Omega Products FLR 1000 Installation Manual

FLR 1000/1000BR/1000ST Series

Flow Sensors & Meters For Liquids

READ THIS MANUAL COMPLETELY BEFORE ATTEMPTING TO CONNECT OR
OPERATE YOUR FLOW SENSOR. FAILURE TO DO SO MAY RESULT IN INJURY
TO YOU OR DAMAGE TO THE FLOW SENSOR.

TABLE OF CONTENTS

A. Introduction ...........................................................................................4

1. Unpacking.........................................................................................4

2. Product Overview And Principle Of Operation ........................................5

B. Installation.............................................................................................6

1. General Considerations.......................................................................6

2. Mounting The Flow Sensor or Flow Meter ...........................................7

3. Tubing Connections ............................................................................8

4. Electrical Connections.........................................................................9

a) Overview .......................................................................................9

b) Connecting A Cable Assembly ........................................................10

c) Electrical Connections – Voltage Output Units...................................11

d) Electrical Connections – Units With Both Voltage & Pulse Outputs........12

e) Electrical Connections – Current Output Units (“I” Suffix) ....................13

f) Using a 0-5VDC Output Power Adapter Package ...............................14

C. Operation ...........................................................................................15

1. Start-Up ..........................................................................................15

2. Entrapped Air or Gas ........................................................................15

3. Flow Readings..................................................................................15

a) 0-5VDC Analog Outputs................................................................16

b) Pulse Outputs ...............................................................................16

c) 4-20mA Outputs...........................................................................16

d) Units with an Integral Display..........................................................17

4. Operating at Flow Rates Outside the Calibrated Flow Range ..................17

a) Flows Above the Maximum Rated Flow.............................................18

b) Flows Below the Maximum Rated Flow .............................................18

5. Zero Adjustments..............................................................................18

6. Recalibration....................................................................................18

7. Calibrating Units for different Liquids...................................................20

D. Maintenance And Product Care..............................................................21

1. General...........................................................................................21

2. Cleaning and Flushing ......................................................................21

3. Returning Units For Repair Or Recalibration..........................................21

E. Specifications.......................................................................................22

F. Dimensions..........................................................................................24

G. Connector Pin And Wire Color Cross Reference........................................29

H. Trouble Shooting Guide ........................................................................30

A. Introduction

1. Unpacking

All units are suitably packaged to prevent damage during shipping. If
external damage is noted upon receipt of the package, please contact

Omega Engineering immediately.

Open the package from the top, taking care not to cut too deeply into the
package. Remove all the documentation and contents. Take care to
remove all the items and check them against the packing slip. The
products should also be checked for any concealed shipping damage. If
any shortages or damage is noted, please contact the shipping company
and/or Omega Engineering to resolve the problem.

Sensor, Calibration Certificate & Instruction Manual

(Model FLR 1000 shown, other models similar).

Typical Contents of Box:

FLR 3100/3100BR/3100ST

Series

drop

Caution: Take care not to

your sensor or subject it to

sudden impact. Read the installation section of this manual
before providing power or tubing connections to the unit. Any
damage caused by improper installation or careless handling will

not be repaired under warranty (see limited warranty on page
32 for more details).

pg. 4 of 33

2. Product Overview and Principle of Operation

The FLR 1000 series of flow meters and sensors for liquids from Omega
Engineering are capable of measuring flows as low as 13-100 ml/min or as
high as 1.0-10.0 l/min. Highly repeatable results are achieved using a
patented Pelton Turbine Wheel flow sensor design. This proven design
minimizes zero drift while maintaining fast response and linear outputs
with virtually no maintenance.
Flow is measured using a miniature turbine wheel similar in size to a U.S.
dime (16 mm diameter, 0.75 mm thick). The micro-turbine wheel is

supported on a very small sapphire shaft that is held in position by two
sapphire bearings. The micro-turbine assembly is so light that it virtually
floats in the liquid. This relieves force on the bearings and almost
eliminates wear.

As flow passes through the sensor, a precision machined nozzle directs the
fluid onto the very small teeth of the micro-turbine wheel. This causes the
wheel to spin at a speed proportional to the flow rate.

