Thermatel® Mass Flow Transmitter Model TA1 ® Instruction Manual and Parts List The advanced microprocessor provides accurate temperature compensation as the process temperature changes. Each instrument is factory calibrated in a NIST flow standard to provide highest level of accuracy. The electronics permit the user to configure the instrument for the pipe or duct size, zero and span, units of measurement, alarms, and other user specific requirements. The instrument provides two 4–20 mA output signals; one for flow measurement, and one for temperature. Each 4–20 signal can be configured from the instrument. PRINCIPLE OF OPERATION The flow element of the TA1 Mass Flow Transmitter utilizes a heater and two resistant temperature detectors (RTDs). The heater and the active RTD are contained in one sensor; the second sensor contains the reference RTD and a mass balancing element. The reference RTD measures the temperature of the process where the flow element is installed. A constant power is provided to the heated sensor. The active RTD measures the temperature of the heated sensor. The electronics measures the temperature difference between the active and reference RTD. TABLE OF CONTENTS PAGE Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Principle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Quick Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Electrostatic Discharge Handling Procedure . . . . . . . . . . .4 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Digital Communication RS-485/Modbus Protocol . . . . . . .21 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 Agency Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Model Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Replacement parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 DESCRIPTION The Thermatel Mass Flow Transmitter Model TA1 provides high performance measurement of the mass flow of air and other gases. Using a heated sensor, the mass flow is determined by accurately measuring the temperature difference between the heated sensor and the reference sensor. Heat transfer is due to the mass of the gas flowing past the sensor providing a measurement of the mass flow rate. There is an inherent non-linear relationship between the temperature difference and the mass flow rate. The microprocessor-based electronics convert the temperature difference signal to provide a linear measurement of the mass flow rate. The electronics also provide advanced temperature compensation which automatically adjusts the flow measurements for changes in process temperature. The 4–20 mA output signal can be adjusted to provide maximum resolution of flow measurement over the desired range of the instrument. A separate 4–20 mA signal provides an output signal of the process temperature. Both 4–20 mA signals can be wired for either active or passive operation. Refer to wiring section, pages 4 and 5. Optional relays provide low or high flow alarm indication and can be used for diagnostics. UNPACKING Unpack the instrument carefully, making sure all components have been removed from the packing material. Inspect all components for damage, and report any concealed damage to the carrier within 24 hours. Check the contents of the carton, making sure it agrees with the packing slip and the purchase order. Verify that the model number imprinted on the nameplate matches the number on the packing slip and the purchase order. Report any discrepancies to the factory. Check and record the serial number for future reference when ordering parts. QUICK START PROBE INSTALLATION WIRING Insert the probe into the pipe or duct, ensuring that the appropriate upstream and downstream dimensions are obtained. It is preferred to have as much straight run as possible. Refer to Magnetrol bulletin 54-131 (STI bulletin 95-165) for additional information on probe location. It is generally suggested that the sensor be mounted on the centerline of the pipe. Insure that the flow arrow on the probe is positioned in the direction of the flow. Refer to Figure 1. Open the cover of the enclosure and locate the input power connections, the 4–20 mA output connections, and the relay connections as show below. Make connections between the probe and the electronics to terminal block TB11. Refer to Figure 2 Probe wiring housing ;; ;; The instrument is configured at the factory with the application information provided with the order. If configuration information was not provided at the time of order, then the information used during the calibration is utilized. To quickly configure the instrument or change the configuration, push the logo button ( ) located at the upper right on the key pad (refer to Figure 3), then enter the requested information. Simply enter the pipe or duct area in square inches and the 4 and 20 mA points for the flow and temperature readings. The configuration software is easily followed. Simply press ENT to enter or change a value and or (up or down arrow) to select. If appears on the second line, enter the number using the keypad, and press ENT. Optional compression fitting Flow CONFIGURATION The complete configuration may be viewed using the software menu which begins on page 8. D/2 D 7 4 8 9 5 6 1 . 2 3 0 DEL ENT MODEL TA1 1.00 Figure 1 Figure 3 Passive 4–20 mA output Wiring Color Codes Probe Wiring Connections 7 No connection 8 9 10 11 Brown w/white stripe Green w/white stripe Blue w/white stripe Orange w/white stripe White w/orange stripe 13 14 15 Shield White w/brown stripe White w/green stripe White w/blue stripe Active 4–20 mA output TB1 Relay 2 NO C NC NO C NC NO C NC Relay 1 Relay 2 Relay 3 Relay 4 TB11 NO TB11 Probe connection Figure 2 2 Relay 1 NO C NC C NC NO C NC NO C NC NO C NC Relay 3 Relay 4 N(-) L1(+) TB1 Power connection INSTALLATION Arrows are etched on the sides of the probe to designate flow direction. The instrument is calibrated with the flow in this direction. Ensure that the flow arrows are oriented in the direction of flow. Refer to Figure 4. CAUTION: The probe and electronics are calibrated and shipped as a matched set. The model number is indicated on both the electronics nameplate and the probe housing nameplate; verify that they are the same. It is generally recommended that the sensor be located in the center of the pipe. This location provides less sensitivity to changes in flow profile. The probe’s length should be specified to position the sensor in the desired location. Sensors mounted through compression fittings have the ability to field adjust the sensor to the desired location by using the dimensions as shown in Figure 4. NOTE: The instrument is rated per IEC 1010 for use in Installation Category II, Pollution Degree 2. ELECTRONICS Various methods of mounting the probe are available, including compression fittings, threaded, and flanged connections. Refer to probe model numbers. The electronics are rated for use in Class I, Division 2 areas. The enclosure is also rated NEMA 4X. The remote electronics should be installed in an easy to access location within 250 feet of the sensor location. The electronics should not be installed in areas where ambient temperature exceeds +160° F (+70° C). If ambient temperatures are less than -4° F (-20° C), then the optional heater is recommended. Provide watertight seals for all wiring entrances in the enclosure to maintain the NEMA 4X rating. The insertion probe can be installed through a compression fitting. The use of a bored-through fitting for 3⁄4" outside diameter tube is recommended. Pressure ratings of the compression fitting are: Stainless steel ferrules 1500 psig at 70° F 1375 psig at 400° F Mount the enclosure to a wall or flat surface using the appropriate screws or bolts. The mounting tabs on the back of the enclosure may be rotated to the sides or top and bottom to facilitate mounting. Refer to Figure 15. Teflon ferrules 100 psig NOTE: The sensor must be installed in a location where moisture cannot drip or come in contact with the heated element. Any contact with condensed moisture in the gas flow will cause a false high flow indication. NOTE: A switch or circuit breaker shall be installed in close proximity to the equipment and within easy reach of the operator. It shall be marked as the disconnecting device for the equipment. FLOW BLOCKAGE The TA1 Mass Flow Transmitter measures the velocity flowing past the sensor, and then determines the flow rate by multiplying the area by the velocity. The probe blocks a portion of the pipe reducing the effective cross sectional area of the pipe and creating a higher velocity. The TA1 compensates for this error by correcting the measured flow by the probe blockage. PROBE The probe enclosure is rated explosion proof for Class I, Division 1 service. The enclosure is also rated NEMA 4X. Use appropriate NEC section when installing the instrument. Proper installation of the probe in the pipe or duct is essential for accurate flow measurement. Normal procedures for installing any type of flow element should be followed. Refer to Magnetrol bulletin 54-131 (STI bulletin 95-165) for additional information on probe location. NOTE: If equipment is used in a manner not specified by manufacturer, protection provided by equipment may be impaired. Probe wiring housing Optional compression fitting 7 4 8 9 5 6 1 . 