Spirax Sarco Colima FLU Series Manuel utilisateur

EXPER

TISE SOLUTIONS SUST

AINABILITY

3.797.5275.200 CH Issue 2 - 2016

Vane Flow Switches

Colima FLU Series

Installation and Maintenance Instructions

1. General safety information

2. General product information

3. Installation and Maintenance

4. Spare parts

23.797.5275.200

1. General safety information

Safe operation of these products can only be guaranteed if they are properly installed, commissioned,

used and maintained by qualied personnel (see Section 1.11) in compliance with the operating

instructions. General installation and safety instructions for pipeline and plant construction, as well

as the proper use of tools and safety equipment must also be complied with.

1.1 Intended use

Referring to the Installation and Maintenance Instructions, name-plate and Technical Information

Sheet, check that the product is suitable for the intended use/application.

The products comply with the requirements of the European Pressure Equipment Directive:

2014/68/EU (PED) falling within category 'SEP'. It should be noted that products within this category

are required by the Directive not to carry the mark.

Products intended for use in the Naval and Marine sectors are RINA, and M.M.I (Italian navy) approved.

i) The products have been specically designed for use on steam, compressed air and inert

industrial gases which are in Group 2 of the above mentioned Pressure Equipment Directive. The

products’ use on other uids may be possible but, if this is contemplated, Spirax Sarco should

be contacted to conrm the suitability of the product for the application being considered.

ii) Check material suitability, pressure and temperature and their maximum and minimum values.

If the maximum operating limits of the product are lower than those of the system in which

it is being tted, or if malfunction of the product could result in a dangerous overpressure or

overtemperature occurrence, ensure a safety device is included in the system to prevent such

over-limit situations.

iii) Determine the correct installation situation and direction of uid ow.

iv) Spirax Sarco products are not intended to withstand external stresses that may be induced

by any system to which they are tted. It is the responsibility of the installer to consider these

stresses and take adequate precautions to minimise them.

v) Remove protection covers from all connections and protective lm from all name-plates, where

appropriate, before installation on steam or other high temperature applications.

1.2 Access

Ensure safe access and if necessary a safe working platform (suitably guarded) before attempting

to work on the product. Arrange suitable lifting gear if required.

1.3 Lighting

Ensure adequate lighting, particularly where detailed or intricate work is required.

1.4 Hazardous liquids or gases in the pipeline

Consider what is in the pipeline or what may have been in the pipeline at some previous time.

Consider: ammable materials, substances hazardous to health, extremes of temperature.

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1.5 Hazardous environment around the product

Consider: explosion risk areas, lack of oxygen (e.g. tanks, pits), dangerous gases, extremes of

temperature, hot surfaces, re hazard (e.g. during welding), excessive noise, moving machinery.

1.6 The system

Consider the e󰀨ect on the complete system of the work proposed. Will any proposed action

(e.g. closing isolation valves, electrical isolation) put any other part of the system or any personnel

at risk?

Dangers might include isolation of vents or protective devices or the rendering ine󰀨ective of controls

or alarms. Ensure isolation valves are turned on and o󰀨 in a gradual way to avoid system shocks.

1.7 Pressure systems

Ensure that any pressure is isolated and safely vented to atmospheric pressure. Consider double

isolation (double block and bleed) and the locking or labelling of closed valves. Do not assume that

the system has depressurised even when the pressure gauge indicates zero.

1.8 Temperature

Allow time for temperature to normalise after isolation to avoid danger of burns and consider whether

protective clothing (inlcuding safety glasses) is required.

1.9 Tools and consumables

Before starting work ensure that you have suitable tools and/or consumables available. Use only

genuine Spirax Sarco replacement parts.

1.10 Protective clothing

Consider whether you and/or others in the vicinity require any protective clothing to protect against

the hazards of, for example, chemicals, high/low temperature, radiation, noise, falling objects, and

dangers to eyes and face.

