FLR 1000 & 1000-BR Series
Flow Sensors & Meters For Gases
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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.
T A B L E O F C O N T E N T S
A.
B.
Introduction....................................................................................4
1. Unpacking .................................................................................4
2. Product Overview And Principle Of Operation ...............................4
Installation .....................................................................................5
1. General Considerations...............................................................6
2. Mounting the Flow Sensor or Flow Meter .......................................6
3. Tubing Connections ....................................................................7
4. Electrical Connections .................................................................8
a) Overview .............................................................................8
b) Connecting a Cable Assembly...................................................9
c) Electrical Connections - Voltage Output Units ...........................10
d) Using a 0-5VDC Output Power Adapter Package......................11
C.
Operation....................................................................................12
1. Start-Up...................................................................................12
2. Flow Readings ..........................................................................12
a) 0-5VDC Analog Outputs ........................................................12
b) Units with an Integral Display ..................................................12
3. Operating at Flow Rates Outside the Calibrated Flow Range .........13
a) Flows Above the Maximum Rated Flow.....................................13
b) Flows Below the Maximum Rated Flow .....................................13
4. Zero Adjustments ......................................................................14
5. Recalibration ............................................................................14
6. Using Flow Sensors or Flow Meters with Different Gases................14
D.
Maintenance And Product Care......................................................16
1. General ...................................................................................16
2. Cleaning and Flushing...............................................................16
3. Returning Units For Repair Or Recalibration.................................16
E.
Specifications ...............................................................................17
Connector Pin and Wire Color Cross Reference ...............................18
Dimensions ..................................................................................19
Trouble Shooting Guide.................................................................26
F.
G.
H.
pg. 3 of 29
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A.
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 Engineering 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 Engineering to resolve the problem.
Typical Contents of Box:
Sensor, Calibration Certificate & Instruction Manual
(Model FLR 1000 shown, other models similar).
FLR 3100/3100BR/3100ST
Series
Caution: Take care not to drop your sensor or subject it to
sudden impact. 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 (see limited warranty on page
28 for more details).
2. Product Overview and Principle of Operation
The FLR 1000 series of flow meters and sensors for gases from Omega
Engineering are capable of measuring volumetric flows as low as 20-100
ml/min or as high as 100-500 l/min. Highly repeatable results are
achieved using a patented Pelton Turbine Wheel flow sensor design. This
pg. 4 of 29
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proven design minimizes zero drift while maintaining fast response and
linear outputs with virtually no maintenance.
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.
As flow passes through the sensor, a precision machined nozzle directs the
gas onto the very small teeth of the micro-turbine wheel. This causes the
wheel to spin at a speed proportional to the volumetric 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 provides analog and/or pulse
output that are linearly proportional to the volumetric flow rate
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 AIR as the reference
media. Flowing gases with different physical characteristics may effect the
calibration.
B.
Installation
Caution: Do not exceed the pressure, temperature or
power operating ranges detailed in the SPECIFICATIONS
section of this manual. Omega Engineering shall not be
liable for any damage or injury caused by incorrect
operation of their products.
pg. 5 of 29
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1. General Considerations
It is recommended that a safety shut-off valve be installed upstream of
(before) the sensor.
All wetted parts should be checked for compatibility with the gas to be
used. If there are any incompatibilities eg. highly corrosive gas, 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 gas 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.
2. Mounting the Flow Sensor or Flow Meter.
Caution: On high flow units (2.0-10.0 L/min, and above)
DO NOT disassemble the shunt / mounting plate
assembly or the unit will not operate correctly and the
warranty will be void.
The Omega Engineering FLR 1000 Series units have no particular
installation requirements so may be mounted in any convenient position.
For optimum results the unit should be mounted with the mounting feet
horizontal on top of a flat horizontal surface. This is the same position that
the unit is calibrated in at the factory. Please contact the Omega
Engineering Service Department if calibration for mounting in another
orientation is desired.
It is recommended that units be fixed to a suitable substrate with #4
screws using the two mounting holes provided.
Mounting The Sensor
(mounting hardware not included with sensor)
pg. 6 of 29
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3. Tubing Connections
CAUTION: DO NOT FLOW ANY LIQUID THROUGH A GAS
FLOW SENSOR OR FLOW METER. THIS WILL SERIOUSLY
EFFECT THE PERFORMANCE AND VOID THE WARRANTY.
