Omega Products FPD1014 Installation Manual

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User’s Guide

FPD2000 Series

Positive Displacement Flow Meters

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It is the policy of OMEGA Engineering, Inc. to comply with all worldwide safety and EMC/EMI
regulations that apply. OMEGA is constantly pursuing certification of its products to the European New
Approach Directives. OMEGA will add the CE mark to every appropriate device upon certification.

The information contained in this document is believed to be correct, but OMEGA accepts no liability for any
errors it contains, and reserves the right to alter specifications without notice.
WARNING: These products are not designed for use in, and should not be used for, human applications.

FPD2000 Series - Positive Displacement Flowmeters

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Fluid Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

Flowmeter Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Trouble Shooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Installation and Technical Data Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8

FPD2001 through FPD2004
FPD2011 through FPD2014
FPD2021 through FPD2024

Installation and Technical Data Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-10

FPD2005 through FPD2015

Installation and Technical Data Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-12

FPD2001-A through FPD2005-A
FPD2011-A through FPD2015-A
FPD2021-A through FPD2024-A

Maintenance Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

FPD2001 through FPD2004
FPD2001-A through FPD2004-A
FPD2011 through FPD2014
FPD2011-A through FPD2014-A
FPD2021 through FPD2024
FPD2021-A through FPD2024-A

Maintenance Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

FPD2005
FPD2015
FPD2015-A

FPD2000 Series Positive Displacement Flow Meters

General Description:

Omega’s positive displacement gear flow meters are similar in design to a gear pump. The principle of
operation is reversed; instead of the gears driving the medium, the medium drives the gears. A non­intrusive hall-effect sensor detects the movement of the gear and as each gear tooth passes the sensor
a square wave pulse is produced and a discrete volume of liquid is measured. The resulting pulse train
is proportional to the actual flow rate and provides a highly accurate representation of the fluid flow. All
meters are designed with highly wear resistant moving parts to provide exceptionally long service life.

Filtration:

Depends upon model

Fluid Compatibility:

The materials of construction are stainless steel or high strength aluminum housing, stainless steel gears
and stainless steel bearings. The fluids should be compatible with these materials.

-1-

Installation Instructions:

The preferred flow direction is etched or marked by an arrow on the meter as this is the flow direction

in which the meter was calibrated however; the flow meters have bi-directional flow capabilities. Damage
will not occur from reverse flow.

The preferred orientation is to mount the meter vertically although horizontal mounting is acceptable
if conditions deter vertical orientation. There is no need for straight run piping upstream or downstream
of the flow meter.

Install the meter upstream from control valves and fluid regulators if possible - see Fig.1. Back
pressure is necessary for stable running.

Eliminate all dirt, debris and metal shavings from the piping as the liquid must be free from any par­ticles larger than allowed by the manufacturer's specifications. Any recommended filtration should be
installed before operation as potential plugging most often occurs at startup.

If possible install a bypass around the meter and flush existing piping with the appropriate solvent
before first use - see Fig.1.

Review the pickup instructional guide prior to installation. Locate the pickup & wiring away from
A/C motors, actuators, heaters, relays etc. Use only shielded cable and do not take power from the same
circuits as other devices. Ensure clean power supplies which utilize a true earth ground. Intrinsic Safety
Barriers must be installed if the circuit is intended to be intrinsically safe.

The pickup sensor should only be installed hand tight… do not use wrenches or channel locks.
Over tightening may cause a dimple to protrude into the meter chamber beneath the pickup and inter­fere with the free gear rotation.

Figure 1

-2-

Operation & Maintenance Instructions:

Maintenance Guides are provided with the meter - these should always be reviewed by personnel prior

to attempting any maintenance work. The overwhelming majority of down time & repairs are the result
of breakages due to improper maintenance actions, lack of training or rough handling.

Never run the meter dry or spin with air only - Gear flow meters are precision engineered flow devices

- they should always be maintained in a clean, lubricated condition with the internals wet at all times. Air
and water should not be allowed in contact with the internal parts except in short (1-2 second) cycles as
part of an automated flush.

Don't use water for flow testing - the viscosity of water is too low to produce accurate results unless
the flow rate is elevated and the internals would then have to be dried and lubricated to avoid corrosion
or scaling. Using a fluid with a viscosity of approximately 30 cSt such as mineral oil or thinned glycerin
is recommended if calibration of the system is necessary - the preferred calibration fluid would be the
actual fluid to be metered.