1.11 Permits to work

All work must be carried out or be supervised by a suitably competent person. Installation and

operating personnel should be trained in the correct use of the product according to the Installation

and Maintenance Instructions. Where a formal 'permit to work' system is in force it must be complied

with. Where there is no such system, it is recommended that a responsible person should know what

work is going on and, where necessary, arrange to have an assistant whose primary responsibility

is safety. Post 'warning notices' if necessary.

1.12 Handling

Manual handling of large and/or heavy products may present a risk of injury. Lifting, pushing, pulling,

carrying or supporting a load by bodily force can cause injury particularly to the back. You are advised

to assess the risks taking into account the task, the individual, the load and the working environment

and use the appropriate handling method depending on the circumstances of the work being done.

43.797.5275.200

1.13 Residual hazards

In normal use the external surface of the product may be very hot. If used at the maximum permitted

operating conditions the surface temperature of some products may reach temperatures of 350°C.

Many products are not self-draining. Take due care when dismantling or removing the product from

an installation (refer to 'Maintenance instructions').

1.14 Freezing

Provision must be made to protect products which are not self-draining against frost damage in

environments where they may be exposed to temperatures below freezing point.

1.15 Safetyinformation(Specictotheproduct)

For any safety requirements relating to particular components and / or materials used in the product

construction, please refer to installation and maintenance instructions below.

1.16 Disposal

This product is recyclable. No ecological hazard is anticipated with the disposal of this product

providing due care is taken.

1.17 Returning products

Customers and stockists are reminded that under EC Health, Safety and Environment Law, when

returning products to Spirax Sarco they must provide information on any hazards and the precautions

to be taken due to contamination residues or mechanical damage which may present a health,

safety or environmental risk. This information must be provided in writing including Health and Safety

data sheets relating to any substances identied as hazardous or potentially hazardous.

3.797.5275.200

2. General product information

2.1 Description

Magnetically activated vane type ow switches for monitoring gas or liquid ow rates are present

in most industrial applications.

The ow switches can be equipped with electrical contacts, SPDT or DPDT micro switches along with

di󰀨erent protective housings and with optional two-colour visual indicator to suit most environmental

and safety conditions.

2.1.1 Applications

- Protects pumps, motors and other equipment against low or no ow

- Controls sequential operation of pumps

- Automatically starts auxiliary pumps and engines

- Stops liquid cooled engines, machines and processing when coolant ow is interrupted

- Shuts down burner when air ow through heating coil fails

2.1.2 Operating principle

Two oscillating magnets on the same axis, one integral with the vane and one integral with the elec-

trical equipment, repel each other reciprocally through a non-magnetic material ange. The ange

separates the housing, containing the electrical equipment, from the vane that is inserted in the pipe.

The vane in absence of ow is maintained in its resting position by balance weight and repulsion

between the two magnets that face each other with the same polarity. When the ow pushes the

vane, the integral vane magnet moves and the magnetic eld pushes the integral switch magnet.

The switching of the electrical contact is quick and reliable.

2.1.3 Mounting

The Flu ow switches can be installed horizontally, directly into a pipe, or in a dedicated chamber

connected between two pipes. Several type of anges are available upon customer request.

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2.2 Materials

No. Part Material

1Housing ALU + Rilsan

2Cover ALU + Rilsan

3Indicator Plexiglass

4Microswicth Omron Z-15GW4-B

5Screw AISI 304

6Magnet Sm Co

7Flange AISI 304

8Magnet Sm Co

9Counter weight AISI 304

10 Vane AISI 304

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2.3 Design conditions

TMA Maximum

allowable temperature Steel -20°C to + 150°C

with cooling extension -20°C to + 350°C

PMA Maximum

allowable pressure Steel Colima's ange < 16 bar g

ange sized according to rating < 100 bar g

2.4 Models

FLU A

Gas ow switch, with IP 67 aluminum

housing.

Can not be tted directly on the pipes but

before the the cooling battery.

FLU O

Liquid ow switch, with IP 67 aluminum housing and

two-colour visual indicator (optional).

