WIKA FSM-6100 User manual

Operating instructions
© 2020 Euromisure Sas di WIKA Italia Srl
All rights reserved.
Prior to starting any work, read the operating instructions!
Keep for later use!
EN
Euromisure Sas di WIKA Italia Srl
Via G. Borghisani 4, 26035 Pieve S.Giacomo (CR) Italy
Tel. [phone]
Fax [phone]
salesflow[email protected]
www.wika.com
Flow switch
For industrial heat exchangers
Model FSM-6100
Contents
1. General information
2. Design and function
3. Safety
4. Transport, packaging and storage
5. Commissioning, operation
6. Faults
7. Maintenance and cleaning
8. Dismounting, return and disposal
9. Specifications
83790004.00 12/2020 EN
Declarations of conformity can be found online at www.wika.com

2
WIKA operating instructions, flow switch, model FSM-6100
83790004.00 12/2020 EN
1. General information
■ The mechanical flow switch described in the operating instructions has been
designed and manufactured using state-of-the-art technology. All components
are subject to stringent quality and environmental criteria during production. Our
management systems are certified to ISO 9001.
■ These operating instructions contain important information on handling the instru-
ment. Working safely requires that all safety instructions and work instructions are
observed.
■ Observe the relevant local accident prevention regulations and general safety
regulations for the instrument’s range of use.
■ The operating instructions are part of the product and must be kept in the immediate
vicinity of the flow measuring instrument and readily accessible to skilled personnel
at any time.
■ Skilled personnel must have carefully read and understood the operating instruc-
tions prior to beginning any work.
■ The manufacturer‘s liability is void in the case of any damage caused by using
the product contrary to its intended use, non-compliance with these operating
instructions, assignment of insufficiently qualified skilled personnel or unauthorised
modifications to the instrument.
■ The general terms and conditions contained in the sales documentation shall apply.
■ Subject to technical modifications.
■ Further information:
- Internet address: www.wika.com
- Relevant data sheet: FV 30.10
Abbreviations, definitions
SPDT Single pole double throw
NC Normally closed contact type (NC = normally closed)
NO Normally open contact type (NO = normally open)
COM Common contact
GND Ground connection
2. Design and function
2.1 Overview
2.2 Description
The flow element of the model FSM-6100 is a paddle which works against a spring
mechanism with an adjustable pre-load force. On the spring mechanism there is a
contact arm for actuating the switch contact.The switch is actuated as soon as the force
generated by the flow is greater than the set pre-load force.
2.3 Terms used
Reset point
The flow value at which the switch returns to the starting position. Mathematically,
the flow value for the reset point is equal to the flow value of the switch point
minus the switch differential on rising flow. On falling flow, the flow value
for the reset point is equal to the flow value of the switch point plus the switch
differential.
Maximum operating flow
The maximum flow with which the instrument can be used without changing the
assured performance data.
Operating pressure
The maximum pressure with which the instrument can be used without changing the
assured performance data.
With stand pressure
The maximum pressure with which the instrument can hold without any damage to the
system and surroundings.
2.4 Scope of delivery
Flow switch, operating instructions
Cross-check scope of delivery with delivery note.

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WIKA operating instructions, flow switch, model FSM-6100
83790004.00 12/2020 EN
3. Safety
3.1 Explanation of symbols
WARNING!
... indicates a potentially dangerous situation that can result in serious injury or
death, if not avoided.
CAUTION!
... indicates a potentially dangerous situation that can result in light injuries or
damage to property or the environment, if not avoided.
DANGER!
... identifies hazards caused by electrical power. Should the safety instructions
not be observed, there is a risk of serious or fatal injury.
WARNING!
... indicates a potentially dangerous situation that can result in burns, caused
by hot surfaces or liquids, if not avoided.
Information
... points out useful tips, recommendations and information for efficient and
trouble-free operation.