2 3 0 DEL A 3/4" or 1" NPT recommended ENT Flow MODEL TA1 D/2 D Height Connection size A 1" NPT 3 ⁄4" NPT 3.1 (79) 2.6 (66) 1.00 NOTE: Typical height when compression fitting is used with half coupling or threadolet. 250 feet maximum (76 m) Figure 4 3 ELECTROSTATIC DISCHARGE (ESD) HANDLING PROCEDURE Magnetrol’s electronic instruments are manufactured to the highest quality standards. These instruments utilize electronic components which may be damaged by static electricity present in most work environments. The following steps are recommended to reduce the risk of component failure due to electrostatic discharge: 2. Use a grounding wrist strap when installing and removing circuit boards. A grounded workstation is also recommended. 1. Ship and store circuit boards in anti-static bags. If an anti-static bag is not available, wrap board in aluminum foil. Do not place boards on foam packing materials. 4. Ensure that all electrical connections are completely made and none are partial or floating. Ground all equipment to a good earth ground. 3. Handle printed circuit boards only by the edges. Do not touch components or connector pins. WIRING WIRING Wiring Color Codes There are three predrilled holes in the enclosure for connecting 1⁄2" conduit. Generally, these are used as: one for input power; one for cable to the probe; and one for communications (4–20 mA and relays). Wiring Color Codes Probe Wiring Connections to TB11 7 8 9 10 PROBE WIRING The probe housing contains a terminal block for ease of wiring between the probe and the electronics. Connections from the probe to the terminal strip are prewired at the factory. An 8-wire shielded interconnecting cable (Belden 8104) from the probe housing to the instrument is required. Refer to Figure 6 for wiring connections for TB11. 11 13 14 15 The layout of the main circuit board giving all user interface points is shown in Figure 6. No connection Brown/white stripe Green/white stripe Blue/white stripe Orange/white stripe White/orange stripe Shield White/brown stripe White/green stripe White/blue stripe Probe Wiring Connections Probe Housing 1 2 3 4 Green/white stripe White/green stripe Blue/white stripe White/blue stripe 5 6 Brown/white stripe White/brown stripe Orange/white stripe White/orange stripe Shield 7 8 GROUND CONNECTION To prevent electromagnetic noise, the instrument must be grounded in accordance with Article 250 of the National Electric Code. Ground wires shall be terminated at the conduit connection using grounding bushings or other similar device as discussed in NEC Article 250-72. Metal conduit must be utilized to ensure proper ground connection. Orange Black or Brown Black Blue White 5 4 3 2 1 8 7 6 5 4 3 2 1 Grounding of the electronics is accomplished with a ground wire between the ground terminal in TB1 and the conduit ground. Probe housing must be grounded via protective ground screw in the base of the housing. TB6 4–20 mA connections active or passive (refer to Figure 7 or Figure 8) Figure 5 Probe Enclosure Wiring Connections JP9 JP1 Relay 1 Relay 2 TB1 A B TB16 RS-485 connection 7 8 9 10 11 Ground L1 (+) N (–) TB11 13 14 15 Probe connections (refer to Figure 5) NO C NC NO C NC Relay 3 Relay 4 Figure 6 4 NC C Relay 2 NO NC C Relay 1 NO WIRING cont. RELAY OUTPUT WIRING CLOSING THE COVER The instrument can be supplied with up to four isolated SPDT relays, rated at 10 amp at 120 VAC or 5 amp at 240 VAC. The relays can be configured for use as high or low level alarm contacts. In addition, Relay 1 can be configured, via software, to de-energize only in the event a fault condition is detected. After all wiring connections are complete, close and secure the cover using the six screws. CAUTION: Do not overtighten the securing screws. Do not use an electrical drive. Overtightening can result in cracking of the housing resulting in leakage into the housing. All relay terminals are labeled C for common, NC for normally closed, NO for normally open. Refer to Figure 6. RS–485/MODBUS OUTPUT POWER CONNECTION Modbus communication via RS-485 is available at terminal block TB16. The instrument is factory wired to accept 24 VDC, 120 VAC, or 240 VAC. Check the nameplate to ensure that the instrument matches the desired input power. The terminals are marked A and B, which correspond to similar connections in the control room. All power wiring connections are made to terminal block TB1. Refer to Figure 6. NOTE: Polarity among units in the loop must be observed. The shield is connected to the NOTE: Use a minimum of 14-AWG wire for power and ground field wires. For supply connection, use wire with a minimum rating of +75° C as required by process conditions. terminal. Jumper JP1 provides the terminal resistor if the instrument is the last instrument in a daisy chain configuration. The position of the jumper at JP1 should be set as follows (refer to Figure 9): 4-20 mA DC OUTPUT C C Two 4–20 mA output connections are available at terminal block TB6. These output signals are electrically isolated from the instrument, but are not isolated with respect to each other. Either an active or passive connection may be selected. To obtain an active 4–20 mA output signal, the positive connection for each loop is made to ACT+. The negative connection is made as follows (refer to Figure 7): Flow signal 1ACT- Temperature signal 2ACT- JP1 JP1 Continuing Position Default Terminating Position Figure 9 RS–232 CONNECTION The RS–232 Connection on TB7 is currently not utilized. 1ACT ACT 2ACT Jumper JP9 provides the selection of either RS–232 or RS–485 connection. The jumper must be left in the position indicated below. Flow signal Temperature signal JP9 Figure 7 A passive 4–20 mA signal requires an external DC power supply (maximum voltage of 32 VDC). The negative connection of the power supply is connected to -PAS (refer to Figure 8): Figure 10 The positive connection is: Flow signal +PAS1 MODBUS WIRING Temperature signal +PAS2 Refer to Modbus section on page 21 for wiring information. Flow signal PAS1 PAS PAS2 Power supply Temperature signal Figure 8 NOTE: The active circuit shares a common positive while the passive circuit shares a common negative. If both a flow and temperature signal are desired using a PLC, it is recommended that the flow signal be treated as an active circuit while the temperature signal be handled as a passive circuit. 5 SOFTWARE CONFIGURATION The electronics of the instrument are easy to set up and configure for the user’s specific requirements. If previously specified, the configuration menu is loaded into the instrument at the factory. If not, or if the user wants to modify the configuration settings, follow these instructions for configuring the instrument. The primary structure of the software is divided into six main groups: Measured Values System Config I/O Config Advanced Config Diagnostics Run Mode View selected values First time configuration (essential programming information) Configure all input/output functions Additional configuration which affects the units operation Test functions Normal operating mode All input of information is done via the keypad located on the front of the instrument. PASSWORD CAUTION: The instrument is shipped from the factory with the password 100. If the password is misplaced or forgotten, please consult the factory for assistance. A password protection system restricts access to portions of the menu which affect the unit’s operation and configuration. The password will be requested whenever programming changes are requested. The password may be changed to any four digit number. This procedure is described under ADV CONFIG menu on page 19. OPERATOR KEYPAD All unit configuration instructions in this manual will appear on the instrument display. The following keys are used: UP arrow: Scroll to the previous menu item or enter “e” for exponential DOWN arrow: Scroll to the next menu item or enter negative number. ENT ENTER: Enter next menu level or confirm information of the current menu item. DEL DELETE: To exit the current item/menu level or delete an entry. 