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FMG-900
Installation Manual
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Omega Products FMG-900 Installation Manual

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Page 1
User's Guide
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FMG-900 SERIES
Insertion Magnetic Flow Meter
Page 2
Page 3
Page 4
GENERAL INFORMATION
The complete lack of moving parts of this insertion flow sensor is the source of its reliability. There is no rotor to stop turning in dirty water and there are no bearings to wear out. Brass and stainless steel models withstand a variety of temperature, pressure, and chemical conditions. Reverse flow output and immersibility are optional.
A rapidly reversing magnetic field is produced in the lower housing. As the fluid moves through this field, a voltage is generated that is measured and translated into a frequency
FEATURES
Cable strain relief
Rugged cast aluminum housing Brass or 316 stainless shaft Compression nut
Adapter fitting
signal proportional to flow rate. This square wave signal can be sent directly to a PLC or other control or can be converted using any of the Omega family of indicators and converters.
The adapter fitting of the FMG-900 Series sensor is standard male NPT, and can be directly threaded into ordinary saddles or threaded weld fittings. The FMG905 and 906 include an isolation valve, allowing hot-tap installation, or installation and removal under pressure. A bronze ball valve is standard, with a 316 stainless steel valve optional.
Housing screw (connect ground to one)
FMG901/902
Sensor housing
Electrodes and cap
SPECIFICATIONS
Power Full Power
Low Power
Flow Range
Fitting Size
Temperature Ambient
Fluid
Pressure
Minimum Conductivity
Materials Shaft/Fitting
Electrodes
Electrode Cap
Housing
Valve Assembly (905/906 Only)
O-Ring (905/906 Only)
Calibration Accuracy
Output
Empty Pipe Detection
FMG905/906
Valve assembly for hot tap installation
12-24 Vdc, 250 mA
12-24 Vdc, 40 mA
0.28 - 20 ft/sec (0.08 - 6.09 m/sec)
FMG901/902 FMG905/906
1-1/2” Male NPT 2” Male NPT
0˚ to 180˚ F (-17˚ to 82˚ C)
32˚ to 200˚ F (0˚ to 93˚ C)
200 psi (13.8 bar)
20 microSiemens/cm
316 SS or Brass
Hastelloy
PVDF
Cast aluminum, powder-coated
Bronze (stainless optional) with bronze ball valve
EPDM
+/- 1% of full scale
Square wave pulse, opto isolated, 550 Hz @ 20 ft/sec 6 mA max, 30 Vdc forward flow standard; reverse flow optional
Software, defaults to zero flow
Page 5
INSTALLATION
Piping. For best results, the FMG-900 Series sensor should
be installed with at least ten diameters of straight pipe upstream and five downstream. Certain extreme situations such as partially-opened valves are particularly difficult and may require more straight diameters upstream (see Straight Pipe Recommendations).
DISTORTED FLOWS
Faster Flow Causes Meter
Distorted Flow Profile
To Read High
FLOW
10X
5X
POSITIONING THE METER
Fair (Unacceptable if
air is present)
Best Position
Fair (Unacceptable if fluid
contains sediment)
Immersion. The FMG901/902 Series standard sensors are not designed for continuous underwater operation.
Chemical Injection or Fertigation. When any magmeter, by any manufacturer, is used in a chemical injection ap­plication (including fertigation), the chemical line must be placed downstream of the magmeter OR far enough up­stream for complete mixing to occur before the fluid reaches the meter. When unmixed chemical or fertilizer alternates with water passing through the meter, the rapid changes in conductivity may cause sudden spikes and drops in the meter’s reading, resulting in inaccurate measurement. The magmeter will restabilize, however, with a steady flow of fluid of uniform conductivity.
Caution: In chemical injection or fer­tigation applications, install chemical line downstream of magmeter, or far enough upstream to allow complete
mixing of fluids before the meter.
Horizontal is the preferred installation orientation, since it
improves low-flow per formance and avoids problems with
trapped air and sediment. Bottom, top, and vertical pipe
installations are all acceptable if required by the piping
layout (See Full Pipe Recommendations).
Caution: These flow sensors are not recommended for installation down­stream of a boiler feedwater pump
where installation fault may expose the flow sensor to boiler pressure and tempera­ture. Maximum recommended temperature is 200°F.
