Spirax Sarco Colima FLU Series User manual

EXPER
TISE SOLUTIONS SUST
AINABILITY
3.797.5275.200 CH Issue 2 - 2016
© Copyright 2013
Vane Flow Switches
Colima FLU Series
Installation and Maintenance Instructions
1. General safety information
2. General product information
3. Installation and Maintenance
4. Spare parts

23.797.5275.200
1. General safety information
Safe operation of these products can only be guaranteed if they are properly installed, commissioned,
used and maintained by qualied personnel (see Section 1.11) in compliance with the operating
instructions. General installation and safety instructions for pipeline and plant construction, as well
as the proper use of tools and safety equipment must also be complied with.
1.1 Intended use
Referring to the Installation and Maintenance Instructions, name-plate and Technical Information
Sheet, check that the product is suitable for the intended use/application.
The products comply with the requirements of the European Pressure Equipment Directive:
2014/68/EU (PED) falling within category 'SEP'. It should be noted that products within this category
are required by the Directive not to carry the mark.
Products intended for use in the Naval and Marine sectors are RINA, and M.M.I (Italian navy) approved.
i) The products have been specically designed for use on steam, compressed air and inert
industrial gases which are in Group 2 of the above mentioned Pressure Equipment Directive. The
products’ use on other uids may be possible but, if this is contemplated, Spirax Sarco should
be contacted to conrm the suitability of the product for the application being considered.
ii) Check material suitability, pressure and temperature and their maximum and minimum values.
If the maximum operating limits of the product are lower than those of the system in which
it is being tted, or if malfunction of the product could result in a dangerous overpressure or
overtemperature occurrence, ensure a safety device is included in the system to prevent such
over-limit situations.
iii) Determine the correct installation situation and direction of uid ow.
iv) Spirax Sarco products are not intended to withstand external stresses that may be induced
by any system to which they are tted. It is the responsibility of the installer to consider these
stresses and take adequate precautions to minimise them.
v) Remove protection covers from all connections and protective lm from all name-plates, where
appropriate, before installation on steam or other high temperature applications.
1.2 Access
Ensure safe access and if necessary a safe working platform (suitably guarded) before attempting
to work on the product. Arrange suitable lifting gear if required.
1.3 Lighting
Ensure adequate lighting, particularly where detailed or intricate work is required.
1.4 Hazardous liquids or gases in the pipeline
Consider what is in the pipeline or what may have been in the pipeline at some previous time.
Consider: ammable materials, substances hazardous to health, extremes of temperature.

3
3.797.5275.200
1.5 Hazardous environment around the product
Consider: explosion risk areas, lack of oxygen (e.g. tanks, pits), dangerous gases, extremes of
temperature, hot surfaces, re hazard (e.g. during welding), excessive noise, moving machinery.
1.6 The system
Consider the e󰀨ect on the complete system of the work proposed. Will any proposed action
(e.g. closing isolation valves, electrical isolation) put any other part of the system or any personnel
at risk?
Dangers might include isolation of vents or protective devices or the rendering ine󰀨ective of controls
or alarms. Ensure isolation valves are turned on and o󰀨 in a gradual way to avoid system shocks.
1.7 Pressure systems
Ensure that any pressure is isolated and safely vented to atmospheric pressure. Consider double
isolation (double block and bleed) and the locking or labelling of closed valves. Do not assume that
the system has depressurised even when the pressure gauge indicates zero.
1.8 Temperature
Allow time for temperature to normalise after isolation to avoid danger of burns and consider whether
protective clothing (inlcuding safety glasses) is required.
1.9 Tools and consumables
Before starting work ensure that you have suitable tools and/or consumables available. Use only
genuine Spirax Sarco replacement parts.
1.10 Protective clothing
Consider whether you and/or others in the vicinity require any protective clothing to protect against
the hazards of, for example, chemicals, high/low temperature, radiation, noise, falling objects, and
dangers to eyes and face.
1.11 Permits to work
All work must be carried out or be supervised by a suitably competent person. Installation and
operating personnel should be trained in the correct use of the product according to the Installation
and Maintenance Instructions. Where a formal 'permit to work' system is in force it must be complied
with. Where there is no such system, it is recommended that a responsible person should know what
work is going on and, where necessary, arrange to have an assistant whose primary responsibility
is safety. Post 'warning notices' if necessary.
1.12 Handling
Manual handling of large and/or heavy products may present a risk of injury. Lifting, pushing, pulling,
carrying or supporting a load by bodily force can cause injury particularly to the back. You are advised
to assess the risks taking into account the task, the individual, the load and the working environment
and use the appropriate handling method depending on the circumstances of the work being done.

