THERMATEL® series TDF/TSF Thermal dispersion flow/level switch ® INSTRUCTION MANUAL AND PARTS LIST DESCRIPTION The Thermatel® is an uncomplicated, and versatile switch for gaseous and liquid flow, level or interface control. Detection is accomplished by sensing changes in the heat transfer characteristics of the media. The Thermatel® has no moving parts and is easy to install and adjust, providing reliable, low maintenance performance in the most demanding applications. MODEL IDENTIFICATION A complete measuring system consists of: 1. THERMATEL® electronics including sensor housing for remote mount units 2. THERMATEL® sensor (see right page) 3. Connecting cable (only applicable for remote mount units) 1. Code for Thermatel® ELECTRONICS T D F T S F Thermatel® - standard electronics for flow, level and interface Thermatel® - electronics with selftest for flow, level and interface - suited for explosion proof zone 1 and 0 - suited for explosion proof zone 1 RELAY OUTPUT – For TDF electronics 1 3 2 4 8 A SPDT relay 5 A DPDT relay - suited for explosion proof zone 1 - suited for explosion proof zone 1 and 0 RELAY OUTPUT – For TSF electronics 8 A DPDT relay 5 A DPDT relay, hermetically sealed relay for use in extreme corrosive environments INPUT POWER 1 240 V AC 2 224 V DC 0 120 V AC MOUNTING CONFIGURATION 0 Integral mount 2 Remote mount units (bracket and sensor housing included) Note: for proces temperatures above +120° C (+250° F): Select a sensor with heat extension with integral mount electronics or select a standard sensor with remote mount electronics HOUSING – ATEX (IP 65), explosion proof housings V W 6 E 0 Dual Dual Single 3/4" NPT cable entry, anti corrosive coated cast aluminium M20 x 1.5 cable entry, anti corrosive coated cast aluminium 3/4" NPT cable entry, cast stainless steel HOUSING – GENERAL PURPOSE (IP 66) Dual 3/4" NPT cable entry, anti corrosive coated cast aluminium 0 0 complete code for Thermatel® ELECTRONICS 2. Code for Thermatel® SENSOR T T T T T T T M M M M M M M A B C D H M L Standard spherical tip Standard spherical tip - with heat extension Standard twin tip Standard twin tip - with heat extension High temperature / high pressure twin tip Mini twin tip (16 mm diam.) Low flow body max max max max max max max 120 200 120 200 450 120 120 °C °C °C °C °C °C °C (250 (390 (250 (390 (850 (250 (250 °F) °F) °F) °F) °F) °F) °F) / / / / / / / max max max max max max max 41 41 207 207 413 207 400 bar bar bar bar bar bar bar ( 600 ( 600 (3000 (3000 (6000 (3000 (5800 psi) psi) psi) psi) psi) psi) - 127 bar (1850 psi) psi) MATERIAL OF CONSTRUCTION FOR SENSOR AND PROCESS CONNECTION A B C 316/316 L (1.4401/1.4404) stainless steel Hastelloy C (2.4819) Monel (2.4360) TMA/TMB/TMC/TMD/TMH/TMM/TML TMC/TMD/TMH TMC/TMD/TMH PROCESS CONNECTION SIZE Threaded 0 1 2 2 T V T V 1 1 1 2 1 1 0 0 Threaded Threaded Threaded Threaded Threaded Threaded Threaded Threaded 1/2" NPT 3/4" NPT 1" NPT G1 (1" BSP) 1/4" NPT 1/2" NPT G 1/4 (1/4" BSP) G 1/2 (1/2" BSP) ANSI RF Flanged (All except TML) 2 2 2 2 3 3 3 3 3 4 4 4 4 4 3 4 5 7 3 4 5 7 8 3 4 5 7 8 1" 150 lbs ANSI RF flange 1" 300 lbs ANSI RF flange 1" 600 lbs ANSI RF flange 1" 900/1500 lbs ANSI RF flange 1 1/2" 150 lbs ANSI RF flange 1 1/2" 300 lbs ANSI RF flange 1 1/2" 600 lbs ANSI RF flange 1 1/2" 900/1500 lbs ANSI RF flange 1 1/2" 2500 lbs ANSI RF flange 2" 150 lbs ANSI RF flange 2" 300 lbs ANSI RF flange 2" 600 lbs ANSI RF flange 2" 900/1500 lbs ANSI RF flange 2" 2500 lbs ANSI RF flange Sanitary Flanged (TMA/TMB) 3 4 B C D T T S S S 1" and 1 1/2" 2" DIN 11.851 DIN 11.851 DIN 11.851 3A compatible 3A compatible DN 25 DN 40 DN 50 TMM All except TML All except TMM/TML All except TMM/TML TML TML TML TML DIN Flanged (All except TML) B B B B C C C C C D D D D D D A B C G A B C G J A B D E G J DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN 25 25 25 25 40 40 40 40 40 50 50 50 50 50 50 PN PN PN PN PN PN PN PN PN PN PN PN PN PN PN V B D V V N N N Varivent NEUMO Bio Control® NEUMO Bio Control® NEUMO Bio Control® INSERTION LENGTH IN INCREMENTS OF 10 mm (0.39") 0 3 0 1 T M 2 0 0 3 0 0 3 0 0 0 Min. 25,4 mm (1") Max. 3300 mm (130") No mounting bracket – low flow body sensor Mounting bracket – low flow body sensor complete code for Thermatel® SENSOR 16 25/40 64/100 250 16 25/40 64/100 250 400 16 25/40 64 100 250 400 DIN DIN DIN DIN DIN DIN DIN DIN DIN DIN DIN DIN DIN DIN DIN 2527, 2527, 2527, 2527, 2527, 2527, 2527, 2527, 2527, 2527, 2527, 2527, 2527, 2527, 2527, DN 65 D 25 D 50 D 65 Form Form Form Form Form Form Form Form Form Form Form Form Form Form Form B B E E B B E E E B B E E E E 3. Code for connecting cable (standard instrument cable) - not for Explosion Proof area 0 0 3 - 1 5 0 From 3 m min. to 150 m max. Specify in increments of 1 m (3.28'). 0 3 7 complete code for connecting cable 3 1 9 8 UNPACKING Unpack the instrument carefully. Make sure all components have been removed from the foam protection. Inspect all components for damage. Report any concealed damage to the carrier within 24 hours. Check the contents of the carton/crates against the packing slip and report any discrepancies to Magnetrol. Check the nameplate model number (Model number/approvals as per inserted separate sheet) to be sure it agrees with the packing slip and purchase order. Check and record the serial number for future reference when ordering parts. These units are in conformity with the provisions of: 1. The EMC Directive: 89/336/EEC. 0038 The units have been tested to EN 0344 61000-6-4/2001 and EN 61000-62/2001. 2. Directive 94/9/EC for Equipment or protective system for use in potentially explosive atmospheres. EC-type examination certificate number ISSeP03ATEX063 (EEx d units) or ISSEP04ATEX021 (EEx d zone 0). 3. The PED directive 97/23/EC (pressure equipment directive). Safety accessories per category IV module H1. Nameplate: - partnumber - amplifier - serial n° - tag n° GENERAL INFORMATION & INSTALLATION PRINCIPLE OF OPERATION MOUNTING POSITION AND LOCATION The Thermatel switch consists of a sensing assembly mounted integrally to the electronics or with a remote mounted sensor which may be located up to 150 m (500 ft) away from the electronics. The sensing assembly contains 2 miniature RTD (Resistance Temperature Detector) tightly encased within a 316L stainless steel, Hastelloy C or Monel tube. The first RTD (unheated) provides a reference temperature of the process conditions. The second RTD is internally heated to establish a temperature differential above the process temperature. The cooling effect on the heated RTD, caused by the presence of flow or level, decreases the differential temperature between the two RTD's. The change in differential temperature is then converted to the actuation of the alarm or control relay. Thermatel® series TDF/TSF flow/level switches should be located to allow easy access for service. Electronics should not be exposed to ambient temperature above +70°C (+160°F) or below -40°C (-40°F). Special precaution should be taken to prevent exposure to corrosive atmosphere, excessive vibration, shock or physical damage. ® GENERAL MOUNTING REQUIREMENTS Thermatel® series TDF/TSF flow/Level switches are shipped assembled to the sensor. Units may be mounted in any position or orientation. When installed in a nozzle, the sensor twin-tips must clear the nozzle. Refer to Figures 1 and 2. Figure 2 Figure 1 3 GENERAL INFORMATION & INSTALLATION (cont.) INSTALLATION The Thermatel® series TDF/TSF flow/level switch has a standard 3/4" NPT mount designed for easy installation through a threaded port. Optional threaded connections or mounting flanges are also available. 1. Apply thread sealant to the sensor and insert the sensor into the tee junction. CAUTION: The switch body must be oriented so that the flow arrow is in the direction of the flow/level being detected. Due to the pipe thread mounting, it may be necessary to make a trial fit, add or remove Teflon® tape or other pipe thread sealant, and reinstall to achieve a satisfactory seal with the sensor assembly properly oriented. Proper orientation is marked on the wrench flats or on the top of the flange for reference. Refer to Figure 4. CAUTION: Tighten unit only at the wrench flats on the sensor using an open-end wrench. DO NOT use the instrument head to tighten the switch to the mounting port. Rotation of the instrument head with respect to the sensor assembly can cause internal wiring damage. 