Thermatel® Installation and Operating Manual Thermal Dispersion Flow/Level Switch Model TDF/TDL Model TSF/TSL Read this Manual Before Installing This manual provides information on the Thermatel Thermal Dispersion Flow/Level Switch. It is important that all instructions are read carefully and followed in sequence. The QuickStart Installation instructions are a brief guide to the sequence of steps for experienced technicians to follow when installing the equipment. Detailed instructions are included in the Complete Installation section of this manual. Conventions Used in this Manual Certain conventions are used in this manual to convey specific types of information. General technical material, support data, and safety information are presented in narrative form. The following styles are used for notes, cautions, and warnings. Notes Notes contain information that augments or clarifies an operating step. Notes do not normally contain actions. They follow the procedural steps to which they refer. Cautions Cautions alert the technician to special conditions that could injure personnel, damage equipment, or reduce a component’s mechanical integrity. Cautions are also used to alert the technician to unsafe practices or the need for special protective equipment or specific materials. In this manual, a caution box indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. Warnings Warnings identify potentially dangerous situations or serious hazards. In this manual, a warning indicates an imminently hazardous situation which, if not avoided, could result in serious injury or death. Safety Messages The Thermatel system is rated by the IEC for use in Category II, Pollution Degree 2 installations. Follow all standard industry procedures for servicing electrical and computer equipment when working with or around high voltage. Always shut off the power supply before touching any components. Although high voltage is not present in this system, it may be present in other systems. WARNING! Explosion hazard. Do not connect or disconnect equipment unless power has been switched off or the area is known to be non-hazardous. 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. Notice of Copyright and Limitations Copyright © 2003 Magnetrol International All rights reserved Magnetrol/STI reserves the right to make changes to the product described in this manual at any time without notice. Magnetrol/STI makes no warranty with respect to the accuracy of the information in this manual. Warranty 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. 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/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. Quality Assurance The quality assurance system in place at Magnetrol/STI guarantees the highest level of quality throughout the company. Magnetrol/STI is committed to providing full customer satisfaction both in quality products and quality service. 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. Electrical components are sensitive to electrostatic discharge. To prevent equipment damage, observe safety procedures when working with electrostatic sensitive components. Thermatel Model TDF/TDL and TSF/TSL Thermal Dispersion Flow/Level Switch, 54-601 Thermatel Model TDF/TDL and TSF/TSL Thermal Dispersion Flow/Level Switch Table of Contents 1.0 Description 1.1 Principle of Operation...........................................1 2.0 Installation 2.1 Unpacking.............................................................1 2.2 Quick Start...............................................................2 2.3.1 Mounting Position and Location ................2 2.3.2 General Mounting Requirements................2 2.4 Installation ............................................................3 2.5 Electrostatic Discharge (ESD) Handling Procedure.3 2.6 Wiring...................................................................4 2.6.1 Relay Connections......................................5 2.6.2 Chart Notes and Definitions ......................6 2.6.3 Remote Electronics Wiring .........................6 2.7 Operation and Calibration ....................................7 2.7.1 Flow Sensing Applications ..........................7 2.7.2 Level Sensing Applications..........................9 2.7.3 Adjust Set