Badger Meter Flow-Alert Reed Switch User Manual

OIL

Flow-Alert Flow Switch

GPM LPM

FORM #04-VAM-UM-00229 (September 2012)

FLOW-ALERT

FLOW SWITCH

6000 PSI / 414 BARS MAX

Installation & Operation Manual

I  INTRODUCTION

The Flow-Alert ow meter combines the rugged proven technology of a direct reading, piston-type, variable area ow meter, coupled with electrical contacts utilized to signal at selected ow rates. This combination is sealed against industrial contamination by a NEMA 12 and 13 (IP52/54) rated enclosure.

This product provides a local ow indication and automatically signals the operator or PLC if ow is too high or too low.

Uses of the Flow-Alert ow meter include: bearing lubrication, case drain verication, gun drill cooling, pump ow conrmation, etc.

GPM LPM

OIL

FLOW-ALERT

FLOW SWITCH

6000 PSI / 414 BARS MAX

FIGURE 1 FLOWALERT FLOW METER

Page 2 Form #04-VAM-UM-00229 09/12

II  SPECIFICATIONS

Enclosure Rating

• NEMA 12 & 13 (equivalent to IP52 & 54)

Temperature Range

• -20 °F to +240 °F (-20 °C to +116 °C)

Pressure Rating Aluminum/Brass

• Liquids (¼” to 1½”): 3500 psi

(241 bar) maximum with a 3:1 safety factor

• Gases (¼” to 1½”): 1000 psi

(69 bar) maximum with a 10:1 safety factor

Pressure Rating Stainless Steel

• Liquids (¼” to ½”): 6000 psi (414

bar) maximum with a 3:1 safety factor

• Liquids (¾” to 1½”): 5000 psi (345

bar) maximum with a 3:1 safety factor

• Gases (¼” to 1½”): 1500 psi (103

bar) maximum with a 10:1 safety factor

Accuracy

• ±2% of full scale

Repeatability

• ±1%

Pressure Drop

• See Appendix for specic meter

information

Micro Switch

• Single (1) or double (2) switch,

pre-wired single-pole, doublethrow (SPDT), UL recognized and CSA certied switch

• Type: SPDT

• Contact Rating VAC: 250 Volt,

10 Amp

• Contact Rating VDC: 125 Volt,

0.5 Amp

• Cable Single Switch: 34”, 4-wire, #18 AWG, SO jacket

• Cable Dual Switch: 18”, 7-wire, #16 AWG, SO jacket

Reed Switch

• Single (1) or double (2) reed switch, pre-wired single -pole, single-throw normally open (SPST-NO); or single-pole, single -throw normally closed (SPST-NC); UL recognized and CSA certied switch

• Type: SPST

• Contact Rating: (maximum, see

Figure 2) Normally Open, 10 Watts; Normally Closed, 5 Watts

• Voltage (maximum at switching): Normally Open, 50 VDC; Normally Closed, 50 VDC

• Current (maximum amps at switching, resistive load): Normally Open, 0.5 Amp; Normally Closed, 0.5 Amps

• Initial Contact Resistance: 0.100 Ohms

• Cable: 15’ (4.6m), 4-wire, #22 AWG, PVC jacket

Form #04-VAM-UM-00229 09/12 Page 3

Safe Operating Area for SPST (NO)

0.6

0.5

0.4

0.3

0.2

(DC Amps)

0.1

Operating Current

0.0 0 4 8 12 16 20 24 28 32 36 40 44 48

Operating Voltage

(VDC)

FIGURE 2  REED SWITCH POWER DISSIPATION

DIMENSIONS

Safe Operating Area for SPST (NC)

0.6

0.5

0.4

0.3

0.2

(DC Amps)

0.1

Operating Current

0.0 0 4 8 12 16 20 24 28 32 36 40 44 48

Operating Voltage

(VDC)

Nominal

Port Size

¼ (SAE 6)

½ (SAE 10)

¾ (SAE 12)

1 (SAE 16)

1¼ (SAE 20) 12.20

1½ (SAE 24) 12.20

LengthCLengthDLengthEWidthFWidthGWidthHWidthIDepthJOset

6.60

(168)

6.60

(168)

7.20

(183)

7.20

(183)

(310)

inches

(mm)

D C

OIL

FLOW-ALERT

FLOW SWITCH

6000 PSI / 414 BARS MAX

FIGURE 3  CASE DIMENSIONS

5.27

(134)

5.27

(134)

5.27

(134)

5.27

(134)

10.68 (271)

6.41

(163)

6.41

(163)

7.04

(179)

7.04

(179)

11.65 (296)

6.00

(152)

6.00

(152)

6.00

(152)

6.00

(152)

7.63

(194)

7.63

(194)

3.23 (82)

3.60 (91)

4.84

(123)

4.84

(123)

GPM LPM

3.00 (76)

3.82 (97)

4.20

(107)

4.20

(107)

4.20

(107)

4.20

(107)

5.02

(128)

5.02

(128)

Hole

Dia.

