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INTRODUCTION/TABLEOFCONTENTS StepOne
The FLCN‐100 SeriesControllersaregeneral‐purposeflowcontrollerthatacceptsoneflowsensorinputand
providesone 16Arelayforlow‐flowpump orprocessprotection.Thispackagehasanoptionalflashingalarm
andisidealforalarmindication.Packagethisflowcontrollerwithourliquidorgasflowswitchsensors.
Features
Fail‐Saferelaycontrolofpumps,valvesoralarmswitha0to60seconddelay
Optionalflashingalarmbringsimmediateattentiontolevelalarmconditions.
PolypropyleneenclosureratedNEMA4Xwithswivelbaseforconduitalignment.
EasysetupwithLEDindicatorsforsensor(s),powerandrelaystatus.
InvertswitchchangesrelaystatefromNOtoNCwithoutrewiring.
ACpowered
TableofContents
Specifications:.........................................................................................................................................................4
Dimensions:.............................................................................................................................................................4
SafetyPrecautions:.................................................................................................................................................5
MakeaFail‐SafeSystem:............................................................................................................................6
Components:...............................................................................................................................................6
GettingStarted:.......................................................................................................................................................7
GuidetoControls:.......................................................................................................................................7
Electrical..................................................................................................................................................................8
ConnectingSwitchestoInputTerminals:...................................................................................................8
VACPowerInputWiring:............................................................................................................................8
RelayInputWiring:.....................................................................................................................................8
StrobeAlertOutput:...................................................................................................................................9
Changingfrom120to240VAC...................................................................................................................9
Installation............................................................................................................................................................10
MountingonaSensor:..............................................................................................................................10
ApplicationExamples............................................................................................................................................12
LowFlowAlarm:........................................................................................................................................12
LEDIndication:..........................................................................................................................................12
FlowSwitchCalibration:.......................................................................................................................................13
SetPoints:.................................................................................................................................................13
AccessingtheAdjustmentPotentiometer:...............................................................................................13
Appendix...............................................................................................................................................................14
ControllerLogic.........................................................................................................................................14
Troubleshooting........................................................................................................................................14
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SPECIFICATIONS/DIMENSIONS StepTwo
Controller
Supplyvoltage: 120/240VAC,50‐60Hz.
Consumption: 5Wattsmax.
Sensorinputs: (1)flowswitch
Sensorsupply: 24VDC@100mA
LEDindication: Sensor,relay&powerstatus
Contacttype: (1)SPDTRelay
Contactrating: 250VAC,16A
Contactoutput: SelectableNOorNC
Contactdelay: 0to60seconds
Electronicstemp.: F:‐40°to158°
C:‐40°to70°
Enclosurerating: NEMA4X(IP65)
Enclosurematerial: PP(U.L.94VO)
Enclosuremount.: 3/4”NPT
Enclosurerotation: 300°swivelbase
Conduitentrance: Single,1/2"NPT
CEcompliance: EN61326EMC
EN61010‐1Safety
StrobeAlert
Flashtype: Xenontube
Flashfrequency: 1persecond
Strobelife: 10Mcycles
Supplyvoltage: 120VAC,50‐60Hz.
Consumption: 3Wattsmax.
Material: Polycarbonate
Enclosurerating: NEMA4X(IP65)
Color: Amber
TerminalLabels:
(S)terminal: Provides14VDCtotheswitchinput
(‐)terminal: Ground
(+)terminal: Provides24VDCpowertotheswitch
SideView
SideViewwithStrobeAlert
FLCN‐100Series FunctionalDiagram
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SAFETYPRECAUTIONS StepThree
AboutThis Manual:PLEASEREADTHEENTIREMANUALPRIORTO INSTALLINGOR USINGTHIS PRODUCT.
ThismanualincludesinformationontwodifferentmodelsofCompactRelayFlowControllersfromOmega
Engineering:FLCN‐101,FLCN‐111 and FLCN‐111‐CE.TheFLCN‐100Series isasingle‐input controller with
anoptionalFlashAlarm™.Manyaspectsofinstallationandusearesimilarbetweenthethreemodels.
