Page 1
Dimension Drawings
DIM 1/2" NPTF Ports 3/4" & 1" NPTF Ports
A 1.94" (49 mm) 3.06" (78 mm)
B 1.13" (29 mm) 1.33" (34 mm)
C 2.00" (51 mm) 2.46" (62 mm)
D 2.45" (62 mm) 2.78" (71 mm)
1
D
E 3.70" (94 mm) 5.25" (133 mm)
F 2.63" (67 mm) 3.80" (97 mm)
2
F
2.60" (66 mm) 2.88" (73 mm)
3.38" (86 mm) n/a
Installation and
Operating Manual
1
Dimension with optional clear cover installed
2
Polypropylene version only
LAKE MONITORS 8809 INDUSTRIAL DRIVE, FRANKSVILLE, WI 53126
P: (800) 850-6110 (262) 884-9800 F: (414) 671-5253 www.lakemonitors.com
Stainless Steel Body
Polypropylene Body
www.lakemonitors.com
FSM-905 Rev.5/24/12 ©2008 AW-Lake Company
Page 2
Introduction
ALL VERSIONS WITH 0-5 VDC CIRCUIT
This manual is a service guide produced by the manufacturer. The
manual provides specific procedures and/or illustrations for installation, inspection, cleaning and filtration of all FlowStat and FlowStat ES
flow sensors. When properly followed, these procedures will keep
your FlowStat flowmeter operating dependably for many years.
It is important for operators and maintenance personnel to be safety
conscience when operating or repairing equipment. Developing a thorough knowledge of the precautionary areas and following safe operating procedures, can prevent equipment damage and/or personal injury.
Before making any repair, read all of the repair procedures to learn
the correct method and all precautions.
General
Lake Monitors' FlowStat flow rate sensors integrates rugged tangential turbine technology with a precision digital to analog conversion
circuit hermetically encapsulated within the body of the sensor. The
flow transmitter is ideal for measuring flow rates in cooling circuits,
HVAC systems and batching operations.
Additional features are:
n simple in-the-field serviceability of its moving components
n the integral 4-20mA circuit design eliminates the need for separate
signal conditioning modules
n units come factory calibrated to your system requirements
n the low impedance 4-20mA circuit can transmit a "clean" signal
over low-cost wire for several thousand feet without degradation
n accurately measures flow in both directions.
Power requirements: 12-35VDC, 20 mA
Maximum Current: 30 mA DC
Max. Trans. Distance: <200 feet recommended
Min. Load Resistance: 1000 Ω
Flow rate accuracy: 2% of full scale
Repeatability: 0.5% of scale
Resolution: infinite
Response time: 2 seconds to 90%
ALL VERSIONS WITH PULSE OUTPUT CIRCUIT
Power requirements: 5-24VDC, 20 mA
Maximum Current: 25 mA DC
Max. Trans. Distance: <200 feet recommended
Flow rate accuracy: 2% of full scale
Linearity: 0.5% of scale
Resolution: Infinite
Response time: < 100 mS
ALL VERSIONS WITH RELAY OUTPUT CIRCUIT
Power Requirements 12-35 VDC
Max. Trans. Distance < 200 feet recommended
Switch Contact Form C, 5A max @120 or 240 VAC
Hysteresis 5% of reading max.
(2)
(11)
Page 3
Mechanical Specifications
FLOW SENSOR WITH STAINLESS STEEL BODY
Maximum pressure: 200 PSI clear cover, 500 PSI SS cover
Maximum temperature: 225ºF
Measuring range*
1/2" NPT Ported: 0.5 - 15 GPM
3/4" & 1" NPT Ported: 1.5 - 50 GPM
Wetted materials: 316SS, acetal copolymer, Buna, PEEK
and polycarbonate
Non-wetted materials: Epoxy, Lexan®and PVC
FLOW SENSOR WITH POLYPROPYLENE BODY
Maximum pressure: 150 PSI
Maximum temperature: 150ºF
Measuring range*
1/2" NPT Ported:: 0.5 - 15 GPM
Wetted materials: 316SS, acetal copolymer, Buna, PEEK,
polycarbonate and polypropylene
Non-wetted materials: Epoxy, Lexan®and PVC
*Important: Chose a maximum flow rate. For 1/2": 5 - 15 maximum GPM.
For 3/4" and 1": 15 - 50 maximum GPM. Minimum flow rate will
be 10% of maximum flow rate. Example: If your maximum flow
rate is 8 GPM, the minimum flow rate would be .8 (8 x .1 = .8).
Thus, the correct flow range would be .8 - 8.0 GPM.
