Omega FLCN-101 & FLCN-111 Series Owner's manual

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INTRODUCTION/TABLEOFCONTENTS StepOne

The FLCN‐100 SeriesControllersaregeneral‐purpose flow controller that accepts one flow sensor input and

providesone16Arelayforlow‐flowpumporprocessprotection.Thispackagehasanoptionalflashingalarm

andisidealforalarmindication.Packagethisflowcontrollerwithourliquidorgasflowswitchsensors.

Features

 Fail‐Saferelaycontrolofpumps,valvesoralarmswitha0to60seconddelay

 Optionalflashingalarmbringsimmediateattentiontolevelalarmconditions.

 PolypropyleneenclosureratedNEMA4Xwithswivelbaseforconduitalignment.

 EasysetupwithLEDindicatorsforsensor(s),powerandrelaystatus.

 InvertswitchchangesrelaystatefromNOtoNCwithoutrewiring.

 ACpowered

TableofContents

Specifications:.........................................................................................................................................................4

Dimensions:.............................................................................................................................................................4

SafetyPrecautions:.................................................................................................................................................5

MakeaFail‐SafeSystem:............................................................................................................................6

Components:...............................................................................................................................................6

GettingStarted:.......................................................................................................................................................7

 GuidetoControls:.......................................................................................................................................7

Electrical..................................................................................................................................................................8

 ConnectingSwitchestoInputTerminals:...................................................................................................8

 VACPowerInputWiring:............................................................................................................................8

 RelayInputWiring:.....................................................................................................................................8

 StrobeAlertOutput:...................................................................................................................................9

 Changingfrom120to240VAC...................................................................................................................9

Installation............................................................................................................................................................10

 MountingonaSensor:..............................................................................................................................10

ApplicationExamples............................................................................................................................................12

 LowFlowAlarm:........................................................................................................................................12

 LEDIndication:..........................................................................................................................................12

FlowSwitchCalibration:.......................................................................................................................................13

 SetPoints:.................................................................................................................................................13

 AccessingtheAdjustmentPotentiometer:...............................................................................................13

Appendix...............................................................................................................................................................14

 ControllerLogic.........................................................................................................................................14

 Troubleshooting........................................................................................................................................14

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SPECIFICATIONS/DIMENSIONS StepTwo

Controller

Supplyvoltage: 120/240VAC,50‐60Hz.

Consumption: 5Wattsmax.

Sensorinputs: (1)flowswitch

Sensorsupply: 24VDC@100mA

LEDindication: Sensor,relay&powerstatus

Contacttype: (1)SPDTRelay

Contactrating: 250VAC,16A

Contactoutput: SelectableNOorNC

Contactdelay: 0to60seconds

Electronicstemp.: F:‐40°to158°

 C:‐40°to70°

Enclosurerating: NEMA4X(IP65)

Enclosurematerial: PP(U.L.94VO)

Enclosuremount.: 3/4”NPT

Enclosurerotation: 300°swivelbase

Conduitentrance: Single,1/2"NPT

CEcompliance: EN61326EMC

 EN61010‐1Safety

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StrobeAlert

Flashtype: Xenontube

Flashfrequency: 1persecond

Strobelife: 10Mcycles

Supplyvoltage: 120VAC,50‐60Hz.

Consumption: 3Wattsmax.

Material: Polycarbonate

Enclosurerating: NEMA4X(IP65)

Color: Amber

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TerminalLabels:

(S)terminal: Provides14VDCtotheswitchinput

(‐)terminal: Ground

(+)terminal: Provides24VDCpowertotheswitch

SideView

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SideViewwithStrobeAlert

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FLCN‐100Series FunctionalDiagram

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SAFETYPRECAUTIONS StepThree

AboutThisManual:PLEASEREADTHEENTIREMANUALPRIORTOINSTALLINGORUSINGTHISPRODUCT.

ThismanualincludesinformationontwodifferentmodelsofCompactRelayFlowControllersfromOmega

Engineering:FLCN‐101,FLCN‐111andFLCN‐111‐CE.TheFLCN‐100Seriesisasingle‐inputcontrollerwith

anoptionalFlashAlarm™.Manyaspectsofinstallationandusearesimilarbetweenthethreemodels.

User’s Responsibility for Safety:OMEGA ENGINEERING manufactures several models of controller, with

differentmountingandswitchingconfigurations.Itistheuser’sresponsibilitytoselectacontrollermodel

that is appropriate for the application, install it properly, perform tests of the installed system, and

maintainallcomponents.

Electrical Shock Hazard:It is possible to contact components on the controller that carry high voltage,

causing serious injury or death.All power to the controller and the relay circuit(s) it controls should be

turned OFF prior to working on the controller.If it is necessary to make adjustments during powered

operation,useextremecautionanduseonlyinsulatedtools.Makingadjustmentstopoweredcontrollers

isnotrecommended.Wiringshouldbeperformedbyqualifiedpersonnelinaccordancewithallapplicable

national,stateandlocalelectricalcodes.

Flammable or Explosive Applications:  Sensor mount controllers should not be used with explosive or

flammable liquids, which require an intrinsically safe or explosion proof rating.If you are unsure of the

suitabilityofacontrollerforyourinstallation,consult your Omega Engineeringrepresentativeforfurther

information.

Install In a Dry Location:The FLCN‐100 Series controller housing is liquid‐resistant and made of

Polypropylene(PP).Wheninstalledproperly,thecontrollerisnotdesignedtobeimmersed.Itshouldbe

mounted in such a way that it does not normally come into contact with fluid.Refer to an industry

referencetoensurethatcompoundsthatmaysplashontothecontrollerhousingwillnotdamageit.Such

damageisnotcoveredbythewarranty.

RelayContactRating:Therelayisratedfora16ampresistiveload.Manyloads(suchasamotorduring

start‐uporincandescentlights)arereactiveandmay haveaninrushcurrentcharacteristicthatmaybe10

to 20 times their steady‐state load rating.The use of a contact protection ci

rcuit may be necessary for

yourinstallationifthe16ampratingdoesnotprovideanamplemarginforsuchinrushcurrents.

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SAFETYPRECAUTIONS(cont.) StepThree

Make a Fail‐Safe System:  Design a fail‐safe system that accommodates the possibility of relay or power

failure.If power is cut off to the controller, it will de‐energize the relay.Make sure that the de‐energized

stateoftherelayisthesafestateinyourprocess.Forexample,ifcontrollerpowerislost,apumpfillingatank

willturnoffifitisconnectedtotheNormallyOpensideoftherelay.

While the internal relay is reliable, over the course of time relay failure is possible in two modes: under a

heavyloadthecontactsmaybe“welded”orstuckintotheenergizedposition,orcorrosionmaybuildupona

contact so that it will not complete the circuit when it should.In critical applications, redundant backup

systems and alarms must be used in addition to the primary system.Such backup systems should use

differentsensortechnologieswherepossible.

While this manual offers some examples and suggestions to help explain the operation of OMEGA

ENGINEERINGproducts,suchexamplesareforinformationonlyandarenotintendedasacompleteguideto

installinganyspecificsystem.

Sensor‐mount controllers:The FLCN‐100 Series is a  cost‐effective, modular flow controller, whose body

incorporatesafemale3/4"NPTfitting,allowingittobemounteddirectlyontoanyOmegaEngineeringsensor

orany3/4"connection.SimplyprovideitsrequiredACpowerandacontrolleddevicesuchasavalve,pump,

oralarmthatcanbeswitchedbythecontroller’srelayinresponsetothesensorinput.

FeaturesoftheFLCN‐100SeriesSingleInputController:TheFLCN‐100SeriesControllerisdesignedtoreceive

asignalfromasingleflowswitch.ItturnsitsinternalrelayOnorOff(assetbytheinvertswitch)inresponseto

thepresenceoffloworno‐flow,andchangestherelaystatusbackagainwhenthesensorreverses.TheFLCN‐

100Seriesmaybeusedwithany OmegaEngineeringrelayflowswitch(FST‐200&FST‐300series).Therelayis

a single pole, double throw type; the controlled device can be connected to either the normally open or

normallyclosedsideoftherelay.Atimedelayfrom0to60secondscanbesetbeforetherelayrespondsto

thesensorinput.

TypicalapplicationsfortheFLCN‐100Seriesarefloworno‐flowswitch/alarmoperations(activatinganalarm

atno‐flow).

Components:

 FLCN‐111 ‐SingleInputFlowController,NPTThread

 FLCN‐111‐CE‐SingleInputFlowController,NPTThreadandCECompliant

 FLCN‐101‐SingleInputFlowController,NPTThreadwithStrobeAlert

 Owner’sManual

CompatibleFlowSwitches:

 LiquidFlowSwitches:

o FST‐211‐SPST–PP/

PPS(resin)‐Short

o FST‐221‐SPST–PP/PPS(resin)‐Long

o FST‐212‐SPST–PVDF‐Short

o FST‐222‐SPST–PVDF‐Long



GasFlowSwitches:

o FST‐321‐SPST–PP/PPS(resin)‐Short

o FST‐323‐SPST–PP/PPS(resin)‐Long

o FST‐322‐SPST–PVDF‐Short

o FST‐324‐SPST–PVDF‐Long

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 7

GETTINGSTARTED StepFour

TheFLCN‐100SeriesmaybeusedwithanyOmegaEngineeringflowswitch(FST‐200&FST‐300series)witha

relayoutput.Therelayisasinglepole,doublethrowtype;thecontrolleddevicecanbeconnectedtoeither

thenormallyopenornormallyclosedsideoftherelay.Atimedelayfrom0to60secondscanbesetbefore

therelayrespondstothesensorinput.TypicalapplicationsfortheFLCN‐100Seriesarepumpprotection,no‐

flowindicationorchemicalinjection.

GuidetoControls:Belowisalistingandthelocationofthedifferentcomponentsforthecontroller:

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1. Powerindicator:ThisgreenLEDlightswhenACpowerisON.

2. Relay indicator:This red LED will light whenever the controller energizes the relay, in response to the

properconditionatthesensorinputandafterthetimedelay.

3. ACPowerterminals:Connectionof120VACpowertothecontroller.Thesettingmaybechangedto240

VAC if desired.This requires changing internal jumpers; thisis covered in the Installation section of the

manual.Polarity(neutralandhot)doesnotmatter.

4. Relay terminals (NC, C, NO):Connect the device you wish to control (pump, alarm etc.) to these

terminals:supplytotheCOMterminal,andthedevicetotheNOorNCterminalasrequired.Theswitched

deviceshouldbe a non inductiveloadofnotmorethan16amps; for reactive loads the currentmustbe

deratedorprotectioncircuitsused.WhentheredLEDisONandtherela

yisintheenergizedstate,theNO

terminalwillbeclosedandtheNCterminalwillbeopen.

5. Invert switch:This DIP switch reverses the logic of the relay control in response to the sensor(s):

conditionsthatusedtoenergizetherelaywillmakeitturnoffandviceversa.

6. TimeDelay:Aftertheinput(s)change(s)state,th

iscontrolsetsadelayfrom0.15to60secondsbeforethe

relaywillrespond.

7. Input1Aindicator:TheseamberLEDwilllightimmediatelywhenevertheappropriatesensorattachedto

the terminals detects no‐flow, and will turn off when it detects flow.This polarit

y can be  reversed by

changeoftheswitchespolarity.

8. Inputterminals:Connect the wiring from the sensors to these  terminals: Note the polarity:(+) is a 24

VDC,100mApowersupply(tobeconnected to the redwireofanOmegaEngin

eeringsensor),and(‐)is

thereturnpathfromthesensor(tobeconnectedtotheblackwireofanOmegaEngineeringsensor).(S)is

therelay signal input to be connectedtothewhite wire.The remaining green wirewillreturntothe(‐)

terminal.Ifpolarityisreversed,thesensorswillnotwork.



 8

ELECTRICAL StepFive

Connecting switches to input terminals:Please note a difference between OMEGA ENGINEERING flow

switches.Allflowswitches(FST‐200&FST‐300series)willbewiredwiththeRedwiretothe(+)terminal,the

Black wire to the (‐) terminal and the White wire to the (S) terminal.See the illustration below to indicate

wiringforyourswitch.Note:theShieldwirewillbeusedonlyforlongcablerunsorwhereexcessiveelectrical

noiseispresent.

NormallyClosed NormallyOpen



SwitchCable:WheninstallinganOmegaEngineering

flow switch, adjust the cable away from the printed

circuitboardsin the controller body.Avoid breaking

the seal betweenthe top of the level switch and the

plasticcoatedcable.



VAC Power Input Wiring:Observe the labeling on

the FLCN‐100 Series.Note: Polarity does not matter

withtheACinputterminal.

 

RelayInputWiring:Therelayisasinglepole,double

throwtyperatedat250VoltsAC,16Amps.Th

etwo

terminal NO and NC (normally open and normally

closed) will be used in different applications.

Rememberthatthe "normal" state is when the relay

coilisde‐energizedandtheRedrelayLEDisOff/de‐

energized.





 9

ELECTRICAL(continued) StepFive

StrobeAlertOutput(FLCN‐101seriesonly): Withthe

StrobeAlertwiredNC;itcanbeusedasa highorlow

level alarm, depending on the setting for the invert

switch.TheStrobeAlertcanalsobewiredNO.



Changingfrom120to240VAC:

1. Remove the two screws from the top of the

printed circuit board (PCB) and gently slide the

PCB from the housing.Use caution when

removingthePCB.

2. LocatedjumpersJWA,JWBandJWConthePCB.

3. Tochangeto240VAC,removejumpersfromJWB

and JWC and place a single jumper across JWA.

To change to 120 VAC, remove jumper JWA and

placejumpersacrossJWBandJWC.

4. Gently return PCB into housing and replace the

twoscrews.



 120VAC 240VAC

 Configuration Configuration





 10

INSTALLATION StepSix

MountingonaSensor:Thefollowingprocedureshouldbeusedwhenmountingthecontroller  directlyona

flowsensor.Allpowertothesystemmustbeoffbeforeinstallingthejunctionbox.

1. Preparethesensor:Thefollowinginstructionsassumethesensorisalreadymountedinapositionon

itsfitting(asdescribedinthesensormanual).Notethatbecausetheinsulationjacketofthesensoris

less flexible than most (to ensure chemical compatibility), it is important that you follow the

instructionsexactly.

a. Cutthewire4‐1/4”fromthetopofthesensor.

b. Usinga10gaugewirestripper,stripthe whiteouterlayerofinsulationfromthelast1‐1/4”of

thesensorwire.Trimoffanddiscardtheexposedfoilshieldflushwiththeinsulationjacket.In

longcableruns,donotcutoffthedrainwire.

c. Usinga20gaugewirestripper,stripthelast¼”ofinsulationfromthesignalwires.



Important:Donotstripmorethan0.2”(5mm)ofinsulationfromanywirethatwillbeconnectedtothe

terminal strip.Longer insulated wire may contact the terminal strip panel, causing a short circuit

leadingtoasystemfailure.

2. Positionthe controller on the sensor:To make themountingand wiring easier,

youmustfirstremovetheprintercircuitboard(PCB)fromthecontroller.

a. Unscrewthelidofthecontroller.

b. RemovethetwoscrewsholdingthePCBtothecontroller.

c. GentlytipthecontrollertoslideoutthePCBandplaceitaside.

d. Threadthepre‐trimmedsensorwiresthroughthe¾”NPTentrancetothe

junctionbox,andplacethecontrollerinpositionoverthesensor.

e. Beingcarefulnottocrossthethreads,screwthecontrolleronthesensor.

Stopwhenthecapofthesensorbecomesflushwiththebottomwallofthe

controller, or when the ½” power conduit entrance is in the desired

location.

3. Connectthesensorinputwires:

a. Routethesensor‐wiresoitstaysasclosetothehousingasp

ossible,butdo

not bend the wire sharply at the cap of the sensor.(if the installation

allows, you may rotate the controller and/or the sensor until the wire

outletofthesensorisinthebestposition.)

b. PositionthePCBinthehousingalignedwiththetwochannelsdesignedto

holdit.Donotinsertthepanelallthewayintothehousing,butletitrest

onthetopofthehousingtofacilitatethewiring.

c. Using a small screwdriv

er, loosen the terminal screws.Insert the sensor

wiresintotheholeon the sensorinputterminal,andtightenthe  terminal

screws.

d. OncecompletedseatthePCBbackintothechannelsandrestoreonlyone

screwtoholdthePCBinplace.



