Omega Products FLR-1600A Installation Manual

FLR-1600A and FLV-4600A Series

Water Flow Meters and Controllers

08/08/2007 Rev.3 DOC-OMEGALIQMAN

Notes for Using FLR-1600A and FLV-4600A Water Flow Devices

USE ONLY PURE, CLEAN DI OR DISTILLED WATER IN THIS DEVICE. ►

DO NOT ► use tap water, water with any biological components, minerals or oils.

Any of these substances will a ect the viscosity of the water (creating  ow

measurement inaccuracies). More importantly, any impurities will quickly

build up inside the small laminar ﬂ ow channels and damage the sensors.

If you cannot meet the requirement of pure water, then do not use the laminar water  ow device in your application. Damage caused by impurity build up is not covered by the warranty.

Please read the operating manual that accompanied your device. Keep the manual ► for future reference.

When  rst using the laminar water meter or controller for the day, please take the ► following precautions:

Apply your source pressure (approx. 20-30 PSIG for best results) to the device 1. with the downstream  ow blocked o .

Then slightly open both bleed ports (DO NOT completely remove the screws) 2. and allow any trapped air to escape. Allow some  ow and let water pass through while bleeding (if the unit is a controller be sure to give it at least a 50% setpoint). See page 8 of the manual for more information regarding bleed ports and bleeding.

Try not to get any water in-between the black electronics case and the stainless 3. steel  ow body. Wipe up any excess water around these seams.

Tighten up both bleed screws, and then block the downstream water  ow again. 4. Visually verify zero  ow through.

Now you can safely tare (zero) a meter (5. page 13) using the tare button on the device, or in the case of a water  ow controller, command the zero set-point (page 18) which will auto-tare the unit.

Smooth and consistent source pressure is highly preferable, as any pulsing or ►  uctuation in water pressure will hydraulically couple to the di erential pressure sensor, and the resultant  ow reading will jump analogously.

Please note that, depending on model and  ow range, water  ow meters have an ► inherent internal pressure drop higher than that of standard gas  ow meters. The minimum water device pressure drop is 2 PSID, going all the way to 20 PSID drop in certain models. Your source input pressure must meet or exceed this speci cation, in addition to any back pressure you may have on the downstream end of your process. Please see page 29 of the manual.

Please contact Omega if you have any questions.

Table of Contents Page

Flow Measurement Operating Principle 5 Flow Control Operating Principle 6 Installation 7 Plumbing 7 Mounting 7 Application 7 Bleed Ports 8 Power and Signal Connections 9 Analog Input Signal 10 RS232 Digital Input Signal 10 Optional RS485 Input Signal 10 RS232 Digital Output Signal 10 Optional RS485 Output Signal 10 Standard Voltage (0-5 Vdc) Output Signal 11 Optional 0-10 Vdc Output Signal 11 Optional Current (4-20 mA) Output Signal 11 Optional 2nd Analog Output Signal 11 FLR-1600A Series Water Flow Meter Operation 13 Main Mode 13 Tare 13 Line Pressure 14 Line Temperature 14 Volume 14 Flashing Error Message 14 Select Menu Mode 14 Communication Select Mode 15 Unit ID 15 Baud 15 Data Rate 15 Manufacturer Data 16 Miscellaneous Mode 16 LCD Contrast 17 Display Zero Deadband 17 Pressure Averaging 17 Flow Averaging 17 FLV-4600A Series Water Flow Meter Operation 18 Main Mode 18 Line Pressure 18 Line Temperature 18 Set Pt. 18 Flashing Error Message 18 Select Menu Mode 19 Control Setup Mode 19 Input 19 Loop 20 Select 20

Table of Contents Page

Communication Select 21 Manufacturer Data 21 Miscellaneous Mode 21 RS232 / RS485 Output and Input 21 Conﬁ guring HyperT erminal® 21 Changing from Streaming to Polling Mode 21 Tareing via RS232 / RS485 22 Sending a Set-Point via RS232 / RS485 22 Adjusting P & D Terms via RS232 / RS485 23 Collecting Data 24 Data Format 24

Sending a Simple Script File to HyperTerminal® 25 Troubleshooting 26 Maintenance and Recalibration 27 Flow Conversion Table 28 Technical Speciﬁ cations 29 Dimensional Drawings 30

Additional Information

Option: Totalizing Mode 33 Option: FLR-1600A -B Portable Meters 34 Accessory: FMA1600-MDB Multi-Drop Box 35 Accessories 35