The micro-turbine wheel has alternating white and black sections evenly
spaced on one side of the wheel. An infrared light beam is directed onto
the wheel. As the wheel rotates the infrared beam is reflected off each
white section. The reflected beam is detected by a phototransistor that
converts the reflections into electrical pulses. As the wheel spins faster the
pulse rate increases. Processing circuitry provides analog and/or pulse
output that are linearly proportional to the flow rate

When the wheel stops (under zero flow conditions), no pulses are
generated. Consequently, zero drift is not possible and zero adjustments
are never required.

Every unit is supplied with a calibration certificate detailing the results
obtained during calibration. Units are calibrated using deionized water as
the reference media. Flowing liquids with different specific gravities or
viscosities may effect the calibration.

pg. 5 of 33

B. Installation

1. General Considerations

It is recommended that a safety shut-off valve be installed upstream of
(before) the sensor.

All wetted parts should be checked for compatibility with the liquid to be
used. If there are any incompatibilities e.g. highly corrosive liquid, then the
unit may be damaged or fail prematurely. Such damage will not be
repaired under warranty.

Units should be installed in a clean, dry environment with an ambient
temperature that is as stable as possible. Avoid areas with strong magnetic
fields, strong air flows or excessive vibration.

If the liquid to be used may contain particles larger than 25 microns then a
filter (25 microns or less) should be installed upstream of (before) the unit.

The required differential press (or pressure drop across the unit)
decreases exponentially with decreases in flow rate.

CAUTI ON: Do not flow any gas throu g h a liquid flow
sensor. This may damage t he micro-turbine assembly
and void the warranty. Do not exceed the pressure,
temperature or power operating ran g es detailed in the
SPECIFICATIONS section of this manual. Omega
Engineering sh all not b e l iable fo r a n y da mage or i njury

caused by incorrect operation of their products.

Pressure Drop vs. Percentage of the Full Scale

Rated Flow (may vary ±10% of indicated psid)

12

0.8

10

8

6

Delta P psid

4

2

0

10 20 30 40 50 60 70 80 90 100

% of rated flow

100-1000 ml/min Units
All Other Ranges

0.7

0.6

0.5

0.4

0.3

0.2

0.1

0

Delta P Bar

pg. 6 of 33

To calculate the pressure drop at a certain flow rate use the formula

PD = (YourFlow / MaxFlow)

2

x PD

max

PD = Pressure drop at YourFlow.
YourFLow = flow rate (ml/min or l/min)
MaxFlow = 100% rated flow for the sensor (in same units as YourFlow)
PD

= Pressure drop at 100% rated flow (see chart above)

max

If the pressure available for the flow sensor is BELOW the pressure drop at
the required flow then flow through the unit will not be possible.

For example: You have a sensor with a 50-500ml/min flow range and want
to know the pressure drop (or minimum differential pressure required) at
300ml/min. According to the chart above, the pressure drop at 100% of
flow is approx 10psi. Using the formula above:

PD = (300 / 500)

Therefore, at 300ml/min the minimum required differential pressure for
this unit is 3.6 psid. This means that if the available pressure is below

3.6psid then flow through the unit may not be possible.

Pressure drop through a system is cumulative. If the total pressure drop
across all the components in a system exceeds the minimum pressure
available then flow will not be possible.

For example: A system has a pressure of 30-40psi. There are several
components and the sum of their pressure drops at the required flow rate
is 32psid. If the system is operating at 30psi flow would not be possible as
the total of the pressure drops would be greater than the pressure
available. The system will only operate if the system pressure is above
32psi.

If there is any possibility that there may be bubbles or entrapped gas in
the system then the outlet tubing should be elevated above the inlet port.
This will enable any gas that may become entrapped in the unit to escape
(see section C2 for details of how to remove entrapped air or gas).

2. Mounting the Flow Sensor or Flow Meter.

The Omega Engineering FLR 1000 Series units have no particular
installation requirements so may be mounted in any convenient position.

It is recommended that units be fixed to a suitable substrate with #4
screws using the two mounting holes provided.

2

x 10 = 3.6 psid

pg. 7 of 33

Mounting The Sensor

(mounting hardware not included with sensor)

3. Tubing Connections

CAUTION: DO NOT FLOW ANY GAS THROUGH A LIQUID
FLOW SENSOR OR FLOW METER. THIS WILL DAMAGE
THE MICRO-TURBINE ASSEMBLY AND VOID THE
WARRANTY.

All tubing must be clean and without crimps, burrs or scratches.