CAUTION: DO NOT FLOW A HIGH PRESSURE GAS
THROUGH THE SENSOR. A BURST OF HIGH PRESSURE
GAS MAY CAUSE THE UNIT TO BE DAMAGED. ALWAYS
FLOW GAS AT A PRESSURE AND FLOW RATE WITHIN
THE SPECIFCATIONS OF THE UNIT
All tubing must be clean, dry and without crimps, burrs or scratches.
Only use the factory installed fittings 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 the Omega
Engineering Company Service Department for assistance.
When connecting the sensor to the tubing a wrench should be used to
stop the fitting rotating in the sensor body. Take care not to over tighten
the fittings or leaking may occur.
Connecting and tightening the Fittings
(FLR 1000-ST-D shown, other models similar)
Caution: DO NOT over tighten the fittings into the flow
sensor or flow meter body. Excessive force may damage
the sensor body. This type of damage will NOT be
repaired under warranty.
The flow direction for the unit is clearly marked on the label. Do not
reverse the flow direction or the unit will not function correctly.
pg. 7 of 29
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Close Up of Label Showing Flow Direction
(FLR 1000 shown, other models similar)
The tubing ID should be as large as possible to avoid restrictions and
turbulence. For the best results, a straight length of tubing before the unit
is recommended. This should be 20 times the tubing I.D. or greater
4. Electrical Connections
Caution: Incorrect wiring may cause severe damage to the unit.
Applying an AC voltage (115VAC or 230VAC) directly to the unit
will cause damage. Read the following instructions carefully
before making any connections.
a) Overview
Omega Engineering flow sensors for gases provide a 0-5VDC output
proportional to the volumetric flow rate. This output may be connected to
a display, data acquisition system or voltmeter. The FLR 1000-D and 1000-
BR-D series feature an integral display that provides a local flow reading.
These units also have a 0-5VDC analog output available. If required, this
may be connected to another display, data acquisition system or
voltmeter.
A stable D.C. power supply is required to operate the unit. The voltage
and current requirements depend on the configuration of the unit. Full
details may be found in the Specification section of this manual.
Connecting wires should be as short as possible to avoid voltage drops.
Twisted 2 pair conductor cable of a suitable gauge should be used if the
length of the power wires is to be longer than 1 meter (3.2 feet).
pg. 8 of 29
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Units are supplied with an integral 4 pin connector. Connections to the unit
are made using a mating cable assembly or power adapter package as
detailed in the following sections. A connector pin and wire color cross
reference may also be found in Appendix F (Page 18) of this manual.
b) Connecting a Cable Assembly
The connector on the end of the cable assembly should be pushed into the
mating socket on the sensor taking care to ensure that it is the correct
way up.
Connecting the Cable Assembly
(FLR 1000 shown, other models similar)
Electrical connections to the cable assembly are made as detailed in the
following sections.
pg. 9 of 29
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c) Electrical Connections – Voltage Output Units
The cable assembly should be connected to the sensor as detailed in
section 5(b) above. Do not apply power to the sensor until all the
connections have been made and checked. Electrical connections should
be made as follows:
Wiring Schematic For Voltage Output Units.
The RED wire should be connected to the Positive of the power source.
The BLACK wire should be connected to the Negative ( Ground ) of the
power source.
The WHITE wire provides the signal output and should be connected to
the positive terminal of the display, data acquisition system or voltmeter
with an impedance greater than 2500Ω (Ohms).
The GREEN wire is not used.
Caution: Avoid high voltage static discharges to any of the
connections. Do not short the input/output signal wires or allow
them to contact the power wires at any time. DAMAGE WILL
RESULT!
pg. 10 of 29
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d) Using a 0-5VDC Output Power Adapter Package.
An optional 0-5VDC Output Power Adapter Package is available for use
with the FLR 1000 series (not the FLR 1000-ST-I). This consists of a power
source (115VAC or 230VAC) and cable assembly with pig-tail (soldered
wire) ends for the signal output. This should be assembled as shown in
the following diagram.
Connecting the Power Adapter to the Flow Sensor
(FLR 1000 shown, other models similar)
The 0-5VDC analog output may be connected to a display, data acquisition
system or voltmeter with a minimum load of 2.5 kΩ (kilo ohms).
The YELLOW wire of the cable assembly provides the 0-5VDC signal
output and should be connected to the positive terminal of the display,
data acquisition system or voltmeter.
The GREEN wire is not used.
The WHITE wire of the cable assembly is the signal negative and should
be connected to the negative (ground) terminal of the voltmeter, display
or data acquisition system.