3.2 Intended use
The model FSM-6100 mechanical flow switch is fitted with an SPDT switch contact
and is used in control, monitoring and alarm applications.The switch point can be
specified by the customer on site.The instrument can switch electrical loads of up to
AC 230 V, 15A). TheFSM-6100owswitchoersmanyapplicationpossibilitiesfor
Water, ethylene glycol, any other liquid non corrosive to brass, Phosphor bronze and
Nitrile material.
WARNING!
Use in the wrong application can lead to considerable personal injury and
damage to equipment.
▶ Only use the instrument in applications that lie within its technical perfor-
mance limits (e.g. max. ambient temperature, material compatibility, ...).
For performance limits see chapter 9 “Specifications”.
▶ This instrument is not permitted to be used in hazardous areas!
The instrument has been designed and built solely for the intended use described here,
and may only be used accordingly.
The manufacturer shall not be liable for claims of any type based on operation contrary
to the intended use.
3.3 Improper use
WARNING!
Injuries through improper use
Improper use of the instrument can lead to hazardous situations and injuries.
▶ Refrain from unauthorised modifications to the instrument.
▶ Do not use the instrument within hazardous areas.
▶ Do not use the instrument with abrasive or corrosive media.
Any use beyond or different to the intended use is considered as improper use.
3.4 Personnel qualification
WARNING!
Risk of injury should qualification be insufficient!
Improper handling can result in considerable injury and damage to equipment.
▶ The activities described in these operating instructions may only be carried
out by skilled personnel who have the qualifications described below.
Skilled electrical personnel
Skilled electrical personnel are understood to be personnel who, based on their
technical training, know-how and experience as well as their knowledge of country-
specific regulations, current standards and directives, are capable of carrying out work
on electrical systems and independently recognising and avoiding potential hazards.
The skilled electrical personnel have been specifically trained for the work environment
they are working in and know the relevant standards and regulations. The skilled
electrical personnel must comply with current legal accident prevention regulations.
3.5 Labelling, safety marks
Product label (example)
Before mounting and commissioning the instrument, ensure you read the
operating instructions!
jModel number
kApprovals
lArticle number
mSerial number
nOperating pressure
oAmbient temperature
pMedium temperature
qElectrical rating
rCoded date of manufacture
sIngress protection
FLOW SWITCH
Euromisure Sas di WIKA Italia Srl,
Via G.Borghisani 4, 26035 Pieve S.Giacomo (CR) Italy. www.wika.com
Ambient temperature
Medium temperature
Electrical rating
Coded date of manufacture
Ingress protection
Model number
Approvals
Article number
Serial number
Operating pressure











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WIKA operating instructions, flow switch, model FSM-6100
83790004.00 12/2020 EN
4. Transport, packaging and storage
4.1 Transport
Check the instrument for any damage that may have been caused by transport.
Obvious damage must be reported immediately.
CAUTION!
Damage through improper transport
With improper transport, a high level of damage to property can occur.
▶ When unloading packed goods upon delivery as well as during internal
transport, proceed carefully and observe the symbols on the packaging.
▶ With internal transport, observe the instructions in chapter 4.2 “Packaging
and storage”.
If the instrument is transported from a cold into a warm environment, the formation of
condensation may result in instrument malfunction. Before putting it back into operation,
wait for the instrument temperature and the room temperature to equalise.
4.2 Packaging and storage
Do not remove packaging until just before mounting.
Keep the packaging as it will provide optimum protection during transport (e.g. change
in installation site, sending for repair).
Permissible conditions at the place of storage:
■ Storage temperature: -20 ... +70 °C (-4 ... +176 °F)
■ Humidity: 35 ... 85 % relative humidity (no condensation)
Avoid exposure to the following factors:
■ Direct sunlight or proximity to hot objects
■ Mechanical vibration, mechanical shock (putting it down hard)
■ Soot, vapour, dust and corrosive gases
■ Hazardous environments, flammable atmospheres
Store the instrument in its original packaging in a location that fulfils the conditions listed
above.
5. Commissioning, operation
Before installation, commissioning and operation, ensure that the appropriate instru-
ment has been selected in terms of design and specific measuring conditions.
Tools: Cross-head screwdriver, open-ended spanner 36 mm, 7 mm, 5.5 mm.