Only use the fittings factory installed on the unit. If the fittings are
removed the calibration of the unit may be effected and leaking may
occur. If different fittings are required please contact the Omega
Engineering Service Department for assistance.
When connecting the sensor to the tubing a wrench should be used to
stop the fitting rotating in the sensor body. Take care not to over tighten
the fittings or leaking may occur.

Connecting and tightening the Fittings

(FLR 1000-ST-D shown, other models similar)

Caution: DO NOT over tighten the fittings into the
sensor body. Excessi ve force may damage the sensor
body and will NOT be repaired under warranty.

pg. 8 of 33

The flow direction for the sensor is clearly marked on the label. Do not
reverse the flow direction or the unit will not function.

Close Up of Label Showing Flow Direction

(FLR 1000 shown, other models similar)

For the best results precautions should be taken to minimize the amount
of turbulence in the flow stream. Avoid valves, fittings, curves in the tube,
changes in the internal diameter or any other restrictions close to the inlet
of the sensor. The tubing ID should be as large as possible and preferably
not smaller than the ID of the fittings installed on the sensor.

For 0.2-2.0 L/min units a 10 cm straight length of tube before the sensor
is recommended. For higher flow range units (0.5-5.0 L/min and 1.0-10.0
L/min), a 20 cm straight length of tubing before the sensor is
recommended. If this is not possible it is recommended that straight
lengths between all connections on the inlet side of the sensor are as long
as possible and 90 degree fittings (with a large enough ID) are used
instead of curves in the tubing.

4. Electrical Con ne ctions

Caution: Incorrect wiring may cause severe damage to the unit.
Applying an AC voltage (115VAC or 230VAC) directly to the unit
will cause damage. Read the following instructions carefully
before making any connections.

a) Overview

The FLR 1000 series of flow sensors and flow meters provide a 0-5VDC, or
4-20mA, or 0-5VDC and pulse output proportional to the flow rate. This
output may be connected to a display, data acquisition system or
voltmeter / current meter.

pg. 9 of 33

The FLR 1000-D, 1000-ST-D and 1000-BR-D series feature an integral
display that provides a local flow reading. These units also have a 0-5VDC
analog output available. If required, this may be connected to another
display, data acquisition system or voltmeter.

A stable D.C. power supply is required to operate the unit. The voltage
and current requirements depend on the configuration of the unit. Full
details may be found in the Specification section of this manual.

Connecting wires should be as short as possible to avoid voltage drops.
Twisted 2 pair conductor cable should be used if the length of the power
wires is to be longer than 1 meter.

Units are supplied with an integral 4 pin connector. Connections to the unit
are made using a mating cable assembly or power adapter package as
detailed in the following sections (parts 5.b to 5.f of this manual). A
connector pin and wire color cross reference may also be found in
Appendix G (Page 29) of this manual.

b) Connecting the Cable Assembly

The connector on the end of the cable assembly should be pushed into the
mating socket on the sensor taking care to ensure that it is the correct
way up.

Connecting the Cable Assembly

(FLR 1000 shown, other models similar)

Electrical Connections are made to the cable assembly as detailed in the
following sections.

pg. 10 of 33

c) Electrical Connections – Voltage Output Units

The cable assembly should be connected to the sensor as detailed in
section 5(b) above. Power should not be applied to the sensor until all the
connections have been made and checked. Electrical connections should
be made as follows:

Wiring Schematic For Voltage Output Units.

The RED wire should be connected to the Positive of the power source.

The BLACK wire should be connected to the Negative ( Ground ) of the

power source.

The WHITE wire provides the signal output and should be connected to

the positive terminal of the display, data acquisition system or voltmeter
with an impedance of greater than 2500Ω (Ohms).

The GREEN wire (if present) is NOT used

Caution: Avoid high voltage static discharges to any of the
connections. Do not short the input/output signal wires or allow
them to contact the power wires at any time. DAMAGE WILL
RESULT!

pg. 11 of 33

d) Electrical Connections –Units with Both Voltage and Pulse

Outputs

The cable assembly should be connected to the sensor as detailed in
section 5(b) above. Power should not be applied to the sensor until all the
connections have been made and checked. Electrical connections should
be made as follows:

Wiring Schematic For Voltage and Pulse Output.

The RED wire should be connected to the Positive of the power source.