43.797.5275.200
1.13 Residual hazards
In normal use the external surface of the product may be very hot. If used at the maximum permitted
operating conditions the surface temperature of some products may reach temperatures of 350°C.
Many products are not self-draining. Take due care when dismantling or removing the product from
an installation (refer to 'Maintenance instructions').
1.14 Freezing
Provision must be made to protect products which are not self-draining against frost damage in
environments where they may be exposed to temperatures below freezing point.
1.15 Safetyinformation(Specictotheproduct)
For any safety requirements relating to particular components and / or materials used in the product
construction, please refer to installation and maintenance instructions below.
1.16 Disposal
This product is recyclable. No ecological hazard is anticipated with the disposal of this product
providing due care is taken.
1.17 Returning products
Customers and stockists are reminded that under EC Health, Safety and Environment Law, when
returning products to Spirax Sarco they must provide information on any hazards and the precautions
to be taken due to contamination residues or mechanical damage which may present a health,
safety or environmental risk. This information must be provided in writing including Health and Safety
data sheets relating to any substances identied as hazardous or potentially hazardous.

5
3.797.5275.200
2. General product information
2.1 Description
Magnetically activated vane type ow switches for monitoring gas or liquid ow rates are present
in most industrial applications.
The ow switches can be equipped with electrical contacts, SPDT or DPDT micro switches along with
di󰀨erent protective housings and with optional two-colour visual indicator to suit most environmental
and safety conditions.
2.1.1 Applications
- Protects pumps, motors and other equipment against low or no ow
- Controls sequential operation of pumps
- Automatically starts auxiliary pumps and engines
- Stops liquid cooled engines, machines and processing when coolant ow is interrupted
- Shuts down burner when air ow through heating coil fails
2.1.2 Operating principle
Two oscillating magnets on the same axis, one integral with the vane and one integral with the elec-
trical equipment, repel each other reciprocally through a non-magnetic material ange. The ange
separates the housing, containing the electrical equipment, from the vane that is inserted in the pipe.
The vane in absence of ow is maintained in its resting position by balance weight and repulsion
between the two magnets that face each other with the same polarity. When the ow pushes the
vane, the integral vane magnet moves and the magnetic eld pushes the integral switch magnet.
The switching of the electrical contact is quick and reliable.
2.1.3 Mounting
The Flu ow switches can be installed horizontally, directly into a pipe, or in a dedicated chamber
connected between two pipes. Several type of anges are available upon customer request.

63.797.5275.200
2.2 Materials
No. Part Material
1Housing ALU + Rilsan
2Cover ALU + Rilsan
3Indicator Plexiglass
4Microswicth Omron Z-15GW4-B
5Screw AISI 304
6Magnet Sm Co
7Flange AISI 304
8Magnet Sm Co
9Counter weight AISI 304
10 Vane AISI 304
4
5
6
7
8
10
9
1
3
2

7
3.797.5275.200
2.3 Design conditions
TMA Maximum
allowable temperature Steel -20°C to + 150°C
with cooling extension -20°C to + 350°C
PMA Maximum
allowable pressure Steel Colima's ange < 16 bar g
ange sized according to rating < 100 bar g
2.4 Models
FLU A
Gas ow switch, with IP 67 aluminum
housing.
Can not be tted directly on the pipes but
before the the cooling battery.
FLU O
Liquid ow switch, with IP 67 aluminum housing and
two-colour visual indicator (optional).

