WaterCompass FM300 Ultrasonic Flow Monitor Direct Wire Installation Instructions

WC-FM300-US-150-OD, WC-FM300-US-200-OD

Introduction

This document covers installation for the WC-FM300-US Ultrasonic Flow Monitor for pipe sizes of 1.5 - 2”.

The WaterCompass FM300 Ultrasonic Flow Monitor is a clamp-on flow monitor with a 30 V power supply that connects to the WaterCompass Data Collector.

The monitor sends real-time flow data to the WaterCompass Data Collector that is viewed from the WaterCompass dashboard. Hourly summation of flow data is stored for analysis and reporting.

Before you begin, review the safety precautions at the end of this installation guide.

Pre-Configured Settings

To ensure accuracy, the Flow Monitor will be pre-configured with the following settings:

•         Pipe size (varies)

•         Pipe type (varies)

•         Flow direction (right)

•         K-value (60.1)

Contact Information:

WaterCompass 707-285-3250

proservices@hydropoint.com

Materials Provided

•   WaterCompass Data Collector (OXR)

•   WaterCompass Flow Monitor

•   50’ of multi-conductor (3+) shielded plenum rated 18 AWG cable

•   4 wire nuts

•   4 Data Collector mounting screws

•   Barrel connector

Equipment Needed

•   Philips head screwdriver with long shaft

•   Torx screwdriver (for pipes larger than 2")

•   Lock Nut

•   Zip ties

•   J-box and fittings

This installation manual details the process a contractor should follow to install an FM300 Flow Monitor on-site, as well as outlining basic troubleshooting steps.

The FM300 Flow Monitor is a non-invasive flow monitor that reads usage data from an existing water pipe with ultrasonic technology, continuously monitors for leaks, and tracks ongoing water usage.

There are three phases to the installation process:

Phase 1: WaterCompass Data Collector installation

Phase 2: Flow Monitor installation

Phase 3: WaterCompass Data Collector flow validation

You do not need to turn off the water or cut any pipes to install the flow monitor. After installation, the flow monitor will be able to read flow on the supply line and the WaterCompass Data Collector will establish a cellular data connection to upload usage data to the WaterCompass dashboard.

If you have any questions or issues when installing the FM300, please call Professional Services at 707-285-3250.

Wall Mounting Instructions

Use the template enclosed with the Water Compass Data Collector for assistance when mounting the enclosure to a wall.

Locate the 2 mounting holes on the back of the enclosure. The two upper mounting holes are keyholes. This design allows the two upper fasteners to be installed first. The enclosure is

then slipped over and pushed down to complete the installation.

A third mounting hole can be found in the center of the enclosure. A typical mounting height for

a wall-mount enclosure is between 41” and 48” above a finished surface.

Before drilling, verify that the controller is level and vertically straight before installing.

1.                Remove the outer door for access to the interior of the enclosure. Slide it upwards, then place it in a location to prevent damage.

2.                Remove front panel and disconnect ribbon cable from the back side of the front panel.

3.                Mark and drill new mounting holes using the paper template, then drill appropriately sized holes with a hammer-drill as needed. Use plastic inserts and mounting screws (taped to the controller with the enclosure keys) to secure the controller.

4.                Hang the enclosure on these fasteners and verify the enclosure is mounted level both vertically and horizontally.

5.                Locate the third center mounting hole and insert the last fastener. Tighten all fasteners to the enclosure to secure to the vertical surface.

Step 1: Mount the Water Compass Data Collection Enclosure, cont.

The WaterCompass Data Collector incorporates a dual voltage power supply and can be connected to a single phase 120 VAC or single phase 240 VAC source. Please refer to the 120 VAC or 240 VAC diagrams on pages 6-7 for proper connections.

The input side of the transformer has 5 color-coded conductors. A label is attached to the transformer body with identification for each conductor. Two of the conductors (specific to 240 VAC connections) have been terminated with wire nuts, shortened and tied together with a zip-tie to avoid confusion for 120 VAC installations.

Do not remove the wire nuts from the 240 VAC connections, as it may cause a short if removed.

1.               Confirm that the WaterCompass Data Collector has been securely fastened to a flat, vertical surface before starting this work.

2.               Open the enclosure door and locate the transformer mounted to the chassis. Thread an approved weatherproof plastic or galvanized metal junction box onto the 1/2” nipple and secure with a conduit locknut.

