Omega FTB500 Series User manual

Manual
OPerator’s
(i%%i
Flowrate
Meters
Low
a
Q
FTBSOO
Series
@a

DFMOSSSFVRIBA
359-RUSH
ti
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and Control
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.21
.20
SECTION 8 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . .
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.20
SECTION 7 ACCESSORIES
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.I8
SECTION 6 RECOMMENDED SPARE PARTS LIST
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15
I5
SECTION 5 TROUBLESHOOTING AND MAINTENANCE
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FTBSOO
Flowmeter (Ball Bearing Design)
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Servicing and Preventative Maintenance of the
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.I5
4.1
4.2
Introduction
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SECTION 4 MAINTENANCE
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.........................
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3.4.1 Setup
........................... .
3.4.2
Equations
FTBSOO
Signal Conditioner Offset
3.4
Calibration of FTB500 Analog Output
.................
3.3 To Confirm
.......................
3.2
Calibration Procedure
.I2
3.1
Introduction
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.9
SECTION 3 CALIBRATION
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8
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7
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6
7
...
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Installation of the FTB500 Mini Flow Signal Conditioner
..................................
General
.................................. .
Installation Wiring Layout for Interconnections
.................................
Operation
.6
2.1
2.2
2.3
2.4
2.5
Unpacking
.................
,
........
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SECTION 2 INSTALLATION
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1.3.3 Viscosity Calibration and UVC Curves
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1.3.2
Viscosity Effects
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1.3.1
Performance Characteristics
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I.3
Theory of Operation
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I.2
Available Models
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.I
1.1
Description
TABLE OF CONTENTS
FTB500 SERIES FLOWMETERS
SECTION
PAGE
SECTION 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . .

503,4
for 504, or 5 for 505.
1
X
1 for 501, 2 for 502, 3 for
tistokesl
of your liquid. The maximum is 25CK.
cen-
(“CK)
in part number with the viscosity (in
*
Replace
NOTE
FTB50_X-t*CK)-5KP
PSIG
FTB5O_X-(*CK)-115VAC
5000
115VAC
signal conditioner power supply
FTB50_X-t”CKb5VDC
FTB50_X-(*CK)-P
0-5VDC
output
TTL
Pulse output
FTB505-(“CK)
‘CK)FTB504-(
“CK)
FTB503-(
“CK)
FTB502-(
“CK)
FTB501-(
(Adalet
XJS DO) rated for class I, groups C and D, and class
II, groups E, F and G.
Features of the FTB500 include:
1.
Integral signal conditioner which provides K-factor offset correction for
the mini-flowmeters.
2. Versatile AC and DC power versions are available.
3. Configurable pulse voltage or analog output options.
1.2
AVAILABLE MODELS
DESCRIPTION
(LINEAR FLOW RANGE)
STANDARD PART NUMBERS
0.02
to
0.15 GPM
0.025
to
0.25 GPM
0.05
to
0.5 GPM
0.1
to
1.0 GPM
0.2
to
2.0 GPM
OPTIONAL PART NUMBERS
PART NUMBER*
pelton
wheel-like
rotor whose motion is converted into a pulse output proportional to flow
by a pickup coil. They come with an integral signal conditioner, powered
by either 15-35 VDC or 115 VAC (optional) to provide amplified frequency
and analog output. The signal conditioner corrects for the inherent zero off-
set of the flowmeter pulse output. It is mounted in a NEMA 4X, explosion
proof enclosure
OMEGA@
FTB500 Series Low Flowmeters offer extremely accurate
low flow measurement of liquids and gases. They utilize a
SECTION 1 INTRODUCTION
1.1
DESCRIPTION
The

AMP.
Figure l-l.
Block Diagram
The basic operation of the system is as follows:
The frequency signal from the flowmeter is connected to the FTB500 with
a twisted pair shielded cable. The signal enters through the SENSITIVITY
control which is used to reject unwanted noise by raising the trigger
threshold above the background noise present.
The low level flowmeter signal is then passed through a special condition-
ing chain where it is filtered, amplified, and shaped into a train of digital
pulses whose frequency is non-linearly related to the volume flow rate.
The digital pulse train is then passed through the linearizer where the off-
set frequency signal is injected into it. For flow rates within the range of the
meter, the linearizer output will be linearly related to the volumetric flow rate
In addition, this circuitry drives the ‘low flow ’out of range indicator.
2
pcA_,,B
CONDITIONER
TURBINE FLOWMETER=
MAIN CHASSIS
FREQ. TO
CONVERTER
- -
CAPACITOR COUPLED
ANALOG
OUTPUT
OUTPUT
FTBBOO
SIGNAL
1.3
THEORY OF OPERATION
A simplified block diagram of the FTB500 Mini Flow Signal Conditioner is
shown in Figure 1-I.
SENSITIVITY
+v

