Malema M-200 User manual

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M-200
High ow,
adjustable ow switch with right angle Flow
Operang Instrucons
and
Quick Start Guide

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Table of Contents
Introducon 03
Operaon 03
Storage and Handling 03
Installaon Instrucon 03
Construcon 03
Specicaon 04
Cercaon 05
Dimensional drawings 05
Flow Seng 07
Ordering Informaon 08
Warranty 08

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Introducon
The M-200 Series ow switches are engineered and eld tested for sensing increasing and decreasing ow rates of gases or
liquids. Pressure variaon eects are minimal. This series features such versality, economy, and accuracy that they can be used
in virtually any applicaon requiring fool-proof inexpensive ow detecon.
Operaon
The ow switch is acvated by ow forcing a piston kept in place by a spring to travel past a reed switch. This provides a posive
signal aer a certain amount of travel. Set point adjustment is controlled by adjusng the posioning of the reed switch.
llustrated is the M-200 Model with 3/8” ports.
Storage and Handling
Storage condions
Store the product under packed condion in an an-stac bag. The storage place shall be free from moisture, mechanical shock
and vibraon. The ambient temperature shall be between 0°C and 60°C and the humidity between 5% and 80% R.H. without
condensaon.
Unpacking and Product Inspecon
On delivery, check the product for damage. Conrm that the model code on the label matches the specicaon in the purchase
order.
Installaon Instrucons
This product can be mounted in any orientaon. Adequate ltraon and sealing procedures should be used when mounng in
ow lines.
Operang Environment
Choose a locaon with an ambient temperature of 10-35°C and relave humidity value <80% RH without exposure to direct
sunlight. Avoid environments with high electromagnec noise or vibraon. Make sure that the module is protected from cor-
rosive liquid or water splashes. For best performance avoid corrosive environments since they may degrade the performance of
the electronics aer a period of me. Easy access for maintenance and inspecon is always recommended.
Construcon
The M-200 Series comprises a Body, piston, and Retaining rings. Selecng a ow switch begins with selecng the body; this
series is available in 316 Stainless Steel. The M-200 series contains one moving part (i.e. the piston) and two retaining rings that
are in the uid path. Construcon of the piston is important from a design perspecve. We manufacture three types of pistons
(It is crical to select the correct piston for your applicaon): 316 Stainless Steel, PTFE encapsulated, and Special All-Metal Pis-
ton.
1. The standard piston is a 316 Stainless Steel piston with epoxy to hold the magnet in place. This piston is recommended for
non-aggressive uids and inert gases. Stainless Steel retaining rings are typically used with this piston type.
03

