Omega Fpdm1000 User Manual

FPDM1000 SERIES  
Positive Displacement  
Mechanical Flowmeters  
To the owner:  
IMPORTANT INFORMATION  
Thank you for purchasing an OMEGA  
FPDM 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 sec-  
tions of the manual.  
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 bas-  
ket type 60 mesh strainer be installed as  
close as possible to the inlet side of the  
meter. (If required, contact OMEGA for fur-  
ther information.)  
This manual contains connection and op-  
erating instructions for the OMEGA FPDM  
Series meters with mechanical displays.  
This includes the following models:  
FPDM1004  
FPDM1005  
FPDM1006  
FPDM1007  
NOTE: When a strainer is installed it should  
be regularly inspected and cleaned.  
Failure to keep the strainer clean will  
dramatically effect flowmeter perfor-  
mance.  
The OMEGA FPDM 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 ac-  
curacy over a wide range of fluid viscosi-  
ties and flowrates are features of the  
OMEGA FPDM Series Flowmeter design.  
The low pressure drop and high pressure  
rating means the OMEGA FPDM Series  
Flowmeter is suitable for both gravity and  
pump (in-line) applications.  
To prevent damage to the meter, slowly fill  
the system with fluid. This will prevent dam-  
age caused by air purge.  
NOTE: Failure to do this could damage the  
meter.  
For pump applications, turn off the pump  
at the end of each day.  
The OMEGA FPDM Series Flowmeters are  
available in either Aluminum or 316 Stain-  
less Steel. Standard rotors are made from  
PPS.  
The OMEGA FPDM Series mechanical dis-  
plays have a resettable batch totalizer and  
non-resettable accumulative totalizer.  
1
Figure 2  
INSTALLATION  
1. OMEGA recommends that when set-  
ting up pipework for meter installations,  
a bypass line be included in the de-  
sign. This provides the facility for a  
meter to be removed for maintenance  
without interrupting production. (See  
Figure 1)  
R I G H T  
Figure 1  
R I G H T  
Flow Inlet  
Bypass Line  
W R O N G  
Strainer  
NOTE: Incorrect installation can cause pre-  
mature wear of meter components  
Flow Outlet  
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.  
2. Use thread sealant on all pipe threads.  
3. For pump applications, ensure pipe  
work has the appropriate working pres-  
sure rating to match the pressure out-  
put of the pump.  
9. Test the system for leaks.  
10. Check the strainer for swarf or foreign  
material. After the first 200 litres, check  
periodically – particularly if the flowrate  
decreases.  
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 di-  
rection of the arrows embossed on the  
meter body.  
6. The meter can be installed in any ori-  
entation 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.  
2
OPERATION  
SERVICE INSTRUCTIONS  
When fluid passes through the meter, the  
rotors turn. The gear located on top of one  
of the rotors drives the mechanical regis-  
ters gear train which provides an accurate  
readout.  
Disassembly:  
Ensure that the fluid supply to the meter is  
disconnected, and the line pressure is re-  
leased before disassembly. Refer to the  
exploded parts diagram on page 6.  
1. Remove the four screws located on the  
face of the register. Then remove the  
faceplate cover including register as-  
sembly.  
2. Remove the four register mounting  
screws. Then remove the lower half of  
the register housing.  
3. Remove the six coverplate screws and  
remove the coverplate.  
4. Remove the four meter cap screws and  
remove the meter cap.  
5. Remove rotors.  
Reassembly:  
1. Clean all components before reassem-  
bly.  
2. Before reassembly, check the condition  
of the rotors. Replace if necessary.  
3. Replace the rotor (with the gear) on the  
short shaft in the housing. Then place  
the second rotor onto the shaft so as  
the rotors are at 90 degrees to each  
other. (See Figure 3)  
Figure 3  
Rotor #1  
Rotor #2  
Rotors must be at 90 to each other  
°
3
Check rotor 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 it correctly  
at 90 degrees to the other rotor. Recheck  
the operation of the rotors.  
10. Place the coverplate onto the meter.  
Replace the coverplate screws and  
tighten the six cap head screws firmly.  
