Flow-Alert
Flow Switch
VAM-UM-00646-EN-04 (April 2017)
User Manual
Flow-Alert, Flow Switch
CONTENTS
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Wiring through Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Microswitch Congurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Reed Switch Congurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Wiring Congurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Microswitch Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Reed Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Quick Recoupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cartridge Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Application Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Liquid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pneumatic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Flow vs Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Microswitch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Reed Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Reed Switch Conguration with Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Microswitch Conguration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Reed Switch Conguration with Strap Assembly . . . . . . . . . . . . . . . . . . . . . . . 27
Page ii April 2017VAM-UM-00646-EN-04
Introduction
INTRODUCTION
The Flow-Alert flow meter combines the rugged proven technology of a direct reading,
piston-type variable area flow meter, coupled with electrical contacts used to signal
operators or PLCs at customer-defined flow rates. This combination is sealed against
industrial contamination by a NEMA 12 and 13 (IP52/54) rated enclosure (does not apply to
strap versions).
This product provides a local flow indication and automatically signals the operator or PLC
if flow is too high or too low.
Uses of the Flow-Alert flow meters include, but are not limited to: bearing lubrication, case
drain verification, gun drill cooling and pump flow confirmation.
INSTALLATION
THIS PRODUCT SHOULD BE INSTALLED AND SERVICED BY
TECHNICALLY QUALIFIED PERSONNEL TRAINED IN MAINTAINING INDUSTRIAL CLASS
FLOW INSTRUMENTATION AND PROCESSING EQUIPMENT.
READ INSTRUCTIONS THOROUGHLY BEFORE INSTALLING THE UNIT. IF
YOU HAVE ANY QUESTIONS REGARDING PRODUCT INSTALLATION OR MAINTENANCE,
CALL YOUR LOCAL SUPPLIER FOR MORE INFORMATION.
THIS FLOW METER MAY CONTAIN RESIDUAL AMOUNTS OF TEST
FLUID AT THE TIME OF SHIPMENT. THIS FLUID SHOULD BE REMOVED PRIOR TO
INSTALLATION AS THE FLUID MAY BE INCOMPATIBLE OR HAZARDOUS WITH SOME
LIQUIDS OR GASES. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN
DAMAGE TO THE EQUIPMENT.
ALL FLOW ALERT FLOW METERS ARE UNIDIRECTIONAL AND HAVE
NO BYPASS OPTION. ATTEMPTS TO FLOW FLUIDS IN THE OPPOSITE DIRECTION OF
THE FLOW ARROW WILL RESULT IN THE FLOW METER ACTING AS A CHECK VALVE,
CREATING A DEADHEADING SITUATION. IF THE DIFFERENTIAL PRESSURE MAGNITUDE
IS GREAT ENOUGH, DAMAGE TO THE INTERNAL PARTS OF THE FLOW METER RESULTS.
DISCONNECT ELECTRICAL POWER BEFORE OPENING WIRING
ENCLOSURE. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN SERIOUS
PERSONAL INJURY OR DEATH AND/OR DAMAGE TO THE EQUIPMENT.
ALL WIRING SHOULD BE INSTALLED IN ACCORDANCE WITH THE
NATIONAL ELECTRICAL CODE AND MUST CONFORM TO ANY APPLICABLE STATE AND
LOCAL CODES. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN SERIOUS
PERSONAL INJURY OR DEATH AND/OR DAMAGE TO THE EQUIPMENT.
AIR/GAS FLOW METERS ARE NOT OXYGEN CLEANED. USE WITH OXYGEN
MAY CAUSE HAZARDOUS OR EXPLOSIVE CONDITIONS THAT MAY CAUSE SERIOUS
PERSONAL INJURY AND/OR DAMAGE TO THE EQUIPMENT.
Page 3 April 2017 VAM-UM-00646-EN-04
Installation
Installation Recommendations
Hedland flow meters are designed for easy installation. However, the following measures
are recommended for reliable,
trouble-free operation:
• Piping should be accurately aligned and of correct length. The high pressure body of the
flow meter can withstand shock and flow/pressure pulsation. Piping should be firmly
supported by external mounting brackets, both upstream and downstream of the flow
meter, to avoid any pipe flexing actions that could reduce flow meter life.
• If the flow meter inlet or outlet is rigidly mounted, and the opposing port is connected
to flexible hose, the end connected with the flexible hose must be rigidly mounted.
• Install a union near the inlet or outlet of the flow meter to facilitate quick and easy flow
meter removal and inspection during periodic maintenance procedures.
• Mount the flow meter either horizontally or vertically (flow arrow pointing to either
side or straight up). If the flow meter must be mounted inverted, special inverted scales
are available.
