ROCON DeltaPoint Jr User manual

DeltaPoint Jr
Installation and Operation Manual
6 GPM (22.7 LPM) Unit
EMERGENCY
24 Hour Service Phone Number
877-684-0589
Effective with products having serial number 040817000 and greater, Firmware Revision 3.15
DPJMAN-1106
ROCON LLC
1755 East Nine Mile Road, Hazel Park, MI 48030
PH 248-542-9635, Fax [phone] www.flowmeters.com
TM

2
ROCON LLC
TABLE OF CONTENTS
TABLE OF CONTENTS................................................................................................................................2
PROPRIETARY NOTICE..............................................................................................................................3
SPECIFICATION...........................................................................................................................................4
DIMENSIONS ...............................................................................................................................................5
DeltaPoint Jr. Top View.............................................................................................................................5
DeltaPoint Jr. End View.............................................................................................................................6
HOW IT WORKS...........................................................................................................................................7
INSTALLATION.............................................................................................................................................8
ELECTRICAL CIRCUIT ................................................................................................................................9
JUMPER SETTINGS ..................................................................................................................................10
SET-UP PROCEDURE...............................................................................................................................11
Configuring the Engineering Units...........................................................................................................11
Configuring the Flow Alarm.....................................................................................................................11
UNIT VERIFICATION..................................................................................................................................13
TROUBLESHOOTING................................................................................................................................14
Unit Will Not Power Up............................................................................................................................14
Unit Will Not Start ....................................................................................................................................14
Insufficient Water Flow.........................................................................................................................14
Water Continues to Flow When Cap is Removed...................................................................................15
Unit.......................................................................................................................................................15
Flowmeter ............................................................................................................................................15
Shut-Off Valve......................................................................................................................................15
Check Valve.........................................................................................................................................15
Unit Will Not Restart Manually or Remotely............................................................................................15
Unit.......................................................................................................................................................15
Flowmeter ............................................................................................................................................16
Shut-Off Valve......................................................................................................................................16
Flowmeter Display Unstable....................................................................................................................16
Solenoid Valve Does Not Open...............................................................................................................16
Fault Alarm Signal Not Received at Weld Controller ..............................................................................16
Flowmeter ............................................................................................................................................16
MAINTENANCE..........................................................................................................................................17
Flowmeter................................................................................................................................................17
Inspect or Replace Bluff Assembly......................................................................................................17
Shut-Off Valve .........................................................................................................................................17
Replace Coil.........................................................................................................................................17
Clean Diaphragm Orifice / Plunger Pilot Hole .....................................................................................17
Override Stem Broken.............................................................................................................................18
Check Valve/Remove Piston...................................................................................................................18
Cleaning...................................................................................................................................................18
Note.........................................................................................................................................................18
MODEL CODES..........................................................................................................................................19
APPENDIX..................................................................................................................................................20
Specifications for DeltaPoint Jr ...............................................................................................................20
Check Valve Specifications.....................................................................................................................21
Shut-Off Valve Specifications..................................................................................................................21
DeltaPoint Uno Elbow Test Results ........................................................................................................22
RMA NOTICE..............................................................................................................................................23
RMA FORM.................................................................................................................................................24
WARRANTY INFORMATION .....................................................................................................................25

3
ROCON LLC
PROPRIETARY NOTICE
The information contained in this publication is derived in part from proprietary and
patented data. This information has been prepared for the express purpose of assisting
in installation, operation, and maintenance of the instruments described herein.
Publication of this information does not convey any rights of use or reproduction other
than in connection with the installation, operation and maintenance of the equipment
described herein. Universal Flow Monitors, Inc. and Rocon LLC reserve the right to
change the information contained in this publication at any time and without prior notice.
Serial numbers are generated by taking the last two digits of the year + month + a five-digit sequential
number.

4
ROCON LLC
GENERAL SPECIFICATION
Maximum Operating Pressure: 150 PSI (10 bar)
Minimum Operating Pressure: 10 PSI of back pressure is required for the formation of vortices.
Temperature Ratings:
Ambient: 14 F to 122 F (-10 C to 50 C)
Fluid Media: 176 F (80 C) Maximum
Flow Rate: 0.35 GPM Min. to 6.0 GPM Max. (22.7 LPM)
Flow Measurement Accuracy: ± 2% full-scale (± 0.2 LPM)
Repeatability: 0.25% of actual flow
Power Requirement: 24 VDC @ 750 mA (18 Watts) Maximum (Solenoid Valve energized)
Alarm Output: 24V = Fault, 0V = OK
Alarm Output Impedance: 2K Ohms (internal pull-up resistor)
Electrical Connection: Turck EURO FS4.6
Wetted Parts: Brass, PVDF, Viton, Buna N (NBR), EPDM, FKM, Beryllium Copper
Caution: The unit shall be supplied by a SELV (separated extra-low voltage) source in
accordance with CSA Standard C22.2 No.1010.1-92 Annex H.
Environmental conditions: This device has been designed for use in Installation Category I,
pollution degree 4, at altitudes up to 2000 meters (6560 ft.),
either indoors or outdoors as defined in CSA Standard C22.2
No.1010.1-92.