Electronic Specifications
ALL VERSIONS WITH 4-20 MA CIRCUIT
Power requirements: 12-35VDC, 20mA
Load driving capacity: Max. Load (Ω) = 50(Power Supply Voltage - 12)
Trans. Distance: limited only by wire resistance & supply voltage
LED: provides power indication
Flow rate accuracy: ±2% of full scale
Repeatability: ±0.5% of scale
Resolution: infinite
Response time: 2 seconds to 90%
Over-current protection: self limiting at 30mA
Fail safe indication: 4 mA
Illustration 1:
Mounting Instructions
Installation - Mechanical
1. The FlowStat has NPT (National Pipe Thread) plumbing connections. Lake Monitors recommends that a paste type pipe
sealant be used on these threads. [Thread sealant can
be used as long as it is applied in such a way that it will not enter
the flow stream. Pieces of thread seal tape can wrap around the
turbine and impede its rotation.]
2. The recommended mounting orientation would be any plane that
will place the axis of the turbine horizontal with respect to the
ground. See Illustration 1. The unit will operate satisfactorily with
its axis at angles other than horizontal, but side loading of the
bearing surfaces will lead to premature wear of the rotating parts.
3. For the best flow measurement results, place the inlet (See Note 1)
of the flow sensor at least 10 straight pipe diameters downstream from any fitting, valve, elbow, reducer, etc. that causes
non-stable flow conditions. Ideally, 5 straight pipe diameters should
be placed at the outlet of the sensor. If the sensor must be placed
closer to a source of non-stable flow than these recommended distances, some instability of the output signal may result. The average signal will be accurate.
(10)
(3)
Page 4
4. It is recommended that the sensor be placed in such a position
that the round access cover can be removed for cleaning and turbine servicing. It is also recommended that a union be placed
near the sensor to allow easy removal.
Note1: The FlowStat is a bi-directional measuring device.
References to “inlet” and “outlet” refer to uni-directional systems.
Installation - Electronic (4-20mA Only)
The FlowStat circuit is a two-wire loop-powered design that transmits a
4-20mA signal that is proportional to flow rate. The noise-immune current transmission from the sensor can be routed with low cost two conductor twisted-pair cable. The circuit operates on 12-35 VDC and
requires a source capable of supplying at least 20mA of current. The
circuit has built in polarity protection and over-current limiting to protect
both the transmitter and what the transmitter is connected to.
1. Connect the red wire (pin 1 for units with the electronic disconnect
option) from the transmitter sensor to the positive 12-35 V
power supply output.
2. Connect the black wire (pin 2 for units with the electronic disconnect
option) from the transmitter to the positive side of the loop load
(resistor, chart recorder, data acquisition board, meter, etc.). This
connection may be labeled "4-20mA Input" or "4-20mA (+)" on
some devices.
DC
1. Relieve pressure in the piping system.
2. Remove the retainer ring that secures the turbine access cover.
3. Remove the access cover with a pliers, taking care not to damage
the o-ring seal.
4. Pull out the turbine assembly and the shaft.
5. Inspect the shaft for things that may have wrapped around it.
6. Inspect the turbine bearing surface for wear and elongation.
Replace as necessary.
7. Clean any rust off of the magnets that may have accumulated.
8. Reassemble the unit by placing the turbine into the body cavity
with the two magnet pockets facing inward. Place the shaft into the
turbine hole and guide it into the retaining hole in the body cavity.
Lubricate the o-ring seal with some glycerin or other lubricant and
press it into the pocket of the body. Replace the retaining ring
securely before applying pressure to the system.
Circuit recalibration (4-20mA version):
1. Place a milliamp meter into the current loop.
3. If applicable, connect the negative side of the loop load to negative
side of the power supply.
4. Apply power to the system.
5. If everything is operating correctly, the green LED on the sensor
will dimly illuminate and 4mA will be flowing in the loop. If there is
fluid flowing through the sensor, the current will be higher than
4mA and the LED will be quite bright.
If the LED does not illuminate:
n check wiring terminations for good connections
n check wiring polarity
n verify correct supply voltage
n ensure that the load impedance is within allowable limits
(4)
2. Turn off the flow going though the sensor. Adjust the OFFSET
control for a reading of 4mA on the milliamp meter.
3. Adjust the flow rate though the meter to full flow rate. Adjust the
SPAN control for a reading of 20mA on the milliamp meter. The
two controls are not interactive, so further adjustment should not
be necessary.
Circuit recalibration (0-5V
DC version):
1. Place a voltmeter across the black & green wires of the sensor pigtail.
2. Turn off the flow going though the sensor. Verify a reading of less
than 50 mV
DC on the voltmeter.
3. Adjust the flow rate though the meter to full-scale flow rate. Adjust
the SPAN control for a reading of 5 V
DC on the voltmeter.
(9)
Page 5
Set Point Adjustment (Relay Output Only)
1) Adjust the flow rate through the line in which the FlowStat sensor is
installed to the rate that corresponds to the desired relay trip point.
2) If the red LED on the back side of the sensor is not illuminated, use a
small flat bladed screwdriver to slowly turn the adjustment screw on the
set point potentiometer counter-clockwise until the red LED illuminates.
3) If the red LED is already illuminated, turn the adjustment screw on
the potentiometer clockwise until red LED turns off. Next, slowly
rotate the adjustment screw counter-clockwise until the red LED
illuminates.
