Omega FP-5200 User guide

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Page 1

User’s Guide

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e-mail: [email protected]

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FP-5200

Flow Sensor

Page 2

omega.com [email protected]

Servicing North America:

U.S.A. Omega Engineering, Inc. Headquarters: Toll-Free: 1-800-826-6342 (USA & Canada only)

Customer Service: 1-800-622-2378 (USA & Canada only) Engineering Service: 1-800-872-9436 (USA & Canada only) Tel: (203) 359-1660 Fax: (203) 359-7700 e-mail: [email protected]

For Other Locations Visit omega.com/worldwide

The information contained in this document is believed to be correct, but OMEGA accepts no liability for any errors it contains, and reserves the right to alter specifications without notice.

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OMEGA FP-5200 Flow Sensor Instructions

uded

SAFETY INSTRUCTIONS

1. Do not remove from pressurized lines.

2. Do not exceed maximum temperature/pressure speciﬁ cations.

3. Pipe ﬁ tting must be installed by certiﬁ ed welder only.

4. Do not install/service without following installation instructions (see sensor manual).

5. Wear safety goggles and face shield during installation/service.

6. Do not alter product construction.

7. Failure to follow safety instructions could result in severe personal injury!

1. Location of Fitting

Recommended sensor upstream/downstream mounting requirements.

Flange

Valve/Gate

Inlet Outlet

10 X I.D. 5 X I.D.

50 X I.D. 5 X I.D.

Reducer

15 X I.D. 5 X I.D.

2 x 90° Elbow

40 X I.D. 5 X I.D.

2. Sensor Mounting Position

• 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 pipe when sediments are present.

Maximum Operating Pressure/Temperature:

FP-5200 Series Sensor with:

• FP-5200 Series Tee & Mini-Tap Fittings: 103 bar (1500 psi) @ 149 °C (300 °F)

90° Elbow

20 X I.D. 5 X I.D.

2 x 90° Elbow

25 X I.D. 5 X I.D.

45°

• Vertical pipe runs: Sensor must be mounted in lines with UPWARD ﬂ ow only.

3. Sensor/Fitting Selection

The FP-5200 Sensor is designed for installation into SCH 40 stainless steel pipes via FP-5200 Series Tee, Mini-Tap or Saddle ﬁ ttings, see options below:

FP-5200 Series Tee Fittings

Pipe (in.) Sensor Fitting

0.50 FP-5200 FP-5205

0.75 FP-5200 FP-5207

1.00 FP-5200 FP-5210

FP-5200 Series Mini-Tap Fittings

Pipe (in.) Sensor Fitting

1.25 FP-5201 FP-5212

1.50 FP-5201 FP-5215

2.00 FP-5201 FP-5220

2.50 FP-5201 FP-5225

3.00 FP-5201 FP-5230

4.00 FP-5201 FP-5240

5.00 FP-5201 FP-5250

6.00 FP-5201 FP-5260

8.00 FP-5201 FP-5280

10.0 FP-5201 FP-5281

12.0 FP-5201 FP-5282

Sensor

Wetted fitting materials: 316 SS

hardware incl

Wetted fitting materials: 316 SS & 347 SS

Mini-Tap Fitting,

hardware included

Tee Fitting,

1OMEGA FP-5200 Flow Sensor Instructions

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4. Fitting Installation, Required Hardware

Tee & Mini-Tap Fittings

• 0.5 to 1 inch pipes, FP-5200 Series ﬁ tting required

• 1.25 to 12 inch pipes: FP-5200 Series ﬁ tting and 27 mm (1-1/16 in.) diameter drill required

• Mini-Tap ﬁ ttings are welded onto the pipe and are used with FP-5200 sensors.

4.1 Installation, Tee & Mini-Tap Fittings

1. Select an appropriate mounting location as outlined in sections 1 and 2.

2. Depressurize and drain pipe.

3. Use the following welding and installation procedures appropriate for your ﬁ tting/pipe size:

FP-5200 Series Tee Fittings, 0.5 to 1 inch:

• Insert pipe into ﬁ tting socket

• Make sure the pipe is parallel to the bottom of the Mini-Tap ﬁ tting.