2. Tighten the sensor directly. DO NOT apply force to the switch housing when tightening the sensor. 3. Make sure the sensor is properly oriented to the flow (refer to Figure 3a) or level (refer to Figure 3b). Direction of level movement Direction of flow Figure 3a (flow) Figure 3b (level) Figure 4 WIRING WIRING WIRING (cont.) All power connections are made at the terminal strip within the electronics enclosure. 12-24 AWG wire is recommended for power and control circuits. 8. Installation is complete. Replace housing cover. 9. Set fail-safe jumper as described. See table on page 5. OBSERVE ALL APPLICABLE ELECTRICAL CODES AND PROPER WIRING PROCEDURES. 1. Make sure the power source is turned off. 2. Unscrew and remove housing cover. 3. Pull power supply and control wires through conduit connection. 4. Connect power leads to proper terminals of the black terminal block. Refer to Figure 5a (TDF - zone 1), 5b (TDF - zone 0) or 5c (TSF). a. 120 V AC - Connect “hot” wire to terminal marked L1 and the “neutral” wire to the terminal marked L2/N. b. 240 V AC - Connect one wire to terminal marked L1 and the other wire to the terminal marked L2/N. c. 24 V DC - Connect wires to terminals (+) and (-) on the black terminal block. The terminal labelled GND provides a connection to the switch housing via the circuit board's mounting screws and bracket. The green screw in the bottom of the housing can also be used for grounding. 5. Perform RELAY CONNECTIONS (see below). 6. Dress wiring to guard against interference or contact with cover or circuit board components. 7. Prevent moisture seepage into housing by installing an approved seal-drain fitting in the conduit run leading to the unit. 4 CAUTION: In hazardous areas, do not power the unit until the conduit is sealed and enclosure cover is screwed down securely. RELAY CONNECTIONS The SPDT (single-pole, double-throw) relay is accessed via the black terminal block. The common terminal is labelled “COM”. The normally open and normally closed contacts are labelled “NO” and “NC” respectively. NOTE: Do not exceed the relay's maximum voltage and current ratings. (8 A – 120/240 V AC 30 V DC). The switch may be configured so that the relay either closes or de-energises when the set point is reached, depending upon the position of the fail-safe jumper (JP1). HLFS: place jumper so that the middle pin is connected with the "H" identified pin LLFS: place jumper so that the middle pin is connected with the "L" identified pin See Figure 5a, 5b and 5c WIRING (cont.) D15 Relay LED (red) JP1 Fail-safe jumper P1 Set P2 Time delay TB1 TP1 CO JP1 Fail-safe jumper NC D10 Relay LED (red) NO TP2 H TB2 TB4 JP2 Delay jumper 0-12 s NO NC C D11 Alarm LED (red) H L NO NC C P1 Set 1 L D6 Power LED (yellow) L1 (+) L2/N (-) P3 Alignment pot 1 L1 (+) L2/N (-) 6 TB1 TB2 6 D5 Power LED yellow P2 Time Delay P3 Alignment pot Figure 5A Figure 5B TDF Electronics for zone 1 TDF Electronics for zone 0 JP1 Fail-safe jumper D15 Relay LED (red) TB4 JP10 Self-test jumper TB3 NO NC C NO NC C D11 Alarm LED (red) P1 Set TP1 JP2 H L TP2 1 L1 (+) L2/N (-) Power Level Fail-safe position On High HLFS LLFS Low HLFS LLFS Fail High HLFS LLFS Low HLFS LLFS Relay coil De-energized Energized Energized De-energized De-energized De-energized De-energized De-energized Relay terminals NC to C NO to C Closed Open Open Closed Open Closed Closed Open Closed Open Closed Open Closed Open Closed Open D5 Power LED yellow 6 TB1 P2 Time Delay TB2 P3 Alignment pot Figure 5C TSF Electronics for zone 1 CHART NOTES AND DEFINITIONS: A. Equipment controlled by Thermatel® relays is assumed to be powered from 1 source, while the Thermatel® unit itself is assumed to be powered from a different source. B. “Fail” means a loss of power to the Thermatel® unit. C. HLFS (High Level Fail-safe) means a flow rate or level which is equal to or above the set point. D. LLFS (Low Level Fail-safe) means a flow rate or level which is equal to or below the set point. E. When the relay coil is de-energized, a connection is made between the terminals COM (common) and NC (normally closed), and there is no connection between COM and NO (normally open). F. When the relay coil is energised, a connection is made between the terminals COM and NO, and there is no connection between COM and NC. G. TDF – The red LED, D10, glows when the relay is energized. H. TSF – The red LED, D15, glows when the relay is energized. The alarm LED (D11) glows when a high flow or high level condition exist. 