Omega Products FPD1204 Installation Manual

FPD1004 thru FPD1007,

FPD1034, FPD1105, FPD1204

and FPD1205

(includes -R Option)

SERIES HIGH FLOW

Positive Displacement Flowmeters

TABLE OF CONTENTS

Important Information ................................. 2

Installation .................................................. 2

Operation .................................................... 3

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

Service Instructions .................................... 5

Troubleshooting .......................................... 6

FPD1004 Aluminum Meter

Parts List ...............................................

FPD1204 Aluminum Meter

Parts List ...............................................

FPD1034 Aluminum Meter

Parts List ...............................................

FPD1105 PPS Meter

Parts List .............................................

FPD1005 Aluminum Meter

Parts List .............................................

FPD1205 Stainless Steel Meter

Parts List .............................................

FPD1006 Aluminum Meter

Parts List .............................................

FPD1007 Aluminum Meter

Parts List .............................................

7

9

11

13

15

17

To the owner:

Thank you for purchasing an OMEGA FPD Series Flowmeter. Please take a few minutes to read through the manual before installing and operating your meter. If you have any problems with the meter, refer to the Maintenance and Troubleshooting sections of the manual.

This manual contains connection and operating instructions for the OMEGA FPD Series meters with pulse outputs. This includes the following models:

FPD1004 FPD1005 FPD1204 FPD1205 FPD1034 FPD1006 FPD1105 FPD1007

Part breakdowns for each model are located at the back of this manual. For models with displays and/or 4-20 mA output, an additional instruction manual is provided.

The OMEGA FPD Series ﬂowmeter has incorporated the oval rotor principal into its design. This has proven to be a reliable and highly accurate method of measuring ﬂow. Exceptional repeatability and high accuracy over a wide range of ﬂuid viscosities and ﬂowrates are features of the OMEGA FPD Series ﬂowmeter design. The low pressure drop and high pressure rating, means the OMEGA FPD Series ﬂowmeters are suitable for both gravity and pump (in-line) applications.

1

IMPORTANT INFORMATION INSTALLATION

Please read this information

!

▲

carefully before use!

Before use, conﬁrm the ﬂuid to be used is compatible with the meter or consult with OMEGA for advice.

To prevent damage from dirt or foreign matter, OMEGA recommends a Y or basket type 60 mesh strainer be installed as close as possible to the inlet side of the meter. (If required, contact OMEGA for further information.)

NOTE: When a strainer is installed it should

be regularly inspected and cleaned. Failure to keep the strainer clean will dramatically effect ﬂowmeter performance.

To prevent damage to the meter, slowly ﬁll the system with ﬂuid. This will prevent damage caused by air purge.

NOTE: Failure to do this could damage the

meter.

Maintenance can be performed on the liquid crystal display and pulse units without removing or isolating the meter from the line. When maintenance to any other part of the meter is required, the meter must be isolated and the line pressure reduced.

The Reed Switch pulse unit can cause inaccurate rate counts when used with high speed counters. It is advised that a debounce circuit be used or alternatively use the Hall Effect sensor option.

1. OMEGA recommends that when set ting up pipework for meter installations, a bypass line be included in the de-

sign. This provides the ability for a

meter to be removed for maintenance without interrupting production. (See Figure 1)

Figure 1

Bypass Line

Flow Outlet

2. Use thread sealant on all pipe threads.

3. For pump applications, ensure pipe work has the appropriate working pressure rating to match the pressure output of the pump.

4. Install a wire mesh strainer (Y or bas-

ket type 60 mesh) as close as possible

to the inlet side of the meter.

5. Ensure that the meter is installed so that the ﬂow of the liquid is in the direction of the arrows embossed on the meter body.

6. The meter can be installed in any orien tation as long as the meter shafts are in a horizontal plane. (See Figure 2) The register assembly may be oriented to suit the individual installation.

