The FlowSwitch FS 600 is an electrostatic flow switch designed to continuously monitor the flow of bulk solids in small pipelines. Using an extended triboelectric measurement principle, it detects naturally charged particles as they pass through the sensing area, allowing reliable flow monitoring without contacting the material. This measurement method makes the sensor suitable for powders, dust, pellets, granules and other dry bulk solids conveyed through pneumatic conveying or freefall systems.

With its compact inline design, the FS 600 helps operators quickly identify conveying interruptions, feeder failures, material blockages and product loss before they develop into costly production downtime. Available for pipe diameters from 10 to 100 mm and supporting relay or 4–20 mA outputs, it integrates easily into new or existing process lines across industries such as food, chemicals, animal feed, pharmaceuticals, building materials and recycling.

What Is the FlowSwitch FS 600 and When Should You Use It?

The FlowSwitch FS 600 is an electrostatic flow switch that continuously monitors the movement of dry bulk solids in small pipelines, providing an early warning when material flow becomes unstable or stops.

Unlike conventional mechanical flow switches, the FS 600 performs contact-free material flow monitoring, making it suitable for continuous industrial operation with minimal wear. It is specifically developed for applications where maintaining a stable flow of powders or granular materials is essential for product quality and process reliability.

What does the FS 600 do?

The sensor continuously detects the movement of electrically charged particles flowing through a pipeline. When the material flow falls below a predefined level or stops completely, the sensor can trigger an alarm through a relay output or provide a continuous 4–20 mA signal for process monitoring and trend analysis.

Its primary purpose is to help operators detect:

• Material flow interruptions
• Feeding failures
• Pipeline blockages
• Product loss during conveying
• Idle conveying lines before they affect production

Early detection allows maintenance teams to respond before these issues result in equipment downtime or reduced process efficiency.

Who should use the FS 600?

The FlowSwitch FS 600 is designed for engineers and plant operators responsible for monitoring dry bulk solids in industrial processes, including:

• Process engineers
• Maintenance engineers
• Automation engineers
• OEM equipment manufacturers
• Plant operators using pneumatic conveying systems

It is particularly valuable when continuous confirmation of material movement is more important than measuring an exact mass flow rate.

Suitable materials

The FS 600 can monitor a wide variety of dry bulk materials, including:

• Powders
• Dust
• Pellets
• Granules

Because the sensor measures the movement of charged particles rather than relying on mechanical contact, it performs reliably across many dry material handling applications.

Typical conveying systems

The sensor is suitable for installation in:

• Pneumatic conveying systems
• Freefall conveying systems
• Small process pipelines
• Feeding lines between process equipment

Multiple sensor versions are available for pipelines with diameters ranging from 10 mm to 100 mm, making the FS 600 suitable for both compact process equipment and larger conveying systems.

Typical industries

The FlowSwitch FS 600 is used across many bulk material handling industries, including:

• Animal feed
• Food processing
• Chemical production
• Pharmaceutical manufacturing
• Building materials
• Ceramics
• Glass production
• Recycling
• Plastics and synthetic materials
• Power generation
• Pigment manufacturing
• Textile production

These industries commonly require reliable confirmation that material continues flowing through pipelines without interruption.

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How Does the FS 600 Detect Material Flow?

The FS 600 detects material flow by sensing the natural electrical charge carried by moving particles, allowing contact-free monitoring without being affected by material deposits inside the pipeline.

Instead of using moving mechanical components, the FlowSwitch FS 600 applies an extended triboelectric (electrostatic) measurement principle. As dry particles travel through a conveying system, they naturally collide with each other and with the pipe wall, generating small electrical charges. These charged particles become the measurement signal used by the sensor.

Extended triboelectric measurement principle

Every moving particle carries a small electrostatic charge generated during transport. As the particles pass through the sensing area, the FS 600 detects these charges without contacting the material stream.

Because the measurement is based on naturally occurring electrostatic effects, no external excitation or moving measuring element is required. This contributes to stable long-term operation and low maintenance requirements.

Charge transfer detection

When electrically charged particles pass close to—or briefly touch—the sensor surface, a charge transfer occurs. The electronics convert these signals into a flow indication.

If the sensor is configured with a relay output, it switches automatically when the measured flow reaches the configured threshold. When equipped with a 4–20 mA analogue output, it can continuously transmit flow trends to a PLC or process control system for ongoing monitoring.

Integral ring sensor measurement

The FS 600 uses an integral ring sensor that measures across almost the entire cross-section of the pipeline rather than at a single point.

This measurement approach offers several advantages:

• Detects the overall movement of material across the pipe
• Reduces sensitivity to localized flow variations
• Provides reliable monitoring in small process pipelines
• Enables contact-free measurement without restricting material flow

Why deposits do not affect measurement

One advantage of electrostatic sensing is that stationary material does not generate a measurement signal.

Dust accumulation or product deposits on the pipe wall remain electrically inactive because they are not moving. As a result, the FS 600 responds only to actual material flow, helping reduce false alarms caused by buildup inside the conveying line.

