Onicon FB-3500 Operating instructions

11451 Belcher Road South, Largo, FL 33773 • USA • Tel [phone] • Fax [phone]
www.onicon.com • [email protected]
FB-3500 BI-DIRECTIONAL ELECTROMAGNETIC FLOW METER
Installation and Operation Guide
12-150718-5 / 18611
FLOW AND ENERGY MEASUREMENT
FB-3500
236251

11451 Belcher Road South, Largo, FL 33773 • USA • Tel [phone] • Fax [phone] • [email protected]
FB-3500 Bi-Directional Insertion Electromagnetic Flow Meter Manual 12/15 - 0718-5 Page 2
SAFETY INFORMATION
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.
i
!
!

11451 Belcher Road South, Largo, FL 33773 • USA • Tel [phone] • Fax [phone] • [email protected]
FB-3500 Bi-Directional Insertion Electromagnetic Flow Meter Manual 12/15 - 0718-5 Page 3
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

11451 Belcher Road South, Largo, FL 33773 • USA • Tel [phone] • Fax [phone] • [email protected]
FB-3500 Bi-Directional Insertion Electromagnetic Flow Meter Manual 12/15 - 0718-5 Page 4

11451 Belcher Road South, Largo, FL 33773 • USA • Tel [phone] • Fax [phone] • [email protected]
FB-3500 Bi-Directional Insertion Electromagnetic Flow Meter Manual 12/15 - 0718-5 Page 5
!
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)
½" FNPT
conduit connection
Insertion depth
gage provided
with each meter
FLOW
Customer provided
conduit and adapters
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.
Typically
30" - 40"
depending on
pipe size and
height of valve
assembly.
CLEARANCE
REQUIRED
FOR INSTALLATION
Standard Installation
Kit for Steel Pipe
1" Full port ball valve
1" Close nipple
1" Branch outlet
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.
• Install in vertical or horizontal pipe
• For horizontal pipe position meter
anywhere in upper 240˚
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.

11451 Belcher Road South, Largo, FL 33773 • USA • Tel [phone] • Fax [phone] • [email protected]
FB-3500 Bi-Directional Insertion Electromagnetic Flow Meter Manual 12/15 - 0718-5 Page 6
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.
ELECTROMAGNETIC INSERTION FLOW METER
NSF/ANSI 61 <MH60590>
ALSO CLASSIFIED
IN ACCORDANCE WITH
NSF/ANSI 372

11451 Belcher Road South, Largo, FL 33773 • USA • Tel [phone] • Fax [phone] • [email protected]
FB-3500 Bi-Directional Insertion Electromagnetic Flow Meter Manual 12/15 - 0718-5 Page 7
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.

11451 Belcher Road South, Largo, FL 33773 • USA • Tel [phone] • Fax [phone] • [email protected]
FB-3500 Bi-Directional Insertion Electromagnetic Flow Meter Manual 12/15 - 0718-5 Page 8
1.5 ADDITIONAL HARDWARE THAT MAY BE REQUIRED
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.
ORDERING INFORMATION
ANSI Class 150
316 Stainless Steel
Grounding Rings (pair)
Nominal
Size
ONICON Part
Number
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
Grounding Ring 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
D
C
3/8
5/8
Bore
A
1/4
1/8”
10 DIA
Gasket (4PL)
Grounding Ring (2PL)
Flow Direction
10 DIA
Typical Installation
Non-conductive Pipe
DIMENSIONS

11451 Belcher Road South, Largo, FL 33773 • USA • Tel [phone] • Fax [phone] • [email protected]
FB-3500 Bi-Directional Insertion Electromagnetic Flow Meter Manual 12/15 - 0718-5 Page 9
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

