| Model | MUTEC Microwave Flow Switch FS 550 with Trend measurement |
| Measuring technology | Microwave |
| Measurement type | Contactless trend measurement |
| Installation distance | Several meters |
| Supply voltage | 24 VDC (18–30 VDC) |
| Analog output | 4–20 mA |
| Housing | Stainless steel |
| Protection rating | IP65 |
| Process temperature | -20 °C to +85 °C |
| Standard process pressure | 6 bar |
| Optional pressure version | 30–60 bar |
| Sensor surface | Teflon (ceramic optional) |
Industrial conveying systems often require more than a simple indication of whether material is flowing. Engineers also need to recognize gradual changes in conveying performance before they develop into costly process interruptions. The FlowSwitch FS 550 is designed for exactly this purpose. Using non-contact microwave technology, it continuously monitors the movement of powders, dusts, pellets, granules and other bulk solids while generating a flow-proportional trend signal for reliable process supervision.
Unlike conventional flow switches that only provide an ON/OFF status, the FS 550 delivers valuable trend information that helps operators identify abnormal conveying conditions early and improve process reliability.
What is the FlowSwitch FS 550?
The FlowSwitch FS 550 is a contactless microwave flow switch designed for monitoring the movement of bulk solids. It detects powders, dusts, pellets and granules without touching the product while producing a flow-proportional trend signal that enables early detection of conveying disturbances before complete process failure occurs.
Unlike mechanical flow switches that simply indicate whether material is present, the FS 550 continuously evaluates material movement using microwave reflections. This makes it suitable for applications where engineers need to monitor conveying performance instead of waiting until the process completely stops.
The sensor can be used across a wide range of industries including:
- Food processing
- Chemical production
- Cement manufacturing
- Pharmaceutical production
- Plastics processing
- Minerals
- Recycling
- Wood and pellet processing
- Power generation
- Pigment production
- Ceramics and lime works
The FlowSwitch FS 550 is suitable for many conveying systems where reliable bulk material flow monitoring is required, including pneumatic conveying lines, screw conveyors, conveyor belts, chutes and gravity drop pipes.
Learn more: MUTEC products distributed by Ecozen
How Does the FS 550 Measure Bulk Material Flow?
The FlowSwitch FS 550 uses non-contact microwave technology. Microwaves are transmitted toward the moving bulk material, reflected by the particles and converted into a signal proportional to material movement. This signal is used for trend measurement, allowing continuous monitoring of conveying activity rather than calculating actual mass flow.
Microwave emission
The sensor continuously emits low-power microwave energy toward the conveying process. Since microwave energy passes through non-metallic process environments, the sensor can observe material movement without entering the product stream.
Reflection from moving particles
As powders, pellets or granules pass through the monitored area, the microwave signal is reflected by the moving particles. The characteristics of these reflections change according to the movement of the material.
Flow-proportional signal generation
Instead of producing only a binary ON/OFF output, the reflected microwave signal is processed into a flow-proportional output signal. Changes in material movement result in corresponding changes in signal intensity, allowing operators to observe process trends rather than simple flow presence.
Trend measurement instead of mass flow measurement
The FS 550 is not a mass flow meter. It does not calculate kg/h or t/h.
Instead, it continuously measures the trend of material movement, making it ideal for:
- Detecting gradual flow reduction
- Monitoring conveying stability
- Identifying unstable feeding
- Detecting process deviations
- Triggering alarms before complete blockage occurs
This approach provides operators with earlier process visibility compared with conventional flow switches.
Measuring principle
Microwave Emission
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Moving Bulk Material
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Microwave Reflection
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Signal Processing
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Flow-Proportional Trend Signal
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PLC / Alarm System
What Can the FlowSwitch FS 550 Detect?
Rather than measuring mass flow, the FS 550 continuously monitors conveying activity and identifies abnormal operating conditions before production is interrupted. This enables preventive maintenance and improves process reliability.
Detects normal material flow
The sensor confirms continuous movement of powders, dusts, pellets and granules throughout the conveying process.
Detects no-flow conditions
If conveying stops unexpectedly, the microwave signal immediately changes, allowing fast alarm generation.