User’s ResponsibilityforSafety:OMEGA ENGINEERING manufactures severalmodelsofcontroller, with
differentmountingandswitchingconfigurations.Itistheuser’sresponsibilitytoselectacontrollermodel
that is appropriate for the application, install it properly, perform tests of the installed system, and
maintainallcomponents.
Electrical Shock Hazard:It is possible to contact components on the controller that carry high voltage,
causing serious injury or death.All power to the controller and the relay circuit(s) it controls should be
turned OFF prior to working on the controller.If it is necessary to make adjustments during powered
operation,use extremecautionanduseonlyinsulatedtools.Making adjustmentstopoweredcontrollers
isnotrecommended.Wiringshouldbeperformedbyqualifiedpersonnelinaccordancewithallapplicable
national,stateandlocalelectricalcodes.
Flammable or Explosive Applications: Sensor mount controllers should not be used with explosive or
flammable liquids, which require an intrinsically safe or explosion proof rating.If you are unsure of the
suitabilityofa controller foryourinstallation,consult yourOmegaEngineering representativeforfurther
information.
Install In a Dry Location:The FLCN‐100 Series controller housing is liquid‐resistant and made of
Polypropylene(PP).When installedproperly,thecontrollerisnotdesignedtobe immersed.Itshouldbe
mounted in such a way that it does not normally come into contact with fluid.Refer to an industry
referencetoensurethatcompoundsthatmaysplashontothecontrollerhousingwillnotdamageit.Such
damageisnotcoveredbythewarranty.
RelayContact Rating:Therelay israted fora 16amp resistiveload.Many loads(such asa motorduring
start‐uporincandescentlights)arereactiveandmayhaveaninrushcurrent characteristicthatmaybe10
to 20 times their steady‐state load rating.The use of a contact protection ci
yourinstallationifthe16ampratingdoesnotprovideanamplemarginforsuchinrushcurrents.
rcuit may be necessary for
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SAFETYPRECAUTIONS(cont.) StepThree
Make a Fail‐Safe System: Design a fail‐safe system that accommodates the possibility of relay or power
failure.If power is cut off to the controller, it will de‐energize the relay.Makesure that the de‐energized
stateoftherelayisthesafestateinyourprocess.Forexample,ifcontrollerpowerislost,apumpfillingatank
willturnoffifitisconnectedtotheNormallyOpensideoftherelay.
While the internal relay is reliable, over the course of time relay failure is possible in two modes: under a
heavyload thecontactsmaybe“welded”orstuckintotheenergizedposition, orcorrosion maybuildup ona
contact so that it will not complete the circuit when it should.In critical applications, redundant backup
systems and alarms must be used in addition to the primary system.Such backup systems should use
differentsensortechnologieswherepossible.
While this manual offers some examples and suggestions to help explain the operation of OMEGA
ENGINEERINGproducts, suchexamplesareforinformationonlyandarenot intendedas acompleteguideto
installinganyspecificsystem.
Sensor‐mount controllers:The FLCN‐100 Series is a cost‐effective, modular flow controller, whose body
incorporatesafemale3/4"NPTfitting,allowingittobemounteddirectlyontoanyOmegaEngineeringsensor
orany 3/4"connection.SimplyprovideitsrequiredACpowerandacontrolleddevicesuchasavalve,pump,
oralarmthatcanbeswitchedbythecontroller’srelayinresponsetothesensorinput.
FeaturesoftheFLCN‐100SeriesSingleInputController:TheFLCN‐100SeriesControllerisdesignedtoreceive
asignalfromasingleflowswitch.ItturnsitsinternalrelayOnorOff(assetbytheinvertswitch)inresponseto
thepresenceoffloworno‐flow,andchangestherelaystatusbackagainwhenthesensorreverses.TheFLCN‐
100SeriesmaybeusedwithanyOmegaEngineeringrelayflowswitch(FST‐200&FST‐300series).Therelayis
a single pole, double throw type; the controlled device can be connected to either the normally open or
normallyclosedside ofthe relay.Atime delayfrom0 to60seconds canbe setbeforethe relayrespondsto
thesensorinput.
Typicalapplicationsfor theFLCN‐100 Seriesarefloworno‐flow switch/alarmoperations(activating analarm
atno‐flow).