Page 6
INSTALLATION
FMG901/902 INSTALLATION
Fitting Installation. FMG901/902 sensors come with a 1-1/2” male
NPT pipe thread adapter fitting. Any fitting that provides the matching NPT female thread may be used. Installation procedure compensates for fitting height differences. Cut a minimum 1-3/4” hole in the pipe. If possible, measure the wall thickness and write it down for use in depth setting. Then install the threaded fitting (saddle, weldolet, etc.) on the pipe.
Meter Installation. Loosen the compression nut so that the adapter slides freely. Pull the meter fully upward and finger-tighten the com­pression nut. Using a thread sealant, install the adapter in the pipe fitting. Do not overtighten. Now loosen the compression nut, lower the meter to the appropriate depth setting (see diagram and instruc­tions that follow). Be sure flow is in the direction of the arrow on the housing. Tighten compression nut fully.
Compression nut
Adapter fitting
with
standard NPT
threads
FMG905/906 INSTALLATION
‘Hot tap’ FMG905/906 meters are designed to be installed and serviced without depressurizing the pipe.
Fitting Installation. FMG905/906 sensors have a 2” NPT thread for compatibility with the 2” isolation valve. Any fitting that provides matching NPT female thread may be used. The installation procedure compensates for differences in fitting height.
If initial installation is per formed on an unpressurized pipe, cut a minimum 1-3/4” hole in the pipe. If possible, measure the wall thickness and write it down for use in depth setting. Then install the threaded fitting (saddle, weldolet, etc.) on the pipe.
If it is necessary to do the initial installation under pressure, any standard hot tap drilling machine with 2” NPT adapter, such as a Transmate or a Mueller, can be used. Ordinarily, it is not necessary to use an installation tool, since the small-diameter tube can be controlled by hand at all but the highest pressures.
Compression
nut
Locking collar
2” adapter re-
moves to mount
hot-tap machine
Full-port 2” ball
valve allows sensor
removal
Standard 2” NPT threads
Meter Installation. Remove the sensor unit from the valve assembly. Using a thread sealant, install the valve assembly on the pipe fitting. If the initial installation is a pressure (“hot”) tap, remove the 1-1/2” x 2” adapter bushing at the back of the valve. Thread the tapping machine on, open the valve, and tap using a minimum of 1-3/4” or maximum 1-7/8” cutter. After retracting the machine and closing the valve, reinstall the flow sensor. When the sensor is secure, open the valve and adjust depth setting (see diagram and instructions that follow). Be sure flow is in the direction of the arrow on the housing. Tighten locking collar and compression nut fully.
FMG905/906 Sensor
Removal
Page 7
INSTALLATION
"D"
PROPER DEPTH SETTING
Depth Setting. It is important for accuracy that the sensor
be inserted to the correct depth into the pipe.
1. In Table 1, find Dimension C for your sensor model and pipe size.
2. Subtract wall thickness of your pipe (Table 2) to find Dimension D.
3. Measuring from the outside of the pipe to the joint in the housing, as shown in the diagram, adjust the sensor to Dimension D and hand-tighten compression nut.
4. Align the conduit housing with the centerline of the pipe, as shown. Be sure the arrow on the housing points in the direction of flow.
strain
relief
FLOW
5. Check Dimension D one more time.
TABLE 1: DIMENSION “C”
NOMINAL PIPE SIZE
3” 4” 6” 8” 10” 12” 14” 16” 18” 20” 24” 30” 36”
FMG901
FMG902
FMG905
FMG906
TABLE 2: PIPE WALL THICKNESS
PVC/Steel Sch. 40
PVC/Steel Sch. 80
Stainless Steel (10S)
10.04 9.93 9.69 9.46 9.22 8.99 8.75 8.52 8.28 8.05 7.58 6.87 6.17
15.04 14.93 14.69 14.46 14.22 13.99 13.75 13.52 13.28 13.05 12.58 11.87 11.17
17.04 16.93 16.69 16.46 16.22 15.99 15.75 15.52 15.28 15.05 14.58 13.87 13.17
21.04 20.93 20.69 20.46 20.22 19.99 19.75 19.52 19.28 19.05 18.58 17.87 17.17
NOMINAL PIPE SIZE
3” 4” 6” 8” 10” 12” 14” 16” 18” 20” 24” 30” 36”