Don't ramp-up flow to a full flow condition instantaneously - Gear flow meters are rugged yet pre­cise instruments which will respond almost instantaneously to changes in fluid flow. Normal pulsating
flows will not damage the meter and will merely cause the output to be unsteady however, if flow is
repeatedly cycled from zero to full flow instantaneously, fluid shock forces may be significant and may
produce premature damage or wear over time. To avoid damage to the system ramp-up to max flow over
a few seconds rather than instantaneously & do not inject high flow speeds into an empty meter.

Filtration is recommended to prevent contaminants from entering the meter. Should the meter
become plugged, a reduced flow may still be observed from the outlet as fluid pressure will squeeze

fluid through the meter - visual flow does not necessarily mean that the meter's gears are turning. If plug­ging is caused by contaminants then filtering should be installed….if plugging is repeatedly caused by
particle build up then review the cleaning and maintenance procedures in the following section. Because
of the vast differences in fluid types and in-plant procedures there may be some trial and error involved
in determining the ideal flushing or cleaning regimen.

A calibration factor (K Factor) is established at the factory on a preferred calibrating fluid - this number
is usually accurate for a wide variety of fluids and should not usually be changed - it is provided with the
meter either on a Calibration Data Sheet or on a tag attached to the meter. Should it be lost, a copy can
be obtained from the factory. A calibration verification procedure is detailed later in this document.

Storage - when the flow meter is idle or stored for any extended period of time the internals should be
thoroughly cleaned with the appropriate solvent, lubricated with a light oil and the ports capped or
plugged to prevent drying.

-3-

Flow Meter Guidelines:

DO: Leave flushing solvent in the lines overnight or during extended off-times.

This keeps internals wet, preventing residual paint from drying, helping start ups.

DO: Follow the Maintenance Guide instructions when opening and cleaning a meter.

During cleaning separate the gears from the shafts. On carbide bearings, clean inside the
center of the gear bearing and on the outer surface of the shafts at the point where the gear
rotates on the shaft. Apply a suitable lubricating fluid before closing the meter. After tightening
the bolts, a short squirt of shop air will briefly spin the gears which should be easily audible.

DO: Install and maintain filters.

The recommended filter should be installed to eliminate potential plugging. Should plugging
occur, the meter will still pass fluid but with no signal output.

DO:

Check electrical compatibility between the meter's output signal and the input of the PLC.

If signals are not being detected at start up, first check wiring and electrical compatibility.

DO: Verify reliable grounding of electrical parts, as per installation guidelines, and a

dedicated power supply is recommended.

Volt age spikes on shared power lines, negligent grounding and sloppy wiring will likely produce
erratic readings and chronic maintenance
The control valve will provide back pressure which is beneficial to stable flow control.

DO: Install the meter immediately upstream of the regulator or control valve.

The control valve provides back pressure which stabilizes the flow.

DON'T: Allow air into the flow meter.

Always keep the meter internally wet.

DON'T: Dry paint lines using pressurized air.

Flow meters are designed to flow liquids. Meters should be closed to air except when air is part
of an automated purge cycle. Do not dry lines after purging.

DON'T: Allow materials to dry inside the meter.

When a meter is removed from the line during maintenance the internals should be cleaned
immediately, lubricated and the fluid ports capped.

DON'T: Over tighten the pickup sensor beyond hand tight.

When installing the pickup sensor turn it in lightly to a hand tight torque. Do not use a wrench
on the pickup as over tightening may cause a dimple of metal under the sensor nose to
protrude into the gear cavity & interfere with the gear's rotation.

DON'T: Use water or solvent for calibration or test purposes.

Water or solvent may not turn the gears at low flow and may leave the impression that the
meter is not functioning. Acalibration factor (k-factor) is issued with the flow meter which is valid
for most fluids except water or equivalent viscosities.

-4-

Calibrations

Each flow meter is calibrated and given a 'K Factor' using a standard calibrating fluid at the factory. This
number is accurate for all fluids, with most viscosities, except the most water-like. There should be no
need to change this except for the very lowest viscosities close to 1.0 cP.

