The BinMaster Flow Detect 2000 is a low-cost, non-intrusive microwave flow/no flow instrument designed to detect the movement of dry solids, powders, and granules in material handling systems. Its single-piece design houses the sensor, power/output connections, and user controls in a rugged NEMA 4X enclosure, eliminating the need for a separate controller.

How It Works: Microwave Doppler Technology

The Flow Detect 2000 uses low-power microwave Doppler technology. It emits a 24.125 GHz microwave signal toward the material being monitored. Part of this signal is reflected back to the sensor. If the material is moving, the reflected signal shifts in frequency (Doppler effect), creating a beat frequency that is detected as flow. If the material is stationary, no beat frequency is produced, and the switch reports a no-flow condition. This technology is so sensitive that the microwaves can pass through non-metallic materials (plastic pipes, glass seals, wooden chutes) to detect movement inside, allowing for truly non-invasive installation.

Key Features

• Non-Contact, Maintenance-Free: The sensor does not touch the material flow, eliminating wear and reducing maintenance requirements.
• Single-Piece Design: Integrates sensor and controller in one NEMA 4X enclosure for easy installation.
• Adjustable Sensitivity and Time Delay: Built-in sensitivity controls and DIP switches for flow/no flow delay selection allow fine-tuning for various materials and flow speeds. A switchable vibration filter eliminates false signals from vibrating equipment.
• Relay Output with NO/NC Contacts: Provides a single analog relay output that communicates flow or no-flow status to a PLC or other control system.
• LED Status Indicators: Clear LED indicators for power, flow/no-flow, and fault conditions simplify setup and troubleshooting.
• Hazardous Location Options: Available with Class II, Division I, Groups E, F & G (North America) and ATEX Zone 21 (Europe) certifications for combustible dust environments.

Technical Specifications

• Power Supply: 24 VDC
• Current Output: 4-20 mA (for fault indication, 22 mA)
• Operating Temperature (Electronics): -30°C to +60°C (-22°F to +140°F)
• Process Temperature (Sensor): Up to +80°C (176°F)
• Storage Temperature: -40°C to +80°C (-40°F to +176°F)
• Enclosure Material: Die-cast aluminum
• Conduit Entry: 3/4" NPT
• Mounting: 1-1/4" NPS threaded bushing; optional saddle-style pipe mount kit available.
• Certifications: Optional North American Class II, Division I, Groups E, F & G; Optional ATEX Zone 21.

Applications

The Flow Detect 2000 is ideal for flow/no-flow detection in a wide range of bulk solids handling applications, including:

• Food & Feed Processing: Ensuring ingredients flow correctly to prevent cross-contamination and comply with FSMA, USDA, and FDA regulations.
• Grain & Milling: Monitoring flow in gravity chutes, distributors, and bucket elevators.
• Cement & Aggregate: Detecting blockages or empty conveyors in harsh industrial environments.
• Plastics & Powders: Verifying material flow in pneumatic pipelines and feeders.
• Chemical Processing: Providing flow/no-flow status for process control and safety interlocks.
• Power Generation: Monitoring coal or biomass fuel flow in handling systems.

This flow switch helps prevent downtime caused by blockages, empty conveyors, loose slide gates, and cross-contamination, improving batch control and reducing waste.