0.216 0.237 0.280 0.322 0.365 0.406 0.438 0.500 0.562 0.593 0.687
0.300 0.337 0.432 0.500 0.593 0.687 0.750 0.843 0.937 1.031 1.218
0.120 0.120 0.134 0.148 0.165 0.180 0.188 0.188 0.188 0.218 0.250 0.312 0.312
6. Tighten the compression nut fully.
Stainless Steel (40S)
Copper Tubing
Copper Tubing
Duct. Iron (Class 52)
(Type L)
(Type K)
Brass Pipe
0.216 0.237 0.280 0.322 0.365 0.375 0.375 0.375 0.375 0.375 0.375 0.375 0.375
0.090 0.110 0.140 0.200 0.250 0.280
0.109 0.134 0.192 0.271 0.338 0.405
0.219 0.250 0.250 0.312 0.365 0.375
0.280 0.290 0.310 0.330 0.350 0.370 0.390 0.400 0.410 0.420 0.440 0.470 0.530
Page 8
INSTALLATION
STRAIGHT PIPE RECOMMENDATIONS
(X = diameter)
Reduced Pipe
Two Elbows In Plane
Two Elbows, Out Of Plane
10X
20X
5X
5X10X
5X
Expanded Pipe
Spiral Flow
Swirling Flow
Propeller Meter
Partially Open
Butterfly Valve
20X
5X
30X
50X
Page 9
INSTALLATION
FULL PIPE RECOMMENDATIONS
Allows air pockets to form at sensor
Better InstallationPossible Problem
Ensures full pipe
Better InstallationPossible Problem
Post-valve cavitation can create air pocket Keeps pipe full at sensor
Better InstallationPossible Problem
Air can be trapped
Allows air to bleed off
Caution: These flow sensors are not recommended for installation down­stream of a boiler feedwater pump where installation fault may expose the flow sensor to boiler pressure and temperature. Maximum recommended temperature is 200°F.
Page 10
ELECTRICAL CONNECTIONS
+ _
+ _
+ _
GENERAL ELECTRICAL GUIDELINES
• Whenever possible, avoid running control cables in the same conduit with AC power.
• Use shielded cable, with one end grounded.
• Avoid routing flow sensor cables in close proximity to a variable frequency drive.
• Recommended power and output wiring is shielded 18-22 AWG control cable.
• Recommended voltage is 12-24 Vdc. Note: unregulated power supplies can vary from name­ plate voltage by a considerable amount. When in doubt, use a regulated power supply.
Power: A 12 - 24 Vdc power supply capable of at least 250 mA current output is needed.
Forward (and Reverse) Flow Output: This open-collector isolated output does not supply power. It functions like a polarity-sensitive switch closure. This pulse is generated in the forward flow direction on the standard unit. (Reverse flow output is available as an option). Note: This output is limited to 6 mA at 30 Vdc maximum.
GROUNDING GUIDELINES
For best results, use a good quality earth ground, such as metallic water piping, or a stake driven into the ground, to ensure a good connection to ear th ground and good noise suppression.
If the flow sensor is installed in metallic piping, for optimum connection clamp wire to the piping a short distance to one side of the flow sensor using a hose type clamp. Connect the wire to the earth ground and to one of the housing screws. (For non-metallic piping, this step is not needed.)
PLACE FERRITE BEAD HERE
Earth Ground
Hose Clamp
Metallic Pipe
FMG-900 Series meters are usually unaffected by moderate levels of electrical noise. In some applications performance may be improved by taking the following steps:
Housing Screw
CONNECTION DIAGRAM
Forward Output
Reverse Output
(Option-15 only)
Power
• Use shielded twisted pair cable (Belden 8723 or equivalent above ground or Alpha 35482 or equivalent burial).
• Clamp a ferrite bead (Steward 28A2029-OAO or equivalent) on meter signal/power wire within 3/4” of the meter strain relief (tape or tie wrap in place if necessar y). See diagram above.
• IMPORTANT - Connect the cable shield ground wire to ground, ONLY at power supply end of cable.
