Installation Manual INTRODUCTION The full WeatherTRAK Flow Installation and Maintenance Manual is available online at www.weathertrak.com General Description A WeatherTRAK Flow combines a hydraulic master valve, water meter and a flow sensor in a single unit. The Flow is designed for high pressure, remote control irrigation and industrial applications. Body: Available Sizes: Horizontal ½,,, 4, and 6 Water Meter / Registers The Flow has two register configurations, either a dry contact (reed switch) type magnetic drive and a higher frequency output photo-diode register transmission water meter. The impeller is the only moving part in contact with the water. A hermetically sealed register contains the dial face and all mechanical meter components. The dial face contains: Totalizer U.S. GALLONS Totalizer Three () analog pointers Rotating flow indicator or leak detector BM 0 9 8 7 0 9 6 4 8 5 7 6 5 0 9 8 7 6 5 4 4 Leak Detector Analog Pointers In the reed switch configuration, a magnetic pointer, located over one of the analog pointers, measures the flow rate and transmits the data to the reed switch transducer in the register cover. Hydraulic Valve (Flow Sensor) The Flow contains a hydraulic master valve operated either manually or by remote control. The Normally Closed configuration has a valve that normally remains closed until the solenoid is energized. The Flow can also be ordered in a Normally Open configuration where the valve is open until a the solenoid is energized and the valve closes.
SPECIFICATIONS AND DIMENSIONS Specifications ½ 4 6 Maximum Working Pressure (psi) 0 0 0 0 0 Minimum Working Pressure (psi) 4 4 4 4 4 Regulated Pressure Ratio : : : : : Maximum Flow Rate (gpm) 55 95 0 80 860 Minimum Flow Rate (gpm) 4.4 0 5 79 98 Accuracy ± % ± % ± % ± % ± % Dimensions H H W L W L ½ 4 6 ½ 4 6 Length (L) 6 5/6 8 /6 /4 4 /6 9 /6 Width (W) 4 5/6 4 5/6 8 /6 9 4 5/6 Height (H) 0 7/6 7 8 /6 4 /6 Weight 4 lbs. 7 lbs. 5 lbs. 65 lbs. 45 lbs.
ELECTRICAL OUTPUT Flow units are equipped with electrical output devices that combine the high reliability of hermetically sealed, magnetically driven registers with a wide variety of electrical output options. Flows (measuring instruments) provide electrical output information about the flow of water. When more than just the traditional register is needed, they also provide the solution for automation and communication with controllers, electronic devices and other water delivery systems. The WeatherTRAK Flow has two types of outputs available which provide three levels of resolution: Photo Diode (PDH) Register - high frequency pulse (open collector) for functions such as rate of flow and recording total volume. (Recommended for most irrigation scenarios) a. When using the PDH register, it requires WTPS-FL power supply, included in the package and dedicated 4 VAC power wire. Refer to WeatherTRAK Optical Flow Sensor Power Supply Installation and Verification Procedure document. b. Note: If the installation does not have a dedicated 4 VAC power wire, please contact support@hydropoint.com for additional options and assistance. Reed Switch (RS) Register - low frequency pulse output for functions related primarily to recording volume. Electrical Output Specifications Reed Switch (RS) Register The flow rate is transmitted as periodic electrical pulses measured by the magnetic pointer in the dial face. The Flow is configured to transmit a pulse according to a pre-defined volume interval (a scaled pulse). The following summarizes the available volume intervals for the Flow. Output definition: Volume Output Output type: RS Reed Switch U.S. GALLONS For sizes ½,,, 4 : The pointer with the magnet is set in the left position and will make one contact of the reed switch for every 60 rotation - the result is an output of pulse per gallon. Reed Switch Register is not available for 6 Flow. BM 0 9 8 0 9 8 7 0 9 7 Pulse per USG 6 4 8 5 7 6 6 4 5 4 5 Pulse per 00 USG Reed Switch (RS) Low Frequency Gallons/Pulse Pulse/Gallon K Factor Offset Pulse per 0 USG ½,,, 4 60.00 0 The sensor is installed in a transparent plastic cover that is mounted on the register. Reed Switch (RS) Register Specifications Magnet activated Acts as a dry contact, uses very little electric power For Volume related functions such as data recorders or simple counters Circuit Diagram Register with Reed Switch Output, Two Wires Electrical Specifications Maximum Contact Current: 50 ma Maximum Contact Voltage: 8 VDC Black / or Brown Red / or White
