Delta Jr. User Manual
Contents
1. UPPER JAW SHUN ED 2 4 Eu M 3 8 INCH 4 LOWER JAW OWER J gt i S o ft RETURN SUPPLY ROCON LLC ELECTRICAL CIRCUIT DPJ A 6 4 6EF2D10 H HA Firmware Version 3 15 9007 80 70 SOVAYSLNI Hf LNIOdY 1130 ONN LNIOdY 1730 ONN LNIOdY1730 a J JAWA 9 9 na GION310S E E S WE v LHM g amva 1dQHH3INI SIE a GION310S ON ON jnoamwAS9uo v 039 er ers ama 2r WOO Are LH wavy T A B a 22 19539 ma zma OA 19599 gt 2 ze dd PNY guy ye Ave Jim av YOOFNI 8 sa l ga 3NWA 3 j A vOOPNI vL E 5 OG0 0 d SI2. tasse due C 6 19 ROCON LLC APPENDIX Specifications for DeltaPoint Jr See page 4 for complete device specifications Mechanical Maximum operating pressure Minimum operating pressure Maximum operating temperature Minimum operating temperature Maximum Flow Minimum Flow Wetted Parts Power Requirement Display 190 PSIG 12 9 Bar See Chart 210 F 99 C Fluid 40 F 4 C Fluid 4 0 GPM 15 LPM 0 4 GPM 1 5 LPM Brass PVDF and Viton 10 30 VDC 80 mA 3 digit LED digital display 0 3 high PRESSURE DROP CHARTS 61 2 5 FLOW GPM 10 50 250 6 200 300 30 100 300 80 2 5 1020 5D 200 600 noe FLOW LPM Electrical Accuracy Repeatability Alarm Output Alarm Deadband Alarm State Electrical Connection 2 full scale 0 3 LPM 0 25 of actual flow Solid state relay rated to 125 mA VDC up to 185 F 85 50 mA 30 VDC between 186 210 F 86 99 C 2 5 of full scale NO 24VDC or NC OVDC with internal 2K pull up resistor factory setting ONLY Direct cable to junction box 20 ROCON LLC Check Valve Specifications Style Maximum operating pressure Maximum operating temperature Cracking Pressure Material Piston Check Valve with embedded O ring
3. 2 Gently push the piston water flow OUT side with the screwdriver until dislodged The O ring remains in place Only the spring and the piston are removed Clean with soap and water 3 Check if the O ring needs replacement 4 Insert the spring over the piston and insert them into return port 5 Replace the retainer ring 6 Testto confirm that the unit is operational If there are problems contact the Service Department at Rocon LLC Cleaning These meters do not require any special cleaning of the external surfaces If cleaning is deemed necessary strong solvents detergents or chemicals should not be used A damp cloth may be used to wipe off dirt or debris Note If used outside the parameters specified in this manual the proper operation of the flowmeter cannot be guaranteed 18 ROCON LLC EXAMPLE DPJ B 6 XXXXD Port Pipe Size Port Pipe Size 4 Digit Number assigned at Factory FLOW SWITCH RANGE Inches in Inches NPT followed by alpha code for Supply and for Pipes To stas i mbo Return Lines and From Cell y Example 0 4 4 0 GPM 2 15 LPM 3 4 eaa 1 8 crois A 6 4 XXXXD DC 0 4 4 0 GPM 2 15 LPM 3 4 6 4 digit code covers Connectors style number of pins wire color and 1 2 12 GPM 5 45 LPM 9 4 code 3 4 UE B 6 function Alarm type restart type and any options picked 2 5 25 GPM 9 95 LPM
4. that seals on seat 500 PSI 34 5 bar 180 F 82 C 1 PSI Brass Body and Piston Beryllium Copper Ring Shut Off Valve Specifications Function Ports Pressure Range Temperature Ratings Ambient Fluid Media Coil Power Rating Electrical Connector Materials of Construction Body Seal Other Wetted Parts Coil Contact Factory for Spare Parts Normal Operation x D z al Manual Override 2 Way Normally Closed 2 PSI to 150 PSI 0 14 bar to 10 bar 14 F to 122 F 10 C to 50 C 176 F 80 C Maximum 24VDC 700 mA 16 Watts Maximum DIN Style Plug w Removable Cable Plug Adaptor Brass Buna Stainless Steel PVDF Brass Class F Molded Continuous Duty UL amp CSA Listed Manual Override Bypass Normal Operation Manual Override Position 90 Degrees ONLY Position i ERR Co T fm T x zd KIP NORGREN VALVE 2 PARKER VALVE 21 ROCON LLC DeltaPoint Uno Elbow Test Results DELTA POINT UNO WATER FLOWMETER TEST With and Without 90 Degree Fitting Installed Inlet Port 2 00 A 2 00 A Master Flow Meter Master Flow Meter 2 00 DeltaPoint Uno C Maste
5. will be waived and a credit issued by UFM The customer will be advised of any non restockable goods and will be charged the 90 00 evaluation fee plus any shipping charges if returned to the customer If no disposition is received by UFM within 30 days the goods will be scrapped and the 90 00 evaluation fee will be billed WARRANTY RETURNS Warranty returns must be shipped prepaid to UFM UFM will review the goods and advise the customer of the evaluation and validity of the warranty claim Valid warranty claims will be repaired or replaced at no charge No evaluation fee will be charged for repairs made under warranty Return shipping costs will be prepaid by UFM Should UFM determine the returned material is not defective under the provisions of UFM s standard warranty the customer will be advised of needed repairs and associated costs All materials returned for warranty repair that are determined to not have a valid warranty claim will be subject to the Repairable Material policy outlined above 23 ROCON LLC RMA FORM UNIVERSAL RETURN MATERIAL AUTHORIZATION E MAIL ufm flowmeters com PH 248 542 9635 U rocon mme FLOW MONITORS Fax 248 398 4274 IMPORTANT This form must be filled out completely and faxed to the Repair Department prior to issuing a RMA UFM NRA Customer Product Information Qty Model Code S N Sales Order Contact Name FA
