Omega Products FP6500 Installation Manual

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FP6500 SERIES

Insertion Pa d d l ewheel Flow Sensor

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User’s Guide

Servicing North America:

U.S.A.: 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, Canada
TEL: [phone] FAX: [phone]
e-mail: [e-mail]

For immediate technical or application assistance:

U.S.A. and Canada: Sales Service: 1-800-826-6342 / 1-800-TC-OMEGA

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Customer Service: 1-800-622-2378 / 1-800-622-BEST

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Engineering Service: 1-800-872-9436 / 1-800-USA-WHEN

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Servicing Europe:

Benelux: Postbus 8034, 1180 LA Amstelveen, The Netherlands

TEL: [phone] FAX: [phone]
Toll Free in Benelux: 0800 0993344
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Czech Republic: Frystatska 184, 733 01 Karviná, Czech Republic

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

France: 11, rue Jacques Cartier, 78280 Guyancourt, France

TEL: [phone] FAX: [phone]
Toll Free in France: 0800 466 342
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Germany/Austria: Daimlerstrasse 26, D-75392 Deckenpfronn, Germany

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Toll Free in Germany: 0800 639 7678
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United Kingdom: One Omega Drive, River Bend Technology Centre

ISO 9002 Certified

Northbank, Irlam, Manchester
M44 5BD United Kingdom
TEL: [phone] FAX: [phone]
Toll Free in United Kingdom: 0800-488-488
e-mail: [e-mail]

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It is the policy of OMEGA Engineering, Inc. 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 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, human applications.

GENERAL INFORMATION

The FP6500 Series are adjustable depth insertion paddle­wheels that come in brass or 316 stainless models to fit
3” to 48” pipe. Installation fittings are standard 1-1/2"
NPT. Fittings such as saddles and weldolets may be
purchased locally or from Omega.

Ruby bearings and a non-drag Hall-effect sensor give these
meters the widest flow range of any of the paddlewheel
types. A sensor detects the passage of miniature mag­nets in the six rotor blades. The resulting square-wave
signal can be sent for hundreds of feet over unshielded
cable without a transmitter and connected directly to
many PLC’s and other controls without any additional
electronics.

SPECIFICATIONS

Sensor

Materials Tube

Rotor

Shaft

Bearings

Flow Range

Accuracy

Maximum Temperature

Maximum Pressure

Insertion Force

Pipe Size

Fitting Size

Power

Cable

Hall Effect Sensor, 12 Vdc
current sinking pulse

Brass or 316 SS

PVDF

Nickel-bound tungsten carbide
(zirconia ceramic optional)

Ruby

0.3 to 30 ft/sec (0.1 to 9 m/s)

+1.5% of full scale

200˚ F (93˚ C)

200 psi (14 bar)

0.44 x pressure in pipe

3” - 48” (50 - 1200mm)

1-1/2” NPT

5-24 Vdc, 1.5 mA

#22 AWG 3-con, 18’ (6m);
Maximum cable run 2,000’ (650m)

FEATURES

Housing screw (connect ground to one)

Cable-seal strain relief

Rugged cast aluminum housing

Compression nut

Adapter fitting with 1-1/2" NPT threads

Rotor housing

Removable jewel bearings
Rotor

10

X Dia.

5

X Dia.

FLOW

INSTALLATION

"D"

These ow sensors are not recommended
for installation downstream of the boiler

feedwater pump where installation fault
may expose the meter to boiler pressure
and temperature. Maximum recommended
temperature is 200ºF.

Piping. For best results, the FP6500 should be installed
with at least ten diameters of straight pipe upstream and five
downstream. Certain extreme situations such as partially­opened valves are particularly difficult and may require fifteen
diameters upstream (See Straight Pipe Recommendations).

Immersion. The FP6500-Series standard sensors are not
designed for continuous underwater operation.

Fitting Installation. FP6500 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
below). Be sure flow is in the direction of the arrow on the
housing. Tighten compression nut fully.

Depth Setting. It is important for accuracy that the sensor
be inserted to the correct depth into the pipe.

Horizontal is the preferred installation orientation, since it
improves low-flow performance slightly and avoids problems
with trapped air. Bottom, top, and vertical pipe installations
are all acceptable if required by the piping layout. See Full
Pipe Recommendations.