This combination of contact-free measurement, integral sensing and electrostatic detection makes the FlowSwitch FS 600 a practical solution for continuous monitoring of dry bulk materials in pneumatic conveying and freefall applications.

Key Features, Technical Specifications and Installation

The FlowSwitch FS 600 combines contact-free electrostatic flow detection with a compact, stainless steel design, making it easy to integrate into existing small pipelines while requiring minimal maintenance.

Designed for continuous industrial operation, the FS 600 provides reliable solids flow monitoring without moving parts. Its compact construction, flexible mounting options and multiple output configurations allow it to fit a wide range of pneumatic conveying and freefall applications.

Key Features

The FS 600 is engineered to simplify flow monitoring while maintaining reliable performance in demanding process environments.

Contact-free electrostatic measurement

The sensor detects moving particles without mechanical contact with the material stream. This measurement method minimizes component wear while providing stable monitoring of powders, dust, pellets and granules.

No moving parts

Unlike mechanical flow switches, the FS 600 contains no moving components inside the measuring section. This reduces routine maintenance requirements and supports long-term operational reliability.

Adjustable operating parameters

To match different conveying conditions, the sensor allows adjustment of:

• Sensitivity
• Damping
• Switching point

These settings help optimize detection performance for different material characteristics and process requirements.

Multiple output options

Depending on the application, the FS 600 can be supplied with:

• Relay output for flow alarm applications
• Transistor output for control integration
• Analogue 4–20 mA output for continuous trend monitoring

This flexibility allows integration with PLCs, SCADA systems and other industrial control platforms.

Technical Specifications

The following specifications summarize the core operating capabilities of the FlowSwitch FS 600.

Specification	Value
Measuring principle	Electrostatic / Extended triboelectric
Pipe diameter	10–100 mm
Housing material	Stainless steel (1.4305)
Process coupling	Stainless steel (1.4571)
Ambient temperature	-20°C to +70°C
Process temperature	-20°C to +90°C
Process pressure	Up to 40 bar
Protection class	IP67
Power supply	17–31 VDC
Current consumption	60–90 mA
Output options	Relay, Transistor or 4–20 mA
Hazardous area option	ATEX Zone 20 or Zone 2 (optional)

These specifications make the FS 600 suitable for installation in industrial environments where compact dimensions, environmental protection and process reliability are important.

Installation

The FlowSwitch FS 600 is designed for quick installation in existing process lines and, in many applications, can be installed without cutting or welding the pipeline.

A major advantage of the FS 600 is its compact mechanical design. The sensing section measures only 20–30 mm in width and is intended for installation between standard pipeline flanges. This minimizes installation time while reducing modifications to existing equipment.

Compatible pipeline connections

The sensor is available for installation between:

• DIN flanges
• ANSI flanges

Multiple versions support pipe diameters ranging from 10 mm to 100 mm, allowing the same product family to be used across different process lines.

Retrofit-friendly installation

For many applications, installation requires only inserting the sensor between existing flanges. This approach offers several practical advantages:

• No cutting of the pipeline in many installations
• No welding required in many cases
• Short installation downtime
• Suitable for both new systems and retrofit projects

These characteristics make the FS 600 particularly attractive for facilities upgrading existing pneumatic conveying systems without extensive mechanical modifications.

Built for industrial environments

The mechanical construction is designed to withstand demanding operating conditions.

Key durability features include:

• Stainless steel housing and process coupling
• IP67 enclosure protection
• Process pressure up to 40 bar
• Optional ATEX versions for Zone 20 or Zone 2 hazardous areas

Combined with its contact-free measuring principle and absence of moving parts, these design features contribute to long service life and consistent operation in continuous industrial processes.

Why Choose the FS 600 for Process Monitoring?

The FlowSwitch FS 600 helps improve process reliability by detecting abnormal material flow early, allowing operators to respond before production interruptions become costly.

Rather than measuring only when a complete blockage occurs, the FS 600 continuously monitors the presence of moving material inside the pipeline. This enables faster detection of conveying problems and provides actionable signals for process control systems.

Detect conveying problems before production stops

Unstable material flow often develops gradually before a complete process failure occurs. Continuous monitoring allows operators to identify these conditions earlier.

Typical issues the FS 600 can detect include:

• Material blockage
• No-flow conditions
• Feeding interruptions
• Material loss during conveying
• Idle conveying lines

Early detection helps reduce unplanned maintenance and improves production continuity.

Support both alarm and process monitoring

The FS 600 offers different output configurations depending on operational requirements.

Relay output

Best suited for applications requiring immediate action when flow drops below a defined threshold, such as:

• Activating alarms
• Stopping upstream equipment
• Triggering safety interlocks

4–20 mA analogue output

For continuous monitoring, the analogue version provides a proportional signal that can be used to:

• Monitor long-term flow trends
• Identify gradual process changes
• Support preventive maintenance
• Improve process optimization

Both options enable straightforward integration into existing automation systems.