If flow readings are too high:

If the display shows significantly more than the volume actually dispensed or shows flow when there is
definitely no flow - this most likely indicates an electrical noise problem. In such cases turn off nearby
motors or heaters or relays, check cable shielding and establish a clean ground independent of other
electrical devices before repeating accuracy tests. If the problem continues it may be necessary to relo­cate the offending device

If flow readings are too low:

If the display shows significantly less than the volume actually dispensed then most likely the meter has
a high slippage factor and the fluid is by-passing the gears and the k-factor may require adjustment.

If it is necessary to adjust the existing k-factor:

Trigger at least 500ml of your sample fluid, in a steady stream, at approximately the desired flow rate,
into a graduated beaker. Compare the volume in the beaker to the volume on the display. Do not time
the operation merely measure the volume dispensed. Repeat the sample 3 times and take an average.
If the result is outside an acceptable margin, adjust the K Factor by the % difference between the aver­age beaker sample and the average displayed total. If the error is not corrected clean the meter thor­oughly and repeat the procedure. Do not use water for this test.

If it is necessary to re-calculate a new k-factor:

You will first need a data collecting instrument to count pulses produced by the meter. An Omega display
may be used in totalizer mode provided the KFT is set to count each pulse (KFT = 10000). Trigger at
least 500ml of your sample fluid, in a steady stream, at approximately the desired flow rate, into a grad­uated beaker. Divide the number of pulses by the volume dispensed and the result is your new k-factor
in the units of your sample…in the example above the k-factor units would be impulses/ml.

-5-

Trouble Shooting Guide:

TROUBLE POSSIBLE CAUSE SOLUTION

Viscosity of fluid is <30cst. Decrease the K-factor by percent error.

Meter indicates Excessive pressure differential
lower than actual across meter causing gears to bind. Reduce flow rate, reduce fluid viscosity.

Debris in measuring chamber. Clean meter, change or add filter.
Upper housing has dimple from

over tightening sensor. Replace upper housing.
Air in lines. Add air eliminator.

Meter indicates Electro-magnetic interference. Ground flow meter and all electronics.
higher than actual.

Reverse fluid flow. Add check valve.

Indicator shows Fluid oscillates. Check pump, add check valve, increase
flow when there is back pressure.
no flow.

Electro-magnetic interference. Ground flow meter and all electronics.

Use shielded cable and relocate away

from electrical noise.
No fluid flow. Check pump.
Debris in measuring chamber or

gears. Clean meter, change or add filter.
Sensor not installed properly. Check sensor is installed to hand tight.

No flow indication. Review sensor guide.

Faulty wiring. Check sensor connection and readout

connection.
Faulty sensor. Replace sensor.
Upper housing has dimple from

over-tightening sensor. Replace upper housing.

Erratic system Ground loop in shielding. Ground shield one place only. Re-route
indication. cables from electrical noise.

Pulsating fluid flow. Add pulse dampener.

-6-

FPD20x1 to FPD20x4 Dual Hall Effect Pickup

Installation and Technical Data Guide

Description:

The Dual Hall Effect Pickups are microprocessor-based sensors for use with the FPD2000 series of pos­itive displacement flow meters. The DH sensors can detect both uni- and bi-directional flow. The sen­sors’ mode of operation is determined by an output selection switch located inside the housing. The DH
detects the rotation of the flow meter’s gears and emits a frequency signal proportional to flow. The out­put signal is a square wave pulse which has a duty cycle of approximately 50%.

DH signal outputs are protected with a self-resetting fuse. This fuse has a 50mAnominal trip point. When
a trip occurs, turn off power to the sensor and remove output load to reset fuse. The sensor has two dif­ferent output configurations: sinking output and sourcing output.

The DH sensor circuit board is equipped with a red and green LED. The red LED is a status LED which,
when the sensor is operating properly, will flash once every 6 seconds, a fast flash will indicate a failure
of one or both of the pick-ups. The green LED indicates the pulse of the input signal. Note that signals
above 20Hz will look as solid green.

Installation:

• Ensure that the flowmeter sensor cavity is free of debris prior to installing pickup

• Make sure the sensor mounting screws line up with the sensor mounting holes. If they do not,
remove and rotate the sensor 180°

• Sensor is equipped with an output test feature for readouts before initial running of your system

TEST FEATURE:

Note: Power must be cycled for new setting to take effect

• Switch setting 8 will cause the pick-up to output a 10 Hz (+/- 20%) Phase = +90 deg pulse output,
simulating low flow conditions without flow through your meter.