The BLACK wire should be connected to the Negative ( Ground ) of the

power source.

The WHITE wire provides the signal output and should be connected to

the positive terminal of the display, data acquisition system or voltmeter
with an impedance of greater than 2500Ω (Ohms).

The GREEN wire (“P” suffix only) is the pulse output and should be

connected to the Positive terminal of the data acquisition system with an
impedance of greater than 10KΩ (Ohms).

The PULSE and VOLTAGE output may be monitored simultaneously.

Caution: Avoid high voltage static discharges to any of the
connections. Do not short the input/output signal wires or allow
them to contact the power wires at any time. DAMAGE WILL
RESULT!

pg. 12 of 33

e) Electrical Connections – Current Output Units (“I” Suffix)

The FLR 1000–ST-I provides a 4-20mA active current output proportional
to the flow rate.

The cable assembly should be connected to the sensor as detailed in
section 5(b) above. Power should not be applied to the sensor until all the
connections have been made and checked. Electrical connections should
be made as follows:

Wiring Schematic For Current Ouput Units (“I” suffix only).

The RED wire should be connected to the Positive of the power source.

The BLACK wire should be connected to the Negative ( Ground ) of the

power source.

The WHITE wire provides the signal output (active current) and should be

connected to the positive terminal of the display, data acquisition system
or current meter with an impedance of 0 - 500Ω (Ohms).

The GREEN wire is NOT used.

Caution: Avoid high voltage static discharges to any of the
connections. Do not short the input/output signal wires or allow
them to contact the power wires at any time. DAMAGE WILL
RESULT!

pg. 13 of 33

f) Using a 0-5VDC Output Power Adapter Package.

An optional 0-5VDC Output Power Adapter Package is available for use
with the FLR 1000 series (not the FLR 1000-ST-I). This consists of a power
source (115VAC or 230VAC) and cable assembly with pig-tail (soldered
wire) ends for the signal output. This should be assembled as shown in
the following diagram.

Connecting the Power Adapter to the Flow Sensor

(FLR 1000 shown, other models similar)

Electrical connections to the cable assembly should be made as follows:

YELLOW WIRE: This provides the 0-5VDC signal output and should be

connected to the positive terminal of the display, data acquisition system
or voltmeter with an impedance of greater than 2500Ω (Ohms).

GREEN WIRE: For Pulse output units (“P” suffix only) the green wire

provides the pulse output and should be connected to the positive terminal
of the data acquisition system with an impedance of greater than 10KΩ
(Ohms).

WHITE WIRE: This is the signal negative and should be connected to the

negative (ground) terminal of the voltmeter, display or data acquisition
system.

Caution: Avoid high voltage static discharges to any of the
connections. Do not short the output signal wires or allow them
to contact the power wires at any time. DAMAGE WILL RESULT!

pg. 14 of 33

C. Operation

CAUTION: USE WITH LIQUIDS ONLY. FLOWING GAS OR
AIR THROUGH YOUR LIQUID F LOW SEN S OR WIL L
DAMAGE THE MICRO-TURBINE ASSEMBLY. THIS TYPE OF
DAMAGE WILL NOT BE REPAIRED UNDER WARRAN TY.

1. Start Up

Before applying power to the unit check all tubing and electrical
connections. Once correct installation is verified switch on the power.

2. Entrapped Air or Gas

There may be a lot of air or gas trapped in your sensor after installation.
This will usually escape the unit when flow (within the range of the unit) is
first started.

Caution: The system should be primed with liquid and flow
started gradually. This will prevent trapped air or gas from being
forced through the sensor at a high velocity that may damage
the sensor.

If gas remains entrapped in the unit it may be necessary to elevate the
outlet tubing above the inlet of the unit. This should enable the trapped
gas to escape the unit. The unit may be returned to it’s original position
once all the gas has escaped.

If elevating the outlet tubing does not work, block or pinch the outlet tube
whilst there is flow in the system. After approximately 5 seconds, release
the restriction to allow normal flow. Doing this will build up pressure in the
flow path that when released will help remove the entrapped gas. Repeat
this until the entrapped gas is removed form the unit.

3. Flow Readin gs

The FLR 1000 Series provide a 0-5VDC, or 4-20mA (I suffix), or 0-5VDC
and pulse output (P suffix) proportional to the flow rate. The type of
output signal is detailed by the part number reference and on the
calibration certificate.