6. 5 42 cee iret hte root eld rare denen ne dd rye an Ed derby oe deine AREE ue 11 Configuring the Engineering Units nennen 11 Configuring the Flow rens nnns internen 11 UNIT VERIFICA MON arere LE 13 TROUBLESHOOTING ys PEE 14 Unrt Will Not Power Up ac theese dienen tritt tetuer ARAE bte 14 Unit Will NOU Start s t eere tetti prx neret darent e Scu ee teer poe EUR epo eds 14 InsuTficient Water Ac 14 Water Continues to Flow When Cap is Removed sse nere 15 UIDI tos tat tea antea tA dde Repo 15 FlOWITIGlor 15 Shut otf Sites 15 ease nel es c Oe CL o 15 Unit Will Not Restart Manually or Remotely 15 UIDI eat oben eb e oc ee 15 EI TI S 16 Shut OT Walve s secos ihe cte D Li Led SAL OL LUE ESO 16 Flowmeter 8 55 16 Solenoid Valve Does 2 44 16 Fault Alarm Signal Not Received at Weld Controller sse 16 dou
7. CTIVE HIGH 1 2 3 JP4 e RESTART SIGNAL 0 0V ACTIVE LOW 1 2 3 JP5 RESTART SIGNAL R 24V ACTIVE HIGH 4 2 JP5 e e RESTART SIGNAL 0 ACTIVE LOW No Jumper 10 ROCON LLC SET UP PROCEDURE Configuring the Engineering Units In order to configure the engineering units GPM or LPM proceed as follows 1 Press and hold the MENU pushbutton the display shows Continue holding the pushbutton for at least 5 seconds 2 display shows either for GPM or L for LPM depending on what engineering unit was previously set 3 Release the ALARM SET pushbutton 4 Use the ALARM SET pushbutton press and release to toggle between G and L then do not touch the pushbutton until the flowmeter returns to normal operation Note It may take up to 20 seconds before the meter returns to normal operation Do not touch the pushbutton unless you want to change the alarm setting as described below Configuring the Flow Alarm In order to configure the flowmeter for alarm output proceed as follows 1 Press and hold the ALARM SET pushbutton the display shows Continue holding the pushbutton for at least 5 seconds 2 The display shows either or L depending on which engineering unit has been selected 3 Wait 5 seconds During the 5 second period you can either continue holding the ALARM SET pushbutton or release it If you release the pushbutton d
8. DeltaPoint Jr Installation and Operation Manual 6 GPM 22 7 LPM Unit c a FUSMIOSTART PUSM TO BYPASS RETURN WATER ae C DeltaPoint Jr 1704 M 2000908 41 SEA STON _ 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 248 584 1490 www flowmeters com ROCON LLC TABLE OF CONTENTS TABEE OE GONTENTS uite tt Rte ric t d ete ied tae uv intend 2 PROPRIETARY NOTICE 2 5 ctt rta eet t Re e te e eto 3 SPECIF CATON pr 4 DIMENSIONS t Ut eee ee theta 5 DeltaPoint Jr VIEW et er e e ec eee Eee rented ra teaches 5 DeltaPoirt Jr Erid VION aterian e Pet ere ER n EE Radeon Pear de el ee gents 6 HOW IT WORKS taret cert 7 6 TON 8 EEEGTRIGAL GCIRGOULT iive irte aperte o ale dirt eddie eed e d de TR 9 JU MPER SETTINGS itai reete etes pep denk nce rea aeo debit err pna d REY 10 SETSUP PROGEDURE 3 3
9. SSVHO ma 2204 HOLIMS 17 YOOPNI am 0 6 L N33H5 1dniBH3LNI n 2 GION310S 9 9 A385 9 v 2 T a moTIaA NOWWOO 2 LHM 2 g 1as3u na v 2 3 0 i IRE Aver e 1 13539 9 SsvdA8 VOOPNI ES 27 Jiuvis D CM voa ree eT HOLIMS 954 Nid 9 MOHNL 31ovid303u var 244 4 030 159 4 ers 4r L 110 284 25 puo 0L Sia z z o H zu 5 LAHO S E 8g UTER ssvdaa 5 9802 s LHM 18 15 e o 9 NH9 bong HILIMS SSVdA8 1915 ROCON LLC JUMPER SETTINGS DeltaPoint Jr JUMPERS E OQ g O z O CE 5 a JP1 JP2 Se 95 5 ris JB 2 8 DeltaPoint Jr Interface Board Jumper Part 7548 JP1 VOLTAGE D2 24V PNP SINKING OV 1 2 3 JP1 e VOLTAGE D1 24V NPN SOURCING 24V 1 2 3 JP2 9 RESTART SIGNAL R 24V ACTIVE HIGH 1 2 3 JP2 e E RESTART SIGNAL 0 0V ACTIVE LOW 1 2 3 JP3 e e OPTIONS H SOLENOID INTERRUPT No Jumper 1 2 JP3 EE OPTIONS NO OPTIONS PICKED 1 2 JP4 EN 9 RESTART SIGNAL R 24V A