11. Place the lower coverplate of the regis-  
ter into position. Replace the four screws  
and tighten.  
4. Inspect the gears in the meter cap for  
wear. Replace if required - refer to spare  
parts on page 6.  
12. Position the register correctly on top of  
the lower register cover. Replace the four  
screws and tighten.  
5. Replace the O-ring into the groove in  
the meter cap. If the O-ring has been  
distorted or is damaged in any way, re-  
place it with a new part.  
13. Test the meter by turning the rotors with  
a finger or by applying low air pressure  
(no more than a good breath) to one end  
of the meter, before returning meter to  
the line.  
6. Replace the meter cap. Make sure the  
meter cap and the gear on the rotor  
meshes correctly with the gear in the  
meter cap. Insert the allen screws and  
tighten in the sequence 1, 4, 2 and 3.  
7. Inspect the bevel gear, O-ring and out-  
put gear for wear or damage. Replace  
faulty components if necessary.  
8. Replace the output shaft, bush and seal.  
Disassembly of output shaft:  
a. Remove the bevel gear.  
b. Remove the circlip and push out the  
output shaft assembly, including the  
washer.  
c. Remove the seal.  
d. Carefully press out the output shaft  
bush (if required).  
Assembly of output shaft:  
a. Carefully press the new output shaft  
bush into place. (Use Loctite Primer  
7471, as per instructions, followed  
by sealant Loctite 262.)  
b. Insert a new seal into the groove of  
the output shaft bush.  
c. Replace the output gear and washer  
and replace the circlip to lock the  
output gear shaft into place.  
d. Replace the bevel gear and tighten  
the grub screw onto the flat face of  
the shaft.  
9. Place the O-ring into the groove in the  
meter cap. Replace the O-ring seal if  
required.  
4
TROUBLESHOOTING  
Symptom  
Probable Cause  
Corrective Action  
FLUID WILL NOT  
FLOW THROUGH  
THE METER  
1. Foreign matter blocking  
rotors  
Dismantle meter, clean rotors. Strainer must  
be fitted in-line.  
2. Line strainer blocked  
3. Damaged rotors  
Clean strainer.  
Replace rotors. Strainer must be fitted in-line.  
Re-adjust connections.  
4. Meter connections over-  
tightened  
5. Fluid is too viscous  
See specifications for maximum viscosity.  
Clean strainer.  
REDUCED FLOW  
THROUGH THE  
METER  
1. Strainer is partially  
blocked  
2. Fluid is too viscous  
See specifications for maximum viscosity.  
METER READING 1. Fluid flowrate is too high  
See specifications for minimum and maximum  
flowrates.  
INACCURATE  
or too low  
2. Fluid is too viscous  
Bleed air from system.  
3. Excess wear caused by  
incorrect installation  
Check meter body and rotors. Replace as  
required. Refer to installation instructions.  
FLUID FLOWS  
BUT NO READING  
ON METER  
1. Bevel gear is loose on  
on shaft  
Tighten grub screws.  
2. Rotor drive gear is  
damaged  
Replace rotor.  
3. Transmission gears  
damaged  
Replace gears.  
4. Register gears damaged  
Replace register assembly.  
FLUID LEAKS  
INTO REGISTER  
1. Seal worn or damaged  
on the coverplate  
Replace seal. Check seal compatibility with  
fluid.  
5
METER PARTS LISTING  
Model: FPDM1004  
1
2
3
4
7
*
20  
6
*
21  
10  
11  
13  
12  
14  
15  
16  
17  
5
8 / 9  
8A / 9A O-Ring Only  
= Parts for US Gallon models only.  
u = Recommended Spare Parts to stock.  
Bold Text = Indicates Stainless Steel model parts.  
*
Item  
Rec.  
