Omega Products FSW 530 Installation Manual

FSW 530 Series

Flow Switches For Liquids

READ THIS MANUAL COMPLETELY BEFORE ATTEMPTING TO CONNECT OR OPERATE YOUR FLOW SENSOR. FAILURE TO DO SO MAY RESULT IN INJURY TO YOU OR DAMAGE TO THE FLOW SENSOR.

TABLE OF CONTENTS

A. Introduction ........................................................................ 4

1. Unpacking ............................................................................. 4

2. Product Overview and Principle of Operation .......................... 4

3. Non Standard Products .......................................................... 5

B. Installation ......................................................................... 6

1. General Considerations ......................................................... 6

2. Mounting the FSW 530 ........................................................ 8

3. Tubing Connections ............................................................... 8

4. Electrical Connections .......................................................... 10

a) Overview ....................................................................... 10

b) Connecting to the FSW 530 .............................................. 11

c) Inductive Loads ................................................................. 12

C. Operation ........................................................................ 13

1. Start-Up .............................................................................. 13

2. Entrapped Air or Gas ........................................................... 13

3. General Operation .............................................................. 13

4. Verifying the Set Point ........................................................... 14

5. Adjusting the Set Point .......................................................... 15

6. Operating at Flow Rates Outside the Calibrated Flow Range .. 16

7. Zero Adjustments ................................................................. 16

8. Recalibration ....................................................................... 16

9. Calibrating the FSW 530 for Different Liquids ........................ 16

D. Maintenance And Product Care .......................................... 17

1. General ............................................................................... 17

2. Cleaning and Flushing ......................................................... 17

3. Returning Units for Repair Or Recalibration ........................... 17

E. Specifications .................................................................... 1 8

F. Dimensions ....................................................................... 19

G. Trouble Shooting Guide ..................................................... 21

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Introduction

1. Unpacking

All units are suitably packaged to prevent damage during shipping. If external damage is noted upon receipt of the package, please contact Omega immediately.

Open the package from the top, taking care not to cut too deeply into the package. Remove all the documentation and contents. Take care to remove all the items and check them against the packing slip. The products should also be checked for any concealed shipping damage. If any shortages or damage is noted, please contact the shipping company and/or Omega to resolve the problem.

Typical Contents of Box:

FSW 530, Calibration Certificate & Instruction Manual

FLR 3100/3100BR/3100ST

CAUTION: Take care not to

drop

your FSW 530. Read the installation section of this manual before providing power or tubing connections to the unit. Any damage caused by improper installation or careless handling will not be repaired under warranty.

2. Product Overview and Principle of Operation

The FSW 530 Series of flow switches for liquids from Omega are capable of monitoring flow ranges as low as 13-100 ml/min or as high as 1.0-10.0 l/min. Highly repeatable results are achieved using a patented Pelton Turbine Wheel flow sensor design. This proven design minimizes zero drift while maintaining fast response and linear outputs with virtually no maintenance.

Series

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Flow is measured using a miniature turbine wheel similar in size to a U.S. dime (16 mm diameter, 0.75 mm thick). The micro-turbine wheel is supported on a very small sapphire shaft that is held in position by two sapphire bearings. The micro-turbine assembly is so light that it virtually floats in the liquid. This relieves force on the bearings and almost eliminates wear.

As flow passes through the FSW 530, a precision machined nozzle directs the fluid onto the very small teeth of the micro-turbine wheel. This causes the wheel to spin at a speed proportional to the flow rate.

The micro-turbine wheel has alternating white and black sections evenly spaced on one side of the wheel. An infrared light beam is directed onto the wheel. As the wheel rotates the infrared beam is reflected off each white section. The reflected beam is detected by a phototransistor that converts the reflections into electrical pulses. As the wheel spins faster the pulse rate increases.

Processing circuitry monitors the flow rate. When the configured set-point is achieved a solid state relay is activated.

When the wheel stops (under zero flow conditions), no pulses are generated. Consequently, zero drift is not possible and zero adjustments are never required.

Every unit is supplied with a calibration certificate detailing the results obtained during calibration. Units are calibrated using deionized water as the reference media. Flowing liquids with different specific gravities or viscosities may affect the calibration.