ELECTRICAL OUTPUT CONT. Photo-Diode (PDH) High Frequency Register Sensor combines an IR light source and a light sensitive diode in one package Signals are created when the light beam created by the IR light is interrupted by a rotating element Requires a constant supply of DC power supplied by the WeatherTRAK WTPS which is included with Flow PDH models NOTE: Only power the WeatherTRAK Flow with PDH Register using the WeatherTRAK WTPS-FL to prevent damage. Photo-Diode (PDH) - Electrical Specifications Positive: powers the IR light (yellow wire) Current Min: 5 ma to a maximum of 5 ma DC through a resistor Maximum Voltage: 8 VDC Output: (clear wire) Open collector (Max. Load ma) Ground: (bare wire) Photo-Diode (PDH) High Frequency SIZE Gallons/Pulse Pulse/Gallon K Factor Offset ½ 0.005 87.900 0.9 0 0.0085 7.000 0.500 0 0.005 48.70. 0 4 0.0556 7.99.5 0 6 0.74 5.747 0.47 0 Note: Sunlight will interfere with the IR light and may corrupt or interfere with the signal keep dust cap closed during operation. 4
ORDERING AND SPECIFICATIONS Ordering MODEL REGISTER + TYPE pulse per gallon gallons per pulse K + Offset + VALVE TYPE WTF-50 RS 60.000 0.0 ½ MPT PDH 87.900 0.005 0.9 0.0 NO = Normally Open WTF-00 RS 60.000 0.0 FPT PDH 7.000 0.0085 0.50 0.0 NC = Normally Closed WTF-00 RS 60.000 0.0 Flanged PDH 48.70 0.005. 0.0 WTF-400 RS 60.000 0.0 4 Flanged PDH 7.9 0.0566.5 0.0 WTF-600 6 Flanged PDH 5.747 0.74 0.47 0.0 RS = Reed Switch (low frequency) PDH = Photo Diode (high frequency) Specifications WTF-00-PDH-NO = Normally Open Flow w/ Photo Diode Register WTF-50-RS-NC = ½ Normally Closed Flow w/ Reed Switch Register Sizes: ½,,, 4, and 6 Maximum working pressure: 5 psi Minimum working pressure:.75 psi Valve construction: Cast iron, polyester coated Solenoid construction: Brass Valve connections: Threaded, flanged Solenoid connections: In/Out NPT Threaded Photo diode power: Requires a constant supply of DC power (see pg. -4) Solenoid power: 4VAC, 5.5 watts, 0. amps inrush Register types: Reed Switch, Photo Diode Register: Odometer style w/ fractional dials Valve diaphragm: Reinforced natural rubber Flanges: Drilled according to ANSI specification Standards: EEC approval (class A) Compatible with: ET Pro, ET Pro, ET Pro -Wire, LC Controllers Compatible with: WeatherTRAK FlowLink, FlowShare Compatible with: WeatherTRAK Central Performance Data Flow Range SIZE LOWEST FLOW WITHIN ± 5% ACCURACY (GPM) LOWEST FLOW WITHIN ± % ACCURACY (GPM) NOMINAL FLOW WITHIN ± % ACCURACY (GPM) MAXIMUM FLOW WITHIN ± % ACCURACY (GPM) ½.8 4.4 44 55 5. 0 66 95 4 5 76 4 79 64 80 6 5 98 660 860 MIN GPM ± 5% MAX GPM ± % ½.8 55 5. 95 4 0 4 80 6 5 860 Friction Loss vs. Pressure Loss (psi) SIZE FLOW RATE (GPM).8 4.4 5. 4 0 5 55 79 95 97 5 50 98 0 50 00 57 80 400 500 700 860 900 950 000 50 500 ½ 0.0 0.04 0. 0.4 0.8 0.8 5. 5.7 0.0 0. 0. 0.4..5 5. 7.4 7.7 0.0 0.05 0. 0. 0.4 0.7...8.7 4.5 5.7 4 0.0 0. 0. 0. 0.5 0.5 0.8..0.5. 4.7 6.6 7.5 6 0.0 0.0 0.05 0. 0. 0. 0. 0. 0.4 0.5 0.7.... 4. 6. ±% ACCURACY ±5% ACCURACY 5
INTERNAL COMPONENTS (Double chamber not available in 6 ) 6
INSTALLATION Installation Requirements Globe configuration Flow units require no straight pipe installation requirements. Do not install valves that will cause a restriction directly upstream or downstream of the Flow. Upstream Distance Downstream Distance Meter Length Total Requirement SIZE ½ 0 0 6 5/6 6 5/6 0 0 8 5/8 8 5/8 0 0 ½ ½ 4 0 0 4 /8 4 /8 6 0 0 9 ½ 9 ½ Unpacking The Flow comes fully assembled according to the customer s specifications. The ½ model is shipped with the appropriate couplings and gaskets. For larger diameter models installation hardware is not included for larger diameter models. Pilot valves and other accessories are factory installed and calibrated according to the customer