FM200

FLOW/NO-FLOW MONITOR

INSTALLATIONANDTECHNICAL
MANUAL
6/12/2008

Maxi-Tronic, Inc.
3530 IRWIN SIMPSON ROAD
MASON, OH 45040
513.398.2500
800.659.8250 FAX: 513.398.2536
info@maxitronic.com
www.maxitronic.com

FM 200 INSTALLATION MANUAL

INTRODUCTION
TheFM200MultiApplicationFlowMonitorisveryeffectiveinmonitoringFLOW/
NOFLOWconditionsinpipes,chutes,spouting,etc.Itsuniqueultrasonicsensing
techniquemakestheFM200versatileforalmostanyFLOW/NOFLOWapplication.
ThefollowingaresomeoftheuniqueadvancedfeatureswhichallowtheFM200to
exceedindustrystandards.

FEATURES
Control Unit:
Monitorsmovementofmostanythingthroughapipeorchutesystem:Air,Liquids,
andSolids.
Sensesthepresenceorabsenceofmaterialsinairflow.
3Userselectablesensitivityranges:
Low
Medium
High
Calibrationfineadjustmenttosuittheapplication.
Monitorspipesystemsfrom1/2to60ormoreindiameter.
ControlOutputs:
RelayContacts:N.O.andN.C.ratedfor4Ampsat125/250VAC
TTL:05Volt
RS232:Low/HighOutput
Standalonecontrolsystem.
EasyInstallation.
NoMaintenance,nomovingparts.
L.E.D.Indicators:
Flow=Green,NoFlow=Red
Polycarbonatehousingwithconduitknockouts:5x7x3(125mmx175mmx75mm).

Flow Sensor:

Sensormountsexternallytotheoutsideofthepipeorchute.
MountingTabsforeasyinstallation.
Prewiredwith6of18AWG2conductorwire.
Lowvoltagesensor:5VDC,200MAmaximum.
3sensorstylesavailable.

Optional Models Available:

NEMA3/4/12and7/9Enclosures
Availablealsofor12VDC,24VAC,and220VACoperation.

FM 200 INSTALLATION MANUAL

FM 200 WIRING
TheFM200polycarbonatehousingcomeswith10PGconduitknockoutsinthehousing.

Highvoltageinputsabove24voltACshouldberoutedintothehousingthroughthe
(20mm)conduithole.
AllLowvoltagewiring(TTL,RS232,andsensor)shouldberoutedthroughthe
(14mm)conduithole.

Figure1

HIGH VOLTAGE INPUTS

Connectthe120VAC,50/60HZ,1AmpsupplyonTB2terminals(Fig.2):
120VAC(Hot)supplyto117VACterminal(or12/24VDC,240VACperthemodel)
ACCommontoACCOMterminal
EarthGroundtoEGNDterminal.Mustconnecttopreventaccidentalelectricalshock.

Figure2

FM 200 INSTALLATION MANUAL

A1Ampfuseislocatednexttothetransformer.

Figure3

SENSOR INPUTS
ConnectthelowvoltageFlowSensortotheSensorterminalsTB1(Fig.4):
PositiveRED(orWhite)sensorleadtothe+SensorterminalonTB1.
NegativeBLACKsensorleadtotheSensorterminalonTB1.
Thesensorwiringshouldbeaminimumof18AWGstranded2conductorcable.
Use18AWGforupto500(155m)and16GAupto2000(620m).
AllSensorwiresplicesmustbeSOLIDandWATERTIGHT.

Figure4

Relay and Low Level Logic Wiring:

Seethosesectionslaterinthismanual.

FM 200 INSTALLATION MANUAL

SENSOR INSTALLATION
TheFM200sensorisinveryruggedpolymerhousingwithasealed6cablepigtail(Fig.5):
Red/Black=Positive
White/Black=Negative(thisiselectricallyconnectedtothemetalsensorstud)

FM200 SENSOR
BLACK LEAD

RED/WHITE LEAD

Figure5

MOUNTING PROCEDURES FOR SENSOR:

TheFM200Sensorcanbescrewed,clampedorstrappedinplaceandisabletodetectflow
throughmostsheetmetal.
Cleanthesurfaceareawherethesensoristobeinstalled.Thesurfaceshouldnothave
anybuilduporscalebutdoesnothavetobeperfectlyclean.
Thesensorstudlocatedatthebottomofthesensorhousingmustmakesolidcontact
withthesurfaceofthepipetobemonitored.