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2. The second piston that is available is a PTFE Encapsulated one. The piston is a magnet that has PTFE moulded around it and
then machined to the appropriate conguraon. These pistons are primarily used in PTFE ow switches and also in other ow
switch bodies ( typically 316SS and Acrylic bodies ) where customer prefer a piston that does not have epoxy in the uid path;
as well as a piston that is impervious to aggressive uids and gases. This piston is highly recommended for medical applicaons.
Hysteresis on these pistons does tend to be slightly higher (10 to 15% ) than metal piston due to friconal eects, weight,
and surface adhesion consideraons. Prior to selecng this piston, uid temperatures, and uid compability with PTFE must
be taken into account because certain aggressive chemicals at specic temperatures tend to swell PTFE causing the piston to
change shape resulng in failure of the product. Stainless or PTFE retaining rings can be used with this piston.
3. The third piston that is available is a Special All-Metal piston with no epoxy ( only available in 316SS ). This piston is fabricated
in a proprietary process with only one weld seam ( leak tested ) which presents an all 316SS surface to the uid path.
This piston is recommended for those applicaons where the piston could experience a lot of cycling wear. This piston has
been tested to 250,000 cycles at 125 psi. Stainless Steel retaining rings are recommended for this piston type for low pressure
applicaons and an orice disc ( See Universal Mounng Diagram ) is recommended for high pressure ( 125 psi ) applicaons.
SPST vs SPDT
The standard unit is provided with a SPST N.O. (N.O = Normally open at rest) dry reed switch. Increasing ow past point will close
(acvate) the switch. Decrease ow will open (de-acvate) the switch).
SPST NC. (N.C = Normally close at rest) models are closed at rest. Increasing ow pass set point opens the switch and decreasing
ow to set point will close the switch( Typically used to detect loss of ow condion in overall systems)
SPDT (Single Pole Double Throw) switches have both N.O. & N.C. conguraons by using a common pole along with two addi-
onal poles to achieve this dual capability.
Conversion from N.O. (Normally Open) to N.C. (Normally closed)
1. Loosen allen set screws (4 - 40) on face of body. These are the set screws holding the reed switch in place.
2. Move the reed switch downwards unl it shows a closed contact on the mul-meter.
3. Tighten (4 - 40) allen set screws on face of the body.
4. Cycle unl on and o by turning upside down to simulate ow. This may necessitate some renement of the exact locaon
of the reed switch as determined in step 2.
Precauons during installaon
1. Avoid any foreign parcles during installaon.
2. Large metallic and/or magnec elds may aect the principle of operaon of these units. if disturbance is detected,
magnec shielding may be necessary to ensure correct operaon of the ow switch.
3. During installaon of explosion proof versions carefully screw in the conduit connector for the electrical leads piping so
as to avoid damaging the reed switch leads or reed switch capsule which may lead to shorng the switch installaon. 6 (Six
threads) have been provided for installaon.
4. Electrical rangs etc. have been discussed later in this bullen. it is advisable to keep within those rangs as excessive
power will FRY the switch.
Electrical Protecon/Rangs
The electrical Reed Switch is rated for several million cycles and should rarely require replacement. Most switch failures are
the result of overloading. DO NOT EXCEED RATED CAPACITY, as this will cook the REED SWITCH, Catalogue rangs are based
upon D.C. resisve loads, however A.C. loads are also commonly switched.
Inducve load switching- Unless appropriate contact protecon is provided with either a diode or R.C. network, inducve load
switching will cause the contacts to sck.
Capacive load switching - The stac capacitance in cables may cause permanent or intermier contact scking. Contacts may
be protected by a series surge protector of 0.5 to 5 mAH, depending on the load. in some instances, a 10-500 ohm resistor can
replace the surge suppressor.
Cleaning
Cleaning the ow switch is easily accomplished without removing from the line. By unscrewing the clean out plug, the mag-
nec piston may be removed and the ow passage ushed or cleaned. Care should be taken to thoroughly clean the piston
before replacing ( replace the piston as shown in see page 3 gure 2. if the piston is replaced incorrectly, incorrect operaon
will result).
1. A magnet may be used to remove the magnec piston.
2. PTFE end plugs (on PTFE models) should not be over ghtened.

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Specicaons
04
Construcon Materials
Reed Switch Replacement
For reed Switch replacement
1. Loosen allen set screws (4-40) on face of body.
2. Remove and replace reed switch if needed.
3. Normally Open
Move switch downward unl switch closes then move upward unl switch opens. Very gently reghten allen screws.
Normally Closed
Move switch downward unl it closes then move upward very slightly maintaining a closed contact. Very gently reghten
allen screws.
4. If possible cycle unit on and o to test. if unit is not installed, turning upside down will simulate the ow.
Housing Acrylic Aluminium Brass 316SS PTFE
Piston 316SS PTFE
Orice Plate or disc 316SS PTFE
Spring 316SS N/A
Retaining Ring Stainless Steel (PH 15-7 MO, AMS 5520, AISI-632)
(Passivated) PTFE
Pressure and Temperature
Specicaons
Maximum Operang (psig)
Burst (psig)
Maximum Operang Temperature
200
400
77°C (170°F)
1,000
3,000
149°C (300°F)
1,500
3,000
149 C (300oF)
3,000
5,000
149 C
(300oF)
80
160
104 C (220oF)
Flow calibraon
Set point Accuracy
Set point Dierenal( Deadband )
Repeatability
( Higher accuracy units available )
10% maximum
15%
± 2 maximum
Reed Switch Data
(Electrical Rangs)
Reed Switch
Switching Voltage
Breakdown Voltage
DC Resisve
AC Resisve
Switching Current
10 Was SPST or 3 Was SPDT (Hermecally Sealed)
UL Recognized. File E47258
Operang temperature -40°C to 125°C
200 VDC ( 170 VDC for SPDT )
250 VDC ( 200 VDC for SPDT )
10 VA (3 VA for SPDT )
10 Was (3 Was for SPDT )
0.5 A ( 0.25 A for SPDT )
1.2 A ( 0.5 A for SPDT )
Lead Wires No 24 to 18 AWG. 18” length, Polymeric UL Recognized
( Belden cable or special shielded cable is available )
Lead Wires Color
SPST: 2 blue wires
SPDT: Green - Common, Yellow - Normally Closed,
Orange - Normally Open

