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.
Page 3
OMEGA FP-5100, FP-5300, FP8500, and FP-319X Paddlewheel Flow Sensors
8
8
4
9
5
SAFETY INSTRUCTIONS
1. Do not remove from pressurized lines.
2. Do not exceed maximum temperature/pressure specifications.
3. Do not install/service without following installation instructions (see sensor manual).
4. Wear safety goggles and faceshield during installation/service.
5. Do not alter product construction.
6. Failure to follow safety instructions could result in severe personal injury!
• Horizontal pipe runs: Mount sensor in
the upright (0°) position for best overall
performance. Mount at a maximum of
45° when air bubbles are present. Do not
mount on the bottom of the pipe when
sediments are present.
• Vertical pipe runs: Sensor must be
mounted in lines with UPWARD flow only.
-45°
Flange
10x I.D.5x I.D.
Valve/Gate
50x I.D.5x I.D.
0°
Inlet
Process
Pipe
Outlet
Reducer
15x I.D.5x I.D.
2 x 90° Elbow
3 dimensions
90° Elbow
20x I.D.5x I.D.
2 x 90° Elbow
40x I.D.5x I.D.
25x I.D.5x I.D.
3. Sensor Wiring
+45°
FP-5100/FP-5300 Series Sensors
black (AC signal out)
red (AC signal out)
silver (shield)
Technical Notes
• Use 2-conductor shielded cable for cable extensions up to 60 m (200 ft).
• Cable shield must be maintained through cable splice.
• Refer to your instrument manual for specific wiring details.
Blk
F-
Red
F+
Shld
Instrument
4. OMEGA Fittings
TypeDescription
Plastic tees
PVC glue-on
saddles
(O-ring not
required)
Iron
strap-on
saddles
Carbon steel
weld-on
weldolets
Carbon steel
threaded tees
• 0.5 to 4 in. versions
• PVC or CPVC
• Mounts via glue-on fittings
• 2 to 4 in., cut 1-7/16 in. hole in pipe
• 6 to 8 in., cut 2-1/4 in. hole in pipe
• Align wedge arrows with saddle arrows during assembly.
• Pipes over 8 in., use iron saddle
• 2 to 4 in., cut 1-7/16 in. hole in pipe
• Over 4 in., cut 2-1/4 in. hole in pipe
• Special order over 12 in.
• 2 to 4 in., cut 1-7/16 in. hole in pipe.
• Over 4 in., cut 2-1/4 in. hole in pipe
• Remove insert before welding
• Installed by certified welder only
• Special order over 12 in.
• 0.5 to 2 in. versions
• Mounts on threaded pipe ends
5. H-Dimensions
The plastic sensor insert in the Weldolet fitting MUST be
removed during the welding process. When reinstalled, it is
important that the insert be threaded to the proper height
("H" dimension).
1. Lubricate the sensor O-rings with a silicone lubricant (e.g. GE silicone compound #G632 or
equivalent). Do not use any petroleum based lubricant that will attack the O-rings.
Figure B
Figure A
2. Using an alternating/twisting motion, lower the sensor into the fitting, making sure the installation
arrows on the black cap are pointing in the direction of flow, see Figure A.
3. Engage one thread of the sensor cap then turn the sensor until the alignment tab is seated in the
fitting notch. Hand tighten the sensor cap. DO NOT use any tools on the sensor cap or the cap
threads and/or fitting flange threads will be damaged, see Figure B.
7. Wet-Tap Installation
The OMEGA FP-319X Wet-Tap Assembly attaches directly onto any FP-53XX or FMG-53XX fitting to enable
sensor removal without system shutdown. It consists of a flange and support plate which thread onto the
pipe fitting insert, and a PVC ball valve through which an extended length sensor is inserted into the pipe.
Procedure
1. Remove six hex nuts and bolts from the Wet-Tap flange. Separate the support plate from the main
assembly. Be sure that the Viton O-ring is properly seated in the support plate groove.
2. Apply sealant to the pipe fitting insert threads to prevent leaks.
3. Screw support plate onto pipe fitting insert. It must be threaded completely down until the notches at
the top of the pipe fitting insert are exposed.