5
ROCON LLC
DeltaPoint Jr
PUSH TO START PUSH TO BYPASS
DIMENSIONS
DeltaPoint Jr. Top View

6
ROCON LLC
DeltaPoint Jr. End View

7
ROCON LLC
HOW IT WORKS
DeltaPoint Jr. is a cooling water flow switch. It is comprised of a flow sensor, a shut-off valve, a check
valve, and all the associated wiring, complete in one package. When installed in the return leg, it can
detect changes in water flow due to cap loss or a break in the line, and shut off the supply/return water
legs.
The flow sensor utilizes the vortex shedding principle and has no moving parts to wear or clog. The water
strikes a bluff body, generating vortices (eddies) that move downstream. The vortices form alternately,
from one side to the other. A piezoelectric sensor housed in a sensor tube directly downstream of the
bluff senses the pressure zones created by the vortices. The sensor generates a frequency directly
proportional to the vortices (flow). The microprocessor measures this frequency and displays the output.
If installed according to the instructions in this manual, the 3-digit LED on the flow sensor displays the
water flow rate in the “return” leg in either LPM (liters per minute) or GPM (gallons per minute) with a high
degree of accuracy.
Mounted on the box is a two-position switch which is used to start the unit for normal operation, or to
bypass the solenoid valve by forcing it to remain open, even in case of a fault (during maintenance, for
example).
If water flow is present and is above the preset value, the flowmeter sends an OK TO WELD signal to the
weld controller, allowing the weld cycle to start. This is a 0V signal coming from the internal solid-state
relay. The shut-off valve is held open by the microprocessor during normal operation, and it closes when
there is either a flow fault or a power failure.
If a cap is pulled, the water flow in the “return” leg drops below the setpoint and the flow switch sends a
FAULT signal (24VDC) to the weld controller. It also shuts off the solenoid valve, thus stopping the water
flow in the “supply” leg. The check valve prevents water from flowing backwards from the gun arms,
effectively preventing a water spill from any source.
The rocker switch has two positions: START and BYPASS. START is a momentary switch that forces
the valve to open. It is typically held down at startup for a few seconds, until all the air trapped in the weld
gun arm circuit is removed and a steady stolid column of water is entering the flow switch. When the
green light inside the START switch is lit, it indicates that the water flow is above the flow switch alarm
setting and, therefore, is OK TO WELD. At this point the microprocessor takes over and continues to
keep the valve open during operation.
BYPASS is a toggle switch (push to turn on) and is used to force the valve open by overriding the internal
logic circuit. When in bypass, the flow sensor continues to monitor the flow in this case, as indicated on
the LED display, but the orange light (inside the BYPASS switch) is a visual reminder that the valve can
no longer be closed if flow fault occurs. The shut-off valve has an independent LED that is built into its
cable connector. When this LED is on it confirms the presence of coil power (valve should be open in this
case). The factory made a change on the operation of the “Bypass” switch mode. Please review below.
Serial Number 040817000 and greater.
The unit will not allow you in “Bypass” mode and ignore alarm fault if no water flow is present or leak
detected. Kit available (Part # “HBO”) to rework as described below.
Serial Number 051200100 and greater.
When the user activates the “Bypass” position of the switch, the unit will ignore the “Alarm Fault” signal
from flowmeter.
Please note: The user could weld without water to the weld guns in this mode.
SOLENOID INTERRUPT (Option H) is active on all units. It is used to remotely shut off the water flow
(Shut-Off Valve Coil) before the Associate changes weld gun arm electrodes.