POSITIONING THE METER

Fair (unacceptable if

air is present)

Best

compression nut

threaded adapter fitting

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 below. Be sure the arrow on the housing
points in the direction of flow.

strain relief

FLOW

Fair (unacceptable if uid

contains sediment)

5. Check Dimension D one more time.

6. Tighten the compression nut fully.

INSTALLATION

Table 1: Dimension "C"

3" 4" 6" 8" 10" 12" 14" 16" 18" 20" 24" 30" 36"

IP101

IP201

9.20 9.03 8.69 8.35 8.01 7.67 7.33 6.99 - - - - -

14.20 14.03 13.69 13.35 13.01 12.67 12.33 11.99 11.65 11.31 10.63 9.61 9.59

Table 2: Pipe Wall Thickness

Nominal Pipe Size

3" 4" 6" 8" 10" 12" 14” 16" 18” 20” 24" 30" 36"

PVC/Steel

Sch. 40

0.216 0.237 0.280 0.322 0.365 0.406 0.438 0.500 0.562 0.593 0.687 - -

Nominal Pipe Size

PVC/Steel

Sch. 80

Stainless

Steel (10S)

Stainless

Steel (40S)

Copper Tubing

(Type L)

Copper Tubing

(Type K)

Brass Pipe

Duct. Iron

(Class 52)

- 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

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

INSTALLATION

Feet / sec.

▲

Flow (GPM) (Sched. 40 pipe)

Nominal pipe size

3" 4" 5" 6" 8" 10" 12" 16" 24" 36" 38" 48"

(0.3)

(0.5)

(1.0)

(2.0)

(5.0)

(10.0)

(20.0)

(30.0)

3.1 4.5 18.7 27 46.8 73.7 105 165 376 874 1060 1690

11.5 19.8 31.2 45 78 123 174 275 627 1460 1770 2820

23 39.7 62.4 90 156 246 349 551 1250 2910 3530 5640

46.1 79.4 125 180 312 492 698 1100 2510 5830 7070 11280

115 198 312 450 780 1230 1740 2750 6270 14570 17670 28200

230 397 624 900 1560 2460 3490 5510 12530 29140 35350 56400

461 794 1250 1800 3120 4920 6980 11020 25060 58270 70700 112800

691 1190 1870 2700 4680 7370 10470 16520 37600 87410 106050 170000

FP6500-Series K-factors

Nominal pipe size

3" 4" 5" 6" 8" 10" 12" 16" 24" 30" 36" 38" 42"

PVC/Steel

Sch. 40

PVC/Steel

Sch. 80

Stainless Steel

(10S)

Stainless Steel

(40S)

Stainless Steel

(80S)

Copper Tubing

(Type K)

Copper Tubing

(Type L)

Brass Pipe

Duct. Iron

(Class 52)

28.92 16.79 10.69 7.40 4.27 2.14 1.51 0.960 0.420 0.250 0.180 0.160 0.135

32.37 18.59 11.75 8.20 4.68 2.35 1.66 1.050 — — — — —

25.61 15.00 9.71 6.74 3.92 1.98 1.40 — — — — — —

28.92 16.79 10.51 7.40 4.27 2.14 1.49 — — — — — —

32.37 18.59 11.75 8.20 4.68 2.26 — — — — — — —

32.21 18.12 11.79 8.26 4.73 — — — — — — — —

31.39 17.85 11.46 7.97 — — — — — — — — —

29.03 17.01 10.62 7.26 4.25 — — — — — — — —

25.93 15.28 — 6.90 3.86 1.99 1.39 0.780 — — — — —

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

INSTALLATION

FULL PIPE RECOMMENDATIONS

Allows air pockets to form at sensor

RECOMMENDEDNOT RECOMMENDED

Ensures full pipe

RECOMMENDEDNOT RECOMMENDED

Post-valve cavitation can create air pocket Keeps pipe full at sensor

RECOMMENDEDNOT RECOMMENDED

Air can be trapped

Allows air to bleed off

Caution: These flow sensors are not recommended for installation down­stream of the boiler feedwater pump where installation fault may expose
the flow sensor to boiler pressure and temperature. Maximum recom­mended temperature is 200°F.

CONNECTION, OPERATION & REPAIR

RED (+) 6-24 Vdc

WHITE (signal)

BLACK (-) Power

18' cable standard

CONNECTION

Sensors are supplied with 18 ft. of cable. See diagram for
color coding of connections.