11451 Belcher Road South, Largo, FL 33773 • USA • Tel [phone] • Fax [phone] • [email protected]
FB-3500 Bi-Directional Insertion Electromagnetic Flow Meter Manual 12/15 - 0718-5 Page 10
SECTION 3.0: INSTALLATION, REMOVAL AND ADJUSTMENT
WARNING
Insertion ow meters may be installed in pipes which are under high pressure. Accidents with
these systems can cause serious injury or death. Only persons experienced with high pressure
systems and related knowledge in the heating, cooling and uid metering elds should attempt
to install, adjust, or remove the ow meter. Please read all instructions before attempting to
insert or remove a ow meter.
!
ONICON will be happy to assist with technical recommendations and to provide guidance by
telephone or e-mail. On-site eld engineering, installation and service is also available at additional cost.
3.1 INSTALLATION SITE SELECTION
Install the ow meter where it will be accessible for personnel to perform necessary periodic
maintenance. The clearance required for installation is typically 30”- 40” from the pipe wall to
the nearest obstruction above the valve assembly. This clearance dimension will increase with
large diameter pipes. The environment should be free of corrosive liquids/fumes, temperature
extremes and heavy vibration. The following diagrams should be used as a guide to the proper
location for installing the meter.
3.1.1 General Site Selection Guidelines
GENERAL PRACTICES:
1. For best results, install the ow meter in a straight run of pipe, free of bends, tees,
valves, transitions and obstructions.
2. Straight run recommendations vary based on the nature of the upstream obstruction.
See the table below for guidelines in determining upstream straight run
recommendations based on the nature of the obstruction. Please note that depending
upon specic location details, more or less straight run may be required to produce a
satisfactory ow prole.
For 3” and larger pipe diameters
Obstruction on either side of meter Straight run distance recommended
between meter and obstruction
Single bend preceded by ≥ 9 diameters of
straight pipe
10 Diameters
Pipe size reduction / expansion in straight
pipe run
10 Diameters
Single bend preceded by ≤ 9 diameters of
straight pipe
15 Diameters
Outowing tee / pump outow 20 Diameters
Multiple bends out of plane 30 Diameters
Inowing tee 30 Diameters
Control / modulating valve 30 Diameters

11451 Belcher Road South, Largo, FL 33773 • USA • Tel [phone] • Fax [phone] • [email protected]
FB-3500 Bi-Directional Insertion Electromagnetic Flow Meter Manual 12/15 - 0718-5 Page 11
IMPORTANT NOTE
Always use the maximum available straight run. When more than the minimum required straight
run is available, place the meter such that the excess straight run is maximized on both sides of
the meter location.
!
i
!
• Acceptable to install in vertical pipe
• Position meter anywhere in upper 240°
for horizontal pipe
CLEARANCE
REQUIRED FOR
INSTALLATION
Typically 30” - 40”
depending on pipe size
and height of valve
assembly.
50%
Upstream
50%
Downstream
3.1.2 Insufcient Straight Run Site Selection Guidelines
If there is insufcient available straight run, allow 50% of the run upstream and 50%
of the run downstream. If the total length of straight run is less than 20 diameters,
performance may degrade and consideration should be given to changing to the F-3100 or
F-3200 In-Line Electromagnetic Flow Meters.
Some installations may work better with straight run optimized for ow in one direction.
For example, with ow meters installed in the bypass line between de-coupled constant
volume primary and variable secondary loops, it may be more important to accurately
measure positive ow (from supply to return.) Negative ow measurements (from return
to supply) are generally less critical, and it may be enough just to know that any negative
ow is present. In this scenario, maximizing straight run for positive ow might be a
preferred strategy.
How To Determine The Available Straight Pipe Diameters:
For each application, locate the longest straight, unobstructed section of pipe (no bends, tees, valves,
other insertion probes, size transitions).
The longest straight pipe run in inches divided by nominal pipe size in inches equals
“diameters of straight pipe.”
For closed loop applications, consider both the supply and return lines as possible locations.

