Omega Products FPUDV1000 Installation Manual

User’s Guide

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FPUDV1000 Series

VARIABLE SPEED

POSITIVE DISPLACEMENT INJECTOR PUMP

OPERATING MANUAL

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

TABLE OF CONTENTS

SECTION HEADING PAGE

1 Introduction 2

2 Specifications 3

3 Features 3

4 How to install the pump 4

4.1 Mounting location 4

4.2 Electrical connections 6

4.2.1 Input Voltage connections 6

4.2.2 External Input Signal connections 6

4.3 How to install the tubing and fittings 8

5 How to operate the pump 9

5.1 How to adjust the output -Cam type Mechanism Adjustments 9

5.2 Description of the electronic adjustment controls 10

Page 2

5.3 Mode 1 - Manually adjusting the output 11

5.4 11

5.5 13

5.6 14

6 How to maintain the FPUDV1000 15

6.1 Routine inspection and cleaning 15

6.2 500 hour service warning timer 15

6.3 How to clean the FPUDV1000 15

Mode 2 - 4-20 mA input

Mode 3 - 0-10VDC input

Mode 4 - Pulse (frequency Hz) Input

Replacement parts drawing 16

Replacement parts list 17

1.0 Introduction

Congratulations on purchasing the positive displacement metering pump. The pump is
designed to inject chemicals into piping systems and is capable of injecting against a high
system pressure up to 150 PSI (10.4 bar). In addition to the front mounted mechanical flow
rate adjustment, the pump is equipped with an external input control circuitry which allows the
pumps output to be externally controlled by either a 4-20mA input signal, a 0-10V DC input
signal or a pulsed input signal.

Page 3

2.0 Specifications

Maximum Working Pressure 150 psig / 10.4 bar*
Maximum Fluid Temperature 130 F / 54 C
Output Accuracy +/- 10% of maximum (water @ 70 F, 0 psig, and 5’ suction

Ambient Temperature Range 14 to 110 F / -10 to 43 C
Duty Cycle Continuous
Maximum Viscosity 1,000 Centipoise
Maximum Suction Lift up to 10 ft. water
Power Requirements 115V60Hz 40 Watts

Signal Inputs 4-20 mA , 0-10 VDC

Dimensions 6-1/4” high x 10” wide x 9-1/4” deep

Weight 14 lb. / 6.35 Kg

o o

o

lift)

o o

220V50Hz 40 Watts
230V60Hz 40 Watts

TTL, CMOS pulses
Hall Effect sensors, Open-collector transistors,
Dry Contact switches (must withstand 12 VDC @ 2 mA )

(159

MM x 254 MM x 235 MM)

3.0 Features

!

Double-ball ceramic check valves.

!

PVDF (Kynar) valve assemblies.

!

High grade Aflas and Viton O-rings.

!

Large outlet flowrate up to 360 GPD / 1363 Liters per day.

!

High outlet pressure capability of 150 PSIG / 10.4 Bar.*

!

Easy access, front mounted mechanical feed rate adjustment.

!

Ball bearing supported motor drive shaft.

!

Permanently lubricated ball bearing motor.

!

Digital electronic feed rate control.

!

400:1 adjustment turn down ratio.

!

Pump output verification system.

!

Pump service inspection warning timer.

!

Corrosion resistant Valox housing.

!

Easy servicing.

!

Includes suction tube foot valve & strainer, suction tube weight, suction tubing, discharge
tubing and injection fitting with internal back-flow check valve and mounting hardware.

* Most models

1

10 IN. (267 MM)

2

Page 4

10 IN. (254 MM)

VARIABLE SPEEDPUMP

FIELD

RUN

STANDBY

PRIME

RESETSERVICE

2- 4-20mA

1-MANUAL

Pumphead

Slide Clamps*

Adjustment knob

FIG. 3.0 PARTS LOCATOR DRAWING

* Slide both top & bottom clamps to the left only far enough to open the control
cover.

4.0 How To Install the Pump

CAUTION: PROPER EYE AND SKIN PROTECTION MUST BE WORN WHEN
INSTALLING AND SERVICING THE FPUDV1000

Note: All diagrams are strictly for guideline purposes only. Always consult an expert before
installing the pump into specialized systems.
The pump should be serviced by qualified persons only.

PROGRAM

INPUTMODES

RUN

PROGRAM

STAND-BY

PRIME

MINIMUM

MAXIMUM

DIGIT MODE

DISPLAY

3- 0-10VDC 4- PULSE (Hz)

J-Box

Control Cover

Motor Housing

Rear Cover

6

(159

1
4

IN.

MM)

4.1 Mounting Location

Choose an area located near the chemical supply tank, chemical injection point and electrical
supply. Although the pump is designed to withstand outdoor conditions, a cool, dry, well
ventilated location is recommended. Install the pump where it can be easily serviced.

!

Mount the pump to a secure surface or wall using the enclosed hardware. Wall mount to a
solid surface only. Mounting to drywall with anchors is not recommended.

!

Keep the outlet (discharge) tubing as short as possible. Longer tubing increases the back
pressure at the pump tube.

!

Do not mount the pump directly over your chemical container. Chemical fumes may damage
the unit. Mount the pump off to the side or at a lower level than the chemical container.

!

Mounting the pump lower than the chemical container will gravity feed the chemical into the
pump. This “flooded suction” installation can reduce the time required to prime the pump.
Install a shut-off valve, pinch clamp or other means to halt the gravity feed to the pump during
servicing.

!

Your solution tank should be sturdy. Keep the tank covered to reduce fumes.