• Weld pipe into place.

FP-5200 Series Mini-Tap Fittings, 1.25 to 12 inch:

• Drill a 27 mm (1-1/16 in.) diameter hole completely through the ONE surface of the pipe. Thoroughly deburr inner and outer edges of hole.

• Tack weld the Mini-Tap ﬁ tting onto the pipe, making sure the hole in the pipe is lined up with the Mini-Tap ﬁ tting hole.

• Weld the Mini-Tap ﬁ tting onto the pipe.

FP-5200 Series Saddle Fitting

• 27 mm (1-1/16 in.) diameter drill required.

5. Sensor Installation

1. Set the gasket supplied with the ﬁ tting onto the ﬁ tting ﬂ ange, making sure the holes align.

2. Remove the red rotor protection cap and insert the sensor into the ﬁ tting, making sure not to bump the rotor assembly. Make sure the arrow on the side of the sensor is pointing in the direction of ﬂ ow.

Fitting

flange

Flow

3. Slip two washers onto each bolt and insert the bolt/washer onto each of the four ﬁ tting ﬂ ange holes.

4. Snug all four ﬂ ange bolts in a criss-cross pattern. Using a torque wrench (when possible), torque the ﬂ ange nuts in a criss-cross pattern to 52 foot-pounds.

Flow sensor arrow

Flange bolt torque pattern

6. Sensor Wiring

1/2 in. NPT conduit port

(AC signal out)

FP-5200 Series

Use 2-conductor shielded cable for cable splices up to 60 m (200 ft). Maintain cable shield through splice. Shield the unjacketed silver (ground) wire using electrical tape to prevent potential noise interference and/or shorting hazards.

black

red

silver

(ground)

Blk F-

Red F+

Shld.

Instruments

2 OMEGA FP-5200 Flow Sensor Instructions

Page 5

7. Sensor Removal Procedure

1. Depressurize and drain pipe.

2. Remove the four sensor ﬂ ange bolts and lockwashers. Pull upward on the sensor ﬂ ange with an alternating twisting motion.

WARNING!

Never remove a sensor from a pressurized pipeline. Always wear protective clothing during sensor installation/service.

8. Maintenance

The FP-5200 Series Sensor requires little or no maintenance of any kind, with the exception of occasionally cleaning the sensor/paddlewheel.

9. Rotor Replacement Procedure

1. With a small pair of needle-nose

Rotor Pin

pliers, ﬁ rmly 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 retainers and free the rotor assembly.

2. Remove retainer from each side by gently tapping it inwards using a punch. Install a new retainer with its rotor pin clearance hole inward. Only install one retainer

Retainer

Punch

at this time.

10. K-Factors

The K-Factor is the number of pulses the sensor will generate for each engineering unit of ﬂ uid which passes. They are listed in U.S. gallons and in liters. For example, in a 1 inch SCH 40S stainless steel pipe, the sensor generates 266.17 pulses per gallon of ﬂ uid passing the rotor. K-Factors are listed for SCH 40S stainless steel pipes up to 12 inch.

3. Insert the new rotor assembly

Rotor Pin

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 retainer.

Existing Retainer

Rotor Assembly

4. Tap the second retainer (rotor pin clearance hole inwards) into the hole while lining up the rotor pin with the center of the retainer hole.

This completes the rotor replacement procedure.

SCH 40S STAINLESS STEEL PIPE PER ANSI B36.19

PIPE SIZE

(in.)