s specifications. Pipeline Installation The following tools are required to perform these procedures: Flat blade and Phillips head screwdrivers in various sizes Open end or box wrenches in various sizes Large pipe wrenches Pliers Dies or pipe threading tools compatible with the pipeline diameter Teflon tape or similar pipe sealing material Preliminary Steps Installing ½ and Models Straight Pipe Installation Requirement 0 x D and 0 x D Connections to the Flow should be the same size as the meter. Example: if a Flow is installed, pipe and fittings should be connected to the Flow. Prior to installation of the meter, the pipeline should be thoroughly flushed. Recommendation: Air Vents of proper size and type, Continuous acting and large acting, be installed to eliminate air.. Before beginning the installation, the line should be thoroughly flushed to remove any foreign matter.. Close the inlet valve in order to shutoff the water flow to the pipeline. The Flow can be attached directly to a male threaded pipeline or to a female threaded pipeline using a coupling. The ½ model can only be attached using a coupling. Pipe COUPLING CONNECTION Create a female threaded connection on both pipe sections. Apply Teflon tape or similar material to seal the connections. Insert the male coupling connections into the pipeline sections and tighten securely. Place a coupling gasket over each male threaded Flow connection and securely tighten the coupling nuts. Coupling Nut Coupling Tail Piece Coupling Gasket 7
INSTALLATION CONT. DIRECT CONNECTION Create a male threaded connection on both pipe sections that are to be attached. Apply Teflon tape or similar material to seal the connections. Insert the male threaded pipe connection into the Flow and tighten securely. Installing - 6 Models The end user is expected to supply the appropriate gaskets and bolts according to the diameter of the pipeline. Place the appropriate gasket onto each flange. Insert the bolts, nuts and washers and tighten securely. CONTROL SYSTEM Solenoid Connection The Flow has can be controlled by the controller via an external solenoid valve. The three-way selector must be in the Auto position. TO CONNECT TO AN INSTALLED SOLENOID:. Connect the electric cable from controller to the attached solenoid valve. Position the three-way selector in the Auto position - in this position the Flow will be controlled by the solenoid. Apply Teflon tape or similar material to seal the connections. Electrical Output The Flow supplies volume and flow rate data to a controller via an electrical connection. A reed switch or high frequency photo diode transducer is factory installed in the register dial. The cable attached to the reed switch transducer attaches to the controller or measuring device. TO CONNECT THE FLOW TO THE CONTROLLER:. Install an appropriate connector onto the bare end of the cable exiting from the reed switch.. Connect the cable to the input port of the controller or measuring device. DRAINAGE VALVE Drainage Valve At the beginning of the winter it is necessary to drain the water from the pipeline in order to prevent the pipes from bursting. (Please refer to the drawing on the right) Before draining, it is very important to ensure that there is no pressure in the line. Disassemble plug () Assemble the drainage ball valve (). Assemble elbow () CAUTION: Do not use compressed air to blow out Flow. 8
WeatherTRAK Flow Photo Diode Hydrometer Wiring Instructions Flow Sensor: P.E. 9 Twisted Pair Cable (Paige Elec. Part #P75D) - MAX. 000ft from controller to Flow Master Valve, Valve Common and AUX 4VAC: AWG #4 or AWG #6 gauge wire Use WeatherTRAK FlowLink if system wire availability or requirements are not met Flow sensor cable must be twisted pair shielded cable Red Translucent Black Flow Sensor Controller Yellow Solenoid Yellow Bare Photo Diode Black All shown connections housed within the Flow s valve box WTPS-FL Orange Master Valve Controller White Valve Common Controller AUX 4VAC Controller M-DBY/R Installation example of the M-6IR Cut wire. Do not strip. 9 Insert completely. M-6IR Press cap evenly......until flush with casing.