Components:
FLCN‐111 ‐SingleInputFlowController,NPTThread
FLCN‐111‐CE‐SingleInputFlowController,NPTThreadandCECompliant
FLCN‐101‐SingleInputFlowController,NPTThreadwithStrobeAlert
Owner’sManual
CompatibleFlowSwitches:
LiquidFlowSwitches:
o FST‐211‐SPST–PP/
o FST‐221‐SPST–PP/PPS(resin)‐Long
o FST‐212‐SPST–PVDF‐Short
o FST‐222‐SPST–PVDF‐Long
PPS(resin)‐Short
GasFlowSwitches:
o FST‐321‐SPST–PP/PPS(resin)‐Short
o FST‐323‐SPST–PP/PPS(resin)‐Long
o FST‐322‐SPST–PVDF‐Short
o FST‐324‐SPST–PVDF‐Long
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GETTINGSTARTED StepFour
TheFLCN‐100SeriesmaybeusedwithanyOmegaEngineeringflowswitch(FST‐200&FST‐300series)with a
relayoutput.The relayisa singlepole, doublethrowtype; thecontrolled devicecanbe connectedto either
thenormallyopenornormally closedside oftherelay.Atimedelayfrom0 to60 secondscanbesetbefore
therelayrespondstothesensorinput.TypicalapplicationsfortheFLCN‐100Seriesarepump protection,no‐
flowindicationorchemicalinjection.
GuidetoControls:Belowisalistingandthelocationofthedifferentcomponentsforthecontroller:
1. Powerindicator:ThisgreenLEDlightswhenACpowerisON.
2. Relay indicator:This red LED will light whenever the controller energizes the relay, in response to the
properconditionatthesensorinputandafterthetimedelay.
3. ACPowerterminals:Connectionof120VACpowertothecontroller.Thesettingmaybechangedto240
VAC if desired.This requires changinginternaljumpers;thisiscoveredintheInstallationsection of the
manual.Polarity(neutralandhot)doesnotmatter.
4. Relay terminals (NC, C, NO):Connect the device you wish to control (pump, alarm etc.) to these
terminals:supplytotheCOMterminal,andthedevicetotheNOorNCterminalasrequired.Theswitched
deviceshouldbea non inductive loadofnotmore than 16amps;forreactive loads the currentmustbe
deratedorprotectioncircuitsused.WhentheredLEDisONandtherela
terminalwillbeclosedandtheNCterminalwillbeopen.
5. Invert switch:This DIP switch reverses the logic of the relay control in response to the sensor(s):
conditionsthatusedtoenergizetherelaywillmakeitturnoffandviceversa.
6. TimeDelay:Aftertheinput(s)change(s)state,th
relaywillrespond.
7. Input1Aindicator:TheseamberLEDwilllightimmediatelywhenevertheappropriate sensorattachedto
the terminals detects no‐flow, and will turn off when it detects flow.This polarit
changeoftheswitchespolarity.
iscontrolsetsadelayfrom0.15to60secondsbeforethe
yisintheenergizedstate,theNO
y can be reversed by
8. Input terminals:Connect the wiring from the sensors to these terminals: Note the polarity:(+) is a 24
VDC,100mA power supply(tobe connected tothered wire ofanOmega Engin
thereturnpathfromthesensor(tobeconnectedtotheblackwireofanOmegaEngineeringsensor).(S)is
therelaysignalinput to be connectedtothe white wire.The remaininggreenwirewill return tothe(‐)
terminal.Ifpolarityisreversed,thesensorswillnotwork.
7
eeringsensor),and (‐) is
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ELECTRICAL StepFive
Connecting switches to input terminals:Please note a difference between OMEGA ENGINEERING flow
switches.Allflowswitches(FST‐200&FST‐300series)willbewiredwiththeRedwiretothe(+) terminal,the
Black wire to the (‐) terminal and the White wire to the (S) terminal.See the illustration below to indicate
wiringfor yourswitch. Note:the Shieldwire willbeusedonlyforlongcableruns orwhere excessiveelectrical
noiseispresent.
NormallyClosed NormallyOpen
SwitchCable:WheninstallinganOmegaEngineering
flow switch, adjust the cable away from the printed
circuitboardsinthe controller body.Avoid breaking
the sealbetweenthe top of thelevelswitchand the
plasticcoatedcable.
