MOULDPRO Flosense 3.0 User manual

User Guidelines –Flosense 3.0 Manifold 07-09-2020 Version 002
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Installation User Guide
Flosense 3.0 manifold

User Guidelines –Flosense 3.0 Manifold 07-09-2020 Version 002
Table of contents
1. Introduction................................................................................................................1
2. Basic Safety Instructions............................................................................................2
2.1. Warning Indications ...........................................................................................2
2.2. Proper Use.........................................................................................................2
2.3. Organisational Precautions................................................................................2
2.4. Safety precautions in relation with the individual operating phases...................3
2.5. Special precautions during use of Flosense, maintenance work and repair of
malfunctions during operation and disposal..................................................................3
2.5.1. Maintenance .................................................................................................3
2.5.2. Disposal........................................................................................................3
2.6. Directions on Special Hazardous Elements.......................................................4
2.7. Safety Precautions for high temperature use.....................................................6
2.8. Startup ...............................................................................................................6
Prior to Startup:..................................................................................................6
Startup Procedure:.............................................................................................7
3. Description of the system...........................................................................................8
3.1. Overview and use of the system........................................................................8
3.2. Technical specifications.....................................................................................9
3.3. General Dimensions ........................................................................................11
3.4. Flow Description ..............................................................................................12
3.5. Installation........................................................................................................13

User Guidelines –Flosense 3.0 Manifold 07-09-2020 Version 002
3.5.1. Brackets......................................................................................................15
4. Service & Maintenance............................................................................................19
4.1. Removing cover...............................................................................................19
4.2. Refitting cables ................................................................................................21
4.3. Refitting Sensor ...............................................................................................23
4.4. Cleaning the system ........................................................................................24
4.5. Recommended tools for different repairs/maintenance....................................25

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User Guidelines –Flosense 3.0 Manifold 07-09-2020 Version 002
1. Introduction
This User guide serves as a reference for the operator of a Flosense Manifold system.
Please ensure that you have read all relevant User guides (Manifold Installation and
Software guides) thoroughly before installing your new Flosense.
During start-up and purge, always follow the quick guide.
Warning
Please ensure that flow never exceeds the sensors’ maximum. If pressurized air flow
exceeds 0.5 bar, the flow sensors may be damaged due to extreme purge speed.
Disclaimer
Costs connected to any damages to the product caused by lack of following the provided
manuals (Installation Manual, Quick guide, Software guide), will be at the customers’ own
expense

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User Guidelines –Flosense 3.0 Manifold 07-09-2020 Version 002
2. Basic Safety Instructions
In order to use the Flosense system correctly please read this section thoroughly.
2.1. Warning Indications
This section covers the safety instructions and proper use of the Flosense system. Please
read and follow these instructions thoroughly, in order to prevent damage, injuries or
extensive property damage
2.2. Proper Use
The Flosense system is designed by using the latest technical knowledge and safety
regulations.
Yet, during use, there can be a risk to cause hazard to the user or third party’s life and body,
or to cause damage to the Flosense system or other property.
The Flosense system may only be used under proper working conditions and only in
accordance with its purpose. It can only be used safely when handling isdone in compliance
with the instruction manual. In particular, disruption, which may impair the safety, shall be
promptly corrected.
The Flosense system is designed exclusively for the stated purpose. Any alternative or
additional use is considered out of scope and therefore, the Manufacturer/supplier cannot
be made liable for damages resulting from such use. The risk is entirely the user’s own.
Proper use also includes observance of operating instructions and compliance with service
and maintenance instructions.
2.3. Organisational Precautions
In addition to the instruction manual, all other applicable safety and environmental
regulations comply.
Prior to handling the product, the staff assigned to work with the Flosense system must have
read the instruction manual thoroughly, especially the chapter on safety.
The owner of the product must ensure that staff uses the Flosense system safely and in
accordance with the instruction manual.
All safety and warning instructions on the Flosense system must be respected.

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If there are safety or operational changes to the Flosense system, please stop immediately
and notify disturbance to the responsible person.
Do not make changes, expansions and renovations on the Flosense system which could
impact the safety, without seeking the supplier's permission beforehand.
Spare parts must conform to the technical requirements established by the manufacturer.
These requirements are always met by original spare parts.
2.4. Safety precautions in relation with the individual operating
phases
Normal running
Any unsafe working methods should be omitted.
Take any necessary precautions in order to ensure that the Flosense system is only used in
safe working environment.
In case of any dysfunctions, the Flosense system must be stopped immediately and
secured. Malfunctions must be corrected immediately.
2.5. Special precautions during use of Flosense, maintenance work
and repair of malfunctions during operation and disposal
The manual prescribed settings, maintenance and service intervals and instructions for
replacement parts / equipment must always be respected. This work must only be performed
by skilled personnel.
When doing any work on the manifold that requires opening the covers, removing hoses, or
otherwise gaining access to the interior of the manifold, please ensure that you have emptied
and depressurized the manifold
2.5.1. Maintenance
Maintenance and service intervals and instructions for replacement parts / equipment must
always be respected. This work must only be performed by skilled personnel.
2.5.2. Disposal
We strongly recommend safe and environmentally conscious disposal of operating
equipment and aids as well as replacement parts!