Flow Inlet

Strainer

-

2

➧

R I G H T

Figure 2

OPERATION

When ﬂuid passes through the meter, the rotors turn. The magnets which are located in the rotors will pass across the pulser circuit board (containing either Reed Switch or Hall Effect sensors).

W R O N G

R I G H T

NOTE: Incorrect installation can cause pre-

mature wear of meter components

7. Do not overtighten meter connections.

8. It is important that after initial installa tion you ﬁll the line slowly, high speed air purge could cause damage to the rotors.

9. Test the system for leaks.

10. Check the strainer for swarf or foreign material. After the ﬁrst 200 liters, check periodically – particularly if the ﬂowrate decreases.

➧

A signal is received which is then sent by the Pulse Circuit Board (PCB) to the relevant LC display or receiving instrument.

-

3

ELECTRICAL CONNECTIONS

1 2 3

4 5

Ground

1

2

3

4

1

2

3

4

1 2 3

4 5

1

2

3

4

5

Figure 3: Reed Switch Connections for PCB Terminals

Contact Rating 15 VA

Maximum Voltage 150 VDC

Figure 4: Hall Effect Sensor Connections

Conﬁguration 1

2 x Pulse Outputs

Double Pulse Output

Hall Effect Voltage 4.5 to 24 VDC Current Draw Minimum 4.6 mA Output NPN Open Collector 25 mA

Conﬁguration 2

Link 2 & 3 for

1 – HE Supply +

2 – HE 1 Signal

3 – HE Common –

4 – HE 2 Signal

5 – HE Ground

4

SERVICE INSTRUCTIONS

Disassembly:

Ensure that the ﬂuid supply to the meter is disconnected, and the line pressure is released before disassembly. This step is not required if you need to repair or perform maintenance on the display or PCB. In this case, there is no need to isolate the meter from the ﬂow. Refer to the exploded parts diagram for your meter.

Units with Pulse Caps – Undo the con-

1.

duit connector, remove pulse cap and

remove the wires from the pulse terminal board.

Standard LC Display – Unscrew the four

large screws on top of the LC Display. Carefully separate the LC Display from the plastic housing and disconnect the wires from the pulse terminal block.

2. Loosen the four cap screws and nuts that hold down the meter cap. Remove the screws and nuts and lift off the cap.

3. Remove the O-ring from the O-ring groove in the meter cap.

4. Remove rotors.

Reassembly:

1. Before reassembling, check the condition of the rotors. Replace if necessary.

2. Rotors must be replaced in the proper orientation (see list that follows). There is no difference between rotor one or rotor two.

1/2 in. Meters: FPD1004 – Plugs Down FPD1204 – Plugs Down 3/4 in. Meters: FPD1034 – Plugs Up 1 in. Meters: FPD1005 – Plugs Up FPD1105 – Plugs Down FPD1205 – Plugs Up 1-1/2 in. Meters: FPD1006 – Plugs Up 2 in. Meters: FPD1007 – Plugs Up

Figure 5

Rotor #1

Rotor #2

Rotors must be at 90° to each other

3. Replace the rotors onto the shafts at 90 degrees to each other. (See Figure 5) Check their operation by turning either of the rotors. If the rotors are not in mesh correctly or do not move freely, remove one of the rotors and replace correctly at 90 degrees to the other rotor. Recheck the operation of the rotors.

4. Replace the O-ring back into the groove in the meter cap. If the O-ring has grown or is damaged in any way, replace it with a new one.

5. Replace the meter cap. Insert the cap head screws and ﬁx nuts and tighten in the sequence 1, 3, 2 and 4. Torque screws to the appropriate pressure per the chart that follows:

Body Screw Material Torque

1/2 in. Meters:

FPD1004 Aluminum 31 in./lbs. FPD1204 S.S. 80 in./lbs. 3/4 in. Meters: FPD1034 Aluminum 31 in./lbs. 1 in. Meters: FPD1005 Aluminum 31 in./lbs. FPD1105 PPS 80 in./lbs. FPD1205 S.S. 80 in./lbs. 1-1/2 in. Meters: FPD1006 Aluminum 75 in./lbs. 2 in. Meters: FPD1007 Aluminum 150 in./lbs.