12 - 24 Vdc
Max. 6 mA, 30 Vdc
Max. 6 mA 30 Vdc
COUNTER OR PLC
DIGITAL INPUT
FMG900 SERIES
Page 11
OPERATION & MAINTENANCE
30Vdc
Max. 6m
A
-+-
+
12-24Vdc
3 4 5 621
Power
Forward
Output
Status LED
Zero
Adjust
Pins
Zero Adjustment. When the FMG-900 Series meter is powered up and there is no flow, there should be no output pulses (or, if connected to a display or controller, flow rate should read “0”). If there are pulses, it may be necessary to adjust the flow meter under no-flow conditions after it has been installed. This should only be done if the indicated flow is low, near the lower cutoff.
Status
LED
Zero
Adjust
Pins
To perform the adjustment, after determining that there is a full pipe with no flow, short between the two pins marked “Zero Adjust”. A red LED light will come on for approxi­mately 50 seconds and then go out. The zero adjustment is completed.
Presence of Flow Indication. To assist in troubleshooting, the “Status LED” has two blinking modes in normal operation. When there is no flow detectable by the meter (below minimum threshold) the LED blinks ever y 8.0 seconds. When there is detectable flow, the same indicator blinks every 3.0 seconds.
Minimum Flow. As with any other flow sensor, there is a rate below which the FMG-900 Series sensor cannot read. Check the table below for the minimum flow rate detectable by the sensor (at 0.2 ft/sec) for a given pipe size.
Filtering. The software of the FMG-900 Series filters out electrical noise and averages sudden variations in the flow to smooth the output. It takes a matter of seconds for the flow sensor to get up to full output when it is powered up or when flow begins.
Electrode Coating. Grease or other adhering, non­conductive materials can stop flow detection if the electrodes become heavily coated. To clean the electrodes, remove the sensor from the pipe and gently scrub the electrodes (three silver bumps) on the reading face of the flow sensor. A mild soap (dishwashing liquid for example) can be used to aid the cleaning process.
Calibration (“K-Factor”). In order to properly process pulses from the flow sensor, a number must be entered into the control to which the sensor is connected. This number, called the K-factor, is the number of pulses the sensor puts out per unit of fluid passing through the pipe. These numbers are based on extensive testing, which has shown close agreement among different FMG-900 Series sensors in the same installation. Typically, most K-factor error can be attributed to installation variables, such as depth setting and fitting configuration.
Find the K-factor for your pipe size and type in the table on the following page and enter it into your controller.
CAUTION! Never attempt to remove a flow sensor when there is pressure in the pipe unless it is specifically designed for hot
tap installation and removal. Loosen the compression nut slowly to release any trapped pres­sure. If fluid sprays out when removing the sensor, stop turning and depressurize the pipe. Failure to do so could result in the sensor being thrown from the pipe, resulting in damage or serious injury.
FLOW RANGE (IN GALLONS PER MINUTE)
NOMINAL PIPE SIZE
3” 4” 6” 8” 10” 12” 14” 16” 18” 20” 24” 30” 36”
4.5 8 18 31 49 70 96 125 159 196 282 440 635
440 783 1762 3133 4895 7050 9596 12533 15863 19584 28200 44064 63452
Feet Per
Second
Min 0.2
Max 20.0
Page 12
K-FACTOR CHART
FMG-900 SERIES K-FACTORS FOR VARIOUS PIPE SIZES
NOMINAL PIPE SIZE
3” 4” 6” 8” 10” 12” 14” 16” 18” 20” 24” 30” 36”
PVC/Steel
Sch. 40
70.397 40.985 18.130 10.497 6.674 4.709 3.900 2.989 2.364 1.904 1.319
PVC/Steel
78.748 45.360 20.084 11.495 7.322 5.184 4.297 3.281 2.588 2.094 1.451
Sch. 80
Stainless
Steel (10S)
Stainless
62.385 36.626 16.510 9.642 6.173 4.373 3.620 2.756 2.169 1.762 1.223 0.784 0.576
70.397 40.985 18.130 10.497 6.674 4.661 3.827 2.893 2.263 1.819 1.249 0.791 0.580
Steel (40S)
Copper Tubing
(Type L)
Copper Tubing
76.371 43.552 19.513 11.201 7.230 5.016
78.371 44.638 20.223 11.622 7.500 5.239
(Type K)
Brass Pipe
Duct. Iron
(Class 52)
70.672 41.517 17.778 10.445 6.674 4.661
57.376 37.320 16.915 9.503 6.197 4.325 3.189 2.443 1.931 1.565 1.088 0.747 0.520
Note: These K-Factors are calculated using actual pipe diameters and wall thicknesses for each pipe type. They are based on the most current testing at the time of printing.