11451 Belcher Road South, Largo, FL 33773 • USA • Tel [phone] • Fax [phone] • [email protected]
FB-3500 Bi-Directional Insertion Electromagnetic Flow Meter Manual 12/15 - 0718-5 Page 12
3.2 MECHANICAL INSTALLATION
ONICON Insertion Electromagnetic Flow Meters employ a hot tap adapter design that allows for
insertion and removal, when necessary, without interrupting ow and draining the pipe. To take
advantage of this feature, the ow meter must be installed through an isolation valve. The
installation must allow for sufcient overhead clearance to fully extract the meter, and a full 1”
opening in the pipe wall is required to clear the sensor head and allow for insertion. Make sure
that your valves and ttings are full port and at least 1” in actual internal diameter.
CAUTION
ONICON insertion style ow meters must be installed through a valve assembly. Failure to do so
negates the ability to remove the meter without shutting down and draining the system. It will
also result in an excessive amount of stem protruding from the pipe. Excessive stem lengths
unneccessarily expose the meter to incidental damage.
!
IMPORTANT NOTE
Flow meters installed through oversized access holes will be subjected to undesirable turbulence
that may affect the accuracy of the meter.
!
i
!
Typically
30" - 40"
depending on
pipe size and
height of valve
assembly.
CLEARANCE
REQUIRED
FOR INSTALLATION
Minimum Hole Size = 1"
Must be centered
Standard Installation
Kit for Steel Pipe
1" Full port ball valve
1" Close nipple
1" Branch outlet
1¼" for
hot tap
NOTE: Use stainless steel or brass
close nipple only.

11451 Belcher Road South, Largo, FL 33773 • USA • Tel [phone] • Fax [phone] • [email protected]
FB-3500 Bi-Directional Insertion Electromagnetic Flow Meter Manual 12/15 - 0718-5 Page 13
3.2.2 ONICON Standard Installation Hardware Kit
Standard installation hardware kits are designed to be installed on piping systems that
are drained and at atmospheric pressure. The access hole is drilled (1” minimum) prior
to installation of the branch outlet with 1” NPT threads, close nipple and full port ball
valve. Once the isolation valve is installed, the piping system can be ushed, lled and
pressurized. The ow meter may now be inserted or removed by hand without having to
drain the system. Please read all instructions before proceeding with meter insertion.
3.2.3 ONICON Hot Tap Installation Hardware Kit
ONICON offers an alternative installation hardware kit when it is not practical to relieve
pressure and drain the system. In this case, a 1¼” branch outlet, close nipple and 1¼” full
port ball valve are installed rst. Then, a hot tap drilling apparatus is used to drill a 1”
diameter hole through the valve. This eliminates the need to shut down and drain the
pipe. Please read all instructions before proceeding with meter insertion.
3.2.1 Installation Kit
ONICON offers a wide range of installation hardware kits for commonly used pipe
materials. The kits are specically designed for ONICON ow meters, and their use is
recommended.
The use of ONICON installation hardware kits accomplishes two important objectives.
First, it ensures that the proper hardware is used. Second, it simplies order processing
by standardizing the dimensions of the installation hardware. ONICON must have an
accurate measurement of the overall height of the installation hardware as measured from
the outside wall of the pipe to the top of the valve in order to determine the correct stem
length when assembling the meter in our factory. ONICON documents refer to this
dimension as the stack height.
ONICON installation hardware kits consist of three separate component parts:
Different pipe materials require different branch outlets and may include additional
bushings to properly size the opening.
Some type of
threaded branch
outlet,
An
interconnecting
close nipple,
And a full port
isolation valve.

11451 Belcher Road South, Largo, FL 33773 • USA • Tel [phone] • Fax [phone] • [email protected]
FB-3500 Bi-Directional Insertion Electromagnetic Flow Meter Manual 12/15 - 0718-5 Page 14
!
3.2.4 Customer Supplied Installation Hardware
There are occasions where circumstances require that the customer provide the
installation hardware or that the ow meter be installed through existing hardware. In
these cases, it is important to conrm that the installation hardware is suitable for use
with the ow meter provided by ONICON before it is installed. The installation must
allow for sufcient overhead clearance to fully extract the meter and a full 1” opening in
the pipe wall is required to clear the sensor head and allow for insertion. Make sure that
your valves and ttings are full port and at least 1” in actual internal diameter.
Installation hardware generally consists of three separate component parts:
CAUTION
In order to provide the ow meter with the correct stem length, ONICON must know the
overall height of the installation hardware as measured from the outside wall of the pipe to
the top of the valve where the meter is installed.
!
CAUTION
Use stainless steel or brass nipple only.
CAUTION
Do not use threaded steel or slip PVC tees to provide the 1” opening in the pipe. Tees of this
type will cause signicant errors in the ow measurement.
!
Some type of
threaded branch
outlet,
An
interconnecting
close nipple,
And a full port
isolation valve.