The FLR 1000-D, FLR 1000-BR-D and FLR 1000-ST-D series features an
integral display that provides a local flow reading and a 0-5VDC analog
output.

Each unit is factory calibrated for a specific flow range. The flow range is
shown on the unit’s label and calibration certificate. Units are calibrated
using deionized water as the reference media.

pg. 15 of 33

a) 0-5VDC Analog Outputs

By monitoring the voltage output signal it is possible to determine the flow
rate of the liquid. Units are configured so that an output signal of 5.0VDC
is provided when the maximum flow (i.e. Full Scale flow) is passing
through the unit. The output signal is linear and scaleable enabling
calculation of flow rates within the sensor’s range. For example:

For a flow range of 50-500ml/min:

At 500ml/min the output signal would be 5VDC

If the output signal were 3.5VDC then the flow rate would be:

(500 ÷ 5) × 3.5 = 350ml/min

If the maximum flow rate is exceeded non-linear and inaccurate readings
will result.

b) Pulse Outputs

By monitoring the Pulse output frequency it is possible to determine the
flow rate of the liquid. The pulse frequency for maximum flow through the
unit (i.e. full scale flow) is detailed on the calibration certificate. This
differs from unit to unit. This output is approximately linear and scaleable
within the sensor’s range. For example:

For a flow range of 1.0-10.0l/min:

The calibration certificate gives the following:

At 10.0l/min the pulse output signal is 312Hz
At 5.0l/min the pulse output signal is 150Hz
At 2.0l/min the pulse output signal is 58Hz

If the output signal were 120Hz then the flow rate would be:

(5.0 ÷ 150) × 120 = 4.0 l/min (using the closest calibration point)

c) 4-20mA Outputs

By monitoring the current output signal it is possible to determine the flow
rate of the liquid. Units are configured so that an output signal of 20mA is
provided when the maximum flow (i.e. Full Scale flow) is passing through
the unit. The output signal is 4mA when there is zero flow through the
unit. The output signal is linear and scaleable enabling calculation of flow
rates within the sensor’s range. For example:

pg. 16 of 33

For a flow range of 20-200ml/min:

At 200ml/min the output signal would be 20mA

If the output signal were 9mA then the flow rate would be:

200 ÷ (20-4) × 9 = 112.5ml/min

d) Units With an Integral Display

The FLR 1000-D, FLR 1000-BR-D and FLR 1000-ST-D series features an
integral 3 ½ digit LCD display. This is configured to read in ml/min for flow
ranges up to 50-500 ml/min and in l/min for flow ranges of 0.1 – 1.0
L/min. The display will only operate if power is applied to the unit.

Flow readings may be taken directly from the display or by monitoring the
0-5VDC analog output provided by using a cable assembly or power
adapter package (see above).

LCD Flow Display

(Model FLR1000-ST-D shown, other models with displays similar)

4. Operating at Flow Rates Outside the Calibrated Flow Range

CAUTION: If the flow through the unit exceeds 120% of
the maximum rated (full scale ) flow the unit may be
damaged. This type of damage will not be repaired under
warranty.

Flow measurement is only accurate within the calibrated flow range for the
unit. This is detailed on the calibration certificate. The unit will still
operate, to some degree, outside this flow range.

Results obtained when operating outside the specified range of the unit
are not accurate but may be considered repeatable.

pg. 17 of 33

a) Flows Above the Maximum Rated Flow.

If the flow rate is above the maximum rated (or full scale) flow, the unit
will still operate and provide an output signal proportional to the flow rate.

Flows must not exceed 120% of the maximum rated flow or the unit may
be damaged.

b) Flows Below the Minimum Rate d Flow.

Signal outputs may be obtained at flow rates below the minimum specified
for your unit. The amount of flow that may be measured below the
minimum specified varies from unit to unit.

5. Zero Adjustments

It is impossible for there to be any zero drift so zero adjustments are
never required.

6. Recalibration

The calibration of the unit may be easily verified using empirical methods.

It should be noted that the use of empirical methods outside a certified
calibration laboratory is subject to inaccuracy and error. These methods
should only be used to gain an indication of a sensor’s performance.
Please contact the Omega Engineering Service Department if accurate,
certified recalibration is required.