3.               Connect approved conduit to the underside of the junction box.

4.               Pull the required number of conductors and terminate them in the junction box with sufficient length so that wire nut connections can be made.

5.               Remove approximately 1/2” of the wire insulation of the conductor and use an appropriately sized wire nut based on the number of wire connections being made. Adhere to local and state electrical codes.

Connecting AC Power

The WaterCompass Data Collector utilizes a single phase, 2.0 amp transformer which can be accessed by removing the safety cover located behind the command module.

Three (3) wire nuts are included with the mounting fasteners to connect to a 3-conductor wire, 120- volt power source as shown below. The primary side of the transformer has three color conductors noted as follows:

•         Green: earth ground

•         Black: positive

•         White: negative

1.                    Swing open the door of the command and unscrew the safety cover from the transformer.

2.                Remove approximately ½” of wire insulation to expose the center conductor. Twist the appropriate colored wires and seal with a wire nut.

3.                Re-install the protective safety cover and tighten the supplied fastener.

Step 2: Connect the WaterCompass Data Collector to AC Power, cont.

120 VAC Applications

For 120 VAC wire applications, connect the conductors as illustrated below from the primary side of the transformer to wiring from an approved electrical source. The unused blue and brown wires are cut short and terminated with a wire nut.

Step 2: Connect the WaterCompass Data Collector to AC Power, cont.

240 VAC Applications

For 240 VAC single-phase applications connect the conductors as illustrated below from the primary side of the transformer to wiring from an approved electrical source.

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Step 5: Attach the Flow Monitor to the Pipe, cont.

Step 5: Attach the Flow Monitor to the Pipe, cont.

Step 5: Attach the Flow Monitor to the Pipe, cont.

Step 5: Attach the Flow Monitor to the Pipe, cont.

Step 5: Attach the Flow Monitor to the Pipe, cont.

1.               

Once the Flow Monitor’s power supply is plugged in, the flow monitor will power up and the Flow Monitor will check for

stability. The stability indicator lights up on the lower left of the display after the initial installation.

2.                The stability indicator shows the rough stability of detection.

3.                There should be 3 or 4 bars visible.

If the stability indicator shows 2 or fewer bars, re-install the flow monitor. If that does not improve stability,

call Pro Services at 707-285-3250.

4.                Check the Zero Cut Flow Rate (ZCFR). Press and hold mode until “out1” and “PULS” displays. Press mode six times until “cut” displays. The value should match the device type as indicated

in Appendix F of this document.

Stability Indicator

OUT

STABILITY

L /min

m3 /h gal /min

How to Select an Installation Location

Some important factors must be considered BEFORE installing the FM300-US Flow Monitor. Read and follow the guidelines below to ensure that the flow monitor is installed in just the right location to deliver the results you need.

•         Choose a location indoors

•         Choose a location that captures all the flow being monitored

•         Install on a pipe that is always full of water

•         Ensure that the monitor has direct contact with the pipe

•         Install in a location that is free of turbulence

•         Install in a room where there is 120V power

Choose a location that captures all the flow being monitored

Whether you want to monitor an entire building or just a floor of a building, you will need to install the device in a place indoors that captures all of the flow entering the section of the building that you want to monitor.

For example, if the objective is to monitor the flow for an entire building, the device should be located on the pipe entering the building from the water source. If the objective is to monitor a specific floor of a building, the device needs to be installed on the pipe supplying all the water for that floor.

Install on a pipe that is always full of water

The device needs to be installed in a location where the pipe is always filled with water. Be aware of situations where low flow may allow the pipe to be only partially full:

Ensure that the monitor has direct contact with the pipe

The flow monitor needs to be installed directly on the pipe. Do not install the device on top of insulation or in areas that contain rust or seams.

Install in a location that is free of turbulence

Changes in pipe size and direction can create turbulence in the water and stop the monitor from accurately reading flow. Select an installation location that will ensure adequate distance upstream and downstream of the monitor to allow any turbulence to settle before passing the flow monitor.

Be sure to select a location that is:

•         Far enough downstream to allow turbulence to settle

•         UPSTREAM of pressure regulating devices

•         Far enough away from sources of large pulsation (like from a pump)

Appendix A: Selecting an Installation Location, cont.

You can use the chart below to help ensure that you are leaving enough space upstream for proper flow.

You will need a caliper and a tape measure to determine the diameter and length of the existing pipe.

The Length (L) should be greater than X times the diameter of the pipe based on the specific pipe change described in the chart.