6. The replacement of cables and connectors are a reversal of the disassembly procedure. Replace conduit ﬁtting if re-

quired.

5

7. Test the meter by turning the rotors with a ﬁnger or by applying very low air pres

sure (a good breath) to one end of the meter, before returning the meter to the line.

Pulse Circuit Board (PCB) Notes:

The PCB board is fastened to the meter

cap by two screws and stand off’s. All care and caution should be taken when removing or handling the PCB as both the Reed Switch and Hall Effect sensors are fragile.

Individual Reed Switches or Hall Effect sensors are not available as replacement parts and are only available with the PCB.

TROUBLESHOOTING

Symptom Probable Cause Corrective Action

FLUID WILL NOT 1. Foreign matter blocking Dismantle meter, clean rotors. Strainer must FLOW THROUGH rotors be ﬁtted in-line. THE METER

2. Line strainer blocked Clean strainer.

3. Damaged rotors Replace rotors. Strainer must be ﬁtted in-line.

4. Meter connections over- Re-adjust connections. tightened

5. Fluid is too viscous See speciﬁcations for rated viscosity.

REDUCED FLOW 1. Line strainer partially Clean strainer. THROUGH THE blocked METER

2. Fluid is too viscous See speciﬁcations for rated viscosity.

METER READING 1. Fluid ﬂowrate is too low See speciﬁcations for ﬂow range. INACCURATE or too high

2. Fluid is too viscous See speciﬁcations for rated viscosity.

3. Excess wear caused by Check meter body and rotors. Replace as incorrect installation required.

METER NOT 1. Faulty Hall Effect sensor Replace PCB Board. GIVING A PULSE SIGNAL 2. Faulty Reed Switch Replace PCB Board.

3. Magnets failed Replace rotors.

6

METER PARTS LISTING

Models: FPD1004 - Aluminum FPD1204 - Stainless Steel

1

2

3

4

5

6

7

8

9

u = Recommended Spare Parts to stock. Bold Text = Indicates Stainless Steel model parts.

Item Rec. Part or Set No. Qty. Parts

1 1 MS298N Meter Body 1/2 in. NPT (Aluminum)

1 1 MS337N Meter Body 1/2 in. NPT (Stainless Steel)

2 1 u BS145TE O-Ring (PTFE) 2 1 u BS145V O-Ring (Fluorocarbon) 3 2 u MS342S Rotors PPS (Polyphenylene Sulﬁde Resins) 3 2 u MS342HS High Viscosity Rotors (PPS) 4 1 MS297 Meter Cap (Aluminum)

4 1 MS338 Meter Cap (Stainless Steel)

5 1 u MS344-R PCB (Standard Reed Switch) 5 1 u MS344-HE PCB (Hall Effect Sensor) 6 2 MS284S PCB Board Screws 7 4 u MS346S Meter Cap Screws (Standard)

7 4 u MS350S Meter Cap Screws (Stainless Steel)

8 1 u MS340S Pulser Cap Gasket 9 1 MS296 Pulser Cap (Aluminum) 20mm Conduit Thread 9 1 MS296N Pulser Cap (Aluminum) 1/2 in. NPT Thread

9 1 MS339 Pulser Cap (S/Steel) 20mm Conduit Thread 9 1 MS339N Pulser Cap (S/Steel) 1/2 in. NPT Thread 10 2 MS347S Pulser Cap Screw (Stainless Steel)

(Order from this column only) Part Description

10

7

SPECIFICATIONS

FPD1004 & FPD1204

Flow Ranges (LPM or GPM) Above 5 centipoise Below 5 centipoise Accuracy of Reading Maximum Viscosity* 1000 Centipoise Maximum Operating Pressure Maximum Operating Temperature Pulse Type Pulses per Liter/Gallon Single Sensor (K-factor)

1 to 30 / 0.26 to 8 3 to 25 / 0.8 to 6.60 ± 0.5%

5500 kPa / 800 PSI / 55 Bar 80°C / 176°F (Stainless Steel 120°C / 248°F) Reed Switch Sensor or Hall Effect Sensor

112 PPL / 424 PPG

* Unless High Viscosity Rotors are ﬁtted.

