we have made up this operating manual in such a way that all necessary information about the
product can be found and understood quickly and easily.
Should you still have any question, please do not hesitate to contact M&C directly or go through your
appointed dealer. Respective contact addresses are to be found in the annexe to this operating
manual.
Please also contact our homepage www.mc-techgroup.com for further information about our
products. There, you can read or download the data sheets and operating manuals of all M&C
products as well as further information in German, English and French.
Gas sampling and conditioning technology 5-6.10-ME
3
Contents
1 General information ................................................................................................................... 4
2 Declaration of conformity ......................................................................................................... 4
The product described in this operating manual has been examined before delivery and left our works
in perfect condition related to safety regulations. In order to keep this condition and to guarantee a
safe operation, it is important to heed the notes and prescriptions made in this operating manual.
Furthermore, attention must be paid to appropriate transportation, correct storage, as well as
professional installation and maintenance work.
All necessary information a skilled staff will need for appropriate use of this product are given in this
operating manual.
2 DECLARATION OF CONFORMITY
CE - Certification
The product described in this operating manual complies with the following EC directives:
EMV-Instruction
The requirements of the EC directive 2004/108/EC “Electromagnetic compatibility“ are met.
Low Voltage Directive
The requirement of the EC directive 2006/95/EC “Low Voltage Directive“ are met.
The compliance with this EC directive has been examined according to DIN EN 61010.
Declaration of conformity
The EU Declaration of conformity can be downloaded from the M&C homepage or directly requested
from M&C.
Gas sampling and conditioning technology 5-6.10-ME
5
3 SAFETY INSTRUCTIONS
Please take care of the following basic safety procedures when mounting, starting up or
operating this equipment:
Read this operating manual before starting up and use of the equipment. The information and
warnings given in this operating manual must be heeded.
Any work on electrical equipment is only to be carried out by trained specialists as per the regulations
currently in force.
Attention must be paid to the requirements of VDE 0100 (IEC 364) when setting high-power electrical
units with nominal voltages of up to 1000 V, together with the associated standards and stipulations.
Check the details on the type plate to ensure that the equipment is connected to the correct mains
voltage.
Protection against touching dangerously high electrical voltages:
Before opening the equipment, it must be switched off and hold no voltages. This also applies to any
external control circuits that are connected.
The device is only to be used within the permitted range of temperatures and pressures.
Check that the location is weather-protected. It should not be subject to either direct rain or moisture.
The devices described in this Operating Manual must not be used in hazardous areas.
Installation, maintenance, monitoring and any repairs may only be done by authorized personnel with
respect to the relevant stipulations.
4 WARRANTY
If the equipment fails, please contact M&C directly or else go via your appointed M&C dealer.
We offer a one year warranty as of the day of delivery as per our normal terms and conditions of sale
and assuming technically correct operation of the device. Consumables are hereby excluded. The
terms of the warranty cover repair at the factory at no cost or the replacement at no cost of the
equipment free ex user location. Reshipments must be sent in a sufficient and proper protective
packaging.
Gas sampling and conditioning technology 5-6.10-ME
6
DANGER!
This means that death, severe physical injuries and/or important
material damages will occur in case the respective safety measures
are not fulfilled.
W ARN IN G !
This means that death, severe physical injuries and/or important
material damages may occur in case the respective safety
measures are not fulfilled.
CARE!
This means that minor physical injuries may occur in case the
respective safety measures are not fulfilled.
CAR E!
Without the warning triangle means that a material damage may
occur in case the respective safety measures are not met.
ATT ENT ION !
This means that an unintentional situation or an unintentional status
may occur in case the respective note is not respected.
NOTE!
These are important information about the product or parts of the
operating manual which require user’s attention.
SKILLED STAFF
These are persons with necessary qualification who are familiar with
installation, use and maintenance of the product.
5 USED TERMS AND SIGNAL INDICATIONS
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7
6 INTRODUCTION
The flow alarm units FA... are used for monitoring failures of sample gas or test gas in analysing
equipment or analyse systems.