2.94 (75)

4.50

(114)

4.50

(114)

1.51 (38)

1.27 (32)

2.20 (56)

.31 (8)

TABLE 1  DIMENSIONAL INFORMATION

Page 4 Form #04-VAM-UM-00229 09/12

III  INSTALLATION

CAUTION

Caution - This product should be installed and serviced by technically qualied personnel trained in maintaining industrial class ow instrumentation and processing equipment.

CAUTION

Caution - Read instructions thoroughly before installing the unit. If you have any questions regarding product installation or maintenance, call your local supplier for more information.

CAUTION

Caution - This meter may contain residual amounts of test uid at the time of shipment. This uid should be removed prior to installation as the uid may be incompatible or hazardous with some liquids or gases. Failure to follow these

WARNING

Warning - Disconnect electrical power before opening wiring enclosure. Failure to follow these instructions could result in serious personal injury or death and/or damage to the equipment.

WARNING

Warning - All wiring should be installed in accordance with the National Electrical Code® and must conform to any applicable state and local codes. Failure to follow these instructions could result in serious personal injury or death and/or damage to the equipment.

CAUTION

Caution - Air/gas meters are NOT oxygen cleaned. Use with oxygen may cause hazardous or explosive conditions that may cause serious personal injury and/or damage to the equipment.

CAUTION

Caution - This standard meter is unidirectional. Attempts to ow uids in the opposite direction of the ow arrow will result in the meter acting as a check valve, creating a deadheading situation. If the dierential pressure magnitude is great enough, damage to the internal parts of the meter will result.

Form #04-VAM-UM-00229 09/12 Page 5

INSTALLATION RECOMMENDATIONS

The in-line ow meter is a simple device to install. However, the following measures are recommended for reliable, trouble-free operation:

Do - Align pipe accurately. Piping should be accurately aligned and of correct length. The high pressure body of the ow meter can withstand shock and ow/pressure pulsation. However, the piping should be rmly supported by external mounting brackets, both upstream and downstream of the meter, to avoid any pipe exing actions that could reduce meter life.

Do - Use rigid mounting. If the ow meter inlet or outlet are to be rigidly mounted, and the opposing port is to be connected to exible hose, the end connected with the exible hose must be rigidly mounted.

Do - Use Teon® tape for sealing NPT tting.

Do - Install unions. Install a union near the inlet or outlet of the meter. This will facilitate quick, easy meter removal and inspection during periodic maintenance procedures.

Do - Mount the meter either horizontally or vertically (ow arrow pointing to either side or straight up). If the meter must be mounted inverted, special inverted scales are available from the factory.

Do - Use at least a 200 mesh (74 micron) lter. The meter will allow particulate to pass that would jam most valves and ow controls. Systems that do not have ltration should be equipped with at least a 200 mesh (74 micron) lter. Most hydraulic systems already have much ner ltration.

Dirt, ferrous metal or sealing agents, such as Teon® tape may lodge and cause malfunction. If the meter is jammed at a xed position, follow cleaning and maintenance instructions.

Don’t - Use thread locking compounds as thread sealant.

Don’t - Install the ow meter near turbulence producing ttings such as elbows, reducers, close coupled valves, etc. The in-line ow meter does not require ow straighteners or special lengths of straight inlet/ outlet piping to stabilize turbulent ow patterns. However, to assure maximum operational reliability, avoid installation of elbows, valves and/or reducers immediately adjacent to the meter inlet.

Do - Ensure the uid is traveling in the direction of the ow arrow (Figure 4 on page 8).

Page 6 Form #04-VAM-UM-00229 09/12

Don’t - Install the meter near fastacting valves. Fast-acting valves have the potential to create high magnitude hydraulic pressure spikes. These spikes can damage the internal components of the meter, resulting in inaccuracies or malfunction.