A typical empirical calibration check may be carried out as follows:

Carefully adjust the flow rate so that the maximum output signal is
obtained. With the flow rate constant, liquid flowing through the unit
should be gathered in a container over a timed interval. The total volume
flowed over the timed period should then be measured using a measuring
cylinder. The actual flow rate (in the same units as the flow sensor
calibration certificate) may then be calculated. The actual maximum flow
rate should then be compared to the specified maximum flow rate to
determine the error in calibration. For example:

For a unit with a flow range of 20-200ml/min and a 0-5VDC
output:

With a constant flow and constant 5VDC output the actual
volume measured over 30 seconds was 102ml.

Therefore the actual flow rate is:

(102 / 30) x 60 = 204ml/min

The error is therefore 204 – 200 = 4ml/min or 2%

pg. 18 of 33

A second empirical check should be made at a flow rate below the
maximum for the unit eg at 50% of full scale. The calculated percentage
error at this flow should then be compared to the error at maximum flow.
If there is a big difference in the percentage errors then the flow signal is
no longer linear and the unit may be damaged (consult the Omega
Engineering Service Department).

Once it has been determined that the linearity is still acceptable and the
error in flow reading at maximum flow has been calculated, there are 3
options:

i.) Minor adjustments to actual calibration of the unit may be made by
turning the gain potentiometer on the side of the unit. For example:

For a unit with a flow range of 13-100ml/min and a 0-5VDC
output:

With a constant flow and constant 5VDC output the actual volume
measured
over 60 seconds was 103ml.

The correct voltage output for a flow of 103 ml/min is:

(5/100) x 103 = 5.15 V

With the flow at a constant 103 ml/min the gain potentiometer
should be carefully adjusted so that a voltage output reading of

5.15 V is obtained.

If the unit cannot be suitably adjusted please contact the Omega
Engineering Service Department. Pulse outputs are not adjustable.

Adjusting the Gain Potentiometer Using a Flat Head Screwdriver

(FLR 1000 shown, other models similar)

pg. 19 of 33

ii.) Adjust the scaling endpoints in the display or data acquisition system.
For example:

For a unit with a flow range of 50-500ml/min and a 0-5VDC output:

With a constant flow and constant 5VDC output the actual volume
measured
over 60 seconds was 405ml.

Therefore the actual flow rate is:

(405 / 60) x 60 = 405ml/min

The display or data acquisition system may now to configured as
follows:

0 VDC = Zero flow
5VDC = 405ml/min

iii.) Apply the error factor to each flow reading taken. For example:

For a unit with a flow range of 0.2-2.0l/min connected to a display:

With a constant flow rate of 2.0 l/min on the display, the actual
volume
measured over 20 seconds was 0.7l

Therefore the actual flow rate is:

(0.7 / 20) x 60 = 2.1 l/min

The error is therefore 2.1 – 2.0 = 0.1 l/min or 5%

If the display shows an uncorrected flow rate of 1.4 l/min then :

Corrected flow rate = Uncorrected flow rate + error = 1.4 + 5% =

1.47 l/min

7. Calibrating Units for Different Liquids

The FLR 1000 Series will operate with most translucent liquids subject to
compatibility of the wetted parts. Best results are obtained with low
viscosity (less than 10 centistokes) liquids. For information regarding
higher viscosity liquids, contact the Omega Engineering Service

Department.

Units are calibrated with deionized water as the reference media. Using
other liquids will effect the calibration. The amount of calibration error will
depend on the characteristics of the liquid being flowed.

pg. 20 of 33

The error in flow reading (or calibration) should be calculated and utilized
as detailed in section 6 above.

D. Maintenance and Product Care

1. General

CAUTION: Do not disassemble your unit for any reason.
If the unit appear s t o be mal f unct i oni n g please contact
the Omega Engineering Se rvic e Depa rtment.

The FLR 1000 Series of flow meters and sensors require no periodic
maintenance if used within the recommended specifications.

The next recommended recalibration date is stated on the calibration
certificate supplied with the unit. Please contact the Omega Engineering
Service Department for further information.

Inlet filters should be periodically checked and cleaned / replaced as
necessary.

Regularly check all electrical and process connections for damage or
deterioration.

If the sensor is to be stored, keep both the inlet and outlet ports sealed.