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UL Recognised
UL Recognised for Non Hazardous locaon – UL 138467
CE Compliance
Malema ow switches meets CE compliance under LVD 2014/35/EU. RoHS and REACH can be obtained from
Malema on request.
Cercaons
Dimensional and Cut-Away drawings
Illustrated is the M-200 model with 3/8” ports
Housing A B
Acrylic 1.25” 0.625”
Aluminum 1” 0.500”
Brass 1” 0.500”
316SS 1” 0.500”
PTFE 1.25” 0.625”
05
CONTACT ARRANGEMENT
Electrical Color Coding
SPST 2 Blue Wires
SPDT
Orange -Normally Open
Yellow - Normally Closed
Green - Common

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Dimensional and Cut-Away drawings
Illustrated is the M-200 model with 3/4” ports
Illustrated is the M-200 Model with SAE8 ports.
* Note: The M-200 Model with 3/4” ports is only available in Brass, PTFE and 316SS
06
* Note: The M-200 Model with SAE8 ports is only available in Brass and 316 Stainless Steel

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FLOW SETTING
The ow seng is adjustable. This is achieved by means of the setscrew. By turning the set-screw clockwise, the ow seng
would be decreased, and by turning it counterclockwise, the ow seng increases.
07
Malema Sensors warrants to the buyer that its products are free from defects in materials and workmanship at the me of
shipment and during the WARRANTY PERIOD. Malema Sensors obligaon under this warranty is limited to the replacement of
the product(s) by same product(s) manufactured by Malema Sensors or repair of the product(s) at the Malema Sensors facility.
Malema Sensors products are sold with the understanding that the buyer has determined the applicability of the product(s)
to its intended use. It is the responsibility of the buyer to verify acceptability of performance to the actual condions of use.
Performance may vary depending upon these actual condions.
Warranty Period
This warranty is in eect for twelve (12) months from the date of shipment from Malema Sensors place of business.
Warranty Claim
If Malema Sensors products are found to be defecve in materials or workmanship within twelve (12) months of the date of
shipment, they will be repaired or replaced with same product at the discreon of Malema Sensors at its place of business at
no charge to the buyer.
Return
To return the products, please obtain an RMA number for the product by contacng Malema Sensors (Corporate Oce), Boca
Raton at [phone] or [phone].
All returns of equipment must go to the following address:
Malema Sensors,
1060 S Rogers Circle
Boca Raton, FL 33487, USA
Warranty
Note: The ow switch performance will be aected in the vicinity of Magnets, Electromagnets, and Ferrous metals. Hence
adequate protecon should be provided while installing in close proximity to such interferences or relocate the ow
switch away from them appropriately.
Ordering Informaon
Standard Part Numbering
M - Model - Material Port Switch
M - 200 - S 1 1
200
A - Aluminum
B - Brass
P - Acrylic
S - 316 Stainless
T - PTFE
3 - 3/8”
4 - 1/2”
6 - 3/4”*
1 - SPST N.O.
3 - SPDT
* The M-200 with 3/4” ports is ONLY available in the Brass, PTFE or 316SS body material.
The M-200 in Brass or 316SS is also available with SAE8 ports.
NOTE: Specicaons are subject to change without noce.
© 2018 Malema Engineering Corporaon. All rights reserved.
Malema Sensors® is a registered trademark of Malema Engineering Corporaon. Malema, the Malema logo, and Malema Engineering Corporaon are trademarks of Malema Engineering
Corporaon. All other trademarks are property of their respecve owners.
Malema supplies this publicaon for informaonal purposes only. While every eort has been made to ensure accuracy, this publicaon is not intended to make performance claims or
process recommendaons. Malema does not warrant, guarantee, or assume any legal liability for the accuracy, completeness, meliness, reliability, or usefulness of any informaon,
product, or process described herein. We reserve the right to modify or improve the designs or specicaons of our products at any me without noce. For actual product informaon and
recommendaons, please contact your local Malema representave.