3. See Figure 6. After installation, rotate meter by hand to view

ow scale.

ELECTRICAL CONNECTIONS

Micro Switch

Equipped Models

Don’t - Allow unidirectional meters

to be operated against the direction of the ow arrow. The standard ow meter is an unidirectional ow meter. The piston acts as a check valve to block ow in the reverse direction. This causes an excessive pressure dierential, which can

All meters (size ¼” to 1½”) are offered in single (1) switch or double (2) switch models. The single switch model is equipped with a 34” length of 4-wire #18 AWG type SO jacketed cable. The double switch model is equipped with a 18” length of 7-wire

#16 AWG type SO jacketed cable. result in damage to internal meter components. The ow meter is also available in a modied design, which oers a reverse ow by-pass feature to accommodate bi-directional ow.

NOTE: In-line meters with a reverse ow by-pass feature are available. Consult factory for details.

INSTALLING THE FLOWALERT

1. See Figure 4. Mount the meter so uid is traveling in the direction of the ow arrow.

2. See Figure 5. Select a mounting location that is suitable for viewing and product service. To connect the ow meter into the piping system, place an open-

One Switch  4-Wire Cable

Red Normally Closed (NC) Black Normally Open (NO) White Common Green Ground

Two Switch  7-Wire Cable

Switch 1

Red Normally Closed (NC) Black Normally Open (NO) White Common

Switch 2

Orange Normally Closed (NC) Blue Normally Open (NO) White/Black Common Green Ground

TABLE 2  MICRO SWITCH

WIRE DESIGNATIONS

ended wrench onto the ow meter wrench ats adjacent to the pipe connection being installed. DO NOT wrench on the opposite end of the ow meter or leakage may result.

Form #04-VAM-UM-00229 09/12 Page 7

Flow Direction Arrows

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FIGURE 4  FLOW DIRECTION ARROWS

GPM LPM

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Flow-Al er t Flow Sw it ch

3500 PSI/241 BARS MAX

GPM LPM

OIL

Flow-A le rt

Flow S wi tc h

3500 PSI/24 1 BA RS MA X

Place wrench on transmitter ats on the same

side plumbing is being tightened

Place wrench on transmitter ats on the

same side plumbing is being tightened

GPM LPM

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Flow-Al er t Flow Sw it ch

3500 PSI/241 BARS MAX

GPM LPM

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Flow-A le rt Flow S wi tc h

3500 PSI/24 1 BA RS MA X

FIGURE 5  INSTALLING THE METER

Never place wrench on transmitter ats

opposite plumbing being tightened

FIGURE 6  ROTATING THE METER

Page 8 Form #04-VAM-UM-00229 09/12

A 4-pin Brad Harrison® quickdisconnect plug is available upon special order.

4-Pin Connector used with

SPDT Micro Switch

Red Normally Closed (NC) Black Normally Open (NO) White Common Green Ground

TABLE 3  4PIN CONNECTOR

MICRO SWITCH

WIRE DESIGNATIONS

NOTE: If the factory supplied cable

is removed for hard wiring the meter, switches must be connected with

0.187” × 0.020” insulated ag termi-

nals designed for the appropriate wire gauge for the application.

REED SWITCH MODELS

Safe operation of the reed switch is dependent on not exceeding the maximum wattage for that switch.

For example the normally open reed switch has a maximum power rating of 10 Watts. If the switch is to operate at 24 VDC the maximum current is found by dividing the wattage by the voltage.

All meters (size ¼” to 1½”) are oered in single (1) switch or double (2) switch models and come equipped with a 4-pin Hirschmann connector. All units are quipped with a 15’ length of 4-wire #22 AWG type PVC jacketed cable.

4-Pin Connector used with

SPST Reed Switch

Red Switch 1 Contact Black Switch 1 Contact White Optional Switch 2 Contact Green Optional Switch 2 Contact

TABLE 4  4PIN CONNECTOR

REED SWITCH

WIRE DESIGNATIONS

ALL MODELS

The strain relief connection on the outside of the enclosure is watertight. Be sure to consult local wiring codes before applying power. Some installations will require rigid conduit. By removing the black strain relief connections from the outside of the enclosure, a conduit connection is accessible.

I =

Form #04-VAM-UM-00229 09/12 Page 9

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