Omega Products FLR 1000-BR Installation Manual
FLR 1000 & 1000-BR Series
Flow Sensors & Meters For Gases
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 ...............................4
B. Installation .....................................................................................5
1. General Considerations ...............................................................6
2. Mounting the Flow Sensor or Flow Meter .......................................6
3. Tubing Connections ....................................................................7
4. Electrical Connections .................................................................8
a) Overview .............................................................................8
b) Connecting a Cable Assembly...................................................9
c) Electrical Connections - Voltage Output Units ...........................10
d) Using a 0-5VDC Output Power Adapter Package ......................11
C. Operation ....................................................................................12
1. Start-Up ...................................................................................12
2. Flow Readings ..........................................................................12
a) 0-5VDC Analog Outputs ........................................................12
b) Units with an Integral Display ..................................................12
3. Operating at Flow Rates Outside the Calibrated Flow Range .........13
a) Flows Above the Maximum Rated Flow.....................................13
b) Flows Below the Maximum Rated Flow .....................................13
4. Zero Adjustments ......................................................................14
5. Recalibration ............................................................................14
6. Using Flow Sensors or Flow Meters with Different Gases................14
D. Maintenance And Product Care ......................................................16
1. General ...................................................................................16
2. Cleaning and Flushing...............................................................16
3. Returning Units For Repair Or Recalibration .................................16
E. Specifications ...............................................................................17
F. Connector Pin and Wire Color Cross Reference ...............................18
G. Dimensions ..................................................................................19
H. Trouble Shooting Guide.................................................................26
pg. 3 of 29
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.
Typical Contents of Box:
Sensor, Calibration Certificate & Instruction Manual
(Model FLR 1000 shown, other models similar).
Caution: Take care not to
FLR 3100/3100BR/3100ST
drop
your sensor or subject it to
Series
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
28 for more details).
2. Product Overview and Principl e of Operati on
The FLR 1000 series of flow meters and sensors for gases from Omega
Engineering are capable of measuring volumetric flows as low as 20-100
ml/min or as high as 100-500 l/min. Highly repeatable results are
achieved using a patented Pelton Turbine Wheel flow sensor design. This
pg. 4 of 29
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.
As flow passes through the sensor, a precision machined nozzle directs the
gas onto the very small teeth of the micro-turbine wheel. This causes the
wheel to spin at a speed proportional to the volumetric 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 volumetric 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 AIR as the reference
media. Flowing gases with different physical characteristics may effect the
calibration.
B.
Installation
Caution: D o not exceed the pressure, temperature or
power operating ranges detailed in the SPECIFICATIONS
section of thi s manu al . Omeg a En gine ering shall not be
liable for any damage or injury caused by incorrect
operation of their products.
pg. 5 of 29
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 gas to be
used. If there are any incompatibilities eg. highly corrosive gas, 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 gas 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.
2. Mounting the Flow Sensor or Flow Meter.
Caution: On high flow units (2.0-10.0 L/min, and above)
DO NOT disassemble the shunt / mounting plate
assembly or the uni t wil l not o perat e co rrectly and the
warranty will be void.
The Omega Engineering FLR 1000 Series units have no particular
installation requirements so may be mounted in any convenient position.
For optimum results the unit should be mounted with the mounting feet
horizontal on top of a flat horizontal surface. This is the same position that
the unit is calibrated in at the factory. Please contact the Omega
Engineering Service Department if calibration for mounting in another
orientation is desired.
It is recommended that units be fixed to a suitable substrate with #4
screws using the two mounting holes provided.
Mounting The Sensor
(mounting hardware not included with sensor)
pg. 6 of 29
3. Tubing Connections
CAUTION: DO NOT FLOW ANY LIQUID THROUGH A GAS
FLOW SENSOR OR FLOW MET ER. THIS WI LL SERI OUS LY
EFFECT T HE PERFO RM ANCE AND VOID THE WARRANTY.
CAUTION: DO NOT FLOW A HIGH PRESSURE GAS
THROUGH THE SENSOR. A BURST OF HIGH PRESSURE
GAS MAY CAUSE THE UNIT TO BE DAMAGED. ALWAYS
FLOW GAS AT A PRE S SU R E A N D FLOW RATE WITHI N
THE SPECIFCATIONS OF THE UNI T
All tubing must be clean, dry and without crimps, burrs or scratches.
Only use the factory installed fittings 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 Company 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 flow
sensor or flow mete r bo dy. Ex ce ssi ve for c e may dama g e
the sensor body. This type of damage will NOT be
repaired under warranty.
The flow direction for the unit is clearly marked on the label. Do not
reverse the flow direction or the unit will not function correctly.
pg. 7 of 29
Close Up of Label Showing Flow Direction
(FLR 1000 shown, other models similar)
The tubing ID should be as large as possible to avoid restrictions and
turbulence. For the best results, a straight length of tubing before the unit
is recommended. This should be 20 times the tubing I.D. or greater
4. Electrical C onnections
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
Omega Engineering flow sensors for gases provide a 0-5VDC output
proportional to the volumetric flow rate. This output may be connected to
a display, data acquisition system or voltmeter. The FLR 1000-D and 1000BR-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 of a suitable gauge should be used if the
length of the power wires is to be longer than 1 meter (3.2 feet).
pg. 8 of 29
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. A connector pin and wire color cross
reference may also be found in Appendix F (Page 18) of this manual.
b) Connecting a Cable Assembl y
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 to the cable assembly are made as detailed in the
following sections.
pg. 9 of 29
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