Do not store a unit with any chemical other than water (or air) inside it
over an extended period of time. Prolonged exposure to chemicals other
than water may lead to precipitation or corrosion.

2. Cleaning and Flushing

If there is a build up of deposits or residues from the measured chemicals
it may be necessary to clean
flowing clean, particle free water through the unit at a flow rate, pressure
and temperature within the specifications of the unit. If necessary, flow
may be reversed to assist flushing.

Under no circumstances should gas or air be flowed through the unit. This
will cause severe damage.

3. Returning Units for Repair or Recalibration

To return a unit for repair or recalibration please contact the Omega
Engineering Customer Service Department. An Authorized Return (AR)
number will then be issued. The AR number should then be noted on the
outside of the package and on any correspondence. Further details may be
found on page 32 of this manual.

or flush

the unit. This should be done by

pg. 21 of 33

E. Specifications For Liquid Units

FLR 1000 FLR 1000-BR FLR 1000-ST FLR 1000-ST-I

Analog Signal Accuracy
(including linearity)

Repeatability ±0.2% Full Scale1

Pressure Rating 100 psig

Temperature Rating Operating Range: 5 to 55ºC

Temperature Sensitivity ±0.2% F.S. 1 or less per ºC

Wetted Materials Ryton®

316 Stainless

O-Ring Material Standard - Viton®

Fitting Material (Standard) Acetal Brass Stainless Steel

Fitting Material Optional Kynar PVDF

Stainless Steel

Recommended Filtration 25 microns or less

Compatible Liquids Low viscosity (ideally <10cS)

(6.8 bar)

Epoxy

Glass

Sapphire

Brass

2

Minimum amount of entrapped air or gas

±1.0% Full Scale1

Storage Range: 0 to 70ºC

Brass

®

Ryton

316 Stainless

Epoxy

Glass

Sapphire

EPDM Optional

Acetal

Kynar PVDF

Stainless Steel

Translucent or transparent

2

500 psig

(34.5 bar)

316 Stainless

Sapphire

Kynar PVDF

Ryton

Epoxy

Glass

Acetal

Brass

®

0-5VDC Output Signal Standard

Pulse Output Signal “P” Suffix Only

4-20mA Output Signal N/A N/A N/A Non Isolated

Typical Power
Consumption

Response Time Typically <1 second for 63% of final value

Reliability 100,000 hours MTBF

Certifications CE Approved

Ratings IP10 (NEMA 1)

Warranty 1 year limited

Minimum 2.5 KΩ load

7.5VDC peak buffered square
wave

Typically 0-400Hz

±3.0% Full Scale accuracy

Standard: 12 VDC @ 35 mA

(11.5-15 VDC)

89/336/EEC (EN 55011 & EN

50082-1)

73/23/EEC Low Voltage Directive

N/A

N/A

Current loop

should be

<500Ω

24VDC @ 65mA

None

1. Specifications from 10-100% of rated flow. Linearity is best fit straight line. All
calibrations performed with deionized water unless otherwise stated on calibration
certificate

pg. 22 of 33

FLR 1000-D FLR 1000-BR-D FLR 1000-ST-D

Display 3.5 Digit Non Backlit LCD, 0.39” (10mm) high digits

Accuracy
(including linearity)

Repeatability ±0.2% Full Scale1

Pressure Rating 100 psig

Temperature Rating Operating Range: 5 to 55ºC

Temperature Sensitivity ±0.2% F.S. 1 or less per ºC

Wetted Materials Ryton®

316 Stainless

O-Ring Material Standard - Viton®

Fitting Material (Standard) Acetal Brass Stainless Steel

Fitting Material Optional Acetal, Kynar PVDF, brass, or stainless steel

Recommended Filtration 25 microns or less

Compatible Liquids Low viscosity (ideally <10cS)

(6.8 bar)

Epoxy

Glass

Sapphire

2

Minimum amount of entrapped air or gas

±1.0% Full Scale1

Storage Range: 0 to 70ºC

Brass

Ryton®

316 Stainless

Epoxy

Glass

Sapphire

EPDM Optional

Translucent or transparent

2

500 psig

(34.5 bar)

316 Stainless*

Ryton

Epoxy

Glass

Sapphire)

®

0-5VDC Output Signal Standard

Typical Power
Consumption

Response Time Typically <1 second for 97% of final value

Reliability 100,000 hours MTBF

Certifications CE Approved

Ratings IP10 (NEMA 1)

Warranty 1 year limited

Standard: 12 VDC @ 35 mA (11.5-15 VDC)

Minimum 2.5 KΩ load

89/336/EEC (EN 55011 & EN 50082-1)

73/23/EEC Low Voltage Directive

1. Specifications from 10-100% of rated flow. Linearity is best fit straight line. All
calibrations performed with deionized water unless otherwise stated on calibration
certificate

.

pg. 23 of 33

F.