The patented M&C flow alarm sensor FA-1/2/3bi can only be used on flow meters with meter tubes
out of transparent material. By means of the optical scanning, it is possible to register also very small
flow quantities for example in case of non-metallic or small particles.
We can also supply a high temperature version for temperatures of up to 180°C.
The M&C flow alarm units FA... are designed for stationary continuous operation and provide a long
service life and a minimum of maintenance work presuming a correct installation.
6.1 PATENTED FLOW ALARM SENSOR
The patented optical flow alarm sensors (forked light barriers) FA1/2/3bi are produced by
M & C TechGroup GmbH, D- 40885 Ratingen. [PATENT-No.: 3528270]
7 APPLICATION
In the analyse technique, the optical flow alarm sensors FA-1/2/3bi are used for the flow monitoring in
flow meters with meter tubes made of transparent material, for example Duran glass. By means of the
optical scanning, it is possible to detect also very low flow quantities in flow meters with non-metallic or
very small particles (1 mm).
The M&C electronic controllers series FA® are to be used for operating the flow alarm sensors FA-
1/2/3bi and FA2-H (see data sheet 5-6.15) as well as the liquid sensor KS 2 (not KS 2.Ex).
Gas sampling and conditioning technology 5-6.10-ME
Flow alarm sensor Type
FA-1, bi
FA-2, bi
FA-3, bi
Part-No.
02E1000
02E2000
02E3000
Meter tube
5-14 mm
13-27 mm
26-55 mm
Dimensions B x T x H in mm
35 x 23 x 15
63 x 40 x 22
103 x 75 x 25
Weight
50 g
100 g
200 g
Operating temperature
-25°C to +70°C
Storage temperature
-25°C to +70°C
Electrical connection
3 m connection cable standard; ø 4,5 mm, 4 cores (for each additional meter of sensor connection cable
= Part-No.: 02E9000, max. 10 meters) (>10 m = with pre-amplifier K-FA.. max. 200 meters)
all, selectable via electrical assignment mono- or bi-stable
Power consumption
2 VA
1 VA1 VA
Alarm Relay
(MC/NC/NO)
Contact rating max.
250V AC/DC
AC=500VA, DC=50W, 3A
250V AC/DC,
AC=500VA, DC=45W, 2A
Pull-in/drop-off time lag
of alarm relay
2 sec.
Cable inlet
1x clamping range 3mm - 6,5mm
2x clamping range 5mm - 10mm
1x clamping range 3mm - 6,5mm
1x clamping range 5mm - 10mm
Electrical connection
Terminals max. 2,5 mm2
Adjustment of sensitivity for
sensor FA..
After removing the lid on the
potentiometer
On the front side of the housing
on the potentiometer
Distance between sensor
and electronic FA-..
max. 10m
>10m, max. 200m
Line break monitoring
Yes
Protection type
IP65 EN 60529
IP20 EN 60529
IP65 EN 60529
Housing material
Polycarbonate
Polyamide
Polycarbonate
Ambient temperature
-25°C to +60°C
Electrical standard
EN61010
Dimensions
W 80 x L 160 x H 55 mm
W 22,8 x L 100 x D 111 mm
W 80 x L 160 x H 55 mm
Weight
0,31 kg
0,18 kg
0,3 kg
8 TECHNICAL DATA
8
* reversible mains voltage 230V 50Hz / 115V 60Hz, adjusted at works: 230V 50Hz.
**To be used in connection with electronic controller FA-1.1 or FA-1.4 for cable lengths of above 10m between forked light barrier and
electronic controller
Serie FA® Version FA-1.4
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9
9 DESCRIPTION
The M&C flow alarm sensor FA-1/2/3bi consists of a compact aluminium body with a fixed, open
prism and a pressure screw. This makes the positioning of the flow alarm sensors FA-1/2/3bi onto the
measuring glass of the flow meter very easy; it is not necessary to disassemble the measuring glass.
