Omega Engineering FP-6000 User's Manual
Contents
1. j brass sensor nut Step 2 TEMM lower hex nut 2nd E 3 7 Hot Tap Installation 1 Thread one hex nut onto each of the three threaded rods included in package Install threaded rod with a lockwasher onto the brass sensor nut Secure rods in place by tightening each hex nut against the brass sensor nut 2 Thread one jam nut and lower hex nut onto each stud so the top surface of each nut is 13 75 in 350 mm from top surface of brass sensor nut Secure each hex nut with a jam nut This setting is critical to ensure an adequate sensor seal and to prevent the rotor from hitting the isolation valve orifice during installation lower hex nuts jam nut T st E Pa 3 16x 1 420 A Y jam nuts 5 32 x 1 4 20 13 5 in 350 mm Vv e brass sensor nut jeg 3 Wipe the FP 6000 Series sensor body with a dry clean cloth Orient the alignment hole on the sensor flange to point downstream Place the slotted flange over the threaded rods Lower the sensor into fitting until the sensor flange rests on the lower hex and jam nuts 4 Secure the sensor with lockwashers and upper hex nuts2. make sure bleed valve clears isolation valve handle process pipe For HotTap installations we assume pipe dimensions are known Wall thickness ID For standard sensor installa tions the ruler may be used to measure wall thickness and LD of pipes up to 5 inches in diameter 4 Open the isolation valve and insert the drill through the valve and cut the sensor clearance hole After the hole is cut withdraw the drill from the isolation valve and close the valve Remove the drilling machine per manufacturer s instructions 5 Install brass sensor nut bleed valve into the top of the isolation valve Make sure the bleed valve clears the handle of the isolation valve during operation 3 5 Calculating the H Dimension Before installing the sensor some critical dimen sions must be established The rotor shaft must be located 10 inside the pipe I D to insure accurate calibration capability To accomplish this the H dimension is measured from the outside surface of the pipe to the bottom of the sensor flange Nominal H dimensions for standard pipes are listed on page 18 19 For irregular pipe dimen sions calculate the H dimension using the given formulas page 7 The 6 inch ruler may be used to measure the I D and wall thickness of pipes up to 5 inch standard sensors only incorrect correct ZZZZZZZZZZZZZZZZZZ ZZZZ 7777277727777 D LLLLLILLLL
3. 2 7730 0 7326 21 637 81 897 0 4819 32 895 12451 SID VVROUGHT STEEL PIPE PER ANSI B36 10 K FACTOR K FACTOR A FACTOR A FACTOR PIPE PULSES PULSES U S SIZE U S GAL LITER GPM HZ LPM HZ 11 2 122 000 32 2325 0 4918 1 8615 78 690 20 7900 0 7625 2 8860 35 530 9 3871 1 6887 6 3918 4 19 840 5 2417 3 0242 11 447 5 12 090 3 1942 4 9628 18 784 6 8 0410 2 1244 7 4618 28 243 8 4 3500 1 1493 13 793 52 207 10 2 6080 0 6890 23 006 87 078 12 1 7400 0 4597 34 483 130 52 14 1 3950 0 3686 43 011 162 80 16 1 0220 0 2700 58 708 222 21 18 0 7800 0 2061 76 923 291 15 20 0 6150 0 1625 97 561 369 27 22 0 4970 0 1313 120 72 456 94 24 0 4110 0 1086 145 99 552 55 XS WROUGHT STEEL PIPE PER ANSI B36 10 K FACTOR K FACTOR A FACTOR A FACTOR PIPE PULSES PULSES U S SIZE U S GAL LITER GPM HZ LPM HZ 11 2 136 100 35 9577 0 4409 1 6686 2 88 590 23 4055 0 6773 2 5635 21 2 62 810 16 5945 0 9553 3 6157 3 39 990 10 5654 1 5004 5 6789 3 1 2 29 220 7 7199 2 0534 7 7721 4 22 160 5 8547 2 7076 10 248 5 13 420 3 5456 4 4709 16 923 6 9 0160 2 3820 6 6548 25 189 8 4 8190 1 2732 12 451 47 126 10 2 7730 0 7326 21 637 81 897 12 1 8240 0 4819 32 895 124 51 14 1 4550 0 3844 41 237 156 08 16 1 0590 0 2798 56 657 214 45 18 0 8050 0 2127 74 534 282 11 20 0 6320 0 1670 94 937 359 34 22 0 5100 0 1347 117 65 445 29
