ITT McDonnell & Miller FS-6 Series Installation and operating instructions

®
Series FS6
Flow Switch
Series FS-6
Series FS6-W
• Before using product, read and understand instructions.
• Save these instructions for future reference.
• All work must be performed by qualified personnel trained in the proper application,
installation, and maintenance of plumbing, steam and electrical equipment and/or systems in
accordance with all applicable codes and ordinances.
• To prevent electrical shock, turn off the electrical power before making electrical
connections.
• To prevent an electrical fire or equipment damage, electrical wiring insulation must have a
rating of 167˚F (75˚C) if the liquid’s temperature exceeds 180˚F (82˚C).
• To prevent electrocution, when the electrical power is connected to the flow switch, do not
touch the terminals.
• Make sure flow switch electrical cover is secured before turning on electric power.
Failure to follow this warning could cause property damage, personal injury or death.
WARNING CAUTION
!
WARNING
OPERATION
This control is an independently mounted water flow
sensing device that makes or breaks an electrical
circuit when flow stops or starts.
(specified models only)
McDonnell & Miller
Installation & Maintenance
Instructions
MM-619(C)

2
Maximum Liquid Pressure: 100 psi (7 kg/cm2)
Liquid Temperature Range (TL): 32 - 225˚F (0 - 107˚C)
Ambient Temperature Range (TS): 32 - 120˚F (0 - 49˚C)
Electrical Enclosure Rating: Nema Type 1 (IP 21)
(All models except “W”)
Nema Type 4X (IP 56) (“W” models)
Maximum Velocity: 10ft/sec (3M/sec)
Pipe Connection Thread Size: 3/4” or 1” NPT
(All models except “J”)
3/4” or 1” BSPT
(“J” models)
Models that meet CE Conformance:
FS6-J-3/4-E
FS6-J-1-E
FS6-WJ-3/4-E
FS6-WJ-1-E
• This Control: is for continuous operations
is not electronic
has Type 1C action (micro interruption
on operation)
• LVD 73/23/EEC
• EMC 89/33/EEC
For applications with loads between 38mA and 3.7
Amps, power factors exceeding 0.65, an anticipated
system
switch operation rate of less than once per 2.5
minutes, and any one cycle greater than 3 seconds
on and 3 seconds off.
Additional suppression may be required for applica-
tions outside these ranges.
• Declaration of Conformity
Available on request.
SPECIFICATIONS
Motor Switch Rating (Amperes)
Voltage Full Load Locked Rotor Pilot Duty
120 VAC 7.4 44.4 125 VA at
240 VAC 3.7 22.2 120 or 240 VAC
50 or 60 cycles
ELECTRICAL RATINGS
CE Circuit Rating
7.4 (7.4)/120~ 0.3/120=
3.7 (3.7)/240~ 0.15/240=

Pipe Mode of Operation
Size NPT Flow No Flow
in. (mm) Settings gpm (lpm) gpm (lpm)
3⁄4
(20) Factory or
or Minimum .12 (.45) .06 (.23)
1 (25) Maximum 2.5 (9.46) 1.5 (5.68)
FLOW RATES
Flow rates required to activate flow switch are shown
in chart below. The values are calculated for sensing
water (potable, non-polluted) in a horizontal pipe.
Settings will vary when used to sense flow of other
fluids.
3
NOTE: DO NOT USE LIQUID FLOW
SWITCHES ON SYSTEMS WITH
FLOW VELOCITY GREATER THAN
10 FEET (3M) PER SECOND.
Flow Rates
Values are ± 10%
Max. Flow
Rate gpm (lpm)
w/o Paddle
Damage
INSTALLATION –
STEP 1 - Determine the Location of the Flow Switch
5 x D
MINIMUM
5 x D
MINIMUM
D= PIPE DIAMETER
3/4" or 1" PIPE
D
• The flow switch should be located in a horizontal
section of pipe where there is a straight horizontal
run of at least 5 pipe diameters on each side of the
flow switch.
• The flow switch
must be installed in the upright
position as shown with arrow mark on side of casting
in the same direction as fluid will flow.
• Some system conditions that require more than 5
pipe diameters are high viscosity fluid and high fluid
velocity.
70 (265)
GPM CAPACITY
FS6 SERIES PRESSURE DROP
90
80
70
60
50
40
30
20
10
DIFFERENTIAL PRESSURE
10 20 30 40 50 60 70
FS6 VELOCITIES IN FPS
40
30
20
10
VELOCITY IN FEET PER SECOND
GPM CAPACITY
10 20 30 40 50 60 70
FS6-
3
/
4
"PIPE
FS6-1" PIPE

4
STEP 2 - Connecting the Flow Switch to Pipe
b. Insert pipe threads into flow switch and turn 2
or 3 times until tight.
• Place one pipe wrench on hex fitting of flow
switch and one wrench on connecting piping.
Tighten to following torque values.
- 47 ft•lb (64 N•m) for 3/4” pipe
- 63 ft•lb (85 N•m) for 1” pipe
• Repeat to connect pipe to opposite side of
flow switch.
a. Apply pipe sealing compound or Teflon®tape to the
pipe threads.
NOTE: Do not apply sealant to first threads as this
switch is grounded (earthed) via the pipe mounting.