Three basic versions FA-1bi, FA-2bi and FA-3bi cover a measuring glass diameter range of 5-55 mm. Inside the sensor’s body, a mechanically protected, high-intensity LED is mounted on the left side as
light source and two phototransistors are mounted on the opposite side as receivers. The standard
connection cable of 3 meters comes out on the left side laterally to the pressure screw. The light beam
of the LED meets the photo transistors through the flow measuring glass. As soon as the floating
particles interrupt the light beam, one or both phototransistors are blacked out.
The M&C electronic controllers series FA® are available in 2 housing types for wall mounting or rail
mounting. Both types contain three service functions to be determined via the electrical connection:
Electronic controller for flow monitoring in bi-stable execution in combination with the flow
alarm sensors (forked light barriers) FA-1/2/3bi.
Electronic controller for flow monitoring in mono-stable execution in combination with the flow
alarm sensors FA-1/2/3bi or FA2-H.
Electronic controller for liquid sensor KS 2 or operation in combination with the external pre-
amplifier K-FA, in case the cable length between flow alarm sensor FA-1/2/3bi and electronic
FA-1.. is more than 10 meters or in case of strong straying signals influencing the evaluation
via the sensor cable.
For sure operation, a line break monitoring is integrated. For sure alarm signalling a potential-free
change-over contact with „Safety-first“ switching is existing. In order to avoid unwanted alarm signals
in case of pulsating gas flow, the alarm switch has got a pull-in and drop-off time-lag. Two LED’s are
signalling operational or fault status.
The electronic controllers FA-1.. are balanced in the factory relating to the flow alarm sensors FA-1/2/3bi and the measuring glasses of the flow meter FM-40 7-70NL/h. Additionally, the luminosity of
the flow monitoring sensor FA-1/2/3bi is automatically controlled in dependence on the ambient and
operating conditions (lighting conditions, temperature, agjng of the LED’s, contamination of the flow
meter glass, etc.).
In case of operating a bi-stable flow monitoring, the identification of the set flow value adjusted by the
flow alarm sensors FA-1/2/3bi is guaranteed in case of exceeding or falling below the present value
(MIN or MAX). In case of mono-stable operation, there is only an indication given whether the floating
particle is located in the light beam of the flow alarm sensor FA-1/2/3bi or above or below it
(see figure 1).
Gas sampling and conditioning technology 5-6.10-ME
10
bistable (bi) min. - Alarm
Monostable (mo)
bistable (bi) max. - Alarm
10 RECEIPT OF GOODS AND STORAGE
Please take the flow alarm units FA... and eventual special accessories carefully out of the
packaging material immediately after arrival, and compare the goods with the items listed on
the packing list.
Check the goods for any damage caused during delivery and, if necessary, notify your
transport insurance company without delay of any damage discovered.
The flow alarm units FA... are containing 1 to 4 parts depending on the desired range of delivery:
1. Flow alarm sensor FA-.bi
2. Electronic controller FA-1..
3. Pre-amplifier K-FA
4. Flow meter FM...
11 INSTALLATION INSTRUCTIONS
In case a complete monitoring unit containing forked light barrier, electronic controller and flow meter
is ordered, we will execute a balance in our works with the flow meter FM-40 7-70Nl/h. This balancing
may also be appropriate for other flow meters depending on the ambient conditions (lighting
conditions).
Should this not be the case, see chapter 14.2 and 14.3.
black floating particle: Alarm; white floating particle: o.K
Figure 1 Flow alarm sensor FA-1/2/3bi on measuring glass with bi-stable or mono-stable function
Gas sampling and conditioning technology 5-6.10-ME
11
W ARN IN G !
Incorrect power supply may destroy the device. When connecting
the equipment, please ensure that the supply voltage is identical
with the information provided on the type plate!
W ARN IN G !