Eight Pin Mini-DIN Pin-Out 36 DB15 Pin-Outs 37 Calibration Certiﬁ cate Pocket 39 Warranty / Returns 41

Table of Figures

Figure 1. Bleed Ports 8 Figure 2. 8 Pin Mini-DIN Connector 9 Figure 3. Simple Method for Providing Set-Point to Controllers 10 Figure 4. Mini-DIN to DB-9 Connection for RS232 Signals 11 Figure 5. Typical Multiple Device (Addressable) Wiring Conﬁ guration 12 Figure 6. Main Mode Display, FLR-1600A Series Flow Meter 13 Figure 7. Proper Set Up for Remote Tare on Meters 14 Figure 8. Select Menu Display 14 Figure 9. Communication Select 15 Figure 10. Manufacturer Data 16 Figure 11. Miscellaneous Mode Display 17 Figure 12. Main Mode Display, FLV-4600A Series Flow Meter 18 Figure 13. FLV-4600A Series Control Setup Display 19

Thank you for purchasing an FLR-1600A Series Water Flow Meter or FLV-4600A Series Water Flow Controller. Please take the time to ﬁ nd and read the information contained in this manual. This will help to ensure that you get the best possible service from your instrument. This manual covers the following Omega instruments:

FLR-1600A Series Water Flow Meters FLV - 4600A Series Water Flow Controllers FLR-1600A-B Series Portable Water Meters (Note: All FLR-1600A-B Series Portable Water Meters operate in accordance with the instructions

found in this manual. Please see page 34 for information regarding battery replacement.)

Flow Measurement Operating Principle

All FLR-1600A or FL V -4600A Series W ater Flow Meters/Controllers accurately determine the ﬂ ow rate by creating a pressure drop across a unique internal restriction, known as a Laminar Flow Element (LFE), and measuring differential pressure across it. The restriction is designed so that the water molecules are forced to move in parallel paths along the entire length of the passage; hence laminar (streamline) ﬂ ow is established for the entire range of operation of the device. Unlike other ﬂ ow measuring devices, in laminar ﬂ ow meters the relationship between pressure drop and ﬂ ow is linear. The underlying principle of operation of the ﬂ ow meters is known as the Poiseuille Equation:

Q = (P1-P2)πr4/8ηL (Equation 1)

Where: Q = Volumetric Flow Rate

= Static pressure at the inlet

P2= Static pressure at the outlet r = Radius of the restriction

= (eta) absolute viscosity of the ﬂ uid

L = Length of the restriction

Since p, r and L are constant; Equation 1 can be rewritten as:

Q = K (ΔP/η) (Equation 2)

Where K is a constant factor determined by the geometry of the restriction. Equation 2 shows the linear relationship between volumetric ﬂ ow rate (Q) differential pressure (DP) and absolute viscosity (h) in a simpler form.

In order to have an accurate reading of the ﬂ ow rate, the absolute viscosity of the ﬂ uid must be established. The rate at which liquids change viscosity with changes in temperature is not linear. The relationship between temperature and viscosity for water is well established and Omega FLR-1600A and FLV -4600A Series units utilize a high accuracy temperature sensor and this relationship to provide an accurate viscosity reference. For this reason, these meters and controllers are generally recommended only for use with pure water. Any additives to water (such as antifreeze or disinfectants) that might affect the viscosity should be avoided. As shown in Equation 2, an error in viscosity between the actual ﬂ uid and water will result in a 1:1 error percentage in the ﬂ ow rate reported by the meter. For instance if the actual ﬂ uid passing through the meter is 5% different than that of pure water at a given temperature, the reported ﬂ ow rate will be 5% inaccurate.

Flow Control Operating Principle

For the purposes of this explanation, the term “valve” will refer to the proportional control valve mounted on the controller. The term “controller” will refer to the ﬂ ow meter and the measurement and control electronics portion of the device. In actuality, the whole device is generally referred to as a controller. The valve normally mounted downstream of the controller.

FLV-4600A Series Flow Controllers ship with a normally closed proportional control valve. No ﬂ ow will occur until the valve receives a voltage signal from the controller, and the controller will not send a voltage signal to the valve until the user provides a set-point to the controller. The user can provide a set-point either locally via the display and user interface buttons, or more commonly, by providing an external signal that corresponds to the ﬂ ow range of the controller. This external signal can be an analog voltage or current signal such as a 0-5 Vdc or 4-20 mA signal, or a digital RS232 / RS485 signal via serial communication with a computer.

