ONICON FB-3500 User Manual

FB-3500 BI-DIRECTIONAL ELECTROMAGNETIC FLOW METER

Installation and Operation Guide

11451 Belcher Road South, Largo, FL 33773 • USA • Tel [phone] • Fax [phone]

www.onicon.com • [e-mail]

05-140718-3 / 18611

SAFETY INFORMATION

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This meter was calibrated at the factory before shipment. To ensure correct use of the meter, please read
this manual thoroughly.

Regarding this Manual:

• This manual should be passed on to the end user.

• Before use, read this manual thoroughly to comprehend its contents.

• The contents of this manual may be changed without prior notice.

• All rights reserved. No part of this manual may be reproduced in any form without
ONICON’s written permission.

• ONICON makes no warranty of any kind with regard to this material, including, but not
limited to, implied warranties of merchantability and suitability for a particular purpose.

• All reasonable effort has been made to ensure the accuracy of the contents of this manual.
However, if any errors are found, please inform ONICON.

• ONICON assumes no responsibilities for this product except as stated in the warranty.

• If the customer or any third party is harmed by the use of this product, ONICON assumes
no responsibility for any such harm owing to any defects in the product which were not
predictable, or for any indirect damages.

Safety Precautions:

The following general safety precautions must be observed during all phases of installation,
operation, service, and repair of this product. Failure to comply with these precautions or with
specic WARNINGS given elsewhere in this manual violates safety standards of design,
manufacture, and intended use of the product. ONICON Incorporated assumes no liability for the
customer’s failure to comply with these requirements. If this product is used in a manner not
specied in this manual, the protection provided by this product may be impaired.

The following symbols are used in this manual:

WARNING

Messages identied as “Warning” contain information regarding the personal safety of
individuals involved in the installation, operation or service of this product.

CAUTION

Messages identied as “Caution” contain information regarding potential damage to the
product or other ancillary products.

IMPORTANT NOTE

Messages identied as “Important Note” contain information critical to the proper operation of
the product.

1 1451 Belcher Road South, Largo, FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
FB-3500 Bi-Directional Insertion Electromagnetic Flow Meter Manual 05/14 - 0718-3 Page 2

TABLE OF CONTENTS

1.0 INTRODUCTION .................................................................................................5

1.1 PURPOSE OF THIS GUIDE .......................................................................5

1.2 TYPICAL INSERTION ELECTROMAGNETIC FLOW METER ................5

1.3 STANDARD FEATURES AND SPECIFICATIONS ....................................6

1.4 ADDITIONAL REQUIRED HARDWARE ...................................................7

1.5 ADDITIONAL HARDWARE THAT MAY BE REQUIRED .........................8

1.5.1 Grounding Rings .......................................................................... 8

2.0 UNPACKING ...................................................................................................... 9

2.1 CHECKING THAT YOU HAVE RECEIVED EVERYTHING ......................9

3.0 INSTALLATION, REMOVAL & ADJUSTMENT ................................................10

3.1 INSTALLATION SITE SELECTION ........................................................10

3.1.1 General Site Selection Guidelines ............................................10

3.1.2 Insufcient Straight Run Site Selection Guidelines .................11

3.2 MECHANICAL INSTALLATION ............................................................. 12

3.2.1 Installation Kit ...........................................................................13

3.2.2 ONICON Standard Installation Hardware Kit ..........................13

3.2.3 ONICON Hot Tap Installation Hardware Kit ............................ 13

3.2.4 Customer Supplied Installation Hardware ............................... 14

3.2.5 Conrming the Stack Height .....................................................15

3.2.6 Installing the Flow Meter ..........................................................16

3.3 INSERTION OF THE METER ..................................................................17

3.3.1 Inserting the Flow Meter ...........................................................17

3.4 REMOVAL OF THE METER .................................................................... 18

3.5 WIRING CONNECTIONS ........................................................................20

3.5.1 Signal & Power Wiring Connections ......................................... 21

3.5.2 Earth Connections ......................................................................22

4.0 START-UP & COMMISSIONIING FOR ONICON INSERTION

ELECTROMAGNETIC FLOW METERS ............................................................. 23

4.1 HELPFUL HINTS FOR START-UP AND COMMISSIONING .................23

4.2 START-UP AND COMMISSIONING ....................................................... 24

4.3 START-UP AND COMMISSIONING WORKSHEET ............................... 25

4.4 TROUBLESHOOTING GUIDE ................................................................. 26

4.4.1 Earth Connections & Electrical Noise Reduction .....................26

APPENDIX

Conditions of Sale

1 1451 Belcher Road South, Largo, FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
FB-3500 Bi-Directional Insertion Electromagnetic Flow Meter Manual 05/14 - 0718-3 Page 3

1 1451 Belcher Road South, Largo, FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
FB-3500 Bi-Directional Insertion Electromagnetic Flow Meter Manual 05/14 - 0718-3 Page 4

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SECTION 1.0: INTRODUCTION

We, at ONICON Incorporated, would like to thank you for purchasing our quality American made
FB-3500 Bi-Directional Electromagnetic Flow Meter. As our valued customer, our commitment to you
is to provide fast reliable service, while continuing to offer you quality products to meet your growing
ow measurement needs.