• Verify the fluid is traveling in the direction of the flow arrow, see Figure 1 on page 5.
• Systems that do not have filtration should be equipped with at least a 200 mesh (74
micron) filter. Most hydraulic system applications already have much finer filtration. The
flow meter will allow particulates to pass that would jam most valves and flow controls.
Dirt, ferrous metal or sealing agents may lodge and cause malfunction. If the flow meter
is jammed at a fixed position, follow cleaning and maintenance instructions.
• Do not use thread locking compounds as thread sealant.
• Do not install the flow meter near turbulence producing fittings such as elbows,
reducers and close coupled valves for maximum reliability. The inline flow meter does
not require flow straighteners or special lengths of straight inlet/outlet piping to
stabilize turbulent flow patterns.
• Do not install the flow meter near fast-acting valves. Fast-acting valves have the
potential to create high magnitude hydraulic pressure spikes. These spikes can damage
the internal components of the flow meter, resulting in inaccuracies or malfunction.
• Do not operate flow meter against the direction of the flow arrow. The flow meter is
unidirectional. The piston acts as a check valve to block flow in the reverse direction. This
causes an excessive pressure differential, which can result in damage to internal flow
meter components.
Page 4 April 2017VAM-UM-00646-EN-04
Installation
Installation Instructions
1. See Figure 1. Mount the ow meter so uid is traveling in the direction of the ow arrow.
Figure 1: Flow direction arrows
2. See Figure 2. Select a mounting location that is suitable for viewing and product service.
To connect the ow meter into the piping system, place an open-ended wrench onto
the ow meter wrench ats adjacent to the pipe connection being installed. DO NOT
wrench on the opposite end of the ow meter or leakage may result.
3. After installation, rotate ow meter by hand to view ow scale.
Place wrench on transmitter flats on the
same side plumbing is being tightened.
Rotate transmitter by hand only to view flow
scale. Never use wrench on flats to
rotate transmitter.
Never place wrench on meter flats opposite
plumbing being tightened.
Figure 2: Installing and rotating the flow meter
Never place wrench on transmitter flats
opposite plumbing being tightened.
Place wrench on meter flats on the same
side plumbing is being tightened.
Rotate meter by hand only to view flow
scale. Never use wrench on flats to
rotate meter.
Page 5 April 2017 VAM-UM-00646-EN-04
Electrical Connections
ELECTRICAL CONNECTIONS
All Flow-Alert flow meters are offered with either single or dual switches. Consult local
wiring codes before applying power.
Wiring through Conduit
Some installations may require a rigid conduit for the wiring. To access a conduit
connection:
• For microswitch equipped models only:
Remove the black, watertight strain-relief/gland connection from the outside of
the enclosure
• For all other models (excluding strap assembly models):
Remove the Hirshmann connection from the outside of the enclosure
Microswitch Congurations
The strain-relief/gland connection outside of the microswitch enclosure is watertight.
Microswitch Cable Specifications
Single Switch: 4-Wire #18 AWG, SJO Jacket Cable
Color Function
Red Normally Closed (N.C.)
Black Normally Open (N.O.)
White Common
Green Ground
Dual Switch: 7-Wire #16 AWG, SJO Jacketed Cable
Color Function Switch ID
Red
Black Normally Open (N.O.)
White Common
Orange
Blue Normally Open (N.O.)
White/
Black
Green Ground
Normally Closed
(N.C.)
Normally Closed
(N.C.)
Common
Cable Length: 1/4…1 in. Meters
Inside Enclosure Overall Inside Enclosure Overall
(101.60 mm)
(50.80 mm)
Table 1: Microswitch single switch specifications
Switch 1
Decreasing
Switch
Switch 2
Increasing
Switch
Table 2: Microswitch dual switch specifications
4.00 in.
2.00 in.
Cable Length for 1/4…1
Inside
Enclosure
4.00 in.
(101.60 mm)
10.5 in.
(266.70 mm)
2.00 in.
(50.80 mm)
42.0 in.
(106.68 cm)
in. Meters
Overall
28.0 in.
(711.20 mm)
Cable Length: 1-1/4…1-1/2
in. Meters
6.00 in.
(152.40 mm)
5.00 in.
(127.00 mm)
Cable Length for 1-1/4…
1-1/2 in. Meters
Inside
Enclosure
10.0 in.
(254.00 mm)
15.0 in.
(381.00 mm)
5.00 in.
(127.00 mm)
50.0 in.
(127.00
Overall
35.0 in.
(889.00 mm)
cm)
Page 6 April 2017VAM-UM-00646-EN-04
Electrical Connections
Power Line
Power Line
Reed Switch Congurations
Most units are equipped with an enclosure and a 15 ft (4.57 m) length of 4-wire #25 AWG
type, PVC jacketed cable with a 4-pin Hirschmann connector.
