Xylem FS-5 Installation and operating instructions

®
Installation & Maintenance
Instructions MM-616
Series FS-5
General Purpose
Liquid Flow Switch
OPERATION
This control is an independently mounted water flow
sensing device that makes or breaks an electrical
circuit when flow stops or starts.
•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 FS-5
(specified models only)

CE Circuit Rating
7.4 (7.4)/120~ 0.3/120=
3.7 (3.7)/240~ 0.15/240=
2
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
Maximum Liquid Pressure: 150 psi (10.5 kg/cm2)
Liquid Temperature Range (TL): 32 - 250˚F (0 - 121˚C) (All models except “S”)
32 - 225˚F (0 - 107˚C) (“S” models)
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: 3/4” or 1” NPT (All models except “J”)
3/4” or 1” BSPT (“J” models)
Models that meet CE Conformance:
FS5-J-3/4-E
FS5-J-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 0.5 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.
For applications with loads 0.5 and 38mA, power
factors exceeding 0.65, an anticipated system
switch operation rate of less than once per 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
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.
3
NOTE: DO NOT USE LIQUID FLOW
SWITCHES ON SYSTEMS WITH
FLOW VELOCITY GREATER THAN
10 FEET (3M) PER SECOND.
INSTALLATION –
STEP 1 - Determine the Location of the Flow Switch
Fluid Flow
3/4" or 1"
PIPE
5 x D
MINIMUM
D
D= PIPE DIAMETER
5 x D
MINIMUM
•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.
•The flow switch should 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.
Flow Rates
Pipe Mode of Operation
Size NPT Flow No Flow
in. (mm) Settings gpm (lpm) gpm (lpm)
3⁄4
(20) Factory or
or Minimum 1.5 (5.7) 1.1 (4.2) 16.62 (63)
1 (25) Maximum 15 (56.8) 10 (37.9) 27 (102)
Values are ± 10%
Max. Flow
Rate gpm
(lpm) w/o
Paddle Damage

4
SECTION 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
•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 screw-
driver, tighten the cover 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.
NOTE: Repeat above to connect wires to second
switch on “D”model flow switches.
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
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
Adjustment is necessary only if required flow/no
flow setpoints are above factory set minimum.
a. Turn off power. Remove electric enclosure
cover.
b. Turn adjusting screw clockwise (1/8 turn) to
increase setpoint.
c. Place the cover on the flow switch and turn on
power.
d. Test the operation of the flow switch after
each adjustment.
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.

3500 N. Spaulding Avenue
Chicago, Illinois 60618
tel: [phone]
fax: [phone]
www.mcdonnellmiller.com
©1999 ITT Industries Inc.
Printed in U.S.A. 10-99 246716
MAINTENANCE
SCHEDULE:
• Inspect 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.
Check to see if plunger moves freely. Some system
piping disassembly may be required.
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.
Check to see if plunger moves freely. Some system
piping disassembly may be required.
3. Flow Switch Does Not Deactivate
Solution:
a.
Check to see if plunger 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.