ICON truflo FES Series User manual

Plastic Flow Switch
FES SERIES
Operating Manual
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Plastic Flow Switch
FES SERIES

Safety Information
Technological Progress
Functional Principle
Pump Protection
Technical Specifications
Installation
Electrical Connection
Dimensions
Warranty, Returns and Limitations
03
04
04
04
05
05
06
08
09
Table of Contents
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02
Plastic Flow Switch
FES SERIES

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Plastic Flow Switch
FES SERIES
Notice : Is used to lead users to helpful information not related to personal injury.
Safety Information
indicates general hazardous situations or cases
which, if not avoided, could result in serious injury or
death.
Warning | Caution | Danger indicates situations or cases which, if not avoided,
could result in damage or failure of the UltraFlo®
equipment.
IMPORTANT!
Please always observe the following safety instructions!
Please pay attention to the safety instructions with the following pictograms and signal words in these operating instructions:
Safety Instructions
Qualified Personnel
The personnel entrusted with installing, operating and maintaining the flow switches have to be suitably qualified; the required
knowledge can be gained via training courses or appropriate on-the-job instruction. The personnel have to be familiar with the
contents of these instructions, which have to be available to them at all times.
The electrical connection should only be carried out by a fully qualified electrician.
All work has to be carried out in accordance with existing national regulations on accident prevention and safety at work and with any
internal regulations of the operator, even if they are not specified in these instructions.
Always read these operating instructions carefully prior to installing the new product. Always adhere to the instructions contained
herein, especially the safety instructions, otherwise there is a potential risk of personal injury and damage to instruments and plants.
Even though we provides assistance through personal consultation or the respective literature, it is the responsibility of the customers
to determine the suitability of the product for the specific application.
The flow switches are state-of-the-art devices. This concerns switching point accuracy, functioning and safe operation of the device.
However, professional and safety conscious conduct of the operator is required to ensure safe operation.
Special Safety Instructions
The operational safety of the supplied equipment is only guaranteed if it is operated according to its intended use. The specified limit
values (see the chapter entitled “Technical data“) should never be exceeded.
To avoid damages to the flow switch and the monitored system, only use flow switches for minimum or maximum monitoring of the
flow of liquids.
Always follow and adhere to the flow switch installation instructions.
Never operate the flow switch in systems which have a greater flow rate than the specified max. flow rate (see the chapter entitled
“Technical data”, details of the max. flow rate). Otherwise it will cause irreparable damage to the flow switch.
Prior to flow switch installation, ensure that all the materials of the flow switch are chemically and mechanically-resistant to the
medium which is to be monitored and to all external factors.
Ensure that the medium is free from magnetic particles.
Suitable measures should be taken to prevent the medium from freezing. If the flow switch is to be used in ambient temperatures of <
39.2 °F, do not carry out any operation beforehand with pure water, e.g. a test run. Residual water in the flow switch can result in frost
damage.
No greases, oils etc. should be used during the installation of the FES Series devices due to the material resistance.
Ensure that the max. specified operating pressure is not exceeded.
Never remove a flow switch or its upper parts from a pipe system under pressure.

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04
Plastic Flow Switch
FES SERIES
Functional Principle
Pump Protection
The flow switch consists of a paddle system (1) which has a
permanent magnet (2) located at its upper end. A reed contact (3) is
positioned outside the flow above this magnet. A second, magnet (4)
with opposite polarity is used to create a reset force.
The paddle system is moved once it comes into contact with the flow
which is to be monitored. The magnet (2) changes its position in
relation to the reed contact (3).
The contact opens/closes depending on the contact type. As soon
as the flow is interrupted, the paddle returns to its original position
and the reed contact opens/closes depending on the contact type.
If the medium which is to be monitored is very hot, the flow switches or their connection fittings will also become very hot. In this case,
neither touch the flow switch nor place any heat-sensitive objects in its vicinity.
Protect the flow switch against external magnetic fields in the immediate vicinity, since these can impair device functioning.
The technical data of special versions (customised versions) can deviate from the details in these instructions. Please observe the
details on the type plate.
Caution: Danger of death due to high voltages! Always de-energize the system before connecting the connector cable.
It is prohibited to remove or make type plates or any other information attached to the equipment indecipherable, otherwise all
warranties and the responsibility of the manufacturer no longer apply.
Ensure that the maximum electrical contact load specified on the type plate is never exceeded; otherwise the reed
contact integrated in the switching unit will be damaged.
The switching capacity is reduced with inductive loads. Details of the protective circuit can be requested from the
manufacturer.
Technological Progress
The manufacturer reserves the right to revise, alter, or modify the flow meter to the most current technology without special prior notice.
Further information about the latest updates and potential additions to these operating instructions are available from
www.iconprocon.com
Magnet (2)
Magnet (4)
Shaft
Paddle System (1)
Reed Contact (3)
N
S
N S
Flow
Pump ON
Reed Contact
FES Series
No Flow
Empty Pipe Empty Pipe
Pump OFF
Reed Contact
FES Series