Dimensions

ALL DIMENSIONS IN INCHES (MILLIMETERS IN BRACKETS)

FLR 1000 For Liquids
1/4” A cetal Fittings Shown

pg. 24 of 33

FLR 1000-BR & FLR 1000-ST For Liquids
1/4” Compression Fittings Sho wn

pg. 25 of 33

FLR 1000-ST-I For Liquids
1/4” Fittings Shown

pg. 26 of 33

FLR 1000-D For Liquids
1/4” A cetal Fittings Shown

pg. 27 of 33

FLR 1000-BR-D & FLR 1000-ST-D For Liquids
1/4” Compression Fittings Sho wn

pg. 28 of 33

G. Connector Pin And Wire Color Cross Reference

End On View of Connector Socket and Connector

Standard Units:

Unit Outp ut Pin Cable Wire

Color

1 Black Signal & Power

2 White Voltage Output Voltage Output Current Output

3 Red Power Positive Power Positive Power Positive

4 Green Not Used Pulse Output Not Used

Voltage Voltage &

Pulse

Negative
(Ground)

Signal & Power

Negative

(Ground)

Signal & Power

Current

Negative

(Ground)

pg. 29 of 33

H. Troubleshooting Guide

Symptom Possible Cause Method of Correction

Unit Leaks Fittings not tight enough.

Sensor assembly cracked

No output signal or flow
indication

Flow indication “bounces”
or fluctuates

No power or low power

No flow passing through
unit

Output shorted or
overloaded

Improper connection

Moisture on internal
electronics

Output circuitry damaged

Liquid not translucent
enough.

Attempting to measure
flows below the specified
minimum for the unit
Flow is actually fluctuating

Not using the fittings
supplied by the
manuafacturer

Entrapped air or gas

Turbulence in tubing or
sensor

Fluctuating input power

Mechanical sensor
assembly damaged

Tighten fittings (see
section B4)

Unit must be returned for
repair (see Section D3)
Apply correct power

Display or output should
read zero if there is no
flow. Increase the flow
rate until a reading is
obtained. (Do not exceed
the specified maximum
flow!)

Check electrical
connections (see section
B5)

Check electrical
connections (see section
B5) and ensure connector
is correctly plugged in.

Allow unit to dry out in a
dry environment.

Unit must be returned for
repair (see Section D3)

Contact the Omega
Engineering Service
Department for
assistance.

Use higher flow rates.

Correct flow source to
obtain steady flow

Use the supplied fittings

Remove entrapped air
(see section C2)

Straighten the inlet tubing
or lengthen it to at least
6” (150mm)

Correct the power source
or change to a regulated
supply

Unit must be returned for
repair (see Section D3)

pg. 30 of 33

Symptom Possible Cause Method of Correction

Flow indication is not
linear and output too low
at lower flows

Flow reading accuracy is
outside the specification

Flow indication is fixed at
one value

Attempting to measure
flows below the specified
minimum for the unit

Liquid is too viscous

Entrapped air or gas

Mechanical sensor
assembly damaged

Liquid has a different
viscosity and / or specific
gravity than water at 20°C

Entrapped air or gas

Mechanical sensor
assembly damaged

The maximum rated flow
for the unit is being
exceeded.

Output circuits may be
damaged

Use higher flow rates

Best results are obtained
with liquids that have a
viscosity of 10cS or less.
Contact the Omega
Engineering Service
Department for further
information

Remove entrapped air
(see section C2)

Unit must be returned for
repair (see Section D3)

Calculate the flow reading
error / offset as explained
in section C6

Remove the entrapped air
(see section C2)

Unit must be returned for
repair (see Section D3)

Reduce the flow

Unit must be returned for
repair (see Section D3)

pg. 31 of 33

.

pg. 32 of 33

M4574/0807 pg. 33 of 33