Instruction/ maintenance manual of the product FP-6000 Omega Engineering
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www .omega.com e-mail: info@omega.com U ser ’ s Guide Shop online at FP-6000 Series Flow Sensors.
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.
T able of Contents Chapter Page 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.
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Impor tant 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.
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.
Chapter 1 Introduction This manual contains description, specifications 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.
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.
3 (max. 30 ° ) will help to avoid these problem areas, 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.
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) 1 1 / 2 in. NPT or ISO 7/1-Rc 1- 1/2 •1 1 / 4 in. (32 mm) diameter drill • Pipe thread sealant • Tape measure 3.
5 4. Remove brass sensor nut from sensor. 5. Thread brass sensor nut into pipe fitting. 3.4 Hot-T ap Fitting Installation 1. Install the pipe fitting on the outside diameter of the pipe according to the manufacturer's instruc- tions. Failure to follow these instructions may result in bodily injury and/or product failure.
6 4. 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.
7 Standard Sensor H = 5.95 - pipe wall thickness - (0.10 X I.D.) Example: 3.0 inch schedule 80 wrought steel; Wall thickness= 0.3 in. Inside diameter = 2.9 in. H = 5.95 - 0.3 - (0.10 X 2.9) H = 5.36 in. Hot-Tap Sensor H = 15.00 - pipe wall thickness - (0.
8 Once the correct dimensions are calculated and recorded, the sensor can be installed in the fitting. The Standard and Hot-Tap versions require substantially different procedures. 3.6 Standard Installation 1. Thread one hex nut onto each of the three threaded rods included in package.
9 4. Place the alignment rod in the hole on the sensor flange. Align the flange so rod is parallel to the process pipe. 5. Thread upper hex nuts with lock-washers until they contact the sensor flange and tighten. Check for proper "H" dimension and readjust if necessary.
10 3.7 Hot-T ap Installation 1. Thread one hex nut onto each of the three threaded rods included in package. Install threaded rod with a lock-washer onto the brass sensor nut. Secure rods in place by tightening each hex nut against the brass sensor nut.
alignment rod sensor flange process pipe (top view) The flow sensor alignment rod MUST be parallel to the process pipe as shown. direction of flow sensor flange 18 inch threaded rods 13.75 in. process pipe (side view) direction of flow alignment rod Upper hex nuts (3/16 x 1/4-20) 1/4 in.
12 Using the Hot-Tap Installation Tool The Hot-Tap installation tool helps to lower the sensor into place against the pressure in the pipe. 1. Thread protector plate hex nuts onto each of the three threaded rods. Adjust each hex to a height of approximately 1 in.
13 3. Align the sensor cable with the swivel mount cable port to prevent cable pinching. Use a 3/8 inch wrench or socket to turn the installation tool shaft clockwise until it is seated in the hole at the top of the sensor flange. 4. Wearing safety face protection, slowly open the isolation valve to the full open position.
14 4.1 Standard Sensor Removal To remove the Standard FP-6000 Series sensor from a depressurized empty pipe, simply remove the cap nuts and upper hex nuts located above the sensor flange.
15 5. Wearing safety face protection, turn the installation tool shaft counterclockwise to withdraw sensor until the sensor flange contacts the upper hex nuts. 6. Raise one lower hex and jam nut to bottom of sensor flange. 7. Close valve, remove bearing plate and tool.
5.1 Maintenance All versions of the FP-6000 series sensor require little or no maintenance, with the exception of an occasional sensor/paddlewheel cleaning.
17 5.3 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 shaft retainers and free the rotor assembly.
5.644 in. 5.589 in. 5.500 in. 5.427 in. 5.369 in. 5.310 in. 5.187 in. 5.064 in. 4.830 in. 4.583 in. 4.350 in. 4.200 in. 3.950 in. 3.700 in. 3.475 in. * 3.000 in. 18 NPS SCH 40 SCH 80 STD XS 5.600 in. 5.538 in. 5.442 in. 5.360 in. 5.296 in. 5.230 in. 5.
19 14.694 in. 14.639 in. 14.550 in. 14.477 in. 14.419 in. 14.360 in. 14.237 in. 14.144 in. 13.880 in. 13.633 in. 13.400 in. 13.250 in. 13.000 in. 12.750 in. 12.525 in. * 12.050 in. NPS SCH 40 SCH 80 STD XS 14.650 in. 14.588 in. 14.492 in. 14.410 in. 14.
K-factors Stainless Steel SCH 5S STAINLESS STEEL PIPE PER ANSI B36.19 K-FACTOR K-FACTOR A-FACTOR A-FACTOR PIPE PULSES/ PULSES/ U .S . SIZE U.S. GAL LITER GPM/HZ LPM/HZ 1 1/2 104.200 27.5297 0.5758 2.1795 2 67.160 17.7437 0.8934 3.3815 2 1/2 46.060 12.
K-factors Wr ought Steel 21 STD WROUGHT STEEL PIPE PER ANSI B36.10 K-FACTOR K-FACTOR A-FACTOR A-FACTOR PIPE PULSES/ PULSES/ U.S. SIZE U.S. GAL LITER GPM/HZ LPM/HZ 1 1/2 122.000 32.2325 0.4918 1.8615 2 78.690 20.7900 0.7625 2.8860 2 1/2 55.630 14.6975 1.
22 K-factors Plastic Pipe To convert K from to multiply K by U.S. gallons cubic feet 7.479 U.S. gallons cubic inches 0.00433 U.S. gallons cubic meters 263.85 U.S. gallons pounds of water 0.120 U.S. gallons acre feet 325853 U.S. gallons liters 0.264 U.
23 Specifications General Data Flow velocity range: 1.6 to 20 ft/s 0.5 to 6 m/s Linearity: ± 1% of full range Repeatability: ± 0.5% of full range Pipe sizes: Standard version: 1.5 to 24 in. (38 to 610 mm) Hot-Tap version: 1.5 to 36 in. (38 to 914 mm) Cable length: 25 ft (7.
operating pressure: 225 psi (15 bar) Maximum operating temperature: 212 ° F (100 ° C) Caution: The FP-6002 and FP-6003 Series Hot- Tap system's overall specifications and limitations depend on the lowest maximum rating of the components associated with the system.
W ARRANTY /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. OME GA ’ s W A RR ANT Y adds an additional one (1) month grace period to the normal one (1) year product warranty to cover handling and shipping time.
6-2517.090-OM/(D-8/02) M-2973/0802 Where Do I Find Ever ything I Need for Process Measurement and Control? OMEGA…Of Course! Shop online at www.omega.
An important point after buying a device Omega Engineering FP-6000 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Omega Engineering FP-6000 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Omega Engineering FP-6000 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Omega Engineering FP-6000 you will learn all the available features of the product, as well as information on its operation. The information that you get Omega Engineering FP-6000 will certainly help you make a decision on the purchase.
If you already are a holder of Omega Engineering FP-6000, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Omega Engineering FP-6000.
However, one of the most important roles played by the user manual is to help in solving problems with Omega Engineering FP-6000. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Omega Engineering FP-6000 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