The controller utilizes what is called PID (Proportional, Integral, Derivative) loop control circuitry and software. The PID loop control works by repeatedly comparing the measured ﬂ ow rate to the set- point and incrementally adjusting the voltage signal to the valve in a continuous attempt to match the measured ﬂ ow rate to the set-point. For example, at any given time the controller looks at the measured ﬂ ow rate and the set-point, if the set-point is higher than the measured ﬂ ow rate, the controller will slightly increase the voltage signal to the valve and thus open it little more. If the set-point is lower than the measured ﬂ ow rate, the controller will slightly decrease the voltage signal to the valve and thus close it off a little more. This look, compare, and adjust “loop” occurs on the order of 1000 times each second.

FLV-4600A Series Flow Controllers ship with a general PID tuning that is usually sufﬁ cient for most applications. Occasionally an application will require the customer to change this tuning. The Proportional and Derivative terms can be ﬁ eld adjusted in all FLV-4600A Series controllers. In very general terms, the P term can be thought of as how fast the controller responds to change and the D term can be

thought of as a damping factor.

Installation

Plumbing

All FLR-1600A Series Meters and FLV-4600A Series Controllers are equipped with female inlet and outlet port connections. Because the ﬂ ow meters set up a laminar ﬂ ow condition within the ﬂ ow body, no straight runs of pipe are required upstream or downstream of the meter. The inlet and outlet ports are equal in size and symmetric (in-line). The port sizes (process connections) and mechanical dimensions for different ﬂ ow ranges are shown on page 30.

Meters with M5 (10-32) ports have o-ring face seals and require no further sealant or tape. On other meters/controllers, avoid the use of pipe dopes or sealants on the ports as these compounds can cause permanent damage to the meter should they get into the ﬂ ow stream. Use of thread sealing PFA tape is recommended to prevent leakage around the threads. When applying the tape, avoid wrapping the ﬁ rst thread or two to minimize the possibility of getting a piece of shredded tape into the ﬂ ow stream. When changing ﬁ ttings, always clean any tape or debris from the port threads.

It is also recommended that a 20 micron ﬁ lter be installed upstream of meters/controllers with full scale ranges of 100CCM or less and a 50 micron ﬁ lter be installed upstream of meters/controllers with full scale ranges above 100CCM.

Note: Avoiding long runs of small diameter tubing upstream or downstream of controllers will reduce water hammer.

Mounting

All FLR-1600A Series Meters and FLV-4600A Series Controllers have mounting holes for convenient mounting to ﬂ at panels. These meters are position insensitive and can be mounted in any orientation. The sizes and dimensions for the mounting holes are shown on pages 31-33.

Note: For applications that may continuously introduce occasional air bubbles to the ﬂ ow stream upstream of the device, the device may be mounted upside down to prevent the bubbles from becoming trapped in the differential pressure sensor ports. If the device has been installed upside down, avoid using the bleed screws as water may leak into the electronics housing causing permanent damage that is not covered under warranty!

Application

Maximum operating line pressure is 100 PSIG (689 kPa). Caution: Exceeding the maximum speciﬁ ed line pressure may cause permanent damage to the solid-state differential pressure transducer.

If the line pressure is higher than the 100 PSIG (689 kPa), a pressure regulator should be used upstream from the ﬂ ow meter to reduce the pressure to 100 PSIG (689 kPa) or less if possible. Although the meter’s operation is uni-directional, reversing the ﬂ ow direction will inﬂ ict no damage as long as the maximum speciﬁ ed limits are not exceeded. The differential pressure sensor utilized in this ﬂ ow meter/ controller is a very sensitive device capable of detecting minute differences in pressure.

Avoid installations (such as snap acting solenoid valves upstream) that apply instantaneous high pressure to the meter as permanent damage to the differential pressure sensor could result. This damage is not covered under warranty!

Bleed Ports

FLR-1600A and FLV-4600A Series ﬂ ow meters and controllers are equipped with bleed ports on the front to aid in the removal of air bubbles from the differential pressure sensor ports. The bleed ports consist of a threaded hole with an 8-32 nylon tipped screw as shown in Figure 1. After installation or anytime it is suspected that air may be trapped in the sensor ports, bleed the ports as follows:

CAUTION: A small amount of water will leak from the device during this procedure. Take necessary precautions to prevent the leaking water from damaging anything around the unit, taking special care to avoid any live electrical devices or lines.