DIMENSIONS

8

METER PARTS LISTING

Model: FPD1034 - Aluminum

1

2

3

4

5

6

u = Recommended Spare Parts to stock. Bold Text = Indicates Stainless Steel model parts.

Item Rec. Part or Set No. Qty. Parts

1 1 MS779NS Meter Body 3/4 in. NPT (Aluminum) 2 1 u BS235TE O-Ring (PTFE) 2 1 u BS235V O-Ring (Fluorocarbon) 3 2 u MS370S Rotors (PPS) (Polyphenylene Sulﬁde Resins) 4 1 MS150 Meter Cap (Aluminum) 5 1 u MS28-R PCB (Standard Reed Switch) 5 1 u MS28-HE PCB (Hall Effect Sensor) 6 4 MS111S PCB Board Screws 7 6 u MS114S Meter Cap Screws (Standard) 8 1 u MS300 Pulser Cap Gasket 9 1 MS160 Pulser Cap (Aluminum) 20mm Conduit Thread 9 1 MS160N Pulser Cap (Aluminum) 1/2 in. NPT Thread

10 4 MS115S Pulser Cap Screw (Stainless Steel)

(Order from this column only) Part Description

7

8

9

10

9

SPECIFICATIONS

FPD1034

Flow Ranges (LPM or GPM) Above 5 centipoise Below 5 centipoise Accuracy of Reading Maximum Viscosity Maximum Operating Pressure Minimum Operating Temperature Maximum Operating Temperature Pulse Type Pulses per Liter/Gallon Single Sensor (K-factor)

3 to 60 / 0.8 to 15.85 8 to 53 / 2.1 to 14 ± 0.5% 1000 Centipoise 5500 kPa / 800 PSI / 55 Bar

-10°C (+14°F) +80°C (+176°F) Reed Switch Sensor or Hall Effect Sensor

52 PPL / 197 PPG

DIMENSIONS

126mm

10

133mm

86mm

112mm

18mm

21.5mm

METER PARTS LISTING

1

2

3

Model: FPD1105 - PPS

4

5

6

7

8

9

10

u = Recommended Spare Parts to stock. Bold Text = Indicates Stainless Steel model parts.

Item Rec. Part or Set No. Qty. Parts

1 1 MS352N Meter Body 1 in. NPT (PPS) & Hastalloy C Shafts 2 1 u BS235TE O-Ring (PTFE) 2 1 u BS235V O-Ring (Fluorocarbon) 3 2 u MS370S Rotors (PPS) 4 1 MS405R Meter Cap (PPS) 5 1 u MS368-R PCB (Standard Reed Switch) 5 1 u MS344-HE PCB (Hall Effect Sensor) 6 2 MS284S PCB Board Screws

7 4 u MS350S Meter Cap Screws (Stainless Steel)

8 1 u MS340S Pulser Cap Gasket 9 1 MS406R Pulser Cap (PPS) 16mm Conduit Thread 9 1 MS406R-N Pulser Cap (PPS) 1/2 in. NPT Thread

10 2 MS347S Pulser Cap Screw (Stainless Steel)

33 1 MS111S Earthing Screw

34 4 MS497S Nut (S/Steel) - not shown, recessed in body

(Order from this column only) Part Description

33

11

SPECIFICATIONS

FPD1105

Flow Ranges (LPM or GPM) Above 5 centipoise Below 5 centipoise Accuracy of Reading Maximum Viscosity Maximum Operating Pressure Maximum Operating Temperature Pulse Type Pulses per Liter/Gallon Single Sensor (K-factor)