4. Mount the main Wet-Tap Assembly on the support plate. Make certain the alignment keys on the flange
mate with the notches on the pipe fitting insert.
5. Replace the six hex nuts and bolts to secure the Wet-Tap Assembly in place. Adjust the support plate
position as necessary to align screws.
6. Check the pressure relief plug on Wet-Tap Assembly. It must closed be finger tight to prevent leaks.
sensor cap
process pipe
(top view)
1-1/4 X 11-1/2 in.
NPSM thread
Valve handle
(shown in
open position)
Viton O-ring
Support plate
Align notch and key
under wet tap flange
parallel with pipe.
sensor bale
direction of flow
Key
Pressure
relief plug
Allen bolts
and hex nuts
Sealant
7. Close ball valve by turning the orange handle to the fully closed position (parallel with pipe).
8. Wet-Tap Sensor Installation
The FP-319X Wet-Tap Assembly allows installation into pressurized pipes without system
shutdown. OMEGA recommends reducing flow system pressure to 25 psi or less during
sensor installation in a pressurized pipe.
Non-Pressurized Installation
Open the orange ball valve handle to the full open position. Follow the steps 1-3 outlined in section 6.
Attach the cable clamps and safety cables to the cable brackets. Verify the relief valve is closed before
system operation, see Figure C.
Pressurized Installation
1. Lubricate the sensor O-rings with a silicone lubricant (e.g. GE silicone compound #G632 or
equivalent). Do not use any petroleum based lubricant that will attack the O-rings.
2. Being careful not to bump the sensor rotor against the closed ball valve orifice, gently insert the
extended sensor into the assembly until the first two O-rings seat inside the bore, see
Figure D.
3. Attach the cable clamps on each of the sensor's safety cables to the assembly cable brackets (Hand
tighten only), see Figure D.
4. Pull the flow sensor upward to remove slack in the safety cables, see Figure E
5. Reduce system pressure to 25 psi or less.
Figure C
Figure D
Figure E
6. Wearing safety face protection, slowly open the ball valve to the full open position (perpendicular to
pipe).
7. Using an alternating/twisting motion, push the extended sensor into the assembly, making sure the
sensor's installation decal is pointing in the direction of flow and the alignment tab seats into the fitting
notch, see Figure F. Align the tab under the red sensor cap in the notches on the fitting insert. Hand
tighten the red sensor cap, see Figure G. DO NOT use any tools on the red sensor cap or the cap
threads and/or fitting flange threads will be damaged.
CAUTION: Maximum FP-319X Wet-Tap operating pressure: 7 bar (100 psi) @
20 °C (68 °F) Maximum sensor installation/removal pressure: 1.7 bar (25 psi) @
22 °C (72 °F)
sensor cap
process pipe
(top view)
Figure F
sensor bale
direction of flow
Figure G
Page 5
9. K-Factors
The K-Factor is the number of pulses the sensor will generate for each engineering unit of fluid which passes. They are listed in U.S. gallons and in liters. For
example, in a 1 inch PVC pipe, the paddlewheel generates 176.670 pulses per gallon of fluid passing the rotor. K-factors are listed for pipes up to 12 inch. For
pipes over 12 inch, please contact OMEGA.
PIPEOMEGA--------KK--FFAACCTTOORR--------PIPEOMEGA--------KK--FFAACCTTOORR--------PIPEOMEGA--------KK--FFAACCTTOORR------SIZEFITTING TYPE U.S. GALLITERSSIZEFITTING TYPE U.S. GALLITERSSIZEFITTING TYPE U.S. GALLITERS
SCH 80 PVC TEES FOR SCH 80 PVC PIPEGALVANIZED IRON TEES ON SCH 40 PIPECOPPER/BRONZE BRAZOLETS ON SCH 40 PIPE
Standard Paddlewheel Flow Sensors All O-rings are Viton®Accessories for FP-5300/FP-5100
Order No.
FP-5300
FP-5301
FP-5302
FP-5100PVDF (natural) Hastelloy CPVDF (natural) 0.5 to 4.0 in.