5
A
a. Cover Removal and Installation Procedure
For FS6 models with NEMA 1 Enclosure
• Using a flathead screwdriver, loosen but do not
remove the two cover screws and remove the cover
(A).
• Place the cover on the flow switch sliding the slots
behind the two loose cover screws. Push the cover
down into the flow switch and using a flat blade
screwdriver, tighten the cover screws to a torque of
10 lb•in (1.13 N•m).
For FS6-W models with NEMA 4X Enclosure
• Using flathead screwdriver, unscrew the six cover
screws and remove cover.
• Place the electrical connection cover on the flow
switch and insert the six cover screws. Tighten the
screws to a torque of 10 lb•in (1.13 N•m).
STEP 3 - Electrical Installation
• To prevent electrical shock, turn off the electrical power before making electrical connections.
• To prevent an electrical fire or equipment damage, electrical wiring insulation must have a rating of
167˚F (75˚C) if the liquid’s temperature exceeds 180˚F (82˚C).
• To prevent electrocution, when the electrical power is connected to the flow switch, do not touch the
terminals.
• Make sure flow switch electrical cover is secured before turning on electric power.
Failure to follow this warning could cause property damage, personal injury or death.
!
WARNING
b. Electrical Conduit Connection
• Connect electric conduit to flow switch electrical enclosure.
• Follow accepted electrical practices when installing fittings
and making connections.
• Refer to and follow local codes and standards when
selecting the types of electrical fittings and conduit to
connect to flow switch.

6
d. Based upon the mode of operation (“Flow” or “No-
Flow”) required, complete the appropriate steps to
connect wires to flow switch. Use a Phillip’s head
screwdriver to loosen and tighten switch terminal
screws when attaching wires.
For “Flow” Mode of Operation (Fig. 1)
If the flow switch will be used to actuate a signal,
alarm or other device when
flow occurs, connect
the wire from that device to the “N.O.” contact.
Connect the “Hot” power supply wire to “C” terminal.
For “No Flow” Mode of Operation (Fig. 2)
If the flow switch will be used to actuate a signal,
alarm or other device when
no flow occurs, connect
the wire from that device to the “N.C.” contact.
Connect the “Hot” power supply wire to “C” terminal.
Flow
Opens
Circuit
Normally
closed
3
Common
1
Flow
Closes
Circuit
2
( (
Normally
open
( (
Common
( (
FS4-3 LINE
LOAD
Fig. 1
HOT
31
2
FS4-3 LINE
LOAD
Fig. 2
HOT
31
2
C. N.O.
FLOW
N.C. C. N.O.
NO FLOW
N.C.
c. Determine which switch action is required for the
flow switch.
• “Flow” means that the switch will close circuit
C.-N.O. and open circuit C.-N.C. when flow rate
is increased above setpoint of flow switch.
• “No Flow” means that the switch will open circuit
C.-N.O. and close circuit C.-N.C. when flow rate
is decreased below setpoint of flow switch.

7
a. Place cover on flow switch and turn on power. Initiate
fluid flow through the system. Observe the device being
activated by the flow switch to determine if device is
operating as required.
b. Turn off fluid flow to determine if device is operating
as required.
c. Repeat initiating and turning off fluid flow several times to
test flow switch and device for proper operation.
- If operating as required, put system into service.
- If not operating as required, flow switch may need
to be adjusted.
OFF
ON
STEP 4 - Testing
STEP 5 - Adjustment
FLOW Adjustment
Lever Screw
Flow
No Flow
0.12
0.06
Flow
No Flow
The Flow Rates Shown
Are Averages, May
Vary –10%
2.5
1.5
MAXIMUM
ADJUSTMENT
MINIMUM
ADJUSTMENT
Adjustment is necessary only if required flow/no
flow setpoints are above factory set minimum.
a. Turn off power.
b. Locate adjustment lever on bottom of unit.
Note that lever will be perpendicular to flow
switch body.
c. Loosen adjustment lever screw but DO NOT
REMOVE.
d. Turn adjustment lever counter-clockwise to
increase setpoint. Maximum setting is with
adjustment lever parallel with flow switch body.
e. Tighten adjustment lever screw.
f. Turn on power.
g. Test the operation of the flow switch after
each adjustment.
ADJUSTMENT DATA
(All flow rates given in GPM - gallons per minute)

MAINTENANCE
SCHEDULE:
• Inspect and clean annually. Turbulent or high
flow velocity conditions may require more
frequent inspection and/or replacement.
• Replace flow switch every 5 years or 100,000
cycles, whichever occurs first.
TROUBLESHOOTING
Problem:
1. Flow Switch Does Not Operate
Solution:
a. Make sure power has been turned on to device
and flow switch.
b. Verify that flow rate is high enough for flow switch
to activate. Measure flow rate and match with
velocities shown in flow rate chart.
c. Flow switch may be located to sense flow in
polluted (scale, rust, sludge, etc.) water. Relocate
switch to a pipe that senses flow of non-polluted
water.
2. Flow Switch Operates Erratically
Solution:
a. Adjustment screw may have been turned below
original factory setpoint. Verify that flow rate is high
enough for flow switch to activate. Measure flow
rate and match with velocities shown in flow rate
chart.
b. Flow switch may be located to sense flow in
polluted (scale, rust, sludge, etc.) water. Relocate
switch to a pipe that senses flow of non-polluted
water.
3. Flow Switch Does Not Deactivate
Solution:
a.
Measure flow rate and match with velocities shown
in flow rate chart. Flow switch must prove flow
before it can indicate no flow.
b. Flow switch may be located to sense flow in
polluted (scale, rust, sludge, etc.) water. Relocate
switch to a pipe that senses flow of non-polluted
water.
ITT
8200 N. Austin Ave.
Morton Grove, IL 60053
tel: [phone]
fax: [phone]
www.mcdonnellmiller.com
McDonnell & Miller
©2007 ITT Corporation
Printed in U.S.A. 3-07 210413