1

2

3

5

4 6

9

10

Page 5

7

8

Drill .156 Dia. (5/32)

For Self-Tap Screw

#10 X 1” Phillips Steel

4 Places

Floor Mount

3-1/2”

FIG. 4.1 - INJECTOR MOUNTING

7-5/8”

7-3/8”

Wall Mount

Drill .156 Dia. (5/32)

For Self-Tap Screw

8-3/16”

#10 X 1” Phillips Steel

2 Places

Note: For wall-mounting, recommend drill & thread into
solid wood only.

7

VARIABLESPEEDPUMP

FIELD

RUN

STANDBY

PRIME

RESETSERVICE

INPUTMODES

2-4-20mA

1-MANUAL

RUN

PROGRAM

STAND-BY

PRIME

MINIMUM

MAXIMUM

DIGIT MODE

DISPLAY

PROGRAM

3-0-10VDC 4-PULSE(Hz)

lPoo

1. Strainer 7. Injector

2. Circulation Pump 8. Solution Tank

3. Filter 9. Injection Fitting (FPU1000-IF)

4. Heater 10. Return Line

5. Check Valve

6. Flowmeter

FIG. 4.2 - SWIMMING POOL INSTALLATION

¼" & ½" NPT Injector

FIG. 4.3 - TYPICAL INSTALLATION

Discharge

Tube

STANDBY

1-MANUAL

VARIABLESPEEDPUMP

RUN

PRIME

RESETSERVICE

RUN

PROGRAM

STAND-BY

PRIME

MINIMUM

MAXIMUM

DIGIT MODE

FIELD

DISPLAY

PROGRAM

INPUTMODES

3-0-10VDC 4-PULSE(Hz)

2-4-20mA

4.2 Electrical Connections

4.2.1 Input Power Connections -

Be certain to connect the pump to the proper supply voltage. Using the incorrect voltage will
damage the pump and may result in injury. The voltage requirement is printed on the pump
serial label.

WARNING-RISK OF ELECTRICAL SHOCK

Jumper pins on the circuit board are factory preset for the correct voltage. See Fig. 4.4, page 7
for details.

The pump is supplied with a ground wire conductor and a grounding type attachment plug
(power cord). To reduce the risk of electric shock, be certain that the power cord is connected
only to a properly grounded, grounding type receptacle.

Note: When in doubt regarding your electrical installation, contact a licensed electrician.

Page 6

4.2.2 External Input Signal Connections -

The pump will accept any one of three different types of external input signals; 4-20 mA, 0-10
VDC, or frequency. Two types of frequency inputs, AC sine waves (magnetic coils type out­puts) and Digital Square waves (Hall Effect signals, contact closures), are acceptable. A
jumper plug located on the circuit board is factory pre-set for AC sine wave signals, the jumper
must be re-positioned when digital square wave signals are being used. (See Fig. 4.4, page 7,
“Hz input jumper settings”)

All wiring connections are to be made inside of the junction box located on the side of the
pump. A liquid-tite connector is supplied and should be used for the external signal cable. The
signal input wires are color coded to the type of signal being used.

INPUT SIGNAL TYPE

4-20 mA

0-10 V DC

AC sine wave, Digital square wave

POSITIVE

WIRE COLOR

BLUE

ORANGE

WHITE

NEGATIVE

WIRE COLOR

BLACK

BLACK

BLACK

FIG. 4.3 WIRING CHART - INPUT SIGNAL WIRE COLORS

Page 7

SIGNAL INPUT MODES / FUNCTIONS & WIRING COLOR CODES

INPUT MODE / FUNCTION

MANUAL

4-20 mA

0-10 VDC

FREQUENCY

ALARM RELAY

FLOW VERIFICATION SENSOR

(Digital square waves)

MOTOR ON SIGNAL

EXTERNAL INPUT CABLE

ACCEPTABLE CABLE JACKET RANGE:

RED (+20VDC)
BLACK (Ground)

BLUE (4-20 mA input)
ORANGE (0-10 VDC input)
WHITE (frequency input)

YELLOW (verification sensor input)
BROWN (motor-on contact output)

PURPLE X2 (alarm relay contacts)

.118 - .255 INCH
.( 3,0-6,5MM)

JUNCTION BOX

WIRES REQUIRED

NO CONNECTIONS

BLUE (+) & BLACK (-)

ORANGE (+) & BLACK (-)

WHITE (+) & BLACK (-)

PURPLE & PURPLE

RED (+ 20VDC) & BLACK (-) & YELLOW (signal)

BROWN (+) & BLACK (-)

(open - factory default)

AC LINE VOLTAGE SETTINGS

Hz INPUT JUMPER SETTINGS

Located under connector

AC sine waves

Jumper Not Installed

Digital square waves

Jumper Installed

INPUT SIGNAL CONNECTOR

7 wire bundle

LIQUID-TIGHT
CONNECTOR

ALARM OUTPUT

(CONTACT CLOSURE)

connect 2-conductor plug to either

normally open (NO) (factory default)

or normally closed (NC) side of receptacle.

1 AMP MAX @ 125VAC (24VDC)

RED (+)

DC

MOTOR

BLACK (-)

Ground (green)

MOTOR
RED (+)

MOTOR

BLACK (-)

NC
ON

AC LINE

NEUTRAL

110

220

110

One Jumper Installed

TS

ROBPE

.187 push tab connectors

1 AMP

250VAC

AC LINE

HOT

Common

Earth Ground (green)

230 VAC

on center position

(ends open)

Two Jumpers Installed

on end positions

(no open pins)

THERMAL SWITCH

2 conductors

PROTECTOR FUSE

1 Amp, 250 Volt AC
(Littlefuse #239001

or Equivalent)

Hot

AC

Input

Power

115 VAC

FIG. 4.4 WIRING DIAGRAM - CIRCUIT BOARD

Page 8

4.3 How To Install the Tubing and Fittings

CAUTION: PROPER EYE AND SKIN PROTECTION MUST BE WORN WHEN
INSTALLING AND SERVICING THE FPUDV1000

4.3.1 Inlet Tubing - Locate the inlet fitting of the pump head, see fig 4.9. Remove the tube nut.

Push the clear PVC suction tubing onto the compression barb of the fitting. Use the tube nut to
secure the tube. Hand tighten only.