Part or Set  
No. Qty. Parts (Order from this column only) Part Description  
1
1
2
2
3
3
4
4
4
4
5
5
6
6
7
8
8A  
9
9A  
10  
10  
11  
11  
12  
12  
12  
12  
1
1
1
1
2
2
1
1
1
1
4
4
1
1
1
1
1
1
1
1
1
1
1
6
6
6
6
MS298N  
MS337N  
BS145TES  
BS145VS  
MS342MS  
MS342MHS  
MS554S  
MS547S  
MS545S  
MS546S  
MS346S  
MS350S  
MS539S  
MS541S  
MS77S  
Meter Body 1/2 in. NPT (Aluminum)  
Meter Body 1/2 in. NPT (Stainless Steel)  
O-Ring (Teflon®)  
O-Ring (Viton)  
Rotors PPS (Polyphenylene Sulfide Resins)  
High Viscosity Rotors (PPS)  
Meter Cap Litres (Aluminum)  
Meter Cap US Gallons (Aluminum)  
Meter Cap Litres (Stainless Steel)  
Meter Cap US Gallons (Stainless Steel)  
Meter Cap Screws (Standard)  
Meter Cap Screws (Stainless Steel)  
Complete Gear Set - Litres  
Complete Gear Set - US Gallons  
Output Gear & Shaft Assembly  
Coverplate Seal / Bush Set Standard  
Solvent O-Ring (Kalrez)  
Coverplate Seal / Bush Set Solvent  
O-Ring (Viton)  
O-Ring (Teflon®)  
O-Ring (Viton)  
Coverplate (Aluminum) includes Bush  
Coverplate (Stainless Steel) includes Bush  
Coverplate Screws - Litre Model  
Coverplate Screws (S/Steel) - Litre Model  
Coverplate Screws - US Gallon Model  
u
u
u
u
u
u
u
u
u
u
u
u
u
u
u
MS78S  
OR42CS  
MS78C  
V7-007S  
BS145TES  
BS145VS  
MS99S  
MS99-1S  
MS312S  
MS313S  
MS419S  
MS420S  
u
u
u
u
Coverplate Screws (S/Steel) - US Gallon Model  
6
Item  
Rec.  
Part or Set  
No. Qty. Parts (Order from this column only) Part Description  
13  
14  
15  
16  
16  
17  
20  
20  
21  
21  
1
1
4
1
1
4
1
1
1
1
u
MS83S  
MS140S  
MS111S  
MS141M4GS  
MS141UGS  
MS129S  
BS145TES  
BS145VS  
MS423S  
Bevel Gear Set  
Bottom Register Coverplate  
Mounting Screws  
Register Assembly w/Coverplate - Litres  
Register Assembly w/Coverplate - US Gallons  
Register Body Screws  
O-Ring (Teflon®)  
O-Ring (Viton)  
Spacer Ring (Aluminum) US Gallon Model Only  
Spacer Ring (S/Steel) US Gallon Model Only  
u
u
u
u
u
u
u
u
MS423-1S  
SPECIFICATIONS  
Mechanical Meter Models  
Flow Ranges (LPM or GPM)  
Above 5 centipoise  
1 to 30 / 0.26 to 8  
Below 5 centipoise  
3 to 25 / 0.8 to 6.6  
Accuracy of Reading  
± 1%  
Maximum Viscosity  
Maximum Operating Pressure  
Operating Temperature Range  
1000 Centipoise  
3450 kPa / 500 PSI / 34.5 Bar  
-10°C to 80°C (+14°F to +176°F)  
*
Unless high viscosity rotors are fitted.  
*
DIMENSIONS  
7
METER PARTS LISTING  
Model: FPDM1005  
1
2
1A  
10  
6
11  
13  
12  
14  
15  
16  
3
17  
4
5
8 / 9  
8A / 9A O-Ring Only  
u = Recommended Spare Parts to stock.  
Bold Text = Indicates Stainless Steel model parts.  
Item  
Rec.  