3. Non-Standard Products

Please note that the installation instructions, operating instructions, and specifications included within this manual apply to standard production models only. If your FSW 530 has a custom alteration then your unit is non-

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standard. Contact the factory to check if the installation, operation, or specifications of your sensor are different than detailed in this manual.

Installation

CAUTION: Do not flow any gas through a liquid flow switch. This will damage the micro-turbine assembly and void the warranty.

CAUTION: Do not exceed the pressure, temperature or power

operating ranges detailed in the SPECIFICATIONS section of this manual. Omega shall not be liable for any damage or injury caused by incorrect operation of their products.

1. General Considerations

It is recommended that a safety shut-off valve be installed upstream of (before) the FSW 530.

All wetted parts should be checked for compatibility with the liquid to be used. If there are any incompatibilities e.g. highly corrosive liquid, then the unit may be damaged or fail prematurely. Such damage will not be repaired under warranty.

Units should be installed in a clean, dry environment with an ambient temperature that is as stable as possible. Avoid areas with strong magnetic fields, strong air flows or excessive vibration.

If the liquid to be used may contain particles larger than 25 microns then a filter (25 microns or less) should be installed upstream of (before) the unit.

The required differential press (or pressure drop across the unit) decreases exponentially with decreases in flow rate.

To calculate the pressure drop at a certain flow rate use the formula:

PD = (YourFlow / MaxFlow)2 x PDmax

PD = Pressure drop at YourFlow. YourFLow = flow rate (ml/min or l/min) MaxFlow = 100% rated flow for the sensor (in same units as YourFlow)

max = Pressure drop at 100% rated flow (see chart above)

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Pressure Drop vs. Percentage of the Full Scale

Rated Flow (may vary ±10% of indicated psid)

0.8

Delta P psid

10 20 30 40 50 60 70 80 90 100

% of rated flow

100-1000 ml/m in Un its

ll Other Ranges

0.7

0.6

0.5

0.4

0.3

0.2

0.1

Delta P Bar

If the pressure available for the FSW 530 is BELOW the pressure drop at the required flow then flow through the unit will not be possible.

For example: You have a FSW 530 with a 60-500ml/min flow range and want to know the pressure drop (or minimum differential pressure required) at 300ml/min. According to the chart above, the pressure drop at 100% of flow is approx 10psi. Using the formula above:

PD = (300 / 500)2 x 10 = 3.6 psid

Therefore, at 300ml/min the minimum required differential pressure for this unit is 3.6 psid. This means that if the available pressure is below 3.6psid then flow through the unit will not be possible.

Pressure drop through a system is cumulative. If the total pressure drop across all the components in a system exceeds the minimum pressure available then flow will not be possible.

For example: A system has a pressure of 30-40psi. There are several components and the sum of their pressure drops at the required flow rate is 32psid. If the system is operating at 30psi, flow would not be possible as the total of the pressure drops would be greater than the pressure available. The system will only operate if the system pressure is above 32psi.

If there is any possibility that there may be bubbles or entrapped gas in the system then the outlet tubing should be elevated above the inlet port. This will enable any gas that may become entrapped in the unit to escape.

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2. Mounting the FSW 530.

FSW 530 units have no particular installation requirements so may be mounted in any convenient position. It is recommended that the outlet of the FSW 530 is parallel with, or elevated above the inlet. This will enable entrapped air in the system to pass through the unit more easily.

It is recommended that units be fixed to a suitable substrate with #4 screws using the two mounting holes provided.

Mounting View From Bottom

(Mounting hardware not included with FSW 530).

3. Tubing Connections

CAUTION: DO NOT FLOW ANY GAS THROUGH A LIQUID FLOW SWITCH. THIS MAY DAMAGE THE MICRO-TURBINE ASSEMBLY AND VOID THE WARRANTY.

All tubing must be clean and without crimps, burrs or scratches.

Only use the fittings factory installed on the unit. If the fittings are removed the calibration of the unit may be effected and leaking may occur. If different fittings are required please contact Omega for assistance.

CAUTION: DO NOT over tighten the fittings into the flow switch body. Excessive force may damage the flow switch body and will NOT be repaired under warranty.

When connecting the FSW 530 to the tubing a wrench should be used to stop the fitting rotating in the FSW 530 body. Take care not to over tighten the fittings or leaking may occur.

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