McDonnell & Miller FS4-3 Series Installation and operating instructions

FLOW
• 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.
WARNINGCAUTION
!
WARNING
Series FS4-3
General Purpose
Liquid Flow Switch
®
Installation & Maintenance
Instructions MM-601(C)
OPERATION
This control is an independently mounted water flow
sensing device that makes or breaks an electrical
circuit when flow stops or starts.
Series FS4-3
(specified models only)
Now
with
Stainless Steel
Paddles

2
Maximum Liquid Pressure: 160 psi (11.3 kg/cm2)
Liquid Temperature Range (TL): 32 - 300˚F (0 - 149˚C)
Ambient Temperature Range (TS): 32 - 120˚F (0 - 49˚C)
Electrical Enclosure Rating: Nema Type 1 (IP 21)
Maximum Velocity: 10ft/sec (3M/sec)
Pipe Connection Thread Size: - 1” NPT - All models
except “J”
- 1” BSPT - “J” models
Models that meet CE Conformance:
FS4-3D-E
FS4-3J-E
FS4-3S-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 14mA and 3.7
Amps, power factors exceeding 0.65, an anticipated
system switch
operation rate of less than 5 times per
minute, 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
CE Circuit Rating
7.4 (7.4)/120~ 0.3/120=
3.7 (3.7)/240~ 0.15/240=
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

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 or if located in a vertical pipe.
3
NOTE: DO NOT USE LIQUID FLOW SWITCHES
ON SYSTEMS WITH FLOW VELOCITY
GREATERTHAN 10 FEET PER SECOND
(3 METERS PER SECOND).
Values are ± 10%
Pipe Mode of Operation
Size NPT Flow No Flow
in. (mm) Settings gpm (lpm) gpm (lpm)
Factory or
1 (25)
Minimum 6 (22.7) 3.6 (13.6) 27
Maximum 10.2 (38.6) 9.2 (34.8) (102)
Factory or
1
1⁄4
(32) Minimum 9.8 (37.1) 5.6 (21.2) 47
Maximum 16.8 (63.6) 15 (56.8) (178)
Factory or
1
1⁄2
(40) Minimum 12.7 (48.1) 7 (26.5) 63
Maximum 23 (87.1) 19.5 (73.8) (239)
Factory or
2 (50) Minimum 18.8 (71.2) 9.4 (35.6) 105
Maximum 32.8 (124.1) 24 (90.8) (398)
Factory or
2
1⁄2
(65) Minimum 24.3 (92) 11.6 (43.9) 149
Maximum 42.4 (160.5) 37.5 (141.9) (565)
Factory or
3 (80) Minimum 30 (113.6) 12 (45.4) 230
Maximum 52.1 (197.2) 46.1 (174.5) (872)
Factory or
4 (100) Minimum 39.7 (150.3) 19.8 (74.9) 397
Maximum 73.5 (278.2) 64.2 (242) (1505)
Factory or
5 (125) Minimum 58.7 (222.2) 29.3 (110.9) 654
Maximum 115 (435.3) 92 (348.2) (2479)
Factory or
6 (150) Minimum 79.2 (300) 39.6 (150) 900
Maximum 166 (628.3) 123 (465.6) (3411)
Max. Flow
Rate gpm
(lpm) w/o
Paddle Damage

4
Pipe Flow No-Flow
Size NPT Maximum Maximum
in. (mm) Adjustment Adjustment
2 (50) 69.2 50.3
3 (80) 162.5 143.5
4 (100) 276.0 241.0
5 (125) 550.0 440.0
6 (150) 977.0 728.0
Series FS4-3 “K”Factor
b. If the flow rate in the pipe exceeds the
maximum adjustment on the Flow Switch
use the following formula to change the
paddle length.
Paddle Length = K
_______________
Flow Rate (GPM)
NOTE: If trimming the paddle for a no-flow action make sure
there is enough flow to activate switch.
a. If the paddle must be trimmed, measure the paddle
from the center of the large hole (A) to the length
required. Using non-serrated tin snips, trim the end (B)
on a curve just like the paddle was originally cut.
A
BRequired
Length
STEP 1 - Paddle Sizing
1" (25mm)
2" (51mm)
3" (76mm)
6" (152mm)
Determine the correct paddle length for your installation from
the chart below.
NOTE:
•All models (except FS4-3RP) include 4 paddles.
•FS4-3RP includes 1”and 6”paddles only.
INSTALLATION –
Pipe Size Paddle Trim to Length
(Standard Length)
in. (mm) in. (mm) in. (mm)
1 (25) 1 (25) N/A
11/4(32) 2 (51) 11/4(32)
11/2(40) 2 (51) 11/2(38)
2 (50) 2 (51) 15/8(41)
21/2(65) 3 (76) 21/4(57)
3 (80) 3 (76) 25/8(67)
4 (100) 6 (152) 35/8(92)
6 (150) 6 (152) 55/8(143)
8+ (200+) 6 (152) N/A