Part or Set  
No. Qty. Parts (Order from this column only) Part Description  
1
1
1
1
2
2
3
3
3
3
3
3
4
4
4
4
5
5
6
6
7
8
8A  
9
9A  
10  
10  
1
1
1
1
1
1
2
2
2
2
2
2
1
1
1
1
6
6
1
1
1
1
1
1
1
1
1
MS188N  
MS186N  
MS188F  
MS186F  
BS235TES  
BS235VS  
MS72S  
MS72-1HS  
MS72-1S  
MS72-2S  
MS72HS  
MS72HG-2S  
MS75S  
MS75US  
MS251S  
MS251US  
MS114S  
MS200S  
MS294S  
MS316S  
MS77S  
Meter Body 1 in. NPT (Aluminum)  
Meter Body 1 in. NPT (Stainless Steel)  
Meter Body 1 in. ANSI 150 lb. Flange (Aluminum)  
Meter Body 1 in. ANSI 150 lb. Flange (S/Steel)  
O-Ring (Teflon®)  
u
u
u
u
u
u
u
u
O-Ring (Viton)  
Rotors (PPS) with Brass Hub  
High Viscosity Rotors (SS) with S/Steel Hub  
Rotors (SS) with S/Steel Hub  
Rotors (PPS) with S/Steel Hub  
High Viscosity Rotors (PPS)  
High Viscosity Rotors (PPS) with S/Steel Hub  
Meter Cap Litres (Aluminum)  
Meter Cap Gallons (Aluminum)  
Meter Cap Litres (Stainless Steel)  
Meter Cap US Gallons (Stainless Steel)  
Meter Cap Screws (Standard)  
Meter Cap Screws (Stainless Steel)  
Complete Gear Set - Litres  
Complete Gear Set - US Gallons  
Output Gear & Shaft Assembly  
Coverplate Seal / Brush Set (Viton)  
Solvent O-Ring (Kalrez)  
Coverplate Seal / Brush Set Solvent  
O-Ring (Viton)  
u
u
u
u
u
u
u
u
u
u
u
MS78VS  
OR42C  
MS78C  
V7-007S  
BS145TES  
BS145VS  
O-Ring (Teflon®)  
O-Ring (Viton)  
8
Item  
Rec.  
Part or Set  
No. Qty. Parts (Order from this column only) Part Description  
11  
11  
12  
12  
13  
14  
15  
16  
16  
17  
18  
19  
1
1
6
6
1
1
4
1
1
4
1
1
MS99S  
MS99-1S  
MS312S  
MS313S  
MS83S  
Coverplate (Aluminum) includes Bush  
Coverplate (Stainless Steel) includes Bush  
Coverplate Screws  
Coverplate Screws (Stainless Steel)  
Bevel Gear Set  
Bottom Register Coverplate  
Mounting Screws  
Register Assembly with Coverplate - Litres  
Register Assembly with Coverplate - US Gallons  
Register Body Screws  
u
u
u
MS140  
u
u
u
u
MS111S  
MS141S  
MS141US  
MS129S  
Customer to specify model Legend Plate (not shown) includes Hammer Screws  
MS37 Warning Label (not shown)  
Note: Complete Register Assembly Part Numbers; “Litre” Register - MS84, “US Gallons” Register - MS84U.  
SPECIFICATIONS  
Mechanical Meter Models  
Flow Ranges (LPM or GPM)  
Above 5 centipoise  
Below 5 centipoise  
Accuracy of Reading  
6 to 120 / 1.6 to 32  
10 to 100 / 2.6 to 26  
± 1%  
Maximum Viscosity  
Maximum Operating Pressure  
Maximum Operating Temperature  
1000 Centipoise  
3450 kPa / 500 PSI / 34.5 Bar or Flange Rule  
80°C / 176°F (Stainless Steel Models 120°C / 248°F)  
*
Unless High Viscosity Rotors are fitted.  
*
DIMENSIONS  
9
METER PARTS LISTING  
Model: FPDM1006  
1
2
10  
1
6
11  
13  
12  
14  
15  
16  
3
17  
4
5
8 / 9  
8A / 9A O-Ring Only  
u = Recommended Spare Parts to stock.  
Bold Text = Indicates Stainless Steel model parts.  
Item  
Rec.  
