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General Information

FR78B FAST RESPONSE FLOW SWITCH/MONITOR

Installation, Operation and Maintenance Guide

Description

This document explains the operating principle of the Model FR78 Basic Low-Flow Switch/Monitor (see Figure 1). The following

pages also present the recommended procedures for the installation, operation, maintenance, and troubleshooting of the Model FR78B.

The Model FR78B is an instrument that is capable of detecting liquid or gaseous environments. The instrument has field adjustable

alarm set points for control of the media.

Flow Element

The operational part of the flow element consists of two Resistance Temperature Detectors (RTD's) and one low power heater. The

heater is positioned adjacent to the Active RTD and will raise it's temperature above the process ambient while the other RTD

(Reference) will stabilize near the process temperature. This arrangement produces a temperature differential between the two RTDs

that is measured and converted into an analog voltage signal. The temperature differential is greatest when the media is not flowing

(no flow). As the process media begins to flow, forced convection cools the Active RTD and reduces the temperature differential

between the two RTDs.

Control Circuit

The basic functions of the control circuit are to provide power to the flow element, measure the resistance differential (∆R) between the

two RTDs, condition the sensing point signals, and provide relay alarm contacts for customer uses.

A Double Pole Double Throw (DPDT) relay is available in the instrument for connections to the customer alarm systems. The relay

outputs can be set to be either open or closed when the sensing point is at low or no flow and closed or open when the sensing point is

at high flow.

The place where the relays change state will vary depending on the type of media, as well as gas or liquid turbulence. Therefore the

instrument has field adjustable alarm set points.

Figure 1 - FR78B Fast Response Flow Switch/Monitor

Summary of content (20 pages)

PAGE 1
FR78B FAST RESPONSE FLOW SWITCH/MONITOR Installation, Operation and Maintenance Guide General Information Description This document explains the operating principle of the Model FR78 Basic Low-Flow Switch/Monitor (see Figure 1). The following pages also present the recommended procedures for the installation, operation, maintenance, and troubleshooting of the Model FR78B. The Model FR78B is an instrument that is capable of detecting liquid or gaseous environments.
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FLUID COMPONENTS INTERNATIONAL LLC FR78B Flow Switch/Monitor Specifications • Sensing/Flow Element Ranges Water: 0.08 to 2.25 cc/sec Oil: 0.05 to 25 cc/sec Air: 4.0 to 1500cc/sec • Adjustable Response Time 1 to 150 seconds • Process Connection 1/4 inch x 2 inch (6.4 x 50mm) long tubing, .0028 (7mm) wall thickness, .53 inches (13.5mm) total length. 3/8 inch (9.5mm) and 1/2 inch (12.7mm) tubing available. • In-Line Sensor Assembly Body Length 5.3 inches (1.
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FR78B Flow Switch/Monitor FLUID COMPONENTS INTERNATIONAL LLC Required Materials Appropriate wire, cable, and conduit. Note: Potting Y's for all the interconnecting wires are recommended when installing the instrument's control circuit in an enclosure. Other requirements may vary based on local wiring codes. Pre-Installation Procedure Warning: Only qualified personnel should install this instrument. Install and follow safety procedures in accordance with the current National Electrical Code.
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FLUID COMPONENTS INTERNATIONAL LLC FR78B Flow Switch/Monitor Cable Connections Caution: In order to prevent circuit or component damage, remove the control circuit from the remote enclosure (if present) prior to the pulling of conduit wire. Note: The installation of an AC line switch between the AC power source and the instrument is recommended. This facilitates easy power disconnection and is an added safety feature.
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FR78B Flow Switch/Monitor FLUID COMPONENTS INTERNATIONAL LLC Figure 2 - Setting Alarm Switch Point Figure 3 - Control Circuit 5181 Outline Drawing Creating a Calibration Curve Using an FM71 Calibrator 1. Apply power to the instrument and establish a constant flow rate in the pipe for the first data point to be taken. Let the instrument stabilize for 10 minutes. 2. Attach an FM71 meter to the control circuit. Dial in the balance number found near the edge of the control circuit. The read out /calib.
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FLUID COMPONENTS INTERNATIONAL LLC FR78B Flow Switch/Monitor Maintenance The instrument requires very little maintenance. There are no moving parts or mechanical parts subject to wear. Warning: To avoid hazards to personnel, ensure that any environmental isolation seals are properly maintained. Without detailed knowledge of the environmental parameters of the application, surroundings, and process media, FCI cannot make specific recommendations for periodic inspection, cleaning, or testing procedures.
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FR78B Flow Switch/Monitor FLUID COMPONENTS INTERNATIONAL LLC Non-maintenance Observations At this point, observe the system setup to verify operation. No disassembly or testing is required at this time. Check Serial Numbers Verify that the serial number of the flow element and the control circuit are the same when the instrument is used with the remote enclosure option. The flow element and the control circuit are a matched set and cannot be operated independently of each other.
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FLUID COMPONENTS INTERNATIONAL LLC FR78B Flow Switch/Monitor Terminal Pin Number (Wire Color) Resistance In Ohms From Pin 7 (White, Black and Shield) To Pin 8 (Yellow) 4000 From Pin 8 (Yellow) To Pin 9 (Red) 4000 From Pin 7 (White, Black and Shield) To Pin 10 (Blue) 221 From Pin 7 (White, Black and Shield) To Pin 9 (Red) 8000 From Pin 8 (Yellow) To Pin 10 (Blue) 4221 From Pin 9 (Red) To Pin 10 (Blue) 8221 Shield To All Pins Open Circuit Table 2 - Flow Element Resistance In Ohms If an open
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FR78B Flow Switch/Monitor FLUID COMPONENTS INTERNATIONAL LLC Defective Parts Before returning any equipment to FCI, obtain an return authorization (RA) number for authorization, tracking, and repair/replacement instructions. If a return is required, remove the defective part or instrument, replace it with a spare, calibrate, and then return the defective part or instrument to FCI freight prepaid for disposition. Customer Service 1.
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FLUID COMPONENTS INTERNATIONAL LLC FR78B Flow Switch/Monitor INTENTIONALLY LEFT BLANK This page is subject to proprietary rights statement on last page 10 Doc. No. 06EN003281 Rev.
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FR78B Flow Switch/Monitor FLUID COMPONENTS INTERNATIONAL LLC Appendix A - Drawings Figure 5 - Wiring Diagram Test Points R5, Set Point Potentiometer. J12, J13 Set Point LED. Figure 6 - Parts Orientation This page is subject to proprietary rights statement on last page Figure 7 - 5181 Circuit Board 11 Doc. No. 06EN003281 Rev.
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FLUID COMPONENTS INTERNATIONAL LLC FR78B Flow Switch/Monitor Figure 8 - Outline Dimensional This page is subject to proprietary rights statement on last page 12 Doc. No. 06EN003281 Rev.
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FR78B Flow Switch/Monitor FLUID COMPONENTS INTERNATIONAL LLC Appendix B - Glossary ABBREVIATIONS Delta R (DR) Differential Resistance Delta T (DT) Differential Temperature DMM Digital Multimeter FCI Fluid Components Intl HTR Heater LED Light Emitting Diode RA Repair Authorization RTD Resistance Temperature Detector DEFINITIONS Active RTD The flow element part that senses the fluid flow rate.
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FLUID COMPONENTS INTERNATIONAL LLC FR78B Flow Switch/Monitor INTENTIONALLY LEFT BLANK This page is subject to proprietary rights statement on last page 14 Doc. No. 06EN003281 Rev.
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FR78B Flow Switch/Monitor FLUID COMPONENTS INTERNATIONAL LLC Appendix C - Customer Service Customer Service/ Technical Support FCI provides full in-house technical support. Additional technical representation is also provided by FCI field representatives. Before contacting a field or in-house representative, please perform the troubleshooting techniques outlined in this document. By Mail Fluid Components International LLC 1755 La Costa Meadows Dr.
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FLUID COMPONENTS INTERNATIONAL LLC FR78B Flow Switch/Monitor Warranty Repairs or Returns FCI prepays ground transportation charges for return of freight to the customer’s door. FCI reserves the right to return equipment by the carrier of our choice. International freight, handling charges, duty/entry fees for return of equipment are paid by the customer.
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FR78B Flow Switch/Monitor FLUID COMPONENTS INTERNATIONAL LLC Fax Cover Sheet Company: ___________________________________ Date: ______________________________________ Attention: ___________________________________ Dept: ______________________________________ Fax No: _____________________________________ Direct Phone: _______________________________ From: ______________________________________ No.
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FLUID COMPONENTS INTERNATIONAL LLC FR78B Flow Switch/Monitor RA #___________ 1755 La Costa Meadows Drive, San Marcos, CA 92078-5115 USA 760-744-6950 / 800-854-1993 / Fax: 760-736-6250 Web Site: www.fluidcomponents.com / E-mail: techsupport@fluidcomponents.com Return Authorization Request 1.
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FR78B Flow Switch/Monitor FLUID COMPONENTS INTERNATIONAL LLC Instrument Warranty Goods furnished by the Seller are to be within the limits and of the sizes published by the Seller and subject to the Seller’s standard tolerances for variations.
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Model FR78B Flow Switch/Monitor FLUID COMPONENTS INTERNATIONAL LLC FCI’s Complete Customer Commitment. Worldwide ISO 9001:2000 and AS9100 Certified Notice of Proprietary Rights This document contains confidential technical data, including trade secrets and proprietary information which is the property of Fluid Components International LLC (FCI).