5 WIRING (cont.) REMOTE ELECTRONICS WIRING In remote electronics applications, the sensor and electronic circuit board are contained in separate housings. The sensor housing includes a 7-position terminal block for connecting a shielded 6-conductor cable. The cable's 6 conductors are connected to terminals 1 through 6 in the sensor housing. The cable shield is connected to the 7th terminal (Ground). Refer to Figure 6. Remote electronics is recommended if the process temperature is greater than +120°C (+250°F) or when access to the electronics is limited. The cable is routed to the electronic circuit board and connected to the green, 6-position terminal block (TB2). The cable's six conductors are connected to terminals 1 through 6. The cable shield must not be connected at this end. 1 white 2 black 3 red 4 green 5 orange 6 blue shield Sensor Figure 6 NOTE: The 6 conductors must be wired so that each terminal on the sensor terminal block is connected to its corresponding terminal on the electronic circuit board. Failure to do so will cause improper switch operation. OPERATION AND CALIBRATION TIME DELAY POWER ON DELAY (TSF Electronics only) Adjusting P2 clockwise will increase the time delay between reaching the set point and energising or de-energising the relay. For fastest response (time delay ranges between 0 and 100 seconds), keep P2 in the full counterclockwise position. The TSF switch incorporates a “Power On Delay.” When power to the switch is first applied, there is no temperature difference between the two sensors, causing a high flow or high level alarm. The “Power On Delay” forces the relay to the fail-safe condition, avoiding a false high level or high flow condition during the warm up period. The power on delay may be set for 12 or 50 seconds or disabled. Jumper JP2 sets the “Power On Delay” time. Refer to figure 5B on Page 5. With the jumper in the 1 position, the initial power on delay will be approximately 12 seconds. With the jumper in the 0 position, the power on delay is disabled. When the jumper is removed, the power on delay will be approximately 50 seconds. The operating yellow LED (D6) glows after power on delay has timed out. ADVANCED CALIBRATION PROCEDURE Measure and record the voltage across resistor TP1 or TP2. This voltage will change with set point and may be used for future reference or adjustment of set point. ELECTRONIC SELF-TEST (TSF Electronics only) Jumper JP10 (refer to Figure 5B on page 5) permits the self-test to be performed in either a normal high flow/level or normal low flow/level condition. When jumper JP10 is placed in the “L” position, the self-test will simulate a low flow/level condition. With jumper JP10 in the “H” position, the self-test will simulate a high flow/level condition. If the switch is used in a normally high flow/level condition, put the jumper in the “L” position; if it is normally used in a low flow/level condition, put the jumper in the “H” position. With power on and all connections made, press and hold the TEST button (S1). Refer to Figure 5B on page 5. For remote self-test, provide contact closure to two wires connected to TB3. The red LED (D11), the relay LED (D15), and the relay will change state to confirm operation of the switch. Release TEST button (S1) or remove contact closure for remote self-test. The switch will return to the initial condition. Note: For units with time delay, output activation is after delay period. 