Part or Set  
No. Qty. Parts (Order from this column only) Part Description  
1
1
1
1
2
2
3
3
3
3
3
4
4
4
4
5
5
6
6
7
8
8A  
9
9A  
10  
10  
1
1
1
1
1
1
2
2
2
2
2
1
1
1
1
6
6
1
1
1
1
1
1
1
2
2
MS192N  
MS190N  
MS192F  
MS190F  
BS243TES  
BS243VS  
MS92S  
MS92-1S  
MS92-2S  
MS92HS  
MS92HS-2S  
MS222S  
MS222US  
MS223S  
MS223US  
MS116S  
MS180S  
MS295S  
MS317S  
MS77S  
Meter Body 11/2 in. NPT (Aluminum)  
Meter Body 11/2 in. NPT (Stainless Steel)  
Meter Body 11/2 in. ANSI 150 lb. Flange (Aluminum)  
Meter Body 11/2 in. ANSI 150 lb. Flange (S/Steel)  
O-Ring (Teflon®)  
u
u
u
u
u
u
u
O-Ring (Viton)  
Rotors (PPS) with Brass Hub  
Rotors (316 Stainless Steel)  
Rotors (PPS) with S/Steel Hub  
High Viscosity Rotors (PPS)  
High Viscosity Rotors (PPS) with S/Steel Hub  
Meter Cap Litres (Aluminum)  
Meter Cap Gallons (Aluminum)  
Meter Cap Litres (Stainless Steel)  
Meter Cap US Gallons (Stainless Steel)  
Meter Cap Screws (Standard)  
Meter Cap Screws (Stainless Steel)  
Complete Gear Set - Litres  
Complete Gear Set - US Gallons  
Output Gear & Shaft Assembly  
Coverplate Seal / Brush Set (Viton)  
Solvent O-Ring (Kalrez)  
Coverplate Seal / Brush Set Solvent  
O-Ring (Viton)  
u
u
u
u
u
u
u
u
u
u
u
MS78VS  
OR42CS  
MS78C  
V7-007S  
BS145TES  
BS145VS  
O-Ring (Teflon®)  
O-Ring (Viton)  
10  
Item  
Rec.  
Part or Set  
No. Qty. Parts (Order from this column only) Part Description  
11  
11  
12  
12  
13  
14  
15  
16  
16  
17  
1
1
6
6
1
1
4
1
1
4
MS99S  
MS99-1S  
MS312S  
MS313S  
MS83S  
Coverplate (Aluminum) includes Bush  
Coverplate (Stainless Steel) includes Bush  
Coverplate Screws - Litre Model  
Coverplate Screws (S/Steel) - Litre Model  
Bevel Gear Set  
Bottom Register Coverplate  
Mounting Screws  
Register Assembly Complete - Litres  
Register Assembly Complete - US Gallons  
Register Body Screws  
u
u
u
MS140RS  
MS111S  
u
u
u
u
MS141RS incl 15 & 17  
MS141RUS incl 15 & 17  
MS129S  
SPECIFICATIONS  
Mechanical Meter Models  
Flow Ranges (LPM or GPM)  
Above 5 centipoise  
10 to 250 / 2.6 to 66  
Below 5 centipoise  
15 to 235 / 4 to 62  
Accuracy of Reading  
± 1%  
Maximum Viscosity  
1000 Centipoise  
*
Maximum Operating Pressure**  
1800 kPa / 260 PSI / 18 Bar or Flange Rule  
-10°C to +80°C (+14°F to +176°F) - Aluminum  
-10°C to +120°C (+14°F to +248°F) - Stainless Steel  
Maximum Operating Temperature  
Unless High Viscosity Rotors are fitted.  
** Meter conforms to PED 97/23/EC CAT 1.  
*
DIMENSIONS  
11  
METER PARTS LISTING  
Model: FPDM1007  
1
5
2
*
10  
1
*
20  
6
10  
11  
13  
12  
14  
3
4
7
15  
16  
17  
5
8 / 9  
8A / 9A O-Ring Only  
= Parts for US Gallon models only.  
u = Recommended Spare Parts to stock.  
*
Bold Text = Indicates Stainless Steel model parts.  
Item  
Rec.  