0–9 Numeric input of data. . Decimal point. QuickCal mode. When the symbol is displayed on the top line, push ENT to program this selection, or press to proceed to the next selection. When the symbol is displayed on the bottom line, push to change the selection; then push ENT to accept. When the symbol is displayed on the bottom line, enter the value, then push ENT to accept. NOTE: Pressing DEL will back you out of the configuration menu and return you to run mode. NOTE: If a key is not pressed for 5 minutes, the display returns to the run mode. 6 SOFTWARE CONFIGURATION cont. DEFINITIONS TAG LINE The following symbols and definitions are used in the software configuration: Initially the tag line on the display reads “Magnetrol Int’l”. This can be changed from the advanced configuration section of the software. Calibration factor: Changes in flow profile will affect the measurements of the TA1. Advanced users have the ability to adjust the measurements for changes in flow profile using a multi-function polynomial relationship in the form of: Corrected flow = a+bx+cx2+dx3+ex4 The default is b = 1; and a, c, d, and e = 0. To use the correction factor, develop a relationship between the flow measured by the TA1 and the flow measured by a second flowmeter. Curve fit the fifth order polynomial (above) using the output of the TA1 for X (units of SFPM) and the output of the second flowmeter for corrected flow. Then enter the appropriate values in the Advanced Configuration menu, page 19. The cursor appears in the left position. To change the position at that location, use the or arrow keys. Pressing the key will start scrolling the characters; pressing the a second time causes a faster scroll. To stop scrolling, press any key. To move to the next position, press the ENT key; to return to the previous position, press the DEL key. Pressing the ENT key moves the cursor to the right. When it reaches the rightmost position, pressing the ENT key one additional time exits and saves changes (password protected). Pressing the DEL key moves the cursor to the left. When it reaches the leftmost position, pressing the DEL key exits the menu and restores the previous tag line. Mass flow: Measured in various units, typically LB/Hr or KG/Hr. An input of the cross sectional area of the pipe or duct is required. STP conditions: The mass flow rate is based on a given set of Standard Temperature and Pressure (STP) conditions. Magnetrol uses default of 70° F and one (1) atmosphere for STP conditions. The STP conditions may be modified to match the user’s standards. If the STP conditions are modified, the TA1 will recalculate the flow rates at the specified STP conditions. The advanced configuration menu permits the user to enter any desired temperature and cycle between selection of one (1) bar or one (1) atmosphere of pressure. Totalized flow: Provides a measurement of the total flow in units specified. Velocity: Measured in SF/M (standard feet per minute) or NM/M (normal meters per minute). This is the mass velocity directly measured by the instrument referenced to the appropriate standard conditions. Volume flow: Measured in various units, typically SCFM (standard cubic feet per minute) or NCMH (normal cubic meters per hour), referenced to standard conditions. An input of the cross sectional area of the pipe or duct is required to obtain this value. 7 SOFTWARE CONFIGURATION cont. GENERAL PROGRAMMING MENU Following is the general menu structure used in the Mass Flow Transmitter. Use the UP or DOWN arrow key ( through any portion of the menu, press ENT key to make a selection, and press DEL to backup. QUICK START Enter password Area (enter area in square inches) 4–20 mA (flow) 4 mA point 20 mA point Previous menu 4–20 mA (temperature) 4 mA point 20 mA point Previous menu Previous menu RUN MODE MEASURED VALUES Velocity On main display Off main display Flow On main display Off main display Mass On main display Off main display Temperature On main display Off main display Loop flow On main display Off main display Loop temperature On main display Off main display Relays 1234 On main display Off main display Total On main display Off main display Previous menu 8 ) to scroll SOFTWARE CONFIGURATION cont. GENERAL PROGRAMMING MENU cont. RUN MODE SYSTEM CONFIG Flow units SCFM SCFS NCM/hour NCM/minute NL/hour Mass units Pounds/hour Pounds/minute Kilograms/hour Kilograms/minute Velocity units Standard feet/minute Normal meters/minute Temperature units Fahrenheit Rankine Celsius Kelvin Diameter units Inches Feet Meters Millimeters Area units Square inches Square feet Meters squared Millimeters squared Flow area Diameter Enter value Area Enter value Previous Menu Previous menu I/O CONFIGURATION Relay settings Select relay Fault relay #1 only Enable/disable Enable/disable Controlled by Velocity Flow Mass Temperature Totalizer Alarm set point Reset point Relay action De-energize < set point De-energize > set point Set point delay (0–255 seconds) Reset delay (0–255 seconds) Fault mode De-energize on fault Hold on fault Previous menu 9 SOFTWARE CONFIGURATION cont. GENERAL PROGRAMMING MENU cont. 4–20 mA (flow) setting Enable/disable Controlled by Velocity Flow Mass 4 mA point 20 mA point Fault mode 22 mA 3.5 mA Hold Previous menu 4–20 mA (temperature) setting Enable/disable 4 mA point 20 mA point Fault mode 22 mA 3.5 mA Hold Previous menu Totalizer Enable/disable Controlled by Flow Mass Totalizer units Standard cubic feet (SCF) Normal cubic meters (NCM) Normal liters (NL) Pounds Kilograms Tons Reset Press ENT to reset Previous menu Comm port setup Previous menu 10 Address (1–247) Baud rate 1200 2400 4800 9600 Parity Odd Even None SOFTWARE CONFIGURATION cont. GENERAL PROGRAMMING MENU cont. RUN MODE ADVANCED CONFIG Damping (1–60) STP conditions Temperature Enter value Pressure 1 atmosphere 1 bar Previous menu Change password Enter old password Enter new password Re-enter new password Previous menu Probe Type TXR Probe TXT Probe Flow Body Calibration factor A=0 B=1 C=0 D=0 E=0 Previous menu Adjust loop flow 4 mA offset 20 mA offset Adjust loop temperature 4 mA offset 20 mA offset Calibration coefficients1* A1 = XXX B1 = XXX C1 = XXX D1 = XXX E1 = XXX Temperature 1 = XXX Previous menu Calibration coefficients2* A2 = XXX B2 = XXX C2 = XXX D2 = XXX E2 = XXX Temperature 1 = XXX Previous menu Gas density* Temp Comp Coef* Temp coeff A Temp coeff B Previous menu Enter tag line Change tag Magnetrol Int’l Previous menu *These values are “Read Only;” contact Magnetrol to change data. 11 SOFTWARE CONFIGURATION cont. GENERAL PROGRAMMING MENU cont. DIAGNOSTICS MENU Test relays Select relay 1–4 Test 4–20 loop 1 Enter loop value 4–20 Test 4–20 loop 2 Enter loop value 4–20 Energize De-energize Sensor signal View version Previous menu MAIN MENU The main menu is used to access the various subroutines. From the Run mode, press chart at right defines the various selections available from the Main Menu or to enter the Main Menu. The Main Menu Display Option Action if ENT is pressed Measured Values to select Press ENT to select or or to continue. Enter Measured Values menu System Config to select Press ENT to select or or to continue. Enter System Configuration menu I/O Config to select Press ENT to select or or to continue. Enter I/O Configuration menu ADV Config to select Press ENT to select or or to continue. Enter Advanced Configuration menu Diagnostics to select Press ENT to select or or to continue. Enter Diagnostics menu Run mode to select Press ENT to select or or to continue. Enter Run mode 12 SOFTWARE CONFIGURATION cont. QUICK START Quick Start Display Option Action if ENT is Pressed Option Action if ENT is Pressed Enter password Enter password Proceed with Quick Start Area xxx in ^2 Press ENT to change area or to continue to next selection. Area xxxx in^2 Enter area of pipe or duct in square inches and press ENT. 4–20 mA (flow) to select Press ENT to select or or to continue to next selection. 4 mA point XXX SCFM Press ENT to select or or to continue to next selection. Enter flow value in SCFM representing 4 mA; press ENT. 20 mA point XXXXX SCFM Press ENT to select or or to continue to next selection. Enter flow value in SCFM representing 20 mA; press ENT. Previous menu to select Press ENT to return to main menu or or to return to 4–20 mA (flow) setting. 4 mA point XX F Press ENT to select or or to continue to next selection. Enter temperature in degrees F representing 4 mA; press ENT. 20 mA point XXX F Press ENT to select or or to continue to next selection. Enter temperature in degrees F representing 20 mA; press ENT. Previous menu to select Press ENT to return to main menu or or to return to 4–20 mA (temperature) setting. 