10. The guide encloses the pressure spring and plunger Spring fits inside the plunger With the guide and screw piece removed check the orifice for any foreign matter If present remove with soap and water 17 ROCON LLC 11 To reassemble Spring fits into the top of the plunger The plunger fits inside the guide with the spring going in first The plunger seat fits on top of the orifice seat With plunger in place screw the screw piece into the valve cover 12 With the valve cover complete set the pressure spring on top of the diaphragm and the valve cover on top of the pressure spring Install the 4 socket head screws 13 With the spring clip pulled slide the coil over the guide When complete push the spring clip over the coil 14 Insert the DIN connector into the coil 15 Energize coil to confirm operation If there is a problem consult Service Department at Rocon LLC Override Stem Broken Spare Part 2705 CAP If the override stem is broken replace the control cover An indication of a broken stem is that the valve will not shut off in fault or when power is removed while the stem is in Normal position This is determined when the valve is disassembled and no foreign object was found that would force open the diaphragm Check Valve Remove Piston Tools Required 1 3 16 box wrench to remove from unit retainer ring puller 1 4 inch flat nose screwdriver Spare Part Check Valve 2081 1 Remove the retainer ring
11. X LL Are before as found and after readings required E mail ______________ Yes No Reason for return Please be detailed as possible Lack of Information may increase labor charges Mechanical Electronics D Leaks D No signal D Sticks Inaccurate signal D Calibration Off No Display D Switch does not work O Other describe below D Other describe below Details Note There will be a minimum evaluation charge of 90 00 for all units returned excluding units covered under warranty Units WILL NOT be accepted without a valid Return Material Authorization Number RMA A Material Safety Data Sheet on the process fluid must be received when applicable prior to the RMA being issued OSHA Requirements to be filled out by customer NO EXCEPTIONS Process Fluid Meter must be flushed to remove all process fluids hereby certify that the material being returned has been properly flushed and cleaned of all hazardous materials and does not require any special handling Print or Type Name Signature Title Date Distributor Information INTERNAL USE ONLY Company Name Contact Name 1 1 1 1 1 1 Authorized by 2222222 Date Document 9 1400 9 Revision 6 Revision Date 11 10 2004 24 ROCON LLC ROCON DELTAPOINT WARRANTY 1 ACCEPTANCE AND INTEGRATION CLAUSE This Sales Order Acknowledgment and the sales order information that Rocon LLC attaches to or assoc
12. ce 16 MAINTENANGE i iei due beet dete diae PH Last bg eoe edocet ob eel ep vade 17 Flowmeter i ied dee Ta de De d ede 17 Inspect or Replace Bluff 17 Shut Off Valve se ERU n iste He eie Ee ar edet eate o e beet e od Dee de 17 miJeEI ae 17 Clean Diaphragm Orifice Plunger Pilot 17 Override Stem Broken iei dii Dd a Pci a d 18 Check Valve Remove 18 eee 18 Mors 18 MODEL CODES itr teh best dit enero eet tres 19 APPENDIX ettet oi ate E ead tan el eine atari ads 20 Specifications for DeltaPoint dete edet iae eter 20 Check Valve Specifications oet erede edet eie ien tee or eine t eda 21 Shut Off Valve Specifications dete eed bee ine it a Per enda 21 DeltaPoint Uno Elbow Test Results 22 5 51 cce ete ate ede te itv tt ete eus 23 RMA FORM zu icit Get i te i Et ie et fede entire uds 24 WARRANT Y INFORMAYT IQN oec dt P Rent E o ems 25 ROCON LLC PROPRIETARY NOTICE The information contained in this publication is derived in part from proprietary and patented data This information has b
13. duct or that form a residue on the product b Exclusive Remedy The buyer s EXCLUSIVE REMEDY for failure of any product to conform to any warranty or otherwise for any defect is at Rocon s sole option i repair ii replacement or iii refund of the entire purchase price for the specific product Without limiting the foregoing in no case will Rocon be liable for deinstallation of any defective product or installation of any repaired or replacement product THIS REMEDY IS THE EXCLUSIVE REMEDY AVAILABLE TO THE BUYER OR ANY OTHER PERSON ROCON SHALL NOT BE LIABLE FOR ANY DIRECT INDIRECT INCIDENTAL CONSEQUENTIAL SPECIAL PUNITIVE OR OTHER DAMAGES IN CONNECTION WITH ANY CAUSE OF ACTION WHETHER IN CONTRACT TORT OR OTHERWISE c Disclaimer of Other Warranties The express warranty in this Acknowledgement is in lieu of any other warranty express or implied Without limiting the foregoing ROCON DISCLAIMS THE IMPLIED WARRANTY OF MERCHANTABILITY AND ANY IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE 5 Products purchased by OEMs original equipment manufacturers are warranted only for the specific programs installations for specific customers designated when so identified 6 Flow sensors are warranted for 5 years electronic parts for 2 years and ancillary check valves and shut off valves for 6 months 25