Detects clogging
Gradual restrictions inside pipelines or transfer equipment can be identified before complete blockage occurs.
Detects pipeline blockage
The trend signal enables operators to recognize developing pipeline obstructions that may eventually stop production.
Detects conveying interruptions
The sensor identifies interruptions caused by upstream equipment, feeder problems or pneumatic conveying failures.
Detects insufficient material feed
Reduced material movement caused by unstable feeding or low product supply can also be recognized through changes in the trend signal.
Where Can the FS 550 Be Installed?
The microwave sensor can monitor material movement from several meters away without contacting the bulk material, providing installation flexibility in applications where conventional contact sensors are difficult to use.
Typical installation locations include:
- Behind screw conveyors
- Above conveyor belts
- On chutes
- On gravity drop pipes
- Along pneumatic conveying pipelines
- Retrofit installations on existing production lines
Because the sensor never contacts the product, installation does not introduce wear components into the conveying system. This is particularly beneficial for abrasive materials or applications requiring minimal maintenance.
Why Choose Microwave Trend Measurement Instead of Conventional Flow Switches?
One of the biggest advantages of the FlowSwitch FS 550 is its ability to combine contactless microwave sensing with continuous trend measurement.
| Conventional Flow Switch | FlowSwitch FS 550 |
|---|---|
| Contact sensor | Contactless microwave measurement |
| Mechanical wear | Wear-free operation |
| Limited mounting position | Installation from several meters away |
| Binary ON/OFF indication | Flow-proportional trend measurement |
| More maintenance | Maintenance-free design |
| Sensitive to abrasive products | Suitable for abrasive bulk materials |
Additional advantages include:
- Reliable microwave measurement
- No contact with the product
- No mechanical wear
- High measurement sensitivity
- Fast response
- Adjustable sensitivity
- Adjustable filter parameters
- Active self-monitoring
- Stainless steel construction
- Easy retrofit installation
- Maintenance-free operation
- Long service life
These characteristics make the FS 550 suitable for continuous industrial operation where dependable powder flow monitoring and granule flow monitoring are essential.
Technical Specifications of the FlowSwitch FS 550
The following specifications represent the most important parameters for engineering selection:
| Specification | Value |
|---|---|
| Measuring technology | Microwave |
| Measurement type | Contactless trend measurement |
| Installation distance | Several meters |
| Supply voltage | 24 VDC (18–30 VDC) |
| Analog output | 4–20 mA |
| Housing | Stainless steel |
| Protection rating | IP65 |
| Process temperature | -20 °C to +85 °C |
| Standard process pressure | 6 bar |
| Optional pressure version | 30–60 bar |
| Sensor surface | Teflon (ceramic optional) |
The adjustable gain and filter settings allow the sensor to be adapted to different conveying conditions, while parameter configuration can be performed directly on the device.
Frequently Asked Questions (FAQ)
What is a microwave flow switch?
A microwave flow switch detects the movement of bulk solids using microwave reflections rather than mechanical contact. The FS 550 monitors powders, dusts, pellets and granules without touching the material.
How does microwave flow monitoring work?
The sensor emits microwaves toward the moving product. Reflected signals are analyzed and converted into a flow-proportional trend signal for continuous process monitoring.
Does the FlowSwitch FS 550 measure mass flow?
No. The FS 550 performs trend measurement and flow monitoring rather than calculating actual mass flow rate.
What is trend measurement?
Trend measurement continuously tracks changes in conveying activity, allowing engineers to detect gradual process deterioration before complete flow failure occurs.
Can the FS 550 detect pipeline blockage?
Yes. Changes in the trend signal can indicate developing blockages, insufficient flow and conveying disturbances.
Can it monitor powders and pellets?
Yes. The sensor is designed for powders, dusts, pellets, granules and many other bulk solid materials.
Does the sensor touch the product?
No. The FS 550 is completely contactless, eliminating mechanical wear and reducing maintenance requirements.
Where can the FlowSwitch FS 550 be installed?
The sensor can be installed on conveyor belts, chutes, drop pipes, pneumatic conveying lines, behind screw conveyors and many existing conveying systems as a retrofit solution.
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