4–20 mA (temp) to select Previous menu Press ENT to select or or to continue to next election. Press ENT to return to run mode or or to return to area setup. 13 SOFTWARE CONFIGURATION cont. MEASURED VALUES The measured values menu is used to display current measured values and to determine which units will be shown on the display during run mode. Access the Measured Values menu by pressing from the run menu; press ENT. The display then cycles through the or various values and permits these values to be displayed during run mode. To display an item during the RUN mode, press ENT when that selection is displayed; then press Display” is indicated on the second line. Then push ENT. Pressing moves up and down the left column; press or until “ON Main to select the item to show on main display. Measured Values Display Option Action if ENT is Pressed Velocity xxxxx units Press ENT to select or or to continue to next selection. Press or to cycle between “ON Main Display” and “OFF Main Display”; press ENT to select. Flow xxxxx units Press ENT to select or or to continue to next selection. Press or to cycle between “ON Main Display” and “OFF Main Display”; press ENT to select. Mass xxxxx units Press ENT to select or or to continue to next selection. Press or to cycle between “ON Main Display” and “OFF Main Display”; press ENT to select. Temp xxxxx units Press ENT to select or or to continue to next selection. Press or to cycle between “ON Main Display” and “OFF Main Display”; press ENT o select. Loop Flow xxxxx mA Press ENT to select or or to continue to next selection. Press or to cycle between “ON Main Display” and “OFF Main Display”; press ENT to select. Loop Temp xxxxx mA Press ENT to select or or to continue to next selection. Press or to cycle between “ON Main Display” and “OFF Main Display”; press ENT to select. Relays 1234 = ENRG Press ENT to select or or to continue to next selection. Press or to cycle between “ON Main Display” and “OFF Main Display”; press ENT to select. Displays Relay status; * signifies that the indicated relay is energized. Total xxxxx units Press ENT to select or or to continue to next selection. Press or to cycle between “ON Main Display” and “OFF Main Display”; press ENT to select. Totalizer must be enabled in I/O Configuration menu for this section to be displayed. Previous menu to select Press ENT to return to main menu or or to continue to selection. 14 Comments Required input of Area in System Config to calculate. Return to previous menu or cycle through measured values. SOFTWARE CONFIGURATION cont. SYSTEM CONFIGURATION MENU The System Configuration menu is used to select the display units and enter specific information for the application. Enter this section by pushing ENT when System Config is displayed. To calculate the flow or mass, it is necessary to accurately enter the area of the pipe or duct. If the pipe or duct is circular, simply enter the value of the diameter; the cross sectional area of the pipe is automatically calculated. If the duct is rectangular, skip over the entry of diameter, and directly enter the cross sectional area in the area section. The instrument will then back calculate an equivalent diameter. System Configuration Display Option Action if ENT is Pressed Comments Flow Units SCFM Press ENT to obtain choice of flow units or or to select next item. Press or to cycle between options; press ENT to select. Choice of SCFM, SCFS, NCM/Hr, NCM/M, NL/Hr Mass Units Pounds/hour Press ENT to obtain choice of mass units or or to select next item. Press or to cycle between options; press ENT to select. Choice of pounds/hour, pounds/minute, kilograms/hour, kilograms/minute. Velocity Units SF/minute Press ENT to obtain choice of velocity units or or to select next item. Press or to cycle between options; press ENT to select. Choice of SF/minute (standard, feet per minute) or NM/minute (normal meters per minute). Temp Units Fahrenheit Press ENT to obtain choice of temperature units or or to select next item. Press or to cycle between options; press ENT to select. Choice: Fahrenheit, Rankine, Celsius, Kelvin. Diameter Units Value Press ENT to obtain choice of measurement units or or to select next item. Press or to cycle between options; press ENT to select. Choice inches, feet, meters, millimeters. Area Units Value Press ENT to obtain choice of area units or or to select next item. Press or to cycle between options; press ENT to select. Choice of square inches, square feet, meters squared, millimeters squared. Flow Area Press ENT to calculate flow area or or to select next item. Press or to cycle between options; press ENT to select. Enter the cross sectional area of the pipe or duct or the pipe diameter. Diameter value Enter the diameter (if circular), press ENT to continue or press or . Area value The cross sectional area of the pipe is calculated based upon the diameter entered. If a square duct, enter the area. Previous menu Press ENT to return to menu or or to return to flow area. to select to select Previous Menu to select Press ENT to return to main menu or or to return to Flow units. Return to previous menu or cycle through System Configuration menu again. I/O CONFIGURATION MENU The I/O Configuration menu is used to setup the operations of the relays (if provided), 4–20 mA outputs, totalizer, and the communication parameters. The I/O Configuration menu is accessible by pushing from the RUN menu until the display reads: I/O Configuration Display Comments Relay Settings to select Configure the relays (if provided). 4–20 mA (flow) to select Configure the 4–20 mA flow signal. 4–20 mA (temp) to select Configure the 4–20 mA temperature signal. Press ENT. Totalizer to select Configure the totalizer. The I/O Configuration menu consists of five main sections described at right. Press ENT to enter the subroutine to setup the appropriate settings or to proceed to the next item. Comm Port Setup to select Configure the communication port settings. Previous Menu to select Return to the previous (Main) menu. I/O Config to select 15 SOFTWARE CONFIGURATION cont. I/O CONFIGURATION MENU cont. Relay Settings This subroutine is accessible from the I/O Configuration menu by pressing ENT when the following is displayed: Relay settings to select Relay 1 can be configured as a fault relay. If the instrument’s diagnostics detect any failure, or the instrument does not pass self-test, the fault relay will de-energize. Optionally, Relay 1 can be setup for regular relay operation. Relays can be controlled by velocity, flow, mass, temperature, or totalizer. The relays can be configured so that there is some hysteresis between alarm set point and alarm reset points.This is accomplished by entering different values for the relay alarm set and alarm reset points. Fail-safe condition of the relay is set via the software, such that the relay is either de-energized (DNRG) when actual conditions are less than set point, or de-energized when the actual conditions are greater than the set point. Refer to Figures 11. ALARM ACTION Increasing flow or temperature DNRG < Set point Set and reset at same value De-energized Energized Typical low level alarm Single point alarm—the alarm is de-energized below the set point and energizes above the set point. DNRG > Set point Set and reset at same value De-energized Energized Typical high level alarm Single point alarm—the alarm is energized below the set point and de-energizes above the set point. DNRG < Set point Reset Set point less than reset point. Set De-energized Energized Low level alarm with hysteresis. Relay energizes above set point and de-energizes below reset point. May be either energized or de-energized between set and reset points. DNRG > Set point Set Set point greater than reset point. Reset De-energized Energized High level alarm with hysteresis. Relay energizes below the set point and de-energizes above the reset point. Between set and reset points, the relay may be either energized or de-energized. Figure 11 16 SOFTWARE CONFIGURATION cont. I/O CONFIGURATION MENU cont. Relay Settings cont. Relay Settings Display Option Action if ENT is Pressed Comments Select Relay 1 Select Relay to configure; then press ENT. Selects the relay (#1–4) to configure. Fault Relay (#1) Disable Press ENT to change or or to continue. Press or to cycle through enable or disable; press ENT to select. Relay 1 can be configured as a fault relay or as standard discrete output. Enable/Disable Enable Press ENT to change or or to continue. Press or to cycle through enable or disable; press ENT to select. Enable or disable the operation of the relay. Controlled by Flow Press ENT to change or or to continue. Press to select the input