14. ectric 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 OV 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
15. een 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 ROCON LLC GENERAL SPECIFICATION Maximum Operating Pressure Minimum Operating Pressure Temperature Ratings Ambient Fluid Media Flow Rate Flow Measurement Accuracy Repeatability Power Requirement Alarm Output Alarm Output Impedance Electrical Connection Wetted Parts 150 PSI 10 bar 10 PSI of back pressure is required for the formation of vortices 14 F to 122 F 10 C to 50 C 176 F 80 C Maximum 0 35 GPM Min to 6 0 GPM Max 22 7 LPM 2 full scale 0 2 LPM 0 25 of actual flow 24 VDC 750 mA 18 Watts Maximum Solenoid Valve energized 24V Fault OV OK 2K Ohms internal pull up resistor Turck EURO FS4 6 Brass PVDF Viton Buna N NBR EPDM FKM Beryllium Copper accordance with CSA Standard 22 2 No 1010 1 92 Annex H Caution The unit shall be supplied by a SELV separated extra low voltage
16. iates with it this Acknowledgement constitutes an acceptance by Rocon of an offer by the buyer upon the conditions and terms and at the prices stated in this Acknowledgement This Acknowledgment contains the entire understanding of Rocon and the buyer regarding the subject matter of this Acknowledgement This Acknowledgement may only be modified by a writing signed by the party against whom enforcement is sought 2 WAIVER Waiver by Rocon of any default s by the buyer shall not constitute waiver by Rocon of any of the conditions of the agreement between Rocon and the buyer as set forth here under with respect to any further or subsequent default by the buyer 3 FORCE MAJEURE Rocon shall not be responsible for failure or delays in deliveries due to fire strikes breakdowns acts of God failure of carriers inability to secure required materials or other causes beyond Rocon s control Buyer waives any claims for damage arising by virtue of delay in delivery of material by Rocon 4 LIMITED WARRANTY a Warranty For a period of one year from the date of manufacture Rocon warrants that each product covered by this Acknowledgement will be free from defects in material and workmanship In order to qualify for any remedy provided in this Acknowledgement buyer must give notice to Rocon within the one year period return the product to Rocon freight paid and intact with Material Safety Data Sheets covering all substances passing through the pro
17. ir bubbles are present in the water line If this is the case you need to purge the pipes If you cannot see any air bubbles through the plastic hose the header system is operating normally Water Continues to Flow When Cap is Removed Unit 1 Make sure the 2 position switch is not in Bypass 2 Make sure the switch is not stuck in Start position Flowmeter 1 Check if the shut off signal is transmitted by the flowmeter See ELECTRICAL CIRCUIT Pin 5 of J2 should go low in order to shut off the solenoid valve This can be verified by checking the voltage on Pin 1 of JP5 If this pin is high there may be a damaged component on the circuit board Consult factory for further assistance 2 Ifthe shut off signal from the flowmeter is low check the LED on the solenoid valve DIN connector If this LED is on there may be a short either in the cable or on the circuit board Neither one of these problems can be fixed in the field Consult factory to arrange for an RMA Shut Off Valve Check the manual bypass screw on the solenoid valve The stem should be in the Normal position 1 Close the supply and return ball valves Remove both weld gun arm caps Gradually turn the supply ball valve 1 2 turn If at any time water begins to leak through the weld gun arms water tube orifice the problem lies within the solenoid valve If no leak is detected refer to Check Valve leak procedure below 2 If solenoid valve is the source of the problem