4. Shop online at omega com CE OMEGA www omega com e mail info omega com FP 6000 Series Flow Sensors omega com EOMEGA OMEGAnet Online Service Internet e mail www omega com info omega com USA ISO 9001 Certified Canada Servicing North America One Omega Drive P O Box 4047 Stamford CT 06907 0047 TEL 203 359 1660 FAX 203 359 7700 e mail info omega com 976 Bergar Laval Quebec H7L 5A1 TEL 514 856 6928 FAX 514 856 6886 e mail info omega ca For immediate technical or application assistance USA and Canada Mexico Benelux Czech Republic France Germany Austria United Kingdom ISO 9002 Certified Sales Service 1 800 826 6342 1 800 TC OMEGA Customer Service 1 800 622 2378 1 800 622 BEST Engineering Service 1 800 872 9436 1 800 USA WHEN TELEX 996404 EASYLINK 62968934 CABLE OMEGA En Espafiol 001 203 359 7803 e mail espanol amp omega com FAX 001 203 359 7807 info omega com mx Servicing Europe Postbus 8034 1180 LA Amstelveen The Netherlands TEL 31 0 20 3472121 FAX 31 0 20 6434643 Toll Free in Benelux 0800 0993344 e mail nl omega com Rud arm dy 1868 733 01 Karvin 8 TEL 420 0 69 6311899 FAX 420 0 69 6311114 Toll Free 0800 1 66342 e mail czech omega com 9 rue Denis Papin 78190 Trappes TEL 33 0 130 621 400 FAX 433 0 130 699 120 Toll Free in France 0800 4 06342
5. 24 0 4200 0 1110 142 86 540 71 K factors Wrought Steel SCH 40 WROUGHT STEEL PIPE PER ANSI B36 10 K FACTOR K FACTOR A FACTOR A FACTOR PULSES PULSES U S U S GAL LITER GPM HZ LPM HZ 122 000 32 232 0 4918 1 8615 78 690 20 790 0 7625 2 8860 55 630 14 697 1 0786 4 0823 35 530 9 3871 1 6887 6 3918 26 070 6 8877 2 3015 08 711 19 840 5 2417 3 0242 11 447 12 090 3 1942 4 9628 18 784 8 0410 2 1244 7 4618 28 243 4 3500 1 1493 13 793 52 207 2 6080 0 6890 23 006 87 078 1 7610 0 4653 34 072 128 96 1 4250 0 3765 42 105 159 37 1 0590 0 2798 56 657 214 45 0 8180 0 2161 73 350 277 63 0 6460 0 1707 92 879 351 55 0 4350 0 1149 137 93 522 07 PIPE PULSES PULSES U S SIZE U S GAL LITER GPM HZ LPM HZ 11 2 136 100 35 9577 0 4409 1 6686 2 88 590 23 4055 0 6773 2 5635 21 2 62 810 16 5945 0 9553 3 6157 3 39 990 10 5654 1 5004 5 6789 3 1 2 29 220 7 7199 2 0534 7 7721 4 22 160 5 8547 2 7076 10 248 5 13 420 3 5456 4 4709 16 923 6 9 0160 2 3820 6 6548 25 189 8 4 8190 1 2732 12 451 47 126 10 2 8970 0 7654 20 711 78 391 12 1 9620 0 5184 30 581 115 75 14 1 5890 0 4198 37 760 142 92 16 1
6. Z Jg 0 D 5033 a 535 SS oS 4234 23 Son Soe a oS ERE n ES SSS SS SS SD SSS SS SS SS ux Conversion Stainless Steel Pipe Per ANSI B36 19 mm inches 25 4 SCH 55 SCH 10S SCH 40S SCH 80S 4 758 4 723 4 694 i 1 650 i L711 4 675 4 639 i 1 588 1 646 4 617 4 550 1 584 4 554 4 477 1 534 4 504 4 419 484 4 454 4 360 i 1 357 4 337 4 237 i 4 250 4 230 i 4 144 i 4 050 4 019 i 3 880 i 3 818 3 793 i 3 633 3 600 3 581 i 3 425 3 475 3 450 i 3 268 3 250 i 3 068 3 050 i 2 850 2 826 i 2 650 2 626 i 2 426 2 400 i in n n o XIX cm ELE E mE SS Ai 5 6 8j 10 12 14 l 8 SS In Da SA IA SS DDD o ans Das c yu cp cv ur Ad i SS Modus d 44S SS SoS ULM ata 3 3 NN ND ANO represents values currently unavailable K factors Stainless Steel SCH 40S STAINLESS STEEL PIPE PER ANSI B36 19 SCH 5S STAINLESS STEEL PIPE PER ANSI B36 19 K FACTOR K FACTOR A FACTOR A FACTOR PULSES U S GAL PULSES LITER LPM HZ 104 200 27 5297 2 1795 67 160 17 7437 3 3815 46 060 12 1691 4 9305 29 790 7 8705 7 6234 22 060 5 8283 10 295 0 7625 2 8860 14 6975 1 0786 4 0823 1 6887 6 3918 4 16 890 4 4624 3 5524 13 446 21 324 5 10 6500 2 8137 5 6338 Le 7 Me0 18801 84317 31914 38700 1 0225 15 504 58 682 30 235
7. contact your OMECA dealer 1 1 Description The FP 6000 Series is an insertion flow sensor used to measure the flow velocity of fluids through process pipes The sensor insertion depth is adjustable allowing installation into metal pipes ranging from 11 to 24 inches in diameter 1 to 36 in for HotTap The HotTap version enables installation in active pipes reducing downtime to a minimum Wetted parts include C36000 brass CDAMCu steel tungsten steel Fluoroloy B and Viton The FP 6000 Series mounts on the pipe through any standard 1 inch female pipe fitting The unit comes equipped with standard NPT threads or optional ISO 7 1 R 117 threads 1 2 Theory of Operation Liquid flowing through a process pipe rotates the sensor paddlewheel An AC frequency is induced into the sensor coil which is proportional to the fluid velocity in amplitude and frequency The AC signal is then input to a control instrument where he frequency is converted to engineering units and used to display flow rate and control external devices Patented open cell rotor design provides a linear AC output over a wider velocity range Chapter 2 The linearity and accuracy of the FP 6000 Series sensor depend on predictable flow conditions in the pipe and proper location of the fitting As Installation and with any insertion flow sensor the pipe must be full Wiring and generally free of air pockets 2 1 Location of Fitting The sensor mus
