Omega Products FP-6000 Installation Manual

User’s Guide

Shop online at

www.omega.com

e-mail: [e-mail]

FP-6000 Series

Flow Sensors

OMEGAnet® Online Service Internet e-mail

www.omega.com [e-mail]

Servicing North America:

USA: One Omega Drive, P.O. Box 4047

ISO 9001 Certified Stamford CT 06907-0047

TEL: [phone] FAX: [phone]
e-mail: [e-mail]

Canada: 976 Bergar

Laval (Quebec) H7L 5A1
TEL: [phone] FAX: [phone]
e-mail: [e-mail]

For immediate technical or application assistance:

USA and Canada: 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

®

®

®

Mexico: En Español: [phone]-7803 e-mail: [e-mail]

FAX: [phone] [e-mail]

Servicing Europe:

Benelux: Postbus 8034, 1180 LA Amstelveen, The Netherlands

TEL: [phone] FAX: [phone]
Toll Free in Benelux: 0800 0993344
e-mail: [e-mail]

Czech Republic: Rudé armády 1868, 733 01 Karviná 8

TEL: [phone] FAX: [phone]
Toll Free: 0800-1-66342 e-mail: [e-mail]

France: 9, rue Denis Papin, 78190 Trappes

TEL: [phone] FAX: [phone]
Toll Free in France: 0800-4-06342
e-mail: [e-mail]

Germany/Austria: Daimlerstrasse 26, D-75392 Deckenpfronn, Germany

TEL: [phone] FAX: [phone]
Toll Free in Germany: 0800 639 7678
e-mail: [e-mail]

United Kingdom: One Omega Drive, River Bend Technology Centre

ISO 9002 Certified Northbank, Irlam, Manchester

M44 5EX United Kingdom
TEL: [phone] FAX: [phone]
Toll Free in United Kingdom: 0800-488-488
e-mail: [e-mail]

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 Page

Table of

1 Introduction 1

1.1 Description 1

1.2 Theory of Operation 1

2 Installation and Wiring 2

2.1 Location of Fitting 2

2.2 Sensor Position 2

2.3 Sensor Wiring 3

3 Installation 4

3.1 Hardware, Standard Sensor 4

3.2 Hardware, Hot-Tap Sensor 4

3.3 Standard Fitting Installation 4

3.4 Hot-Tap Fitting Installation 5

3.5 Calculating the H Dimension 6

3.6 Standard Installation 8

3.7 Hot-Tap Installation 10

4 Sensor Removal Procedures 14

4.1 Standard Sensor Removal 14

4.2 Hot-Tap Sensor Removal 14

Contents

5Maintenance and Replacement Parts 16

5.1 Maintenance 16

5.2 Replacement Parts 16

5.3 Rotor Replacement Procedure 17

"H" Dimensions for Standard Sensors 18
"H" Dimensions for Hot-Tap Sensors 19

Calibration Constants 20

Specifications 23
Warranty 25

.

Important Safety Information!

CAUTION:
(Standard version) Never remove the flow sensor
from a pressurized pipe. Always wear safety 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 Hot-Tap system's overall specifica­tions and limitations depend on the lowest maxi­mum 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 @ 185 °F, limiting the entire
system's maximum pressure/temperature rating to
100 psi @ 185 °F. All higher maximum specifica­tions MUST yield to the component with the lowest
maximum specification.

Maximum Operating Pressure:

225 psi (15 bar)

Maximum Operating Temperature:

212 °F (100 °C)

OMEGA FP-6000, -6001
Adjustable Brass Flow Sensor

Order Number:

FP-6000

1-1/2 in. NPT threads

FP-6001

7/1-R 1-

1/2

ISO threads

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

Warranty Record

For your protection, record your sensor's purchase
information for future reference. The serial number
is located on the metal tag attached to the upper
portion of the sensor body.

Type: OMEGA FP-6000 Series

Adjustable Brass Flow Sensor

OMEGA FP-6002, -6003
Adjustable Brass Flow Sensor
for Hot-Tap installations

Order Number:

FP-6002

1-1/2 in. NPT threads

FP-6003

7/1-R 1-

1/2

ISO threads

Purchase Date: __________________________

Model Number: _________________________

Serial Number: __________________________

Purchased From: _________________________

Purchase Order Number: _________________

This manual contains description, specifications

Fluid
Flow

and instruction for the installation, removal, and
operation of the OMEGA FP-6000 Series
Adjustable Brass Flow Sensor. Please read the
manual thoroughly. If you require further
assistance, please contact your OMEGA 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 11/2 to 24 inches in diameter (11/
to 36 in. for Hot-Tap). The Hot-Tap version
enables installation in active pipes, reducing
downtime to a minimum. Wetted parts include
C36000 brass, CD4MCu steel, tungsten steel,
Fluoroloy B, and Viton®.

Chapter 1

Introduction

2

The FP-6000 Series mounts on the pipe through
any standard 1

1

/2 inch female pipe fitting. The
unit comes equipped with standard NPT threads
or optional ISO 7/1-R 11/2 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
the 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.

1

Chapter 2

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

Reducer

Flange

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

2 x 90° Elbow
3 dimensions

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

90° Elbow

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

Valve/Gate

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

25 X D 5 X I.D.

2 x 90°
Elbow

Inlet OutletInlet Outlet

Installation and
Wiring

Figure 1

Sensor upstream/
downstream mounting
requirements

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
with any insertion flow sensor, the pipe must be full
and generally free of air pockets.

2.1 Location of Fitting

The sensor must be located in a free-flowing
straight run of pipe. OMEGA recommends a
minimum of 10 pipe diameters of straight pipe
upstream and a minimum of 5 diameters down­stream to insure a fully developed flow profile.
Any obstructions to the flow will require consider­ably longer straight runs. Figure 1 illustrates
several common situations and recommended
piping distances.

2

2.2 Sensor Position

When installing the sensor in a horizontal pipe run
the optimum position is at 0° 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,

blk
F-

red
F+

shld

black

(AC signal out)

red

(AC signal out)

silver

(shield)

instrument

1/2 in. conduit
port

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.

0°

+30°-30°

Maximum Sensor

Installation Range

Process Pipe

Special Considerations

For Hot-Tap installations allow at least 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

Both Standard and Hot-Tap sensor
versions include 25 feet of cable. The
cable may be extended up to 200 feet
without amplification. A 1/2 inch
conduit port is available in the sensor to
install the cable in protective conduit.

Figure 2

Sensor Installation Range

Vertical mounting is recom­mended to provide best
overall performance.

3

Chapter 3

Installation

The following items are required to properly install
the OMEGA FP-6000 Series Adjustable Brass flow
sensor.

3.1 Hardware, Standard Sensor

• female pipe fitting (weld-on or saddle)
11/2 in. NPT or ISO 7/1-Rc 1-1/2

•11/4 in. (32 mm) diameter drill

• Pipe thread sealant

• Tape measure

3.2 Hardware, Hot-Tap Sensor

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

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

• Female ball or gate valve (full port only)
11/2 in. NPT or ISO 7/1-Rc 1-1/2

Caution: Depressurize and
drain pipe before drilling .

4

• Male pipe nipple, 11/2 x 2 in./32 x 50 mm
11/2 in. NPT or ISO 7/1-R 11/

•Hot-Tap installation tool (purchased separately)

2

3.3 Standard Fitting Installation

1. Depressurize and drain pipe.

2. Wearing safety face protection, drill a 11/4 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.