Designed for reliable long-term operation

Several design characteristics contribute to stable performance over time:

• Contact-free electrostatic measurement
• No moving mechanical components
• Stainless steel construction
• Adjustable sensitivity and switching parameters
• Low maintenance requirements

These features make the FS 600 suitable for continuous operation in industrial bulk solids handling processes where dependable flow indication is critical.

Applications Across Industries

The FlowSwitch FS 600 is designed for any industry that needs reliable confirmation of dry bulk material flow in pneumatic conveying or freefall systems.

Because the FS 600 monitors the movement of naturally charged particles rather than measuring a specific product type, it can be applied across a wide range of industries handling powders, dust, pellets and granules. This versatility allows the same sensing technology to be used in different production environments while maintaining a consistent monitoring approach.

Cement and Building Materials

Problem

Fine mineral powders are continuously transported through pneumatic conveying lines. Material build-up, blocked pipelines or interrupted feeding can reduce production efficiency and affect downstream processes.

Solution

The FS 600 continuously monitors material movement inside small pipelines and detects abnormal flow conditions before they develop into complete process interruptions.

Benefits

• Early blockage detection
• Continuous flow confirmation
• Reduced production downtime
• Improved process reliability

Chemical and Detergent Production

Problem

Chemical powders often require stable and uninterrupted feeding to maintain consistent production conditions. Flow interruptions can lead to process instability and unnecessary product loss.

Solution

Using its contact-free electrostatic measurement principle, the FS 600 continuously verifies material movement without interfering with the conveying process.

Benefits

• Stable powder conveying
• Reliable feeder monitoring
• Fast detection of conveying failures
• Easy integration into automated production systems

Animal Feed Processing

Problem

Animal feed manufacturing commonly conveys pellets, granules and powdered ingredients through multiple pneumatic transport lines. Undetected feeder failures may interrupt production or affect batching consistency.

Solution

The FS 600 monitors the movement of pellets, granules and feed powders, allowing operators to quickly identify no-flow conditions and feeding interruptions.

Benefits

• Improved conveying reliability
• Faster maintenance response
• Reduced unexpected production stops
• Better utilization of conveying equipment

Food and Pharmaceutical Manufacturing

Problem

Food ingredients and pharmaceutical powders require reliable conveying while minimizing mechanical contact with the product and maintaining stable process conditions.

Solution

The FS 600 performs contact-free flow monitoring using electrostatic sensing, allowing continuous confirmation of product movement without introducing moving measuring components into the material stream.

• Continuous product flow verification
• Low-maintenance operation
• Reliable process monitoring
• Suitable for automated production lines

Plastics, Recycling and Power Generation

Problem

Processes handling plastic granules, recycled materials and industrial bulk solids often experience inconsistent flow caused by bridging, blockages or interruptions in conveying systems.

Solution

The FS 600 continuously monitors bulk material movement and provides immediate indication when conveying conditions change.

Benefits

• Early warning of conveying problems
• Improved equipment availability
• Better process visibility
• Reduced unplanned downtime

Typical Industries

According to the manufacturer, the FlowSwitch FS 600 is suitable for applications in:

• Animal feed industry
• Building materials
• Ceramics production
• Chemical industry
• Detergent manufacturing
• Food industry
• Glass production
• Metal production
• Pharmaceutical industry
• Pigment production
• Power plants
• Rubber processing
• Recycling
• Synthetic materials
• Textile industry

These industries share a common requirement: maintaining reliable movement of dry bulk materials throughout the production process while minimizing unexpected interruptions.

Frequently Asked Questions About the FlowSwitch FS 600

Can the FlowSwitch FS 600 detect powder flow?

Yes. The FS 600 is designed to monitor the movement of powders, dust, pellets and granules in pneumatic conveying and freefall systems using an electrostatic measurement principle.

Does the sensor need to touch the material?

No. The FS 600 performs contact-free measurement by detecting the electrical charge carried by moving particles. This helps minimize wear because there are no moving measuring components in contact with the product.

Can the FS 600 monitor pellet and granular materials?

Yes. In addition to powders and dust, the sensor is suitable for monitoring pellets and granules commonly used in industries such as animal feed, plastics and chemical processing.

Can it be installed without cutting the pipeline?

In many applications, yes. The FS 600 is designed for installation between DIN or ANSI flanges and can often be integrated into existing pipelines without cutting or welding. Installation requirements should always be verified against the actual pipeline configuration.

What output options are available?

The FlowSwitch FS 600 is available with:

• Relay output
• Transistor output
• Analogue 4–20 mA output

Relay outputs are commonly used for alarm functions, while the analogue output supports continuous process monitoring and trend analysis.

Is an ATEX version available?

Yes. Optional versions are available for ATEX Zone 20 and Zone 2 hazardous areas, allowing installation in applications where explosion protection is required.

What pipe sizes does the FS 600 support?

The FlowSwitch FS 600 is available for pipeline diameters ranging from 10 mm to 100 mm, with versions compatible with both DIN and ANSI flange standards.

Does the FS 600 require regular maintenance?

The sensor is designed for low-maintenance operation because it uses a contact-free electrostatic measurement principle and contains no moving parts. These design characteristics help support long service life under continuous industrial operating conditions.