6 OPERATION AND CALIBRATION (cont.) CAUTION: Gain potentiometer (P3) is set at the factory and should not be field adjusted. FLOW SENSING APPLICATIONS FLOW SENSING APPLICATIONS (cont.) Adjustment procedure FLOW/NO FLOW Adjustment procedure VARIABLE FLOW RATE (cont.) 11. Rotate P2 (time delay) fully counterclockwise (zero time delay). 12. Place JP1 (fail-safe) in the "L" position. 13. Reduce the flow rate to minimum (no-flow). 14. Slowly rotate P1 counterclockwise until the red LED (D10 or D11) illuminates. 15. Slowly rotate P1 clockwise until the red LED (D10 or D11) goes out. 16. Repeat steps 4 and 5 several times. Each repeat of steps 4 and 5 stabilises the switch around the set point. 17. Wait 20 sec. for water, 1 minute for air and hydrocarbons. 18. If the red LED (D10 or D11) is not illuminated, slowly rotate P1 counterclockwise until it illuminates. 19. Slowly rotate P1 clockwise until the red LED (D10 or D11) goes out. Continue to rotate P1 clockwise another 1⁄2 turn. 10. Resume flow. 11. If the response time required to sense Flow is too long, rotate P1 counterclockwise 1⁄4 turn. 12. If the response time required to sense No Flow is too long, rotate P1 clockwise 1⁄4 turn. 13. Repeat steps 11 and 12 until desired response times for Flow and No Flow are attained. Normal delays range from 2 seconds to over 1 minute, depending on the material and the flow rate. 14. If high flow fail-safe operation is desired, move jumper JP1 to the "H" position as described on page 5. B. Maintain normal flow rate 11. Rotate P2 (time delay) fully counterclockwise. 12. Place JP1 (fail-safe) in the "L" position. 13. Maintain flow at normal operating conditions. 14. Slowly rotate P1 counterclockwise until the red LED (D10 or D11) illuminates. 15. Slowly rotate P1 clockwise until the red LED (D10 or D11) goes out. 16. Repeat steps 4 and 5 several times. 17. Wait 20 sec. for water, 1 minute for air and hydrocarbons. 18. If the red LED (D10 or D11) is illuminated, very slowly rotate P1 (set) clockwise until the red LED (D10 or D11) goes out. 19. a. Switch on decreasing flow Slowly rotate P1 (set) counterclockwise until the red LED (D10 or D11) illuminates. The set point is now just below the present flow rate. When the flow rate drops below the present flow rate, the relay will change state. b. Switch on increasing flow The set point is now just above the present flow rate. When the flow rate increases, the relay will change state. 10. Move jumper JP1 to the "H" position as described on page 5. Adjustment procedure VARIABLE FLOW RATE If the flow can be reduced to the set point, follow procedure A; if it cannot be reduced, follow procedure B. A. Adjust flow to desired switch point: 11. Rotate P2 (delay) fully counterclockwise. 12. Place JP1 (fail-safe) in the "L" position. 13. Establish the flow rate at the desired switching point. 14. Slowly rotate P1 counterclockwise until the red LED (D10 or D11) illuminates. 15. Slowly rotate P1 clockwise until the red LED (D10 or D11) goes out. 16. Repeat steps 4 and 5 several times. 17. Wait 20 seconds for water, 1 minute for air and hydrocarbons. 18. If the red LED (D10 or D11) is illuminated, very slowly rotate P1 (set point) clockwise until the red LED (D10 or D11) goes out. 19. a. Switch on increasing flow The set point is now at the actual flow rate. Increase the flow rate to normal operating conditions (the relay will change state). When the flow rate drops to the desired switching level, the relay will change state. b. Switch on decreasing flow Slowly rotate P1 (set counter) clockwise until the red LED (D10 or D11) illuminates. The set point is now at the actual flow rate. Decrease the flow to normal operating conditions (the relay will change state). When the flow rate increases to the desired switching level, the relay will change state. 10. Move jumper JP1 to the "H" position as described on page 5. LEVEL SENSING APPLICATIONS Adjustment procedure 11. Make sure that P2 (time delay) is fully counterclockwise (zero time delay). 12. Make sure that JP1 (fail-safe) is in the "L" position. 13. Submerge the sensor in still liquid. 14. Slowly rotate P1 (threshold) counterclockwise until the red LED (D10 or D11) illuminates. 