When setting high-power electrical units with nominal voltages of
up to 1000 V, attention must be paid to the requirements of VDE
0100 together with the associated standards and stipulations!
A main switch must be provided externally.
The main circuit of the device must be equipped with a fuse
corresponding to the nominal voltage (over current protection); for
electrical details see technical data.
12 MOUNTING
Fix the flow alarm sensor , while the connection cable points to the left side (M&C-imprinting is
readable) and using the locking screw onto the flow meter’s measuring tube on the desired
control point for a min.-alarm (floating particle is situated in normal operation above the flow alarm
sensor) in such a way that the light beam of the flow alarm sensor will not be deflected by eventual
inscriptions or coloured background of the measuring tube.
The design of the optical flow alarm sensor (forked light barrier) provides perfect function in case of
normal day light or normal illumination. A strong incidence of light from outside to the sensor should
however be avoided.
In case the flow alarm sensor is mounted by 180° distorted, (connection cable points to the right side),
the function is reversed (max.-alarm, floating particle is in normal operation below the forked light
barrier).
The electronic controller FA1.1 is destined for wall mounting. Mounting dimensions see figure 2,
page 13 .
The electronic controller FA1.4 is destined for rail mounting according to EN 50022. Mounting
dimensions see figure 3, page 14.
13 ELECTRICAL CONNECTION
The sensor cable should not be too short when being fixed in order to assure a simple dismounting of
the forked light barrier in case of control or cleaning.
The electronic controllers FA-1.1 are equipped with a selector switch S3 for the power supply of 230 or
115 V. At the factory, this switch is adjusted to 230 V. Before starting, check the desired supply
voltage and adjust the selector switch if necessary by means of a screw driver.
The electronic controllers FA-1.4 in 24 V execution are suitable for both direct voltage as well as
alternating voltage.
Gas sampling and conditioning technology 5-6.10-ME
12
80
50
148
160
210
Ø4,3
13.1 ELECTRONIC CONTROLLER FA-1.1
For the electrical connection, the following steps have to be executed (see figure 2):
Loosen the 4 lid screws and remove the lid.
Direct the connection cable through the respective clamping screws.
The electrical connection of the sensors FA-1/2/3bi is to be made according to the colours of
the terminals 5 = yellow, 6 = green, 7 = white and 8 = brown.
The electrical connection of the sensor KS 2 and the pre-amplifier K-FA.. is to be made
according to the colours of the terminals 15 = yellow, 16 = green, 17 = white and 18 = brown.
The voltage supply occurs on the terminals 1 = L, 2 = N and 3 = PE.
The alarm is to be connected to terminal 11 = centre contact (MC), 12 = alarm (NC) and 14 =
o.k. (NO).
For a mono-stable evaluation, the attached jumper must be mounted between terminals 16 and
17 (this is not necessary for operation with pre-amplifier K-FA.. because a bi-stable or monostable operation is set on the pre-amplifier (see chapter 13.3))
Figure 2 Electrical connection and dimensions FA-1.1
Gas sampling and conditioning technology 5-6.10-ME
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5 6 7 8
15 16 17 18
L/+ N/- PE PE
11 12 14 NC
1 2 3 4
ye. gn. wh. bn.
ye. gn. wh. bn.
22,5
13.2 ELECTRONIC CONTROLLER FA-1.4
For the electrical connection, the following steps have to be carried out (see also figure 3):
The electrical connection of the sensors FA-1/2/3bi is to be made on the terminals 5 = yellow,
6 = green, 7m = white and 8 = brown.
The electrical connection of sensor KS 2 and the pre-amplifier K-FA.. is to be made on the
terminals 15 = yellow, 16 = green, 17 = white and 18 = brown.
The voltage supply happens on the terminals 1 = L, 2 = N and 4 = PE.
The alarm is to be connected to terminals 11 (MC), 12 (NC) and 14 (NO). In case of alarm
contact 11 and 12 are closed and voltage free.
