Omega | FP-5200 | Owner Manual | Omega FP-5200 Owner Manual

Omega FP-5200 Owner Manual
User’s Guide
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FP-5200
Flow Sensor
omega.com info@omega.com
Servicing North America:
U.S.A.
Headquarters:
Omega Engineering, Inc.
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: info@omega.com
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.
OMEGA FP-5200 Flow Sensor Instructions
SAFETY INSTRUCTIONS
1. Do not remove from pressurized lines.
2. Do not exceed maximum temperature/pressure specifications.
3. Pipe fitting must be installed by certified 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
Flange
Recommended sensor
upstream/downstream mounting
requirements.
Inlet
10 X I.D.
Outlet
5 X I.D.
Valve/Gate
Maximum Operating Pressure/Temperature:
FP-5200 Series Sensor with:
• FP-5200 Series Tee & Mini-Tap Fittings:
103 bar (1500 psi) @ 149 °C (300 °F)
Reducer
90° Elbow
15 X I.D.
5 X I.D.
5 X I.D.
40 X I.D.
2. Sensor Mounting Position
5 X I.D.
45
•
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.
•
Vertical pipe runs: Sensor must be mounted in lines with UPWARD flow only.
5 X I.D.
2 x 90° Elbow
2 x 90° Elbow
50 X I.D.
20 X I.D.
°
25 X I.D.
45
5 X I.D.
°
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
fittings, 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
OMEGA FP-5200 Flow Sensor Instructions
Wetted fitting materials:
316 SS
Sensor
Tee Fitting,
hardware included
Wetted fitting materials:
316 SS & 347 SS
Sensor
Mini-Tap Fitting,
hardware included
1
4. Fitting Installation, Required Hardware
Tee & Mini-Tap Fittings
• 0.5 to 1 inch pipes, FP-5200 Series fitting required
• 1.25 to 12 inch pipes: FP-5200 Series fitting and 27 mm (1-1/16 in.) diameter drill required
• Mini-Tap fittings 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 fitting/pipe size:
FP-5200 Series Tee Fittings, 0.5 to 1 inch:
• Insert pipe into fitting socket
• Make sure the pipe is parallel to the bottom of the Mini-Tap fitting.
• 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 fitting onto the pipe, making sure the hole in the pipe is lined up with the Mini-Tap fitting hole.
• Weld the Mini-Tap fitting onto the pipe.
FP-5200 Series Saddle Fitting
• 27 mm (1-1/16 in.) diameter drill required.
5. Sensor Installation
6. Sensor Wiring
1. Set the gasket supplied with the fitting onto the fitting flange,
making sure the holes align.
1/2 in. NPT
conduit port
2. Remove the red rotor protection cap and insert the sensor into
the fitting, making sure not to bump the rotor assembly. Make
sure the arrow on the side of the sensor is pointing in the
direction of flow.
black
(AC signal out)
Blk
FRed
F+
Shld.
red
(AC signal out)
Fitting
flange
Flow sensor
arrow
Flow
3. Slip two washers onto each bolt and insert the bolt/washer
onto each of the four fitting flange holes.
FP-5200 Series
silver
(ground)
Instruments
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.
4. Snug all four flange bolts in a criss-cross pattern. Using a
torque wrench (when possible), torque the flange nuts in a
criss-cross pattern to 52 foot-pounds.
1
4
Flange
bolt torque
pattern
3
2
2
OMEGA FP-5200 Flow Sensor Instructions
7. Sensor Removal Procedure
WARNING!
Never remove a sensor from a pressurized
pipeline. Always wear protective clothing
during sensor installation/service.
1. Depressurize and drain pipe.
2. Remove the four sensor flange bolts and lockwashers.
Pull upward on the sensor flange with an alternating twisting
motion.
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
pliers, firmly 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
at this time.
3. Insert the new rotor assembly
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.
Rotor Pin
Retainer
Punch
Existing
Retainer
New
Bearings
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.
10. K-Factors
The K-Factor is the number of pulses the sensor will generate for
each engineering unit of fluid 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 fluid
passing the rotor. K-Factors are listed for SCH 40S stainless steel
pipes up to 12 inch.
Rotor Pin
SCH 40S STAINLESS STEEL PIPE PER ANSI B36.19
PIPE
SIZE
(in.)
K-FACTOR
PULSES/
U.S. GAL
K-FACTOR
PULSES/
U.S. LITER
A-FACTOR
GPM/Hz
A-FACTOR
LPM/Hz
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
Conversion Formulas
1 U.S. gallon =
0.003785 cubic meters
0.000003069 Acre feet
8.3454 pounds of water
OMEGA FP-5200 Flow Sensor Instructions
3
11. Specifications
General Data
Flow velocity range:
Frequency output:
Linearity:
Repeatability:
Pipe size range:
Cable length:
Cable type:
Materials
Sensor body:
Rotor material:
Rotor pin:
Retainers (2):
Rotor bearings (2):
0.5 to 6 m/s (1.6 to 20 ft/s)
29 to 46 Hz per m/s (9 to 14 Hz per ft/s)
±1% of full range
±0.5% of full range
13 to 305 mm (0.5 to 12 in.)
7.6 m (25 ft), can splice up to 60 m
(200 ft.) with no significant degradation of
signal strength
150 °C 22 AWG, 2-conductor w/shield
ACI type CF-8M (316 cast stainless steel)
per ASTM A351
CD4MCu stainless steel
Tungsten Carbide (316 stainless steel,
optional)
316 stainless steel
Fluoroloy B®
12. Accessories
Electrical Data
Voltage output:
Coil resistance:
Coil inductance:
Approximate sine wave,
0.005 to 0.008 Vpp per Hz
11.6 kΩ @ 25 °C
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)
retainer
rotor pin
retainer
Refer to section 3 for a list of available sensors and fittings.
Part no.
FP-52648
FP-52509
FP-52509-2
M2489
Description
Fitting cap kit, cap and gasket
Rotor kit, 316 SS pin
Rotor kit, Tungsten pin
Instruction manual
bearing
bearing
rotor
FP-52509/FP-52509-2 Rotor kit
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 fluid 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
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/DISCLAIMER 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 NON-WARRANTY REPAIRS, consult
FOR WARRANTY RETURNS, please have the
OMEGA for current repair charges. Have
following information available BEFORE contacting
the following information available BEFORE
OMEGA:
contacting OMEGA:
1. Purchase Order number under which the product
1. Purchase Order number to cover the COST
was PURCHASED,
of the repair,
2. Model and serial number of the product under
2. Model and serial number of the product, and
warranty, and
3. Repair instructions and/or specific problems
3. Repair instructions and/or specific problems
relative to the product.
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 2016 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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