Caution: Avoid high voltage static discharges to any of the
connections. Do not short the output signal wires or allow them
to contact the power wires at any time. DAMAGE WILL RESULT!
pg. 11 of 29
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C.
Operation
CAUTION: DO NOT FLOW ANY LIQUID THROUGH A GAS
FLOW SENSOR OR FLOW METER. THIS WILL SERIOUSLY
EFFECT THE PERFORMANCE AND VOID THE WARRANTY.
1. Start Up
Before applying power to the unit check all tubing and electrical
connections. Once correct installation is verified switch on the power.
2. Flow Readings
The FLR 1000 Series for gases provide a 0-5VDC output proportional to
the volumetric flow rate.
The FLR 1000-D and FLR 1000-BR-D series feature an integral 3.5 digit
display that provides a local flow reading and a 0-5VDC analog output
proportional to the volumetric flow rate.
Each unit is factory calibrated for a specific flow range. The flow range is
shown on the unit’s label and calibration certificate. Units are calibrated
using AIR as the reference media unless otherwise noted. Calibrations are
carried out with the mounting feet horizontal on a flat horizontal surface.
a) 0-5VDC Analog Outputs
By monitoring the voltage output signal it is possible to determine the flow
rate of the gas. Units are configured so that an output signal of 5.0VDC is
provided when the maximum flow (i.e. Full Scale flow) is passing through
the unit. The output signal is linear and scaleable enabling calculation of
flow rates within the sensor’s range.
For example:
For a flow range of 100-500ml/min:
At 500ml/min the output signal would be 5VDC
If the output signal were 3.5VDC then the flow rate would be:
(500 ÷ 5) × 3.5 = 350ml/min
If the maximum flow rate is exceeded non-linear and inaccurate readings
will result.
b) Units With an Integral Display
The FLR 1000-D and FLR 1000-BR-D series features an integral 3 ½ digit
LCD display. This is configured to read in ml/min for flow ranges up to
pg. 12 of 29
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100-500 ml/min and in l/min for flow ranges of 0.2 – 1.0 L/min and above.
The display will only operate if power is applied to the unit.
Flow readings may be taken directly from the display or by monitoring the
0-5VDC analog output provided by using a cable assembly or power
adapter package (see above).
LCD Flow Display
(Model FLR1000-ST-D shown, other models with displays similar)
3. Operating at Flow Rates Outside the Calibrated Flow Range
CAUTION:. If the flow through the unit exceeds 120% of
the maximum rated (full scale) flow the unit may be
damaged. This type of damage will not be repaired under
warranty.
Flow measurement is only accurate within the calibrated flow range for the
unit. This is detailed on the calibration certificate. The unit will still
operate, to some degree, outside this flow range.
Results obtained when operating outside the specified range of the unit
are not accurate but may be considered repeatable.
a) Flows Above the Maximum Rated Flow.
If the flow rate is above the maximum rated (or full scale) flow, the unit
will still operate and provide an output signal proportional to the flow rate.
Flows must not exceed 120% of the maximum rated flow or the unit may
be damaged.
b) Flows Below the Minimum Rated Flow.
Signal outputs may be obtained at flow rates below the minimum specified
for your unit. The amount of flow that may be measured below the
minimum specified varies from unit to unit.
pg. 13 of 29
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4. Zero Adjustments
It is impossible for there to be any zero drift so zero adjustments are
never required.
5. Recalibration
Please contact the Omega Engineering Service Department if your flow
sensor or flow meter needs recalibration.
6. Using Flow Sensors or Flow Meters with Different Gases
The FLR 1000 Series will operate with most gases subject to compatibility
of the wetted parts. For information about calibrating for Hydrogen or
Helium, contact the Omega Engineering Service Department.
Units are calibrated with AIR at a pressure of 760mmHg and temperature
of 23°C unless otherwise detailed on the calibration certificate. Using other
gases will effect the calibration. The amount of calibration error will
depend on the characteristics of the gas being flowed.
The flow reading correction factor (or calibration factor) may be
approximately calculated with the following formula:
0.3
Cf = ( Snew ÷ Scurrent
)
Cf = Correction factor
S
S
new = Specific gravity of new gas
current = Specific gravity of original calibration gas
A corrected flow reading may then be calculated using the correction
factor as follows:
Corrected Flow = Flow reading X Correction Factor
For example, if the unit is calibrated for AIR but the user wants to
measure the flow of Carbon Dioxide (CO2) with a specific gravity of 1.517
the flow reading correction factor would be calculated as follows:
Snew = Specific gravity of CO2 = 1.517
Scurrent = Specific gravity of Air = 1.000
0.3
Cf = (Scurrent ÷ Snew
Cf = ( 1.000 ÷ 1.517 )0.3
Cf = 0.88
)
pg. 14 of 29
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If the unit has a flow reading of 200ml/min then the corrected flow
reading (for CO2) would be:
Corrected Flow = 200 X 0.88 = 176 ml/min
CAUTION:. The use of correction factors can be subject
to inaccuracy and errors of up to ±10%. Please contact
the Omega Engineering Service Department if accurate,
certified recalibration is required.