VAC Power Input Wiring:Observe the labeling on
the FLCN‐100 Series.Note: Polarity does not matter
withtheACinputterminal.
RelayInputWiring:Therelayis asinglepole,double
throwtyperatedat250 VoltsAC,16Amps.Th
terminal NO and NC (normally open and normally
closed) will be used in different applications.
Rememberthatthe"normal" state is whentherelay
coilis de‐energizedand theRed relayLED isOff /de‐
energized.
etwo
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ELECTRICAL(continued) StepFive
StrobeAlertOutput(FLCN‐101seriesonly): Withthe
StrobeAlertwiredNC;itcanbeusedasa highor low
level alarm, depending on the setting for the invert
switch.TheStrobeAlertcanalsobewiredNO.
Changingfrom120to240VAC:
1. Remove the two screws from the top of the
printed circuit board (PCB) and gently slide the
PCB from the housing.Use caution when
removingthePCB.
2. LocatedjumpersJWA,JWBandJWConthePCB.
3. Tochangeto240VAC,removejumpersfromJWB
and JWC and place a single jumper across JWA.
To change to 120 VAC, remove jumper JWA and
placejumpersacrossJWBandJWC.
4. Gently return PCB into housing and replace the
twoscrews.
120VAC 240VAC
Configuration Configuration
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INSTALLATION StepSix
Mountingona Sensor:Thefollowingprocedure shouldbeused whenmountingthe controllerdirectlyon a
flowsensor.Allpowertothesystemmustbeoffbeforeinstallingthejunctionbox.
1. Preparethesensor:Thefollowing instructionsassumethesensoris alreadymountedinaposition on
itsfitting(asdescribedinthesensor manual).Notethatbecausetheinsulation jacketofthesensoris
less flexible than most (to ensure chemical compatibility), it is important that you follow the
instructionsexactly.
a. Cutthewire4‐1/4”fromthetopofthesensor.
b. Usinga10 gaugewire stripper,strip thewhiteouterlayerofinsulationfrom thelast 1‐1/4”of
thesensorwire.Trimoffanddiscardtheexposedfoilshieldflushwiththeinsulationjacket.In
longcableruns,donotcutoffthedrainwire.
c. Usinga20gaugewirestripper,stripthelast¼”ofinsulationfromthesignalwires.
Important:Donotstripmorethan0.2”(5mm)ofinsulationfromanywirethatwillbeconnectedtothe
terminal strip.Longer insulated wire may contact the terminal strip panel, causing a short circuit
leadingtoasystemfailure.
2. Position the controller onthesensor:To make the mounting and wiringeasier,
youmustfirstremovetheprintercircuitboard(PCB)fromthecontroller.
a. Unscrewthelidofthecontroller.
b. RemovethetwoscrewsholdingthePCBtothecontroller.
c. GentlytipthecontrollertoslideoutthePCBandplaceitaside.
d. Threadthepre‐trimmed sensorwiresthroughthe¾” NPTentrancetothe
junctionbox,andplacethecontrollerinpositionoverthesensor.
e. Being carefulnot tocrossthethreads,screw thecontrolleron thesensor.
Stopwhenthecapofthesensorbecomesflushwiththebottomwallofthe
controller, or when the ½” power conduit entrance is in the desired
location.
3. Connectthesensorinputwires:
a. Routethesensor‐wiresoitstaysasclosetothehousingasp
not bend the wire sharply at the cap of the sensor.(if the installation
allows, you may rotate the controller and/or the sensor until the wire
outletofthesensorisinthebestposition.)
b. PositionthePCBinthehousingalignedwith thetwochannelsdesignedto
holdit.Do notinsertthepanelallthewayintothe housing,but letitrest
onthetopofthehousingtofacilitatethewiring.
c. Using a small screwdriv
wiresintothe hole onthesensor inputterminal,and tighten theterminal
screws.
d. OncecompletedseatthePCBbackintothechannelsandrestoreonlyone
screwtoholdthePCBinplace.
er, loosen the terminal screws.Insert the sensor
ossible,butdo
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INSTALLATION(continued) StepSix
4. Mechanical connectionto conduit:Allwiring betweenacontrollerandsensorsshouldbe inconduit.
The powerentranceofthe controller is astandard½”NPT female fitting that willattachtostandard
electrical conduit,eitherplasticormetal,as specified by local codes.Keep in mindthatthehousing
mayhavetobeunscrewedfromthesensorforperiodiccleaningofthesensor.Forthisreasontheuse
offlexibleconduit,providingenoughslackforeasyaccessisrecommended.