For example, on a 2” pipe the monitor’s best section of pipe is directly downstream of a 90° elbow. We’d look for at least 10x2” or 20” of pipe between the end of the bend and the beginning of the monitor to allow for the turbulence caused by the elbow to settle.

Install in a room where there is 120V power

The WaterCompass FM300-US Flow Monitor runs on DC power. It is best to install the device in a room where there is a power outlet or where power conduit can be tapped into for use.

The DC supply wire and the two-wire can run in parallel and inside the same outer jacket. The DC supply wire cannot have more than 25ohms* of resistance: 12.5 out, 12.5 back.

Appendix A: Selecting an Installation Location, cont.

If you neeed to edit or change the Flow Sensor configurations, follow the steps below. You will need to place the Data Collector into maintenance mode in order to access the panel. This step unlocks the control panel so you can make changes. If you need password assistance, contact ProServices at 707-285-3250.

Appendix D: Changing Configurations for the Flow Sensor, Cont.

If you need to extend the length of the Flow Monitor wires, follow the steps below.

Appendix E: Extending the Flow Monitor Wires, Cont.

Appendix E: Extending the Flow Monitor Wires, Cont.

Appendix E: Extending the Flow Monitor Wires, Cont.

Appendix E: Extending the Flow Monitor Wires, Cont.

Route Cable

1.                Install the cord grip into the Water Compass Data Collector housing.

2.                Feed the 18 AWG plenum wire through the cord grip.

Preparer the opposite side of the plenum wire

1.                Strip 3-4” of sheath from the 18 AWG plenum wire.

2.                Peel back the foil shield to expose the stranded shield wire.

3.                Remove the foil but leave the stranded shield wire.

4.                Cut the shield wire to 1”.

5.                Cut the red wire close to the sheath cable.

Extend the Wire

1.                Cut a 3 -4” piece of black 18 AWG wire. You can use a piece from the plenum wire or any other 18 AWG wire that you may have on hand.

2.                Use a wire nut to wire the black 18 AWG to the shield wire.

Connect to Data Collector

1.                Strip 1/2” of insulation from Blue, Black and Brown wires.

2.                Insert the shield wire into the earth ground lug and tighten securely.

3.                Insert the blue wire into the VC port.

4.                Insert the black wire into the FL1 port.

5.                Use a wire nut to connect the brown 18 AWG plenum wire with the brown power supply wire.

Zero Cut Flow Rates vary according to the size of the flow device you are using. If you need to change the ZCFR, reference the table and instructions below for proper settings and instructions.

General Cautions

Precautions for Handling

Precautions for Detectable Fluid

The content on this page is from the Keyence FD-R Series Instruction Manual. Used with permission.

Safety Precautions for the FM300-US Flow Monitor, cont.

Precautions for Installation

•        

Install the FM300-US Flow Monitor at a location where the inside the measuring pipe is always filled with the fluid.

•         To prevent a situation where the FM300-US Flow Monitor is affected by air bubbles or the pipe not being filled with fluid, it is recommended to secure it in a position where the display surface is perpendicular to the ground.

•         Arrange piping so that gas does not enter it. When the fluid contains bubbles, detection performance of the FM300-US Flow Monitor may be affected.

•         When installing the FM300-US Flow Monitor on a vertical pipe, choose the position where the fluid flows in the upward direction.

•         To improve the detection stability, it is recommended that the monitor be installed in a location with straight sections of pipe upstream that are at least five times the length of the pipe`s inside diameter.

•         Install the monitor on the upstream side of a flow regulating valve or similar piece of equipment.

•         Install the FM300-US Flow Monitor on a surface with no seams or rust.

•         Do not install the FM300-US Flow Monitor in a location exposed to intense light, such as direct sunlight, or radiation from a heat source.

•         Do not install the FM300-US Flow Monitor at a location where it may become submerged in a liquid.

•         When installing the FM300-US Flow Monitor at a location where vibrations occur, fix the pipe with tubes or supports as close to the main unit as possible. Excessive vibration may cause unstable operation.

•         To avoid interference of detection signals, do not install multiple units closely in series.

The content on this page is from the Keyence FD-R Series Instruction Manual. Used with permission.

Safety Precautions for the FM300-US Flow Monitor, cont.

Precautions for Wiring

Other Precautions

The content on this page is from the Keyence FD-R Series Instruction Manual. Used with permission.

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