Onicon FT-4600 Operating instructions

ON I CON
Flow and Ener
gy
Measurement
FT-4600
FT-4600
INLINE ULTRASONIC FLOW METER
INLINE ULTRASONIC FLOW METER
Installation and Operation Guide
Installation and Operation Guide
DOC-0005361 Rev.A

FT-4600 INLINE ULTRASONIC FLOW METER
ONICON Incorporated 727.447.6140 Page 2 onicon.com
SAFETY INFORMATION
The FT-4600 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 Incorporated’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 Incorporated.
• 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 specific WARNINGS given elsewhere in this manual
violates safety standards of design, manufacture, and intended use of the product. ONICON assumes no liability for the
customer’s failure to comply with these requirements. If this product is used in a manner not specified in this manual, the
protection provided by this product may be impaired.
The following messages are used in this manual:
WARNING
Messages identified as “WARNING” contain information regarding the personal safety of individuals involved in
the installation, operation or service of this product.
CAUTION
Messages identified as “CAUTION” contain information regarding potential damage to the product or other
ancillary products.
IMPORTANT NOTE
Messages identified as “IMPORTANT NOTE” contain information critical to the proper operation of the product.

FT-4600 INLINE ULTRASONIC FLOW METER
ONICON Incorporated 727.447.6140 Page 3 onicon.com
TABLE OF CONTENTS
SECTION 1.0 GENERAL INFORMATION ................................................................................................................. 4
1.1 PURPOSE OF THIS MANUAL......................................................................................................................................................4
1.2 TYPICAL FT-4600 FLOW METER................................................................................................................................................4
1.3 STANDARD FEATURES AND SPECIFICATIONS..................................................................................................................4
1.4 WORKING ENVIRONMENT.........................................................................................................................................................6
1.5 SERIAL NUMBER ..............................................................................................................................................................................6
SECTION 2.0 UNPACKING ....................................................................................................................................... 6
2.1 CHECKING THAT YOU HAVE RECEIVED EVERYTHING ..................................................................................................6
SECTION 3.0 INSTALLATION.................................................................................................................................... 7
3.1 SITE SELECTION ...............................................................................................................................................................................7
3.2 INSTALLING THE FLOW METER ................................................................................................................................................8
3.3 POWER & SIGNAL WIRING CONNECTIONS ...................................................................................................................13
SECTION 4.0 INSTALLATION.................................................................................................................................. 14
4.1 FLOW SIMULATION.....................................................................................................................................................................14
4.2 LED STATUS .....................................................................................................................................................................................14

FT-4600 INLINE ULTRASONIC FLOW METER
ONICON Incorporated 727.447.6140 Page 4 onicon.com
SECTION 1.0 GENERAL INFORMATION
1.1 PURPOSE OF THIS MANUAL
1.2 TYPICAL FT-4600 FLOW METER
We at ONICON Incorporated would like to thank you for purchasing our quality American made FT-4600 Inline Ultrasonic
Flow Meter. As our valued customer, our commitment to you is to provide fast reliable service, while continuing to offer
quality products to meet your growing flow measurement needs.
The purpose of this guide is to provide installation and commissioning procedures and basic operating and servicing
instructions for the blink version of the ONICON FT-4600 Flow Meter.
CAUTION
Only qualified service personnel should attempt to install or service this product. The improper installation or use
of this product may result in a loss of integrity in the piping system.
The FT-4600 Inline Flow Meter utilizes direct path wetted ultrasonic tranducers for measuring the volumetric flow of
liquids in a wide variety of applications.
1.3 STANDARD FEATURES AND SPECIFICATIONS
• 4-20 mA output for flow rate
• Scaled pulse output for totalization
• All weather NEMA4 enclosure
• ANSI/NSF 61 & 372 compliant
• LED alarm for meter diagnostics
• FCC: Part 15, Subpart B compliant
• EN 61326-1:203, EN 55011:2009 compliant