Technical Specifications
Installation
Max. Working Temperature 190°F | 88°C
Max. Working Pressure | Non-Shock 145 psi | 10 bar
Relay SPST Reed Switch | NO | NC |Adjustable
Protection Class IP 65 | NEMA4X
Max. Contact Current 1.5A
Max. Power Supply 85 VDC | 250 VAC
Body PP
O-Ring Viton
General
General Installation Instructions
When choosing the installation site, ensure that the specified limit
values (see "Technical Specifications") are not exceeded.
Select suitable measures to prevent the medium from freezing.
If the flow switch is to be used in ambient temperatures of < 39.2 °F,
do not carry out any operation beforehand with pure water, e.g. a test
run. Residual water in the flow switch can result in frost damage.
Firstly, clean the pipe system in which the flow switch is to be installed
and remove any magnetic particles, e.g. welding residue.
The straight in- and outlet pipe (in front of and behind the flow switch)
has to be at least 5 x ID.
The nominal installation position of the flow switch is an "upright
standing position" in horizontal pipework.
The switches should only be installed in a vertical position, deviation
max. 45 (Fig. 1).
Please contact the manufacturer if other installation positions are
desired.
Please make sure that there are no external magnetic fields in the
immediate vicinity of the flow switch, since these can impair device
functioning (Fig. 2).
There is an arrow on the flow switch. Ensure that this arrow is parallel
with the pipe shaft and is facing in the direction of flow
during installation (Fig. 2).
The brass and Plastic union nuts ¾" BSP have a tightening torque of
18.439 ... 22.127 ft lb.
The plastic union nuts have a tightening torque of 5.163 ... 5.901 ft lb.
Fig. 1
max. 45°
Fig. 2
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Plastic Flow Switch
FES SERIES

During flow switch installation, ensure that the paddle does not touch the wall of the pipe.
Carry out installation of your device type as described in the table below.
In order to shorten the paddle to the required length, use a
side cutter.
When cutting, hold the paddle tight above the cut surface.
Electrical Connection
Elbow Plug Connector
Fig. 3 Fig. 4
Loosen the central screw (pos. 1) and disconnect the junction box (pos. 2) from the connector (pos. 3), Fig. 1.
Use a screwdriver or similar tool to press out the core (pos. 4) of the junction box (Fig. 2).
Loosen the screw Cable Gland (pos. 5) Fig. 3.
Feed the connecting cable into the junction box via the screw connection (pos. 5), the clamping ring (pos.6) and the rubber insert
(pos. 7) and subsequently connect the wires as displayed in the connection diagram (see Fig. 4).
Danger of death due to electrical voltage!
Work on electrical installations may only be carried out by qualified electricians or by instructed persons working under the
guidance and supervision of a qualified electrician, in accordance with the electrical regulations.
Always de-energize the system before connecting the wires of the mains cable.
CAUTION: Ensure that the maximum electrical contact load specified on the type plate is never exceeded; otherwise the reed
contact integrated in the switching unit will be damaged.
Inductive loads impair switching capacity. Please ask the manufacturer for information on protective circuits.
Fig. 1 Fig. 2 Fig. 3 Fig. 4
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06
Plastic Flow Switch
FES SERIES
¾" BSP
½" NPT
L3
9
15
20
30
40
50
60
9
15
20
30
40
50
60
70
80
2
1
45
3core
5
67

Relay Position
NO NC
Make Contact (NO) RED arrow
Break Contact (NC) WHITE or BLUE arrow
Contact Type Setting
Increasing
Decreasing
Increasing
Decreasing
Flow Rate
Closing
Opening
Opening
Closing
Electric Contact
Press the core (pos. 4) until it locks into position in the junction box (pos. 2).
Tighten the cable gland (pos. 5).
Place the junction box (pos. 2) on the connector (pos. 3) and retighten the central screw (pos.1).
To guarantee the protection class IP 65 per EN 60529, the applied connecting cable has to have a sheathing diameter of between 4.5
and 7 mm.
Furthermore, ensure that all the connector seals (pos. 2, 3 and 7) have been correctly inserted.
In order to adjust the switching unit, open the cover of the switching head
Subsequently loosen the locking screw (2.5 hexagon socket screw) and position the switching unit until the red or white arrow are
visible at the entry of the switching contact guide for a desired make contact or break contact respectively.
You can use the arrow length to make fine adjustments to the switching point: Adjust to the arrowhead means: Switching point is at a
lower flow rate. Adjust to the arrow end: Switching point is at a higher flow rate.
Adjust Switching Unit
Standard Contact
The switching unit of the control switch enables 2 contact types:
1. Make contact (normally open): "RED" arrow on the switching unit
2. Break contact (normally closed): "WHITE" arrow on the switching unit
Unless otherwise agreed to with the customer, the switching unit is factory set to make contact, i.e. opens if the set switching point is
exceeded.
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Plastic Flow Switch
FES SERIES
Lift To Open
Relay Housing
Housing
to open here
12
3
4
Reed Contact Reed Contact
1. Reed Contact
2. Reed Contact
3. Not occupied
4. Not occupied