5.1 Requirements at the measuring point
■ The process pressure and flow must not exceed the specified maximum operating
pressure and flow.
■ Permissible ambient and medium temperatures remain within the performance limits.
■ Protected from weather influences.
■ Protected from drop
■ The instrument must not be subjected to any external loading (e.g. use as a climbing
aid, support for objects).
■ Sealing faces are clean and undamaged.
■ Sufficient space for a safe electrical installation.
→For performance limits see chapter 9 “Specifications”
5.2 During commissioning
■ After unpacking the instrument, a visual inspection for damage must be carried out.
■ Suitable paddle is selected according to the line size and tightened to the paddle
arm by screws and nylock nut (Approx. 0.6 Nm).
■ Paddles should be assembled starting from smaller paddle followed by larger, while
using multiple paddles.
■ Ensure that paddle is free to move inside the pipe and does not rub the sides.
Paddles assembly
1. Withdrawal of paddle
adjoining screws
2. Tightening paddles
Front viewBack view

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WIKA operating instructions, flow switch, model FSM-6100
83790004.00 12/2020 EN
5.3 Mechanical mounting
■ Mounting is only permitted in the no flow state. Reliably isolate the line without any
fluid, using the available valves and protective devices.
■ Use seals suitable for the process connection provided.
■ When screwing the instruments in, the force required for sealing must not be
applied through the case, but only through the spanner flats provided for this
purpose on the process connection and using a suitable tool.The tightening torque
is dependent on the selected process connection.
■ After screwing in, make sure that no damage or cracks have occurred at the
process connection.
■ Ensure the flow should be along the direction of arrow mark indicated on process
connection.
■ Flow switches should be mounted in horizontal/Vertical section of pipe with a
minimum straight run of 5 pipe diameter on both upstream and downstream. The
straight run should be free of bends, valves and other restrictions.
■ Drill a 30mm dia hole in pipe. Ensure hole is free of bur and sharp edges, weld
a 1” BSPT/1”NPT female shank to the pipe, shank height should be maintained
as 25mm, as shown in the below (fig.2), changing the dimension will result in
malfunctioning.
5.4 Electrical mounting
The connection cable must provide basic insulation for external circuits of protection
class I. The instrument must be able to be switched off completely by means of a switch
or a control unit. Depending on the load, additional protective measures, e.g. for motor
protection, may be required.
DANGER!
Danger to life caused by electrical current
Upon contact with live parts, there is a direct danger to life
▶The instrument may only be installed and mounted by skilled personnel.
▶Switch off the load circuit before starting work and secure against being
switched on unauthorised.
Cable preparation
The cable gland used must be suitable for achieving an IP30 ingress protection. Provide
strain relief for the installed cables. Size the connecting cables for the largest current
strength in the circuits and ensure sufficient UV resistance and mechanical stability.
Recommendation: 4-wire cable with conductor cross-section of 2 ... 2.5 mm². Wire ends
fitted with insulated ring lugs suitable for 2 ... 2.5 mm² wire cross section.
Grounding
Include the ground connection in the inside of the instrument into the grounding
concept of the installation.
Clamping the cable
1. Remove 2 screws and open the
cover. Maximum torque: 1.5Nm
2. Fit suitable cable gland and route the
cable via cable gland.
3. Carry out the terminal assignment
according to the switching function,
maximum tightening torque: 2 Nm
4. Closethecoveragainandxitwith
2 supplied screws

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WIKA operating instructions, flow switch, model FSM-6100
83790004.00 12/2020 EN
5.5 Switch point setting
1. Flow switch is approximately pre-setted at minimum limit of flow, falling condition
prior to dispatch.
2. For an exact setting of the switch point, a test assembly with corresponding
flow rate and flow reference is needed.This test assembly can, for example, be
realised with a flow meter and a flow generation pump (not shown). Connect the
model FSM-6100 flow switch, flow reference and flow generation to a common
flow system.
3. Drive slowly towards the required switch point flow with the flow generation and
flow reference.