FT-4600 INLINE ULTRASONIC FLOW METER
ONICON Incorporated 727.447.6140 Page 5 onicon.com
*SPECIFICATIONS subject to change without notice.
1.3 STANDARD FEATURES AND SPECIFICATIONS (CONTINUTED)*
Meter Size Process
Connection Type
Typical Design
Flow
1% of Rate
Flow Range
2% of Rate
Flow Range
Minimum
Flow Cv
(Nominal) (Nominal) (gpm) (gpm) (gpm) (gpm) (gpm)
½” Male NPT 6.6 0.6 – 15 0.15 – 0.6 0.03 6.08
¾” Male NPT 6.6 0.6 – 15 0.15 – 0.6 0.03 6.08
¾” (high flow) Male NPT 11 1 – 25 0.25 – 1 0.05 8.81
1” Male NPT 11 1 – 25 0.25 – 1 0.05 8.81
1” (high flow) Male NPT 15.4 1.4 – 35 0.35 – 1.4 0.07 12.17
1¼" Male NPT 26.4 3 – 60 0.6 – 3 0.12 36.95
1½” Male NPT 44 5 – 100 1 – 5 0.2 51.20
2” Male NPT 66 8 – 150 1.5 – 8 0.3 101.2
2½” Class 150 Flange 110 12 - 225 2.5 - 12 0.5 156.2
ACCURACY ±1% of reading over 25:1 turndown
±2% of reading over 100:1 turndown
Repeatability: ≤± 0.2%
OVERALL FLOW RANGE 500:1 turndown
SENSING METHOD Direct beam path wetted ultrasonic sensors utilizing differential transit time velocity
measurement
METER SIZES ½ - 2½” nominal diameter
ELECTRONIC ENCLOSURE Polycarbonate NEMA4
FLOW BODY AND SENSOR MATERIAL Lead-free brass flow body, (PPS) with 40% glass-reinforced transducer
PIPING SYSTEM CONNECTIONS Male NPT threads
2½” meter provided with ANSI Class 150 raised face flanges
TEMPERATURE SENSORS 2-wire 1000Ωplatinum RTD
FLUID TEMPERATURE RANGE 0°F to 250°F
AMBIENT TEMPERATURE RANGE -13°F to 131°F
MAXIMUM OPERATING PRESSURE 400 psi
PRESSURE DROP Less than 1 psi at 4 ft/s, decreasing at lower velocities
POWER SUPPLY REQUIREMENTS 20-28V AC/DC; 50/60 Hz, 5 VA maximum
ANALOG OUTPUT Configurable as 4-20mA (non-isolated)
Optional 0-5 V or 0-10 V output
ISOLATED TOTALIZING SOLID STATE
CONTACT CLOSURE PULSE OUTPUTS
Contact ratings: 50mA, 30 VDC maximum
Contact Pulse duration: 1000 ms

FT-4600 INLINE ULTRASONIC FLOW METER
ONICON Incorporated 727.447.6140 Page 6 onicon.com
1.4 WORKING ENVIRONMENT
The on-display version of the FT-4600 was designed for indoor or outdoor installation and use in residential, commercial
and light industrial environments that are free of corrosive liquids and fumes, temperature extremes and excess vibration.
Avoid installing the meter in direct sunlight.
The operating ambient air temperature range is -13°F to 131°F. Electrical power should be relatively clean, free of excess
high frequency noise and large voltage transients.
1.5 SERIAL NUMBER
The serial number of your FT-4600 is located on the side of the enclosure. The serial number is a unique identifier for the
product. Please have this number available when contacting ONICON for assistance.
SECTION 2.0 UNPACKING
2.1 CHECKING THAT YOU HAVE RECEIVED EVERYTHING
The FT-4600 is generally shipped in one package unless optional hardware or equipment is ordered. Notify the freight
carrier and ONICON if any items are damaged in transit.
The following items have been provided with your FT-4600 Flow Meter:
(2) Line size process connection meter couplings* with male NPT threads and sealing
gaskets (shipped attached to meter)
(1) FT-4600 Meter Certificate of Calibration
(1) FT-4600 Meter Quick Start Guide
Please notify ONICON if any of these items are missing.
* NOTE: The 2½” version of the meter is provided with flanges.

FT-4600 INLINE ULTRASONIC FLOW METER
ONICON Incorporated 727.447.6140 Page 7 onicon.com
SECTION 3.0 INSTALLATION
3.1 SITE SELECTION
The FT-4600 Flow Meter should be installed by experienced plumbers, electricians, and others with related knowledge
and experience in the heating, cooling, and fluid metering fields. ONICON technical support personnel are available via
telephone or e-mail to provide technical assistance before, during and after installation. The installer should use good
trade practices and must adhere to all applicable state and local building or other codes.
Careful attention to the site selection for the meter will help the installers with the initial installation, reduce start-up
problems, and make future maintenance easier. For example, do not install the meter where it will be difficult for personnel
to perform periodic maintenance. When selecting a site, consider the criteria under Section 1.4: WORKING ENVIRONMENT,
as well as the information below.
The following limitations apply to the installation of the meter:
• The flow meter must be correctly oriented with respect to the direction of flow in the pipe. Meters installed with
reversed flow will not function.
• The maximum operating pressure for the flow meter is 400 psi.
• Do not install the meter in close proximity to strong sources of electromagnetic interference
(e.g. electric motors, VFD’s, fluorescent light fixtures, etc.)
Ubody Overall Dimensions
Size L Total L W H
½” 11.2” 7.48” 5.55” 4.50”
¾” 11.7” 7.48” 5.55” 4.50”
¾” high flow 11.7” 7.48” 5.55” 4.50”
1” 12.3” 7.48” 5.55” 4.50”
1” high flow 15” 10.23” 5.55” 4.65”
Crossfire Overall Dimensions
Size L Total L W H
1 ¼” 15.25” 10.20” 6.42” 4.92”
1 ½” 17.00” 11.80” 6.68” 5.00”
2” 17.60” 11.80” 7.09” 5.14”
2 ½” 11.81” 10.23” 9.25” 7.00”
TOP VIEW
SIDE VIEW
TOP VIEW
SIDE VIEW

