Johnson Controls F61 series User manual

Installation Instructions F61
Issue Date July 30, 2002
©2002 Johnson Controls, Inc. 1
Part No. 24-7664-2330, Rev. C www.johnsoncontrols.com
F61 Series Sensitive Flow Switches
Installation
IMPORTANT: All F61 Series Flow Switches are
intended to control equipment under normal
operating conditions. Where failure or malfunction of
an F61 Flow Switch could lead to an abnormal
operating condition that could cause personal injury
or damage to the equipment or other property, other
devices (limit or safety controls) or systems (alarm or
supervisory) intended to warn of, or protect against,
failure or malfunction of the F61 Flow Switch must
be incorporated into and maintained as part of the
control system.
F61 Series Sensitive Flow Switches do not require
adjustment prior to mounting the flow switch. See
Mounting and Wiring for further information.
Mounting
!
CAUTION: Risk of Equipment Damage.
To avoid damaging the switch, do not tighten the
switch to the tee by grasping the switch enclosure.
Use only the wrench flats provided.
Mount the F61 Series Flow Switches using the
following guidelines:
•Install the switch so that the cover and interior are
accessible.
•Mount the switch so that the flow of fluid is in the
direction of the arrow on the switch casing.
•Use a pipe union on each side of the flow switch to
allow easy removal or replacement.
•Mount the switch so that the pipe does not extend
too far into the flow switch casing.
•Use pipe thread sealer on male threads only.
•Do not remove the cover gasket or the wire
grommet from the conduit opening.
Mount the flow switch so the terminals or wire leads
are easily accessible for wiring. The arrow on the side
of the case must point in the direction of the flow.
Location Considerations
Mount the F61 flow switch in a horizontal pipeline or a
vertical pipeline with upward fluid flow. Do not use in a
vertical pipeline with downward flow. When mounted in
a vertical pipe with upward flow, the switch trips at a
slightly higher flow than shown in Table 2, due to the
effect of gravity on the switch mechanism.
Mount the F61 flow switch in a section of pipe where
there is a straight run of at least five pipe diameters on
each side of the flow switch from the nearest elbow,
valve, or other pipe restriction. See Figure 1.
Dimension must be at least
five pipe diameters from the nearest
elbow, valve, or other pipe restriction.
A
AA
Tee or Welded
Half-coupling
Figure 1: Required Piping Distance
Do not subject the flow switches to water hammer.
Use a suitable water hammer arrester if a fast-closing
valve is located downstream of the flow switch. See
Figure 2.
Flow
Switch
Water
Hammer
Arrester
Valve
Flow
Figure 2: Water Hammer Arrester Location
Schematic

2F61 Series Sensitive Flow Switches Installation Instructions
Dimensions
4
(102) 2
(51)
2-5/16
(59)
1-3/16
(30)
2-3/4
(71)
1-3/8
(35)
1-1/2
38 Hex,
Both
Ends
7/8
(22)
1-3/4
(44)
1-1/2
(38)
2-3/8
(60)
1/2 in.-14 Dryseal Thread
OR
3/4 in.-14 Dryseal Thread
As Specified (Both Ends)
1-3/4
(44)
2-11/16
(68)
Grounding
Screw
Hole
7/8
(22) Diameter Hole for
1/2 in. Trade Size
Conduit
Diameter Knockout
Ring for 3/4 in.
Trade Size
Conduit
1-1/8
29
Figure 3: NEMA 1 Enclosure (F61KD Type) Dimensions, in./mm
3-11/16
(94)
1-1/8
(29)
1-13/16
(47)
2-5/16
(59)
1-3/16
(30)
2-3/4
(71)
1-3/8
(35)
1/2 in.-14 NPSM
Thread
on MD Models
2-7/8
(73)
1-9/16
(40)
1-1/2
(38)
2-3/8
(60)
1/2 in.-14 Dryseal Thread
OR
3/4 in.-14 Dryseal Thread
As Specified (Both Ends)
7/8
(22)
1-3/4
(44)
1-1/2
(38) Hex,
Both
Ends
Figure 4: NEMA 3 or NEMA 3R Enclosure (F61MD Type) Dimensions, in./mm