Point........................................10 2.7.4 Time Delay...............................................10 2.7.5 Electronic Self-test ....................................10 2.7.6 Advanced Calibration Procedure...............11 2.7.7 Power On Delay .......................................11 3.0 General Information 3.1 Maintenance........................................................12 3.1.1 Cleaning ...................................................12 3.1.2 Probe Replacement–Integral Housing.......12 3.1.3 Probe Replacement–Remote Housing.......12 3.1.4 Probe Replacement–Remote Housing.......13 4.0 Reference Information 4.1 Specifications.......................................................14 4.2 Troubleshooting...................................................17 4.3 Agency Approvals ................................................17 4.3.1 FM (Factory Mutual)................................17 4.3.2 CSA (Canadian Standards Association).....18 4.3.3 CENELEC ...............................................18 4.3.4 SAA ..........................................................18 4.3.5 Explosion Proof ........................................19 4.4 Parts ....................................................................19 4.4.1 Replacement Parts Drawings.....................19 4.4.2 Replacement Parts ....................................20 4.5 Model Numbers ..................................................21 4.5.1 Electronic Models .....................................21 4.5.2 Electronic Models .....................................22 4.5.3 Electronic Models .....................................23 4.5.4 Electronic Models .....................................24 4.5.5 Electronic Models .....................................24 Thermatel Model TDF/TDL and TSF/TSL Thermal Dispersion Flow/Level Switch, 54-601 1.0 Description Thermatel Flow/Level Switches use state-of-the-art thermal dispersion technology for gas flow and liquid flow/level monitoring and control. Flow/level detection is accomplished by sensing changes in the heat transfer characteristics of the media. The sensor is available in 316L stainless steel, Hastelloy C, or Monel welded construction with no moving parts. The easy to install and adjust units provide reliable, low maintenance performance in the most demanding applications. 1.1 Principle of Operation The Thermatel Flow/Level Switch consists of a dual element sensing assembly mounted integrally to the electronics, or the sensor may be remote mounted up to 500 feet (150 meters) from the electronics. Each element of the sensor is a miniature RTD (Resistance Temperature Detector). One element measures the temperature of the process at the sensor location, providing a reference temperature. The second RTD is self-heated to establish a temperature differential above the reference temperature. The cooling effect on the heated RTD, caused by the presence of flow or level, decreases the differential temperature between the two RTDs. This decrease in temperature differential is then converted to a relay actuation. The sensors are suitable for operation in temperatures of -100° F to +850° F (-73° C to +454° C). 2.0 Installation 2.1 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. 1 Thermatel Model TDF/TDL and TSF/TSL Thermal Dispersion Flow/Level Switch, 54-601 2.2 Quick Start Unless ordered with factory calibration, the Thermatel switch is adjusted for a level switch between air and water. The set point of the unit must be adjusted for your application. To calibrate for other applications, adjust the set point potentiometer, P1. Turning P1 clockwise decreases the sensitivity for use as a liquid flow switch. Turning P1 counterclockwise increases the sensitivity. Refer to Operation and Calibration section on page 5 for detailed procedure. The gain adjustment is factory set to handle the majority of applications. However, there may be occasions when standard set point adjustment using P1 does not provide the desired performance. In these cases, adjust the gain potentiometer (P3) following the directions on page 7 (also refer to Probe Replacement and Gain Adjustment on Page 13). 