• Switch setting 9 will cause the pick-up to output a 250 Hz (+/- 20%) Phase = -90 deg pulse output,
simulating medium flow conditions without flow through your meter.

NOTE: WIRING SHOULD BE INSTALLED BY A QUALIFIED INSTRUMENTATION TECHNICIAN

Pin Number Wire Color
Signal 2: 2 Green
Signal 1: 4 White
Ground: 5 Black

Supply Voltage: 6 Red

Wiring Color Code:

Pin Number Function

1 NC
2 Output 2
3 NC
4 Output 1
5 Ground

6 Supply

Electrical Connection for Pin Connector

1 3 5

6

Pinout looking at male

connector on sensor

Switch Output 1 Output 2

0 Direction Signal 2
1 Signal 1 Signal 2
2 Direction Signal 1 + 2 (2x frequency)
3 Signal 1 Signal 1 + 2 (2x frequency)
4 Signal 1 (both outputs in phase)
5 Signal 2 (both outputs in phase)
6 Signal 1 + 2 (both 2x frequency & both outputs in phase)
7 Reserved
8 Test: S1 & S2 == 10 Hz (+/- 20%) Phase = +90 deg.
9 Test: S1 & S2 == 250 Hz (+/- 20%) Phase = -90 deg.

Operating Modes

Top view of circuit board with

view of LED’s and switch

Note: Power must be cycled for new

setting to take effect

-7-

FPD20x1 to 20x4 Dual Hall Effect Pickup

Installation and Technical Data Guide

Sourcing Output Circuit

~40 Ohm

SUPPLY

OUTPUT

GROUND

Analog
Switch

• Signal output square wave :
V

high

= Supply -1V @ no output load

V

low

= 0.1V

• Max sourced output voltage: Supply -0.5V

• Max current sourcing capabilities: 50mA

Supply Voltage: +10 to 27 Volt DC
Supply Current: 18 mA @ 12 VDC, 25 mA @ 24 VDC
Duty Signal: 50% ± 15%
Minimum Signal: 0.5 Hz
Frequency Output: Flow dependent, up to 2,000 Hz
Driving Capacity: 50 mA Max resistive load
Output Impedance: ~ 40 Ohm - analog switch and self-resetting fuse
Temperature Range: -40° F to 185° F (-40° C to 85° C)

Technical Data:

1.19"

DH-X: (2.12")

DH-XX: (2.39")

Part number configuration:

DH Sensors can be used with all Aluminum, 303
Stainless Steel and 316 Stainless Steel body flow meters

FPD20x1,2,3: (2.12”)
FPD20x4: (2.39”)

-8-

Switch Output 1 Output 2

0 Flow Direction Signal 2
1 1x frequency +90 deg phase
2 Flow Direction 2x frequency
3 2x frequency +90 deg phase
4 Flow Direction 4x frequency
5 Both outputs 4x frequency in phase
6 Reserved
7 Forward pulses Reverse pulses
8 Test: S1 & S2 == 10 Hz (+/- 20%) Phase = +90 deg.
9 Test: S1 & S2 == 250 Hz (+/- 20%) Phase = -90 deg.

FPD2005 and 2015 Hall Effect Pickup

Installation and Technical Data Guide

NOTE: WIRING SHOULD BE INSTALLED BY A QUALIFIED INSTRUMENTATION TECHNICIAN

Pin Number Wire Color
Signal 2: 2 Green
Signal 1: 4 White
Ground: 5 Black

Supply Voltage: 6 Red

Wiring Color Code:

Pin Number Function

1 NC
2 Output 2
3 NC
4 Output 1
5 Ground

6 Supply

Electrical Connection for Pin Connector

1

Pinout looking at

male connector

on sensor

Operating Modes

Top view of circuit
board with view of

LED’s and switch

Description:

The 4-Hall Effect Pickups are microprocessor-based sensors for use with the FPD2000 series of
positive displacement flow meters. The sensor can detect both uni- and bi-directional flow, and
sensors’ mode of operation is determined by an output selection switch located inside the housing. The
sensor detects the rotation of the flow meter gears and emits a frequency signal proportional to flow.
The output signal is a square wave pulse which has a duty cycle of approximately 50%.

Signal outputs are protected with a self-resetting fuse. This fuse has a 50mAnominal trip point. When a
trip occurs, turn off power to the sensor and remove output load to reset fuse. The sensor has two
different output configurations: sinking output when jumpers JP1 & JP2 are removed and sourcing
when jumpers JP1 & JP2 are shorting pins.