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2.6. Directions on Special Hazardous Elements
Only use original cables with the prescribed amperage. If disruption / malfunction of the
electrical energy supply occurs, then stop the Flosense system immediately.
Working on electrical systems or equipment must only be performed by an electrician or by
trained personnel and must be done under supervision and in compliance with electrical
regulations.
When performing inspection-, maintenance- and repair work, Flosense parts must be made
electricity free. It should first be checked that these parts are disconnected (electrically), and
then they are grounded and short circuited. Parts which are mounted near parts which still
are electrical connected, must be insulated.
Risk of metallic corrosion
Galvanic corrosion will occur when different metals are used in the same water installation.
This can potentially lower the lifetime of the product.
Be aware that insufficient grounding of machine parts included in the water system can
increase the corrosion of metal parts.
Corrosion will occur very rapidly if the fluid in the system has PH values higher than 8 or
lower than 5. This will potentially lower the lifetime of the product.

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Be aware that temperatures exceeding 90° Celsius can increase the corrosion of metal
parts. High temperatures will potentially lower the lifetime of the product
RISK OF LEAKING
Metal corrosion will accrue and can cause leakage. Please make frequent inspections and
maintenance of the manifolds metal to prevent this.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
Required water quality
The cooling water must fulfill certain requirements, depending on the type of cooling or
tempering of products.
Check the quality of cooling water to protect the environment and machines from corrosion
and deposition.
The recommended procedure to treat and/or care the cooling water is based on:
•Water ingredients
•Degree of contamination
•Materials used
•Type and size of cooling or tempering products
Treatment of water must always be managed by professionals, to ensure minimal corrosion
and lime scale build up. Untreated and contaminated water is not recommended and will
reduce lifetime of the products.

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RISK OF CORROSION
If there are any faults or damages to the manifold or sensors caused by different water
quality, we cannot guarantee the lifetime.
2.7. Safety Precautions for high temperature use
When operating with high temperatures please ensure that you are wearing gloves, safety
glasses and any other necessary safety equipment.
2.8. Startup
Check the label on the sensor to identify the flow or pressure sensor type:
Prior to Startup:

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Flow must never exceed the maximum capacity; failure to comply with this precaution may
damage the sensor.
Flow sensors are called:
VFS8 1-18 E (1-20 l/min standard)
VFS8 2-40 E (2-40 l/min standard)
VFS8 1-18 K (1-20 l/min high temperature)
VFS8 2-40 K (2-40 l/min high temperature)
Pressure sensors are called:
RPS6 0-10 E (0-10 bar standard)
RPS6 0-10 K (0-10 bar high temperature)
A 3-way ball valve is recommended to be installed either on, or before the main inlet, to
enable purging of the manifold and mould with pressurized air. If needed for draining, also
add a 3-way ball valve after the main outlet of the manifold. Pressurized air inlet must be
adjustable (pressure reducer)
During startup (empty mould and manifold)
1. Fully open all ball valves to/from the mould
2. Open the main return outlet valve on the manifold
3. Slowly open the main inlet valves on the manifold and start filling the system
4. Adjust the inlet flow to match the needed flow only.
5. Let it run until all air is out of the system before fully opening the main valve.
Purging (emptying mould with pressurized air)
1. Turn the main inlet valve in blocked/closed position.
2. Turn the main outlet valve in “drain” position
3. Turn the main inlet valve in “pressure air in position”
4. Open the adjustable air without exceeding 0.5 bar and ensure slow purge of water.
5. When the system has been emptied, you can fully open the air supply to blow the
circuits dry.
Startup Procedure:

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User Guidelines –Flosense 3.0 Manifold 07-09-2020 Version 002
Warning: if pressurized air supply exceeds 0,5 bar, the flow sensors may be damaged
due to extreme purge speed.
3. Description of the system
This section describes the system and its components.
3.1. Overview and use of the system
The Flosense system, is produced as an independent system solution, with the ability to
interact and communicate with machines and network connected it.
The Flosense system is capable of measuring, monitoring and logging data from a given
number of ports. Furthermore, the Flosense system is capable of sending signals, warnings,
activating and deactivating any connected machinery.

