Omega Engineering Automobile Parts FPR 200 User Manual

User’s Guide  
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Flow Sensor with  
Polypropylene Body  
ISO 9001  
CERTIFIED  
ISO 9002  
CERTIFIED  
CORPORATE QUALITY  
CORPORATE QUALITY  
MANCHESTER, UK  
STAMFORD, CT  
Flow Sensor with Stainless Steel Body  
FPR 200  
Flow Sensor  
 
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)  
 
Illustration 1:  
Mounting Instructions  
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)  
 
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  
Flow Rate vs. Frequency Output  
Flow Rate vs. Frequency Output  
Standard 1/2" NPTF Units  
Standard 3/4" & 1" NPTF Units  
60  
50  
40  
30  
20  
10  
0
60  
50  
40  
30  
20  
10  
0
0
2
4
6
8
10  
12  
14  
16  
0
10  
20  
30  
40  
50  
60  
Flow Rate (GPM)  
Flow Rate (GPM)  
7. The installation should be complete. The relationship between the  
frequency output and flow rate is shown in the graphs above.  
(7)  
 
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  
GROUND SCREW  
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  
Illustration 2  
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  
Wire Color  
Connection  
Red  
+12-35 VDC  
Black  
DC Ground  
Green  
White  
Relay Common  
Relay Normally Closed Contact  
Relay Normally Open Contact  
Brown  
(8)  
 
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  
Relay NC  
Contact  
Relay NO  
Contact  
Condition  
Red LED  
Green LED  
Illuminated  
Illuminated  
Flow rate<  
set point  
Open  
Closed  
Open  
Closed  
Open  
Illuminated  
Flow rate >  
set point  
Not  
Illuminated  
Not  
Loss of power  
to sensor  
Not  
Closed  
Illuminated  
Illuminated  
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)  
 
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)  
 
Mechanical Specifications  
FLOW SENSOR WITH STAINLESS STEEL BODY  
Maximum pressure:  
200 PSI clear cover, 500 PSI SS cover  
º
Maximum temperature: 225 F  
Measuring range*  
1/2" NPT Ported:  
0.5 - 15 GPM  
3/4" & 1" NPT Ported: 1.5 - 50 GPM  
Wetted materials:  
316SS, acetal copolymer, Buna, PEEK  
and polycarbonate  
Non-wetted materials: Epoxy, Lexan® and PVC  
FLOW SENSOR WITH POLYPROPYLENE BODY  
Maximum pressure:  
150 PSI  
º
Maximum temperature: 150 F  
Measuring range*  
1/2" NPT Ported::  
0.5 - 15 GPM  
Wetted materials:  
316SS, acetal copolymer, Buna, PEEK,  
polycarbonate and polypropylene  
Non-wetted materials: Epoxy, Lexan® and PVC  
*Important: Chose a maximum flow rate. For 1/2": 5 - 15 maximum GPM.  
For 3/4" and 1": 15 - 50 maximum GPM. Minimum flow rate will  
be 10% of maximum flow rate. Example: If your maximum flow  
rate is 8 GPM, the minimum flow rate would be .8 (8 x .1 = .8).  
Thus, the correct flow range would be .8 - 8.0 GPM.  
Electronic Specifications  
ALL VERSIONS WITH 4-20 MA CIRCUIT  
Power requirements:  
12-35VDC, 20mA  
Load driving capacity:  
Max. Load () = 50(Power Supply Voltage - 12)  
Trans. Distance:  
LED:  
limited only by wire resistance & supply voltage  
provides power indication  
±2% of full scale  
Flow rate accuracy:  
Repeatability:  
Resolution:  
±0.5% of scale  
infinite  
Response time:  
2 seconds to 90%  
Over-current protection: self limiting at 30mA  
Fail safe indication: 4 mA  
(11)  
 
ALL VERSIONS WITH 0-5 VDC CIRCUIT  
Power requirements:  
Maximum Current:  
Max. Trans. Distance:  
Min. Load Resistance:  
Flow rate accuracy:  
Repeatability:  
12-35VDC, 20 mA  
30 mA DC  
<200 feet recommended  
1000 Ω  
2% of full scale  
0.5% of scale  
infinite  
Resolution:  
Response time:  
2 seconds to 90%  
ALL VERSIONS WITH PULSE OUTPUT CIRCUIT  
Power requirements:  
Maximum Current:  
Max. Trans. Distance:  
Flow rate accuracy:  
Linearity:  
5-24VDC, 20 mA  
25 mA DC  
<200 feet recommended  
2% of full scale  
0.5% of scale  
Infinite  
Resolution:  
Response time:  
< 100 mS  
ALL VERSIONS WITH RELAY OUTPUT CIRCUIT  
Power Requirements  
Max. Trans. Distance  
Switch Contact  
12-35 VDC  
< 200 feet recommended  
Form C, 5A max @120 or 240 VAC  
5% of reading max.  
Hysteresis  
(12)  
 
Dimension Drawings  
DIM  
A
1/2" NPTF Ports  
3/4" & 1" NPTF Ports  
3.06" (78 mm)  
1.33" (34 mm)  
2.46" (62 mm)  
2.78" (71 mm)  
2.88" (73 mm)  
5.25" (133 mm)  
3.80" (97 mm)  
n/a  
1.94" (49 mm)  
1.13" (29 mm)  
2.00" (51 mm)  
2.45" (62 mm)  
2.60" (66 mm)  
3.70" (94 mm)  
2.63" (67 mm)  
3.38" (86 mm)  
B
C
D
D1  
E
F
F2  
1Dimension with optional clear cover installed  
2Polypropylene version only  
(13)  
 
NOTES:  
_______________________________________________________  
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_______________________________________________________  
_______________________________________________________  
_______________________________________________________  
_______________________________________________________  
_______________________________________________________  
_______________________________________________________  
_______________________________________________________  
_______________________________________________________  
_______________________________________________________  
_______________________________________________________  
_______________________________________________________  
(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 vibra-  
tion; 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 pur-  
chaser 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 WARRANTY 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.  
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.  
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 2005 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.  
 
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Process Measurement and Control?  
OMEGA…Of Course!  
Shop online at omega.com  
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