Omega Engineering FPR 200 Manuale utente

FPR 200

Flow Sensor

Flow Sensor with Stainless Steel Body

Flow Sensor with

Polypropylene Body

User’s Guide

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OMEGAnet®Online Service Internet e-mail

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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.

Introduction

This manual is a service guide produced by the manufacturer. The

manual provides specific procedures and/or illustrations for installa-

tion, inspection, cleaning and filtration of all Omega FPR 200 flow

sensors. When properly followed, these procedures will keep your

flow sensor operating dependably for many years.

It is important for operators and maintenance personnel to be safety

conscience when operating or repairing equipment. Developing a thor-

ough knowledge of the precautionary areas and following safe operat-

ing procedures, can prevent equipment damage and/or personal injury.

Before making any repair, read all of the repair procedures to learn

the correct method and all precautions.

General

Omega’s flow sensors integrate rugged tangential turbine technology

with a precision digital to analog conversion circuit hermetically

encapsulated within the body of the sensor. The flow sensor is ideal

for measuring flow rates in cooling circuits, HVAC systems and batch-

ing operations.

Additional features are:

simple in-the-field serviceability of its moving components

the integral 4-20mA circuit design eliminates the need for separate

signal conditioning modules

units come factory calibrated to your system requirements

the low impedance 4-20mA circuit can transmit a "clean" signal

over low-cost wire for several thousand feet without degradation

accurately measures flow in both directions.

(3)

Installation - Mechanical

1. The flow sensor has NPT (National Pipe Thread) plumbing con-

nections. It is recommended that a paste type pipe sealant be

used on these threads. [Teflon tape sealant can be used as long

as it is applied in such a way that it will not enter the flow stream.

Pieces of Teflon tape can wrap around the turbine and impede its

rotation.]

2. The recommended mounting orientation would be any plane that

will place the axis of the turbine horizontal with respect to the

ground. See Illustration 1. The unit will operate satisfactorily with

its axis at angles other than horizontal, but side loading of the

bearing surfaces will lead to premature wear of the rotating parts.

3. For the best flow measurement results, place the inlet (See Note 1)

of the flow sensor at least 10 straight pipe diameters down-

stream from any fitting, valve, elbow, reducer, etc. that causes

non-stable flow conditions. Ideally, 5 straight pipe diameters should

be placed at the outlet of the sensor. If the sensor must be placed

closer to a source of non-stable flow than these recommended dis-

tances, some instability of the output signal may result. The aver-

age signal will be accurate.

(4)

Illustration 1:

Mounting Instructions

4. It is recommended that the sensor be placed in such a position

that the round access cover can be removed for cleaning and tur-

bine servicing. It is also recommended that a union be placed

near the sensor to allow easy removal.

Note1: The flow sensor is a bi-directional measuring device.

References to “inlet” and “outlet” refer to uni-directional systems.

Installation - Electronic (4-20mA Only)

The flow sensor circuit is a two-wire loop-powered design that transmits

a 4-20mA signal that is proportional to flow rate. The noise-immune cur-

rent transmission from the sensor can be routed with low cost two con-

ductor twisted-pair cable. The circuit operates on 12-35 VDC and

requires a source capable of supplying at least 20mA of current. The

circuit has built in polarity protection and over-current limiting to protect

both the transmitter and what the transmitter is connected to.

1. Connect the red wire (pin 1 for units with the electronic disconnect

option) from the transmitter sensor to the positive 12-35 VDC

power supply output.

2. Connect the black wire (pin 2 for units with the electronic disconnect

option) from the transmitter to the positive side of the loop load

(resistor, chart recorder, data acquisition board, meter, etc.). This

connection may be labeled "4-20mA Input" or "4-20mA (+)" on

some devices.

3. If applicable, connect the negative side of the loop load to negative

side of the power supply.

4. Apply power to the system.

5. If everything is operating correctly, the green LED on the sensor

will dimly illuminate and 4mA will be flowing in the loop. If there is

fluid flowing through the sensor, the current will be higher than

4mA and the LED will be quite bright.

If the LED does not illuminate:

check wiring terminations for good connections

check wiring polarity

verify correct supply voltage

ensure that the load impedance is within allowable limits

(5)

Apply the DC supply voltage directly across the sensor wires. If

the LED does illuminate, the load is either: too great of imped-

ance or an open circuit. If the LED does not illuminate, the sen-

sor's lead wires or circuit are defective.

6. The installation should be complete.

Installation - Electronic (0-5VDC Output Only)

1. Connect the red wire (pin 1 for units with the electronic disconnect

option) from the sensor to the positive terminal of the 12-35 VDC

power supply.

2. Connect the black wire from the transmitter (pin 2 for units with the

electronic disconnect option) to the negative terminal of the 12-35

VDC power supply.

3. Connect the green wire from the transmitter (pin 3 for units with

electronic disconnect) to the (+) 0-5 VDC input of the data acquisi-

tion device. This connection may be labeled "Voltage Input" or

"Analog Input" on some devices.

4. If applicable, connect the negative side of the power supply to the

negative side of the pulse input.

5. Apply power to the system.

6. If everything is operating correctly, the green LED will illuminate

brightly and the data acquisition device should show an increase in

flow rate as fluid starts flowing through the sensor.

If data acquisition device does not show an increase in flow rate:

check wiring terminations for good connections

verify that the LED is illuminated

verify that the DC supply voltage is between 12 and 35 VDC

(6)

Installation - Electronic (Pulse Output Only)

The flow sensor pulse output circuit is a three-wire DC-powered design

that transmits a frequency proportional to flow rate. The circuit operates on

5-24 VDC and will consume a maximum of 25 mA from the power supply.