4.3.2 Footvalve/Strainer -Trim the inlet end of the suction tubing so that the strainer will rest

approximately one inche from the bottom of the solution tank. This will prevent sediment from
clogging the strainer. Slip the ceramic weight over the end of the suction tube. Press the
footvalve/strainer into the end of the tube. Secure the ceramic weight to the strainer. Drop the
strainer into the solution tank.

4.3.3 Outlet Tubing - Locate the outlet fitting of the pump head, see fig 4.9. Remove the tube nut.

Push the opaque outlet (discharge) tubing onto the compression barb of the fitting. Use the
tube nut to secure the tube. Hand tighten only.

Trim the other end of the outlet tube leaving only enough slack to connect it to the
Injection/Check valve Fitting (see below). Increasing the length of the outlet tube increases the
back pressure at the pump head, particularly when pumping viscous fluids.

Discharge Tube
(Rigid P.E.)

Tube Nut

Outlet Adapter

Pump Head

VARIABLE SPEED PUMP

FIELD

RUN

STANDBY

PRIME

RESETSERVICE

PROGRAM

INPUTMODES

2- 4-20mA

1-MANUAL

RUN

PROGRAM

STAND-BY

PRIME

MINIMUM

MAXIMUM

DIGIT MODE

DISPLAY

3- 0-10VDC 4- PULSE (Hz)

Suction Tubing

Ceramic
Weight

FootValve

Sub-Assembly

Footvalve Adapter

O-Ring

Ceramic Ball

O-Ring

Footvalve Body

Footvalve Strainer

Inlet Adapter

Tub e Nut

Suction Tubing
(clear PVC)

FootValve

FIG. 4.9

FIG. 4.10 FOOTVALVE ASSY.

Page 9

4.3.4 Injection/Check Valve Fitting Installation - The Injection/Check valve fitting is designed to

install directly into either 1/4” or 1/2” female pipe threads. This fitting will require periodic
cleaning, especially when injecting fluids that calcify such as sodium hypochlorite. These lime
deposits and other build ups can clog the fitting increasing the back pressure and interfering
with the check valve operation. See section 6.0.

Install the Injection/Check valve directly into the piping system. Do not use a pipe stud with a
tee for insertion of the injection valve. The solution must inject directly into the flow stream.

Use Teflon thread sealing tape on the pipe threads. Push the opaque outlet (discharge) tubing
onto the compression barb of the Injection/Check valve fitting. Use the tube nut to secure the
tube. Hand tighten only.

EXPLODED VIEW

FIG. 4.11

TEE INSTALLATION

TEE INSTALLATION AND EXPLODED VIEW

INJECTION/CHECK VALVE

5.0 How To Operate The Pump

5.1 How to adjust the output- Cam-Type Mechanism Adjustment (fig. 5.1) - The flow

rate can be adjusted within a range of 5% -100% of maximum output (20:1 turndown ration) by
means of a mechanical, cam type mechanism. The mechanism adjusts the pump’s stroke
length to an infinite number of settings within the flow range. Because the pump’s output is
reduced by increasing the pressure of the system being injected into, the amount of suction lift,
and the viscosity of the fluid being injected, the pump must be over-sized to allow for these
factors. Sizing the pump to allow adjustment within the midrange is preferred to maintain
accuracy. Consult the factory for individual pump model output curve data.

To adjust the pump’s output:

1. With the pump running, loosen the lock screw.

2. Turn the adjustment knob to the desired setting.

3. Re-tighten the lock screw.

Adjustment Knob
(Cam Type Mechanism)

Lock screw

FIG. 5.1

5.2 Description of Electronic Adjustment Controls -

Open the control panel door by sliding the upper and lower slide
clamps to the left. FIG. 5.2

!

RUN/STANDBY Button -

4

Press to start and stop the pump. The ARROW next to the

RUN will light when in the run mode. The ARROW next

word
to the word

4

Press to clear ALARM.

4

When pressed with the FIELD Button, initiates a 99 second

STAND-BY will blink when in the stand-by mode.

prime cycle which temporarily overrides the mode setting and
runs the pump motor at 100% speed. The ARROW next to
the word

4

When pressed with the DIGIT button, resets the 500 hour

PRIME will blink.

service warning timer to zero.

4

When pressed with the MODE button, initiates the program­ming mode. The ARROW next to the word

PROGRAM will

blink.

!

FIELD Button -

4

In the programming mode, selects the digit to be changed.

VARIABLE SPEED PUMP

1

VDC

mA Hz

SERVICE

DIGIT MODE

PROGRAM

3 - 0-10VDC 4 - PULSE (Hz)

RUN

STANDBY

1 - MANUAL

MODE

% SPEED

1000

ALARM

FIELD

PRIME

RESET SERVICE

INPUT MODES

2 - 4-20mA

Page 10

RUN

PROGRAM

STAND-BY

PRIME

MINIMUM

MAXIMUM

DISPLAY

!

DIGIT Button -

4

In the programming mode, increases the selected digit.