2.3 Figure 1 Mounting 2.3.1 Mounting Position and Location Thermatel Flow/Level Switches should be located to allow easy access for service. Electronics should not be exposed to ambient temperature above +160° F (+71° C) or below -40° F (-40° C). Special precaution should be taken to prevent exposure to corrosive atmosphere, excessive vibration, shock or physical damage. 2.3.2 General Mounting Requirements Figure 2 Thermatel Flow/Level Switches are shipped assembled to the sensor. Units may be mounted in any position or orientation. Refer to Figures 1 and 2. Note: When installed in a nozzle, the sensor tips must clear the nozzle. Note: All wiring, conduit and electrical fittings must conform to local electrical codes for the location selected. Thermatel Model TDF/TDL and TSF/TSL Thermal Dispersion Flow/Level Switch, 54-601 2 2.4 Installation The Thermatel Flow/Level Switch has a standard 3⁄4" NPT mount designed for easy installation through a threaded port. Optional 1" NPT thread mount or mounting flanges are also available. Direction of Level Movement 1. Apply thread sealant to the sensor and insert the sensor into the tee junction. Caution: Figure 3C (Level) 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. Direction of Flow 3. Make sure the sensor is properly oriented to the flow (refer to Figures 3A and 3B) or level (refer to Figure 3C). Caution: The switch body must be oriented so that the flow arrow is in the direction of the flow/level being detected. Proper orientation is marked on the wrench flats or on the top of the flange for reference. Refer to Figure 4. Figure 3A (Flow) 2.5 Direction of Flow Figure 3B (Flow) 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: 1. Ship and store circuit boards in anti-static bags. If an antistatic bag is not available, wrap board in aluminum foil. Do not place boards on foam packing materials. 2. Use a grounding wrist strap when installing and removing circuit boards. A grounded workstation is also recommended. 3. Handle printed circuit boards only by the edges. Do not touch components or connector pins. 4. Ensure that all electrical connections are completely made and none are partial or floating. Ground all equipment to a good, earth ground. Figure 4 3 Thermatel Model TDF/TDL and TSF/TSL Thermal Dispersion Flow/Level Switch, 54-601 2.6 All power and control connections are made at the terminal strip within the electronics enclosure. 12-24 AWG wire is recommended for power and control circuits. P1 Set P2 Time delay TB1 TP1 CO JP1 Fail-safe jumper NC D10 Relay LED (red) NO OBSERVE ALL APPLICABLE ELECTRICAL CODES AND PROPER WIRING PROCEDURES. 1 TP2 TB2 1. Make sure the power source is turned off. L1 (+) 6 L2/N (–) 2. Unscrew and remove housing cover. P3 Alignment pot 3. Pull power supply and control wires through conduit connection. D5 Power LED yellow 4. Connect power leads to proper terminals of the black terminal block. Refer to Figure 5A for TDF/TDL or 5B for TSF/TSL electronics. a. 120 VAC - Connect “hot” wire to terminal marked L1 and the “neutral” wire to the terminal marked L2/N. b. 240 VAC - Connect one wire to terminal marked L1 and the other wire to the terminal marked L2/N. c. 24 VDC - Connect wires to terminals (+) and (-) on the black terminal block. The green screw in the bottom of the housing should be used for grounding. Figure 5A TDF/TDL Electronics JP1 Fail-safe jumper D15 Relay LED (red) TB4 S1 Self-test pushbutton JP10 Self-test jumper TB3 NO NC C D11 Alarm LED (red) NO NC C Wiring 5. Perform Relay Connections (refer to Figure 5A for TDF/TDL or Figure 5B for TSF/TSL electronics). P1 Set TP1 1 L1 (+) L2/N (–) 6. Dress wiring to guard against interference or contact with cover or circuit board components. JP2 Power on Delay Jumper 7. Prevent moisture seepage into housing by installing an approved seal-drain fitting in the conduit run leading to the unit. TP2 TB1 6 D5 Power LED (yellow) P2 Time Delay TB2 8. Set fail-safe jumper as described below. 