Sensor circuit board is equipped with a red and green LED. The red LED is a status LED which, when
the sensor is operating properly, will flash once every 4 seconds, a fast flash will indicate a failure of
one or more of the pick-ups. The green LED indicates the pulse of the input signal. Note that signals
above 20Hz will look as solid green.

Installation:

• Ensure that the flowmeter sensor cavity is free of debris prior to installing pickup

• Install flow meter and sensor - CYCLE POWER - or sensor will not function properly!!

• Sensor is equipped with an output test feature for readouts before initial running of your system

TEST FEATURE:

Note: Power must be cycled for new setting to take effect

• Switch setting 8 will cause the pick-up to output a 10 Hz (+/- 20%) Phase = +90 deg pulse output, sim­ulating low flow conditions without flow through the meter.

• For sourcing outputs remove shorting block from JP1 & JP2
For sinking outputs place shorting block across JP1 & JP2 (factory default)

• Switch setting 9 will cause the pick-up to output a 250 Hz (+/- 20%) Phase = -90 deg pulse output,
simulating medium flow conditions without flow through the meter.

Note: Power must be cycled for

new setting to take effect

-9-

RED LED

GREEN LED

SWITCH

JP2

JP1

FPD2005 and 2015 Dual Hall Effect Pickup

Installation and Technical Data Guide

Sinking Output Circuit

~40 Ohm

SUPPLY

OUTPUT

GROUND

Analog
Switch

Sourcing Output Circuit - Default from Factory

~40 Ohm

SUPPLY

OUTPUT

GROUND

Analog
Switch

• Output selection jumper off: remove shorting
block from JP1 & JP2

• User may need to add external components
to interface to displays or other instruments

• User must limit output voltage to Supply -1V

• Max current sinking capability: 50mA

• Output selection jumper on: place shorting
block across JP1 & JP2

• Signal output square wave :
V

high

= Supply -1V @ no output load

V

low

= 0.1V

• Max sourced output voltage: Supply -0.5V

• Max current sourcing capabilities: 50mA

Supply Voltage: +10 to 27 Volt DC
Supply Current: 75 mA @ 24 VDC
Duty Signal: 50% ± 15%
Minimum Signal: 0.5 Hz
Maximum Signal: 1,000 Hz
Frequency Output: Flow dependent, up to 2,000 Hz
Driving Capacity: 50 mAMax resistive load
Output Impedance: ~ 40 Ohm - analog switch and self-resetting fuse
Temperature Range: -40° F to 185° F (-40° C to 85° C)

Technical Data:

-10-

To Secure Sensor to Flow Meter:
Use a 9/64 hex key to tighten
internal screws.

1.38

FPD20xx-A Analog Output Sensor

The FPD20xx-A is a microprocessor based, meter mounted, analog output sensor. Each unit has a sen­sor, amplifier and converter module built into an Ex housing. The FIP is designed to handle frequencies
up to 5,000 Hz. The operational frequency range is user defined via four BCD rotary switches, where the
high flow rate in frequency is set to 20 mA and the output signal is automatically scaled. End connection
is a 3-pin male connector.

NOTE: This is a 3 wire hookup and is not suitable for a 2 wire installation.

Technical Specifications:

Supply Voltage: 10-30 VDC
Supply Current: 60 mAmax
Signal Output: 4-20mA or
Maximum Load

Impedance (Vcc/0.02): 275 ohm (for mA out)
Temperature Range: 0-185° F

Jumper Settings:

J1 AB: Analog Output

BC: Frequency Output
J2 AB: Housing Ground
CB: Signal ground
Response Time: 1/F + 25 msec
Frequency Input: 5 KHz max
Diagnostics: A glowing LED indicates the

unit is working. The LED will

blink to show an active

frequency.

-11-

"S" VERSION
CONNECTOR

(A) +10-30 VDC

C

A

(B) COMMON

B

(C) SIGNAL OUT

+10-30 VDC

COMMON

SIGNAL OUT

"E" VERSION
PIGTAIL LEADS

RED

BLACK

WHITE

S1 S2 S3 S4

1

1

0

2

9

3

8

4

7

5

6

J1

ABC

OUT

1

0

0

2

2

9

9

3

3

8

8

4

4

7

7

5

5

6

6

CBA

J2

1

0

2

9

3

8

4

7

5

6

Scaling Analog Output:

On the front panel there are four rotary switches which are
adjustable with a small screwdriver. It is not necessary to
power the unit down to change the settings. The switches are
read from left to right in order of decreasing value as shown in
the figure to the right.