4

When pressed with the MODE Button, toggles the display
from % motor speed to input signal value.

!

MODE Button -

4

Used to select one of four operating modes.

Mode 1 - Manual Adjustment (external input disabled)
Mode 2 - 4-20mA input
Mode 3 - 0-10VDC input
Mode 4 - Frequency (Hz) input

SLIDE CLAMP

Slide both top & bottom

clamps to the left only far enough

(as shown) to open the control cover

Adjustment Knob
(Cam Type Mechanism)

RUN

STANDBY

1-MANUAL

VARIABLE SPEED PUMP

DIGIT MODE

FIELD

PRIME

DISPLAY

RESETSERVICE

PROGRAM

INPUTMODES

3- 0-10VDC 4 - PULSE (Hz)

2- 4-20mA

RUN

PROGRAM

STAND-BY

PRIME

MINIMUM

MAXIMUM

FIG. 5.1

Electronic Control Panel

FIG. 5.2

Page 11

5.3 OPERATING MODE 1 - Output adjusted manually -

In this mode, the pump’s motor speed is adjusted manually using the front panel touch
pad. The motor speed can be adjusted from 0-100%. To adjust the speed:

4

Set the pump for mode 1. Press the MODE button until MODE 1 is shown on the
LCD display. The %SPEED icon will light. The large 3-DIGIT LCD will indicate the
currently programmed percentage of speed.

4

Enter the programming mode. At the same time, press the RUN/STANDBY button
and the MODE button. A blinking ARROW will point to the word PROGRAM indicat­ing the program mode has been activated.

4

Press the FIELD button to select the digit to program. The digit will blink when
selected.

4

Press the DIGIT button to change the selected digit.

4

Repeat until all digits are programmed.

4

To exit the programming mode, press the RUN/STANDBY button and the MODE
button at the same time. The arrow next to the word PROGRAM will disappear.

[

NOTE: If while in the program mode no buttons are pressed within 20 seconds, the
circuitry will automatically return to the run mode, without saving changes.

[

5.4 -

OPERATING MODE 2 - Output adjusted by 4-20 mA input signal

In this mode, the pump’s motor speed is adjusted automatically based on the value of the
4-20 mA input signal. Any motor speed can be assigned to either the minimum or
maximum milliamp input values. However, the programmed minimum mA value must
be less than the programmed maximum mA value. The ALARM and SERVICE icons
will blink if the programming is in error. To assign the minimum and maximum motor
speed and the minimum and maximum mA input signal values:

4

Set the pump for mode 2. Press the MODE button until MODE 2 is shown on the
LCD display. The %SPEED or mA icon will light depending on the current display
setting. The large 3-DIGIT LCD will indicate the current motor speed or the current
mA input value.

4

Enter the programming mode. At the same time, press the RUN/STANDBY and
MODE buttons. A blinking ARROW will point to the word PROGRAM indicating the
program mode is activated. A blinking ARROW will point to the word MINIMUM
indicating the minimum value is ready to be programmed. The % SPEED icon will
blink indicating the percentage of speed is ready to be programmed.

4

Enter the motor speed at the minimum mA input signal value. Press the FIELD
button to select the digit to program. The digit will blink when selected.

4

Press the DIGIT button to change the selected digit.

4

Repeat until all digits are programmed.

4

Press the mode button. The % SPEED icon will stop blinking and the mA icon will
blink indicating the minimum mA value is ready to be programmed. The currently
programmed minimum value is shown on the 3-DIGIT LCD.

4

Enter the minimum mA input signal value. Note: this value must be less than the
maximum mA input signal value. Press the FIELD button to select the digit to pro­gram. The digit will blink when selected.

4

Press the DIGIT button to change the selected digit.

4

Repeat until all digits are programmed.

4

Press the mode button. The

Ma icon will stop blinking and the % SPEED icon will
blink. The ARROW next to the word MAXIMUM will blink indicating the maximum
value is ready to be programmed. The currently programmed maximum motor speed
value is shown on the 3-DIGIT LCD.

4

Enter the motor speed at the maximum mA input signal value. Press the FIELD
button to select the digit to program. The digit will blink when selected.

4

Press the DIGIT button to change the selected digit.

4

Repeat until all digits are programmed.

4

Press the mode button. The % SPEED icon will stop blinking and the mA icon will
blink indicating the maximum mA value is ready to be programmed. The currently
programmed maximum value is shown on the 3-DIGIT LCD.

4

Enter the maximum mA input signal value. Note: this value must be greater than
the minimum mA input signal value. Press the FIELD button to select the digit to
program. The digit will blink when selected..

4

Press the DIGIT button to change the selected digit.

4

Repeat until all digits are programmed.

RUN MODE 1

MODE

%SPEED

100

1

RUN

PROGRAM

STAND-BY

PRIME

MINIMUM

MAXIMUM

PROGRAM MODE 1

constant speed % setting

MODE

%SPEED

000

1

RUN

PROGRAM

STAND-BY

PRIME

MINIMUM

MAXIMUM

RUN MODE 2

MODE

2

mA

04.0

RUN

PROGRAM

STAND-BY

PRIME

MINIMUM

MAXIMUM

PROGRAM MODE 2

% speed at the minimum input

RUN

MODE

%SPEED

000

2

PROGRAM

STAND-BY

PRIME

MINIMUM

MAXIMUM

PROGRAM MODE 2

minimum input value

RUN

mA

2

PROGRAM

STAND-BY

PRIME

MINIMUM

MAXIMUM

MODE

04.0

4

Press the mode button. The Ma icon will stop blinking and the %
SPEED icon will blink. The ARROW next to the word MAXIMUM will

blink indicating the maximum value is ready to be programmed. The
currently programmed maximum motor speed value is shown on the 3-
DIGIT LCD.

