.90

Minimum flow dependant on back pressure
Turndown = 63.61 : 1
* Standard Condition: 14.696 psia and 70 F
** Standard Condition: 14.696 psia and 32 F

Estimated Performance for Other Gases Multiply the flow rate values above by the following constants
Gas	Mass Flow	Volume Flow
Argon	1.246	0.90
CO2	1.201	0.79
Helium	0.395	2.86
Hydrogen	0.264	3.79
Methane	0.725	1.31
Natural Gas	0.774	1.29
Nitrogen	0.983	1.02
Oxygen	1.051	0.95

Estimated Performance of FC500-FC 4×4(8-13)

Assumptions:

Gas Temperature = 70 F
Barometric Pressure = 14.696 psia

Maximum Back Pressure: (Maximum Back Pressure is due to the Choking Pressure Ratio of the smallest Sonic Nozzle in the Array)

85 psia
70 psig

Values For Air
Sonic Nozzle	Throat Diameter	Inlet Pressure	Inlet Temperature	Mass Flow					Actual Volume Flow
#	inches	psia	degree F	lbm / sec	SCFM*	SLPM**	kg / hr	g / sec	ACFM	ALPM
13	0.500	100	70	0.45	361.56	9501.61	737.16	204.77	62.41	1767.18
12	0.354	100	70	0.23	180.73	4749.51	368.48	102.36	31.20	883.35
11	0.250	100	70	0.11	90.33	2373.98	184.18	51.16	441.53	29.39
10	0.177	100	70	0.06	45.15	1186.53	92.05	25.57	7.79	220.68
9	0.125	100	70	0.03	22.56	592.99	46.01	12.78	3.89	110.29
8	0.088	100	70	0.01	11.28	296.41	23.00	6.39	1.95	55.11
Maximum	0.702	100	70	0.89	711.97	18710.50	1451.61	403.22	122.89	3479.92
Minimum	0.088	100	70	0.01	11.28	296.41	23.00	6.39	1.95	55.11

Minimum flow dependant on back pressure
Turndown = 63.14 : 1
* Standard Condition: 14.696 psia and 70 F
** Standard Condition: 14.696 psia and 32 F

Estimated Performance for Other Gases Multiply the flow rate values above by the following constants
Gas	Mass Flow	Volume Flow
Argon	1.246	0.90
CO2	1.201	0.79
Helium	0.395	2.86
Hydrogen	0.264	3.79
Methane	0.725	1.31
Natural Gas	0.774	1.29
Nitrogen	0.983	1.02
Oxygen	1.051	0.95

Software

The Flow Controller FC500-FC combines the Flow Computer FC500 with a multiple sonic nozzle array. Thus, the software features described below are identical to that of the Flow Computer FC500.

The FC500-FC can operate as a stand-alone flow device for flow measurement and control; it does not need to be connected to a computer to operate. However, the controller software which is installed on a customer-supplied computer is required for initial configuration and remote data logging.

Controller software is written using National Instruments LabVIEW™.

Configure Software for Testing & Meter Calibrations

• Configure a test by specifying: meter type, fluid state, fluid type, number of meters, units, time base, standard pressure and temperature, and measurement stability criteria
• Configure a meter calibration by specifying a variety of input parameters in order to calculate discharge coefficient (Cd) as a function of throat Reynolds Number

Monitor & Log Measured Flowrates

• Configure output logging parameters for the digital and analog channels
• Data can be either logged to the FC500’s internal memory or to the connected PC
• Data may be logged automatically or at a user-defined interval
• Data can be plotted (all parameters simultaneously) in real-time
• When connected, the CFV pattern can also be controlled in real-time
• Iterative solution for Discharge Coefficient (Cd) based on actual calibration data or theoretical models
• Two independent analog output (4 to 20ma dc) channels which may be configured for remote monitoring of flow or other variables such as pressure or temperature by another device or data logger
• Two independent digital outputs (24vdc, <400 ma each) may be configured to indicate specific conditions that can be sensed by another device

Customize Controller Software and Integrate Data

• Controller software can be customized to fit a wide variety of customer needs
• Data can be integrated with customer’s local databases and/or information systems

Configure Instrument Calibration Settings

• Enter calibration coefficients for each instrument connected to the FC500-FC (i.e. pressure transducers, RTD’s, and dew point transmitters)
• Coefficients can be generated then saved to file, which can then be associated with instruments

Flowrate Calculations Meet ASME Standards

• Calculations for sonic nozzles are in accordance with ASME MFC-7M / ISO 9300
• Computations for subsonic Venturis meet the requirements of ASME MFC-3M / ISO 5167

Additional Software Screenshots

Facility Requirements

The facility requirements below are to be supplied by the customer at the installation site.

Electrical Power:		100 – 240 VAC/ 50 – 60Hz / 1 Phase / 6 AMPS
Analog Outputs:		(2) 4 – 20 ma dc
Digital Outputs:		(2) 24 vdc (400 ma each, max.)
Multiple Sonic Nozzle Array:		0.25 A per Solenoid Valve (Sonic Nozzle). 1.5 A per 6 Nozzle Plenum.

Compressed Air Requirements

Flow:		5 SCFM
Inlet Air Connection:		3/8″ OD Nylon Tubing, Push-In type compression fitting
Pressure Range:		70 – 100 psig
Temperature Range:		60° – 90° F
Particulates:		Less than 10 microns
Moisture Content:		39°F Dewpoint, Maximum
Oil Content:		Less than 10 ppm

Flow Rate: Equal to the lesser of the maximum capacity of the flow bench or the requirement of the largest part for a 100% duty cycle. An air receiver will allow for maximum flow at less than 100% duty cycle.

Photos & Schematics

Additional Software Screenshots

The following are pictures and schematics of the Flow Controller FC500-FC. Keep in mind that the FC500-FC combines an FC500 with a multiple sonic nozzle array, so the pictures below all reference the Flow Computer FC500

Options

The following is a list of options available for the FC500-FC:

• 11Mb internal data storage
• System check standard
• Humidity sensor (atmospheric air)
• Dewpoint sensor (compressed air)