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. It is provided in pulses per
gallon, and is given on the chart “K-factors for Various Pipe
Sizes.” These numbers are based on extensive testing, which
has shown close agreement between different FP6500-Series
sensors in the same installation. Typically, most K-factor er­ror can be attributed to installation variables, such as depth
setting and fitting configuration.

Flow Range. These sensors are designed to operate at
flow velocities of 0.3 to 30 feet per second. (See char t
for conversion to gallons per minute.) If erratic readings
are encountered at low flows, check the chart to see if
flow is below minimum for the pipe size. The standard
shaft and bearings should have a long life at continuous
high flow.

REPAIR

CAUTION! Never attempt to remove

a ow sensor when there is pressure
in the pipe. Loosen the compression
nut slowly to release any trapped

pressure. If uid 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.

Rotor Replacement. Rotors are easily field-replaced.
Shaft and rotor are a single unit, and are not replaced
separately. If replacement is due only to normal shaft
wear, bearing replacement is probably not necessary.
If the rotor has been damaged by impact, the bearings
should also be replaced. Rotor and bearings can be or­dered as a kit, FP15827. Follow these steps:

It is occasionally possible to field calibrate a sensor by catch­ing the fluid in a measured container and comparing with the
number of pulses recorded. (To record individual pulses, set
the K-factor on the control to 1.00.) This is especially desir­able if the installation has less than the recommended length
of straight pipe upstream of the sensor.

OPERATION
Theory. In principle, an inser tion flow sensor measures the

velocity of flow at one point in the pipe, and flow rate and total
can be inferred from this one point. Accuracy is decreased
by any factor which makes the flow at the measured point
unrepresentative of the entire flow stream. This includes
distorted flow patterns caused by upstream fittings too close
to the sensor. The worst offenders are fittings that increase
the flow on one side of the pipe, such as partially-opened gate
or butterfly valves. Fluid moving in a pipe does not all flow at
the same velocity. Toward the center of the pipe, fluid moves
faster than at the wall, and the relationship between the two
changes as overall flow rate increases. This change in the
“velocity profile” can result in non-linearity, which means that
the K-factor that is correct for one flow rate may be incorrect
for another. The recommended depth settings have been
carefully chosen to minimize this source of error, and should
be followed carefully, especially in the smaller pipe sizes.

1. Unscrew the threaded bearing housings to expose
the shaft ends. If bearings are being replaced, back
them completely out.

2. Remove the rotor. Put the new rotor in its place.

3. Thread in one bearing housing part way, then the
other. Take care to star t the end of the shaft into
the bearing hole before tightening further.

4. Screw in bearing housings until they bottom.
Note: Do not use excessive force.

5. Check for free spin. Blowing lightly on the rotor
should result in it spinning rapidly and coasting to
a smooth stop.

2

1

9

14

8

15

16

12

5

6

4

3

7

13

11

10

15

8

PARTS EXPLOSION

Troubleshooting. The flow sensor has only one moving part,

the rotor. If this is turning properly and there is no signal,
the Hall-effect sensor is not operating properly. To check
the signal, apply 12 Vdc power to the red (+) and black (-)
leads. Set a multimeter to voltage reading. Put the positive
multimeter lead on the red wire and the negative lead on the
white wire. Slowly turn the rotor. Voltage reading should swing
between +12 Volts and 0 Volts as the rotor turns. If it does
not, the Hall effect sensor is not working properly. Checking
for continuity is not a useful test of these sensors.

This flow sensor can be returned to the factor y for repair.

FP6500-Series Parts Listing

IP Parts Listing

1 Upper housing

2 Gasket

3 Lower housing

4 Housing screw

5 Plug, steel

6 Plug, plastic

7 Strain relief

8 Sensor with cable

9 Tube

10 Compression nut

11 Ferrule

12 Adapter fitting

13 Rotor housing O-ring

14 Rotor housing

15 Jewel bearings

16 Rotor with shaft

Rotor repair kit

17

(includes of #15 & #16)

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 pleased to offer suggestions on the use of its various products. Howev er,
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
component upon which liab ility is bas ed. In no event shal l O MEGA be liabl e 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/ DISCLAIMER 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 M ER SERVICE DE PA RT M E NT (IN O R 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.

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