1/2 873.03 230.66 0.0687 0.2601

3/4 515.41 136.17 0.1164 0.4406

1 266.17 70.322 0.2254 0.8532

1-1/4 148.84 39.324 0.4031 1.5258

1-1/2 107.98 28.528 0.5557 2.1032

2 64.808 17.122 0.9258 3.5042

2-1/2 44.685 11.806 1.3427 5.0822

3 28.579 7.5506 2.0994 7.9464

4 16.302 4.3070 3.6805 13.931

5 10.237 2.7046 5.8611 22.184

6 7.0057 1.8509 8.5645 32.416

8 3.9641 1.0473 15.136 57.289

10 2.4690 0.6523 24.301 91.981

12 1.6894 0.4463 35.516 134.43

K-FACTOR

PULSES/ U.S. GAL

K-FACTOR

PULSES/

U.S. LITER

A-FACTOR

GPM/Hz

A-FACTOR

LPM/Hz

New Bearings

Conversion Formulas 1 U.S. gallon = 0.003785 cubic meters

0.000003069 Acre feet

8.3454 pounds of water

3OMEGA FP-5200 Flow Sensor Instructions

Page 6

11. Speciﬁ cations

General Data

Flow velocity range: 0.5 to 6 m/s (1.6 to 20 ft/s) Frequency output: 29 to 46 Hz per m/s (9 to 14 Hz per ft/s) Linearity: ±1% of full range Repeatability: ±0.5% of full range Pipe size range: 13 to 305 mm (0.5 to 12 in.) Cable length: 7.6 m (25 ft), can splice up to 60 m

(200 ft.) with no signiﬁ cant degradation of signal strength

Cable type: 150 °C 22 AWG, 2-conductor w/shield

Materials

Sensor body: ACI type CF-8M (316 cast stainless steel)

per ASTM A351 Rotor material: CD4MCu stainless steel Rotor pin: Tungsten Carbide (316 stainless steel,

optional) Retainers (2): 316 stainless steel Rotor bearings (2): Fluoroloy B

Electrical Data

Voltage output: Approximate sine wave,

0.005 to 0.008 Vpp per Hz

Coil resistance: 11.6 kΩ @ 25 °C Coil inductance: 3.5 H @ 25 °C

Quality Standards

• CE

• Manufactured under ISO 9001

Ambient Conditions

Maximum Pressure/Temperature Limitations:

• FP-5200 Series Sensor with FP-5200 Series Tee or Mini-Tap Fitting: 103 bar (1500 psi) max.

@ 149 °C (300 °F)

12. Accessories

retainer retaine

rotor pin

Refer to section 3 for a list of available sensors and ﬁ ttings.

Part no. Description

FP-52648 Fitting cap kit, cap and gasket

bearing

FP-52509 Rotor kit, 316 SS pin FP-52509-2 Rotor kit, Tungsten pin M2489 Instruction manual

FP-52509/FP-52509-2 Rotor kit

rotor

Chemical Compatibility Warning

The retaining nuts of paddlewheel sensors, pH and ORP sensors as well as Magmeters are not designed for prolonged contact with aggressive substances. Strong acids, caustic substances and solvents or their vapor may lead to failure of the

retaining nut, ejection of the sensor and loss of the process ﬂ uid with possibly serious consequences, such as damage to equipment and serious personal injury. Retaining nuts that may have been in contact with such substances e.g. due to leakage or spilling, must be replaced.

4 OMEGA FP-5200 Flow Sensor Instructions

Page 7

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, 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 in which wear is not warranted, include but are 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 the company 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/D ISCLAIMER 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 following information available BEFORE contacting OMEGA:

1. Purchase Order number under which the product was PURCHASED,

2. Model and serial number of the product under warranty, and

3. Repair instructions and/or specific problems

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.

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.

FOR NON-WARRANTY REPAIRS, OMEGA for current repair charges. Have the following information available BEFORE contacting OMEGA:

1. Purchase Order number to cover the COST of the repair,

2. Model and serial number of the product, and

3. Repair instructions and/or specific problems relative to the product.

consult

Page 8

Where Do I Find Everything I Need for

Process Measurement and Control?

OMEGA…Of Course!

Shop online at omega.com

TEMPERATURE

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Thermocouple, RTD & Thermistor Probes, Connectors, Panels & Assemblies

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Wire: Thermocouple, RTD & Thermistor

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pH Electrodes, Testers & Accessories

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DATA ACQUISITION

 Communications-Based Acquisition Systems  Data Logging Systems  Wireless Sensors, Transmitters, & Receivers  Signal Conditioners  Data Acquisition Software

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M-2489/0916