WeatherTRAK Flow Reed Switch Hydrometer Wiring Instructions Flow Sensor: P.E. 9 Twisted Pair Cable (Paige Elec. Part #P75D) - MAX. 000ft from controller to Flow Master Valve, and Valve Common: AWG #4 or AWG #6 gauge wire Use WeatherTRAK FlowLink if system wire availability or requirements are not met Red (White) Flow sensor cable must be twisted pair shielded cable Red Black Reed Switch Flow Sensor Controller Black (Brown) Master Valve Controller Valve Common Controller Solenoid All shown connections housed within the Flow s valve box M-DBY/R Installation example of the M-6IR Cut wire. Do not strip. 0 Insert completely. M-6IR Press cap evenly......until flush with casing.
WeatherTRAK Flow Photo Diode / FlowLink Wiring Instructions Leading to Controller* Yellow Yellow Leading to Controller* Black Red Translucent Blue Bare *wires lead to FlowLink-EXT if using FlowLink-XT+ (AWG #4 or AWG #6) White Solenoid Photo Diode All shown connections housed within the Flow s valve box FlowLink - FXT M-DBY/R Installation example of the M-6IR Cut wire. Do not strip. Insert completely. M-6IR Press cap evenly......until flush with casing.
WeatherTRAK Flow Reed Switch / FlowLink Wiring Instructions Not used/cap Leading to Controller* Yellow Leading to Controller* Black Red Red (White) Blue Black (Brown) *wires lead to FlowLink-EXT if using FlowLink-XT+ (AWG #4 or AWG #6) White Solenoid Reed Switch All shown connections housed within the Flow s valve box FlowLink - FXT M-DBY/R Installation example of the M-6IR Cut wire. Do not strip. Insert completely. M-6IR Press cap evenly......until flush with casing.
OPERATIONAL TESTING Installation Verification Before the Flow is placed into service, you should perform the following tests to verify that it is operating properly TO TEST WATER FLOW AND MANUAL OPERATION: Set -Way Selector to the Open position. Turn on the water flow to the Flow. Visually verify that water is flowing downstream from the Flow in appropriate quantities. Verify that the leak detector, pointers and the totalizer are functioning properly. Check all hoses, connections, pilot valves, etc. for leakage and repair as necessary. Set -Way Selector to the Close position. Verify that the water flow downstream has stopped. TO TEST AUTOMATIC OPERATION: Set -Way Selector to the Auto position. Turn on the water flow to Flow. Verify that the controller correctly receives the Flow output. Use the controller to close the Flow. Verify that the water flow downstream has stopped. Use the controller to test operation of the Flow under various applications and conditions. Your Flow is now ready for routine use. OPERATIONS The Flow is designed to operate in a variety of automatic and remote control applications. The Flow valve is also capable of manual operation and the register dial may be read as an ordinary water meter. Manual Operation The Flow may be manually operated using the -Way Selector: To manually open the valve: Rotate the -Way Selector to the Open position. To manually close the valve: Rotate the -Way Selector to the Close position. Automatic Operation CLOSE AUTO OPEN -Way Selector Automatic operation is made possible by direct hydraulic control from a remote irrigation controller (i.e. WeatherTRAK ET Pro irrigation controller). Volume and/or flow data is electronically transmitted to the remote irrigation controller by means of a reed switch transducer. The command to open or close the Flow valve is transmitted from the irrigation controller to a solenoid, which, in turn, transmits a hydraulic command to the Flow. To enable automatic and/or remote operation, rotate the -Way Selector to the Auto position. Solenoid Operation The Flow is always controlled via an external solenoid valve (included). A normally open (NO), high pressure, -Way solenoid valve is required for this purpose resulting in a normally closed Flow. When a normally closed solenoid is used it will result in a normally open Flow. An electric cable connects the irrigation controller and the solenoid valve (not included). 8 mm polyethylene tubing runs from the solenoid valve to the Auto connection on the -Way Selector. Automatic Position SOLENOID Operated by the Controller Open Position SOLENOID Manual Override
TROUBLESHOOTING This chapter provides detailed troubleshooting procedures and solutions for a variety of common problems. The procedures described below are general in nature and are presented in a Quick Reference style outline format. We recommend that you perform the steps in order until the specific problem is solved. It may not be necessary to complete all of the steps in a given procedure. LEAKAGE FROM FLOW CONNECTION TO PIPELINE Inspect and tighten the couplings or flange bolts. Replace the coupling, bolts and nuts as necessary. Apply Teflon tape, or other similar material, to seal the connection. Inspect and replace gaskets as necessary. Inspect and clean the orifice and associated gaskets (flow control applications only). Replace as necessary. NO ELECTRICAL OUTPUT SIGNAL FROM FLOW Inspect all cables and electrical connections. Repair or replace cables as necessary. Verify that the reed switch transducer is properly inserted into the register dial. Verify that the controller is functioning properly. If not, restart the controller and make certain that your software is properly configured. Replace the reed switch transducer. Verify that the flow indicator on the meter dial is rotating. THE CONTROLLER INDICATES WATER IS NOT FLOWING AS INSTRUCTED Verify that the controller is functioning properly. If not, restart the controller and verify that your software is properly configured. Move the -Way Selector to the Open position. Check to see if the controller shows water flow. If so, this indicates that the solenoid is not functioning properly. Repair or replace as necessary. Verify that the reed switch transducer is properly inserted into the register dial. Check all electrical connections. Replace cables as necessary. Verify that the flow indicator on the meter dial is rotating. NO INDICATION OF FLOW ON METER DIAL Remove the register assembly. Place a small magnet on the bottom of the register assembly and move it in a circular motion. This should cause the flow indicator to rotate freely. If it does not, replace the register. Disassemble the Flow. Clean or replace the strainer (½ and models only). Verify that the impeller rotates freely. If it does not, inspect the impeller, impeller shaft and other related components. Replace as necessary. Inspect the diaphragm and O-rings. Replace as necessary. 4
TROUBLESHOOTING CONT. CONTROLLER INDICATES VALVE OPENING FAILURE Verify that the -Way Selector is in the Auto position. If it is not, turn the switch to the Auto position and then check to see if the controller indicates that the valve is open. Verify that the controller and your software are functioning properly. If not, restart the controller and make certain that your software is properly configured. Verify if there is water flow downstream from the Flow. If there is not, this indicates that the valve is indeed closed. Check the electrical connections. Check the register. Remove the -Way Selector. Clean or replace as necessary. Verify solenoid operation. Repair or replace as necessary. Disassemble the Flow as described in the Maintenance section. Clean or replace the strainer (½ and models only). Inspect the diaphragm and O-rings. Replace as necessary. CLOSE AUTO OPEN -Way Selector CONTROLLER INDICATES VALVE CLOSURE FAILURE Verify that the -Way Selector is in the Auto position. If it is not, turn the switch to the Auto position and then check to see if the controller indicates that the valve is open. Verify that the controller and your software are functioning properly. If not, restart the controller and make certain that your software is properly configured. Move the -Way Selector to the Close position. Check to see if the controller indicates that the valve is closed. If so, this indicates that the solenoid is not functioning properly. Repair or replace as necessary. Verify if there is water flow downstream from the Flow. If there is, this indicates that the valve is indeed open. Check the electrical connections. Check the register. Remove the -Way Selector. Clean or replace as necessary. Remove and clean the finger strainer. Replace if necessary. Disassemble the Flow as described in the Maintenance section. Inspect the diaphragm, valve cover and O-rings. Replace as necessary. LEAKAGE FROM VALVES OR CONNECTORS Inspect the control hoses, connectors, shuttle valves and adapters. Tighten and replace as necessary. CONSTANT DRAINAGE FROM PILOT VALVE Repair or replace the pilot valve. 5 WTFLOWINSTALL07905 All trademarks are the property of HydroPoint Data Systems, Inc.