9. Installation is complete. Replace housing cover. Caution: P3 Allignment Pot In hazardous areas, do not power the unit until the conduit is sealed and enclosure cover is screwed down securely. Figure 5B TSF/TSL Electronics Thermatel Model TDF/TDL and TSF/TSL Thermal Dispersion Flow/Level Switch, 54-601 4 2.6.1 Relay Connections Relay Connections and Maximum Ratings Model Relay Type Terminal Block TDF/TDL SPDT TB1 Maximum ratings 10 amp at 120 - 250 VAC 8 amp at 30 VDC 0.5 amp at 125 VDC TSF/TSL DPDT TB4 10 amp at 120-250 VDC 8 amp at 28 VAC 0.5 amp at 125 VDC Hermetically sealed TB4 DPDT 5 amp at 120-250 VDC 5 amp at 28 VAC The switch may be configured so that the relay either energizes or de-energizes when the set point is reached. Locating the fail-safe jumper (JP1) in the L position places the switch in a low level failsafe (LLFS) position. This causes the relay to energize when the set point is exceeded. Locating the fail-safe jumper (JP1) in the H position places the switch in a high level fail-safe (HLFS) position. This causes the relay to de-energize when the set point is exceeded. Refer to the following chart. Power On On Fail Fail 5 Flow Level High Low High Low Fail-Safe Position Relay Coil Relay Terminal NC to CO NO to CO HLFS De-energized Closed Open LLFS Energized Open Closed HLFS Energized Open Closed LLFS De-energized Closed Open HLFS De-energized Closed Open LLFS De-Energized Closed Open HLFS De-Energized Closed Open LLFS De-energized Closed Open Thermatel Model TDF/TDL and TSF/TSL Thermal Dispersion Flow/Level Switch, 54-601 2.6.2 Chart Notes and Definitions A. Equipment controlled by Thermatel relay is assumed to be powered from one 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 adjusted set point. D. LLFS (Low Level Fail-safe) means a flow rate or level which is less than the adjusted set point. E. When the relay coil is de-energized, a connection is made between the terminals CO (common) and NC (normally closed), and there is no connection between CO and NO (normally open). F. When the relay coil is energized, a connection is made between the terminals CO and NO, and there is no connection between CO and NC. 1 G. TDF/TDL – The red LED, D10, glows when the relay is energized. H. TSF/TSL – The red LED, D15, glows when the relay is energized. The alarm LED (D11) glows when a high flow or high level condition exists. 6 2.6.3 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 six conductors are connected to terminals 1 through 6 in the sensor housing. The cable shield is connected to the seventh terminal (Ground). Refer to Figure 6. 1 white 2 black 3 red 4 green 5 orange 6 blue shield Remote electronics is recommended if the process temperature is greater than +250° F (+121° C) 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 should be connected to the green ground screw in the electronics housing base. Figure 6 Note: The six conductors must be wired so that each terminal on the sensor terminal block TB2 (see Figure 5) is connected to its corresponding terminal on the electronic circuit board. Failure to do so will cause improper switch operation. Thermatel Model TDF/TDL and TSF/TSL Thermal Dispersion Flow/Level Switch, 54-601 6 2.7 Operation and Calibration Note: Calibration should be performed using the actual fluid at the operating temperature. Note: Potentiometer (P3) is set at the factory to handle most applications. The performance of the switch may be changed by adjusting P3: 1. Switch does not detect flow or level or response time is too long, turn P3 counterclockwise one turn and recalibrate; 2. Switch detects flow or level, but fails to reset for low flow/level, turn P3 clockwise one turn and recalibrate. 2.7.1 Flow Sensing Applications Adjustment procedure FLOW/NO FLOW 1. Rotate P2 (time delay) fully counterclockwise (zero time delay). 2. Place JP1 (fail-safe) in the “L” position. 3. Reduce the flow rate to no flow. Allow 30 seconds for the sensor to stabilize. 4. Slowly rotate P1 counterclockwise until the red LED (D10 for the TDF/TDL or D11 for the TSF/TSL) illuminates. 5. Slowly rotate P1 clockwise until the red LED (D10 or D11) goes out. 6. Repeat steps 4 and 5 several times. 7. Slowly rotate P1 clockwise until the red LED (D10 or D11) goes out. Continue to rotate P1 clockwise another turn. 8. Resume flow. 9. If the response time required to sense no flow is too long, rotate P1 clockwise 1⁄4 turn. 10. If the response time required to sense flow is too long, rotate P1 counterclockwise 1⁄4 turn. 11. Repeat steps 11 and 12 until desired response times for flow and no flow are attained. Normal delays range from two seconds to over fifteen seconds, depending on the material and the flow rate. 12. If high level fail-safe operation is desired, move jumper, JP1, to the H position as described on page 4. 