With the meter/controller installed and line pressure applied, gently loosen the upstream bleed port screw 1-2 turns or until water begins to leak from the threads. DO NOT REMOVE THE SCREW as the port is subject to line pressures and injury, equipment damage, or loss of required parts may result!

Gently tap the ﬂ ow body (a wooden or plastic screwdriver handle works well for this) to encourage air bubbles to exit the port.

Any air in the port will generally be removed as the water leaks out even though you may not see or hear it.

Gently tighten the screw until the leakage stops, taking care not to crush the nylon tip. Repeat steps 1-4 with the second bleed port.

8-32 Nylon Tipped Bleed Screw 5/64 Hex Loosen to Bleed DO NOT REMOVE!

Figure 1. Bleed Ports

Power and Signal Connections

7 8

1 2

3 4 5

AC/DC Adap ter Jack

Power can be supplied to your meter or controller through either the AC/DC adapter jack or through the 8 pin Mini-DIN connector as shown in Figure 2.

A 2.1mm, positive center, 7-30 Vdc AC/DC adapter rated for at least 100 mA is required to use the adapter jack in a FLR-1600A Series meter.

A 2.1mm, positive center, 12-30 Vdc AC/DC adapter rated for at least 250 mA is required to use the adapter jack in a Small Valve FLV -4600A Series controller. Note: 4-20mA output requires at least 15 Vdc.

A 2.1mm, positive center, 24-30 Vdc AC/DC adapter rated for at least 500 mA is required to use the adapter jack in a Large Valve FLV-4600A Series controller.

Cables can be purchased from Omega (see Accessories on page 40) or they are available from electronics suppliers. Alternatively, power can be supplied through the Mini-DIN connector as shown below:

Pin Function

1 2 3 RS232 Input Signal Red 4 5 RS232 Output Signal Yellow

6 7 Power In (as descibed above) Blue 8 Ground (common for power, communications and signals) Purple

Note: The above pin-out is applicable to all the ﬂ ow meters and controllers available with the Mini- DIN connector. The availability of different output signals depends on the ﬂ ow meter options ordered. Underlined Items in the above table are optional conﬁ gurations that are noted on the unit’s calibration sheet.

Inactive or 4-20mA Primary Output Signal Black Static 5.12 Vdc or Secondary Analog Output (4-20mA, 5Vdc, 10Vdc) or

Basic Alarm

Analog Input Signal = Remote Tare (Meters - see Figure 8) = Set-Point In (Controllers - see Figure 3)

0-5 Vdc (or 0-10 Vdc) Output Signal Green

4 5

Mini-DIN

cable color

Brown

Orange

Figure 2. 8 Pin Mini-DIN Connector

CAUTION:Do not connect power to pins 1 through 6 as permanent damage can occur!

Note: Upon initial review of the pin out diagram in Figure 2, it is common to mistake Pin 2 (labeled

5.12 Vdc Output) as the standard 0-5 Vdc analog output signal! In fact Pin 2 is normally a constant

5.12 Vdc that reﬂ ects the system bus voltage and can be used as a source for the input signal. This allows the user in the ﬁ eld to run this output through a 50K ohm potentiometer and back into the analog set-point pin to create a 0-5 Vdc set-point source (see Figure 3).

Analog Input Signal

Apply analog input to Pin 4 as shown in Figure 2. Unless ordered otherwise, 0-5 Vdc is the standard analog input signal. Apply the 0-5 Vdc input signal

to pin 4, with common ground on pin 8. The 5.12 Vdc output on pin 2 can be wired through a 50K ohm potentiometer and back to the analog input on pin 4 to create an adjustable 0-5 Vdc input signal source as in Figure 3 below.

0-5 Vd c

5.12 Vdc

50 KOhm

P o te n ti o meter

Figure 3. Simple Method for Providing Set-Point to Controllers

Optional 0-10 Vdc: If speciﬁ ed at time of order, a 0-10 Vdc input signal can be applied to pin 4, with common ground on pin 8.

Optional 4-20 mA: If speciﬁ ed at time of order, a 4-20 mA input signal can be applied to pin 4, with common ground on pin 8.