MOUNTING TO A FLAT SURFACE:

Refertothemountingholeslocatedateachendofsensorhousing(Fig.6).
Markmountingholes.
Drillpilotholesformountingscrews.
Screwsensorhousingtoflatsurface.

SIDE VIEW

FM200
SENSOR

FRONT VIEW

NOTE: Pilot holes are

drilled into flat surface and
mounted with proper
hardware.

FM200
SENSOR

Figure6

FM 200 INSTALLATION MANUAL

MOUNTING TO A ROUND OR NON-FLAT SURFACE: (Fig. 7)

Usingstrapping(suchasheavydutywireties)orclampstosecurethesensor
housingtothepipesothemetalsensingstudmakesfirmcontactwiththesurface.

FRONT VIEW

SIDE VIEW

FM200
SENSOR

NOTE: Straps or
Clamps are Used
for Mounting to
NON-FLAT
SURFACE.

FM200
SENSOR

Figure7

SENSOR LOCATION:
TOENHANCESENSITIVYINSTALLTHESENSORWHERETHEFLOWISMOST
TURBULENTORWHEREMATERIALIMPACTSTHEPIPEWALL.

Thefollowingpointsareideal(Fig8):
Pipeelbow
Pointwherematerialdropsintospoutingorchutes
Pointwherematerialdropsfromconveyorontothechute

BE SURE SENSOR STUD

IS MAKING A GOOD
TIGHT CONTACT WITH
MOUNTING SURFACE.
STUD SENSOR

INPUT

PUMP

Figure8

FM 200 INSTALLATION MANUAL

LOW LEVEL (LOGIC) OUTPUT WIRING

Lowleveloutputsavailable(Fig.9):
TTLlogicoutput
RS232logicoutput

Figure9

TTL LOGIC OUTPUT:

The TTL Logic output is a 5VDC output.
ToobtainaTTLLogicOutputinstalljumperJ3asindicatedontheFM200PCB.
ConnectlogicleveloutputwiringtotheOut(+5V)terminalandtheSensor(0V)
terminalsonTB1.

NOFLOW:RedLEDlightsand0VDCwillbepresentattheOUTterminal.
FLOW:GreenLEDwilllightand5VDCwillbepresentattheOUTterminal.

RS232 LOGIC OUTPUT:

TheRS232outputisanindustrystandard5VDCminimuminto3Kload.

ToobtainanRS232logicaloutputdonotinstalljumperJ3asindicatedonFM200PCB.

NOFLOW:RedLEDlightsand0VDCwillbepresentattheOUTterminal.
FLOW:GreenLEDwilllightand5VDCmin.willbepresentattheOUTterminal.

NOTE:forproperlogicinputtoyourcomputer,consultyourcomputermanualforthe
correctpinconfigurationforRS232orTTL.

FM 200 INSTALLATION MANUAL

RELAY OUTPUT WIRING

Relay(CTR1)ContactSpecifications:
4ampat125or250VAC
1/10HPat125or250VAC
3ampat30VDC

RelayOutputWiringonTB2(Fig.10):
COM=Commoncontact
N/C=Normallyclosed
N/O=Normallyopen

Figure10

SOUNDING AN ALARM TO INDICATE DECREASES FLOW:

Analarmwillsoundwhenflowdropsbelowthepresetamount(Fig.11):
Whenflowdropstherelaycontactsclosetoenergizethealarm.
Thepowertothealarm(connectedtotheCOMterminal)isfromthemotorstarter
circuitsothealarmcanonlysoundwhenthemotorisrunning.WhenthemotorStop
buttonispressedthealarmwillsilence.