FTB500
Series of meters establish a linear
response after an initial offset correction when operating at a constant
viscosity.
3
FTBSOO
flowmeter are shown
in Figures l-2 and 1-3. The
pelton
rotor causing it to
rotate The motion of the rotor is sensed by the pickup coil and converted
to a pulsing output signal where the frequency is related to the flowrate, and
the accumulated pulses are related to the total volume passing through the
flowmeter.
1.3.1
Performance Characteristics
The basic performance characteristics of the
pelton
wheel-like rotor. The measured fluid is directed
tangentially through a velocity nozzle against the
FTBSOO
integral signal conditioner will compensate for the frequen-
cy offset characteristics of the flowmeter, by using the method of offset
frequency injection. Offset frequency injection is implemented electronically
by adding a signal equal to the offset frequency required to linearize the out-
put of the flowmeter. This effectively shifts the output characteristic to that
of the desired ideal. A low-flow cutout feature is provided where the off-
set signal is inhibited during no flow to prevent false outputs from being
generated.
The FTB500 Series Turbine Meter is a family of low flow rate measurement
devices based on a
flowrate
which
does not pass through zero. left uncorrected, this will result in a K-factor
which varies with flow rate.
The
CMOS/lTL
compatible output. The attenuator produces a capacitor coupled AC out-
put which is suitable for driving other signal conditioners, indicators, or con-
trollers which require an AC signal input.
The output frequency from the FTB500 Series Turbine Meter versus flow
is essentially a straight line of frequency as a function of
The signal entering the frequency to analog converter is passed through a
combination of divide by N and DIP switch matrix. The output is chosen
whose pulse rate is between 75 and 150 Hz at the maximum flow rate to
be measured. This scaled pulse rate is fed into a precision monostable cir-
cuit. The output of the monostable is then filtered into an analog voltage
that is proportional to flow.
The output amplifier will take this voltage and perform either a voltage to
voltage amplifier or voltage to current amplifier.
Finally, the output is divided by 8 to reduce irregular pulse spacing. Then,
the pulse train enters a buffer and an attenuator simultaneously. The buf-
fer output produces a square wave pulse which can be used as a

FTBIOO
Calibration Curve
4
FLOWRATE
Figure 1-3.
Normalized
%
OF MAX IMUM
.80
10 50 100
I_7
f
1.00
7
!
UNLINEARIZED
5
90
8
u
FTBSOO
Output Characterlstlcs Diagram
LINEARIZED
(GPM)
Figure 1-2.
/
UN LINEARIZED OUTPUT
FLOW RATE
lL

H,O
is the pressure drop from Figure l-4
Figure 14.
Gross Pressure Drop Characteristic Curve on Water
5
PSID
SpGr
is the specific gravity
H,O
where:
Cpse is viscosity in centipoise
PSID
(SpGr)”
x
(Cpsel”
x
PSID
=
flowrate
and the fluids viscosity and density.
FTB500 Series
Turbine Meter given the pressure drop on water at the maximum
FTB500
Series Turbine Meter.
The K-Factor is the number of pulses per unit volume produced by the
flowmeter under a given set of conditions. Repeatability is a measure of the
stability of the output under a given set of flowing conditions. The
repeatability is defined as the allowable percentage deviation from the
stated K-Factor.
The pressure drop characteristics are given based on water at a viscosity
of 1 Cpse and a specific gravity of 1.00. For other fluid ’s, the following equa-
tion may be used to estimate the pressure drop across the
*2%
are possible using smart transmitters which can store the
entire characteristics of the
*l%
of
reading are typical after initial correction for offset. Better accuracies ap-
proaching
FTB500
Series Turbine Meter requires the use of a linearization con-
ditioner available in all OMEGA instrumentation. Accuracies of
Over the linear flow range, the input/output characteristics takes the form of:
Equation 1
Frequency = C, x Flowrate-C,
The