Calculating a correction factor for a gas enables the calibration of the unit
to be adjusted for that gas. This is accomplished by:
i)
Calculate the corrected flow reading or VDC output at 100% of
flow using the above formulas.
ii)
iii)
Adjust the flow of (the new) gas to give this flow reading
Maintain this flow and ensure a stable reading.
iv)
Adjust the gain potentiometer on the unit so that a 5VDC output
is obtained. The unit is now calibrated for the new gas.
For example: A 2.0 -10.0 l/min unit that has been calibrated for Air is to
be used with CO2. The correction factor, calculated as above, is 0.88.
When flowing CO2 the unit will read high i.e. at 5VDC the flow of CO2
would actually be 8.8 l/min and not 10 L/min. A flow of 10 l/min of CO2
through the unit would give a reading of 10/0.88 = 11.36 l/min or 5.68
VDC on the unit. Flow should be adjusted so that an output of 5.68VDC or
reading of 11.36l/min is obtained. The gain potentiometer is then adjusted
so that the voltage output becomes 5VDC or the display reads 10l/min.
The unit has now been adjusted for CO2 and no further corrections to flow
readings are required (if flowing CO2).
It should be noted that the maximum output voltage for the units is
approximately 5.9VDC. It is not possible to adjust units if an output of
greater than 5.9 VDC is required.
Adjusting the Gain Potentiometer Using a Flat Head Screwdriver
(FLR 1000 shown, other models similar)
pg. 15 of 29
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D.
Maintenance and Product Care
1. General
CAUTION: Do not disassemble your unit for any reason.
If the unit appears to be malfunctioning please contact
the Omega Engineering Service Department.
The FLR 1000 Series of flow meters and sensors require no periodic
maintenance if used within the recommended specifications.
The next recommended recalibration date is stated on the calibration
certificate supplied with the unit. Please contact the Omega Engineering
Service Department for further information.
Inlet filters should be periodically checked and cleaned / replaced as
necessary.
Regularly check all electrical and process connections for damage or
deterioration.
If the sensor is to be stored, keep both the inlet and outlet ports sealed.
2. Cleaning and Flushing
If there is a build up of deposits or particles from the measured gases it
may be necessary to clean or flush the unit. This should be done by
flowing clean, particle free air (or Nitrogen) through the unit at a flow rate,
pressure and temperature within the specifications of the unit. If
necessary, flow may be reversed to assist flushing.
CAUTION: Do not flow a high pressure gas through the
sensor. A burst of high pressure gas may cause the
turbine wheel sensor to be damaged. Always flow gas at
a pressure and flow rate within the specifications of the
unit
3. Returning Units for Repair or Recalibration
To return a unit for repair or recalibration please contact the Omega
Engineering Customer Service Department. An Authorized Return (AR)
number will then be issued. The AR number should then be noted on the
outside of the package and on any correspondence. Further details may be
found on page 28 of this manual.
pg. 16 of 29
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E.
Specifications For Gas Units
FLR1000
FLR1000-D
FLR1000-BR-D
Display
None
3.5 Digit LCD,
0.39” (10mm) high digits
Accuracy
(including linearity)
±3.0% Full Scale*
±0.5% Full Scale*
Repeatability
Pressure Rating
40 psig
(2.8 bar)
Temperature Rating
Operating Range: 5 to 55ºC
Storage Range: 0 to 70ºC
Temperature
Sensitivity
±0.2% F.S.* or less per ºC
Wetted Materials
Ryton®
316 Stainless*
Brass
Ryton®
Epoxy
Glass
316 Stainless*
Epoxy
Sapphire
Glass
Sapphire
O-Ring Material
Standard - Viton®
EPDM Optional
Fitting Material
(Standard)
Acetal
Brass
Fitting Material
Optional
Acetal, brass, or stainless steel
25 microns or less
Clean, dry
Recommended
Filtration
Compatible Gases
0-5VDC Output Signal
Standard
Minimum 2.5 KΩ load
Typical Power
Consumption
Standard: 12 VDC @ 35 mA (11.5-15 VDC)
Model 110 Power Adapter 115/230VAC
Response Time
Reliability
Typically <30 seconds for 67% of final value
100,000 hours MTBF
Certifications
CE Approved
89/336/EEC (EN 55011 & EN 50082-1)
73/23/EEC Low Voltage Directive
Ratings
IP10 (NEMA 1)
1 year limited
Warranty
*Specifications from 20-100% of rated flow. Linearity is best fit straight line. All calibrations
performed with AIR unless otherwise stated on calibration certificate
pg. 17 of 29
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F.
