COMAC CAL FPW Use and care manual

FPW Manual Page 1 (total 18) COMAC CAL s.r.o.
Paddle wheel flow meter
FPW
Ver. 1.2
Installation and technical conditions
Date of issue 18/06/2019

FPW Manual Page 2 (total 18) COMAC CAL s.r.o.
Contents:
Description of device .............................................................................................................................3
Scope of delivery................................................................................................................................3
Process connection.............................................................................................................................3
Storage conditions .................................................................................................................................4
Warranty ................................................................................................................................................4
Installation in pipeline ..........................................................................................................................4
Important information for selection of location.................................................................................4
Paddle wheel flow meter arrangement...............................................................................................6
Paddle wheel and motion sensor........................................................................................................7
Fitting adapters...................................................................................................................................8
Assembly procedure using the fitting adapter..................................................................................10
Installation by means of the welding fitting.....................................................................................10
Installation by means of the drilling device .....................................................................................11
Sources of disturbances....................................................................................................................12
Wiring...................................................................................................................................................13
Meter wiring.....................................................................................................................................13
Pulse output (FPW 05 only).............................................................................................................14
Pulse output or make/break contact (FPW 10 and FPW 20 only)....................................................14
4-20mA output (FPW 20 only).........................................................................................................15
Putting into operation .........................................................................................................................15
Customization and control of FPW meter..........................................................................................16
Technical parameters ..........................................................................................................................17
Basic dimensions.................................................................................................................................18
Ordering code ......................................................................................................................................18

FPW Manual Page 3 (total 18) COMAC CAL s.r.o.
Description of device
The FPW paddle wheel flow meter is designed for clean liquid fluids with flow velocity within the
range of 0,3 ÷ 6 m/s (ideally 2÷3 m/s) and it is based on mechanical measurement principle
according to which the flow velocity of a fluid is proportional to the speed of the paddle wheel
populated with stainless steel needles picked up by the proximity sensor. Thanks to this solution
instead of using the magnetic needles and Hall probe there is no deposition of minute ferrous
particles and thus long service life and stability of the meter is ensured. Prompt and simple
installation ranks among basic advantages as wall as the price thanks to its simple construction.
The accuracy of paddle wheel flow meters may deteriorate for liquids with high viscosity. The
liquids with high viscosity tend to create a laminar flow profile with impaired centre of the flowing
liquid and thus the changed profile of the running liquid whereas it is desirable for accuracy that the
liquid velocity is ideally equal across the entire pipe diameter. Therefore, Reynolds number of liquid
should be higher than 4500. Reynolds number is a dimensionless value connecting the effects of
viscosity, density and flow velocity.
The meter is manufactured in three versions:
•FPW 05 –Pulse signal only
•FPW 10 – Pulse / switching contact
•FPW 20 – Pulse / switching contact + 4÷20mA
Scope of delivery
The device is delivered with an adapter for connection as per purchase order.
Process connection
The installation in the piping can be carried out by direct welding/bonding into the piping (according
to material) or any of the fitting adapter delivered for simple installation (thread or mount) into
diameter piping can be used. Drilling devices for simple installation without necessary welding and
T-pieces in materials according to the customer requirements. The flow meter output can be
connected to a display unit CC 100 (this is not standard order, to be ordered separately) or to various
control systems.
Accessories to the flow meter can also be cable connections in various lengths with M12 (4-pin)
connectors for electric connection. However, these are not part of delivery owing to standard solution
of individual elements and thus the possibility of deliveries also from other manufacturers of these
parts
The FPW 05 design is not equipped with the M12 connector but only with a cable entry bushing and
three-core PVC cable (cable length is 2 m as standard). Optionally can be also equipped with a M12
connector.