18. ition See the shut off valve Manual Override illustration under MAINTENANCE Remove the bluff stem underneath the DeltaPoint Uno flowmeter and clean if dirty Turn the Supply water shut off valve open 1 4 turn or until water is slowly flowing out of the bluff mounting hole This is to ensure that air does not leak into the piping Replace the bluff turn the shut off valve manual bypass stem back to normal position Open the supply water valve and connect the power cable to the unit If the display is normal unit is ready for operation If not consult factory Solenoid Valve Does Not Open Make sure there is power to the unit Push BYPASS switch orange light on Check the LED on the solenoid valve DIN connector If the light is not on the problem may lie in the internal wiring Contact the factory for further instructions If the light is on make sure the valve connector is plugged in tightly If this does not fix the problem replace the coil see MAINTENANCE Fault Alarm Signal Not Received at Weld Controller Flowmeter 1 Make sure the flowmeter is indicating flow fault 3 digit LED flashing 2 Check the setting of JP1 see JUMPER SETTINGS 3 Check the connector J4 see ELECTRICAL CIRCUIT to ensure that the 6 pin receptacle is plugged in correctly to the board 4 Checkthe voltage on Pin 2 of the 6 pin receptacle see ELECTRICAL CIRCUIT This pin should be high in fault mode Supervisor If Step
19. lled If all steps are completed satisfactorily unit is ready for final test System Verification Restart Unit Remotely Close the return water leg ball valve from weld gun arms Unit shuts off water LED flashing 0 00 and sends fault alarm to weld controller Open the return leg ball valve Restart unit remotely If yes unit is ready for production operation If no see Troubleshooting Unit Will Not Restart Manually or Remotely 13 ROCON LLC TROUBLESHOOTING Unit Will Not Power Up 1 2 3 Make sure the power cable is correctly plugged into the unit The DeltaPoint Uno flowmeter display shows a 3 digit number bright red digits It may or may not be flashing Check the connector on J4 see ELECTRICAL CIRCUIT to ensure that the 6 pin receptacle is plugged in correctly to the board If the power cable is plugged in correctly and you have ensured that the 24 V is present unit must be replaced Contact factory for RMA number and a box for shipping if necessary Unit Will Not Start The flowmeter requires a minimum of 1 5 LPM 0 4 GPM to operate If water flow is below minimum the display will blink 0 00 and send a fault alarm The following tests determine the amount of water flow available if the hose or fittings are restricting water flow or if the weld gun arms are faulty Insufficient Water Flow Suggested procedure to confirm amount of water flow available or if there is some restricti
20. low gt setpoint hysteresis display stops blinking 12 ROCON LLC UNIT VERIFICATION Initial Water Flow Present to Operate 1 2 3 6 7 Confirm that the hoses to weld gun arms are hose dressed properly Refer to the INSTALLATION section of this manual Open the water shut off ball valves to weld gun arms or cell Plug in the Turck Euro connector to the unit The flowmeter LED display lights up and shows the firmware revision followed by a 5 second countdown Restart delay It then shows a blinking 0 00 to indicate that there is No Water Flow Alarm Fault mode Press the BYPASS switch The orange light turns on and the shut off valve opens Shut off Valve Coil DIN connector LED turned on Wait a few seconds for the water flow to stabilize and then record the water flow as shown on the 3 digit LED display on the DeltaPoint Uno flowmeter nameplate If yes proceed to the next step If no see Troubleshooting Unit Will Not Start Insufficient Water Flow Alarm setpoint is 4 00 LPM factory setting Change the BYPASS switch to START position The orange light turns off and the green light remains on Unit has passed basic water flow setup test sufficient water flow present to keep the unit in operation Flow Fault Verification Cap Pulled 8 9 14 15 Pull upper weld gun arm cap off The LED display on the flowmeter is reading 0 00 and flashing If yes proceed to the nex
21. o not push it again If you press and release the pushbutton at this point the display toggles between and L assuming that you are changing the engineering units 4 The 3 digit value that starts blinking on the display is the alarm setpoint as stored in the memory If you do not press ALARM SET the display continues to blink for 10 seconds then the meter reverts back to normal operation 5 Usethe ALARM SET pushbutton to change the alarm setpoint if needed Note When ALARM SET is pressed once the display stops blinking and increments to the next value ALARM SET can either be held down continuously or pressed and released repeatedly When the maximum setpoint value is reached the display rolls over to the minimum value again Setpoint values are pre programmed Please refer to Table 1 below for more details 6 When the desired alarm setpoint is displayed do not touch the pushbutton for 10 seconds The displayed value is saved in the memory and the meter returns to normal operation Pre programmed Setpoint Min Setpoint Max Hysteresis Meremees LPM GPM LPM GPM LPM GPM LPM GPM 1 5 0 40 12 0 3 00 0 4 0 1 0 5 0 2 Table 1 Flow Alarm Range 11 ROCON LLC Note Flow fault occurs when flow lt setpoint The LED display starts blinking to indicate this After the occurrence of a flow fault the unit must be restarted If in bypass mode the alarm signal returns to normal when f