If the maximum frequency is known at which the resulting output should be 20mA, set the switches to
this frequency. The output will automatically scale itself. If the maximum frequency is not known, the correct

switch settings can be determined in 2 ways.
The following equation can be used to determine what the switch setting should be for any particular meter and

flow rate.

Switch Setting =

Where: K Factor is the flow meter scaling factor in pulses / volume (found on calibration sheet)
Max. Flow Rate is the flow rate at which the analog output should be at it's max.
Note: K-Factor and Max flow rate MUST have same units, ie: gallon/GPM, liter/LPM
60 is the scaling factor when max. flow rate is in volume/minute. Use 3600 for volume/hour

Ex: K Factor = 89,100 pulses/gallon (for a FPD2001-A), Max flow rate = 0.2 GPM
Switch Setting = = 297

If the numerical flow rate is not known, the unit can be calibrated in systems with the following:

1) Adjust system flow to the rate at which analog output should read 20 mA.

2) Set scaling switches to a value known to be above the maximum frequency (ex. 9, 49, 799, 2999) if unsure,
use 4999

3) If S1 is 0, go to step 4. Decrease S1 until output shows 20 mA. Then increase its setting by one unless value
is 4, in which case value should remain 4. If the switch value is 0 and the output is below 20 mA, leave switch
at 0 and go to next switch.

4) If S2 is 0, go to step 5. Decrease S2 until output shows 20 mA. Then increase its setting by one unless value
is 9, in which case value should remain 9. If the switch value is 0 and the output is below 20 mA, leave switch
at 0 and go to next switch.

5) If S3 is 0, go to step 6. Decrease S3 until output shows 20 mA. Then increase its setting by one unless value
is 9, in which case value should remain 9. If the switch value is 0 and the output is below 20 mA, leave switch
at 0 and go to next switch.

6) Decrease S4 until output shows 20 mA and leave setting. DO NOT increase this setting by one. The switches
are now set at the frequency which will result in a 20 mA output.

When setting switches in step 1, try to use numbers ending in 9 for example: 9, 39, 299 and 2999. Any switch
setting above 5000 Hz is read as 4999 Hz.

Example: Actual maximum input frequency is 538 Hz. Switches are set to 0999 Hz, a value known to be above
actual maximum input frequency. The output shows 12.64 mA.

Starting with the switch of highest order, in this case S2 since S1 is 0, its value is decreased until the output
shows 20 mA (S2 shows 4). The switch is then increased by 1 (S2 is set to 5). S3 is then decreased until the
output shows 20 mA (S3 shows 2). The switch is then increased by 1 (S3 is set to 3). Finally, S4 is decreased
until the output shows 20 mA and left as such (S4 set at 8) the switches are now set to 538 Hz, the frequency
which will cause maximum output current / voltage.

K Factor * Max Flow Rate

60

89,100 * 0.2

60

-12-

x1000 x100 x10 x1

1

0

2

9

3

8

4

7

5

6

1

0

2

9

3

8

4

7

5

6

1

0

2

9

3

8

4

7

5

6

S1 S2 S3 S4

1

0

2

9

3

8

4

7

5

6

Maintenance Guide

For Flow Meter Series: FPD2001-2004, FPD2001-A - 2004-A, FPD2011 - 1014,

FPD2011-A - 2014-A, FPD2021 - 2024, FPD2021-A - 2024-A

Cleaning, inspecting or repairing a gear flow meter is easily accomplished by following the procedures
below.

1. Remove the Sensor (1) from the flow meter body Upper Housing (4).

Using a 3mm hex key, loosen the 2 mounting screws inside the sensor.

2. For the FPD20x3 size and smaller use M6 Bolts (2), loosen them using a

5mm hex key. The FPD20x4 uses M10 Bolts (2), loosen them using an
8mm hex key. Keep the 2 opposing bolts near the Locating Pins (7)
engaged by a few threads to avoid stress on the shafts and the locating
pins during housing separation. Please note the orientation of the

Upper and Lower housings with respect to each other so that the
meter is reassembled the same way.

