Omega Products FP-2540 Installation Manual

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User’s Guide

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FP-2540/FP-3-1500 Series

Flow Sensors

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dy 1868, 733 01 Karvin. 8

It is the policy of OMEGA to comply with all worldwide safety and EMC/EMI regulations that apply. OMEGA is
constantly pursuing certifi cation of its products to the European New Approach Directives. OMEGA will add the CE
mark to every appropriate device upon certifi cation.

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 specifi cations without notice.
WARNING: These products are not designed for use in, and should not be used for, patient-connected applications.

Omega FP-2540/FP-3-1500 Series

SAFETY INSTRUCTIONS

1. Do not remove from pressurized lines.

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

3. Wear safety goggles or faceshield during installation/service.

4. Do not alter product construction.

5. Apply sealant or PTFE tape to sensor threads, inspecting threads to ensure integrity.
Do not install a sensor with damaged threads.

Pipe fi ttings MUST be installed by a certifi ed welder only. Omega will not assume liability of any kind for improper fi tting
installations.

Omega FP-3-1500 Series Hot-Tap sensor specifi cations and limitations depend on the lowest maximum rating of the
components associated with the system. If a ball valve, a component of the system, is rated at a maximum 100 psi @ 175°F,
the entire system's maximum pressure/temperature rating is limited to 100 psi @ 175°F. All higher maximum specifi cations

MUST yield to the component with the lowest maximum specifi cation.

Maximum Operating Pressure/Temperature:

• 17 bar (250 psi) @ 82°C (180°F) with standard FPM sensor fi tting O-rings.

• 17 bar (250 psi) @ 100°C ( 212°F) with optional EPR sensor fi tting O-rings.

Inlet

1. Location of Fitting

Recommended sensor upstream/
downstream
mounting requirements.

Flange

10x I.D. 5x I.D.

Outlet

Reducer

15x I.D. 5x I.D.

2 x 90° Elbow
3 dimensions

Valve/Pump

50x I.D. 5x I.D.

40x I.D. 5x I.D.

2. Sensor Mounting Position

Vertical mounting is recommended for best overall performance. Mount at a maximum of 30°
when air bubbles are present. DO NOT mount on the bottom of the pipe when sediments are
present.

3. Sensor Wiring

Omega FPM Series Instruments

Other Brands

90° Elbow

20x I.D. 5x I.D.

2 x90° Elbow

25x I.D. 5x I.D.

0°

-

30°

Process Pipe

+30°

1/2 in. NPT conduit port

Black (5 to 24 VDC)

Blk, sensor
power

Red, freq.
input

Shld,
Gnd

Red (signal out)

Silver (DC return)

Use 2-conductor shielded cable for cable extensions up to 300m (1000 ft.)
Maintain cable shield through splice.

instrument

black

silver

red

pull-up resistor required (10 kΩ recommended).
Use 2-conductor shielded cable for cable extensions up to 300m (1000 ft.)
Maintain cable shield through splice.

10 kΩ

+

-

Gnd.

Input

5 to 24
VDC

Other
instrument

1

4. Electronics Module Installation and Removal

The electronics module of this sensor can be replaced without removing the steel sensor body from the line.

1. Loosen liquid tight connector cap.

2. Loosen liquid tight connector compression fi tting from sensor body.

3. Grasp the electronics at the rubber strain relief (do not pull on cable) and pull fi rmly.

To reinstall the electronics module:

• Insert module into sensor housing, making sure module is fully seated. Electronic pick-up module tip must bottom-out in the sensor
housing.

• Replace the liquid tight connector assembly.

To install the cable inside protective conduit, remove the liquid tight connector completely. Thread 1/2 in. conduit into top of sensor body.

Liquid Tight Connector-

Liquid Tight Connector-Cap

Compression Fitting
w/ 1/2 in. NPT threads

Grip the electronics
module at rubber
strain relief

1/2 in. NPT Threads

Electronics Module
FP-2540-EM (for Standard sensor)
FP-3-1500-EM (for Hot-tap sensor)

2

5. Installation

The following items are required to properly install Omega FP-2540/FP-3-1500 series Sensors.

5.1 Hardware, Standard Sensor

• Female pipe fi tting (weld-on or saddle) with 1.5 in. NPT or ISO 7/1-Rc 1.5 threads

• 32 mm (1.25 in.) diameter drill

• Pipe thread sealant

• Tape measure

5.2 Hardware, Hot-Tap Sensor

The Hot-Tap sensor requires all the standard sensor items plus:

• Hot-Tap drilling machine (e.g., Mueller drilling machine or equivalent)

• Female ball or gate valve (full port only) with 1.5 in. NPT or ISO 7/1-Rc 1.5 threads

• Male pipe nipple, 32 x 50 mm (1.5 x 2 in.) with 1.5 in. NPT or ISO 7/1-R 1.5 threads

• Hot-Tap installation tool (purchased separately)

5.3 Standard Fitting Installation

A. Depressurize and drain pipe.

B. Wearing safety face protection, drill a 32 mm (1.25 in.) diameter hole in the

pipe.

C. Install the pipe fi tting of the outside of the pipe according to the manufacturer's

instructions. Failure to follow these instructions may result in serious bodily
injury and/or product failure.

pipe

sensor
fitting

process
pipe

fitting

D. Remove sensor fi tting from sensor assembly.

E. Thread sensor fi tting into pipe fi tting. (Fig. 1)

5.4 Hot-Tap Fitting Installation

A. Install the pipe fi tting on the outside diameter of the pipe according to the manufacturer's instructions. Failure to follow these

instructions may result in serious bodily injury and/or product failure.

B. Install the pipe nipple and isolation valve (ball or gate valve) onto the external pipe fi tting using pipe sealant on the

threads. (Fig. 2)

C. Wearing safety face protection, install an appropriate hole cutting tool per manufacturer's instructions (e.g., Mueller

drilling machine) with a 32 mm (1.25 in.) drill onto the top of the isolation valve, ensuring a tight fi t. Use the

recommended drill bit size or damage to the isolation valve may occur.

D. 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. (Fig. 3)

pipe sealant recommended

Fig. 1

E. Install the sensor fi tting/bleed valve into the top of the isolation valve. Make sure the bleed valve clears the handle of the isolation

valve during operation.

sensor fitting

bleed valve

make sure
bleed valve
clears isolation
valve handle

Fig. 2

customer supplied
ball or gate valve

customer supplied
nipple: 32 x 50 mm
(1.25 x 2 in.) long

process pipe (side view)

Fig. 3

process pipe

3