3 to 80 / 0.8 to 21 8 to 70 / 2 to 18.5 ± 0.5% 1000 Centipoise 1000 kPa / 150 PSI / 10 Bar 80°C / 176°F Reed Switch Sensor or Hall Effect Sensor

52 PPL / 197 PPG

DIMENSIONS

12

METER PARTS LISTING

Models: FPD1005 - Aluminum FPD1205 - Stainless Steel

1

2

3

4

5

6

u = Recommended Spare Parts to stock. Bold Text = Indicates Stainless Steel model parts.

Item Rec. Part or Set No. Qty. Parts

1 1 MS187N Meter Body 1 in. NPT (Aluminum)

1 1 MS185N Meter Body 1 in. NPT (Stainless Steel)

1 1 MS187F Meter Body 1 in. ANSI 150 lb. Flange (Aluminum)

1 1 MS185F Meter Body 1 in. ANSI 150 lb. Flange (S/Steel) 1 1 MS185T Meter Body 1 in. Tri-Clover

2 1 u BS235TE O-Ring (PTFE) 2 1 u BS235V O-Ring (Fluorocarbon)

3 2 u MS50-1S Rotors (Stainless Steel) 3 2 u MS50-1HS High Viscosity Rotors (Stainless Steel)

4 1 MS150 Meter Cap (Aluminum)

4 1 MS250 Meter Cap (Stainless Steel)

5 1 u MS28-R PCB (Standard Reed Switch) 5 1 u MS28-HE PCB (Hall Effect Sensor) 6 4 MS111S PCB Board Screws 7 6 u MS114S Meter Cap Screws (Standard)

7 6 u MS200S Meter Cap Screws (Stainless Steel)

8 1 u MS300 Pulser Cap Gasket 9 1 MS160 Pulser Cap (Aluminum) 20mm Conduit Thread 9 1 MS160N Pulser Cap (Aluminum) 1/2 in. NPT Thread

9 1 MS170 Pulser Cap (S/Steel) 20mm Conduit Thread 10 4 MS115S Pulser Cap Screw (Stainless Steel)

(Order from this column only) Part Description

7

®

Flange (S/Steel)

8

9

10

13

SPECIFICATIONS

FPD1005 & FDP1205

Flow Ranges (LPM or GPM) Above 5 centipoise Below 5 centipoise Accuracy of Reading Maximum Viscosity* 1000 Centipoise Maximum Operating Pressure Maximum Operating Temperature Pulse Type Pulses per Liter/Gallon Single Sensor (K-factor) Double Sensor (K-factor)

6 to 120 / 1.6 to 32 10 to 100 / 2.6 to 26 ± 0.5%

NPT – 5500 kPa / 800 PSI / 55 Bar or Flange Rule 80°C / 176°F (Stainless Steel 120°C / 248°F) Reed Switch Sensor or Hall Effect Sensor

36 PPL / 136.3 PPG 72 PPL / 272.6 PPG

* Unless High Viscosity Rotors are ﬁtted.

DIMENSIONS

14

METER PARTS LISTING

Model: FPD1006 - Aluminum

1

2

3

4

5

6

u = Recommended Spare Parts to stock. Bold Text = Indicates Stainless Steel model parts.