Part or Set  
No. Qty. Parts (Order from this column only) Part Description  
1
1
1
1
2
2
3
3
3
3
4
4
4
4
5
5
6
6
7
8
8A  
9
9A  
10  
10  
11  
11  
1
1
1
1
1
1
2
2
2
1
1
1
1
1
6
6
1
1
1
1
1
1
1
2
2
1
1
MS520N  
MS520-1N  
MS483F  
Meter Body 2 in. NPT (Aluminum)  
Meter Body 2 in. NPT (Stainless Steel)  
Meter Body 2 in. ANSI 150 lb. Flange (Aluminum)  
Meter Body 2 in. ANSI 150 lb. Flange (S/Steel)  
O-Ring (Teflon®)  
MS481F  
u
u
u
u
u
u
BS252TES  
BS252VS  
MS105-1S  
MS105-2S  
MS105HS-2S  
MS105-1HS  
MS232S  
MS335US  
MS233S  
MS425US  
MS243S  
MS282S  
MS363S  
MS470S  
MS77S  
MS78VS  
OR42CS  
MS78C  
O-Ring (Viton)  
Rotors (316 S/Steel) with S/Steel Pinion  
Rotors (PPS) with S/Steel Pinion  
High Viscosity Rotors (PPS) with S/Steel Pinion  
High Viscosity Rotors (S/Steel) S/Steel Pinion  
Meter Cap Litres (Aluminum)  
Meter Cap US Gallons (Aluminum)  
Meter Cap Litres (Stainless Steel)  
Meter Cap US Gallons (Stainless Steel)  
Meter Cap Screws (Standard)  
Meter Cap Screws (Stainless Steel)  
Complete Gear Set - Litres  
Complete Gear Set - US Gallons  
Output Gear & Shaft Assembly  
Coverplate Seal / Brush Set (Viton)  
Solvent O-Ring (Kalrez)  
u
u
u
u
u
u
u
u
u
u
Coverplate Seal / Brush Set Solvent  
O-Ring (Viton)  
O-Ring (Teflon®)  
O-Ring (Viton)  
Coverplate (Aluminum) includes Bush  
Coverplate (Stainless Steel) includes Bush  
V7-007S  
BS145TES  
BS145VS  
MS99S  
MS99-1S  
12  
Item  
Rec.  
Part or Set  
No. Qty. Parts (Order from this column only) Part Description  
12  
12  
12  
12  
13  
14  
15  
16  
16  
17  
20  
20  
6
6
6
6
1
1
4
1
1
4
1
1
u
u
u
u
u
MS312S  
MS313S  
MS419S  
MS420S  
MS83S  
Coverplate Screws - Litre Model  
Coverplate Screws (S/Steel) - Litre Model  
Coverplate Screws - US Gallon Model  
Coverplate Screws (S/Steel) - US Gallon Model  
Bevel Gear Set  
Bottom Register Coverplate  
Mounting Screws  
Register Assembly with Coverplate - Litres  
Register Assembly with Coverplate - US Gallons  
Register Body Screws  
Spacer Ring (Aluminum) - US Gallons Model Only  
Spacer Ring (S/Steel) - US Gallon Model Only  
MS140  
u
u
u
u
u
u
MS111S  
MS141S  
MS141US  
MS129S  
MS423S  
MS423-1S  
Note: Complete Register Assembly Part Numbers; “Litre” Register - MS84, “US Gallons” Register - MS84U.  
SPECIFICATIONS  
Mechanical Meter Models  
Flow Ranges (LPM or GPM)  
Above 5 centipoise  
Below 5 centipoise  
Accuracy of Reading  
15 to 350 / 3.96 to 92.46  
30 to 300 / 7.93 to 79.25  
± 1%  
Maximum Viscosity  
1000 Centipoise  
*
Maximum Operating Pressure**  
1800 kPa / 260 PSI / 18 Bar  
-10°C to +80°C (+14°F to +176°F) - Aluminum  
-10°C to +120°C (+14°F to +248°F) - Stainless Steel  
Operating Temperature Range  
Unless High Viscosity Rotors are fitted.  
** Meter conforms to PED 97/23/EC CAT 1.  
*
DIMENSIONS  
13  
M-4103/0405  

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