4) Once the set point has been adjusted, the relay will operate as
shown in the Truth Table illustrated in Table 2 below.
n Apply the DC supply voltage directly across the sensor wires. If
the LED does illuminate, the load is either: too great of impedance or an open circuit. If the LED does not illuminate, the sensor's lead wires or circuit are defective.
6. The installation should be complete.
Installation - Electronic (0-5VDC Output Only)
1. Connect the red wire (pin 1 for units with the electronic disconnect
option) from the sensor to the positive terminal of the 12-35 VDC
power supply.
2. Connect the black wire from the transmitter (pin 2 for units with the
electronic disconnect option) to the negative terminal of the 12-35
VDC power supply.
Table 2.: Truth Table - Relay Operation
Condition
Flow rate<
set point
Flow rate >
set point
Loss of power
to sensor
Relay NC
Contact
Open Closed Illuminated Illuminated
Closed Open
Open Closed
Relay NO
Contact
Red LED Green LED
Not
Illuminated
Not
Illuminated
Illuminated
Not
Illuminated
Service and Maintenance
The sensor is designed to provide years of low maintenance service
in industrial environments. As with all mechanical rotating devices, the
bearing surfaces will wear with use. The life of the parts will depend
on factors such as cleanliness of the fluid, media, mounting orientation, temperature, fluid velocity and frequency of operation. The
FlowStat sensor was designed with simple field-replacement of the
rotating parts in mind. To inspect or replace the rotating components:
3. Connect the green wire from the transmitter (pin 3 for units with
electronic disconnect) to the (+) 0-5 VDC input of the data acquisition device. This connection may be labeled "Voltage Input" or
"Analog Input" on some devices.
4. If applicable, connect the negative side of the power supply to the
negative side of the pulse input.
5. Apply power to the system.
6. If everything is operating correctly, the green LED will illuminate
brightly and the data acquisition device should show an increase in
flow rate as fluid starts flowing through the sensor.
If data acquisition device does not show an increase in flow rate:
n check wiring terminations for good connections
n verify that the LED is illuminated
n verify that the DC supply voltage is between 12 and 35 V
DC
(8)
(5)
Page 6
Installation - Electronic (Pulse Output Only)
Flow Rate vs. Frequency Output
Standard 1/2" NPTF Units
0
10
20
30
40
50
60
0 2 4 6 8 10 12 14 16
Flow Rate (GPM)
Frequency (Hz)
Flow Rate vs. Frequency Output
Standard 3/4" & 1" NPTF Units
0
10
20
30
40
50
60
0 10 20 30 40 50 60
Flow Rate (GPM)
Frequency (Hz)
Installation - Electronic (Relay Output Only)
The FlowStat pulse output circuit is a three-wire DC-powered design that
transmits a frequency proportional to flow rate. The circuit operates on 524 VDC and will consume a maximum of 25 mA from the power supply.
1. Connect the red wire (pin 1 for units with the electronic disconnect
option) from the sensor to the positive terminal of the 5-24VDC
power supply.
2. Connect the black wire from the transmitter (pin 2 for units with the
electronic disconnect option) to the negative terminal of the 5-24
DC power supply.
V
3. Connect the green wire from the transmitter (pin 3 for units with
electronic disconnect) to the (+) pulse input of the data acquisition
device. This connection may be labeled "Pulse In" or "DC Input"
on some devices.
4. If applicable, connect the negative side of the power supply to the
negative side of the pulse input.
5. Apply power to the system.
6. If everything is operating correctly, the data acquisition device should
begin "counting" pulses when fluid starts flowing through the sensor.
If the data acquisition device is not “counting”:
n check wiring terminations for good connections
n verify correct supply voltage and current
1. Connect the red wire from the sensor to the positive terminal of the
12-35 VDC power supply.
2. Connect the black wire from the transmitter to the negative terminal
of the 12-35 VDC power supply.
3. (Versions with stainless steel sensor body only) Be sure to properly
ground the FlowStat sensor by using the ground screw shown
in Illustration 2 to connect the sensor body Earth ground.
This step may be
unnecessary if the
GROUND
SCREW
piping system that the
flow sensor is plumbed
into is already connected
to Earth ground.
4. Wire the appropriate
Illustration 2
relay contacts to the load
that is to be switched per Table 1 below.
5. If the unit is operating correctly, the green power indication LED
and the red relay status LED should illuminate after the DC supply
voltage is turned on. As fluid flow is increased above the factoryadjusted set point, the red relay status LED should turn off.
If the LEDs do not illuminate when power is applied:
n check wiring terminations for good connections
7. The installation should be complete. The relationship between the
frequency output and flow rate is shown in the graphs above.
(6)
n verify that the DC supply voltage is between 12 and 35 V
DC
Table 1.: Wiring Connections
Wire Color Connection
Red +12-35 VDC
Black DC Ground
Green Relay Common
White Relay Normally Closed Contact
Brown Relay Normally Open Contact
(7)
Loading...