3. Holding the Upper Housing (4), gently tap on the top of the 2 opposing bolt

heads to separate the Upper Housing (4) from the Lower Housing (9). Do

NOT use chisels or screwdrivers to split and pry apart the housings.
This can cause damage to the meter bodies and meter internal parts.

4. After separation, remove, clean and inspect the gear assemblies (6) and

shafts (5). Clean out the o-ring groove, shaft holes and meter cavity.

IMPORTANT: The gear assembly consists of two bearings (6a), the

Gear (6b), and a Bearing Spacer (6c. These parts are loosely fitted
and can fall out. These parts are matched together and careful
attention MUST be made to their orientation and location as they
MUST be replaced the exact way they were.

5. After cleaning all parts completely, the Gear Assemblies (6), Shafts (5) and

Locating Pins (7) can be reinserted. Check for free and easy rotation of
the gears.

6. Replace the O-Ring (8). Teflon o-rings should always be replaced. Viton

o-rings can be reused if they are not damaged.

7. During reassembly keep the meter housings as parallel as possible. Make

sure the housings are orientated the same way they were prior to
disassembly.

8. Replace the Washers (3) and the Bolts (2). Torque the bolts to 15Nm for

the12, 20 and 30 size meters and 30Nm for the 60 size meters. Do not
force the meter housings together. Do NOT use a hammer or other such
device. Over tightening will not cause damage to the meter, but may
fatigue the bolts and/or restrict the operation if internal surfaces are not
completely clean.

9. After reassembly, gently blow air through the meter so the gears spin. This

should be clearly audible given a moderate background noise level.

10. Clean any debris from the pickup holes before remounting the sensor (1)

to the Upper Housing (4). Use a 3mm hex key to tighten the mounting
screws in the sensor to mount the sensor on the housing. Note that there

is a correct and incorrect orientation for the sensor to be mounted on
the flow meter. Please see the Omega website for documentation if you

do not have it. The orientation is noted by the sensor's connector with
respect to the outlet port of the flow meter.

-13-

Maintenance Guide

For Flow Meter Series: FPD2005, FPD2015, FPD2015-A

Cleaning, inspecting or repairing a FPD20x5 Series gear flow meter is easily accomplished by following
the procedures below.

1. Remove the Sensor (3) from the flow meter body Upper Housing

(5). Using a 9/64 hex key, loosen the 2 mounting screws inside
the sensor.

2. Remove the hex bolts (1) with a 3/8 hex key.

3. Turn 2 of the hex bolts into the extraction bolt holes (4) until they

make contact with the lower housing (10). Using these bolts for
separating the housings helps to reduce any stress on the
locating pins and gear shafts.

4. With the extraction bolts turned down to the lower housing, give

each bolt a half-turn, alternating them, until the housings have
separated enough to where you can lift the upper housing (5)
straight off the locating pins. CAUTION: When lifting the top

housing off, make sure the gears stay in the lower housing.
If they come out with the upper housing, they may fall off
and damage the lower housing or the gears themselves.

5. After separation, inspect the gears (7) and bearings (9). Carefully

remove the gears and thoroughly clean them with solvent.
Special care must be observed when cleaning or flushing either
the upper (5) or lower housing (10) as the bearing could dislodge
from the housing. NOTE: Do not remove the bearings. For

bearing repairs the meter should be returned to the factory.

6. After cleaning, add lubrication if possible. The gears can be

reinserted into their previous positions. Check for free and easy
rotation of the gears.

7. Replace the O-ring (6) if it is damaged or deformed.

8. Keep the meter housings parallel during reassembly and align

the index marks on the housings so they are on the same side.

NOTE: Do not force the housings together using a hammer
or other similar device. Make sure to turn out the bolts from
the extraction holes.

9. Replace the hex bolts and torque all the bolts to 50 ft/lbs, once

one bolt is torqued, move to the bolt that is opposite it and repeat
until all bolts have been torqued. Over tightening will not cause
damage, but may restrict operation if surfaces are not completely
clean.

10.After reassembly, gently blow air into the meter so the gears

spin. This should be clearly audible given a moderate
background noise level.

11.The bearings should be lubricated prior to storage. Never

allow contact with water without immediately drying and
lubricating after use.

Shown with Quad-4 Sensor.