FT-4600 INLINE ULTRASONIC FLOW METER
ONICON Incorporated 727.447.6140 Page 8 onicon.com
3.2 INSTALLING THE FLOW METER
A. This is a recommended position for the flow meter.
B. This is a recommended position for the flow meter.
C. Avoid installation locations where air can become trapped in the piping system, for example, meters
installed between two vertical runs, at a high elevation.
D. This is an acceptable installation location for closed loop pressurized systems.
E. Do not install the meter downstream of modulating valves or partially open valves. Fully open isolation
valves (e.g. ball valves) are OK.
F. Do not install the flow sensor at the inlet of a pump. To prevent cavitation, the minimum operating
pressure at the inlet of the meter must always exceed the pressure drop across the meter. Refer to
Appendix A-1 for calculating pressure the drop at different flow rates.
G. Avoid installing the meter downstream of multiple bends out of plane with each other where there are
less than 10 diameters of straight unobstructed pipe between bends.
Before you install the meter, the entire piping system should be flushed and free of debris. Please refer to the diagrams
below when selecting the installation location. Upstream straight unobstructed pipe requirements vary considerably
based on the nature of the upstream obstructions. As a general rule, ONICON recommends a minimum of 10 diameters of
straight unobstructed pipe whenever possible; keeping in mind that it is always recommended that the meter be located
with as much straight pipe upstream as possible.
STRAIGHT RUN REQUIREMENTS
1.UPDATE WITH OTHER METER TYPES? STEAM/GAS/ETC
Upstream Obstruction
Minimum Upstream Straight Run Required
(Pipe Diameters)
Meter Size
0.5 - 1.0" 1.25 - 2.5"
Single Elbow 0 0
Expander / Reducer 0 0
Coil, Upstream 3 3
Isolation Valve, 2 Position 3 5
Control Valve 10 15
Notes:
1 Straight run is based on use of manufacturer provided couplings
2 Avoid the following obstructions where possible: Modulating valves, pump
discharge, multiple elbows out of plane.
A
B
C
D
E & F
G
Flow Direction
Flow Direction

FT-4600 INLINE ULTRASONIC FLOW METER
ONICON Incorporated 727.447.6140 Page 9 onicon.com
The flow meter is installed with threaded meter couplings and flat sealing gaskets as shown below. Orient the sensor body
by aligning the flow direction arrow with the direction of flow in the pipe.
Flow Direction
Retaining Nut SealCoupling
Model Meter Size Min.
Compression
Min. Turn Past
Initial Contact
Degrees of
Rotation
FT-4600-050 ½” 30% 1/2 180°
FT-4600-340 ¾” 30% 1/3 120°
FT-4600-341 ¾” 30% 1/3 120°
FT-4600-010 1” 30% 2/5 140°
FT-4600-011 1” 30% 2/5 140°
FT-4600-130 1¼” 30% 2/5 140°
FT-4600-150 1½” 30% 4/9 160°
FT-4600-200 2” 30% 1/2 180°
INSTALLING METER COUPLINGS
• Inspect seating surfaces on the meter’s body and tail piece prior to assembly. Surfaces should be clean and free of
any burs or markings.
• Install the gasket in tail piece. Thread union onto meter’s body, by hand, until gasket and mating surfaces make first
contact. Mark coupling nut and tail piece.
• Place a corresponding mark on the coupling nut, # of degrees (based on table above) counter clockwise. Hold
meter body while rotating coupling nut clockwise until marks line up. DO NOT over-tighten.
• Repeat process on opposite side of flow meter body.
NOTE: Torque setting is not an accurate means of gaging compression on gasket due to the lack of resilience in the
gasket material.
Pressurize system and check for leaks. If any leak is present, DO NOT over-tighten. Relieve pressure and loosen coupling
nuts. Remove and inspect the gasket for damage. Repeat installation process.