 11

INSTALLATION(continued) StepSix

4. Mechanicalconnectiontoconduit:Allwiringbetweenacontrollerandsensorsshouldbeinconduit.

The power entrance ofthecontrolleris a standard ½” NPT female fitting that will attachto standard

electrical conduit, either plastic or metal, as specified bylocal codes.Keep in mind that the housing

mayhavetobeunscrewedfromthesensorforperiodiccleaningofthesensor.Forthisreasontheuse

offlexibleconduit,providingenoughslackforeasyaccessisrecommended.

5. Connecttheextensionwiring:

Beforemakingconnections,makesureallpowertothesystem(controller,motor,valve,alarm,etc.)

isOFFwithasafetylockoutonthecircuitbreaker.

a. Theextensionwiringtocontrollershouldtakeintoaccountlongcableruns.Iftherunislong,it

mayneedtobeaslightlythickergaugesotheseriesresistanceiskelpwithinallowablelimits.

b. Threadtheextensionwiringthroughthepowerconduitentranceofthehousing.

c. Strip¼”oftheinsulationfromtheendsofthewires.

d. Loosen the appropriate terminal screws.Insert the extension wires into the corresponding

terminals,matchingthesensorwires.

e. Tightentheterminalscrews.

f. Return the wire protector to its location and restore the final  screw which holds the wire

protectedandPCBinitsplace.

g. Replacethecap.

Note:Insomecases,additionaluser‐providedcomponents mayneedtobeattachedtotheterminals.If

so, make sure that both wires and/or components entering the terminal are secureafter the screws are

tightened.

Note:Alwaystightenthecontrollerfromthewrenchflatlocatedonthe

swivelbase.Nevertightenfromthebodyofthecontroller.





 12

APPLICATIONEXAMPLES StepSeven

LowFlowAlarm:Thegoalistoindicatewhentheflowratefallsbelowacertainpoint.Ifitdoes,analarmis

supposedtosound,alertingtheoperatorofalowflowcondition.

Ifpowerisaccidentallycuttothecontroller,thesensor'sability tonotifytheoperatorofalowflowcondition

couldbelost.Thesystemmustalerttheoperatornotonlytolowflow,buttocontrollerpowerloss.

Todothis,connectthehotleadofthealarmtotheNCsideoftherelayterminalofthecontroller.Ifpoweris

lost,therelaywillbede‐energized,andthealarmwillsound(ifthereisstillpowertothealarmcircuititself).

The alarm circuit should have a noninterruptible power supply or some other indicator or backup alarm to

warnofapowerfailureinthealarmcircuit.

In this application, the normal status is when the sensor is in the flow condition, and the relay will be

energizedholdingthealarmcircuitopen.Pleasenotethattheflowswitchcanbewiredeithernormallyclosed

ornormallyopen(Step5).WhentheswitchiswiredNC,theinputLEDwillbe offandtherelayLEDwillbeon.

Soforthisapplication,InvertshouldbesettotheOnposition.WhentheswitchiswiredNO,theinputLED

andtherelayLEDwillbeonsimultaneously.Soforthisapplication,InvertshouldbesettotheOffposition.

LEDIndication:UseLED'slocatedabovetheinputterminalstoindicatewhethertheswitchisinafloworno‐

flow state. When the switch is wired NC, Amber indicates no‐flow and Off indicates flow. Reversing the

polarity(NormallyOpen),AmberindicatesflowandOffindicatesno‐flow.

NormallyClosed(NC)

AmberLED

NormallyClosed(NC)

LEDOFF

NormallyOpen(NO)

AmberLED

NormallyOpen(NO)

LEDOFF







 13

FLOWSWITCHCALIBRATION StepEight

Set Points: If the presetfactory calibration is notadequate for your application, followthe calibration steps

listedbelow.Note:theswitch'sinternalLEDwillbeonwhentheswitchdetectsno‐flowandwilloffwhenthe

switchdetectsflow.

1. Install the fitting and flow switch as described in the Installation  section of this manual.Turn the flow

switchand controller power on and adjust theflow rate to the application setting.If the medium to be

sensed is likely to be subject to high temperature variations, the flow switch

shouldbesetatthehighestnormaltemperaturelikelytobeencountered.

2. Locatethe potentiometer knob at the topoftheflowswitch.The red LED is 

visible through the potentiometer.(If the LED is on, sl owly adjust the

potentiometer counterclockwise, with asmall flat head screwdriver unti l the

LED turns off.)The  adjustment is a single turn 270° potentiometer.The 

initial response time of  the  flow switch after adjustment is 1 to 10 seconds.