11451 Belcher Road South, Largo, FL 33773 • USA • Tel [phone] • Fax [phone] • [email protected]
FB-3500 Bi-Directional Insertion Electromagnetic Flow Meter Manual 12/15 - 0718-5 Page 15
3.2.5 Conrming the Stack Height
ONICON insertion ow meter stem lengths vary according to the pipe diameter and the
height of the installation hardware stack. ONICON records the stack height dimension
provided by the customer at the time of order entry, and the information is used to size the
stem. The dimension is shown on the laminated insertion depth gage tag attached to the
meter.
Prior to installing the meter, conrm that the stack height recorded on the tag is close
to the actual stack height. Flow meter stems are intentionally over sized to allow for
variations of at least 2” in the stack height. Contact ONICON prior to installation if there is
any question regarding stack height or stem length. This way ONICON can offer you credit
for your meter if you decide to exchange the meter for one with a different stem length.
Returns may be subject to a restocking fee.

11451 Belcher Road South, Largo, FL 33773 • USA • Tel [phone] • Fax [phone] • [email protected]
FB-3500 Bi-Directional Insertion Electromagnetic Flow Meter Manual 12/15 - 0718-5 Page 16
Tools needed for standard installation:
• 1 5/16” wrench or adjustable wrench
• 5/8” wrench or small adjustable wrench
• pipe wrench (to hold valve in place)
• pipe thread sealant
CAUTION
If there are any leaks around the clamping nut or stem, DO NOT ATTEMPT TO STOP THE
LEAKAGE BY OVERTIGHTENING THE CLAMPING NUT. Damage to this nut or the clamping
ring under the nut may prevent the assembly from properly holding the meter in the pipe. The
clamping nut is not part of the sealing mechanism. Any leaks in this area indicate that the “O”
ring is not sealing properly and you must contact ONICON for assistance.
WARNING
When you are ready to rell the system, make sure that all lines are lled with water before
inserting the meter into the ow stream. If the lines are not lled and this is a hot water
system, some water may ash to steam and exceed the high temperature limit for the sensor
head assembly. This ash over could also exceed the pressure ratings of the meter and the
assembly could fail allowing steam and hot water to escape causing serious injury.
!
3.2.6 Installing the Flow Meter
Flush, ll and pressure test the piping system prior to installing the meter. Loosen
clamping nut to facilitate installation.
Clamping nut
Keep sensor
head fully
withdrawn
during
installation.
Apply paste or
Teon tape as
necessary.
Thread hot
tap adaper on
to ball valve
and tighten as
necessary.
Maintain a rm
grip on the
enclosure when
opening valve.
Crack
valve to
test for
leaks.
!

11451 Belcher Road South, Largo, FL 33773 • USA • Tel [phone] • Fax [phone] • [email protected]
FB-3500 Bi-Directional Insertion Electromagnetic Flow Meter Manual 12/15 - 0718-5 Page 17
Begin by calculating the effort that will be required to hold the meter. Establish adequate footing
for this task, taking extra caution when working from a ladder or platform. Use the following
formula:
E=0.11 x P Where: E = effort in pounds
P = system pressure in pounds per square inch
Example: In a 300 PSI system, 33 pounds of effort is required to insert the meter into the pipe.
3.3.1 Inserting the Flow Meter
WARNING
SYSTEM MAY BE UNDER HIGH PRESSURE. When adjusting the meter position or removing
it, be sure to hold the electronics enclosure rmly by hand before SLOWLY loosening the
positioning clamping nut. Failure to do this will allow the pressure to suddenly and rapidly
force the meter from the pipe causing serious injury. The meter could also be damaged or break
apart causing a break in the water seal with the resultant loss of large amounts of water. The
hand effort required to hold the meter will be 0.11 times the pipe pressure.
!
Step 2:
Slowly open the
valve to the full
open position.
Step 1:
Maintain a rm grip
on the enclosure
to counteract
the effects of the
pressure in the pipe.
Step 4:
Orient the enclosure to parallel with the pipe and
in alignment with the ow direction arrow.
Step 3:
Use the end of the depth gage to pierce any
insulation that may be present and rest the
gage on the outside wall of the pipe.
Step 6:
Carefully tighten
the clamping
nut. DO NOT
OVERTIGHTEN.
Step 5:
Slowly push down on
the ow meter until
the bottom of the
enclosure rests on the
top of the depth gage.
3.3 INSERTION OF THE METER