F61 Series Sensitive Flow Switches Installation Instructions 3
Wiring
!
WARNING: Risk of Electrical Shock.
Disconnect power supply before making electrical
connections. Failure to follow this precaution may
result in electrical shock or death
!
CAUTION: Risk of Equipment Damage.
Using terminal screws other than those provided will
void the warranty and may damage the switch. Use
only the terminal screws furnished.
IMPORTANT: To prevent moisture from entering
and condensate forming inside the NEMA 3R
enclosure, do not remove the cover gasket or the
wire grommet from the conduit opening.
IMPORTANT: Install all wiring in accordance with
the National Electrical Code and local regulations.
Make all wiring connections using copper conductors
only. Do not exceed the control’s electrical rating.
The F61KD type has three color-coded terminals. Red
is common. See Table 1 and Figure 5 for switch
action. The F61MD type has four color-coded wire
leads. Red is common, green is ground. See Table 1.
Table 1: Switch Action
Flow Action Switch Closure
Increase Red to Yellow
Decrease Red to Blue
Red
Ye ll ow
Blue
Decrease in Flow
Above Setpoint
Increase in Flow
Above Setpoint
Figure 5: Switch Action
Setup and Adjustments
!
WARNING: Risk of Electrical Shock.
Disconnect power supply before making electrical
connections. Failure to follow this precaution may
result in electrical shock or death.
!
CAUTION: Risk of Improper Operation.
The switch is factory set at approximately the
minimum flow rate (see Table 2). Do not set lower
than the factory setting as this may result in the
switch failing to return to a no flow position.
!
CAUTION: Risk of Equipment Damage.
Sealed settings (screws marked with black paint) are
not intended to be changed. Adjustment attempts
may damage the control or cause loss of calibration,
voiding the warranty.
To adjust the setting of the flow switch:
1. Disconnect power supply before making electrical
connections.
2. Remove the F61 flow switch cover.
3. Turn the adjusting screw clockwise to raise the
flow rate. Turn the adjusting screw
counterclockwise to lower the flow rate. See
Figure 6.
4. Replace the cover after completing adjustments.
Tighten the cover screws to 12 in⋅lbs of torque.
Note: Do not lower the flow rate unless it has been
raised from the factory setting.
Red
Ye ll ow
Blue
Adjusting Screw
Higher Flow Rates
More liquid flow
required to switch
from R-Y to R-B.
Lower Flow Rates
Less liquid flow
required to switch
from R-Y to R-B.
Figure 6: Flow Rate Adjustment

4F61 Series Sensitive Flow Switches Installation Instructions
To verify that the flow rate is set above the factory
minimum (see Figure 7):
1. depress the main lever numerous times. If the
lever fails to click upon return at any time, the flow
rate is set below the factory-set minimum.
2. raise the flow rate to approximately the factory
minimum by turning the adjusting screw clockwise
until the lever clicks upon return every time.
Adjusting
Screw
Main
Lever
Figure 7: Minimum Adjustment
Typical Flow Rates for Sensitive F61 Flow Switches
Table 2: Sensitive F61 Flow Switches
GPM (L/Min) Required to Actuate Switch
Pipe Size (in.) 1/2 in. x 1/2 in. Female NPTF1
3/4 in. x 3/4 in. Female NPTF2
3/4 in. x 3/4 in. Female NPTF3
Flow Increase (R to Y Closes) 0.60 (2.27) 8.50 (32.2)
Minimum
Adjustment Flow Decrease (R to B Closes) 0.30 (1.14) 4.50 (17.1)
Flow Increase (R to Y Closes) 1.10 (4.17) 9.00 (34.1)
Maximum
Adjustment Flow Decrease (R to B Closes) 0.90 (3.41) 6.30 (23.9)
1. F61KD-3C, F61MD-1C
2. F61KD-4C, F61MD-2C
3. F61KD-8C (designed for steam applications)
07.6
15.1 22.7 30.3 37.9 45.4 53.0 60.6 68.1 75.7 83.3 90.9 98.4 106
Flow Rate
(L/Min)
0
2
4
6
8
10
12
14
16
18
20 137.9
124.1
110.3
96.5
82.7
69.0
55.2
41.4
27.6
13.8
0
02
46 8 10 12 14 16 18 20 22 24 26 28
Flow Rate
GPM
Pressure
Drop
PSI
Pressure
Drop
kPa
1/2 in. Pipe Size 3/4 in. Pipe Size
Figure 8: Pressure Drop versus Flow Rate, F61 Sensitive Flow Switches