8
ROCON LLC
INSTALLATION
There are no upstream or downstream piping requirements to achieve proper operation. Refer to page 22
to review requested water flow test using 90 degree elbow. The unit should be installed on the fence line
for best results. The unit can be installed in any position as long as good piping installation requirements
are adhered to. Unions of the same pipe size and full ported isolation valves may be installed for ease of
servicing the unit and shutting off the water. Teflon® tape or pipe sealant can be used in mounting the
unit to the piping system. Teflon® tape, if not applied properly to the connecting pipe, can become caught
on the bluff and affect the flow measurement.
Piping systems should be filled slowly to prevent water hammer from damaging sensor.
Hold Down hole pattern - 2 holes, 5/16-inch (8 mm) diameter, inline and 6 3/16 inches (157 mm) apart.
Porting –Supply and Return water ports - ¾ NPTF,
To Cell and From Cell –½ NPTF
Flow path and Port Identification located switch box cover.
Electrical Circuit –See page 10
Suggested Hose Dress:
UPPER JAW
LOWER JAW
SHUNT
De l t aP oi n t U noTM
FLOW R ATE
AL ARM
SE T
ROCON LL C
0.00
IN
OUT
PUSH TO START
RETURN
DELTAPOIN T TM
ROCON LLC
1755 E 9 MI LE RD., HAZEL PARK MI 48030 PHONE [phone]. WWW.RO CONL LC.CO M
MOD EL #
SERIAL #
PUSH TO BYPASS
WATER FROM
CELL
SUPPLY
WATER TO
CELL
24VDC ONLY
SUPPLY
RETURN
TRANSFORMER
3/8 INCH 1/2 INCH

9
ROCON LLC
ELECTRICAL CIRCUIT
DPJ-A-6/4-6EF2D10-H-HA
Firmware Version 3.15
SOLENOID
VALVE
BLACK BLUE
GREEN
+
-
1
2
2 1
VALVE
J3
K1
70M-0DC
+24V
D2
IN4004
24
31
++
--
3.74 k
R1
POWER
J4
+24V
DELTAPOINT UNO
FLOW METER
NC NO
4
1
3
3 2 1
4
5
66
+24V
SWITCH
START
10 ORG
5 4
3
2 1 6
7
YELLOW
LED
GREEN
LED
3.47 k R3
VCC
RESET
ALARM
+24V
3.74 k
R2
PS2701-1
1 23
4
1
2
3
D3
IN4004
+24V
VALVE
IN4004
D1
IN4004
D5
IN4004
D4
+
_
SJ1
RST CFG
13
2
OUTPUT
START / BYPASS
SWITCH
G
A
J1 SWITCH
RED +24V
ORG VALVE OUT
BLK 24V COM
GRN VCC
DELTAPOINT JR. DC INTERFACE BOARD
3
12
JP3
SJ3
SOLENOID
INTERRUPT
12
RESET
J2
DELTAPOINT UNO
12
JP1
3
12
JP5
SJ5
12
12
JP4
3
1
2 3
JP2
SJ4
1
2
3
SJ2
BYPASS
2 ORG BYPASS
12
3
4
5
6
WHT ALARM
BLU RESET 2
5
GRN
BLU
WHT RED
ORG
BLK
(1) BRN +24VDC
(2) WHT 24VDC COMMON
(3) BLU
CHASSIS
GRD
(4) BLK RESET (5) GREY ALARM (6) PINK
SOLENOID
INTERRUPT
RECEPTACLE
TURCK - 6 PIN, MICRO, FS4.6
(EOA)
3 2 1
4
START
BLK 1
WHT 3
BLK 5 BLK 8
GRN 6
GRY 7
02/08/2006

10
ROCON LLC
JUMPER SETTINGS
DELTAPOINT JR. DC INTERFACE BOARD REV: X.XX XX/XX/XXXX (C) UNIVERSAL FLOW MONITORS
JP3 JP4JP5
JP1 JP2
VOLTAGE = D2 - 24V PNP (SINKING) (0V A)
JP1
JP1
3
12
312
JP2
312
JP2
312
JP3
12
JP3
12
JP4
312
JP4
312
JP5
12
JP5
12
VOLTAGE = D1 - 24V NPN (SOURCING) (24V A)
RESTART SIGNAL = R - 24V ACTIVE HIGH
OPTIONS = H - SOLENOID INTERRUPT (No Jumper)
OPTIONS = N - NO OPTIONS PICKED
RESTART SIGNAL = R - 24V ACTIVE HIGH
RESTART SIGNAL = R - 24V ACTIVE HIGH
RESTART SIGNAL = 0 - 0V ACTIVE LOW
RESTART SIGNAL = 0 - 0V ACTIVE LOW
RESTART SIGNAL = 0 - 0V ACTIVE LOW (No Jumper)
DeltaPoint Jr - JUMPERS
DeltaPoint Jr Interface Board
Jumper Part # 7548