8. face protection cover the bleed valve with suitable protection rag towel etc and open the bleed valve ccw rotation to relieve internal pressure Pull sensor up until bleed valve purges some fluid indicating sensor is past Ist oring seal inside brass sensor nut then remove sensor from brass sensor nut threaded rod assembly Caution n case of a leaky isolation valve the sensor will be under a slight amount of pressure Care should be taken when removing the sensor Use the bleed valve to relieve this pressure taking care not to spray fluid on yourself or others A When reinstalling the sensor leave one lower hex nut in position to guide sensor to proper height before opening valve Return to H dimension height after valve is opened Chapter 5 5 1 Maintenance All versions of the FP 6000 series sensor require little or no maintenance with the exception of an Maintenance occasional sensor paddlewheel cleaning p 9 and 5 2 Replacement Parts Replacement Parts Standard version 1 Standard sensor assembly FP 6000 6001 2 Rotor kit bearings shaft retainers and rotor included see table below e FP52509 1 kit with stainless steel shaft e FP52509 2 kit with Tungsten Carbide shaft 3 Instruction manual M 2973 Rotor Kit FP52509 1 Rotor Kit retainer retainer e Retainer material 316 stainless steel e Rotor shaft material 316 stainless steel e Bearing material Fluoroloy B e Rotor material CDAMCu st
9. 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 vibration improper specification misapplication misuse or other operating conditions outside of OMEGA s control Components which wear are not warranted including but 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 it will be as specified and free of defects OMEGA MAKES NO OTHER WARRANTIES OR REPRESENTATIONS OF ANY KIND WHATSOEVER EXPRESS 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 purchaser 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 inci
10. on the top of the flange Before tighten ing align the sensor flange so that the alignment rod is parallel and level with the process pipe 5 Make sure the bleed valve is closed full clockwise position sensor flange Ma alignment pe ae de ait Upper hex nuts direction of flovv pi 3 16 x 1 4 20 The flow sensor alignment rod MUST be Toce A ini lock washers parallel to the process pipe as shown l process pipe top view alignment rod lower hex nut and am nuts 18 inch threaded rods 13 75 in B EE Brass sensor nut Bp Bleed valve process pipe side view protector plate cap nuts z cable grommit Using the Hot Tap Installation Tool The HotTap installation tool helps to lower the sensor into place against the pressure in the pipe 1 Thread protector plate hex nuts onto each of the three threaded rods Adjust each hex to a height of approximately 1 in 25 mm from the top of each rod Remove the black plastic cable grom met in top of sensor with a screwdriver Slide the grommet up the cable away from sensor 2 Position the installation tool bearing plate by rotating it so that it is approximately 2 inches away from the swivel mount Mount the installation tool by placing the threaded rods through the holes in the tool s bearing pl
11. 1750 0 3104 51 064 193 28 18 0 9040 0 2388 66 372 251 22 20 0 7160 0 1892 83 799 317 18 22 0 5820 0 1538 103 093 390 21 24 0 4820 0 1273 124 48 471 16 K factors Plastic Pipe Schedule 40 Plastic pipe per ASTM D 1785 KFACTOR K FACTOR A FACTOR A FACTOR pipe Putses PuisES Us size U s GAL UTER GPM HZ IPM HZ 1172 124400 328666 04823 18256 7 2 80140 21 1731 07487 28338 2172 56730 14 9881 10576 40032 31 2 26500 70013 22642 8 5698 4 20 140 53210 29791 11 276 5 12250 32365 48980 18539 6 8 1430 21514 73683 27889 8 43980 1 1620 13643 51637 10 26340 0 6959 22779 86219 12 17770 04695 33765 12780 The Kfactor is Schedule 80 Plastic pipe per ASTM D 1785 K FACTOR K FACTOR A FACTOR A FACTOR PIPE PULSES PULSES Us _ 11 21 139 400 36 8296 0 4304 1 6291 2 90 790 23 9868 0 6609 2 5014 21 2 64 610 17 0700 0 9286 3 5149 10 022 5 13700 3 6196 4 3796 16 577 6 9 1990 2 4304 6 5224 24 687 8 12 230 46290 10 12 1 9930 0 5266 30 105 113 95 factors and Afactors are listed in U S gallons and in liters Conversion formulas for other engineering units are listed below he number of pulses generated K 60 A by the FP 6000 series paddlewheel per unit of liquid in a specific pipe size e The Afactor