FT-4600 INLINE ULTRASONIC FLOW METER
ONICON Incorporated 727.447.6140 Page 10 onicon.com
Orient the meter as shown below. The meter may be installed with upward or downward flow in vertical pipes
in closed loop pressurized systems. Avoid any installation locations where the pipe may not be completely full.
Preferred Orientation for Horizontal Pipes
Caps should be horizontal to ensure that no
air is trapped in the body.
Do not orient meter as shown below
Meter Sizes ½ - 1”
Caps that are pointed up or down can trap
air in the body.

FT-4600 INLINE ULTRASONIC FLOW METER
ONICON Incorporated 727.447.6140 Page 11 onicon.com
Preferred Orientation for Horizontal Pipes
Do not orient meter as shown below
Meter Sizes 1¼ - 2.5”
Caps should be horizontal to ensure that no
air is trapped in the body.
Caps should be horizontal to ensure that no
air is trapped in the body.

FT-4600 INLINE ULTRASONIC FLOW METER
ONICON Incorporated 727.447.6140 Page 12 onicon.com
Preferred Orientation for Horizontal Housing
Side View
Do not orient meter as shown below
Flow Direction

FT-4600 INLINE ULTRASONIC FLOW METER
ONICON Incorporated 727.447.6140 Page 13 onicon.com
IMPORTANT NOTE
Open isolation valves, leak test and purge the piping system of air prior to wiring the meter.
The FT-4600 is provided with an unterminated 10 foot PVC jacketed cable for power and signal connections. Do not
attempt to remove this cable. Doing so will damage the weather-tight seal and may void the product warranty. Use AWG
18 - 22 shielded cable for power and signal connections.
3.3 POWER AND SIGNAL WIRING CONNECTIONS
FT-4600 Wiring Information
Wire Color Description Notes
Red (+) 24V AC/DC Positive (+) supply connection
Black (-) Common ground Negative (-) supply connection
Blue (+) Analog 4-20 mA signal Active 4-20 mA (non-isolated) output*
Brown (-) Analog 4-20 mA signal
Orange Non polarized dry contact switch output Scaled to provide one pulse per unit volume
White
Metal Shield/Earth Ground Connection Cable Shield connection to Earth Ground
*4-20 mA signal is active. Do not connect external voltage to the blue & brown wires.
FT-4600 WIRING DIAGRAM
Flow meter into control system (no display or BTU meter)
Control System
•
•
BLUE
BROWN •
•
BINARY (DIGITAL) INPUT
ORANGE
WHITE •
•
•
•
ANALOG SIGNAL INPUT
SIGNAL GROUND
1/2” Submersible Cable

ON I CON
Flow and Energy Measurement
ONICON Incorporated • 11451 Belcher Road South • Largo, FL 33773 • USA
(P) 727.447.6140 • [email protected] • onicon.com
SECTION 4.0 DIAGNOSTICS
4.1 FLOW SIMULATION
For flow simulation, press and hold the SW2 button. The flow meter will enter simulation mode. The meter will simulate
16mA and it will pulse accordingly. Press the RST button to exit simulation mode
4.2 LED STATUS
When active, a fast flash pattern gets your attention. Then each active code is counted out with a pause between codes. This
pattern repeats while any alarms are active.
LED BEHAVIOR STATUS NEXT STEP
No LED Meter offor dead
Check whether the meter is receiving 24VAC or DC.
Check that the power supply can provide enough current to
all connected devices.
If the power is correct, the meter board needs to be replaced.
Solid LED Good No action is needed. Meter is reading flow properly.
1 blink Blink Unused Blink Unused
2 blinks Signal Issue Ensure meter is oriented properly. Check page 10-12.
3 blinks Reverse Flow Ensure the arrow on the meter body is pointed in the
direction of the flow.
4 blinks Temperature or Flow Limits
Ensure the meter does not exceed the limits indicated on
page 5. The meter will send a 4mA signal when the flow or
temperature is outside of its limits.
5 blinks High Temp Exceeded
This alarm only shows if another alarm is active to indicate
that the possible cause of the meter malfunction was the
failure in the system caused by a high-temperature fluid
passing through the meter. For example, steam trap failures
can cause.
6 blinks Hardware Fault Board or sensors failure. Please contact ONICON to
determine where the failure is.
7 blinks Config Fault Bad config or corrupt flash/EEPROM. Contact ONICON.