Connector Pin And Wire Color Cross Reference
Pin Configuration for Connector Socket and Connector
Pin
Cable Wire Color
Description
1
Black
Signal & Power Negative
(Ground)
2
3
4
White
Red
Voltage Output
Power Positive
Not Used
Green
pg. 18 of 29
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G.
Dimensions
ALL DIMENSIONS IN INCHES (MILLIMETERS IN BRACKETS)
FLR 1000 For Gases
20-200 ml/min To 1.0-5.0 l/min Units
1/4” Acetal Fittings Shown
pg. 19 of 29
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FLR 1000 For Gases
2.0-10.0 l/min Units
1/4” Acetal Fittings Shown
pg. 20 of 29
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FLR 1000 For Gases
4.0-20.0 l/min To 100-500 l/min Units
1/2” Acetal Fittings Shown
pg. 21 of 29
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FLR 1000-D For Gases
20-200 ml/min To 1.0-5.0 l/min Units
1/4” Acetal Fittings Shown
pg. 22 of 29
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FLR 1000-D For Gases
2.0-10.0 l/min Units
1/4” Acetal Fittings Shown
pg. 23 of 29
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FLR 1000-D For Gases
4.0-20.0 l/min To 100-500 l/min Units
1/2” Acetal Fittings Shown
pg. 24 of 29
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FLR 1000-BR-D For Gases
20-200 ml/min To 1.0-5.0 l/min Units
1/4” Brass Fittings Shown
pg. 25 of 29
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H.
Troubleshooting Guide
Symptom
Unit Leaks
Possible Cause
Fittings not tight enough.
Method of Correction
Tighten fittings (see section
B4)
Sensor assembly cracked
No power or low power
Unit must be returned for
repair (see Section J)
Apply correct power
No output signal or
flow indication
No flow passing through
unit
Display or output should
read zero.
Output shorted or
overloaded
Check electrical connections
(see section B5)
Improper connection
Check electrical connections
(see section B5) and ensure
connector is correctly
plugged in.
Moisture on internal
electronics
Allow unit to dry out in a
dry environment.
Output circuitry damaged
Flow is actually fluctuating
Unit must be returned for
repair (see Section J)
Flow indication
“bounces” or
fluctuates
Correct flow source to
obtain steady flow
Using a pulsatile or piston
pump that causes a
Switch to a stable source of
gas
pulsating flow of gas
Not using the fittings
supplied by the
manufacturer
Use the supplied fittings
Moisture in sensor
Remove moisture and allow
unit to dry out
Turbulence in tubing or
sensor
Straighten the inlet tubing
or lengthen it to at least 6”
(150mm)
Fluctuating input power
Correct the power source or
change to a regulated
supply
Mechanical sensor assembly
damaged
Unit must be returned for
repair (see Section J)
pg. 26 of 29
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Symptom
Flow indication is not
linear and output too
low at lower flows
Possible Cause
Attempting to measure
flows below the specified
minimum for the unit
Method of Correction
Use higher flow rates
Moisture or liquid in sensor
Remove moisture and allow
sensor to dry out
Mechanical sensor assembly
damaged
Unit must be returned for
repair (see Section J)
Flow reading accuracy
is outside the
specification
Gas has a specific gravity
other than Air at 20°C
Calculate the flow reading
error / offset as explained in
section C6
Moisture in sensor
Allow sensor to dry out.
Ensure gas is dry.
Mechanical sensor assembly
damaged
Unit must be returned for
repair (see Section J)
Pressure drop issue
Correct for the pressure
drop ( ΔP )
Flow indication is fixed
at one value
The maximum rated flow for
the unit is being exceeded.
Reduce the flow
Output circuits may be
damaged
Unit must be returned for
repair (see Section J)
pg. 27 of 29
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.
pg. 28 of 29
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M4575/0807 pg. 29 of 29
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