FPW Manual Page 4 (total 18) COMAC CAL s.r.o.
Storage conditions
The temperature during transportation and storage of the meter must be within the range of -20 °C up
to 60 °C.
Warranty
Unprofessional installation or improper use of the device may result in a loss of warranty rights as
well as failure to comply with installation or operating conditions according to this manual.
Repairs are not possible. The warranty becomes null and void by repairs or intervention in the device
by a person other than the manufacturer.
Installation in pipeline
Important information for selection of location
Prior to dismantling or splitting the piping or service carried on the meter always be particular
about safety instructions for pressure and temperature in case of the fluid given. As there is a risk of
pressurized liquid jet or high temperature, we recommend you to use essential personal protective
equipment.
Outdoor conditions
It is necessary to ensure that the sensor is not exposed to weather effects and that the measured
medium cannot freeze around the flow sensor as it would damage the sensor itself.
In case of outdoor location, the manufacturer recommends using a protective roof to avoid direct
solar exposure so that the evaluation electronics cannot get overheated.
Vibration
Levels and range of vibrations must be under 2.2 in the frequency range of 20 ÷ 50 Hz according to
IEC 068-2-34.
Actual location
The paddle wheel flow meters operate with clean liquids best. Particles and impurities may prevent
the propeller from proper rotation and can contribute to faster component wear.
For installation of the meter, it is necessary to select such a location so that the correct length of
straight pipe before and after the meter is available. Thanks to the fact that the paddle wheel
interferes with the flow to a small extent only, the flow must have a consistent velocity all over the
pipe’s inside diameter and due to this accurate reading is made possible. Calming lengths of straight
pipe segments make it possible to disperse possible whirling occurred in the flow prior to the
respective measurement of the paddle wheel. The turbulent flow may be caused by obstacles such as
an elbow, T-piece, pump, etc. Minimum lengths of the calming length of the pipe’s straight segment
will depend on the type of obstacle before the paddle wheel. The absolute minimum is typically ten
times the amount of inside diameter of the straight pipe before the meter and five times the amount
after the meter.

FPW Manual Page 5 (total 18) COMAC CAL s.r.o.
Recommended calming segments before the meter according to the obstacle on the piping, where ID
means internal diameter of pipe (it is always 5x ID after the meter)
Standard calming segments –10xID
2x 90° elbow in two planes – 40xID
1x 90° elbow –20xID
Reducer to pipe’s inside diameter –15xID
2x 90° elbow in one plane – 25xID
Valve –50xID
When installing the meter, be particular placing the meter in such a manner that the paddle wheel
rotation axis is in horizontal position so that damage to the rotor by impurities in liquids can be
avoided). In case of a vertical pipe, the positioning does not matter; however, we recommend you to
place the meter in the ascending part to reduce the risk of aeration.
The measurement point must always be full of water free of bubbles; in case of air space, an
erroneous measurement may take place. If necessary, it is possible to use the installation of
measuring track in the form of U, by which means permanent submersion of the lower part with the
meter is ensured. For the same reason, we recommend you to place the meter on the upstream side of
the ascending piping.

FPW Manual Page 6 (total 18) COMAC CAL s.r.o.
For installation in piping, it is necessary to ensure the parallel run of the flow with the arrow
indicated on the flow meter body.
WARNING : The actual installation of the weld-on adapter or fittings or gluing of plastic adapter
onto the piping always carry out with the removed electronic unit so that mechanical and temperature
damage can be avoided.
When blending a mixture, it is necessary to incorporate the flow meter either before the blending
point or at a sufficient distance after it (min. 50x d), otherwise the indication may be inaccurate.
Paddle wheel flow meter arrangement
Paddle wheel flow meters consist of three basic components:
•Paddle wheel
•Wheel motion sensor (possibly display unit)
•Fitting adapters
These components can be purchased separately or as a package in order to meet particular
requirements of your application. The paddle sensor is designed for insertion in the pipe fitting.
Approximately a half of the paddle protrudes into the flow. The liquid flowing through the pipe
causes the rotational motion of the rotor with paddles. The proximity sensor scans the movement of
stainless steel rods located in the paddles and transforms them into electric pulses that are
proportional to the flow velocity (possibly also 4÷20mA current output for FPW 20 version). Since
the rotational motion of the paddle wheel depends on flow velocity, the number of output pulses
(4÷20mA current output) depends on velocity flow in the place of the paddle wheel and the volume
flow depends on pipe cross-section and velocity flow. This relation is indicated by a figure called K-
factor. The K-factor indicates then the number of output pulses per volume unit for every particular
pipe size, eventually when using a particular pipe fitting as mounting accessories.