7 Thermatel Model TDF/TDL and TSF/TSL Thermal Dispersion Flow/Level Switch, 54-601 Adjustment procedure VARIABLE FLOW RATE A. Adjust flow to desired switch point: 1. Rotate P2 (delay) fully counterclockwise. 2. Place JP1 (fail-safe) in the “L” position. 3. Establish the flow rate at the desired switching point. Allow 30 seconds for the sensor to stabilize. 4. Slowly rotate P1 counterclockwise until the red LED (D10 for the TDF/TDL or D11 for the TSF/TSL) illuminates. 5. Slowly rotate P1 clockwise until the red LED goes out. 6. Repeat steps 4 and 5 several times. 7. If the red LED (D10 or D11) is illuminated, very slowly rotate P1 (set) clockwise until the red LED (D10 or D11) goes out. 8. a. Switch on decreasing 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 increasing flow: Slowly rotate P1 (set) 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. B. Maintain normal flow rate: 1. Rotate P2 (delay) fully counterclockwise. 2. Place JP1 (fail-safe) in the “L” position. 3. Maintain flow rate at normal operating conditions. Allow 30 seconds for the sensor to stabilize. 4. Slowly rotate P1 counterclockwise until the red LED (D10 or D11) illuminates. 5. Slowly rotate P1 clockwise until the red LED goes out. 6. Repeat steps 4 and 5 several times. 7. If the red LED (D10 or D11) is illuminated, very slowly rotate P1 (set) clockwise until the red LED (D10 or D11) goes out. Thermatel Model TDF/TDL and TSF/TSL Thermal Dispersion Flow/Level Switch, 54-601 8 8. If the flow can be reduced to the set point, follow procedure A; if it cannot be reduced, follow procedure B. 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: Slowly rotate P1 (set) clockwise until the red LED (D10 or D11) goes out. The set point is now just above the present flow rate. When the flow rate increases, the relay will change state. 9. If high level fail-safe operation is desired, move the jumper to the “H” position, as described on page 4. 2.7.2 Level Sensing Applications Adjustment procedure 1. Make sure that P2 (time delay) is fully counterclockwise (zero time delay). 2. Place JP1 (fail-safe) in the “L” position. 3. Submerge the sensor in still liquid. The liquid should have the same properties as the liquid being detected in the tank. If used for interface detection, put the sensor in the fluid with the highest thermal conductivity (typically water). 4. Slowly rotate P1 (set point) counterclockwise until the red LED (D10 on the TDF/TDL or D11 on the TSF/TSL) illuminates. 5. Slowly rotate P1 clockwise until D10 or D11 goes out. 6. Repeat steps 4 and 5 several times. 7. Ensure that LED D10 or D11 is illuminated. 8. a. Low level alarm. Remove the sensor from the liquid. The alarm should indicate a dry condition in approximately 5 to 15 seconds depending upon application. If the response time to detect a dry condition is too long, rotate P1 clockwise 1⁄2 turn and test again. b. High level alarm. Remove the sensor from the liquid and allow for the red LED (D10 or D11) to turn on. Submerge the sensor in still liquid; the alarm should indicate in approximately three seconds. If the response time to detect liquid is too long, rotate P1 (set point) counterclockwise 1⁄2 turn and test again. 9. If high level fail-safe operation is desired, move the jumper to the “H” position, as described on page 4. 9 Thermatel Model TDF/TDL and TSF/TSL Thermal Dispersion Flow/Level Switch, 54-601 2.7.3 Adjust Set Point Following is a quick guide for adjusting the set point on Thermatel Flow/Level Switch. Process condition LED status Low flow ● off Adjust to detect High flow, High level Low flow, Low level — OK Low level ✲ on — o Turn P1 clockwise until LED is off. High flow ● off o Turn P1 clockwise until LED is on. — High level ✲ on OK — NOTE: Jumper is in low level fail-safe (LLFS) position. 2.7.4 Time Delay Adjusting P2 clockwise will increase the time delay between reaching the set point and energizing or de-energizing the relay. For fastest response, keep P2 in the full counterclockwise position. 2.7.5 Electronic Self-test – TSF/TSL Electronics Only Jumper JP10 (refer to Figure 5B on page 4) 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 4. 