NOTE
The carrier will not honor any claims unless all shipping material
is saved for their examination. After examining and removing con-
tents, save packing material and carton in the event reshipment
is necessary.
*l%
of reading.
In some applications, the fluid viscosity is a known function of temperature
A PC could be used to eliminate the otherwise adverse viscosity effect on
the flow measurement.
SECTION 2 INSTALLATION
2.1
UNPACKING
Remove the Packing list and verify that all equipment has been received.
If there are any questions about the shipment, please call the OMEGA
Customer Service.
Upon receipt of shipment, inspect the container and equipment for any
signs of damage. Take particular note of any evidence of rough handling in
transit. Immediately report any damage to the shipping agent.
FTB500
Series Turbine Meter may be used over wide viscosity ranges,
since the flowmeter has a unique, documented, Universal Viscosity Curve
(abbreviated UVC) which is accurate to
FTB500
Series Flowmeter for operation on a viscous fluid,
it is generally preferable to size the flowmeter so it will be operating in the
higher portion of its range to minimize viscosity effects in the measurement.
Some loss in flow turndown range may be expected.
1.3.3
Viscosity Calibration and UVC Curves
In some flowmeter applications the viscosity is held nearly constant owing
to regulated conditions of temperature and fluid consistency. For such ap-
plications it is only necessary to document the flowmeter ’s performance
at the expected operating viscosity. For such fixed viscosity applications
the standard specifications usually apply.
The
1.3.2 Viscosity Effects
An ideal flowmeter may be defined as one in which the output is solely a
function of the fluid flow being measured. Real flowmeters display
dependencies on secondary fluid properties, such as viscosity temperature,
and/or pressure. These effects tend to obscure or degrade the precision of
the flow measurement.
In very few flowmeter designs, the viscosity dependency is well understood
and given suitable documentation, may be compensated for. The OMEGA
instruments are among this select group.
In selecting an

7
-
2-I.
Typical Turbine Meter Installation
METER RUN
V3
= BYPASS VALVE
S = STRAINER
FS = FLOW STRAIGHTENER
TFM = TURBINE FLOWMETER
Figure
Vl, V2 = BLOCKING VALVE
v2
t
TFM
I
FS
2.5V.
Slowly turn the SENSITIVITY threshold control counter-clockwise until in-
dication stops.
2.3
GENERAL
Proper application of the turbine flowmeter requires a suitable piping installa-
tion in order to achieve accurate and reliable operation. Refer to Figure 2-l.
BYPASS RUN
2.2
OPERATION
Perform any purging of piping with spool piece in place. Once completed,
install the flowmeter and connect cabling to pickup coil.
With the FTB500 Mini Flow Signal Conditioner properly installed and
calibrated, verify the following performance.
With the power ON and no flow through the flowmeter, there should be no
pulse output from the unit. To verify this, connect either a digital Frequen-
cy Counter or an AC voltmeter.
If using a Digital Frequency Counter, the display should display zero. If some
other constant or varying indication occurs, noise may be present.
Slowly turn the SENSITIVITY threshold control counter-clockwise until in-
dication stops.
NOTE
Turning the sensitivity control FULLY counter-clockwise will
render the outputs inoperative. Turn potentiometer clockwise to
return to normal operation.
If using an AC voltmeter, the meter should be at zera If noise is present, the
voltmeter will deflect and swing from 0 to