▶If the instrument switches before the required switch point is reached, the
adjustment screw must be corrected towards anti-clockwise direction (+).
▶If the instrument switches after the required switch point is reached, the
adjustment screw must be corrected towards clockwise direction (-).
After each correction, release the flow and repeat this procedure until the switch
point is set correctly.
4. Release the flow slowly and check the reset point.
5. If the switch point and the reset point coincide with the required flow values, the
switch point setting is complete.
The switch point setting must be checked after every 3 months.
On-line Mounting 1. Loosen the hex nut
2. Adjust the Hex
head screw ×
3. Tighten the hex nut again
6. Faults
CAUTION!
Physical injuries and damage to property and the environment
If faults cannot be eliminated by means of the listed measures, the instrument
must be taken out of operation immediately.
▶Ensure that there is no pressure in the instrument and that the load circuit
is switched off. Protect against being put into operation accidentally.
▶Contact the manufacturer.
▶If a return is needed, please follow the instructions given in chapter 8.2
“Return”.
WARNING!
Physical injuries and damage to property and the environment caused
by media
Upon contact with hazardous media, harmful media (e.g. corrosive, toxic,
carcinogenic), and also with refrigeration plants and compressors, there is a
danger of physical injuries and damage to property and the environment.
Should a failure occur, aggressive media with extremely high temperature and
under high pressure or vacuum may be present at the instrument.
▶For these media, in addition to all standard regulations, the appropriate
existing codes or regulations must also be followed.
For contact details see chapter 1 “General information”.
×Adjust the Hex head screw clockwise (–) or Anti-clockwise (+) accordingly
(also see 5.5 Switch point setting)
Faults Causes Measures
Contact is not
switching in
accordance with the
specification at the
set switch point/reset
point
Electrical connection is
interrupted.
Carry out a continuity test on the
electrical connection lines.
Wiring error, e.g. short
circuit
Check the pin assignment and
correct it if necessary
Electrical load
unsuitable
Maintain the permissible
electrical loads
Contact contaminated Replace instrument
Short circuit Moisture in the
instrument.
Only use in ambient conditions
for which the ingress protection
is suitable.
Contact chatter
(repeated, short-
duration opening and
closing).
Turbulent flow
vibrations
Maintain a laminar flow with
control valves, decouple the
instrument mechanically

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WIKA operating instructions, flow switch, model FSM-6100
83790004.00 12/2020 EN
Faults Causes Measures
Switching
status remains
unchanged
despite reaching
the switch point/
reset point.
Error with switch
point setting.
Carry out switch point setting with
matching test assembly, see chapter 5.5.
Contacts defective
(e.g. fused contact
zone).
Replace instrument. Before
recommissioning the new instrument,
provide a protective circuit for the contact.
Flow port blocked. Replace instrument
Leakage Carry out a leak test. Seal the process
connection or replace the instrument.
For the exchange of the instrument chapters 8 “Dismounting, return and disposal”
and 5 “Commissioning, operation” must be observed.
7. Maintenance and cleaning
7.1 Maintenance
The instruments are maintenance-free. The switch point setting must be checked after
3 months. Carry out switch point setting with matching test assembly, see chapter 5.5.
Repairs must only be carried out by the manufacturer.
7.2 Cleaning
WARNING!
Risk of burns
With cleaning there is a risk through hot surface.
▶ Before cleaning the instrument, allow it to cool sufficiently or use protective
equipment.
CAUTION!
Physical injuries and damage to property and the environment
Improper cleaning may lead to physical injuries and damage to property and
the environment. Residual media in the dismounted instrument can result in a
risk to persons, the environment and equipment.
▶ Carry out the cleaning process as described below.
1. Before cleaning, correctly disconnect the instrument from the flow system and
switch the load circuit off.
2. Use the requisite protective equipment.
3. Clean the instrument with a moist cloth.
Electrical connections must not come into contact with moisture!
CAUTION!
Damage to the instrument
Improper cleaning may lead to damage to the instrument!
▶ Do not use any aggressive cleaning agents.
▶ Do not use any hard or pointed objects for cleaning.