12. 70 06227 25 456 096 35 1 6060 04243 37360 141 41 34 12980 03429 46225 17496 16 09620 02547 62370 236 07 318 07400 0 1955 81081 306 89 20 0 5900 0 1559 101695 38492 22 04790 01266 12526 4741 24 03990 0 1054 150 38 569 17 PULSES LITER 35 9577 A FACTOR 0 4409 A FACTOR LPM HZ 1 6686 23 4055 0 6773 2 5635 16 5945 0 9553 3 6157 SCH 10S STAINLESS STEEL PIPE PER ANSI B36 19 K FACTOR K FACTOR A FACTOR A FACTOR 10 5654 1 5004 5 6789 PIPE PULSES PULSES EE SIZE U S GAL LITER GPM HZ LPM HZ 113 600 30 0132 0 5282 1 9991 11 2 2 72560 19 1704 0 8269 3 1298 2172 48750 128798 12308 4 6585 3 31250 82563 7 2672 3172 23010 60793 2 6076 09 870 4 17540 46341 34208 12948 5 7 7199 2 0534 7 7721 5 8547 2 7076 10 248 3 5456 4 4709 16 923 2 3820 6 6548 25 189 1 2732 12 451 47 126 10 8700 2 8719 5 5198 20 892 6 7 2410 1 9131 8 2861 31 363 8 3 9520 1 0441 15 182 57 465 10 2 3880 0 6309 25 126 095 10 12 1 6200 0 4280 37 037 140 19 14 1 3110 0 3464 45 767 173 23 16 0 9680 0 2557 61 983 234 61 18 0 7440 0 1966 80 645 305 24 20 0 5930 0 1567 101 180 382 97 22 0 4820 0 1273 124 48 471 16 24 0 4020 0 1062 149 25 564 93
13. LLLLLD Standard Sensor H 5 95 pipe wall thickness 0 10 X I D Record your pipes H dimension for future Example reference 3 0 inch schedule 80 wrought steel Wall thickness 0 3 in H nside diameter 2 9 in 95 0 3 0 10 X 2 9 36 in 5 5 sensor flange A rod process pipe direction of flow Hot Tap Sensor H 15 00 pipe wall thickness 0 10 X I D protector plate Example 10 inch schedule 40 wrought steel A Slammer El VVall thickness 0 365 in nside diameter 10 02 in 15 00 0 365 0 10 X 10 02 13 635 in H p i U Record your pipes H Y dimension for future K A reference o O direction of flow ia uS process pipe side view 7 Step AZ e hex nut lock washer 1 brass sensor nut Step 2 lower hex nut 2nd 3 jam nut 1 st Once the correct dimensions are calculated and recorded the sensor can be installed in the fitting The Standard and HotTap versions require substantially different procedures 3 6 Standard Installation 1 Thread one hex nut onto each of the three threaded rods included in package Install threaded rod with a lockwasher onto the brass sensor nut Secure rods in place by tig
14. ainless steel rotor shaft c ing P beari Nx rotor FP52509 2 Rotor Kit e Retainer material 316 stainless steel e Rotor shaft material Tungsten Carbide Refer to rotor replacement e Bearing material Fluoroloy B instructions pg 17 e Rotor material CDAMCU stainless steel Hot Tap version 4 HotTap sensor assembly FP 6000 6001 5 Rotor kit bearings shaft retainers and rotor included see table above e FP52509 1 kit with stainless steel shaft e FP52509 kit with Tungsten Carbide shaft 6 Instruction manual M 2973 5 3 Rotor Replacement Procedure 1 With a small pair of needle nose pliers firmly grip the center of the rotor pin axle and with a twisting motion bend the rotor pin into an S shape This should pull the ends of the pin out of the shaft retainers and free the rotor assembly 2 Remove shaft retainer from each side by gently tapping it inwards using a punch Install a new shaft retainer with the rotor shaft clearance hole inward Only install one shaft retainer at this time 3 Insert the new rotor assembly and bearings into the rotor housing of the sensor and place the new rotor pin axle through the open end of the rotor housing through the rotor and bearings and into the previously installed shaft retainer 4 Tap the second shaft retainer rotor shaft clear ance hole inwards into the hole while lining up the rotor pin with the
15. areful to not damage cable Snap cable grommet into top of sensor and replace protector plate and cap nuts protector plate gt fin dia da cap nuts installation tool Mis FAN cap nuts T opino shaft Em EIE upper hex nuts ee ak oH protector plate E alignment rod i bd i protector plate hex nut mi N lower hex nuts Nes am nuts H N Hr E Chapter 4 4 1 Standard Sensor Removal To remove the Standard FP 6000 Series sensor from a depressurized empiy pipe simply remove Sensor Removal the cap nuts and upper hex nuts located above the Procedures sensor flange Pull up on sensor flange with twisting motion 4 2 Hot Tap Sensor Removal To remove the HotTap sensor safely from a pressurized active pipe the entire installation process must be reversed protector plate 1 Remove the cap nuts protector plate protector i gin cap nuts plate hex nuts and sensor cable grommet 2 Thread installation tool in place and secure Protector pole bearing plate in place of sensor protector plate I i protector plate E eene 3 Turn shaft of installation tool clockwise to lower tool into opening in sensor flange Guide cable into the por