pickoff
device.
BYPASS RUN -A properly sized bypass run with suitable blocking valves
may be equipped where an interruption in fluid flow for turbine meters ser-
vicing can not be tolerated.
STRAINER-A strainer, filter and/or air eliminator is recommended to reduce
the potential of fouling or damage Recommended mesh size is at least 100
microns. Finer filters are preferred.
On initial startup of a line, it is advisable to install a spool piece purging the
line to eliminate damaging the flowmeter, due to flux, tape, solder, welds
or other contaminants carried along by the fluid stream.
2.4
INSTALLATION
WIRING LAYOUT FOR INTERCONNECTIONS
In considering the interconnections between the flowmeter and the flow
measurement system some attention must be given to anticipated noise
sources and to the coupling of these noise sources to the interconnecting
wiring.
Noise signals may be coupled inductively or capacitively into the wiring bet-
ween the flowmeter and the electronic measuring systems. In general, utiliz-
ing a shielded, twisted pair for the interconnection greatly reduces this
coupling. The shield should be grounded on one end of the cable only. In
general, grounding only on the electronic measuring system is best.
However, even with proper interconnecting cabling cross talk with other
signal lines or power lines may still occur and should be avoided. Physical
isolation in the manner in which the wiring is run reduces the chance of
potential problems.
B
pickoff
device.
The metering section should not be subjected to excessive vibration or
shock. Such a condition may result in a mechanically induced output signal
from the
-In
general, the meter run should be chosen to have the same
inner diameter as the meter bore. A minimum of IO pipe diameters of
straight pipe upstream and 5 pipe diameters downstream are required.
Where this optimum line configuration can not be implemented, it is ad-
visable to install a flow straightener properly positioned upstream of the
flowmeter. Orientation is not a critical factor, however, horizontal is a pre-
ferred orientation.
RELATIVE-The performance of the turbine flowmeter is affected by fluid
swirl and non-uniform velocity profiles. The following recommendation will
reduce such flow irregularities.
It is advisable not to locate the meter run immediately downstream of
pumps, partially opened valves, bends or other similar piping configurations.
In addition, the area surrounding the flowmeter should be free of sources
of electrical noise such as motors, solinoids, transformers and power lines
which may be coupled to the
preceeding
and following the
flowmeter is termed the meter run.
METER RUN
The piping configuration immediately

”
I.D. CONDUIT
Figure 2-2.
Mounting Holes Location Diagram
9
H
NPT
FOR
35/4”
Tl=t.aJ
/
-
a--+------_,
115VAC
(optional) for
appropriate terminals for installation. Connect the flowmeter cable to the
FTB500 including shield.
“0” RING
REMOVABLE COVER
FTB500
should be placed in a convenient location with sufficient room
for easy opening of the enclosure Refer to Figure 2-2 for the mounting draw-
ing for the FTB500.
Drill appropriate mounting holes as required. Mount the unit to the panel.
Refer to Figure 2-3 for DC hookup or Figure 2-4 for
FTB500
MINI FLOW SIGNAL CONDITIONER
The
It is common to transmit the low level output signal from the flowmeter
several hundred feet through a shielded, twisted pair instrument cable.
Where a noisy environment is suspect, it is recommended that a pre-
amplifier be installed on or near the flowmeter to assure the preservation
of flow information from the flowmeter to the electronic measuring system.
Suitable accessory models are available from the manufacturer.
2.5
INSTALLATION OF THE

Wiring
Diagram
10
EQUlPPEDWITH AN INTEGRAL
CALIBRATION SIGNAL. TO INJECT THIS TEST
SIGNAL, INSTALL A JUMPER FROM TERMINAL
8 TO TERMINAL 1.
Figure 2-3. DC Input Installation
FTB500
IS
NOTE
THE
-
DC VOLTAGE
INPUT
TERMINAL
BLOCK 2
1234567 8
@
F(TEBT)
0
1-P
OPTION) COMMON
@
_
0
+SIGNAL
PULSE OUTPUT
-
RETURN
@
TERMINAL
ANALOG OUTPUT
BLOCK 1
(STANDARD)
+
SIGNAL
1
Lo
0
--_
.-
:,’
B:,’
0
1
I
1
I
i
:
To
PICKUPCOIL
7x
-\-
I
--
A

115VAC
Input Installation Wiring Diagram
11
NOTE
Figure 24.
\TlON
SIGNAL. TO INJECT THIS TEST
INSTALL A JUMPER FROM TERMINAL
FTB500
IS EQUIPPED WITH AN INTEGRAL
CALIBRE
SIGNAL,
8 TO TERMINAL 1.
THE
(NEUTRALS
TERMINAL
BLOCK 1
TERMINAL
BLOCK 2
E
u
@
F(TEST)
IIBVAC
50160 Hz
INPUT
Ayy==+--~
Xl
PICKUP COIL