controls operation of the relay; press ENT to select. Choices are velocity, flow, mass, temperature, totalizer. Alarm Set Point xx.xx units Press ENT to change or or to continue. Enter relay set point using the keypad; press ENT. Appropriate units are selected based upon choice under Controlled By. Reset Point xx.xx units Press ENT to change or or to continue. Enter relay reset point using the keypad; press ENT. Appropriate units are selected based upon choice under “Controlled By.” Relay Action DNRG<setpoint Press ENT to change or or to continue. Press or to cycle between “DNRG < set point” or “DNRG > set point” operation; press ENT. Determines if the relay is deenergized at conditions less than or greater than the set point. Set Point Delay 0 sec Press ENT to change or or to continue. Enter time delay using keypad; press ENT. Enter desired time delay (0–255 seconds). Reset Delay 0 sec Press ENT to change or or to continue. Enter time delay using keypad; press ENT. Enter desired time delay (0–255 seconds). Fault mode DNRG on Fault Press ENT to change or or to continue. Press or to cycle between “DNRG on Fault” and “HOLD on Fault.” Selects if relay will de-energize or hold the output state in event of system fault. Previous Menu to select Press ENT to return to main menu or or to review relay selection. I/O CONFIGURATION MENU cont. 4–20 mA There are two 4–20 mA output loops which are independently configured. One loop is for the flow signal, the second is for the temperature output. The configuration menu for each loop is the same with the exception of the units. To configure the 4–20 mA loop in the I/O Configuration menu, scroll down until the display shows: 4–20 mA to select 4–20 mA Display Option Action if ENT is Pressed Press ENT to change or or to continue. Press Controlled by flow Press ENT to change or or to continue. Press or to cycle between velocity, flow, or mass. Not required on 4–20 (temp) loop. 4 mA Point xxxxx units Press ENT to change or or to continue. Set 4 mA value. Enter desired 4 mA output. Units are selected based upon “Controlled By.” 20 mA Point xxxxxx units Press ENT to change or or to continue. Set 20 mA value. Enter desired 20 mA output. Fault Mode 22 mA Press ENT to reset or or to continue. Press or to cycle between 22 mA, 3.5 mA, or hold. Select status of 4–20 mA output in event of a unit fault. Previous Menu Press ENT to return to previous menu or or to review 4–20 mA settings. to select or to cycle through options. Comments Enable/Disable Enable Enable or disable the 4–20 mA output signal. 17 SOFTWARE CONFIGURATION cont. I/O CONFIGURATION MENU cont. Totalizer The totalizer in the TA1 maintains a continuous, running total of the flow in selectable units. The totalizer utilizes eeprom memory, eliminating the need for a battery backup. The totalizer can be reset to zero via the software configuration menu or by the Modbus communication. The totalizer displays the totalized flow or mass with up to eight significant digits. As the total increases, the decimal point will move to always display the largest eight significant digits. After the total exceeds eight significant digits, the totalizer will display the total in scientific notation. The totalizer must be enabled from the Totalizer section of the I/O Configuration menu. In the event of a power failure, the totalizer will typically loose less than one minute of data. The totalizer function configures the operation and resets the totalizer. To configure the totalizer in the I/O Configuration menu, scroll down until the display shows: Totalizer to select Totalizer Display Option Action if ENT is Pressed Status Disable Press ENT to change or or to continue. Press Controlled by flow Press ENT to change or or to continue. Press or or mass. Totalizer units units Press ENT to change or or to continue. Press or to cycle between SCF, NCM, NL, pounds, Kg, tons. Reset Press ENT to reset or DEL to return Reset totalizer to 0000. to select Previous Menu to select or Comments to cycle through options. Enable or disable the totalizer. to cycle between flow Totalizer will total either flow or mass. Totalizer units based upon “Controlled By” selection. Press ENT to return to previous menu or or to review totalizer settings. NOTE: The totalizer must be enabled for the value to be displayed under “Measured Values.” I/O CONFIGURATION MENU cont. Communication Port Setup The Communication Port Setup function configures the Modbus digital communication of the instrument. To configure the Communication Port, in the I/O Configuration menu, scroll down until the display shows: Comm port setup to select Communication Port Setup Display Option Action if ENT is Pressed Comments Address (1–247) 1 Press ENT to change or or to continue. Enter address via keypad. Set the specific address for this instrument. Ensure that no other instrument uses this same address. Baud Rate 9600 Press ENT to change or or to continue. Press or 4800, 9600. Sets communication speed from instrument. Parity Even Previous Menu Press ENT to change or or to continue. Press or to cycle between Odd, Even, or None. to select 18 Press ENT to return to previous menu or or to review settings. to cycle between 1200, 2400, Sets the parity bid. Must match Modbus settings of user’s system. SOFTWARE CONFIGURATION cont. ADVANCED CONFIGURATION MENU The Advanced configuration menu sets advanced parameters not normally used in the operation of the instrument. Access the Advanced Configuration Menu from the Run mode by pushing either the or arrow until the display shows: Adv config to select Advanced Configuration Menu Display Option Action if ENT is Pressed Comments Damping (1–60) 1 Press ENT to change or or to continue. Enter damping factor via keypad. Increase the damping factor to decrease the effect of turbulence. STP Conditions Press ENT to change or or to continue. Permit review or entry of STP conditions. Refer to Definitions section (page 7) for information on STP conditions. Press ENT to change or or to continue. 1. Enter old password; press ENT. 2. Enter new password; press ENT. 3. Re-enter new password. Change the instrument’s password. to select Change Password to select Cal Factor to select Probe Type Press ENT to change or or to continue. Press or to cycle through TXR, TXT probe, or TFT flow body, press ENT to select Probes have different blockage factors. See nameplate for probe type. 4 mA Offset Use or arrow keys to adjust actual output current until 4 mA is exact. 20 mA Offset Use or arrow keys to adjust actual output current until 20 mA is exact. 4 mA Offset Use or arrow keys to adjust actual output current until 4 mA is exact. 20 mA Offset Use or arrow keys to adjust actual output current until 20 mA is exact. Press ENT to review or or to continue. Review values of factory calibration data. Read only values of factory calibration coefficients. Press ENT to change or or to continue. Review values of gas density at STP conditions. Read only values of gas density at 70° F and 14.7 psia Press ENT to change or or to continue. Review factory calibration information. Read only values of factory data; contact Magnetrol to change. Tag Line Press ENT to change or or to continue. Change tag line. Refer to page 7 to change tag line. Previous Menu Press ENT to return to previous menu or or to review selection. TXR Adj Loop Flow to select Adj Loop Temp to select Cal Coeff 1 & 2 to select Gas Density 7.50e–02 lb/Ft3 Temp Comp Coef to select to select Press ENT to change or or to continue. Refer to Definitions section (page 7) for information on calibration factors. Press ENT to change or or to continue. Press ENT to change or or to continue. 