5. Connecttheextensionwiring:
Beforemakingconnections,makesureallpowertothesystem(controller,motor,valve,alarm,etc.)
isOFFwithasafetylockoutonthecircuitbreaker.
a. Theextensionwiringtocontrollershouldtakeintoaccountlongcableruns.Iftherunislong,it
mayneedtobeaslightlythickergaugesotheseriesresistanceiskelpwithinallowablelimits.
b. Threadtheextensionwiringthroughthepowerconduitentranceofthehousing.
c. Strip¼”oftheinsulationfromtheendsofthewires.
d. Loosen the appropriate terminal screws.Insert the extension wires into the corresponding
terminals,matchingthesensorwires.
e. Tightentheterminalscrews.
f. Return the wire protector to its location and restore the final screw which holds the wire
protectedandPCBinitsplace.
g. Replacethecap.
Note:Insome cases, additionaluser‐providedcomponents mayneedtobe attachedtothe terminals.If
so, makesurethatbothwiresand/or components entering the terminal aresecureafterthescrews are
tightened.
Note:Alwaystightenthecontrollerfromthewrenchflatlocatedonthe
swivelbase.Nevertightenfromthebodyofthecontroller.
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APPLICATIONEXAMPLES StepSeven
LowFlow Alarm:Thegoalistoindicatewhenthe flowrate fallsbelow acertain point.Ifitdoes,analarmis
supposedtosound,alertingtheoperatorofalowflowcondition.
Ifpowerisaccidentallycuttothecontroller,thesensor'sabilitytonotifytheoperatorofa lowflowcondition
couldbelost.Thesystemmustalerttheoperatornotonlytolowflow,buttocontrollerpowerloss.
Todothis,connectthehotleadofthealarmtotheNCsideoftherelayterminalofthecontroller.Ifpoweris
lost,the relaywill bede‐energized,andthe alarmwillsound(ifthereisstillpower tothe alarmcircuit itself).
The alarm circuit should have a noninterruptible power supply orsome other indicator or backup alarm to
warnofapowerfailureinthealarmcircuit.
In this application, the normal status is when the sensor is in the flow condition, and the relay will be
energizedholdingthealarmcircuitopen.Pleasenotethattheflowswitchcanbewiredeithernormallyclosed
ornormallyopen(Step5).WhentheswitchiswiredNC,theinputLEDwillbeoffandtherelayLEDwillbeon.
Soforthis application, Invertshouldbeset to theOnposition.Whenthe switchiswiredNO, the inputLED
andtherelayLEDwillbeonsimultaneously.Soforthisapplication,InvertshouldbesettotheOffposition.
LEDIndication:UseLED'slocatedabovetheinputterminalstoindicatewhethertheswitchisinafloworno‐
flow state. When the switch is wired NC, Amber indicates no‐flow and Off indicates flow. Reversing the
polarity(NormallyOpen),AmberindicatesflowandOffindicatesno‐flow.
NormallyClosed(NC)
AmberLED
NormallyClosed(NC)
LEDOFF
NormallyOpen(NO)
AmberLED
NormallyOpen(NO)
LEDOFF
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FLOWSWITCHCALIBRATION StepEight
Set Points:Ifthepreset factory calibration is not adequate foryourapplication,followthecalibration steps
listedbelow.Note:theswitch'sinternalLEDwillbeonwhentheswitchdetectsno‐flowandwilloffwhenthe
switchdetectsflow.
1. Install the fitting and flow switch as described in the Installation section of this manual.Turn the flow
switchandcontrollerpoweron and adjust the flow ratetotheapplication setting.If the medium tobe
sensed is likely to be subject to high temperature variations, the flow switch
shouldbesetatthehighestnormaltemperaturelikelytobeencountered.