16. ate resting the bearing plate on top of the protector plate hex nuts Make sure the swivel mount s ears are mounted between the threaded rods not over the rods Install the bearing plate cap nuts Tighten the bearing plate cap nuts to secure the installation tool in place Protector plate removed during sensor installation Protector plate hex nut 3 16 x 1 4 20 EE RN installation tool cap nuts threaded shaft protector plat ee i bearing plate ex nuts E E LE E swivel mount paras gl E w cable port cable E sensor flange sensor body Im 3 Align the sensor cable with the swivel mount cable port to prevent cable pinching Use a 3 8 inch wrench or socket to turn the installation tool shaft clockwise until it is seated in the hole at the top of the sensor flange 4 Wearing safety face protection slowly open the isolation valve to the full open position Loosen the lower hex and jam nuts and move them to the required H dimension Turn the installation a tool shaft clockwise until the sensor flange contacts the lower hex and jam nuts Thread the upper hex nuts down until they contact the sensor flange Tighten the upper hex nuts to secure the sensor 5 Remove cap nuts and withdraw the installation tool by turning shaft counterclockwise Be c
17. center of the shaft retaining hole This completes the rotor replacement procedure e Rotor Pin p Existing Retainer Punch Retainer Assembly f H Dimensions H Dimensions for Standard Sensors Wrought Steel Pipe Per ANSI 36 10 in in in in in in in in in in in in in in in in x in in in in Ai in in in in 5i in in in in Gi in in in in 8i in in in in 101 in in in in 12i in in in in 14i in in in in l i in in in in 18i in in in in i in in in in in in in in in in in Conversion Stainless Steel Pipe Per ANSI B36 19 mm inches 25 4 SCH 55 SCH 80S 5 708 5 600 i 5 660i 5 538i 5 596 5 442 5 534 i 5 360 i 5 484 5 296 i 5 434 5 230 i 5 306 i 5 094 i 5 200 i 4 942 5 000 i 4 688 4 768 i 4 475 4 550 i 4 275 4 425 i 4 218i 4 018i 3 800 i 3 600 i 3 376 i in in in SS 3 300023 33 3 3 Sp Duc uc 4 400 4 200 i 4 000 3 776 i 3 576 i 3 350 i 4i D 6 8 0 2 4 6 8 X 3 SS SSNS B OO 123 3 3 BS 3002 02 23 SS Ss SS 123425 o SS SS SS SS SS MNN ANO represents values currently unavailable H Dimensions for Hot Tap Sensors H Dimensions Wrought Steel Pipe Per ANSI 36 10 SS 5 E 33303329 33335353 5 5 5 5 oe sien Sear ae aes 5 I OG
18. dental 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 FOR NON WARRANTY REPAIRS consult OMEGA following information available BEFORE for current repair charges Have the following contacting OMEGA information available BEFORE contacting OMEGA 1 Purchase Order number
19. e mail france omega com Daimlerstrasse 26 D 75392 Deckenpfronn Germany TEL 449 0 7059 9398 0 FAX 449 0 7056 9398 29 Toll Free in Germany 0800 639 7678 e mail germany omega com One Omega Drive River Bend Technology Centre Northbank Irlam Manchester M44 5EX United Kingdom TEL 44 0 161 777 6611 FAX 44 0 161 777 6622 Toll Free in United Kingdom 0800 488 488 e mail sales amp omega co uk It is the policy of OMEGA to comply with all worldwide safety and EMC EMI regulations that apply OMEGA is constantly pursuing certification of its products to the European New Approach Directives OMEGA will add the CE mark to every appropriate device upon certification The information contained in this document is believed to be correct but OMEGA Engineering Inc accepts no liability for any errors it contains and reserves the right to alter specifications without notice WARNING These products are not designed for use in and should not be used for patient connected applications Chapter Introduction Description 1 2 Theory of Operation 2 Installation and Wiring 2 1 location of Fitting 2 2 Sensor Position 2 3 Sensor Wiring 3 Installation 3 1 Hardware Standard Sensor 3 2 Hardware HotTap Sensor 3 3 Standard Fitting Installation 3 4 HotTap Fitting Installation 3 5 Calculating the H Dimension 3 6 Standard Installation 3 7 HotTap Installation 4 Sensor Removal Procedures 4 1 Standard Sensor Re