1. Connect the red wire (pin 1 for units with the electronic disconnect

option) from the sensor to the positive terminal of the 5-24VDC

power supply.

2. Connect the black wire from the transmitter (pin 2 for units with the

electronic disconnect option) to the negative terminal of the 5-24

VDC power supply.

3. Connect the green wire from the transmitter (pin 3 for units with

electronic disconnect) to the (+) pulse input of the data acquisition

device. This connection may be labeled "Pulse In" or "DC Input"

on some devices.

4. If applicable, connect the negative side of the power supply to the

negative side of the pulse input.

5. Apply power to the system.

6. If everything is operating correctly, the data acquisition device should

begin "counting" pulses when fluid starts flowing through the sensor.

If the data acquisition device is not “counting”:

check wiring terminations for good connections

verify correct supply voltage and current

7. The installation should be complete. The relationship between the

frequency output and flow rate is shown in the graphs above.

(7)

Flow Rate vs. Fre

uenc

Out

Standard 1/2" NPTF Units

0246810121416

Flow Rate (GPM)

Frequency (Hz)

Flow Rate vs. Fre

uenc

Out

Standard 3/4" & 1" NPTF Units

0 102030405060

Flow Rate (GPM)

Frequency (Hz)

Installation - Electronic (Relay Output Only)

1. Connect the red wire from the sensor to the positive terminal of the

12-35 VDC power supply.

2. Connect the black wire from the transmitter to the negative terminal

of the 12-35 VDC power supply.

3. (Versions with stainless steel sensor body only) Be sure to properly

ground the flow sensor by using the ground screw shown

in Illustration 2 to

connect the sensor body

Earth ground. This step

may be unnecessary if

the piping system that the

flow sensor is plumbed

into is already connected

to Earth ground.

4. Wire the appropriate relay contacts to the load that is to be

switched per Table 1 below.

5. If the unit is operating correctly, the green power indication LED

and the red relay status LED should illuminate after the DC supply

voltage is turned on. As fluid flow is increased above the factory-

adjusted set point, the red relay status LED should turn off.

If the LEDs do not illuminate when power is applied:

check wiring terminations for good connections

verify that the DC supply voltage is between 12 and 35 VDC

Table 1.: Wiring Connections

(8)

Wire Color Connection

Red +12-35 VDC

Black DC Ground

Green Relay Common

White Relay Normally Closed Contact

Brown Relay Normally Open Contact

Illustration 2

GROUND SCREW

Set Point Adjustment (Relay Output Only)

1) Adjust the flow rate through the line in which the flow sensor is

installed to the rate that corresponds to the desired relay trip point.

2) If the red LED on the back side of the sensor is not illuminated, use a

small flat bladed screwdriver to slowly turn the adjustment screw on the

set point potentiometer counter-clockwise until the red LED illuminates.

3) If the red LED is already illuminated, turn the adjustment screw on

the potentiometer clockwise until red LED turns off. Next, slowly

rotate the adjustment screw counter-clockwise until the red LED

illuminates.

4) Once the set point has been adjusted, the relay will operate as

shown in the Truth Table illustrated in Table 2 below.

Table 2.: Truth Table - Relay Operation

Service and Maintenance

The sensor is designed to provide years of low maintenance service

in industrial environments. As with all mechanical rotating devices, the

bearing surfaces will wear with use. The life of the parts will depend

on factors such as cleanliness of the fluid, media, mounting orienta-

tion, temperature, fluid velocity and frequency of operation. The flow

sensor was designed with simple field-replacement of the rotating

parts in mind. To inspect or replace the rotating components:

(9)

Condition Relay NC

Contact Relay NO

Contact Red LED Green LED

Flow rate<

set point Open Closed Illuminated Illuminated

Flow rate >

set point Closed Open Not

Illuminated Illuminated

Loss of power

to sensor Open Closed Not

Illuminated Not

Illuminated

1. Relieve pressure in the piping system.

2. Remove the retainer ring that secures the turbine access cover.

3. Remove the access cover with a pliers, taking care not to damage

the o-ring seal.

4. Pull out the turbine assembly and the shaft.

5. Inspect the shaft for things that may have wrapped around it.

6. Inspect the turbine bearing surface for wear and elongation.

Replace as necessary.

7. Clean any rust off of the magnets that may have accumulated.

8. Reassemble the unit by placing the turbine into the body cavity

with the two magnet pockets facing inward. Place the shaft into the

turbine hole and guide it into the retaining hole in the body cavity.

Lubricate the o-ring seal with some glycerin or other lubricant and

press it into the pocket of the body. Replace the retaining ring

securely before applying pressure to the system.

Circuit recalibration (4-20mA version):

1. Place a milliamp meter into the current loop.

2. Turn off the flow going though the sensor. Adjust the OFFSET

control for a reading of 4mA on the milliamp meter.

3. Adjust the flow rate though the meter to full flow rate. Adjust the

SPAN control for a reading of 20mA on the milliamp meter. The

two controls are not interactive, so further adjustment should not

be necessary.

Circuit recalibration (0-5VDC version):

1. Place a voltmeter across the black & green wires of the sensor pigtail.

2. Turn off the flow going though the sensor. Verify a reading of less

than 50 mVDC on the voltmeter.

3. Adjust the flow rate though the meter to full-scale flow rate. Adjust

the SPAN control for a reading of 20mA on the milliamp meter.

The two controls are not interactive, so further adjustment should

not be necessary.

(10)

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