2. Locatethepotentiometerknob at thetopof the flowswitch.TheredLED is
visible through the potentiometer.(If the LED is on, slowly adjust the
potentiometer counterclockwise, witha small flat headscrewdriveruntilthe
LED turns off.)The adjustment is a single turn 270° potentiometer.The
initial response time of the flow switch after adjustment is 1 to 10 seconds.
Adjust the potentiometer in slow increments and wait for the response.If
theLEDisoff, slowly adjustthe potentiometerclockwiseunti l the lightturns
on.Then turn the potentiometer counterclockwise to bring the LED off at a
reliablesetting.Remember,adjustthepotentiometerinslowincrementsand
waitfortheresponse .
3. Verifythat thenewcalibration is correctbylowering the systemflowrate below
thesetpointandchecktoseethattheredLEDturnson.Thenincreasetheflowrateabovethesetpointand
verifythattheredLEDturnsoffaccordingly.
LiquidSwitch
FST‐200Series
AccessingtheAdjustmentPotentiometer:Removethe twoscrewsfromthetop ofthe printedcircuitboard
(PCB)and gentlyslidethe PCBfrom thehousing.Use cautionwhen removingthe PCB.Youwill nowbeable
toseethepotentiometerthroughthehousing.Makeanynecessaryadjustment.Note:Electricalwiringofany
liquid level control system should be performed in accordance with all applicable national, state, and local
codes.Whencompleted,gentlyreturnPCBintohousingandreplacethetwoscrews.
GasSwitch
FST‐300Series
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APPENDIX StepNine
ControllerLogic:Pleaseusethefollowingguidetounderstandtheoperationofthecontrollers.
1. PowerLED:MakesuretheGreenpowerLEDisONwhenpowerissuppliedtothecontroller.
2. InputLED:ForNCswitchwiring,theinputLEDonthecontrollerwillbeAmberwhentheswitchreadsno‐
flowandOFFwhentheswitchreadsflow.
3. InvertOperation:WhentheinputLEDturnOffandOn,therelayLEDwillalsoswitch.WithinvertOff,the
relayLEDwillbeOnwhentheinputLEDisOnandOffwhentheinputLEDisOff.WithinvertOn,there
LEDwillbeOffwhentheinputLEDisOnandOnwhentheinputLEDisOff
.
lay
4. RelayOperation:TherelaymaybewiredeitherNOorNC.ThenormalstateoftherelayiswhenitsLEDis
Off.WiththeLEDOn,therelayisintheenergizedmodeandallterminalconnectionsarereversed.
Troubleshooting:
PROBLEM SOLUTION
Controllerispowered,butnothing
happens.
FirstcheckthePowerLEDtomakesureitisGreen.Ifnot,check
the wiring, power and make sure the terminal is seated
correctlyoverthe6‐pins.
A Flow or No‐Flow condition is
metbuttherelaydidnotswitch.
The Flow or No‐Flow is not
switchingatthecorrectflowrate.
Check the relay by switching the invert switch.Confirm that
relayclickonandoffaswellastherelayLED.
The flow switch may need to be adjusted.Review the Flow
SwitchCalibration sectionon theprevious pageforinstructions
on setting the actual flow switch.Note: access to the flow
switch adjustment is difficult and requires the removal of the
PCBassembly.Usecautionwhenperformingthisstep.
Trying to start the flow but the
controller keeps turning the flow
off.
Torestartaflowcondition, thesensorneedstosenseanactual
flow condition before changing the relay in the controller.A
flow switch over‐ride may need to be added across the relay
contacts that allows for a true flow to occur before switching
back to the controller.The use of a moment switch is
recommendedfortheover‐rideswitch.
RelayLEDdoesnotmatchmyflow
condition.
TherelayLEDcanbeswitchedbyeitherthereversingthewiring
of the sensor to the controllerorbyflippingtheinvertswitch.
This means that the relay LED can either be set to turn on
during a flow condition or to turn off during a no‐flow
condition.This is all dependent on the wiring and the invert
position.
Relay LED does not match the
sensor’sLEDindicator.
Thesensor’s LEDwill alwaysbeONduringaNo‐Flowstateand
OFF during a Flow state, regardless of the switches wiring.As
per above the input LED can beinverted to any condition.In
some applications, they will match and in others they will be
opposite.This is all dependent on the application
parameter/setup.
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