83.797.5275.200
3. Installation and Maintenance
Note: Before actioning any installation or maintenance work
observe the 'Safety information' in Section 1.
Refering to the Installation and Maintenance Instructions, name-plate and Technical Information
Sheet, check that the product is suitable for the intended installation.
Check: materials, pressure and temperature to ensure compatibility of the product with the required
application. Also make sure that the ambient temperature in proximity of the device is between the
values reported on the label (-20 - 40 ° C).
Remove protective covers from all connections and the protective lm from the name-plate.
3.1 Assembly
The Colima FLU magnetic ow switches are delivered packed.
3.1.1 Fit the ow switch into the tank paying attention to avoid any damage at vane.
Any damage can interfere with the correct operation of the unit.
3.1.2 Place the supplied gasket between the anges.
3.1.3 Fix the anges with bolts. Firmly secure the xing by tightening the ange bolts.
3.1.4 In case of threaded connection, tighten the instrument and place it in the direction indicated
by the arrow on the housing base.
Caution:
Always ensure that correct earthing of the equipment is carried out. Specic points are set inside
and outside the housing.
Caution:
These products should only be used for what they are designed for. Anything outside of the stipulated
application range may be subject to unforeseen and dangerous circumstances and full responsibility
will be with the installer.
3.2 Electrical equipment and housings for
  ColimaFLUseriesowswitches
The electrical equipment for the FLU series level switches comprises a support and a contact.
The oscillating element includes a magnet whose south pole points towards the ange that separates
the electrical equipment from the liquid or gas contained in the pipe. According to the pressure on
the vane provided by the liquid or gas ow in the pipe, the vane works by pivoting a sealed cartridge
containing a magnet, with south polarity on the end towards the ange.
As the two magnets on the two oscillating devices repel each other, they are never in line on the
same axis. Consequently, the status of the electrical equipment switches from the normally open
(NO) to normally closed (NC) position or vice versa.

9
3.797.5275.200
Requisiti dei contatti elettrici
Standard SPDT Contact
Standard microswitches are recommended for general purpose
Contact resistance: 15 mOhm Max (Initial value)
Mechanical life: >106
Electrical life: >105
V ~ A = Load
250 15 0,25 Resistive
15 0,03 Inductive
125 15 0,5 Resistive
15 0,05 Inductive
30 NA 6 Resistive
NA 5 Inductive
SPDT execution
COM
(Common)
NO
(Normally Open)
NC
(Normally Closed)
DPDT execution
(two simultaneous SPDT contacts)
NC
(Normally Closed)
NO
(Normally Open)
COM
(Common)

10 3.797.5275.200
3.3 Disassembly
Before disassembly of the ow switch disconnect or isolate any electricity supply or circuit and
depressurize the pipe.
Warning: do not disassemble the level switch before the pipe has been emptied.
3.3.1 Open the housing.
3.3.2 Disconnect the electric circuit cables. Close the housing.
3.3.3 Unscrew the connection bolts.
3.3.4 Extract the instrument from its slot paying attention to avoid any damage to the vane.
Periodical inspections are necessary to guarantee complete e󰀩ciency of the unit. A regular maintenance
programme starting from its initial installation is recommended. The suggested precautions are
important to obtain the best operating conditions of the level control.
The instrument does not require preventive maintenance, however it is recommended that from
time-to-time a check of the liquid uidity is actioned to avoid any suspensions or deposits that can
inuence wetted parts.
The available spare parts are detailed below. No other parts are supplied as spares.
Available spares
Contacts
To replace the contact:
1. Open the housing and remove the visual indicator (if present).
2. Disconnect cables from the electrical circuit, taking note of their position on the microswitch.
3. Unscrew the screws (1) and remove the block with the switch.
4. Unscrew the screws (2) and remove the switch from the bracket.
5. Place the new switch onto the bracket and secure it by tightening the screws (2).
6. Place the block with the switch and secure it by tightening the screws (1).
7. Reconnect the electrical cables and close the housing after repositioning the visual indicator
(if present).
4. Spare parts
2
1