For a mono-stable evaluation, the attached jumper must be mounted between the terminals 16
and 17 (this is not necessary for operation with pre-amplifier K-FA.. because a bi-stable or
mono-stable operation is set on the pre-amplifier (see chapter 13.3))
Figure 3 Electrical connection and dimensions FA-1.4
Gas sampling and conditioning technology 5-6.10-ME
14
Figure 4 Assembly plan of the FA-1.4
13.3 PRE-AMPLIFIER K-FA
For the electrical connection, the following steps have to be carried out (see also figure 4):
Loosen the 4 lid screws and remove the lid.
Lead the connection cable through the respective clamping screws.
The electrical connection of the sensors FA-1/2/3bi is to be made on the terminals 5 = yellow,
6 = green, 7 = white and 8 = brown, clamping block X2.
The electronic controller FA-1.. is to be mounted on clamping block X1, terminals 5 = yellow,
7 = white and 8 = brown.
The function mono-stable or bi-stable is determined via the 3 jumpers S1, S2 and S4.
Gas sampling and conditioning technology 5-6.10-ME
15
W ARN IN G !
Wrong power supply may destroy the equipment. When
connecting, please ensure that the supply voltage is identical with
the information provided on the model type plate!
80
50
148
160
210
Ø4,3
Figure 5 Electrical connection K-FA
14 STARTING
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16
NOTE!
For bi-stable electronic controller:
If the floating particle is situated above the flow alarm sensor when
starting and before the power supply of the electronic controller FA-1.. is
switched, the red LED is beaming and signalises alarm (Safety-Firstswitching). The same applies in case of a short-time voltage failure during
operation.
This alarm is cleared by cutting first and re-feeding of gas.
Without feeding of gas, the floating particle is placed on the float stopper on the bottom of
the flow meter measuring glass.
In case of mono-stable function, the sensor is fixed to the meter tube in such a way that the
floating particle is placed on the lowest position (alarm point) and the light beam of the sensor
is blacked out. For adjusting the alarm level, the float stopper must be regulated.
In case of bi-stable function, the sensor is fixed to the meter tube in such a way that it marks
the necessary minimum flow rate (min. alarm) or the maximum admissible flow rate (max.
alarm).
Switch on the power supply for the electronic controller.
The red LED of the electronic controller or the pre-amplifier is beaming – alarm situation.
Move the floating particle by feeding of gas into a position above the flow alarm sensor .
The green LED of the electronic controller or the pre-amplifier is beaming - O.K. situation.
The flow control unit is ready for work!
14.1 SENSITIVITY ADJUSTMENT FOR ELECTRONIC CONTROLLERS FA1.1 AND
FA1.4
The standard adjustment of the electronic controllers FA-1.. is made at works for the flow alarm sensor
(forked light barrier) FA-1bi and the measuring glasses of the flow meters FM-40 for 7-70Nl/h.
If the client composes a system with single components and if the alarm function is not given in case
of using other measuring glasses than ours, the adjustment of the forked light barriers FA-1/2/3bi can
be made as follows:
The forked light barrier must be mounted onto the flow meter glass.
The floating particle of the flow meter must not be inside the light beam of the forked light
barrier FA-1/2/3bi.
Concerning the wall mounting version FA-1.1 : Loosen the 4 screws and remove the lid. Press
the button S1 and search simultaneously the respective spot on the potentiometer P1 where
the LED indication changes from read to green or from green to red (turn clockwise in order to
change from red to green).
Concerning the rail mounting version FA-1.4 : Press the button Bal.-Control and search
simultaneously the respective spot on the potentiometer (Balance-adj.) where the LED
indication changes from red to green or from green to red.
14.2 SENSITIVITY ADJUSTMENT FOR USE OF PRE-AMPLIFIER K-FA..
When using a pre-amplifier K-FA.., the sensitivity adjustment is only to be made on the pre-amplifier
and not on the connected electronic controller FA-1.. .
For executing the sensitivity adjustment, loosen the 4 screws and remove the lid.