F61 Series Sensitive Flow Switches Installation Instructions 5
Checkout
IMPORTANT: Ensure installation, wiring and control
settings are according to the application
requirements. Refer to the controlled system’s
manufacturer specifications for the proper settings
when adjusting these controls.
Apply power to the control and controlled equipment.
Cycle the controlled system at least three times at
normal operating conditions.
The circuit between the red and the yellow leads
(terminals) closes when sufficient fluid flows through
the pipe to trip the F61 flow switch.
Repairs and Replacement
Field repairs, except for replacement of the cover and
paddles, must not be made. For a replacement flow
switch, paddle kit, or cover, contact the nearest
Johnson Controls/PENN™ distributor. For more
information, contact Refrigeration Application
Engineering at 1-800-275-5676.
Troubleshooting
Table 3: Troubleshooting
Symptom/Problem Solution
Water (condensate) is within the enclosure. Use a model with a NEMA 3R enclosure. If using a model with
a NEMA 3R enclosure, inspect the grommet in the conduit
fitting. Replace the control if the grommet is defective.
Fluid from the tank is leaking into enclosure due to
bellows failure.
Replace the flow switch.
Switch will not activate due to debris caught within
the switch mechanism.
Clear any debris within the switch mechanism. Test the
operation of the switch several times for proper operation.
Control switch action is reversed. Ensure connections follow wiring diagrams.
Control does not switch. Check connections.
Switch fails to return to the no flow position. Switch is set lower than the factory setting. Increase the setting.
On vertical pipes, ensure that the direction of flow is up. The
arrow on the switch must point in the direction of flow (up).
Control does not switch on flow increase. Check for a cracked/broken paddle. Replace the control if the
paddle is cracked or broken.
Electrical Ratings
Table 4: Electrical Ratings for KD and MD Models
Electrical Ratings 120V 208V 240V 277V
Horsepower 11 1 —
AC Full Load Amperes 16.0 8.8 8.0 —
AC Locked Rotor Amperes 96.0 52.8 48.0 —
Non-Inductive or Resistance Load Amperes 16 16 16 16
Pilot Duty 125 VA, 24 to 277 VAC

6F61 Series Sensitive Flow Switches Installation Instructions
Technical Specifications
Product F61 Series Sensitive Flow Switches
Maximum Fluid Pressure 150 psig (1034 kPa)
Minimum Fluid
Temperature
32°F (0°C) (F61KD)
-20°F (-29°C) (F61MD)
Maximum Fluid
Temperature 250°F (121°C)
Switch Single Pole Double Throw
Wiring Connections Screw Type Terminals (F61KD)
Four Color-coded No. 14 AWG Solid Conductor Wire Leads, 7 in. (178 mm) Long (F61MD)
Pipe Connector See Figure 3 and Figure 4.
Conduit Connection
One 7/8 in. (22 mm) Hole for 1/2 in. Conduit with 1-1/8 in. (29 mm) Knockout Ring for
3/4 in. Conduit (F61KD)
Female Hub for 1/2 in. Conduit, 1/2-14 NPSM Threads (F61MD)
Agency Listings
UL Listed E5368, CCN NMFT
CSA Certified LR948, Class 3211 06, Class 4813 02, Class 1222 01 (F61KD)
LR948, Class 3211 06 [F61MD]
Shipping Weight 2.8 lb (1.3 kg)
The performance specifications are nominal and conform to acceptable industry standards. For application at conditions beyond these
specifications, consult Johnson Controls/Penn Application Engineering at 1-800-275-5676. Johnson Controls, Inc. shall not be liable for
damages resulting from misapplication or misuse of its products.
Refer to the F61 Series Flow Switches Product/Technical Bulletin (LIT-125225) for necessary information on operating and performance
specifications of this product.
Controls Group
507 E. Michigan Street
P.O. Box 423 Printed in U.S.A.
Milwaukee, WI 53201 www.johnsoncontrols.com