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3. Installation and Maintenance

Note: Before actioning any installation or maintenance work

observe the 'Safety information' in Section 1.

Refering to the Installation and Maintenance Instructions, name-plate and Technical Information

Sheet, check that the product is suitable for the intended installation.

Check: materials, pressure and temperature to ensure compatibility of the product with the required

application. Also make sure that the ambient temperature in proximity of the device is between the

values reported on the label (-20 - 40 ° C).

Remove protective covers from all connections and the protective lm from the name-plate.

3.1 Assembly

The Colima FLU magnetic ow switches are delivered packed.

3.1.1 Fit the ow switch into the tank paying attention to avoid any damage at vane.

Any damage can interfere with the correct operation of the unit.

3.1.2 Place the supplied gasket between the anges.

3.1.3 Fix the anges with bolts. Firmly secure the xing by tightening the ange bolts.

3.1.4 In case of threaded connection, tighten the instrument and place it in the direction indicated

by the arrow on the housing base.

Caution:

Always ensure that correct earthing of the equipment is carried out. Specic points are set inside

and outside the housing.

Caution:

These products should only be used for what they are designed for. Anything outside of the stipulated

application range may be subject to unforeseen and dangerous circumstances and full responsibility

will be with the installer.

3.2 Electrical equipment and housings for

  ColimaFLUseriesowswitches

The electrical equipment for the FLU series level switches comprises a support and a contact.

The oscillating element includes a magnet whose south pole points towards the ange that separates

the electrical equipment from the liquid or gas contained in the pipe. According to the pressure on

the vane provided by the liquid or gas ow in the pipe, the vane works by pivoting a sealed cartridge

containing a magnet, with south polarity on the end towards the ange.

As the two magnets on the two oscillating devices repel each other, they are never in line on the

same axis. Consequently, the status of the electrical equipment switches from the normally open

(NO) to normally closed (NC) position or vice versa.

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Requisiti dei contatti elettrici

Standard SPDT Contact

Standard microswitches are recommended for general purpose

Contact resistance: 15 mOhm Max (Initial value)

Mechanical life: >106

Electrical life: >105

V ~ A = Load

250 15 0,25 Resistive

15 0,03 Inductive

125 15 0,5 Resistive

15 0,05 Inductive

30 NA 6 Resistive

NA 5 Inductive

SPDT execution

COM

(Common)

(Normally Open)

(Normally Closed)

DPDT execution

(two simultaneous SPDT contacts)

(Normally Closed)

(Normally Open)

COM

(Common)

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3.3 Disassembly

Before disassembly of the ow switch disconnect or isolate any electricity supply or circuit and

depressurize the pipe.

Warning: do not disassemble the level switch before the pipe has been emptied.

3.3.1 Open the housing.

3.3.2 Disconnect the electric circuit cables. Close the housing.

3.3.3 Unscrew the connection bolts.

3.3.4 Extract the instrument from its slot paying attention to avoid any damage to the vane.

Periodical inspections are necessary to guarantee complete e󰀩ciency of the unit. A regular maintenance

programme starting from its initial installation is recommended. The suggested precautions are

important to obtain the best operating conditions of the level control.

The instrument does not require preventive maintenance, however it is recommended that from

time-to-time a check of the liquid uidity is actioned to avoid any suspensions or deposits that can

inuence wetted parts.

The available spare parts are detailed below. No other parts are supplied as spares.

Available spares

Contacts

To replace the contact:

1. Open the housing and remove the visual indicator (if present).

2. Disconnect cables from the electrical circuit, taking note of their position on the microswitch.

3. Unscrew the screws (1) and remove the block with the switch.

4. Unscrew the screws (2) and remove the switch from the bracket.

5. Place the new switch onto the bracket and secure it by tightening the screws (2).

6. Place the block with the switch and secure it by tightening the screws (1).

7. Reconnect the electrical cables and close the housing after repositioning the visual indicator

(if present).

4. Spare parts

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