1.1 PURPOSE OF THIS GUIDE

We have written this guide to provide the persons responsible for the installation, operation and
maintenance of your ow meter with the most specic equipment information they will need.
This is NOT an electrical or plumbing trade manual.

WARNING

Please do not permit persons to install, operate or maintain this equipment unless they have a
complete knowledge of their trade skills and are competent to work on high pressure hot and cold
water and steam systems, according to their individual trades. Death or permanent injury may
result from accidents with these systems.

This guide is the basic reference tool for all ONICON FB-3500 Bi-Directional Electromagnetic
Flow Meters. If you have not purchased all of the options, there will be references in this manual
which are not applicable to your meter(s).

1.2 TYPICAL INSERTION ELECTROMAGNETIC FLOW METER

Faraday’s Law of electromagnetic induction states that a voltage will be induced in a conductor
when it passes through a magnetic eld, and the induced voltage will be directly proportional to
the velocity of the conductor.

ONICON FB-3500 Bi-Directional Electromagnetic Flow Meters generate pulsating magnetic elds
that are used to induce a voltage into the conductive uid owing through the pipe. Electrodes
located on the ow meter sensor head measure the induced voltage. Circuitry within the ow
meter electronics enclosure then converts the voltage to digital and analog signals that convey
ow rate and total data via connecting the cable to any of ONICON’s display devices, Btu meters
and/or to a data acquisition system.

Typical Meter Installation

(New construction or scheduled shutdown)

Output signal(s)

to control

system

ONICON

Display or

BTU Meter

(Optional)

Allow enough slack
in the flexible conduit
to permit the meter
to be removed
from the valve.

Customer provided
conduit and adapters

Insertion depth
gage provided
with each meter

½" FNPT
conduit connection

• Install in vertical or horizontal pipe

• For horizontal pipe position meter
anywhere in upper 240˚

Standard Installation
Kit for Steel Pipe

1" Full port ball valve
1" Close nipple
1" Branch outlet

CLEARANCE

REQUIRED

FOR INSTALLATION

Typically

30" - 40"

depending on

pipe size and

height of valve

assembly.

1¼" for
hot tap

Minimum Hole Size = 1"
Must be centered

Note: Installation kits vary based on pipe material and application. For installations in pressurized (live)
systems, use "Hot tap" 1¼ inch installation kit and drill hole using a 1 inch wet tap drill.

FLOW

1 1451 Belcher Road South, Largo, FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
FB-3500 Bi-Directional Insertion Electromagnetic Flow Meter Manual 05/14 - 0718-3 Page 5

1.3 STANDARD FEATURES AND SPECIFICATIONS

Accuracy

± 1.0% of reading from 2 to 20 ft/sec
± 0.02 ft/sec below 2 ft/sec

Sensing Method

Electromagnetic, no moving parts

Pipe Size Range

3” through 72” nominal

Input Power

20 - 28 VAC 50/60 Hz, 250 mA maximum
20 - 28 VDC, 250 mA maximum

Liquid Temperature Range

15° to 250° F

Ambient Temperature Range

-5° to 150° F

Operating Pressure

400 PSI maximum

Pressure Drop

Less than 0.1 psi at 12 ft/s velocity in 3” and larger pipes

Materials of Construction

Wetted metal components - 316L stainless steel
Sensor head - Polypropylene
Electronics enclosure - Powder coat painted cast aluminum

Enclosure Rating

Weathertight, NEMA 4

Electrical Connections

10’ of PVC jacketed cable with ½” NPT conduit connection

OUTPUT SIGNALS PROVIDED
Analog Output (Isolated)

Selectable: 4-20 mA, 0-10 V or 0-5 V
Frequency Output
0 – 15 VDC, 0 – 500 Hz
Pulse/Contact Closure Outputs (four)
Isolated solid state dry contact
Contact maximum ratings: 100 mA, 50 VDC

Scalable Pulse Outputs (two)
Forward & Reverse Flow Totalization

Pulse Duration: 0.5, 1, 2 or 6 seconds
Directional Contact Output:
Switch closed when ow is in direction of ow arrow on enclosure
Latches at 0.2 ft/s
Switches within 20 seconds of direction change
Master Alarm Output:
Switch closed indicates alarm condition

This product is covered by one or more of the following patents: 6,431,011 and 6,463,807.

1 1451 Belcher Road South, Largo, FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
FB-3500 Bi-Directional Insertion Electromagnetic Flow Meter Manual 05/14 - 0718-3 Page 6

1.4 ADDITIONAL REQUIRED HARDWARE

All ONICON insertion type meters can be installed and removed via
a 1” or larger full port ball valve without system shutdown. The
terms “Standard” and “Hot Tap” refer to the installation method of
the isolation valve kit only.