22. on in the circuit 1 Turn water off by closing the water shut off valves 2 Remove hoses TO CELL and FROM CELL from the unit and install a 5 foot hose loop between them the loop will be the same hose size and mating fitting 3 Open the water shut off valves 4 Power up the unit Does the flowmeter indicate water flow If yes proceed to next step If not contact supervisor Unit indicates that water is present The next step is to determine if there is a blockage or hose dress problem between the unit and the weld gun arms 5 Close the water shut off valves remove the 5 foot hose loop and reinstall the gun arm hoses to the unit 6 Remove the hoses at the manifold or tee just before they are divided into 2 separate hoses to each weld gun arm 7 Connectthe supply and return hoses together and turn the water shutoff valves open 8 Power up the unit Does the flowmeter indicate water flow If yes proceed to next step If no inspect hose and fitting for a blockage i e the fitting is not drilled through or dirt is blocking flow in hose or fitting or hose is kinked Unit indicates that water is present The next step is to determine if there is a blockage in the weld gun arms 9 Close the water shut off valves Connect the hoses to the manifold 10 Turn the water back on 11 Power up the unit Does the flowmeter indicate water flow If yes unit is working If no inspect hose fitting and weld gun a
23. r B DP Uno B DP Uno DP Uno DP Uno GPM Increasing Decreasing Increasing Decreasing 1 0 98 0 99 0 98 0 95 2 1 97 1 98 1 98 1 99 3 2 96 2 96 2 96 2 98 4 3 96 3 95 3 98 3 99 Based on the above results there is no difference in performance in the installation of a 90 degree fitting in the inlet port of the flow switch on the DeltaPoint Jr unit 22 ROCON LLC RMA NOTICE RMA NOTICE RETURN MATERIAL AUTHORIZATION Please read the following UFM policy information carefully By following the guidelines outlined below you will assist in providing a timely evaluation and response regarding the status of your flow meter UFM evaluates all AUTHORIZED RETURNED MATERIALS in a timely manner and will promptly provide notification regarding the status of the related materials and or a written quotation indicating the total charges and description of the necessary repairs 1 All returns must have a RMA form completed by the customer 2 Any meter returned that was previously in service must have the OSHA requirements completed and a MSDS included where applicable 3 An RMA number will only be issued when UFM has received copy of the completed RMA form and any applicable MSDS 4 A Return Goods shipping label located in the back of the Instruction Manual must be used for returning materials to UFM 5 Returned goods must be shipped prepaid or they will be rejected REPAIRABLE MATERIAL Written or verbal authorization
24. rms for a blockage i e the fitting is not drilled through or dirt is blocking flow in hose or fitting The hose dress may be incorrect The water tubes are too close to the caps or the water tube is pinched or the weld gun arms have never been tested for water flow and must be disassembled Supervisor Above testing indicated no water flow from main header to hose drops to cell Please confirm that 1 the number of pumps in operation is correct for a normal production day 2 the headers to zone in question are operational and no bypass valves are open and 3 no shut off valves have closed thus blocking the water flow through the header Check for air buildup in the cooling header circuit Since electrode tips are replaced daily small amounts of air can leak into and get trapped in the piping The rusty water that is observed in closed loop cooling Systems is the result of this trapped air Please note that trapped air can also damage the flow sensor The vortex flowmeter requires that there is continuous presence of water moving past the bluff body If there is any air in the line water hammering can fracture the internal components of the sensor 14 ROCON LLC Check to determine if air is trapped in the cooling water circuit Remove the hoses TO CELL and FROM Cell Attach a 5 foot plastic see through loop hose between TO CELL and FROM CELL on the unit Power up the unit Use a flashlight to look through the plastic hose and see if a
25. 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 B