4. Wash or clean the dismounted instrument, in order to protect persons and the
environment from exposure to residual media.
8. Dismounting, return and disposal
WARNING!
Physical injuries and damage to property and the environment through
residual media
Residual media in the dismounted instrument can result in a risk to persons,
the environment and equipment.
▶ Observe the information in the material safety data sheet for the
corresponding medium.
▶ Wash or clean the dismounted instrument, in order to protect persons and
the environment from exposure to residual media.
8.1 Dismounting
WARNING!
Risk of burns
During dismounting there is a risk of dangerously hot media escaping.
▶ Let the instrument cool down sufficiently before dismounting it!
DANGER!
Danger to life caused by electric current
Upon contact with live parts, there is a direct danger to life.
▶ The dismounting of the instrument may only be carried out by skilled personnel.
▶ Remove the instrument once the system has been isolated from power
sources.
WARNING!
Physical injury
When dismounting, there is a danger from aggressive media and high pressures.
▶ Observe the information in the material safety data sheet for the
corresponding medium.
▶ Dismount the instrument when there is no flow.
8.2 Return
Strictly observe the following when shipping the instrument:
All instruments delivered to WIKA must be free from any kind of hazardous substances
(acids, bases, solutions, etc.) and must therefore be cleaned before being returned.
WARNING!
Physical injuries and damage to property and the environment through
residual media
Residual media in the dismounted instrument can result in a risk to persons,
the environment and equipment.
▶ With hazardous substances, include the material safety data sheet for the
corresponding medium.
▶ Clean the instrument, see chapter 7.2 “Cleaning”.
When returning the instrument, use the original packaging or a suitable transport packaging.
8.3 Disposal
Incorrect disposal can put the environment at risk.
Dispose of instrument components and packaging materials in an environmentally
compatible way and in accordance with the country-specific waste disposal regulations.

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WIKA operating instructions, flow switch, model FSM-6100
83790004.00 12/2020 EN
9. Specifications
Permissible temperature ranges
■Ambient: -20 ... 70°C [-4 ... 158°F]
■Medium: -20 ... 100°C [-4 ... 212°F]
■Storage: -20 ... 70°C [-4 ... 158°F]
Ingress protection per IEC/EN 60529
IP30
Process media
Water, ethylene glycol, any other liquid non corrosive to brass, phosphor bronze and
Nitrile material.
Switch point repeatability
±5% of FSR
Switching function
1 × SPDT (single pole double throw)
Silver - alloy contacts, UL certified
Electrical rating
AC rating DC rating
Resistive load Inductive load Resistive load Inductive load
125V 250V 125V 250V 125V 250V 30V 125V 250V
15A 15A 15A 15A 0.5A 0.25A 5A 0.05A 0.03A
Nominal
Bore
Paddle
combinations
'ON' falling ow
(LPM)
'ON' rising ow
(LPM) Maximum
operating
ow (LPM)
in mm 'L' mm Mini-
mum
Maxi-
mum
Mini-
mum
Maxi-
mum
1 25 28 15 50 25 60 150
1.25 32 28 45 100 50 110 150
1.5 40 28 50 140 60 160 350
2 50 37 100 240 110 260 450
37+50 50 160 60 180 450
2.5 65 37 225 480 230 520 1000
37+50 140 320 150 340 1000
3 80
37 320 750 380 860 1300
37+50 210 550 225 635 1000
37+50+80 105 320 115 340 1000
4 100
37 500 1400 590 1700 2500
37+50 350 1100 400 1300 2000
37+50+80 200 580 230 680 2000
5 125
37 730 1750 1030 2100 3000
37+50 500 1500 650 2050 3000
37+50+80 400 1000 475 1250 2000
37+50+80+100 300 800 330 930 2000
6 150
37 2650 3000 2750 3100 3200
37+50 850 2400 990 2600 3200
37+50+80 650 1800 750 1900 3200
37+50+80+100 350 1450 450 1550 3200
Setting range
Above flow ranges are considered with water as medium
(atdensity=1000kg/m³,pressure=1atm,temperature=25⁰C)