Standard Installation Hardware: For new construction or
scheduled shutdown, once kit is installed, the ow meter can
be installed or removed without system shutdown.

Hot Tap Installation Hardware: For applications which require the
access hole in the pipe to be drilled through the valve using a
wet tap drilling machine while the hydronic system is
pressurized and operating.

NOTE: Installation hardware materials vary greatly based on pipe material, pipe size and
standard vs. hot tap versions.

1 1451 Belcher Road South, Largo, FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
FB-3500 Bi-Directional Insertion Electromagnetic Flow Meter Manual 05/14 - 0718-3 Page 7

1.5 ADDITIONAL HARDWARE THAT MAY BE REQUIRED

5/8

1.5.1 Grounding Rings

Grounding rings may be required whenever meters are installed in non-metallic or lined pipes.
Grounding rings placed before and after the meter eliminate electrical noise that will interfere
with the proper operation of the meter. ONICON provides grounding rings as an optional
accessory. Grounding ring dimensional information and part numbers are listed below. For proper
operation, grounding rings are required before and after the meter.

Typical Installation

Non-conductive Pipe

Gasket (4PL)

Flow Direction

DIMENSIONS

Nominal Size Bore A C D

1” 1 - 1/16 2 - 5/8 4 - 9/16 1 - 15/16

1.5” 1 – 9/16 3 – 3/8 5 - 5/16 1 - 15/16

2” 2 – 1/16 4 – 1/8 6 - 1/16 1 - 15/16

3” 3 – 1/16 5 – 3/8 7 - 5/16 1 - 15/16

4” 4 – 1/16 6 – 7/8 8 - 13/16 1 - 15/16

6” 6 8 – 3/4 10 - 11/16 1 - 15/16

8” 8 11 12 - 15/16 1 - 15/16

10” 9 – 1/2 13 – 3/8 15 - 5/8 2 - 1/4

12” 11 – 9/16 16 – 1/8 18 - 9/16 2 - 7/16

14” 13 – 1/2 17 – 3/4 20 - 3/8 2 - 5/8

16” 15 – 1/4 20 – 1/4 22 - 7/8 2 - 5/8

18” 17 – 3/8 21 – 5/8 24 - 1/4 2 - 5/8

20” 19 23 - 7/8 26 - 11/16 2 - 13/16

24” 23 28 – 1/4 31 - 1/8 2 - 7/8

30” 29 34 – 3/4 38 3 - 1/2

36” 35 41 – 1/4 45 - 1/4 4

42” 41 48 52 - 1/2 4 - 1/2

3/8

D

C

1/8”

A

Grounding Ring Dimensions

10 DIA

1/4

Bore

10 DIA

Grounding Ring (2PL)

ORDERING INFORMATION

ANSI Class 150

316 Stainless Steel

Grounding Rings (pair)

Nominal

Size

1” 19265

1½” 19266

2” 19267

3” 19268

4” 19269

6” 19270

8” 19271

10” 19272

12” 19273

14” 19274

16” 19275

18” 19276

20” 19277

24” 19278

30” 19279

36” 19280

42” 19281

ONICON Part

Number

1 1451 Belcher Road South, Largo, FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
FB-3500 Bi-Directional Insertion Electromagnetic Flow Meter Manual 05/14 - 0718-3 Page 8

SECTION 2.0: UNPACKING

ONICON insertion magnetic ow meters are packed and shipped in individual cartons. An optional
installation hardware kit INSTL 1 or INSTL 2, if ordered, will be packaged with each meter. All other
installation hardware and peripheral devices, including Btu meters and display modules, will be packaged
and shipped separately.

Please open all packages with care to prevent damage to their contents. Carefully inspect each item for
signs of damage in transit. The ow meter stem should be straight and free of blemishes or abrasions. The
sensor head should have a smooth continuous surface that is free of abrasions.

All ONICON products are shipped insured unless the customer specically requests otherwise. Please
notify the shipping company and ONICON immediately if any items are damaged in transit. Save all
packing material for inspection by the shipper.

2.1 CHECKING THAT YOU HAVE RECEIVED EVERYTHING

• Standard Documentation

Enclosed with each meter is a comprehensive documentation package that includes the
following items:

Installation and Operation Guide
Flow Meter Certicate of Calibration

Please notify the ONICON if any of these documents are missing.

FB-3500 Bi-Directional Insertion Electromagnetic Flow Meter
Optional INSTL1 or INSTL2 Installation Hardware Kit, if ordered

1 1451 Belcher Road South, Largo, FL 33773 • USA • Tel [phone] • Fax [phone] • [e-mail]
FB-3500 Bi-Directional Insertion Electromagnetic Flow Meter Manual 05/14 - 0718-3 Page 9