FP-5101PVDF (natural) Hastelloy CPVDF (natural) 5.0 to 8.0 in.
FP-5102PVDF (natural) Hastelloy CPVDF (natural) 10 to 36 in.
FP-5100-APPVDF (natural) PVDF (natural) PVDF (natural) 0.5 to 4.0 in.
FP-5101-APPVDF (natural) PVDF (natural) PVDF (natural) 5.0 to 8.0 in.
FP-5102-APPVDF (natural) PVDF (natural) PVDF (natural) 10 to 36 in.
FP-319X Wet-Tap Assembly Rotor pin material is Titanium O-RingsMaterialFMK-51542Sensor cap, PP
Including Extended Sensor
Order No.ValveBodyRotorPipe SizeFPP-1228-0021 Kalrez (natural) with PP cap
FP-3193
FP-3194
FP-3195PVCPolypro.PVDF (black)10 to 36 in.
FP-319X Wet-Tap Without Sensor
Order No.
FP-319PVC319 Wet-Tap
Extended Sensors for FP-319 Wet-TapRotor pin material is Titanium FP85NMIntegral sensor mounting kit with 1/2 in. NPT ports
Order No.
FMK-515-3P3
FMK-515-3P4
FMK-515-3P5Polypro.TitaniumPVDF (black)10 to 36 in.FP8503Integral sensor, PVDF (natural)0.5 to 4 inch
SensorOrder No.Order No.
Body
Polypro.
Polypro.
Polypro.
PVCPolypro.
PVCPolypro.
Material
Sensor
Body
Polypro.
Polypro.
Rotor PinRotorPipe Size
TitaniumPVDF (black)0.5 to 4.0 in.
TitaniumPVDF (black)5.0 to 8.0 in.
TitaniumPVDF (black)10 to 36 in.
FMK-1538-4TefzelFMK-1546-3 Tantalum
3-0515.320-3Tefzel with Fluoroloy G sleeveFMK-1546-4 Stainless steel
3-0515.320-2PVDF (natural) with Fluoroloy G sleeve FMK-51545Ceramic
3-0515.320-1PVDF (black) with Fluoroloy G sleeve
1. To remove the rotor, insert a small screwdriver between the rotor and the ear of the sensor.
2. Twist the screwdriver blade to flex the ear outward enough to remove one end of the rotor and pin. DO NOT flex the ear
any more than necessary! If it breaks, the sensor cannot be repaired.
3. Install the new rotor by inserting one ear into the hole, then flex the opposite ear back enough to slip rotor into place.
12. Specifications
General Data
Flow Rate Range:0.3 to 6 m/s (1 to 20 ft/s)
Linearity:± 1% of maximum range
Repeatability:±0.5% of maximum range
Pipe Size Range:15 to 900 mm (0.5 to 36 in.)
Cable Length:7.6 m (25 ft) can splice up to 60 m (200 ft) without
amplification
Cable type:2-conductor twisted pair with shield
Materials
Sensor Assembly:Various thermoplastics available. Contact your OMEGA
OMEGA ENGINEERING, INC. warrants this unit to be free of defects in materials and workmanship for a
period of 25 months from date of purchase. OMEGA Warranty adds an additional one (1) month grace
period to the normal two (2) year product warranty to cover handling and shipping time. This
ensures that OMEGA’s customers receive maximum coverage on each product.
If the unit should malfunction, 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,
improper repair, or unauthorized modification. This WARRANTY is VOID if the unit shows evidence of
having been tampered with or shows evidence of being 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, EXPRESSED 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, incidental 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 W
following information available BEFORE
contacting OMEGA:
1. P.O. number under which the product was
2. Model and serial number of the product under
3. Repair instructions and/or specific problems
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.
reproduced, translated, or reduced to any electronic medium or machine-readable form, in whole or in part, without prior
written consent of OMEGA ENGINEERING, INC.
ARRANTY RETURNS, please have the
PURCHASED,
warranty, and
relative to the product.
FOR NON-WARRANTY REPAIRS,
consult OMEGA
for current repair charges. Have the following
information available BEFORE contacting OMEGA: