Jesco FLOWCON Mode d’emploi
FLOWCON
Flow sensor
Operation &
Maintenance Instructions
Read these operation and maintenance instructions
before start up!
To be held for future reference.
Dosing
Conveying
Control
Liquids
Gases
Systems
EN 02
2 | Operation & Maintenance Instructions FLOWCON | Contents
Contents
1. Safety advice ....................................................................................................... 3
1.1 General.......................................................................................................... 3
1.2 Instruction symbols used in the operating manual ............................................ 3
1.3 Qualification and training of personnel ............................................................. 3
1.4 Important safety instructions ........................................................................... 4
1.5 Hazards due to non-compliance with safety instructions ................................... 4
1.6 Safe operation................................................................................................ 4
1.7 Safety instructions for the owner/operator........................................................ 4
1.8 Unauthorised modifications and production of spare parts................................. 4
1.9 Metering of chemicals .................................................................................... 5
1.10 Scope of delivery.......................................................................................... 5
2. Function ............................................................................................................... 6
2.1 Evaluation unit FLOWCON............................................................................... 6
3. Dimensions .......................................................................................................... 7
4. Technical data.................................................................................................... 10
4.1 Flow Sensor FLOWCON ................................................................................ 10
4.2 Electronic Evaluation Unit FLOWCON ............................................................. 10
4.3 FLOWCON part numbers............................................................................... 11
4.4 Selection guide ............................................................................................ 11
5. Installation ......................................................................................................... 12
5.1 General........................................................................................................ 12
5.2 Installation location....................................................................................... 13
6. Start-up.............................................................................................................. 14
6.1 Wartung....................................................................................................... 15
7. Control panel of the electronic evaluation unit ................................................ 16
8. Wiring................................................................................................................. 16
8.1 Wiring for control by external contacts ........................................................... 17
8.2 Wiring for internal or analog controlled solenoid pump .................................... 17
8.3 Wiring for internal or analog controlled motor pump........................................ 17
8.4 Setting of maximum stroke frequency at DIP switch........................................ 17
8.5 Setting of allowable faulty strokes ................................................................. 18
9. Spare parts list FLOWCON ................................................................................. 18
10. Warranty........................................................................................................... 19
Safety advice | Operation & Maintenance Instructions FLOWCON | 3
1. Safety advice
1.1 General
This operating manual contains basic information to be adhered to during installation,
operation and maintenace. It is therefore essential that the fitter as well as the relevant
qualified staff/operator read the operating manual before installing and starting up. It must
be accessible at the dosing pump/system at all times.
Not only must the general safety instructions under this main heading of Safety be obser-
ved, but also the specific safety instructions outlined under the other headings.
1.2 Instruction symbols used in the operating manual
If the safety instructions in this operating manual are not adhered to it may endanger
people, the environment and the dosing pump/system. These instructions are denoted by
the following symbols:
DANGER!
Refers to an imminent danger. Non-compliance can lead to death or serious injury.
WARNING!
Refers to a potentially dangerous situation. Non-compliance can lead to death or serious
injury.
CAUTION!
Refers to a potentially dangerous situation. Non-compliance can lead to minor injury or
damage to property.
NOTICE! or INFORMATION!
Are safety instructions which if ignored can lead to danger to the machine and its func-
tions.
IMPORTANT!
This is additional information to ensure that work is facilitated and a trouble-free operation.
There are marking affixed directly onto the device, e.g.:
• specification label
• warning notices
that must be observed without fail and remain fully legible at all times.
1.3 Qualification and training of personnel
The personnel employed for the installation, opertaion, inspection and maintence work
must be qualified to do so. The user has to define precisley the areas of responsibility,
competence and supervision of the personnel. If the personnel do not have the necessary
knowledge, they must be trained and instructed. If necessary, the manufacturer/supplier
4 | Operation & Maintenance Instructions FLOWCON | Safety advice
may do this on behalf of the pump’s owner. Furthermore, the owner of the system has to
ensure that the contents of this operating manual is fully understood by the personnel.
1.4 Important safety instructions
When installing and using this electrical equipment, basic safety precautions should
always be followed, including the following:
READ AND FOLLOW ALL INSTRUCTIONS!
WARNING!
To reduce the risk of injury, children are not permitted to use this product, they should be
closely supervised at all times.
WARNING!
To reduce the risk of an electric shock, replace a damaged cable immediately.
WARNING!
To reduce the risk of an electric shock, do not connect the unit to an extension cord with
electric voltage, use a suitably located socket instead.
SAVE THESE INSTRUCTIONS!
1.5 Hazards due to non-compliance with safety instructions
Failure to comply with safety instructions may endanger not only people, but also the
environment and the dosing pump/system. Non-compliance with the safety instructions
can lead to the loss of all claims for damages. Non-compliance can lead to the following
hazards:
• Malfunction of the dosing pump/system’s important functions.
• Malfunction of prescribed methods of maintenance and servicing.
• Endangering people through electrical, mechanical and chemical causes.
• Endangering the environment due to leakages of hazardous substances.
1.6 Safe operation
The safety instructions in this operating manual have to be observed. The owner is respon-
sible for ensuring compliance with local safety regulations.
1.7 Safety instructions for the owner/operator
Leakages (e.g. due to ruptures in the hose) of hazardous materials conveyed (e.g. abrasive,
toxic) have to be discharged in such a way so that there is no danger to people and the
environment. Statutory regulations must be observed.
1.8 Unauthorised modifications and production of spare parts
Modifications and alterations are only permitted after consulting with the manufacturer.
Genuine spare parts and accessories authorised by the manufacturer ensure security.
Safety advice | Operation & Maintenance Instructions FLOWCON | 5
IMPORTANT!
The use of spare parts that are not genuine negates all claims for damages.
1.9 Metering of chemicals
CAUTION!
When working on batchers the accident prevention regulations applicable on-site must
be observed and the prescribed personal protective clothing must be worn This operating
manual contains basic information to be adhered to during installation, operation and
maintenace. It is therefore essential that the fitter as well as the relevant qualified staff/
operator read the operating manual before installing and starting up. It must be accessible
at the dosing pump/system at all times.
Not only must the general safety instructions under this main heading of Safety be obser-
ved, but also the specific safety instructions outlined under the other headings.
CAUTION!
Chemical could spray out. This may lead to caustic or other burns. Always relieve the
system/pump pressure before starting work on the dosing pump.
WARNING!
Never look into the open end of a clogged line or valve.
Chemical may emerge unexpectedly and cause caustic or other burns to face and hands.
Before start up, all connections must be inspected for correct tightness and, if necessary,
must be further tightened using appropriate tools.
1.10 Scope of delivery
IMPORTANT!
Please unpack the hose pump and ordered accessories attached with great care, so
that small parts do not remain unnoticed in the packaging. Please compare the scope of
delivery immediately with the delivery note. The reason for any discrepancies has to be
ascertained.
6 | Operation & Maintenance Instructions FLOWCON | Function
2. Function
FLOWCON is a flow monitoring system comprised of several components specifically
desigened for pulsating flows associated with positive displacement solenoid or mo-
tor-driven dosing pumps. Its function is based on the evaluation of pulsations occuring
typically in the discharged volume flow of dosing pumps. During the discharge stroke a
float element is lifted by the pulsating liquid and thus operates a reed contact. By setting a
switch point, the flow rate determined previously by gauging is monitored. Thus the sensor
is not only sensing, whether the pump is operating, but also whether the preset flow rate is
maintained. Provided that system pressure and fluid viscosity are constant, the repeat-
ability is 10-20%.
A bypass valve allows for the monitoring of a dosing range of 0.05...12 l/h for solenoid-
driven dosing pumps and 1...50 l/h for motor-driven dosing pumps.
The electronic evaluation can be carried out by an on-site PLC, a meter or an electronic
unit, specifically developed for this purpose.
2.1 Evaluation unit FLOWCON
The evaluation unit FLOWCON allows for the monitoring of a dosing pump‘s discharge
volume in an electronic way. Failure or incorrect operation of the dosing pump is indicated
by means of a relay contact.
Monitoring of solenoid-driven dosing pumps
A stroke sensor attached to the pump (refer to MB 1 32 01) registers, when the dosing
pump has carried out a discharge stroke. In the case of accurate dosing this discharge
stroke is confirmed by the reed contact of the FLOWCON flow sensor. As the stroke sensor
senses the stray field of the drive solenoid, it does not matter whether the pump is control-
led internally or externally.
If the pump is triggered by controller or water meter contacts only, it is also possible to
compare the pump control signal with the acknowledgement of the FLOWCON flow sensor.
Monitoring of motor-driven dosing pumps
In the case of motor-driven pumps, the contact of a proximity initiator at the drive eccentric
is compared with the contact of the FLOWCON flow sensor.
The proximity sensor can be omitted if the pump is controlled by external contacts.
The evaluation unit can be set to accept a tolerable number (max. 7) of faulty strokes. Only
after exceeding this number of faulty strokes, an alarm (relay contact) is released.
If the defined number of acceptable faulty strokes is not reached within 128 discharge
strokes, the faulty strokes indicated so far will be cleared. Thus an unnecessary failure
indication is avoided (i.e. 1 faulty stroke / 128 discharge strokes = 0,78% dosing error
rate).
Dimensions | Operation & Maintenance Instructions FLOWCON | 7
3. Dimensions
FLOWCON
G L
G 5/8 152
G 3/4 154
Base mount
G i/a A
G 5/8 4/6 45
6/12 58
G 3/4 6/12 58
3L
G
G
28~ 40~
A
19,5
G
4,4
Ø
45
Ø
58
Ø
i/a
8 | Operation & Maintenance Instructions FLOWCON | Dimensions
Wall mount
G B
G 5/8 72
G 3/4 76
Stroke Sensor HR-K
Stroke Sensor
9Ø
89
M12 x 1
Benennung
Zg.-Nr.
Ersatz für Ersetzt durch
Bl.
Blatt
Maßstab Werkstoff
gez.
gepr.
Datum Name
Allgemeintoleranzen
DIN ISO 2768 T.1 mittel
Index Änderung Datum Name
> 6 bis 30 +/-0,2
> 30 bis 100 +/-0,3
>100 bis 300 +/-0,5
>300 bis 1000 +/-0,8
bis 6 +/-0,1
Postfach 10 01 64 / D-30891 Wedemark
Lutz-Jesco GmbH
26
O
4,6
O
15
25
22.07.03 Metz
2:1
Maßbild Hubsensor
MB 1 33 11/3
39
52
B
G
4,8Ø
50Ø
64Ø
Dimensions | Operation & Maintenance Instructions FLOWCON | 9
Electronic Evaluation Unit
wall mount
Electronic Evaluation Unit
panel mount
10 | Operation & Maintenance Instructions FLOWCON | Technical data
4. Technical data
4.1 Flow Sensor FLOWCON
Housing material PVC and PMMA
Sealing material FPM or EPDM
Connections Inlet:
Union nut G 5/8 or G 3/4
Outlet:
G 5/8 or G 3/4 spigot
Dosing range Solenoid-driven dosing pump
0.05...12 l/h
(Not applicable for MAGDOS LT 17.)
Motor-driven dosing pump
0.5...50 l/h
Max. system pressure 10 bar
Max. viscosity at stroke frequency 100/min 20 mPa∙s (20 cps)
Max. viscosity at stroke frequency 150/min 10 mPa∙s (10 cps)
Max. temperature of process fluid 35 °C (95 °F)
Switching capacity of reed contact 48 VAC/DC, 0.5 A, max. 12 VA
4.2 Electronic Evaluation Unit FLOWCON
Mounting Wall mount IP65 or Panel mount
Electrical data 230 VAC, 1 Ph, 50/60 Hz, 5VA
115 VAC, 1 Ph, 50/60 Hz, 5VA
Alarm relay
switching capacity
230 VAC or 110VAC, 4 A
1-pole switch, normally open at alarm
Display
1 red LED (Start)
blinks short on triggering of a stroke. Blinks long on a faulty stroke.
1 green LED (Flow)
blinks on every stroke that is verified by the stroke sensor.
1 green LED (0)
is ON as long as there is no faulty stroke.
7 green LED‘s (Error)
indicate faulty strokes by turning red.
1 red LED (Alarm)
lights when the number of allowable faulty strokes is exceeded (alarm output relay switches).
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