MACHINE
SUPPLYING
MATERIAL

MOTOR
STARTER

START
SWITCH

TB2

117VAC

COM
N/O

NOTE: Auxillary Set of Normally

Closed Contacts (Closed When
Stater is Energized).

117VAC
ALARM

N/C
AC COM

Figure11

FM 200 INSTALLATION MANUAL

SHUTTING DOWN EQUIPMENT WHEN FLOW DECREASES:

Whenanequipmentshutdownmodeisrequirediftheflowratedropsbelowthepresetlevel.
Therelayisoftenwiredtostoptheequipmentthatissupplyingthematerial(Fig.12and13).

STOP

START
STARTER
COIL

NORMAL STARTER CIRCUIT

Figure12

Beforethecontrolledequipmentcanbestartedagain,thefollowingmustoccur:
MaterialisflowingpasttheFM200sensor.
TheGreenL.E.D.(FLOW)indicatorlightislitindicatingmaterialflow.
YoumayhavetoholddowntheStartbuttonuntilflowreachesthepresetrate.

AslongasmaterialcontinuestoflowpasttheFM200sensorabovethepresetrate,the
machineequipmentsupplyingmaterialwillcontinuetorun.Iftherateofmaterialflow
fallsbelowthepresetlevel,therelaywillopenandthemachineequipmentsupplyingthe
materialwillstop.

STOP

START
STARTER
COIL

TB2

COM
N/O
N/C
STARTER CIRCUIT WITH FM200 SHUTDOWN

Figure13

FM 200 INSTALLATION MANUAL

SENSITIVITY RANGE ADJUSTMENT AND CALIBRATION

TheFM200has(3)threesensitivityrangeinputs.Selecttherangetogetthedesiredsensitivity
fortheapplication.

IMPORTANT:TOAVOIDELECTRICALSHOCKDISCONNECTACSUPPLY
VOLTAGEBEFOREADDINGORREMOVINGJUMPERSONTB1.

Minimum(low)range:
InstalljumperJ2(only)
Mediumrange:

Nojumpersinstalled(asshippedfromfactory)
Maximum(high)range:
InstalljumperJ1(only)

ADJUSTING THE SENSITIVITY RANGE:

NOTE:ThesensitivityrangeisfactorypresettotheMediumrange(nojumpersinstalled).
Verifythesupplyvoltageandtheflowsensorarewiredandinstalledcorrectlypriortotesting
(Fig.14).Afterselectingpropersensitivityrange,proceedtothenextcalibrationsection.

1. WithnomaterialflowingturntheSensitivityadjustmenttothefullclockwiseposition:
REDLEDwillturnon.
2. Startthematerialflowingatthefullrateyouwishtomonitor:
IftheGREENLEDturnson,thenturntheSensitivityadjustmentfullycounter
clockwise.
IfthatcausestheREDLEDtoturnonthenthecorrectsensitivityrangeis
selected.
IfthatdoesnotcausetheREDLEDtoturnon(Greenstayslit)theninstall
jumperJ2(Minimumrange)andrepeatthetestbeginningwithstep#1.
IftheGREENLEDdoesnotturnonwhenmaterialisflowing,theninstalljumper
J2(Maximumrange)andrepeatthetestbeginningwithstep#1.

Figure14

10

FM 200 INSTALLATION MANUAL

FM200 CALIBRATION:
Performsensitivityrangejumperselectionbeforeperformingcalibration.

1. Stopallmaterialfromflowing.
2. TurntheSensitivityadjustmentfullyclockwise.
3. Startmaterialflowingattheminimumfullflowratedesired
GREENL.E.D.willlighttoindicateFLOW.
4. TurntheSensitivityadjustmentcounterclockwiseuntiltheREDLEDlightstoindicate
NOFLOW.
5. TurntheSensitivityadjustmentclockwiseveryslowlyuntilGREENLEDlightsto
indicateFLOW.
6. Calibrationisnowcomplete.

FINAL SYSTEM CHECK:

StoporreduceflowofmaterialandtheGREENLED(FLOW)willgooutandtheRED
LED(NOFLOW)willlight.

11