RS232 Digital Input Signal

If you will be using the RS232 output signal, it is necessary to connect the RS232 Output Signal (Pin 5), the RS232 Input Signal (Pin 3), and Ground (Pin 8) to your computer serial port as shown in Figure 4. Adapter cables are available from Omega (see Accessories page 40) or they can be constructed in the ﬁ eld with parts from a local electronic supply house. In Figure 4, note that the diagrams represent the “port” side of the connections, i.e. the connector on top of the meter and the physical DB-9 serial port on the back of the computer. The cable ends will be mirror images of the diagram shown in Figure 4. (See page 22 for details on accessing RS232 output and input.)

Optional RS485 Digital Input Signal

If you will be using the RS485 output signal, it is necessary to connect the RS485 Input Signal with the appropriate DB15 pin out as shown on pages 43 and 44. (See page 22 for details on accessing RS485 output.)

RS232 Digital Output Signal

If you will be using the RS232 output signal, it is necessary to connect the RS232 Output Signal (Pin 5), the RS232 Input Signal (Pin 3), and Ground (Pin 8) to your computer serial port as shown in Figure 4. Adapter cables are available from the manufacturer or they can be constructed in the ﬁ eld with parts from an electronics supply house. In Figure 4, note that the diagrams represent the “port” side of the connections, i.e. the connector on top of the meter and the physical DB-9 serial port on the back of the computer. The cable ends will be mirror images of the diagram shown in Figure 4. (See page 22 for details on accessing RS232 output.)

Optional RS485 Digital Output Signal

If you will be using the RS485 output signal, it is necessary to connect the RS485 Output Signal with the appropriate DB15 pin out as shown on pages 43 and 44. (See page 22 for details on accessing RS485 output.)

Standard Voltage (0-5 Vdc) Output Signal

DB-9 Serial Port

5----------Ground--------------------------------------Ground----------8 3----------Transmit------------------------------------Receive---------3 2----------Receive-------------------------------------Transmit--------5

8 Pin Min i-DIN Port

1 2 3 4 5

6 7

8 9

All FLR-1600A and FLV -4600A Series ﬂ ow meters/controllers have a 0-5 Vdc (optional 0-10 Vdc) output signal available on Pin 6. This is generally available in addition to other optionally ordered outputs. This voltage is usually in the range of 0.010 Vdc for zero ﬂ ow and 5.0 Vdc for full-scale ﬂ ow. The output voltage is linear over the entire range. Ground for this signal is common on Pin 8.

Optional 0-10 Vdc Output Signal

If your meter/controller was ordered with a 0-10 Vdc output signal, it will be available on Pin 6. (See the Calibration Data Sheet that shipped with your device to determine which output signals were ordered.) This voltage is usually in the range of 0.010 Vdc for zero ﬂ ow and 10.0 Vdc for full-scale ﬂ ow. The output voltage is linear over the entire range. Ground for this signal is common on Pin 8.

Optional Current (4-20 mA) Output Signal

If your meter/controller was ordered with a 4-20 mA current output signal, it will be available on Pin 1. (See the Calibration Data Sheet that shipped with your device to determine which output signals were ordered.) The current signal is 4 mA at 0 ﬂ ow and 20 mA at the meter’s full scale ﬂ ow . The output current is linear over the entire range. Ground for this signal is common on Pin 8. (Current output units require 15-30Vdc power.)

Note: This is a current sourcing device. Do not attempt to connect it to “loop powered “ systems.

Optional 2nd Analog Output Signal

You may specify an optional 2nd analog output on Pin 2 at time of order. (See the Calibration Data Sheet that shipped with your device to determine which output signals were ordered.) This output may be a 0-5 Vdc, 0-10 Vdc, or 4-20 mA analog signal that can represent any measured parameter.

Note: This is a current sourcing device. Do not attempt to connect it to “loop powered “ systems.

Figure 4. Mini-DIN to DB-9 Connection for RS232 Signals

Purple (Ground)

Red

Yellow

Unit A

Purple

Red

Yellow

Unit B

Purple

Red

Yellow

Unit C

Female Serial Cable Front

Figure 5. Typical Multiple Device (Addressable) Wiring Conﬁ guration

Note: The easiest way to connect multiple devices is with a FMA1600-MDB Multi-Drop Box (page 35).

(Note: FMA1600-MDB Multi-Drop Box is not compatible with RS485.)

DB15 Pin-out Diagrams:

Pin-out diagrams for devices ordered with a DB15 connector can be found on pages 37 and 38 .

All devices ordered with RS485 communications require a DB15 connector.

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