FPW Manual Page 7 (total 18) COMAC CAL s.r.o.
Paddle wheel and motion sensor
Individual parts of the meter
Spare parts
Replaceable part
Ordering number
O-rings (EPDM)
FPW-RK1
Paddle wheel (PEEK)
FPW-RK2
Paddle wheel shaft (stainless steel DIN 1.4401)
FPW-RK3.1
Paddle wheel shaft (zirconium ceramics)
FPW-RK3.2
Sleeve nut (DIN 1.4401)
FPW-RK4

FPW Manual Page 8 (total 18) COMAC CAL s.r.o.
Fitting adapters
Particular fittings for installation:
Various pipe fixtures (fittings) are available. These are designed so as to facilitate the installation
right into the piping by means of various connection methods, for example, with female or male
threads, by welding, bonding, etc. These "in-line" fixtures are available in various materials, e.g.
polyproplylene, PVC, and stainless steels. Further, it is possible to use the drilling device where after
simple drilling a hole in piping, the attachment yoke can be placed right onto the pipe. Thanks to this,
it is not necessary to cut the piping or install it using special adapters. The offer is in “Optional
accessories“ section.
Pipe saddle, PP (+AISI 304), PN10
Order code
Connect
K-factor
DPPP-10-D50
OD 50
According to the inside diameter
of pipe
viz “Table of K-factor for the
most common size of pipes”
DPPP-10-D63
OD 63
DPPP-10-D75
OD 75
DPPP-10-D90
OD 90
DPPP-10-D110
OD 110
DPPP-10-D125
OD 125
DPPP-10-D140
OD 140
DPPP-10-D160
OD 160
DPPP-10-D200
OD 200
DPPP-10-D225
OD 225
DPPP-10-D315
OD 315
Plastic T-piece for glue connection in PVC, PN16
Order code
Connect
Flow range
K-factor [imp/l]
TPVC-16-DN40
OD 40
2,3 ÷27 m3/h
30
TPVC-16-DN50
OD 50
3,5 ÷42 m3/h
19
TPVC-16-DN63
OD 63
5,6 ÷67 m3/h
11,5
TPVC-16-DN75
OD 75
7,9 ÷95 m3/h
7,5
TPVC-16-DN90
OD 90
11,5 ÷137 m3/h
5
Stainless steel T-part with thread connection G, AISI304, PN25
Order code
Thread
Flow range
K-factor [imp/l]
TSS304-25-G1/8
G 1/8
0,03 ÷0,6 m3/h
1100
TSS304-25-G1/4
G 1/4
0,05 ÷1,1 m3/h
662
TSS304-25-G3/8
G 3/8
0,09 ÷1,7 m3/h
408
TSS304-25-G1/2
G 1/2
0,19 ÷3,8 m3/h
216
TSS304-25-G3/4
G 3/4
0,56 ÷6,8 m3/h
100
TSS304-25-G1
G 1
0,88 ÷10,6 m3/h
61
TSS304-25-G1 1/4
G1 1/4
1,4 ÷17,4 m3/h
42
TSS304-25-G1 1/2
G1 1/2
1.8 ÷22 m3/h
37