Item Rec. Part or Set No. Qty. Parts

1 1 MS191N Meter Body 1-1/2 in. NPT (Aluminum) 1 1 MS191F Meter Body 1-1/2 in. ANSI 150 lb. Flange (Alum.) 2 1 u BS243TE O-Ring (PTFE) 2 1 u BS243V O-Ring (Fluorocarbon) 3 2 u MS58S Rotors (PPS) 3 2 u MS58HS High Viscosity Rotors (PPS) 4 1 MS220 Meter Cap (Aluminum) 5 1 u MS201-R PCB (Standard Reed Switch) 5 1 u MS201-HE PCB (Hall Effect Sensor) 6 4 MS284S PCB Board Screws 7 6 u MS116S Meter Cap Screws (Standard) 8 1 u MS300 Pulser Cap Gasket 9 1 MS160 Pulser Cap (Aluminum) 20mm Conduit Thread 9 1 MS160N Pulser Cap (Aluminum) 1/2 in. NPT Thread

10 4 MS115S Pulser Cap Screw (Stainless Steel)

(Order from this column only) Part Description

7

8

9

10

15

SPECIFICATIONS

FPD1006

Flow Ranges (LPM or GPM) Above 5 centipoise Below 5 centipoise Accuracy of Reading Maximum Viscosity* 1000 Centipoise Maximum Operating Pressure** NPT – 5500 kPa / 800 PSI / 55 Bar Maximum Operating Temperature

-10°C to 120°C (14°F to 248°F) (Stainless Steel)

Pulse Type Pulses per Liter/Gallon Single Sensor (K-factor) Double Sensor (K-factor)

10 to 250 / 2.6 to 66 15 to 235 / 4 to 62 ± 0.5%

-10°C to 80°C (14°F to 176°F) (Aluminum)

Reed Switch Sensor or Hall Effect Sensor

14.5 PPL / 54.9 PPG 29 PPL / 109.8 PPG

* Unless High Viscosity Rotors are ﬁtted. ** Meter conforms to PED 97/23/EC CAT 1.

DIMENSIONS

16

METER PARTS LISTING

Model: FPD1007 - Aluminum

1

2

3

4

5

6

u = Recommended Spare Parts to stock. Bold Text = Indicates Stainless Steel model parts.

Item Rec. Part or Set No. Qty. Parts

1 1 MS283F Meter Body 2 in. ANSI 150 lb. Flange (Alum.) 1 1 MS283N Meter Body 2 in. NPT (Aluminum) 2 1 u BS252TE O-Ring (PTFE) 2 1 u BS252V O-Ring (Fluorocarbon) 3 2 u MS147S Rotors (PPS) 3 2 u MS147HS High Viscosity Rotors (PPS) 4 1 MS230 Meter Cap (Aluminum) 5 1 u MS201-R PCB (Standard Reed Switch) 5 1 u MS201-HE PCB (Hall Effect Sensor) 6 4 MS284S PCB Board Screws 7 6 u MS243S Meter Cap Screws (Standard) 8 1 u MS300 Pulser Cap Gasket 9 1 MS160 Pulser Cap (Aluminum) 20mm Conduit Thread 9 1 MS160N Pulser Cap (Aluminum) 1/2 in. NPT Thread

10 4 MS115S Pulser Cap Screw (Stainless Steel)

(Order from this column only) Part Description

7

8

9

1

0

17

SPECIFICATIONS

FPD1007

Flow Ranges (LPM or GPM) Above 5 centipoise Below 5 centipoise Accuracy of Reading Maximum Viscosity* 1000 Centipoise Maximum Operating Pressure** NPT – 5500 kPa / 800 PSI / 55 Bar or Flange Rule Maximum Operating Temperature

-10°C to 120°C (14°F to 248°F) (Stainless Steel)

Pulse Type Pulses per Liter/Gallon Single Sensor (K-factor) Double Sensor (K-factor)

15 to 350 / 4 to 92 33 to 300 / 9 to 79 ± 0.5%

-10°C to 80°C (14°F to 176°F) (Aluminum)

Reed Switch Sensor or Hall Effect Sensor

6.68 PPL / 25.3 PPG

13.4 PPL / 50.6 PPG

* Unless High Viscosity Rotors are ﬁtted. ** Meter conforms to PED 97/23/EC CAT 1.

DIMENSIONS

18