11451 Belcher Road South, Largo, FL 33773 • USA • Tel [phone] • Fax [phone] • [email protected]
FB-3500 Bi-Directional Insertion Electromagnetic Flow Meter Manual 12/15 - 0718-5 Page 18
WARNING
SYSTEM MAY BE UNDER HIGH PRESSURE. When removing the ow meter, be sure to hold
the electronics enclosure rmly by hand before slowly loosening the positioning clamping
nut. Failure to do this will allow the pressure in the pipe to suddenly and rapidly force the
meter from the pipe causing serious injury. The meter could also be damaged or break apart
causing a break in the water seal with the resultant loss of large amounts of water. The hand
effort required to hold the meter will be 0.11 times the pipe pressure.
!
Step 1:
Slowly loosen the position
clamping nut while
maintaining a rm grip on the
enclosure to counteract the
effect of pressure in the pipe.
Step 2:
Carefully withdraw the
ow meter stem from
the pipe until the sensor
head is fully inside the
hot tap adapter.
3.4 REMOVAL OF THE METER

11451 Belcher Road South, Largo, FL 33773 • USA • Tel [phone] • Fax [phone] • [email protected]
FB-3500 Bi-Directional Insertion Electromagnetic Flow Meter Manual 12/15 - 0718-5 Page 19
WARNING
In hot water systems, even a small amount of water can cause serious personal injury. Use extra
caution when working with hot water meters.
!
CAUTION
The main cause of damage to meters comes from accidentally closing the valve on the sensor
head. To avoid this, gently rotate the meter by twisting the electronics enclosure back and forth
(twist the stem, do not bend it) while you slowly close the valve. If the valve touches any part of
the meter, you will feel it as you are twisting the meter. If the valve touches anything, it means
the meter is not fully withdrawn. Usually a gentle twisting motion while withdrawing the meter
will clear any obstruction and permit the meter to withdraw completely. (Excessive build-up on
the stem may require the hot tap “O” ring to be lubricated with silicone.)
!
Step 4:
After the valve is completely closed,
unscrew the hot tap adapter from the
valve. For hot water meters, partially
unscrew the adapter to vent pressure
before fully removing the meter.
NOTE:
The hot tap adapter will contain
a small amount of water.
Step 3:
After the meter is completely
withdrawn, slowly close the
valve to isolate ow.

11451 Belcher Road South, Largo, FL 33773 • USA • Tel [phone] • Fax [phone] • [email protected]
FB-3500 Bi-Directional Insertion Electromagnetic Flow Meter Manual 12/15 - 0718-5 Page 20
3.5 WIRING CONNECTIONS
Make all connections to the attached 10ft cable.
The most common causes of electronic failures are miswired connections during installation.
When adding additional cable, record and carefully document any substitution of wire colors.
Additional cable may be purchased from ONICON that will allow you to maintain the existing
color coding.
All electrical connections to the FB-3500 must be made through the 10ft cable provided with the
meter. This cable is not designed to be removed in the eld, and any attempt to do so will
compromise the weather tight integrity of the enclosure.
The cable provided contains 22 AWG color-coded wires for signal and power and a separate
18 AWG green/yellow earth wire.
Special care is required to ensure that the FB-3500 is connected to earth through the green/yellow
earth wire. This connection is required to prevent random electrical noise from interfering with
the operation of the meter. (See section 3.5.2 for details.)
CAUTION
Do not attempt to remove the existing cable or to remove the factory installed connection tting.
Doing so will compromise the weather tight integrity of the enclosure and may void the warranty.
CAUTION
Only qualied personnel should attempt to make electrical connections to the FB-3500. Failure
to properly connect the FB-3500 power, signal or earth connections may result in damage to the
FB-3500 and/or to associated peripheral equipment.
!
!