26. s 1 3 checked out okay please check for proper wiring between the unit and the weld controller 16 ROCON LLC MAINTENANCE Flowmeter 4 GPM Model Code 1 4 Inspect or Replace Bluff Assembly Tools required 4 Allen wrench clean paper towels within easy reach Spare parts Bluff body PN 7482 2 O Ring PN 345 2 010 Reference 4 40 x lg stainless socket head screw PN 109 approved O Ring lube Procedure to remove bluff 1 1 Place unit on clean surface upside down 1 2 Remove both 4 40 SSHS with the 4 Allen wrench 1 3 Pull the bluff from the body Note the flat side of the bluff flange head The orientation of the flat side is critical when reassembling the unit 4 Remove the O ring 5 Inspect bluff for wear or foreign material wrapped around it 6 Inspect the O Ring to see if it needs to be replaced 1 7 Clean bluff with soap and water or simply replace it with a new one Procedure to reinstall bluff 2 1 Install O ring P N 345 2 010 with light coating of approved O ring lube oil into counter bore in body Make sure that the O ring is not twisted 2 2 Insert the bluff into the body Note that the flat on the bluff flange head will only allow the bluff to be installed in one position Secure the bluff to the body using 2 44 40 x 1419 stainless socket head screws P N 109 Do not over tighten Shut Off Valve Replace Coil Tool Required No Tools Required Spare Par
27. source in Environmental conditions This device has been designed for use in Installation Category 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 ROCON LLC DIMENSIONS DeltaPoint Jr Top View 1 2 o gt 24 E Y L 5 Ww 89mm T e x lt 7 B z aua s g gt 43 S lt au 4 il hy 11 44 291mm cn 4 35 110mm A 5 575 n 8 146mm E TX 2 t 7 3 4NPT Y Y 3 4NPT 6 35 161mm ROCON LLC DeltaPoint Jr End View 6 27 159mm i i 4 10 104mm 8 19 C 208mm Y al 136 40mm 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 piezoel
28. t step If no see Troubleshooting Water Continues to Flow When Cap is Removed Fault alarm signal received at weld controller and robot stops welding If yes proceed to next step If no see Troubleshooting Fault Alarm Signal Not Received at Weld Controller Water is off not leaking at the gun arm Shut off and check valves closed and the LED on the DIN connector to the shut off valve coil is turned off If yes proceed to next step If no see Troubleshooting Water Continues to Flow When Cap is Removed Replace cap and upper gun arm Press the START switch and hold it down until the green light turns on This forces the shut off valve to remain open until water flow is stabilized throughout the system flow above 4 00 LPM Release the START switch The unit should continue to operate normally If yes proceed to next step If no see Troubleshooting Unit Will Not Start Insufficient Water Flow Perform steps 9 thru 13 on the lower weld gun arm If all steps are completed satisfactorily the unit has passed the basic cap pull test Cap pulled fault alarm received at weld controller water was shut off and no leaks were observed It is ready for the next step Flow Fault Verification Water Flow Shut off or Below 4 00 LPM 16 17 18 Close the supply water leg ball valve to weld gun arms or close until below 4 00 LPM Repeat steps 9 thru 13 from Flow Fault Verification Cap Pu
29. the following 1 Check the Reset signal Pin 4 of the receptacle for correct polarity It should be Active Low signal going low issues a Restart 15 ROCON LLC 2 Check the solenoid interrupt line Pin 6 of the receptacle and make sure it is low 3 Check the jumper settings on JP2 JP4 and JP5 Make sure they are all set for Active Low Flowmeter See TROUBLESHOOTING Unit Will Not Start to ensure sufficient water flow is available for flowmeter to operate Shut Off Valve Internal Plunger Pilot Hole May Be Plugged The following procedure will determine if pilot is the problem 1 Close the water supply and return ball valves 2 Turn the manual bypass stem on the shut off valve 90 degrees to the Bypass position See the shut off valve Manual Override illustration under MAINTENANCE 3 Open the water supply and return ball valves 4 Doesthe flowmeter indicate water flow If yes see MAINTENANCE Shut Off Valve Clean Diaphragm Orifice Plunger Pilot Hole If no consult factory Flowmeter Display Unstable 1 Check Unit Will Not Start to ensure that no air is trapped in the water line Also foreign object trapped on the bluff could cause an unstable condition See MAINTENANCE for the required tools and the proper method to remove the bluff Close water supply and return ball valves Remove the power connector from the unit Put the shut off valve manual bypass stem in the bypass pos