FfOSl
is the offset frequency
12
FfTEST)
is the test frequency
FfOUTl
is the output frequency of the linearizer
F(OS)l
where:
[F(TEST)
+
F(OUT)
= 1.8
2-41,
injects an internally generated
frequency. When using this feature, F (TEST) is equal to 120 Hz.
jumpered
to the input terminal (connecting Terminal
8 to Terminal 1, refer to Figure 2-3 or
[F(OSl].
The mini flow signal conditioner may be calibrated with the internal TEST
frequency used in conjunction with a frequency counter.
The TEST switch, when
F(OSl
and low flow setpoint.
Field calibration is only required when a change has occurred. Such a
change may be due to repair, replacement or recalibration of the flowmeter.
3.2
CALIBRATION PROCEDURE
Before calibrating the FTB500 flowmeter, analog outputs, be sure the
response time adjustment potentiometer is turned fully clockwise for
fastest response time (0.5 seconds nominal). This potentiometer is found
inside the signal conditioner, inside the rectangular case, on the top printed
circuit board, just beneath terminal I. Slowest response time, with poten-
tiometer fully counter-clockwise, is 2 seconds. Increasing the response time
can act to reduce “jitter” in the analog output.
Begin by determining the offset frequency of the mini flowmeter. This is sup-
plied on the calibration card
FTB500
flowmeter systems supplied by OMEGA Engineering,
Inc. have been factory calibrated at the time of purchase
All systems which were factory calibrated have a calibration card attached
prior to shipment. This card contains the flow rate, offset frequency
Connect the line power and ground to appropriate terminals. The line power
should be an ‘instrument grade ’line whose various loads do not contain
solenoids, valves or other similar transient producing load which might
adversely affect the operation of the system.
Connect the cabling to the pulse output and to the inputs of the final
measurement system. Observe same precautions listed for interconnecting
cabling.
SECTION 3 CALIBRATION
3.1
INTRODUCTION
In general, all

(OS)1
13
[F(MAXl
+ F
ZERO
(OS11
x SPAN +
[F
(TEST) + F
5mA,
or OV
Equation 3
Set (SPAN) =
4mA,
F(GS)
60
Equation 2
Set (ZERO) = SET TO NO FLOW CONDITION
i.e.,
F(MAX)
= K FACTOR x R (MAX) _
11,
injects an internally generated frequency into the unit.
When using this feature, F (TEST) is equal to 120 Hz and is used in the
following equation.
Alternate or external oscillator may be used to supply a test frequency. In
this method, the external oscillator is connected to the signal input ter-
minals. The oscillator ’s output frequency is set to equal F (MAX) as in-
dicated on the frequency counter. For this approach, use F (MAX) in the
following equations for F (TEST).
Regardless of the method used, begin by calculating the following set points
indicated by Equation I through Equation 3. Use the frequency F (TEST)
depending on calibration method chosen above
3.4.2 Equations
Equation
1
jumpered
to the input (Terminal 8
tied to Terminal
FTBBOO
ANALOG OUTPUT
3.4.1 Set Up
The signal conditioner may be calibrated with an internal “TEST” frequency
or an external oscillator used in conjunction with a frequency counter.
METHOD 1
As stated before, the “TEST” frequency
F(OUT)
in the equation stated above.
3.4
CALIBRATION OF
F(OS).
For analog, go to Section 3.4.
For pulse, continue to step 3.
3.
Connect frequency counter to the output of the unit and with an in-
jected TEST frequency, verify that the output frequency equals
FTBSOO
SIGNAL CONDITIONER OFFSET
1. Connect frequency counter to the offset frequency test point of the unit.
2.
Inject the TEST frequency and observe that the frequency equals 10
x
l7I
CONFIRM
3.3

Potentiometer
locations
14
’
Figure 3-1.
Dimensions and
* EQUIPPED FOR ANALOG OUTPUT OPTION
mA
output, OV for 0 to
5v output.
1.
The Range Adjustment is accomplished by selecting a switch position
on a DIP switch located on the PCA-112 printed circuit card depending
on the model. Refer to Table 3-l to determine required switch position,
and select the switch position on the top printed circuit board adjacent
to the zero adjust potentiometer.
TABLE 3-1
RANGE SELECT SWITCHES
F (MAX)
RANGE SELECT
SWITCH
POSITION
300 to 600
3
600 to 1200
4
1200 to 2400
5
2400 to 4800
6
2.
Turn the “SPAN” potentiometer fully counter-clockwise until slippage
is felt or 25 turns. Refer to Figure 3-1.
mA
for 4 to 20
mA
output, 5V for 0 to 5V output
ZERO
= fixed offset component of analog output. For
example, 4
mA
for 4 to 20
ifi,
PULSE/GAL
SPAN = varying component of analog output. For example,
16
F(MAX)
was defined.
K Factor
= in units of readout,
R(MAXl when
at the reference condition at which the relation with
F(MAX) = the flowmeter output frequency at
F(OSl = offset frequency
F(TEST)
= test frequency used
where:

FTBBOO
FLOWMETER (BALL BEARING DESIGN)
Preventative maintenance requires that the Mini Flowmeter under go a
general inspection. Refer to Figure 4-I and the following procedure to
remove the flowmeter internals from the housing. A clean work area is
required.
15
Measurement_Systems
are constructed to give a long ser-
vice life. However, problems do occur from time to time and the following
points should be considered for preventative maintenance and repairs.
The bearing type used in the flowmeter was chosen to give compromise
between long life, chemical resistance, ease of maintenance and perfor-
mance. A preventative maintenance schedule should be established to
determine the amount of wear which has occurred since last overhaul.
In case the flow measurement system malfunctions or becomes in-
operative, refer to the Troubleshooting Guide in Section 5.
SERVICING AND PREVENTATIVE MAINTENANCE OF THE
3-l) so the current equals to SET (SPAN).
6.
Repeat steps 4 and 5 until no change is observed.
FOR VOLTAGE OUTPUT OPTION ONLY
7.
Connect a digital voltmeter across the voltage output terminals.
8. Inject the test frequency while adjusting “SPAN” potentiometer so
voltage equals to SET (SPAN).
SECTION 4 MAINTENANCE
4.1
4.2
INTRODUCTION
OMEGA ’s Flow
mA).
5.
Inject the test frequency while adjusting “SPAN” potentiometer (refer
to Figure
3-l) for desired “ZERO”
current (i.e., 4
milli-ammeter
or equivalent, across the current out-
put terminals.
4.
Adjust “ZERO” potentiometer (refer to Figure
FOR CURRENT OUTPUT OPTION ONLY
3.
Connect a digital

ROTOR
WHEN LOOKING
DOWN FROM TOP
DETAIL OF ROTOR
Figure 4-1. Standard BallBearing Cutaway Diagram
16
WELO-
CORRECT
ORIENTATION
OF
FLOW-8
FL OW -

#77-545-018 or equivalent on the insert.
NOTE
“0” ring should be lightly lubricated with “0” ring lubrication
wh ich is silicone based.
12.
P lace insert on the shaft. W hen properly seated gently push the
insert back on the shaft.
13.
Install and tighten the threaded plug. Tighten plug until snug. Do
not over tighten.
The flow m eter is ready for service W hen installing the flow m eter be sure
to orient the input and output correctly.
17
pelton
whee l faces the IN side of the
housing. Refer to Figure 4-1 detail.
NOTE
IF THE ROTOR IS INSTALLED BACKWARDS , THE METER W ILL
NOT G IVE YOU THE ACCURACY YOU REQU IRE . REFER TO THE
DETA IL CLOSELY.
Il.
Install a new Viton “0” ring
FTB500
Flow m eter m ust be held in place by a vise. Me ter orien-
tation should be such that the threaded plug is facing upwards.
Using a screwdriver and turning counter clockwise, break the seal and
re move the plug.
Using tweezers or needle nose pliers, slowly pull the insert out, while
taking care not to da m age the shaft or lose the thrust stop.
Remove the rotor by using a pair of tweezers.
Remove the shaft asse m bly with s m ooth needle nose pliers. Care
should be taken in not defor m ing the shaft and loss of any parts.
Exa m ine the flo wme ter internals for signs of corrosion or fouling by
foreign m aterials.
Exa m ine the shaft and bearings for signs of wear or corrosion on the
m ating surface.
If wear or corrosion is present in bearings, obtain new bearings fro m
stock of the m anufacturer.
Insert ball bearings in rotor.
10.
Gu ide the rotor bearing asse m bly onto the shaft. Make sure to orient
the rotor so the cup side of the
1.
2.
3.
4.
5.
6.
7.
8.
9.
The
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