-14-

WARRANTY/DISCLAIMER

OMEGA ENGINEERING, INC. warrants this unit to be free of defects in materials and workmanship for a period of 13
months from date of purchase. OMEGA’s WARRANTY adds an additional one (1) month grace period to the normal
one (1) year product warranty to cover handling and shipping time. This ensures that OMEGA’s customers receive

maximum coverage on each product.

If the unit malfunctions, it must be returned to the factory for evaluation. OMEGA’s Customer Service Department will
issue an Authorized Return (AR) number immediately upon phone or written request. Upon examination by OMEGA, if
the unit is found to be defective, it will be repaired or replaced at no charge. OMEGA’s WARRANTY does not apply to
defects resulting from any action of the purchaser, including but not limited to mishandling, improper interfacing,
operation outside of design limits, improper repair, or unauthorized modification. This WARRANTY is VOID if the unit
shows evidence of having been tampered with or shows evidence of having been damaged as a result of excessive
corrosion; or current, heat, moisture or vibration; improper specification; misapplication; misuse or other operating
conditions outside of OMEGA’s control. Components in which wear is not warranted, include but are not limited to
contact points, fuses, and triacs.

OMEGA is pleased to offer suggestions on the use of its various products. However,
OMEGA neither assumes responsibility for any omissions or errors nor assumes liability for any damages
that result from the use of its products in accordance with information provided by OMEGA, either
verbal or written. OMEGA warrants only that the parts manufactured by the company will be as
specified and free of defects. OMEGA MAKES NO OTHER WARRANTIES OR REPRESENTATIONS OF ANY
KIND WHATSOEVER, EXPRESSED OR IMPLIED, EXCEPT THAT OF TITLE, AND ALL IMPLIED WARRANTIES
INCLUDING ANY WARRANTY OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE
HEREBY DISCLAIMED. LIMITATION OF LIABILITY: The remedies of purchaser set forth herein are
exclusive, and the total liability of OMEGA with respect to this order, whether based on contract,
warranty, negligence, indemnification, strict liability or otherwise, shall not exceed the purchase price of
the component upon which liability is based. In no event shall OMEGA be liable for consequential,
incidental or special damages.

CONDITIONS: Equipment sold by OMEGA is not intended to be used, nor shall it be used: (1) as a “Basic Component”
under 10 CFR 21 (NRC), used in or with any nuclear installation or activity; or (2) in medical applications or used on
humans. Should any Product(s) be used in or with any nuclear installation or activity, medical application, used on
humans, or misused in any way, OMEGA assumes no responsibility as set forth in our basic WARRANTY/ DISCLAIMER
language, and, additionally, purchaser will indemnify OMEGA and hold OMEGA harmless from any liability or damage
whatsoever arising out of the use of the Product(s) in such a manner.

RETURN REQUESTS/INQUIRIES

Direct all warranty and repair requests/inquiries to the OMEGA Customer Service Department. BEFORE RETURNING
ANY PRODUCT(S) TO OMEGA, PURCHASER MUST OBTAIN AN AUTHORIZED RETURN (AR) NUMBER FROM
OMEGA’S CUSTOMER SERVICE DEPARTMENT (IN ORDER TO AVOID PROCESSING DELAYS). The assigned AR number
should then be marked on the outside of the return package and on any correspondence.

The purchaser is responsible for shipping charges, freight, insurance and proper packaging to prevent breakage in
transit.

FOR W

ARRANTY RETURNS, please have the following

information available BEFORE contacting OMEGA:

1. Purchase Order number under which the product
was PURCHASED,

2. Model and serial number of the product under
warranty, and

3. Repair instructions and/or specific problems
relative to the product.

OMEGA’s policy is to make running changes, not model changes, whenever an improvement is possible.
This affords our customers the latest in technology and engineering.

OMEGA is a registered trademark of OMEGA ENGINEERING, INC.

© Copyright 2007 OMEGA ENGINEERING, INC. All rights reserved. This document may not be copied, photocopied,
reproduced, translated, or reduced to any electronic medium or machine-readable form, in whole or in part, without the
prior written consent of OMEGA ENGINEERING, INC.

FOR NON-WARRANTY REPAIRS,

consult OMEGA for
current repair charges. Have the following information
available BEFORE contacting OMEGA:

1. Purchase Order number to cover the COST of the

repair,

2. Model and serial number of the product, and

3. Repair instructions and/or specific problems

relative to the product.

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Shop online at omega.com

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