19 SOFTWARE CONFIGURATION cont. DIAGNOSTICS MENU The Diagnostics menu provides a method of testing the instrument’s functionality. It also has useful information for troubleshooting. Access to Diagnostics menu is obtained from the Run mode by pushing either the or arrows until the display shows: Diagnostics to select Communication Port Setup Display Test Relays to select Test 4–20 Loop1 to select Test 4–20 Loop2 to select Option Action if ENT is Pressed Comments Press ENT to test or or to continue. Select relay to test, ENT, then. use or to energize/de-energize relay. Allows user to energize any relay individually. Press ENT when complete. Press ENT to test or or to continue. Enter desired current output. Allows user to output desired 4–20 mA on loop 1 (flow). Press ENT when complete. Press ENT to test or or to continue. Enter desired current output. Allows user to output desired 4–20 mA on loop 2 (temperature). Press ENT when complete. Sensor Signal xxxxxxxxxx Press or to continue. Displays value from sensor of the flow rate. View Version # xxxxxxxxxx Press or to continue. Display software version number. Previous Menu Press ENT to return to previous menu or or to review selection. to select DIGITAL COMMUNICATION RS-485/MODBUS PROTOCOL INTRODUCTION This section of the manual provides basic information on Modbus communication with the TA1 Thermal Mass Flow Transmitter. It is assumed for this manual that the user has a working knowledge of Modbus communication and RS-485 wiring practice. performed. Other characteristics are user selectable. These are transmission medium and transmission mode, RTU or ASCII. The user characteristics are set at each device and the configuration cannot be changed when the system is running. IMPLEMENTATION TRANSMISSION MEDIUM Magnetrol provides this guide to explain the operation of the Modbus protocol per Modicon® document PI-MBUS-300. The Modbus protocol provides frames for the transmission of messages between master and slaves. The transmission medium selected for Magnetrol devices is RS-485. The RS-485 standard is the most versatile of the EIA interface standards. RS-485 permits multi-drop network connections on two wires and provides reliable serial data communication for: Magnetrol implementation of the Modbus protocol provides for the passing of measured and calculated variables and diagnostics in data registers. Data is set in these registers as integer values, status summary words (packed bits), or individual flags (single bits). The information in the message is the address of the intended device, what the device must do, the data needed to perform the action, and a means of checking errors. The slave reads the message, and, if there is no error, it performs the task and sends a response back to the master. The information in the response message is the slave address, the action performed, the result of the action and a means of checking errors. Certain characteristics of the Modbus protocol are fixed, such as frame format, frame sequences (synchronization), handling of communications errors and exception conditions, and the functions 20 • Distances up to 5000 feet • Data rates up to 9600 bps • 31 slave devices • 1 master device One master and up to 31 slave devices may be multidropped on a single RS-485 communication bus. TRANSMISSION MODE Modbus provides two types of formats, Modbus RTU and Modbus ASCII. Magnetrol devices support the Remote Terminal Unit (RTU) mode of transmission. RTU provides improved error detection capabilities and higher throughput than the ASCII mode. DIGITAL COMMUNICATION RS-485/MODBUS PROTOCOL (cont.) CONFIGURATION WIRING The Modbus port on the Magnetrol device must be configured to establish communications. The keypad allows the user to set the Magnetrol device RS-485/Modbus port to match the RS-485/Modbus master. The address, baud rate, and parity must be configured through the keypad. Standard Belden 8451 shielded, twisted pair, 22-gauge stranded conductors may be used for interconnection of units. Magnetrol device addresses provide unique identification for each device. This address may range from 1 to 247 and must be unique. Each Magnetrol device only responds when a poll has been sent to its unique address by the master. The RS-485 port of each device must be configured for a transmission speed (baud rate) to match the master’s transmission speed. Selectable values are 1200, 2400, 4800, or 9600 bits per second. The RS-485 port of each device must be configured for a parity check bit that matches the master. Selectable options are odd, even, and none. FUNCTIONS Each request frame contains a function code that defines the action expected of the target device. The meaning of the request data fields is dependent on the function code specified. Function Code Function Information Type MODBUS Nomenclature 03 Read 16-bit register Read holding registers 04 Read 16-bit register Read input registers 06 16 Write Write 16-bit register 16-bit register Preset single register Force multiple registers Magnetrol part number 009-7146-XXX (XXX = cable length in feet) Example: 009-7146-050 = 50 feet of cable (10 feet minimum (3 m), 5000 feet maximum (1524 m) The preferred method of wiring is that all units be wired in parallel, refer to Figure 12. It is permissible to have branches,not exceeding five feet from the main wiring trunk as shown in diagram. One master with a maximum of 31 slave devices is allowable. Connect terminal A from the master device to terminal A on all slave devices. Connect terminal B from the master device to terminal B on all slave devices. Connect shielding from ground of master to ground on all slave devices. NOTE: Polarity among units in loop must be observed. The master device and the last (farthest) slave device in the loop must have a termination resistor. This resistor is provided in the Model TA1 by jumper placement of JP1, refer to Figure 9 (page 5). All slave devices in the loop, except the last (farthest) slave device, should have jumper JP1 in the “C” position for continuing. The last (farthest) slave device should have the jumper in the “T” position. MODEL TA1 REGISTER MAPPING Command Register # Operation Fault Flags 30001 Relay status Totalizer clear Totalizer Velocity Mass Flow Temperature 30003 30036 30037 30038 30039 30040 30041 33042 30043 30044 30045 Write Only to Read Only to Read Only to Read Only to Read Only to Read Only Slave device A B A B Comments Read Only Bits 0–7: Not used Bit 8: A/D converter fault Bit 9: Flow error Bit 10: Temperature error Bits 11–15: Not used Read Only Bits 0-7: Not used Bit 8: Relay 1 status Bit 9: Relay 2 status Bit 10: Relay 3 status Bit 11: Relay 4 status Bits 12–15: Not used 30002 Slave device 0 = de-energized 1 = energized 1: Clear totalizer data 0: No operation Totalizer value in units of standard cubic feet. Velocity value in units of SFPM. Mass value in units of pounds per minute. Flow value in units of SCFM. Temperature value in units of degrees celsius. Master Slave device A B A B 5' max. (1.52 m) Terminating device A B Jumper TP1 in "T" position Figure 12 21 TROUBLESHOOTING SOFTWARE The following troubleshooting displays may occur on the instrument: Message Password invalid Err New Pwd Fail Error:max = Error:min = Action Re-enter data and correct password. When changing the password, the second entry of the new password does not match the first entry. Entry of numeric data is outside the acceptable range. Maximum allowed value is displayed. Entry of numeric data is outside the acceptable range. Minimum allowed value is displayed. The instrument has self-diagnostics which will detect several specific faults. The following error messages can appear on the display: Display Flow Error Temp. Error A/D Conv. Error Action Check the interconnecting wiring between the probe and the electronics. Check the resistance values (refer to Figures 13 and 14). Power down; power up. Check the interconnecting wiring between the probe and the electronics. Check the resistance values (refer to Figures 13 and 14). Power down; power up. Power down, then power up. Call Magnetrol Technical Support (1-800-624-8765). The following displays will only occur on reinitialization or in the event of eeprom memory failure. This is for information only; press DEL or ENT to proceed. This instrument must be reconfigured following the procedure in Software Configuration section on page 8. Display Probe Param Fail Loop Preset Fail Loop Par 1 Fail Loop Par 2 Fail Relay Param Fail Sys Param Fail Totalizer Loss! Failure or Occurrence eeprom eeprom eeprom eeprom eeprom eeprom eeprom memory memory memory memory memory memory memory failure failure failure failure failure failure failure for for for for for for for probe data storage. 4 mA or 20 mA point data storage. loop 1 data storage. loop 2 data storage. relay data storage. system parameter data storage. totalizer data storage. RESISTANCE CHART Figures 13 and 14 provide expected resistance value at the probe connection (TB11) in the remote electronics and at the probe enclosure. Probe enclosure TB11 Terminals Expected Resistance Terminals Expected Resistance 1–3 1,000 to 1,770 ohms 8–9 1,000 to 1,770 ohms 2–3 1,000 to 1,770 ohms 8–10 1,000 to 1,770 ohms 4–5 20 ohm 8–11 20 ohm 13–14 1,000 to 1,770 ohms 13–15 1,000 to 1,770 ohms 8–13, 9–14, 10–15 Dependent on cable length, will be less than 2.0 ohms. Figure 13 NOTE: When contacting Magnetrol for assistance, please provide measurement of the velocity and temperature from measured value and the signal strength from diagnostics menu. Figure 14 MAINTENANCE CLEANING Depending upon the application, the sensor may require periodic cleaning. A buildup on the sensor will reduce the heat transfer, resulting in flow readings lower than expected. The frequency of cleaning is dependent upon the application. 