15. Slowly rotate P1 clockwise until the red LED (D10 or D11) goes out. 16. Repeat steps 4 and 5 several times. Each repeat of steps 4 and 5 stabilises the switch around the set point. 17. Wait 20 seconds for the sensor to stabilise. 18. If the red LED (D10 or D11) illuminates, slowly rotate P1 clockwise until it goes out; otherwise, continue to step 9. 19. Slowly rotate P1 counterclockwise until the red LED (D10 or D11) illuminates. 10. Continue to rotate P1 counterclockwise another 1⁄2 turn to set the switching set point. 11. Test switch operation. Normally the response time for sensing dry conditions is about twice as long as the delay for sensing wet conditions. 12. If the response time required to sense dry conditions is too long, rotate P1 clockwise 1/4 turn. The time required to sense dry conditions should be at least 3 sec.; otherwise, false sensing of dry conditions may occur. 13. If the time required to sense dry conditions is too short, rotate P1 counterclockwise 1/4 turn. 14. If high level fail-safe operation is desired, move jumper JP1 to the "H" position, towards the relay LED (D10 or D11), as described on page 5. 7 TROUBLESHOOTING NO POWER INOPERATIVE SENSOR The power LED (D5) should glow at all times when power is applied. If it is not glowing, check for sufficient supply voltage. If it fails to glow when proper voltage is applied, the circuit is defective and must be repaired or replaced. Sensor wiring may be checked with an ohmmeter. Make sure that power is OFF before testing sensor wiring. Connect an ohmmeter between the terminals indicated, and check that measured values are within specified limits. INOPERABLE RELAY If the relay fails to open for any setting of P1 (threshold), make sure that the fail-safe jumper (JP1) is installed. Also, make sure that P2 (delay) is fully counterclockwise when setting the switching threshold. The potentiometer (P3), next to the red LED (D10), is adjusted and sealed at the factory. This potentiometer should not be readjusted. If the seal is broken, the circuit is probably misaligned and requires realignment. Consult the factory for alignment instructions, or return the switch for repair. Terminal pairs 2 3 1 3 5 and and and and and 5 6 2 4 6 Expected resistance 90 to 140 Ω (275 Ω for TMH probe) 90 to 140 Ω (275 Ω for TMH probe) 0 to 10 Ω 0 to 10 Ω 0 to 10 Ω If the switch is configured for remote sensing, terminals at both ends of the cable must be tested. Resistance values should fall within specified limits. MAINTENANCE CLEANING GAIN ADJUSTMENT The probe may be cleaned by soaking, spraying solvents or detergent and water onto the sensor tubes, or by ultrasonic cleaning. Lime deposits may be safely removed by soaking in 20% hydrochloric acid. Warming to +65°C (+150°F) is permissible to speed this process. For unusual cleaning problems, contact the factory and determine the exact materials of construction and chemical compatibility before using strong acids or unusual cleansers. (Refer to figure 5 on page 5) This procedure will adjust the gain of the circuit board to match the sensors in the probe. For best results, perform this procedure at the actual operating conditions. 1. Rotate P2 (time delay) fully counterclockwise. 2. Place Jumper JP1 (fail-safe) in the “L” position. 3. Rotate the gain adjustment potentiometer P3 fully counterclockwise. 4. Turn P1 fully clockwise until clicks are heard, then turn counterclockwise approximately ten (10) turns to obtain a midrange adjustment. 5. Rotate gain adjustment P3 (alignment pot) clockwise until the red LED (D10 or D11) illuminates. This signifies that the set point has been reached and the relay is energized. 6. Slowly rotate P3 counterclockwise until the red LED (D10 or D11) goes out. 7. Slowly repeat steps 5 and 6 several times. 8. Ensure that the red LED (D10 or D11) is on. 9. Gain adjustment of the sensor and electronics is now complete. Proceed with the operation and calibration on page 6. PROBE REPLACEMENT The probe assembly may be replaced in the field; however, the electronics must be tuned to the new sensors. 