4

Enter the motor speed at the maximum mA input signal value.

Press the FIELD button to select the digit to program. The digit will
blink when selected.

4

Press the DIGIT button to change the selected digit.

4

Repeat until all digits are programmed.

4

Press the mode button. The % SPEED icon will stop blinking and the
mA icon will blink indicating the maximum mA value is ready to be

programmed. The currently programmed maximum value is shown on
the 3-DIGIT LCD.

4

Enter the maximum mA input signal value. Note: this value must be
greater than the minimum mA input signal value. Press the FIELD
button to select the digit to program. The digit will blink when selected..

4

Press the DIGIT button to change the selected digit.

4

Repeat until all digits are programmed.

4

Press the mode button. Programming is complete.

4

To exit the programming mode, press the RUN/STANDBY button and
the MODE button at the same time. The

PROGRAM arrow will disap-

pear.

Page 12

PROGRAM MODE 2

% speed at the maximum input

RUN

100

mA

2

PROGRAM

STAND-BY

PRIME

MINIMUM

MAXIMUM

RUN

2

PROGRAM

STAND-BY

PRIME

MINIMUM

MAXIMUM

MODE

% SPEED

PROGRAM MODE 2

maximum input value

MODE

20.0

Example 1

4 mA = 0% OUTPUT

20 mA = 100% OUTPUT

100

75

50

25

Pump Motor Speed (%)

0

6

8

4

Milliamp input (mA)

4 mA = 0% OUTPUT

20 mA = 75% OUTPUT

100

75

50

12

10

Example 3

MODE 2 PROGRAMMING EXAMPLES

Example 2

4 mA = 100% OUTPUT

20 mA = 0% OUTPUT

100

75

50

25

Pump Motor Speed (%)

0

6

8

14

16

18

20

4

Milliamp input (mA)

Example 4

4mA=20%OUTPUT

20 mA = 50% OUTPUT

100

75

50

10

12

14

16

18

20

Pump Motor Speed (%)

25

0

6

8

4

Milliamp input (mA)

10

12

14

16

18

20

Pump Motor Speed (%)

25

0

6

8

4

Milliamp input (mA)

10

12

14

16

18

20

Page 13

5.5 - OPERATING MODE 3 - Output adjusted by 0-10VDC input signal

In this mode, the pump’s motor speed is adjusted automatically based on the
value of the 0-10VDC input signal. Any motor speed can be assigned to either
the minimum or maximum DC input signal values. However, the

programmed minimum VDC value must be less than the programmed
maximum VDC value. The ALARM and SERVICE icons will blink if the

programming is in error. To assign the minimum and maximum motor speed
and the minimum and maximum VDC input signal values:

4

Set the pump for mode 3. Press the MODE button until MODE 3 is
shown on the LCD display. The % SPEED or VDC icon will light depend­ing on the current display setting. The large 3-DIGIT LCD will indicate the
current motor speed or the VDC input value.

4

Enter the programming mode. At the same time, press the
RUN/STANDBY and MODE buttons. A blinking ARROW will point to the
word PROGRAM indicating the program mode is activated. A blinking
ARROW will point to the word MINIMUM indicating the minimum value is
ready to be programmed. The % SPEED icon will blink indicating the
percentage of speed is ready to be programmed.

4

Enter the motor speed at the minimum VDC input signal value. Press
the FIELD button to select the digit to program. The digit will blink when
selected.

4

Press the DIGIT button to change the selected digit.

4

Repeat until all digits are programmed.

4

Press the mode button. The % SPEED icon will stop blinking and the VDC
icon will blink indicating the minimum VDC value is ready to be pro­grammed. The currently programmed minimum value is shown on the 3-
DIGIT LCD.

4

Enter the minimum VDC input signal value. Note: this value must be
less than the maximum VDC input signal value. Press the FIELD button to
select the digit to program. The digit will blink when selected.

4

Press the DIGIT button to change the selected digit.

4

Repeat until all digits are programmed.

4

Press the mode button. The VDC icon will stop blinking and the % SPEED
icon will blink. The ARROW next to the word MAXIMUM will blink indicat-
ing the maximum value is ready to be programmed. The currently pro­grammed maximum motor speed value is shown on the 3-DIGIT LCD.

4

Enter the motor speed at the maximum VDC input signal value. Press
the FIELD button to select the digit to program. The digit will blink when
selected.

4

Press the DIGIT button to change the selected digit.

4

Repeat until all digits are programmed.

4

Press the mode button. The % SPEED icon will stop blinking and the VDC
icon will blink indicating the maximum VDC value is ready to be pro­grammed. The currently programmed maximum value is shown on the 3-
DIGIT LCD.

4

Enter the maximum VDC input signal value. Note: this value must be
greater than the minimum VDC input signal value. Press the FIELD button
to select the digit to program. The digit will blink when selected.

4

Press the DIGIT button to change the selected digit.

4

Repeat until all digits are programmed.

4

Press the mode button. Programming is complete.

4

To exit the programming mode, press the RUN/STANDBY button and the
MODE button at the same time. The PROGRAM arrow will disappear.