20. earing safety face protection drill a 1 in 32 mm diameter hole in the pipe 3 Install the pipe fitting on the outside of the pipe according to the manufacturer s instructions Failure to follow these instructions may result in bodily injury and or product failure 4 Remove brass sensor nut from sensor brass sensor nut process pipe pipe fitting Teflon tape recommended 5 Thread brass sensor nut into pipe fitting 3 4 Hot Tap Fitting Installation 1 Install the pipe fitting on the outside diameter of the pipe according to the manufacturer s instruc tions Failure to follow these instructions may result in bodily injury and or product failure 2 Install the pipe nipple and isolation valve ball or gate valve onto the external pipe fitting using pipe sealant on the threads customer supplied fe ball or gate valve TI o d TA customer supplied nipple 1 25 x 2 in 32x50 mm long process pipe side view 3 VVearing safety face protection install an appropriate hole cutting tool per manufacturers instructions e g Mueller drilling machine with a 177 in 32 mm drill onto the top of the isolation valve ensuring a tight fit Use the recommended drill bit size or damage to the isolation valve may occur brass sensor nut bleed valve
21. htening each hex nut against the brass sensor nut 2 Thread one jam nut and lower hex nut onto each stud so that the top surface of each nut is at the proper H dimension for your pipe Secure each hex nut with a jam nut 3 Insert the flow sensor into the brass sensor nut making sure the alignment hole on the sensor flange is pointing downstream lower hex nuts 3 16 x 174 20 ma 89 nuts 5 32x 1 4 20 mm H hex nut and lock washer a brass sensor nut process pipe 4 Place the alignment rod in the hole on the sensor flange Align the flange so rod is parallel to the process pipe sensor flange direction of flow process pipe top view The flow sensor alignment rod MUST be parallel to the process pipe as shown 5 Thread upper hex nuts with lockewashers until they contact the sensor flange and tighten Check for proper H dimension and readjust if necessary i a cap nuts sensor flange 53 upper hex nuts and lock washers d jam nuts 7 5 95 in 151 mm brass sensor nut 1 172 in NPT or 9 ISO 7 Rc 1 1 2 in female pipe fitting v PARR EES EDAR EE EE IE a at ROS OOS ee EE ena Iesu pipe I D FLOW ZZZZZZZZZIZIZZIZ ZE ZIZIZIZIZIZIZIDIZIZIDIID process pipe hex nut lock vvasher
22. i Q 185 F All higher maximum specifica tions MUST yield to the component with the lowest maximum specification Maximum Operating Pressure 225 psi 15 bar Maximum Operating Temperature 212 F 100 C gt Pb Unpacking and Inspection Your flow sensor package includes the following items OMEGA FP 6000 Series Adjustable Brass Flow Sensor 6 inch ruler Standard sensor version only 10 inch brass alignment rod OMEGA FP 6000 6001 Adjustable Brass Flow Sensor Order Number FP 6000 1 1 2 in NPT threads Warranty Record For your protection record your sensor s purchase FP 6001 information for future reference The serial number 7 1R 1 1 2 ISO threads is located on the metal tag attached to the upper portion of the sensor body Type OMEGA FP 6000 Series Adjustable Brass Flow Sensor Purchase Date mm Ep hr y Am Hun Model Number Serial Number Purchased From OMEGA FP 6002 6003 Adjustable Brass Flow Sensor Purchase Order Number for HotTap installations Order Number FP 6002 1 1 2 in NPT threads FP 6003 7 1 R 1 1 2 ISO threads This manual contains description specifications Chapter 1 and instruction for the installation removal and operation of the OMEGA FP 6000 Series Adjustable Brass Flow Sensor Please read the Introduction manual thoroughly If you require further assistance please