8 SPECIFICATIONS DIMENSIONS IN mm (inches) TWIN TIP with SINGLE cable entry housing SPHERICAL TIP with DUAL cable entry housing 117.6 (4.64) 76 (3.00) Rotation clearance 87 (3.41) 175 (6.87) 3/4" NPT or M20 x 1.5 single electrical connection Cable entry: 3/4" NPT or M20 x 1.5 175 (6.87) 46 (1.79) Threaded: 28 (1.12) Welded flange: 53 (2.08) Threaded: 28 (1.12) Welded flange: 53 (2.08) Insertion length: 30 to 3300 mm (1" to 130") In 10 mm (0.39") increments. Consult factory for longer lengths. Separate or seal welded flange Insertion length: 50 to 3300 mm (2" to 130") In 10 mm (0.39") increments. Consult factory for longer lengths. Separate or seal welded flange 22 ø (0.87) 22 ø (0.87) REMOTE MOUNT VERSION Housing-electronics Housing-sensor Rotation clearance: Single hub - 76 (3.00) Dual hub - 87 (3.41) 118 ø (4.63) Rotation clearance 76 (3.00) 197 (7.75) 70 (2.75) 3/4" NPT or M20 x 1.5 single/dual electrical connection Single electrical connection, (size in accordance with housing electronics) 70 (2.75) 2 holes 10 ø (0.38) 76 (3.00) 51 (2.00) Separate or seal welded flange 89 (3.50) 95 (3.75) 3/4" NPT M20 x 1.5 Transducer/amplifier cable connector Threaded: 28 (1.12) Welded flange: 53 (2.08) Insertion length: 30 to 3300 mm (1" to 130") In 10 mm (0.39") increments. Consult factory for longer lengths. Cable is ordered separately 22 ø (0.87) 9 CONNECTIONS insertion length BSP connection insertion length insertion length insertion length NPT connection Threaded Welded flange ANSI / DIN insertion length Sanitary 3A insertion length Varivent NEUMO Bio Control® Threaded G1A (BSP) insertion length Sanitary DIN 11851 ELECTRICAL SPECIFICATIONS Description Specifications Supply voltage 240/120 V AC (+ 10 % / - 15 %), 50-60 Hz 24 V DC (± 20 %) 5 W max. SPDT, 8 A, 250/120 V AC; 30 V DC – with gold flash contacts DPDT, 5 A, 250/120 V AC; 28 V DC – with gold flash contacts DPDT, 8 A, 250/120 V AC, 28 V DC – with gold flash contacts DPDT, 5 A, 250/120 V AC, 28 V DC – hermetically sealed/with gold flash contacts Switch selectable (jumper) HIGH (level/flow) or LOW (level/flow) Yellow LED – indicates POWER ON red LED – indicates an alarm condition Adjustable via potentiometer inside housing Insertion probes: 0,005 to 1,5 meters per second (0.01 to 5.0 fps) – water 0,03 to 150 meters per second (0.1 to 500 fps) – air 1/4" Low flow body: 0,3 to 38 l/h (0.08 to 10 GPH) for water – from 0,2 l/min (0.42 SCFH) for air/gas 1/2" Low flow body: 3,8 to 115 l/h (1.0 to 30 GPH) for water – from 1,0 l/min (2.1 SCFH) for air/gas 1 to 10 sec. (typical - liquid) 0-100 seconds adjustable < 1 % at constant temperature -40 °C to +70 °C (-40 °F to +160 °F) - for all except ATEX EEx d -40 °C to +55 °C (-40 °F to +130 °F) - for ATEX EEx d units TMH sensors: -70°C to +450°C (-100°F to +850°F) TMM/TML sensors: -70°C to +120°C (-100°F to +250°F) TMx sensors: -70°C to +200°C (-100°F to +390°F) Twin tip sensor: To 207 bar (3000 psi) standard length >50 mm (2") To 124 bar (1800 psi) extended length >50 mm (2") Spherical tip sensor: To 040 bar (1600 psi) Mini sensor: To 207 bar (3000 psi) standard length >25 mm (1") To 127 bar (1850 psi) extended length >25 mm (1") Low flow body sensor: To 400 bar (5800 psi) High temperature sensor: To 413 bar (6000 psi) Twin tip sensor: 316L SST (1.4401), Hastelloy C (2.4819) or Monel (2.4360) Spherical/Mini and Low flow body sensor: 316L SST (1.4401) High temperature sensor: 316L SST (1.4401), Hastelloy C (2.4819) 0,82 µm (32 micro inch) (electropolishing available, consult factory) Twin tip/Spherical tip sensor: min. 50 mm (2") - max. 3300 mm (130") Mini sensor: min. 25 mm (1") - max. 1500 mm (59") High temperature sensor: min. 50 mm (2") - max. 900 mm (35.4") 0 - 99 % non condensing IP 65, Cast Aluminium or Stainless Steel Meets CE requirements (EN 50081-2, EN 50082-2) ATEX II 2 G EEx d II C T5/T4, explosion proof for zone 1 ATEX II 1/2 G EEx d + ib, d[ib] II C T5/T4, explosion proof for zone 0 FM and CSA, Non Incendive and Explosion Proof GOST/GOSGORTECHNADZOR - Russian Authorisation Standards 2 kg. (4.6 lbs.) with 50 mm (2") sensor