Gas sampling and conditioning technology 5-6.10-ME
17
NOTE!
When adjusting the sensitivity, the following principle should be considered:
As sensitive as necessary, as insensitive as possible.
Resistor
Slow operation
Resistor
Slow release
R17 1 KΩ
approx. 0 seconds
R16 1 KΩ
approx. 0 seconds
R17 100 KΩ*
approx. 3 seconds
R16 100 KΩ*
approx. 2 seconds
R17 270 KΩ
approx. 7 seconds
R16 270 KΩ
approx. 6 seconds
R17 560 KΩ
approx. 11 seconds
R16 560 KΩ
approx. 10 seconds
R17 1 MΩ
approx. 14 seconds
R16 1 MΩ
approx. 13 seconds
Adjust the voltage signal on the electronic board of the pre-amplifier K-FA.. for both photo
transistors to a value between +0,08 (lowest sensitivity) to + 0,18 VDC (highest sensitivity). The
tension is to be measured on the connection points of the sensor’s connection cables or the
soldering points M1 – M3. The adjustment is to be made on the potentiometers P1andP2.
ws (white) resp. M2 = lower phototransistor, adjustable at P1
gn (green) resp. M1 = upper phototransistor, adjustable at P2
ge (yellow) resp. M3 = earth
Measurement to be made in bi-stable version between:
ge (yellow) resp. M3 = 0V and ws (white) resp. M2 = +V (lower phototransistor)
ge (gelb) resp. M3 = 0V and gn (green) resp. M1 = +V (upper photoransistor)
Measurement to be made in mono-stable version between:
ge (yellow) resp. M3 = 0V and ws (white) resp. M2 = +V (only lower phototransistor)
14.3 ADJUSTMENT OF THE DELAY TIME
By applying the following, unwanted alarm indication in case of pulsating gas flow can be avoided.
Slow operation: Alarm release is given with a time-lag.
Slow release: Alarm is given with a time-lag.
The electronic board is accessible as follows:
In wall mounting version FA-1.1 by removing the 4 lid screws.
In the rail mounting version FA-1.4 you have to loosen the locking behind the terminals on the
upper and lower side by using a screw driver. Then, you can tear the printed board together
with the housing front out of the back housing part.
The pick-up and drop-out time delay of the alarm relay is adjustable with the fixed resistors R16/R17 at
the adjusting points on the electronic board of the electronic controller FA-1.. .
The position of the resistors is to be seen in figures 2 and 4.
* Standard adjustment at works = 33 KΩ = 1second pick-up and drop-out time delay
The times represent approximate values and are dependent on the tolerances of the components.
Gas sampling and conditioning technology 5-6.10-ME
18
NOTE!
Before carrying out any maintenance or repair work, the specific safety
procedures pertaining to the system and the operational process have to
be observed!
15 CLOSING DOWN
For closing down the equipment, no special measures are to be taken.
16 MAINTENANCE AND REPAIR
The flow control units series FA® are functioning without necessity of maintenance over a long time. It
may be that the LED and the phototransistors of the flow alarm sensor FA-1/2/3bi must be cleaned
due to dust deposits.
Please execute this cleaning with a dry cotton bud (Q-tip). If you want to humid this cotton bud, do only
use water !
If there is any defect on the electronics, please return the device for repair to M&C.
17 LIST OF SPARE PARTS
Flow alarm unit FA...
(C) Consumable parts, (R) Recommended spare parts and (S) Spare parts
Recommended quantity
for operation time of:
Part-No.: Description (V/E/T) 1 2 3 years
________________________________________________________________________________
Sensor FA-1bi:
02 E 1000 Optical flow sensor FA-1,bi with 3m connection cable (S) 1
02 E 1010 Optical flow sensor FA-1,bi with 6m connection cable (S) 1
02 E 9000 Connection cable FA.., per meter (S)
Gas sampling and conditioning technology 5-6.10-ME