RUN MODE 3

MODE

3

VDC

00.0

PROGRAM MODE 3

% speed at the minimum input

MODE

%SPEED

000

PROGRAM MODE 3

minimum input value

MODE

VDC

00.0

PROGRAM MODE 3

% speed at the maximum input

MODE

%SPEED

100

PROGRAM MODE 3

maximum input value

MODE

VDC

10.0

RUN

PROGRAM

STAND-BY

PRIME

MINIMUM

MAXIMUM

RUN

3

PROGRAM

STAND-BY

PRIME

MINIMUM

MAXIMUM

RUN

3

PROGRAM

STAND-BY

PRIME

MINIMUM

MAXIMUM

RUN

3

PROGRAM

STAND-BY

PRIME

MINIMUM

MAXIMUM

RUN

3

PROGRAM

STAND-BY

PRIME

MINIMUM

MAXIMUM

5.6 - OPERATING MODE 4 - Output adjusted by frequency (Hz) input signal

In this mode, the pump’s motor speed is adjusted automatically based on the
frequency (Hz) of the input signal. Any motor speed can be assigned to either
the minimum or maximum Hz input signals. However, the programmed

minimum Hz value must be less than the programmed maximum Hz
value. The ALARM and SERVICE icons will blink if the programming is in

error. To assign the minimum and maximum motor speed and the minimum
and maximum Hz input signal values:

4

Set the pump for mode 4. Press the MODE button until MODE 4 is
shown on the LCD display. The % SPEED or Hz icon will light depending
on the current display setting. The large 3-DIGIT LCD will indicate the
current motor speed or the Hz input value.

4

Enter the programming mode. At the same time, press the
RUN/STANDBY and MODE buttons. A blinking ARROW will point to the
word PROGRAM indicating the program mode is activated. A blinking
ARROW will point to the word MINIMUM indicating the minimum value is
ready to be programmed. The % SPEED icon will blink indicating the
percentage of speed is ready to be programmed.

4

Enter the motor speed at the minimum Hz input signal value. Press
the FIELD button to select the digit to program. The digit will blink when
selected.

4

Press the DIGIT button to change the selected digit.

4

Repeat until all digits are programmed.

4

Press the mode button. The % SPEED icon will stop blinking and the Hz
icon will blink indicating the minimum Hz value is ready to be pro­grammed. The currently programmed minimum value is shown on the 3-
DIGIT LCD.

4

Enter the minimum Hz input signal value. Note: this value must be less
than the maximum Hz input signal value. Press the FIELD button to select
the digit to program. The digit will blink when selected.

4

Press the DIGIT button to change the selected digit.

4

Repeat until all digits are programmed.

4

Press the mode button. The Hz icon will stop blinking and the % SPEED
icon will blink. The ARROW next to the word MAXIMUM will blink indicat-
ing the maximum value is ready to be programmed. The currently pro­grammed maximum motor speed value is shown on the 3-DIGIT LCD.

4

Enter the motor speed at the maximum VDC input signal value. Press
the FIELD button to select the digit to program. The digit will blink when
selected.

4

Press the DIGIT button to change the selected digit.

4

Repeat until all digits are programmed.

4

Press the mode button. The % SPEED icon will stop blinking and the Hz
icon will blink indicating the maximum Hz value is ready to be pro­grammed. The currently programmed maximum value is shown on the 3-
DIGIT LCD.

4

Enter the maximum Hz input signal value. Note: this value must be
greater than the minimum Hz input signal value. Press the FIELD button
to select the digit to program. The digit will blink when selected.

4

Press the DIGIT button to change the selected digit.

4

Repeat until all digits are programmed.

4

Press the mode button. Programming is complete.

4

To exit the programming mode, press the RUN/STANDBY button and the
MODE button at the same time. The PROGRAM arrow will disappear.

Page 14

RUN MODE 4

MODE

4

000

PROGRAM MODE 4

% speed at the minimum input

MODE

% SPEED

000

PROGRAM MODE 4

minimum input value

MODE

000

PROGRAM MODE 4

% speed at the maximum input

MODE

% SPEED

82.5

PROGRAM MODE 4

minimum input value

MODE

628

RUN

PROGRAM

Hz

STAND-BY

PRIME

MINIMUM

MAXIMUM

RUN

4

PROGRAM

STAND-BY

PRIME

MINIMUM

MAXIMUM

RUN

4

PROGRAM

Hz

STAND-BY

PRIME

MINIMUM

MAXIMUM

RUN

4

PROGRAM

STAND-BY

PRIME

MINIMUM

MAXIMUM

RUN

4

PROGRAM

Hz

STAND-BY

PRIME

MINIMUM

MAXIMUM

Page 15

Example 1

0 Hz = 0% OUTPUT

1000 Hz = 100% OUTPUT

100

MODE 4 PROGRAMMING EXAMPLES

Example 2

0 Hz = 100% OUTPUT

1000 Hz = 0% OUTPUT

100

Example 3

0 Hz = 10% OUTPUT

275Hz=75%OUTPUT

100

75

50

25

Pump Motor Speed (%)

0

0

Pump Motor Speed (%)

75

50

25

0

200

0

400

Frequency input (Hz)

600

800

1000

6.0 How to Maintain the Pump

CAUTION: PROPER EYE AND SKIN PROTECTION MUST BE WORN WHEN

INSTALLING AND SERVICING THE FPUDV1000

6.1 Routine Inspection and Maintenance

The pump requires very little maintenance. However, the pump and all accessories should be
checked regularly. This is especially important when pumping chemicals. Inspect all compo­nents for signs of leaking, swelling, cracking, discoloration or corrosion. Replace worn or dam­aged components immediately.

Cracking, crazing, discoloration and the like during the first week of operation are signs of
severe chemical attack. If this occurs, immediately remove the chemical from the pump.
Determine which parts are being attacked and replace them with parts that have been manufac­tured using more suitable materials. The manufacturer does not assume responsibility for
damage to the pump that has been caused by chemical attack.