30. there are three possible reasons 1 the orifice in the diaphragm is plugged 2 a foreign object is trapped between the valve seat and the diaphragm 3 the internal pilot hole is blocked between the plunger and valve cover See MAINTENANCE for required tools and procedure to disassemble valve Check Valve 1 Close the supply and return ball valves Remove both weld gun arm caps Gradually turn the return ball valve 1 turn If at any time water begins to leak through the weld gun arms around the water tube the problem lies within the check valve If no leak is detected check for proper hose dress 2 Remove the check valve from manifold See MAINTENANCE for required tools and procedure 3 Check valve inspection With a flat nose screwdriver push the piston back and forth to make sure it moves freely If not remove the piston from the housing If it moves freely but you can see a foreign object on the seat run some water through it to dislodge the object If you cannot remove the foreign object then either replace the check valve or see MAINTENANCE Check Valve Remove Piston 4 Reinstall the check valve after cleaning Be careful about the flow direction on the check valve Unit Will Not Restart Manually or Remotely Unit 2 Position Switch Defective If the lights in the switch do not activate when the unit is powered up replace the switch Reset Signal and Jumpers See ELECTRICAL CIRCUIT and JUMPER SETTINGS while testing
31. to proceed with the repair under an assigned Purchase Order must be received within 30 days of repair quotation If the unit s are repaired the 90 00 evaluation charge will be applied to the quoted repair costs If no repairs are authorized within this 30 day period the customer will be billed 90 00 plus shipping charges and the materials will be returned to the customer NON REPAIRABLE MATERIAL If materials are found not repairable a written notice that the material is not repairable will be provided to the customer by UFM If no disposition to scrap or return the material is received from the customer within 30 days unrepairable material will be scrapped and the customer will be billed the 90 00 evaluation charge If a UFM replacement unit is purchased within 30 days of non repairable condition notice the 90 00 evaluation fee will be waived The return of non repairable materials may be ordered by customer Purchase Order providing for shipping and handling charges RETURN FOR RESTOCK All goods returned for restock adjustment must be A New and unused B Returned to the factory within ONE YEAR of date of original shipment C Returned through the distributor where the goods were originally purchased This material will also be subject to an evaluation charge of 90 00 The customer will be advised of the restocking adjustment for all restockable goods Upon acceptance of the restocking adjustment by the customer the 90 00 evaluation fee
32. ts 2705 24V COIL Remove the DIN connector with the Phillips screwdriver and pull from coil grs ood Pull spring clip from side of coil until you can remove coil off Guide DC Coil part number Install new coil push spring clip inward over coil and plug in DIN connector to coil Test to determine if coil is operational If there are problems contact Service Department at Rocon LLC 248 542 9635 Clean Diaphragm Orifice Plunger Pilot Hole Tools required 4 Allen wrench 22 mm Open End Wrench Remove the DIN connector with the Phillips screwdriver Remove coil by pulling spring clip outward until coil can be removed Remove the 4 socket head screws with the 4 Allen wrench Gently pull the valve cover upward Caution Pressure spring is located in valve cover With valve cover and pressure spring removed the diaphragm is sitting on the valve body Lift diaphragm off its seat and examine Remove any foreign material on the diaphragm with soap and water Hold the diaphragm up to light source Observe small orifice below the pilot hole in diaphragm If itis plugged remove dirt with soap and water Replace diaphragm in valve body with 4 guide legs going in first and the outer pilot hole fitting into the valve body molded surface With the valve cover upside down direct flashlight into the pilot hole If you suspect hole is plugged you will have to remove the screw piece and the guide with the inch box wrench
33. ypass 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 7 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 34 NPTF To Cell and From Cell NPTF Flow path and Port Identification located switch box cover Electrical Circuit See page 10 Suggested Hose Dress
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