Certain 1/4 in. or SAE 6 meters with lower flow ranges are equipped with a strap housing.
For safe operation of the reed switch, do not exceed the maximum wattage for that switch.
For example, the normally open (N.O.) reed switch has a maximum power rating of 10
Watts. If the switch is to operate at 24V DC, the maximum current is the wattage divided by
the voltage.
W
I =
Exceeding the maximum power rating for a particular switch will damage it.
Reed Switch Cable Specifications
10
=
= 0.417A
E
24
Single Switch (Strap Version): 2-Wire #24 AWG with Flying Leads
Color Function Wire Length
Yellow Normally Open (N.O.) 40.0 in. (101.60 cm)
Green and Blue Normally Closed (N.C.) 18.0 in. (457.20 mm)
Table 3: Reed switch (strap version) single switch specifications
Single or Dual Switch: 4-Wire #25 AWG, PVC Jacketed Cable with Hirschmann Connector
Color
Single Switch Dual Switch
Red (Pin 1) X
Black (Pin 2) X
Green (Pin 3) Not Used
White (Pin 4) Not Used
Wire Assignment
Decreasing Switch
Increasing Switch
Switch 1
Switch 2
Cable Length
15 ft (4.57 m)
Table 4: Configuration of reed switch with enclosure
Wiring Congurations
BLACK
Load
Load turns ON when ow exceeds setpoint.
Relay
Coil
Load
Power Line
Load turns OFF when ow exceeds setpoint.
Flow-Alert
BLACK
R
1
Flow-Alert
R1
WHITE
Power Line
Load turns OFF when ow exceeds setpoint.
Figure 3: Loads within contact rating
WHITE
Power Line
Load turns ON when ow exceeds setpoint.
Figure 4: Loads outside contact rating
Power Line
Load
Relay
Coil
R
1
Load
WHITE
RED
Flow-Alert
WHITE
BLACK
Flow-Alert
R1
Power Line
Power Line
Page 7 April 2017 VAM-UM-00646-EN-04
Operation
OPERATION
See “Application Information” on page 12 for application information and fluid charts.
Microswitch Adjustment
1. Remove cover screws and front cover.
OTE:N On flow meters equipped with dual microswitches, the side closest to the connector is the
decreasing flow switch and the side opposite the connector is the increasing flow switch.
OTE:N See “Microswitch Cable Specifications” on page 6 for cable lengths and specifications.
2. Loosen the screws securing the switching roller and latching rollers to the guide bar.
Turn each screw a maximum of one full turn.
Latching Roller
Spacer Strip
Switching Roller
Latching Roller
Pointer
Guide Bar
Figure 5: Microswitch adjustment
Screws
3. All rollers are secured as a set to the spacer strip. Slide the entire roller set until the
pointer is at the desired setting.
OTE:N The spacer strip controls the maximum distance between rollers. This distance may be
shortened when the switch setting is close to the end of the flow scale. Latching rollers may
also be removed if the switch setting is close to the end of the flow scale.
4. Make sure the roller brackets are ush against the guide bar. Tighten the roller screws.
5. For dual switch models, repeat steps 1…4 for the increasing switch setting.
6. Install the cover gasket and front cover and secure with screws. To properly seat the
cover gasket, tighten cover screws in a crisscross pattern (see Figure 6).
Figure 6: Cover screw tightening sequence
Page 8 April 2017VAM-UM-00646-EN-04
Operation
Reed Switch Adjustment
1/4 inch Models with Strap Assembly
1. Loosen the screw securing the switch assembly (see Figure 7).
Arrow Pointers
on Switch Band
Screw
Figure 7: Reed switch adjustment (1/4 in. models)
2. Slide the switch assembly until the arrow pointers on the switch band are aligned with
the desired ow rate indicated on the scale.
3. Tighten the screw.
1/4…1-1/2 inch Models with Enclosure
1. Remove cover screws and front cover.
2. Loosen the screw securing the switch assembly (see Figure 8).
Arrow Pointer
Screw
Figure 8: Reed switch adjustment (1/4…1-1/2 in. models)
OTE:N On flow meters equipped with dual reed switches, the side closest to the connector is the
decreasing flow switch and the side opposite the connector is the increasing flow switch.
OTE:N See “Reed Switch Cable Specifications” on page 7 for cable lengths
and specifications.
3. Slide the switch assembly until the arrow pointer aligns with the desired ow rate
indicated on the scale.
4. Tighten the screw.
5. For dual switch models, repeat steps 1…4 for the increasing switch setting.
Page 9 April 2017 VAM-UM-00646-EN-04