ge or responsible for its content.
51565-20/20-EOM FCSII/SPCI r1 EOM-FCSII 3/03
TT2985
REPLACES EOM-FCSII 9/00
FLOW CONTROL SYSTEM
PRINTED IN THE USA WILDEN PUMP & ENGINEERING, LLC
TABLE OF CONTENTS
PAGE #
CAUTIONS/WARNINGS ................................................................................................
INSIDE FRONT COVER
FLOW CONTROL SYSTEM II (FCSII) ............................................................
1A
WILDEN ACCU-FLO PUMP TECHNOLOGY .............................................
1A
OPTIMAL ACCURACY AND REPEATABILITY..........................................
2A
DIMENSIONAL DRAWING/SPECIFICATIONS ............................................
3A
KEYPAD FUNCTIONS....................................................................................................
4A COUNTER/TOTALIZER.....................................................................................................
4A
FCSII TERMINAL DESCRIPTIONS ......................................................................
5A
INSTALLATION
.................................................................................................................
6A GENERAL
.................................................................................................................
6A AUTO-ON FEATURE.........................................................................................................
6A LEAK DETECT .................................................................................................................
6A CONFIGURATION SECURITY ..........................................................................................
6A AUTO-FILL
.................................................................................................................
6A
SYSTEM CONFIGURATION/PROGRAMMING ...........................................
8A BATCH MODE PROGRAMMING .....................................................................................
8A CONSTANT RUN MODE PROGRAMMING ....................................................................
9A 4 - 20 mA MODE PROGRAMMING ................................................................................
9A
EXAMPLE
.................................................................................................................
10A
TROUBLESHOOTING ......................................................................................................
11A
FCSII HOOKUP SCHEMATIC ...................................................................................
12A STANDARD INSTALLATION .............................................................................................
12A AUTO-FILL MODE INSTALLATION...................................................................................
12A EXTERNAL INPUT SIGNAL EXAMPLES ..........................................................................
13A 4 - 20 mA EXTERNAL INPUT...........................................................................................
13A
CAUTIONS/WARNINGS READ FIRST!
The Flow Control System II is designed to be used with
Wildens Nema 4 or Nema 7 12V DC solenoid-operated pumps
only. Do not power other coil options available from Wilden
Pump & Engineering Company with the FCSII.
Incorrect electrical connection may cause damage
Unit is designed to power a 12V DC solenoid coil only.
Vibration and shock to this equipment should be avoided.
Disconnect all power sources prior to opening control
module.
Dont mount in splash area.
The unit can have high voltages present inside the enclo-
sure. Never power the FCSII with the cover off.
The input to the unit requires a dry contact (SPST normally
open). Never apply a voltage to the inputs.
Use caution when programming FCSII to ensure that auto-
matic, pre-programmed pump operation cannot cause injury
or damage.
The units output is fused, but an external fuse should be
used to safeguard the equipment.
Totalizer will roll-over to zero at a count of 10,000,000
cycles.
When operating auto-fill function, a redundant float switch
above the top one (N.O.) may be connected to Leak Det.
terminals for added protection.
WARNING: Unit may cause electric shock if used or installed improperly.
This equipment generates and uses radio frequency energy and
may cause interference to radio and television reception. If this
equipment does cause interference to radio or television reception,
which can be determined by turning the equipment off and on, the
user is encouraged to try to correct the interference by one or more
of the following measures: Reorient the receiving antenna Relocate the computer with respect to the receiver Plug the computer into a different outlet so that the computer
and receiver are on different branch circuits
If necessary, the user should consult the dealer or an experienced
radio/television technician for additional suggestions. The user may
find the following booklet prepared by the Federal Communications
Commission helpful: How to Identify and Resolve Radio-TV Inter-
ference Problems. This booklet is available from the U.S. Govern-
ment Printing Office, Washington, DC 20402, Stock No.
004-000-00345-4. 1A
WILDEN PUMP & ENGINEERING, LLC
THE FLOW CONTROL SYSTEM II
(FCSII)
WILDEN ACCU-FLO
PUMP TECHNOLOGY
The Flow Control System
TM
II, a state of the art
microprocessor controlled batching computer,
further broadens the scope of applications suit-
able for the Wilden pump to include batching and
metering. The principles of operation are quite
simple. A Wilden Accu-flo pump discharges a
repeatable amount of process fluid on every
stroke of the diaphragm. The FCSII counts the
strokes and controls the pump so that specific,
repeatable quantities can be batched.
The FCSII has a user-friendly interface. The oper-
ating software within the FCSII has been
designed to be configured for use in a variety of
applications. The system allows the user to
customize data based on specific application
calculations. Once the system is programmed,
the data is held in memory even when the unit is
off or disconnected. The back-lit LCD display is
easy to read, even in poor lighting conditions. It
displays text and numbers, which enables the
user to interface with the FCSII in English, instead
of referring to a thick technical manual.
The FCSII allows three separate batch quantities
to be programmed. In addition, the FCSII can
accept input from a host of external sensors or
switches supplied by the user to customize the
application. The FCSII also allows the user to
program a batch to repeat itself at preset time
intervals, for a specific number of cycles. In addi-
tion, an external 420 mA input signal can control
the flow by regulating the pump speed.
This unit incorporates the latest advancements in
computer technology to accomplish its task. It
features optically isolated, solid state solenoid
control for safe, consistent, trouble-free opera-
tion. The water resistant, heavy-duty enclosure
and a polyester membrane switch keypad allows
the unit to withstand most harsh environments.
Wilden Accu-Flo pump technology uses
compressed air as a driving force to displace
process fluid while electric signals control pump
speed. Inherent characteristics allow solenoid-
operated pumps to excel in difficult pumping
applications where other pump types fail.
The Wilden Accu-Flo solenoid valve uses elec-
trical impulses to stroke the pump. This valve is a
two-position, four-way solenoid valve that has a
single operator and spring return. When electric
power is applied, the solenoid shifts to allow an
air chamber to be pressurized with air. When the
electric power is removed, the spring return
mechanism shifts the solenoid valve to a position
where the pressurized air chamber is exhausted
while the opposite air chamber is pressurized. By
alternately applying and removing electrical
power, the pump reciprocates much like a stan-
dard Wilden pump. The faster the electrical
impulses are provided to the pump, the faster the
pump operates. 2A
WILDEN PUMP & ENGINEERING, LLC
OPTIMAL ACCURACY
AND REPEATABILITY
Wilden air-operated, double-diaphragm pumps
discharge a repeatable volume of process fluid
on each discharge stroke. For this reason, meter-
ing and batching are easily accomplished with
the FCSII. The FCSII simply counts the strokes
and controls the pump so that specific, repeat-
able quantities can be batched. The process can
only be batched in multiples of the displacement
figure. In addition, the unit always stops the sole-
noid pump on an even stroke count to insure that
the pump is normally unpowered. The FCSII can
generate batch quantities with up to 99%
repeatability if the application is installed as
noted below and programming is executed
correctly.
Consistent displacement per stroke of process
fluid is the key to insure that repeatable batch
quantities are achieved. Displacement per stroke
is dependent on many factors. If any of these
factors change, then the displacement per stroke
and batch quantity may be altered. This would
lead to a decrease in accuracy.
THERE ARE A FEW MEASURES WHICH OPTI-
MIZE ACCURACY BY ENSURING DISPLACE-
MENT CONSISTENCY.
Inlet and discharge lines to be primed at all
times. This is accomplished by utilizing a foot
valve on suction lift conditions and a check
valve on the discharge line.
Consistent pump fluid inlet and discharge pres-
sures.
Consistent air inlet pressure to