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3.2. Technical specifications
Model
Type
FFRM
No.:
01
Anno:
2020
Screen
Screen dimensions (L x W x H) [mm]
220 x 145 x 60
Cables for manifold
1 M8 cable per manifold
Power supply
12 V 1 Amp
System
Noise Level
≤ 70 dB
Measuring range
1-20 & 2-40 l/min
Accuracy (±1σ) at 0-120°C
120-160°C
±1% FS
±2% FS
Response time (63.2 %)
< 2 s
Resolution
0.2 l/min
System burst pressure at 100°C
At 160°C
16 bar
10 bar

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Temperature
Measuring range
≤ 0 to 160° C
Accuracy (±1σ), 0 to 120°C
± 1°C
Accuracy (±1σ), 120 to 160°C
± 2°C
Response time (63.2 % at 50%FS flow)
250 ms
Resolution
0.006 °C
Media and environment
Liquid/Media types
Aqueous media compatible with wetted
materials.
Kinematic viscosity ≤ 2 mm2/s (cSt)
System/Media temperature (operation)
0 to 160°C
System/Media temperature (peak)
-25 (non-freezing) to 160°C
Ambient air temperature (operation)
-25 to 60 °C
Ambient air temperature (peak)
-55 to 90 °C
Humidity, relative
0 –95%, non-condensing

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User Guidelines –Flosense 3.0 Manifold 07-09-2020 Version 002
3.3. General Dimensions
Model
Channels
A [mm]
B [mm]
C [mm]
Flosense 4-Zone
4
220
59.5
33.5
Flosense 6-Zone
6
287
59.5
33.5
Flosense 8-Zone
8
354
59.5
33.5
Flosense 10-Zone
10
421
59.5
33.5
Flosense 12-Zone
12
488
59.5
33.5
Water inlet & outlet:
G 1” (BSP)
Channel valve inlet & outlet:
G ½” (BSP)

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3.4. Flow Description

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1. The water enters the manifold form the water supply in the inlet (Water in)
2. The water is then distributed in the channels in the manifold (upper piping)
3. From the Channels the water is then supplied to the mould by whichever method the
user prefers (most often hoses)
4. After passing through the mould the water is then returned to the manifold (lower
piping)
5. The water is finally returned to the water supply
3.5. Installation
Complete 12 zone manifold
Incomplete 8 zone manifold
Remember that depending on the size of the
manifold, you may need between 8 and 24
fittings in order to fill all channels.
1. Select fittings appropriate for your needs.
Remember to have an appropriate O ring on the
fitting. The thread in the channels is G 1/2”.
2. Insert the fitting in the first channel. It is
recommended to start with the top row.

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User Guidelines –Flosense 3.0 Manifold 07-09-2020 Version 002
3. Tighten the fitting well, to ensure that the manifold
does not leak.
4. Continue mounting fittings for the rest of the
channels
5. It is possible to fit the fittings in any order, but it is
recommended to finish either the top or bottom row
before starting on the other row.
6. Finish mounting all of the fittings. Once that
is done, the manifold isready tobe connected
to your system.

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3.5.1. Brackets
If you wish to mount the manifold on a surface, or if you wish to replace the old flow regulator,
Flosense comes with brackets. These brackets are dimensioned so the Flosense system
can replace the flow regulators used on most injection moulding machines, and fit in the
same place.
1. The underside of the flosense has screws in place, which can be removed to place the
brackets.
WARNING! The perforations may be sharp, so be careful when mounting brackets.

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2. Remove up to four screws, two for each
bracket. DO NOT remove more than
four, as these screws are also a part of
how the internal pipings are mounted.
3. Mount the brackets by using the same
screws which were just removed.
Beware that the bracket should be
mounted so the holes at the ends point
“upwards” as on the picture. If the holes
are pointing “downwards”, then the
manifold can still be mounted, if you turn
it upside down.
When mounting the Flosense system, a minimum of two brackets are required, and it is
highly recommended to place them in the outermost positions as shown in step 3 above,
especially for the larger models.

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The position of the holes for the bracket can be seen in the figure above, and the dimensions
for each model can be seen in the table below.
Model
Channels
A [mm]
B [mm]
C [mm]
Flosense 4-Zone
4
100.50
180
59.5
Flosense 6-Zone
6
167.50
180
59.5
Flosense 8-Zone
8
234.50
180
59.5
Flosense 10-Zone
10
301.50
180
59.5
Flosense 12-Zone
12
368.5
180
59.5