23. ions and limitations depend on the lowest maximum rating of the components associated with the system For example a ball valve a component of the system is rated ata maximum 100 psi 185 F limiting the entire system s maximum pressure temperature rating to 100 psi 185 F All higher maximum specitications MUST yield to the component with the lowest maximum specification Note Pressure temperature specitications refer to sensor performance in water Certain chemical limitations may apply Chemical compatibility should be veritied before sensor installation MA USA 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
24. is the flow rate per minute repre A 60 K sented by 1 Hz output from the FP 6000 series sensor in a specific pipe size 22 To convert K from gallons gallon gallon gallon gallon gallon gallon To convert K from iters iters iters to cubic feet cubic inches cubic meters pounds of water acre feet liters Imperial gallons to cubic meters kilograms of water gallons multiply K by 7 4 9 0 00433 263 85 0 120 325859 0 264 1 201 multiply K by 1000 3 785 General Data Flovv velocity range Linearity Repeatability Pipe sizes Standard version HotTap version Cable length Materials Sensor material Rotor material Rotor bearings Rotor shaft O ring material Electrical Data Power requirements Load impedance Ambient Conditions Maximum ification 1 6 to 20 ft s specincahons 0 5 to 6 m s 1 of full range 0 5 of full range 1 5 to 24 in 38 to 610 mm 125 16 36 tn 38 to 914 mm 25 ft 7 6 m can extend up to 200 ft 61 m without amplification C36000 free cutting brass CDAM Cu stainless steel Fluoroloy BE 316 stainless steel opt Tungsten Carbide std Viton Self powered O to 1000 Q max 23 Specifications 24 operating pressure 225 psi 15 bar Maximum operating temperature 212 F 100 C Caution The FP 6002 and FP 6003 Series Hot Tap system s overall specificat
25. moval 4 2 HotTap Sensor Removal 5 Maintenance and Replacement Parts 5 Maintenance 5 2 Replacement Parts 5 3 Rotor Replacement Procedure H Dimensions for Standard Sensors H Dimensions for Hot Tap Sensors Calibration Constants Specifications Warranty Page 1 i COOESESESR CO h2 h2 N KERR oo o 19 20 23 25 Table of Contents Important Safety Information CAUTION Standard version Never remove the flow sensor from a pressurized pipe Always wear sofety face protection during sensor installation removal Hot Tap version Follow the recommended installation removal instructions in this manual Always wear safety face protection during sensor installation removal Pipe fittings MUST be installed by a certified welder only OMEGA will not assume liability of any kind for improper fitting installations Serious bodily injury and or damage to the sensor can result if the conditions and specifications presented in this manual are exceeded DO NOT exceed specifications under any circumstances The FP 6000 HotTap system s overall specifica tions and limitations depend on the lowest maxi mum rating of the components associated with the system In other words the Hot Tap system is only as strong as its weakest link For example a ball valve a component of the system is rated at a maximum 100 psi Q 185 PF limiting the entire system s maximum pressure temperature rating to 100 ps
26. s Mass Flowmeters amp Flow Computers A Air Velocity Indicators A Turbine Paddlewheel Systems 4 Totalizers amp Batch Controllers pH CONDUCTIVITY lA pH Electrodes Testers amp Accessories A Benchtop Laboratory Meters HM Controllers Calibrators Simulators amp Pumps 4 Industrial pH amp Conductivity Equipment DATA ACQUISITION Data Acquisition amp Engineering Software 14 Communications Based Acquisition Systems 14 Plug in Cards for Apple IBM amp Compatibles 14 Datalogging Systems 4 Recorders Printers amp Plotters HEATERS WA Heating Cable lA Cartridge amp Strip Heaters 14 Immersion amp Band Heaters A Flexible Heaters IA Laboratory Heaters ENVIRONMENTAL MONITORING AND CONTROL 14 Metering amp Control Instrumentation 14 Refractometers L Pumps amp Tubing A Air Soil amp Water Monitors Industrial Water amp Wastewater Treatment A pH Conductivity amp Dissolved Oxygen Instruments M 2973 0802