5
STEP 2 - Determine the Location of the Flow Switch
D
FLOW
FLUID FLOW
1" PIPE
CONNECTION
5 x D
MINIMUM 5 x D MINIMUM
D= PIPE DIAMETER
a. The flow switch must be installed in the pipe using
a threaded tee connection or welded fitting of
minimum length such as a half coupling. Use a
face or hex bushing to reduce the tee outlet to 1”
(25mm) pipe thread if a reduced tee outlet thread
size fitting is not available.
•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 may be installed in a vertical
pipe if the flow is in the upward direction.
•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.
•The flow switch must be installed in the pump suction
piping when spring-loaded check valves and/or other
close coupled accessories are installed in the pump
discharge piping.
1" (25mm)
1"
(25mm)
1"
(25mm)
1" (25mm)
2"
(50mm)
11/4"
(32mm)
11/2"
(40mm)
11/4"
(32mm)
2"
(50mm)
11/2"
(40mm)
FACE OR HEX.
BUSHING
2" (50mm)
3" (80mm)
2" (50mm)
3" (80mm)
11/4" (32mm) 1
1/4" (32mm)
11/2" (40mm)11/2" (40mm)
21/2" (65mm) 21/2" (65mm)
2" (50mm)
3" (80mm)
1" MAX
(25mm)
1" (25mm)
4" (100mm)
6" (150mm)
2" (50mm)
3" (80mm)
4" (100mm)
6" (150mm)
21/2"(65mm) 21/2" (65mm)
Threaded
Pipe Threaded
Pipe Threaded
Pipe Welded
Pipe
1" MAX
(25mm)
FLOW
Paddle Arm
b. When installing in brazed/soldered copper pipe,
size the threaded adapter to ensure the paddle
arm extends into the main run of the pipe
STEP 3 - Connecting the Flow Switch to Pipe
FLOW
a. Insert the 8/32 x 1/4”flathead screw through
washer and paddle. Attach screw to opposite side
of the paddle arm’s curve and tighten to a torque
of approximately 12-16 lb•in (1.36-1.81 N•m).
CORRECT INCORRECT
FLOW

a. Cover Removal and Installation Procedure
•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).
STEP 4 - 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.
6
!
WARNING
FLOW
A
c. Insert the flow switch into the pipe tee. Turn
the flow switch two (2) or three (3) revolutions
clockwise until tight. Do not put excessive
force on cover when turning.
FLOW
d. Place a 1 3/8”open end wrench on flow switch
body to tighten to final position. Final position
is with arrow on housing aligned in the same
direction as liquid flow.
FLOW
FLOW
FLOW
Teflon®
b. Apply pipe sealing compound or Teflon tape to the
flow switch pipe threads.
NOTE: Do not apply sealant to first threads as this
switch is grounded (earthed) via the pipe mounting.

7
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.
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.
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
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.
NOTE: Repeat above to connect wires to second
switch on “D”model flow switches.
STEP 5 - Testing
Flow
Opens
Circuit
Normally
closed
3
Common
1Flow
Closes
Circuit
2(
(
Normally
open
( (
Common
( (
FS4-3 LINE
LOAD
Fig. 1
HOT
31
2FS4-3 LINE
LOAD
Fig. 2
HOT
31
2
FLOW
OPENS
CIRCUIT
FLOW
CLOSES
CIRCUITCOMMON
1
2
3
FLOW

3500 N. Spaulding Avenue
Chicago, Illinois 60618
tel: [phone]
fax: [phone]
www.mcdonnellmiller.com
©2000 ITT Industries Inc.
Printed in U.S.A. 12-00 246796
MAINTENANCE
SCHEDULE:
• Inspect paddle annually.Turbulent or high
flow velocity conditions may require more
frequent inspection and/or replacement.
• Replace paddle if damaged or showing signs
of wear.
• 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.
Check to see if paddle moves freely. Some system
piping disassembly may be required.
2. Flow Switch Operates Erratically
Solution:
a. Flow switch may be located in an area of high
turbulence causing paddles to flutter.
b. 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.
c.
Check to see if paddle moves freely. Some system
piping disassembly may be required.
3. Flow Switch Does Not Deactivate
Solution:
a.
Check to see if paddle moves freely. Some system
piping disassembly may be required.
b.
Measure flow rate and match with velocities shown
in flow rate chart. Flow switch must prove flow
before it can indicate no flow.
STEP 6 - Adjustment
Adjustment is necessary only if required flow/no-
flow setpoints are above factory set minimum.
a. Turn off power. Remove switch cover.
b. Turn the adjusting screw clockwise to
increase setpoint.
c. Place cover on the flow switch and turn on
power.
d. Test the operation of the flow switch after
each adjustment.
Single Switch Models Double Switch Models
LOW
OPENS
CIRCUIT
FLOW
CLOSES
CIRCUIT COMMON
1
2
3
COMMON
NORM
OPEN
NORM
CLOSED
FLOW
COMMON
NORM
NORM
OPENCLOSED
OR
IMPORTANT: Do not attempt to lower flow switch
setpoint from original factory minimum setting.
Lowering (turning adjusting screw counterclock-
wise) the setpoint from original factory setting
may cause erratic flow switch operation.