22 Cleaning Procedure: 1. Remove probe from pipe/duct. 2. Wipe sensor tips with a clean cloth; if necessary, solvent may be used. 3. When sensors are clean, reinstall probe into pipe/duct. AGENCY APPROVALS FACTORY MUTUAL (FM) MODEL Electronics: TA1-X2XX-110 Probe: TXR-XXX0-XXX Flow Body: TFT-XXXX-000 CANADIAN STANDARDS ASSOCIATION (CSA) APPROVALS Hazardous environments: Class I, Div. 2 Groups A, B, C, & D Class II, Div. 2 Groups F & G Class III Indoors and outdoors: NEMA Type 4X and IP 65 Hazardous environments: Class I, Div. 1 Groups B, C, & D Class II, Div. 1 Groups E, F, G Class III (Maximum surface temperature of probe is +73° C above process temperature.) Indoors and outdoors: NEMA Type 4X and IP 65 MODEL Electronics: TA1-X2XX-110 Probe: TXR-XXX0-XXX Flow Body: TFT-XXXX-000 APPROVALS Hazardous environments: Class I, Div. 2 Groups A, B, C, & D Class II, Div. 2 Groups E, F, G Class III Indoors and outdoors: Type 4X Hazardous environments: Class I, Div. 1 Groups C & D Class II, Div. 1 Groups E, F, & G Class III (Maximum surface temperature of probe is +73° C above process temperature.) Indoors and outdoors: Type 4X These units have been tested to EN 61326 and are in compliance with the EMC Directive 89/336/EEC. SPECIFICATIONS ELECTRICAL SPECIFICATIONS Description Supply voltage Power consumption Analog output signal Active Analog output signal Passive Digital output Relays (optional) Fail-safe Ambient temperature Electronics Ambient temperature Sensor enclosure Display Keypad Humidity (electronics) Cable length Fuse size Specification 120 VAC, 50-60 Hz, +10%/-15% 240 VAC, 50-60 Hz, +10%/-15% 24 VDC, ±20% 12 watts maximum/15 VA maximum (without heater option) 62 watts maximum/65 VA maximum (with heater option) 4–20 mA flow (isolated) 4–20 mA temperature (isolated) maximum 1,000 ohms loop resistance 4–20 mA flow (isolated) 4–20 mA temperature (isolated) loop resistance dependent on power supply RS–485/Modbus, RTU mode 0, 2, 4 10 amp SPDT resistive w/gold flash contacts Software selectable Without heater and thermostat -4° to +160° F (-20° to +70° C) With heater and thermostat -40° to +160° F (-40° to +70° C) -40° to +160° F (-40° to +70° C) Two-line alphanumeric LCD (16-characters per line) 16-button integral to front panel 99% non-condensing 250 feet (75 meters) maximum Replaceable slow acting: 3/8 amp, 250 VAC for AC version 0.5 amp, 24 VDC version PROBE SPECIFICATIONS Description Materials Process connections Pressure rating* Temperature rating Specification 316L stainless steel all welded Refer to model number optional hot tap 1500 psig @ +70° F (103 bar @ +21° C) 1375 psig @ +400° F (95 bar @ +200° C) -50° to +400° F (-45° to +200° C) *Pressure rating dependent upon process connection. FLOW BODY SPECIFICATIONS Description Materials Process connections Pressure rating Temperature rating* Specification 316/316L stainless steel all welded Carbon steel with stainless steel sensor NPT or 150 lb flange Refer to model number 1500 psig @ +70° F (103 bar @ +21° C) 1100 psig @ +200° F (79 bar @ +200° C) -50° to +400° F (-45° to +200° C) *For operating temperatures between +250° F and +400° F (+120° C and +200° C), either use remote electronics or a longer length insertion probe to provide an additional four inches (100 mm) between the electronics and the compression fitting. PERFORMANCE SPECIFICATIONS Description Flow range Temperature range Accuracy Repeatability Linearity Temperature coefficient Turn down Calibration Specification 25–40,000 SFPM (0.15–200 NM/sec) air reference to standard conditions. Higher ranges and other gases available, contact factory. -50° to +400° F (-45° to +200° C) ±1% of reading +0.5% of full scale ±0.5% of reading Included in accuracy 0.05%/° C 100:1 NIST traceable 23 SPECIFICATIONS cont. DIMENSIONAL SPECIFICATIONS INCHES (MM) 4.63 (118) Dia. 2.75 (70) 9.50 (241) 6.75 (171) 3/4" NPT or M20 Conduit connection 3.23 (82) 9.50 (241) 7 8 9 4 5 6 1 2 3 0 DEL 13.00 (330) Insertion length ENT MODEL TA1 3/4" 6.00 (152) Figure 15 Electronics (side view) Figure 15 Electronics (front view) Figure 16 Insertion probe for use with compression fitting 4.63 (118) Dia. 3/4" NPT threads 2.75 (70) 3/4" NPT or M20 Conduit connection 3.23 (82) Insertion length 3/4" Insertion length Figure 18 Insertion probe w/NPT threads 3/4" NPT connection 3/4" Figure 17 Probe with flange process connection Mounting: The following optional parts are available for installing the TXR probe: Compression fitting Connection size 1" NPT ⁄4" NPT 3 Teflon* ferrules Stainless steel ferrules 011-4719-009 011-4719-008 011-4719-007 011-4719-006 100 psi maximum pressure rating 1500 psi maximum pressure rating 24 6.00 dia. (152.4) Figure 19 Duct mounting bracket with 3/4" NPT Part number 089-7247-001 SPECIFICATIONS cont. DIMENSIONAL SPECIFICATIONS INCHES (MM) A A B B L1 L L1 L Length (L) Code Overall Height (B) Height to With Flow Without Flow With Flow Without Flow Centerline Size (A) Conditioning Conditioning Conditioning Conditioning NPT Flange inches (mm) inches (mm) inches (mm) inches (mm) inches (mm) inches (mm) inches (mm) 0 1 1 3 L1 ⁄2" 8 (203) — 5 (127) — 8.0 (203) 8.7 (221) 9.75 (248) ⁄4" 11.25 (381) — 7.5 (190) — 8.0 (203) 8.7 (221) 9.9 (251) 2 1" 15 (203) — 10 (254) — 8.0 (203) 8.7 (221) 10.1 (257) 3 11⁄2" 19.5 (495) 7.5 (191) 12 (305) 3.75 (95) 8.35 (212) 9.3 (236) 10.85 (276) 4 2" 26 (660) 7.5 (191) 16 (406) 3.75 (95) 9.25 (235) 10.4 (264) 12.25 (311) 5 3" 39 (991) 10 (254) 24 (610) 5 (127) 9.25 (235) N/A 13.0 (330) 6 4" 52 (1321) 12 (305) 36 (914) 6 (152) 9.25 (235) N/A 13.75 (349) FLOW BODY SIZING The following table is a general guide on flow sizing. Contact Magnetrol or your local representative for specific application information. Code Size Air, N2, O2 Natural Gas, Methane Digester Gas Propane Hydrogen CO2, Argon ⁄2" 65 SCFM 110 NM3/h 45 SCFM 76 NM3/h 25 SCFM 42 NM3/h 30 SCFM 51 NM3/h 15 SCFM 27 NM3/h 60 SCFM 105 NM3/h 0 1 1 3 ⁄4" 120 SCFM 204 NM3/h 85 SCFM 140 NM3/h 45 SCFM 76 NM3/h 55 SCFM 93 NM3/h 30 SCFM 52 NM3/h 110 SCFM 190 NM3/h 2 1" 200 SCFM 340 NM3/h 140 SCFM 238 NM3/h 75 SCFM 127 NM3/h 95 SCFM 161 NM3/h 50 SCFM 85 NM3/h 190 SCFM 320 NM3/h 3 11⁄2" 490 SCFM 833 NM3/h 340 SCFM 580 NM3/h 180 SCFM 310 NM3/h 230 SCFM 395 NM3/h 120 SCFM 208 NM3/h 465 SCFM 790 NM3/h 4 2" 715 SCFM 1220 NM3/h 505 SCFM 855 NM3/h 280 SCFM 480 NM3/h 350 SCFM 600 NM3/h 195 SCFM 332 NM3/h 680 SCFM 1155 NM3/h 5 3" 1765 SCFM 3000 NM3/h 1240 SCFM 2110 NM3/h 695 SCFM 1180 NM3/h 860 SCFM 1470 NM3/h 475 SCFM 812 NM3/h 1680 SCFM 2855 NM3/h 6 4" 3230 SCFM 5490 NM3/h 2260 SCFM 3845 NM3/h 1265 SCFM 2145 NM3/h 1575 SCFM 2675 NM3/h 865 SCFM 1478 NM3/h 3060 SCFM 5210 NM3/h 25 MODEL NUMBER REMOTE TRANSMITTER WITH INSERTION PROBE INPUT VOLTAGE 0 120 VAC 1 240 VAC 2 24 VDC 3 120 VAC with heater 4 240 VAC with heater NUMBER OF RELAYS 0 2 4 None Two Four CALIBRATION Actual Gas Calibration 0 1 2 3 4 5 6 7 9 Special Air Nitrogen or Oxygen Hydrogen Natural Gas Methane Digester Gas Propane Air Equivalency Calibration Air Equivalency PROBE HOUSING 1 D FM/CSA approved ATEX approved CONDUIT CONNECTION 0 1 T 26 A 1 2 1 ⁄4" NPT M20 3 MODEL NUMBER INSERTION PROBE UNIT OF MEASUREMENT TER TMR Probe length in tenths of an inch Probe length in centimeters MATERIALS OF CONSTRUCTION A B 316/316L stainless steel Hastelloy C-276 PROCESS CONNECTION Compression fitting utilized 3 ⁄4" NPT threaded 1" NPT 1" BSP 1" 150# ANSI raised face flange 1" 300# ANSI raised face flange 11⁄2" 150# ANSI raised face flange 11⁄2" 300# ANSI raised face flange 00 11 21 22 23 24 33 34 43 44 BA BB CA CB DA DB 2" 150# ANSI raised face flange 2" 300# ANSI raised face flange DN25 PN 16, DIN 2527, Form B DN25 PN 25/4, DIN 2527, Form B DN40 PN 16, DIN 2527, Form B DN40 PN 25/4, DIN 2527, Form B DN50 PN 16, DIN 2527, Form B DN50 PN 25/40, DIN 2527, Form B Not available with Hastelloy C construction Customer supplied or purchased separately PROBE LENGTH (see page 24 for part numbers) 2.6 to 99.9 inches (example: 8.5" = 085) Minimum lengths: 2.6" (026) with threaded process connection 2.8" (028) with flanged process connection 4.5" (045) with compression fitting process connection 7 to 253 centimeters (example: 18 cm = 018) Minimum lengths: 7 cm (007) with threaded or flanged process connection 11 cm (011) with compression fitting process connection T R 0 MODEL NUMBER CONNECTING CABLE CABLE LENGTH IN FEET 10 feet minimum, 250 feet maximum length Example: 50 feet = 050 0 3 7 3 3 1 3 CABLE LENGTH IN METERS 3 meters minimum, 75 meters maximum length Example: 8 meters = 008 0 3 7 3 3 1 4 27 MODEL NUMBER REMOTE TRANSMITTER WITH FLOW BODY INPUT VOLTAGE 0 120 VAC 1 240 VAC 2 24 VDC 3 120 VAC with heater 4 240 VAC with heater NUMBER OF RELAYS 0 2 4 None Two Four CALIBRATION Actual Gas Calibration A B C D E F G H K Special Air Nitrogen or Oxygen Hydrogen Natural Gas Methane Digester Gas Propane Air Equivalency Calibration Air Equivalency PROBE HOUSING 1 D FM/CSA approved ATEX approved CONDUIT CONNECTION 0 1 T 28 A 1 2 1 ⁄4" NPT M20 3 MODEL NUMBER FLOW BODY MATERIALS OF CONSTRUCTION A All stainless steel 1 Carbon steel body with stainless steel sensor SIZE 0 1 1 3 ⁄2 inch 2 1 inch 3 11⁄2 inch 4 2 inch 5 3 inch 6 4 inch ⁄4 inch PROCESS CONNECTION TYPE 1 NPT Threads (only when Digit 5 = 0, 1, 2, 3, or 4) 3 150# Flange FLOW CONDITIONER (stainless steel) 0 Not provided 1 Provided (only when Digit 5 = 3, 4, 5, or 6) T F T 0 0 0 MODEL NUMBER CONNECTING CABLE CABLE LENGTH IN FEET 10 feet minimum, 250 feet maximum length Example: 50 feet = 050 Longer cable lengths possible. Consult Magnetrol with application details. 