FPW Manual Page 9 (total 18) COMAC CAL s.r.o.
Stainless steel T-part for welding connection, AISI304, PN25
Order code
Connect
Flow range
K-factor [imp/l]
WTSS304-25-42,4x2
42,4x2
2 ÷25 m3/h
29
WTSS304-25-48,3x2
48,3x2
2,7 ÷33 m3/h
19
WTSS304-25-60,3x2
60,3x2
4,6 ÷55 m3/h
11
WTSS304-25-76,1x2
76,1x2
7,3 ÷88 m3/h
8
WTSS304-25-88,9x2
88,9x2
10,2 ÷120 m3/h
5,5
WTSS304-25-114,3x2
114,3x2
17 ÷205 m3/h
3,5
WTSS304-25-139,7x2
139,7x2
26 ÷313 m3/h
2,2
Stainless steel welding adapter, AISI304, PN25
Order code
Connect
K-factor [imp/l]
WSS304-25-D44
pipe
ID≥48,3
According to the
inside diameter
of pipe
In case of welding fitting is K-factor depending on the inner diameter of the installed pipe.
Table of K-factor for the most common size of pipes
Dimension of pipe
Inner diameter ID
Flow range
K-factor [imp/l]
48,3x2
44,3
2,7 ÷33 m3/h
24,8
53x1,5
50
3,5 ÷42 m3/h
19,5
60,3x2
56,3
4,5 ÷53 m3/h
15,5
76,1x2
72,1
7,5 ÷88 m3/h
8,7
84x2
80
9 ÷108 m3/h
6,6
88,9x2
84,9
10 ÷122 m3/h
5,8
108x4
100
14 ÷170 m3/h
3,9
114,3x2
110,3
17 ÷206 m3/h
3,3
139,7x2
135,7
26 ÷312 m3/h
2,5
168,3x2
164,3
38 ÷458 m3/h
1,5
219,1x2
215,1
65 ÷784 m3/h
0.9
ID = inner diameter of pipe OD = outside diameter of pipe
If the inside dimension of the piping is beyond the given table, K-factor is then given by the
conversion formula:
K-factor_new = (KTABLE x IDTABLE2) / IDNEW2
IDTABLE is the closest inside diameter selected from the table to the tube used
KTABLE is K-factor from the table to the corresponding IDTABLE used
IDNEW is the inside diameter of the tube used for installation
For version FPW FPW-10 and FPW-20 may K-factors vary depending on the setting of pulse
constant meter (dividing ratio).All values of K-factor are valid for water at 25 ° C.
All dimensions are in millimetre.

FPW Manual Page 10 (total 18) COMAC CAL s.r.o.
Assembly procedure using the fitting adapter
Before starting the actual assembly, make sure that the system is
pressureless or discharged. Install then a suitable adapter, drilling
device or T-piece by screwing or bonding, or possibly install the
welding adapter if appropriate. Install then the paddle wheel flow
meter by inserting it into the adapter. When installing the meter in the
piping and for ensuring the most accurate flow rate evaluation, you
need to observe the direction of angular displacement of the meter in
such a way that the axis of the paddle wheel is perpendicular to the
direction of the flow to which corresponds the positional key when
inserting the meter (in the event of the weld-on version and the
drilling device, the notch for the positional key must be created by the
installation technician. That is why you should check the correct
location of the slot for the positional key on the adapter against the
piping.
Always place the meter in horizontal position, preferably from above onto the piping so that excess
wear or possible damage to the paddle wheel shaft by deposits or impurities in the piping can be
avoided.
Before inserting the meter in the adapter, you should apply grease (silicone vaseline) to O-rings and
to the interior of the adapter so as to avoid damage to the sealing EPDM O-rings. You need to
proceed to insertion with due care and insert evenly and perpendicularly to the adapter. After
insertion of the meter (the positional key must fit in the slot), screw in the sleeve nut and tighten it by
hand until it does not come loose.
Warning: Do not cause pollution of paddle or axis by vaseline!
Installation by means of the welding fitting
In the location selected for installation of the meter, drill a 42 mm
diameter hole in the piping with an annular bit. We recommend you to
install the meter to the piping always from above so as to avoid excessive
wear on the paddle wheel axle and potential damage to the paddle wheel
by sediment deposits or debris in the piping. Now, you can weld the
adapter on the selected place on the piping.
Screw the sleeve nut on the adapter to prevent it from falling into the
piping by coincidence. Slide the adapter in the hole in the piping as
shown in the Figure. It is suitable to make a mark on the adapter
according to the thickness of the pipe wall so that the depth of insertion in
the piping can be correct. Apply spot welding to two or three locations
and check the perpendicularity to the piping axes. If everything is correct,
make a weld all round, making sure that the adapter cannot be deformed
by welding.