600

200

400

Frequency input (Hz)

800

1000

Pump Motor Speed (%)

75

50

25

0

200

0

400

Frequency input (Hz)

600

800

1000

6.2 500 Hour Service Warning Timer

The pump is equipped with a service warning timer. After 500 hours of accumulated running
time, the SERVICE icon will light. This is a reminder that the pump should be inspected for
service. Your actual service period will depend on many factors such as the chemical used, back

pressure, temperature, viscosity, and motor RPM.

Simultaneously press the RUN/STANDBY and DIGIT buttons to reset the service timer to zero.
Note: Pressing the FIELD and DIGIT buttons will display the currently accumulated time value.

6.3 How to Clean the Pump

The pump will require occasional cleaning, especially the Injection fitting, the Footvalve/Strainer,
and the pump head valves. The frequency will depend on the type and severity of service.

]

Inspect and replace the pumphead valves as required.

]

When changing the diaphragm, the pump head chamber and pump head cover should be
wiped free of any dirt and debris.

]

Periodically clean the injection/check valve assembly, especially when injecting fluids that calcify
such as sodium hypochlorite. These lime deposits and other build ups can clog the fitting,
increase the back pressure and interfere with the check valve operation. See section 4.3.4. Fig.

4.11.

]

Periodically clean the suction strainer. Fig.4.10

]

Periodically inspect the air vents located under the motor housing and in the back on the rear
housing cover. Clean if necessary.