Page 13
TROUBLESHOOTING
Problem
No pulse output
Output pulses incorrect
Probable Cause Try...
Unit not grounded
Below minimum flow cutoff
Flow reversed
Output connections reversed
Pipe not full
Excessive electrical noise
No power
Power reversed
Fluid conductivity <20 microSiemens/cm
Missing or incorrect ground wire
Connect to earth ground
Check the Presence of Flow LED (see p. 12)
Note flow direction arrow, reverse direction to meter
Change output connections
Check plumbing
Check for proper electrical wiring
Check for power across power input terminals
Reverse connections
Select another flow meter
Check for proper ground
Jumpy reading
Incorrect depth setting
Fluid conductivity <20 microSiemens/cm
Empty pipe
Not enough straight pipe
Excessive electrical noise
Rapidly changing conductivity (in chemical injection or fertigation applications)
Check depth setting from Dimension “C” table (page 4)
Select another flow meter
Check for full pipe or install meter in the vertical position
Check for air pockets or turbulence. Refer to installation, page 6
Check for proper electrical wiring
Install chemical injection line downstream of magmeter (or far enough upstream to allow complete mixing of fluids before meter)
Page 14
Page 15
WARRANTY/DISCLAIMER
OMEGA ENGINEERING, INC. warrants this unit to be free of defects in materials and workmanship for a period of 13 months f rom 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 re t u rned to the factory for evaluation. O M E G A’s Customer Serv i c e D e p a rtment will issue an Authorized Return (AR) number immediately upon phone or written re q u e s t . Upon examination by OMEGA, if the unit is found to be defective, it will be re p a i red or replaced at no c h a rge. O M E G A’s WARRANTY does not apply to defects resulting from any action of the purc h a s e r, including but not limited to mishandling, improper interfacing, operation outside of design limits, i m p roper re p a i r, 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 corro s i o n ; or current, heat, moisture or vibration; improper specification; misapplication; misuse or other operating conditions outside of OMEGA’s c o n t rol. Components in which wear is not warranted, include but are not limited to contact points, fuses, and triacs.
OMEGA is pl eased to offer suggestions on the use of its various p roducts. 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 R E P R E S E N TATIONS OF ANY KIND WHATSOEVER, EXPRESSED OR IMPLIED, EXCEPT THAT OF TITLE, AND ALL IMPLIED WARRANTIES INCLUDING ANY WARRANTY OF MERCHANTA B I L I T Y AND FITNESS FOR A PA RTICULAR PURPOSE ARE HEREBY DISCLAIMED. LIMITATION OF L I A B I L I T Y: The remedies of purchaser set forth herein are exclusive, and the total liability of OMEGA with respect to this ord e r, whether based on contract, warr a n t y, negligence, indemnification, strict liability or otherwise, shall not exceed the purchase price of the compone nt upon which liabi lity is bas ed. I n no ev ent shal l O MEGA be lia ble 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 a c t i v i t y, medical application, used on humans, or misused in any way, OMEGA assumes no re s p o n s i b i l i t y as set forth in our basic WA R R A N TY/ D ISCLAIMER language, and, additionally, purchaser will indemnify OMEGA and hold OMEGA h a rmless from any liability or damage whatsoever arising out of the use of the P roduct(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 ) N U MBER F R OM OMEG A’S CUSTO MER SERVIC E D E PA RT M E NT (IN OR D ER TO AV O I D 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 . P u rchase Order number under which the pro d u c t
was PURCHASED,
2. Model and serial number of the product under warranty, and
3. Repair instructions and/or specific problems relative to the product.
FOR NON-WARRANTY REPAIRS,
consult 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.
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 2005 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.
Page 16
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