Power consumption Output relays TDF TSF Failsafe LED indication Power Alarm Set point Flow Range Response time Time delay Repeatability Ambient temperature Process temperature Max process pressure @ 40°C (100°F) Materials of construction - wetted parts Sanitary sensor finish Insertion length ① (consult factory for longer lengths) Humidity Housing Materials Electromagnetic compatibility Approvals Shipping weight ① For flow switches, insertion length must be long enough to locate the tip of the sensor at least 10% (of pipe Ø) inside pipe. 10 REPLACEMENT PARTS No. Description Part Number single entry C/F dual entry C/F 1 Base, NEMA 4X/7/9 2 Cover, NEMA 4X/7/9 002-6204-600 3 O-ring, NEMA 4X/7/9 012-2101-345 TDF 8A SPDT (zone 1) 4 Main PC board, integral sensor Main PC board, remote sensor TSF 5A DPDT (zone 1/0) 8A DPDT (zone1) 5A DPDT HS (zone1) 240 V AC 030-3536-004 030-3578-003 030-3572-003 030-3571-003 120 V AC 030-3536-002 030-3578-001 030-3572-001 030-3571-001 24 V DC 030-3536-006 030-3578-005 030-3572-005 030-3571-005 240 V AC 030-3536-005 030-3578-004 030-3572-004 030-3571-004 120 V AC 030-3536-003 030-3578-002 030-3572-002 030-3571-002 24 V DC 030-3536-007 030-3578-006 030-3572-006 030-3571-006 5 Bracket kit 089-5212-001 6 Remote mounting bracket C/F 7 Remote sensor housing base, single entry C/F 8 Remote sensor housing cover 004-9105-001 9 Remote sensor housing O-ring 012-2101-345 10 Remote sensor PC board 030-3540-001 11 12 13 14 Remote sensor bracket kit 089-5212-002 Probe – See probe selection, page 2 2 8 10 4 9 11 5 7 3 1 6 12 13 14 Front view Side view AGENCY APPROVALS Agency ATEX Approvals ATEX II 2G EEx d II C T4/T5, explosion proof for zone “1” ATEX II 1/2G EEx d + ib, d[ib] II C T4/T5, explosion proof for zone “0” FM/CSA➀ Non Incendive / Explosion proof GOST/ Russian Authorisation Standards GOSGORTECHNADZOR➀ ➀ Consult factory for proper partnumbers 11 IMPORTANT SERVICE POLICY Owners of Magnetrol products 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. Magnetrol International will repair or replace the control, at no cost to the purchaser, (or owner) other than transportation cost if: a. Returned within the warranty period; and, b. The factory inspection finds the cause of the malfunction to be defective material or workmanship. If the trouble is the result of conditions beyond our control; or, is NOT covered by the warranty, there will be charges for labour 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, labour, direct or consequential damage will be allowed. RETURNED MATERIAL PROCEDURE So that we may efficiently process any materials that are returned, it is essential that a “Return Material Authorisation” (RMA) form will be obtained from the factory. It is mandatory that this form will be attached to each material returned. This form is available through Magnetrol’s local representative or by contacting the factory. Please supply the following information: 1. Purchaser Name 2. Description of Material 3. Serial Number 4. Desired Action 5. Reason for Return 6. Process details All shipments returned to the factory must be by prepaid transportation. Magnetrol will not accept collect shipments. All replacements will be shipped FOB factory. BULLETIN N°: EFFECTIVE: SUPERSEDES: UNDER RESERVE OF MODIFICATIONS www.magnetrol.com ® BE 54-601.9 JULY 2004 September 2003 BENELUX Heikensstraat 6, 9240 Zele, België Tel. +32 (0)52.45.11.11 • Fax. +32 (0)52.45.09.93 • E-Mail: [email protected] DEUTSCHLAND Alte Ziegelei 2-4, D-51491 Overath Tel. 02204 / 9536-0 • Fax. 02204 / 9536-53 • E-Mail: [email protected] FRANCE 40 - 42, rue Gabriel Péri, 95130 Le Plessis Bouchard Tél. 01.34.44.26.10 • Fax. 01.34.44.26.06 • E-Mail: [email protected] ITALIA Via Arese 12, I-20159 Milano Tel. (02) 607.22.98 (R.A.) • Fax. (02) 668.66.52 • E-Mail: [email protected] UNITED KINGDOM Unit 1 Regent Business Centre, Jubilee Road Burgess Hill West Sussex RH 15 9TL Tel. (01444) 871313 • Fax (01444) 871317 • E-Mail: [email protected] INDIA E-22, Anand Niketan, New Delhi - 110 021 Tel. 91 (11) 6186211 • Fax 91 (11) 6186418 • E-Mail: [email protected]