Adjust the potentiome ter in slow increments and wait for the response.If

theLEDisoff, slowly adjustthepotentiometerclockwise unti lthe lightturns

on.Then turn the potentiometer counterclockwise to bring the LE D off at a

reliablesetting.Remember,adjustthepotentiometer inslowincrementsand

waitfortheresponse .

3. Verify that thenewcalibrationiscorrectbyloweringthesystemflowrat e below

thesetpointandchecktoseethattheredLEDturnson.Thenincreaseth e flowrateabovethesetpointand

verifythattheredLEDturnsoffaccordingly.

LiquidSwitch

FST‐200Series

GasSwitch

FST‐300Series



AccessingtheAdjustmentPotentiometer:Removethetwoscrewsfromthetopoftheprintedcircuitboard

(PCB)andgentlyslidethePCBfromthehousing.UsecautionwhenremovingthePCB.Youwillnowbeable

toseethepotentiometerthroughthehousing.Makeanynecessaryadjustment.Note:Electricalwiringofany

liquid level control system should be performed in accordance with all applicable national, state, and local

codes.Whencompleted,gentlyreturnPCBintohousingandreplacethetwoscrews.



 14

APPENDIX StepNine

ControllerLogic:Pleaseusethefollowingguidetounderstandtheoperationofthecontrollers.

1. PowerLED:MakesuretheGreenpowerLEDisONwhenpowerissuppliedtothecontroller.

2. InputLED:ForNCswitchwiring,theinputLEDonthecontrollerwillbeAmberwhentheswitchreadsno‐

flowandOFFwhentheswitchreadsflow.

3. InvertOperation:WhentheinputLEDturnOffandOn,therelayLEDwillalsoswitch.WithinvertOff,the

relayLEDwillbeOnwhentheinputLEDisOnandOffwhentheinputLEDisOff.WithinvertOn,there

lay

LEDwillbeOffwhentheinputLEDisOnandOnwhentheinputLEDisOff

.

4. RelayOperation:TherelaymaybewiredeitherNOorNC.ThenormalstateoftherelayiswhenitsLEDis

Off.WiththeLEDOn,therelayisintheenergizedmodeandallterminalconnectionsarereversed.

Troubleshooting:

PROBLEM SOLUTION

Controllerispowered,butnothing

happens.

FirstcheckthePowerLEDtomakesureitisGreen.Ifnot,check

the wiring, power and make sure the terminal is seated

correctlyoverthe6‐pins.

A Flow or No‐Flow condition is

metbuttherelaydidnotswitch.

Check the relay by switching the invert switch.Confirm that

relayclickonandoffaswellastherelayLED.

The Flow or No‐Flow is not

switchingatthecorrectflowrate.

The flow switch may need to be adjusted.Review the Flow

SwitchCalibrationsectiononthepreviouspageforinstructions

on setting the actual flow switch.Note: access to the flow

switch adjustment is difficult and requires the removal of the

PCBassembly.Usecautionwhenperformingthisstep.

Trying to start the flow but the

controller keeps turning the flow

off.

Torestartaflowcondition,thesensorneedstosenseanactual

flow condition before changing the relay in the controller.A

flow switch over‐ride may need to be added across the relay

contacts that allows for a true flow to occur before switching

back to the  controller.The use of a  moment switch is

recommendedfortheover‐rideswitch.

RelayLEDdoesnotmatchmyflow

condition.

TherelayLEDcanbeswitchedbyeitherthereversingthewiring

of thesensor to the  controller or by flipping the invert switch.

This means that the relay LED can either be set to turn on

during a  flow condition or to turn off during a no‐flow

condition.This is all dependent on the wiring and the invert

position.

Relay LED does not match the

sensor’sLEDindicator.

Thesensor’sLEDwillalwaysbeONduringaNo‐Flowstateand

OFF during a Flow state, regardless of the switches wiring.As

per above the input LED can be inverted to any  condition.In

some applications, they will match and in others they will be

opposite.This is all dependent on the application

parameter/setup.





 15



 16



Omega FLCN-101 & FLCN-111 Series Owner's manual

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