0 3 7 3 3 1 3 CABLE LENGTH IN METERS 3 meters minimum, 75 meters maximum length Example: 8 meters = 008 Longer cable lengths possible. Consult Magnetrol with application details. 0 3 7 3 3 1 4 29 REPLACEMENT PARTS No. 1 2 3 4 5 6 7 8 9 Description Part Number NEMA 4X enclosure Enclosure gasket Keypad overlay 120 VAC, 0 relays 120 VAC, 2 relays 120 VAC, 4 relays 240 VAC, 0 relays Relay PC board 240 VAC, 2 relays 240 VAC, 4 relays 24 VDC, 0 relays 24 VDC, 2 relays 24 VDC, 4 relays 120 VAC Heater assembly 240 VAC Remote housing base 3⁄4" NPT conduit connection Remote housing cover Remote housing O-ring Probe replacement kit Consult Factory 012-1606-001 Consult Factory Z30-2218-001 Z30-2218-002 Z30-2218-003 Z30-2218-004 Z30-2218-005 Z30-2218-006 Z30-2218-007 Z30-2218-008 Z30-2218-009 036-2202-003 036-2202-004 WARNING: EXPLOSION HAZARD Substitution of components may impair suitability for Class I, Division 2. WARNING: EXPLOSION HAZARD Do not disconnect equipment unless power has been switched off or the area is known to be non-hazardous. 004-9104-001 004-9105-001 012-2101-345 * * Probe and board are matched set. Consult factory for information. 1 7 8 6 4 3 5 2 Figure 20 30 GLOSSARY Atmospheric pressure: Average pressure at sea level. One atmosphere pressure is equal to 14.696 psia or 29.921 inches of mercury or 406.8 inches of water. Bar: Unit of pressure measurement. One bar equals 14.504 pounds per square inch or 100 kilopascals. Celsius (C): Unit of temperature measurement. At one atmosphere pressure: at zero degrees Celsius, water freezes; at 100 degrees Celsius, water boils. One degree Celsius is equal to 1.8 degrees Fahrenheit. Tc = (Tf -32)/1.8 Fahrenheit (F): Unit of temperature measurement. At one atmosphere pressure: at 32 degrees Fahrenheit, water freezes; at 212 degrees Fahrenheit, water boils. Tf = 1.8 x Tc + 32 Kelvin: Unit of temperature measurement referenced to absolute conditions. Degrees Kelvin = Degrees Celsius + 273.15 NCM/M (normal cubic meters per minute): Flow measurement at normal (standard) conditions (STP). PSIG: Gauge pressure in pounds per square inch above atmospheric pressure. Rankine: Unit of temperature measurement referenced to absolute conditions. Degrees Rankine = Degrees Fahrenheit + 459.67 SCFM (standard cubic feet per minute): Flow measurement at standard (STP) conditions. SFPM (standard feet per minute): Velocity of gas flowing in the pipe or duct referenced to standard (STP) conditions. Standard Conditions: Typical is 70° F and one atmosphere pressure (14.7 psia) or 0° C and one bar pressure (14.5 psia). STP (standard pressure and temperature): Also referred to as standard conditions. Velocity: Measured in SF/M (standard feet per minute) or NM/M (normal meters per minute). This is the mass velocity directly measured by the instrument referenced to the appropriate standard conditions. NM/M (normal meters per minute): Velocity of the gas referenced to standard (STP) conditions. PSIA: Absolute pressure in pounds per square inch. Zero psia is an absolute vacuum. 1 atmosphere pressure = 14.696 psia PSIA = PSIG + 14.696 31 IMPORTANT PRODUCT WARRANTY QUALITY ASSURANCE All Magnetrol/STI electronic level and flow controls are warranted free of defects in materials or workmanship for one full year from the date of original factory shipment. Repair parts are warranted free of defects in materials and workmanship for one year from the date of shipment. Materials, specifications, and contents are subject to change without prior written notice. The quality assurance system in place at Magnetrol/STI guarantees the highest level o f q u a l i t y t h r o u g h o u t t h e c o m p a n y. Magnetrol/STI is committed to providing full customer satisfaction both in quality products and quality service. If returned within the warranty period; and, upon factory inspection of the control, the cause of the claim is determined to be covered under the warranty; then, Magnetrol/STI will repair or replace the control at no cost to the purchaser (or owner) other than transportation. Magnetrol’s quality assurance system is registered to ISO 9001 affirming its commitment to known international quality standards providing the strongest assurance of product/service quality available. Magnetrol/STI shall not be liable for misapplication, labor claims, direct or consequential damage or expense arising from the installation or use of equipment. There are no other warranties expressed or implied, except special written warranties covering some Magnetrol/STI products. ASSURED QUALITY & SERVICE COST LESS SERVICE POLICY RETURN MATERIAL PROCEDURE Owners of Magnetrol/STI controls may request the return of a control or any part of a control for complete rebuilding or replacement. They will be rebuilt or replaced promptly. Controls returned under our service policy must be returned by Prepaid transportation. Magnetrol/STI will repair or replace the control at no cost to the purchaser (or owner) other than transportation if: So that we may efficiently process any materials that are returned, it is essential that a “Return Material Authorization” (RMA) number be obtained from the factory, prior to the material's return. This is available through Magnetrol/STI's local representative or by contacting the factory. Please supply the following information: 1. Returned within the warranty period; and 2. The factory inspection finds the cause of the claim to be covered under the warranty. If the trouble is the result of conditions beyond our control; or, is NOT covered by the warranty, there will be charges for labor and the parts required to rebuild or replace the equipment. In some cases it may be expedient to ship replacement parts; or, in extreme cases a complete new control, to replace the original equipment before it is returned. If this is desired, notify the factory of both the model and serial numbers of the control to be replaced. In such cases, credit for the materials returned will be determined on the basis of the applicability of our warranty. No claims for misapplication, labor, direct or consequential damage will be allowed. 1. 2. 3. 4. 5. Company Name Description of Material Serial Number Reason for Return Application Any unit that was used in a process must be properly cleaned in accordance with OSHA standards, before it is returned to the factory. A Material Safety Data Sheet (MSDS) must accompany material that was used in any media. All shipments returned to the factory must be by prepaid transportation. All replacements will be shipped F.O.B. factory. NOTE: See Electrostatic Discharge Handling Procedure on page 4. LOW VOLTAGE DIRECTIVE For use in Category II installations. If equipment is used in a manner not specified by the manufacturer, protection provided by equipment may be impaired. 5300 Belmont Road • Downers Grove, Illinois 60515-4499 • 630-969-4000 • Fax 630-969-9489 • www.magnetrol.com 145 Jardin Drive, Units 1 & 2 • Concord, Ontario Canada L4K 1X7 • 905-738-9600 • Fax 905-738-1306 Heikensstraat 6 • B 9240 Zele, Belgium • 052 45.11.11 • Fax 052 45.09.93 Regent Business Ctr., Jubilee Rd. • Burgess Hill, Sussex RH15 9TL U.K. • 01444-871313 • Fax 01444-871317 5300 Belmont Road • Downers Grove, Illinois 60515-4499 • 630-969-4028 • Fax 630-969-9489 • www.sticontrols.com Copyright © 2006 Magnetrol International, Incorporated. All rights reserved. Printed in the USA. Magnetrol and Magnetrol logotype are registered trademarks of Magnetrol International. STI and STI logotype are registered trademarks of Magnetrol International. Performance specifications are effective with date of issue and are subject to change without notice. BULLETIN: 54-620.5 EFFECTIVE: March 2006 SUPERSEDES: February 2003