27. t 3 feet of vertical clearance for sensor installation plus the distance required for the isolation valve and fittings attached to the pipe More clearance may be necessary to suit the drilling machine used during sensor installation 2 3 Sensor Wiring oued Both Standard and HotTap sensor Le pon versions include 25 feet of cable The Km cable may be extended up to 200 feet without amplification A inch conduit port is available in the sensor to install the cable in protective conduit black AC signal out red AC signal out silver instrument shield Chapter 3 Installation Caution Depressurize and drain pipe before drilling A LS The following items are required to properly install the OMEGA FP 6000 Series Adjustable Brass flow Sensor 3 1 Hardware Standard Sensor e female pipe fitting weld on or saddle 117 in NPT or ISO 7 T Rc 1 1 2 e 1 in 32 mm diameter drill e Pipe thread sealan e Tape measure 3 2 Hardware Hot Tap Sensor The HotTap sensor requires all the above items plus e HotTap drilling machine e g Mueller drilling machine or equivalent Female ball or gate valve full port only 117 in NPT or ISO 7 1 Re 1 172 e Male pipe nipple 11 x 2 in 32 x 50 mm 11 in NPT or ISO 7 18 117 e HotTap installation tool purchased separately 3 3 Standard Fitting Installation 1 Depressurize and drain pipe 2 W
28. t be located in a freeflowing straight run of pipe OMEGA recommends a minimum of 1O pipe diameters of straight pipe upstream and a minimum of 5 diameters down stream to insure a fully developed flow profile Any obstructions to the flow will require consider ably longer straight runs Figure 1 illustrates several common situations and recommended piping distances Figure 1 Sensor upstream downstream mounting requirements Flange Valve Gate PEL 2 2 Sensor Position When installing the sensor in a horizontal pipe run the optimum position is at O or 180 assuming the line is always full and contains no solids Air pockets or sediment in the line will disturb the rotation of the paddlewheel causing inaccuracy in the calibration Installing the sensor at an angle max 30 will help to avoid these problem areas but use caution Excessive angles will cause bearing drag at lower flow rates On a vertical pipe run locate the sensor where the flow is upward If downward flow is necessary the system must be designed to prevent air water vapor pockets from developing in the pipe which will affect the performance of the sensor Figure 2 Sensor Installation Range Vertical mounting is recom mended to provide best overall performance Maximum Sensor e Installation Range Process Pipe Special Considerations For HotTap installations allow at leas
29. t to prevent damage ML UU installation tool 4 threaded shaft 4 Wearing mM upper hex nuts and lock washers safety face HE A ue RAE flange protection Wad loosen the upper 7 hex nuts and raise to 14 2 in 361 mm from top of brass sensor nut to bottom of nut This measurement is critical to maintain watertight seal in 8 sensor while allowing clearance to close the isolation valve Eu HET mommy lower hex and 361 mm jam nuts Y process pipe side view E C NES installation tool threaded shaft cap nuts a installation tool E I bearing plate protector plat ex nuts swivel mount w cable port sensor cable MT mm s upper hex nuts 4 sensor flange EH BE HF lower hex nut H 8 B and jam nut E H E sensor body dE d 5 Wearing sofety face protection turn the installation tool shaft counterclockwise to withdraw sensor until the sensor flange contacts the upper hex nuts 6 Raise one lower hex and jam nut to bottom of sensor flange 7 Close valve remove bearing plate and tool To remove the sensor 8 Wearing safety
30. under which the 1 Purchase Order number to cover the COST of product was PURCHASED the repair 2 Model m senal number of the product under 2 Model and serial number of the product and 3 Ba Ei ti d ifi bl 3 Repair instructions and or specific problems i eparr Instructions and or specitic problems relative to the product 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 2000 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 6 2517 090 OM D 8 02 Where Do Find Everything Need for Process Measurement and Control OMEGA Of Course Shop online at www omega com TEMPERATURE 4 Thermocouple RTD amp Thermistor Probes Connectors Panels amp Assemblies Wire Thermocouple RTD amp Thermistor A Calibrators z Ice Point References Recorders Controllers amp Process Monitors 14 Infrared Pyrometers PRESSURE STRAIN AND FORCE A Transducers amp Strain Gages lA Load Cells amp Pressure Gages A Displacement Transducers Instrumentation amp Accessories FLOW LEVEL 4 Rotameters Ga
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