age 1P6

epl c e a raw ngR a em nt P rts D i

36

61

06

14

62

67

86

42

40

39

38

35

37

56

36

52

51

43

59

55

32

66

64

53

65

45

75

52

31

z

E

H
(

D

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S

O

L
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P
=
4

T

C

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D

M

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0

D

G

TE

0

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=-1

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WIN

A

RE

D

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UT

F

E

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AN

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51

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9
6

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4444

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Page 17

Item Part No Description Qty

FPURV4 Inj. Valve .50-.25 Mpt X .37od, 6lb 1

66 76001-254 Junction Box, Ext. Input, Valox 1

67 90011-129 Screw, 6-32 X .25 Phil Pan SS Black 2

68 71000-133 Cover, J-Box with Gasket and Label 1

69 FPU1000-1F Inj. Valve .50-.25 Mpt X .37od, ½ lb 1

PARTS LIS T

Part No Description

34 C-618N-14 Gearbox, 14 RPM 1

Item

FPUDV 1000 SERIES

C-618N-30 Gearbox, 30 RPM 1

C-618N-45 Gearbox, 45 RPM 1

C-618N-60 Gearbox, 60 RPM 1

C-618N-125 Gearbox, 125 RPM 1

C-618N-250 Gearbox, 250 RPM 1

35 90011-078 Washer, Ground Screw, #8 Intrl/Star 1

36 90010-222 Lead Wire, ground, Green 1

37 90011-024 Ground Screw 8-32 x .25 Hex SL ST 1

38 90011-074 Washer, motor, #8 split-lock 2

39 90011-023 Screw, motor, 8-32 x .50 2

40 90010-244 Motor, 24V DC 1

70002-256 Gearmotor, 30 Rpm, 24 VDC 1

70002-257 Gearmotor, 45 Rpm, 24 VDC 1

70002-258 Gearmotor, 60 Rpm, 24 VDC 1

70002-259 Gearmotor, 125 Rpm, 24 VDC 1

70002-260 Gearmotor, 250 Rpm, 24 VDC 1

41 FPUD1000-BK Motor brush kit, (2 pc.) 24V DC 1

42 70002-255 Gearmotor, 14 Rpm, 24 VDC 1

44 90002-191 Door, Electronic Controls Cover 1

45 90006-579 Gasket, Enclosure Front, Neoprene 1

46 90012-245 Label Digital Timer w/ Ext. Input 1

47 76000-999 Slide Clamp, Enclosure Front 2

48 76001-000 Slide Clamp, Enclosure Rear 2

49 76001-253 Enclosure, Digital w/ Ext. Input 1

50 90003-559 Mounting Feet, Rubber 4

51 90011-091 Mounting Screw, #10 X 1.0” PhillipsSteel6

71000-176 Power Cord, 220v50hz, Digital Models 1

71000-177 Power Cord, 230v60hz, Digital Models 1

52 90011-094 Washer, Mounting, #10 Stainless 6

53 71000-175 Power Cord, 115v60hz, Digital Models 1

54 70000-589 Connector Liq-tite w/ nut .375 1

A-023N-V-230 Circuit board, 220V/230V 1

55 90010-235 Fuse, 1A, 250VAC 1

56 A-023N-V-115 Circuit board, 115V 1

57 90010-246 Wire set W/plug, alarm relay 1

59 90006-580 Gasket, Enclosure Back Plate,Neoprene1

60 90010-036 Wire Nut, Blue 2

61 76001-001 Tubing Spacer, Digital Circuit Board 2

62 71000-489 Enclosure Back Plate with Gasket, Valox1

63 90011-044 Screw 6-32 x .37 Swag Form 2

64 90007-515 Bushing, Junction Box Connector, Alum. 1

65 90008-199 Connector Liq-tite w/ nut .187 1

Part No Description

Item

1 C-345S Screen, FootValve, P.P. 1

2 90002-214 Body, FootValve, PVDF 1

2-108E O-ring Seat, FootValve, E.P. 1

3 2-108A O-ring Seat, FootValve, Aflas 1

90003-015 O-ring, FootValve, E.P. 1

4 C-385C Ball, FootValve, Ceramic 1

5 90003-014 O-ring, FootValve, Viton 1

FPUSV-V FootValve S/A, C-340V, Viton/Aflas 1

6 90002-215 Adapter, FootValve, PVDF 1

7 FPUSV-E FootValve S/A, C-340E, EP 1

8 C-346 Ceramic weight, C-346 1

9 C-334-6 Tubing Suction 3/8x5FT 1

C-560-6E Adapter S/A Bullet .37T EP 2

C-560-6S Adapter S/A Bullet .37T Silicon 2

10 C-330-6 Tube Nut, .37T, P.P. 2

11 C-560-6V Adapter S/A Bullet .37T Viton 2

12 FPUD1000-BCCartridge Bullet Valve S/A, Double-Ball 2

13 C-535 P/Head Noir Molded, P.P. 1

14 C-504HD Screw 10-32 x 1.25 4

C-535A6-6E Kit P/Head, HDN 37T E.P. P-P 1

15 C-535FW Cover P/Head, 1

16 C-535A6-6 Kit P/Head, HDN 37T Viton/Aflas, P-P 1

R-1505N Offset Cam #2 .055” 1

C-1505N-3 Offset Cam #3 .187” 1

C-1505N-4 Offset Cam #4 .100” 1

17 C-334-6-10 Tubing D/Charge, 3/8 x 10 FT 1

18 C-1505N Offset Cam #1 .125” 1

19 C-1514N Return Spring 2

20 C-1513N Stirrup with slide bearings 1

22 C-1502 Dial Knob 1

23 90011-168 Screw #6 x .62 PH oval ‘A’ 4

24 C-1519N Thumb Screw 6-32 x 1.125 1

R-1507A Drive Cam S/A #2 .055” 1

C-1507-3A Drive Cam S/A #3 .187” 1

C-1507-4A Drive Cam S/A #4 .100” 1

25 71000-363 Cover Cam S/A C-1100 1

28 C-1507A Drive Cam S/A #1 .125” 1

29 A-031 Spacer, Rotor 1

30 C-624N Screw 10-32 x .50 PHL PAN 4

31 90008-138 Plug .312 Hole Black 1

FPUD1000-15N Diaphragm S/A 2.015NEP/TFE 1

32 76001-183 Motor Mount, Large Diaphragm 1

33 C-406VT-15N Diaphragm S/A 2.0 15N, Viton/TFE 1

USA

IN

MADE

RETURN REQUESTS / INQUIRIES

OMEGA warrants this unit to be free of defects in materials and workmanship and to give satisfactory
service for a period of from date of purchase. OMEGA Warranty adds an additional one
(1)month grace period to the normal one to cover handling and shipping time.
This ensures that OMEGA’s customers receive maximum coverage on each product. If the unit should
malfunction, 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. However, this
WARRANTY is void if the unit shows evidence of having been tampered with or shows evidence of being
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 which wear
or which are damaged by misuse are not warranted. These include contact points, fuses, and triacs.

Every precaution for accuracy has been taken in the preparation of this manual; however, OMEGA
ENGINEERING, INC. Neither assumes responsibility for any omissions or errors that may appear nor
assumes liability for any damages that result from the use of the products in accordance with the
information contained in this manual.

: Should this equipment be used in or with any nuclear installation or activity,

purchaser will indemnify OMEGA and hold OMEGA harmless from any liability or damage whatsoever

13 months

(1) year product warranty

OMEGA is glad to offer suggestions on the use of it’s various products. Nevertheless, OMEGA only
warrants that the parts manufactured by it 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.

SPECIAL CONDITION

Direct all warranty and repair requests/inquiries to the OMEGA ENGINEERING 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.

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 1995 OMEGA ENGINEERING, INC.
All rights reserved. This documentation may not be copied, photocopied, reproduced, translated, or
reduced to any electronic medium or machine-readable form, in whole or in part, without written
consent of OMEGA ENGINEERING, INC.

OMEGA warrants this unit to be free of defects in materials and workmanship and to give satisfactory
service for a period of 13 months from date of purchase. OMEGA 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 should
malfunction, 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. However, this
WARRANTY is void if the unit shows evidence of having been tampered with or shows evidence of being
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 which wear
or which are damaged by misuse are not warranted. These include contact points, fuses, and triacs.

OMEGA is glad to offer suggestions on the use of it’s various products. Nevertheless, OMEGA only
warrants that the parts manufactured by it 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.

WARRANTY/DISCLAIMER

Every precaution for accuracy has been taken in the preparation of this manual; however, OMEGA
ENGINEERING, INC. Neither assumes responsibility for any omissions or errors that may appear nor
assumes liability for any damages that result from the use of the products in accordance with the
information contained in this manual.
SPECIAL CONDITION: Should this equipment be used in or with any nuclear installation or activity,
purchaser will indemnify OMEGA and hold OMEGA harmless from any liability or damage whatsoever

Direct all warranty and repair requests/inquiries to the OMEGA ENGINEERING 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.

RETURN REQUESTS / INQUIRIES

FOR WARRANTY RETURNS, please have FOR NON WARRANTY REPAIRS OR
The following information available CALIBRATION, consult OMEGA for

1. P.O. Number under which the product current repair/calbration charges. Have
was PURCHASED. Information before contacting OMEGA.

2. Model and serial number of the product 1. P.O. Number to cover the COAST of
under warranty, and the repair/ calibration.

3. Repair Instructions and/or specific 2. Model and serial number of product,
Problems relative to the Product. 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 1995 OMEGA ENGINEERING, INC.
All rights reserved. This documentation may not be copied, photocopied, reproduced, translated, or
reduced to any electronic medium or machine-readable form, in whole or in part, without written
consent of OMEGA ENGINEERING, INC.

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