Carefully retighten the locking screw.
We recommend you to use lacquer/thread locker to secure the locking screw of the switching unit after carrying out individual
adjustments.
Close the cover until it locks into place.
Dimensions
Pipe Size Connection
DMax. Flow m3/h, Water
Rising
Flow Rate
L/min, Water
AA
(mm) L (mm) D (mm)
Falling
Flow Rate
L/min, Water
½ - 2"
3"
4"
4"
6"
8"
Model
FES-005-2
FES-005-3
FES-005-4
FES-005-41
FES-005-6
FES-005-8
½" NPT
½" NPT
½" NPT
½" NPT
½" NPT
½" NPT
20
30
40
70
110
120
1 | 2
3 | 6
4.8 | 8
4.5 | 5.5
8 | 11
18 | 24.2
0.9 | 1.9
2.9 | 5.5
4.6 | 7.5
4 | 5
7.8 | 10
17.5 | 24
27
27
27
27
27
27
52
52
52
112
112
112
12 X 20
12 X 20
12 X 20
12 X 80
12 X 80
12 X 80
116.3
98
127
AA
AA D
D
d
d
L
L
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Plastic Flow Switch
FES SERIES
The switching unit does not need to be adjusted when the customer requests a factory set switching point.
Locking Screw
High flow rate
Low flow rate
Setting Range
Red
White
Locking Screw
High flow rate
Low flow rate
Setting Range
Red
White
Make Contact (Red arrow) Break Contact (White arrow)

Warranty, Returns and Limitations
Icon Process Controls Ltd warrants to the original purchaser of its products that such products will be free from defects in
material and workmanship under normal use and service in accordance with instructions furnished by Icon Process Controls Ltd
for a period of one years from the date of sale of such products. Icon Process Controls Ltd obligation under this warranty is
solely and exclusively limited to the repair or replacement, at Icon Process Controls Ltd option, of the products or components,
which Icon Process Controls Ltd examination determines to its satisfaction to be defective in material or workmanship within the
warranty period. Icon Process Controls Ltd must be notified pursuant to the instructions below of any claim under this warranty
within thirty (30) days of any claimed lack of conformity of the product. Any product repaired under this warranty will be warranted
only for the remainder of the original warranty period. Any product provided as a replacement under this warranty will be warranted
for the one year from the date of replacement.
Warranty
Products cannot be returned to Icon Process Controls Ltd without prior authorization. To return a product that is thought to be
defective, go to www.iconprocon.com, and submit a customer return (MRA) request form and follow the instructions therein. All
warranty and non-warranty product returns to Icon Process Controls Ltd must be shipped prepaid and insured. Icon Process
Controls Ltd will not be responsible for any products lost or damaged in shipment.
Returns
This warranty does not apply to products which: 1) are beyond the warranty period or are products for which the original purchaser
does not follow the warranty procedures outlined above; 2) have been subjected to electrical, mechanical or chemical damage due
to improper, accidental or negligent use; 3) have been modified or altered; 4) anyone other than service personnel authorized by
Icon Process Controls Ltd have attempted to repair; 5) have been involved in accidents or natural disasters; or 6) are damaged
during return shipment to Icon Process Controls Ltd reserves the right to unilaterally waive this warranty and dispose of any
product returned to Icon Process Controls Ltd where: 1) there is evidence of a potentially hazardous material present with the
product; or 2) the product has remained unclaimed at Icon Process Controls Ltd for more than 30 days after Icon Process Controls
Ltd has dutifully requested disposition. This warranty contains the sole express warranty made by Icon Process Controls Ltd in
connection with its products. ALL IMPLIED WARRANTIES, INCLUDING WITHOUT LIMITATION, THE WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE EXPRESSLY DISCLAIMED. The remedies of repair
or replacement as stated above are the exclusive remedies for the breach of this warranty. IN NO EVENT SHALL Icon Process
Controls Ltd BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND INCLUDING PERSONAL
OR REAL PROPERTY OR FOR INJURY TO ANY PERSON. THIS WARRANTY CONSTITUTES THE FINAL, COMPLETE AND
EXCLUSIVE STATEMENT OF WARRANTY TERMS AND NO PERSON IS AUTHORIZED TO MAKE ANY OTHER
WARRANTIES OR REPRESENTATIONS ON BEHALF OF Icon Process Controls Ltd. This warranty will be interpreted pursuant
to the laws of the province of Ontario, Canada.
If any portion of this warranty is held to be invalid or unenforceable for any reason, such finding will not invalidate any other
provision of this warranty
For additional product documentation and technical support visit www.iconprocon.com | e-mail: [email protected]
[email protected] | Ph: 905.469.9283
Limitations
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09
Plastic Flow Switch
FES SERIES