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. Thermatel Model TDF/TDL and TSF/TSL Thermal Dispersion Flow/Level Switch, 54-601 10 2.7.6 Advanced Calibration Procedure Measure and record the voltage between TP1 and TP2. This voltage will change with set point and may be used for future reference or adjustment of set point. 2.7.7 Power On Delay The TSF/TSL 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 4. With the jumper in the 12 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. 11 Thermatel Model TDF/TDL and TSF/TSL Thermal Dispersion Flow/Level Switch, 54-601 3.0 General Information 3.1 Maintenance 3.1.1 Cleaning 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 +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. 3.1.2 Probe Replacement – Integral Housing 1. 2. 3. 4. 1. 2. 3. 4. 5. Removal of probe Make sure the power source is turned off. Unscrew and remove housing cover. Loosen the screws on the six position terminal block (TB2) to remove the four leads from the probe. Unscrew probe from enclosure. Installation of replacement probe (Refer to Figure 5 on page 4.) The probe's leads have been separated at the factory. Connect leads from RTD #1, which are grouped and marked, to terminal block TB2 at the numbers 3 and 6 position. Connect the other pair of leads, which are not marked, to terminal block TB2 at the numbers 2 and 5 position. Replace housing cover. Apply power. After probe is installed, proceed to Gain adjustment. Section 3.1.4. 3.1.3 Probe Replacement – Remote Housing Removal of probe 1. Make sure the power source is turned off. 2. Unscrew and remove housing cover. Thermatel Model TDF/TDL and TSF/TSL Thermal Dispersion Flow/Level Switch, 54-601 12 3. Loosen the screws on the four position terminal block (TB1) to remove the leads from the probe. 4. Unscrew probe from enclosure. Installation of replacement probe (Refer to Figure 6 on page 6.) 1. The probe's leads have been separated at the factory. Connect leads from RTD #1, which are grouped and marked, to the two terminals on TB1 closest to the sensor label (refer to Figure 6). 2. Connect the other pair of leads, which are not marked, to the remaining two positions on TB1. 3. Replace housing cover. 4. Apply power. 5. After probe is installed, proceed to Gain adjustment. 3.1.4 Gain Adjustment (Refer to Figure 5 on Page 4) 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 on the TDF/TDL or D11 on the TSF/TSL electronics) 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 6 and 7 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 in section 2.7. Note: If P1 is rotated fully clockwise (until clicks are heard) and the red LED (D10 or D11) does not go out, then the gain is too high. Reduce the gain by turning P3 counterclockwise and repeat. 13 Thermatel Model TDF/TDL and TSF/TSL Thermal Dispersion Flow/Level Switch, 54-601 4.0 Reference Information 4.1 Specifications Description Supply Voltage Specification 120 VAC, +10%, -15% 50-60 Hz 240 VAC, +10%, -15% 50-60 Hz 24 VDC, ±20% Power Consumption 5 Watts maximum Output Relay TD Electronics Gold Flash Contacts SPDT, 10 Amp, 120 VAC, 250 VAC 8 Amp, 30 VDC, 0.5 Amp, 125 VDC TS Electronics Gold Flash Contacts DPDT, 10 Amp, 120 VAC, 250 VAC 10 Amp, 28 VDC, 0.5 Amp, 125 VDC or Hermetically Sealed DPDT 5 Amp, 120 VAC, 250 VAC 5 amp, 28 VDC Operating temperature Electronics -40° F to +160° F (-40° C to +71° C) Operating temperature ➀ Sensor -100° F to +392° F (-73° C to +200° C) High temperature design -100° F to +850° F (-73° C to +454° C) Response Type 1 to 10 seconds (typical - liquid) Set Point Range–Flow Water: 0.01 to 5.0 fps (0.003 to 1.5 m/s) Air: 0.1 to 500 fps (0.3 to 150 m/s) Time Delay 0-100 seconds adjustable Repeatability <1% @ constant temperature Probe Materials of Construction Twin Tip All wetted parts of 316L stainless steel, Hastelloy C, or Monel Spherical Tip/ Low Flow Body 316L stainless steel Process Connection Refer to part number construction Probe Insertion Length ➁➂ 2" (5 cm) minimum. Available in lengths from 2 to 130" in 1" increments (5 to 330 cm in 1 cm increments) 1 ⁄2" NPT, 1" (2.5 cm) minimum. Available insertion lengths from 1" to 60" (5 to 152 cm) Cable Length 500 ft. maximum (152 meters maximum) Shipping Weight 4.6 lbs. (w/2" probe) ➀ Remote electronics or heat extension recommended for operating temperatures greater than +250° F (+121° C). ➁ Probes longer than 30" (76 cm) must be secured within the pipe or duct by the customer to prevent movement of the probe. Consult factory for assistance. ➂ Consult factory for longer lengths. Thermatel Model TDF/TDL and TSF/TSL Thermal Dispersion Flow/Level Switch, 54-601 14 4.1 Specifications (cont.) DIMENSIONAL SPECIFICATIONS INCHES (MM) 5.25 (133) Rotation clearance NEMA 4X/7/9: 3.44 (87) 3/4" NPT Conduit connection 6.95 (177) 3.87 (98) 9.18 (233) 9.25 (235) NPT Process connection 1.57 (44) 1.57 (44) BSP Thread Insertion length* NPT Insertion length* 1" NPT Conduit connection 1" NPT Conduit connection NPT Insertion length* .87 (22) Dia. 2.18 (55) NPT Process connection Welded flange process connection BSP Thread Insertion length* .87 (22) Dia. Insertion length .87 (22) Dia. Figure 10 Figure 11 Figure 12 NEMA 4X/7/9 Group C, D, E, F, & G, Cast Aluminum or Stainless Steel Housing NEMA 4X/7/9 Group B, Polymer Coated Cast Iron Housing Housing Code J NEMA 4X/7/9 Group B, Cast Aluminum Housing Housing Code R 3.44 (87) NEMA 4X/7/9 7.75 (197) 3/4" NPT Conduit connection 2 Holes .38 (10) dia. 2.37 (60) 2.00 (51) 3.00 (76) 2.00 (51) 3.50 (89) 15 2 Holes .38 (10) dia. 3.75 (95) 1/2" 3/4" NPT (std.) NPT (opt.) Transducer/Amplifier cable connector 2.37 (60) Optional mounting bracket 1/4" or 1/2" NPT or BSP 3.00 (76) 3.50 (89) 3.75 (95) 1.25 (32) Side view 2.0 (51) Front view Figure 13 Figure 14 Remote Electronics Housing Low Flow Body Thermatel Model TDF/TDL and TSF/TSL Thermal Dispersion Flow/Level Switch, 54-601 4.1 Specifications (cont.) DIMENSIONAL SPECIFICATIONS INCHES (MM) 4.63 (118) Dia. 3.00 (76) Rotation clearance 2.75 (70) 8.00 (203) Insertion length ➁ Insertion length ➀ 3/4" NPT Conduit connection 10.75 (273) .87 (22) Dia. .62 (16) Dia. Insertion length ➂ Figure 17 Figure 15 Figure 16 Remote Sensor Housing Spherical Tip Probe 1 ⁄2" NPT Probe ➀ Insertion length: 2" to 130" in 1" increments (5 to 330 cm in 1 cm increments). Consult factory for longer lengths. ➁ Insertion length: 1" (2.5 cm) minimum; 2" to 60" (5 to 152 cm) available. Figure 18 High Temperature Probe with 8" heat extension ➂ Insertion length: 2" to 36" (5 to 91 cm) Pressure/Temperature Rating Tip Style Insertion Length 2" (5 cm) 3–130" (6–330 cm) Spherical 2–130" (5-330 cm) 1" (2.5 cm) Twin w/ 1⁄2" NPT process connection 2–60" (5–152 cm) Low flow body — High temperature 2–36" (5–90 cm) Twin Pressure/Temperature Rating +100° F (+38° C) +392° F (+200° C) +850° F (+450° C) 3000 1250 600 3000 1850 5800 6000 psig psig psig psig psig psig psig (206 bar) (86 bar) (41 bar) (206 bar) (127 bar) (400 bar) (413 bar) 2280 1140 415 2280 1680 4100 4280 psig psig psig psig psig psig psig (157 bar) — (78 bar) — (28 bar) — (157 bar) — (115 bar) — (285 bar) — (295 bar) 3380 psig (233 bar) Thermatel Model TDF/TDL and TSF/TSL Thermal Dispersion Flow/Level Switch, 54-601 16 4.2 Troubleshooting Is the unit getting supply voltage? Is the yellow power LED lit? NO YES Does the red LED (D10 or D11) and relay change state? NO YES NO Are results within specified range? YES Does the unit respond to flow or level change? NO Check voltage at terminal strip. Check fuse. Turn time delay (P2) fully counterclockwise. Move fail-safe jumper to opposite position. Replace PC board. With an ohmmeter set at 200 ohm scale, check resistance on TB2 between terminals: 2 and 5 = 90–180 ohms (275 ohms for High Temperature probe) 3 and 6 = 90–180 ohms (275 ohms for High Temperature probe) 1 and 2 = 0–12 ohms 3 and 4 = 0–12 ohms 5 and 6 = 0–12 ohms Replace sensor. Recalibrate the unit (refer to Operation and Calibration section on page 5). Does sensor extend at least 10% into flow? NO Replace with properly sized sensor. YES YES Adjust gain, refer to Gain Adjustment procedure, section 3.1.4, and recalibrate. Test complete. 4.3 Agency Approvals 4.3.1 FM (Factory Mutual) ➀ AGENCY MODEL APPROVED APPROVAL CATEGORY TXX-XXX0-E00 Explosion Proof APPROVAL CLASSES Class I, Div 1; Groups C, D Class II & III, Div 1; Groups E, F, G TXX-XXX0-Y00 Nema Type 4X and IP65 TXX-XX00-J00 Explosion Proof Class I, Div 1; Groups B, C, D Class II & III, Div 1; Groups E, F, G TXX-XXX0-R00 NEMA Type 4X and IP 65 TXX-XXX0-E00 Non-Incendive Class I, Div 2; Groups A, B, C, D TXX-XXX0-R00 Class II & III, Div 2; Groups E, F, G T4A TXX-XXX0-J00 NEMA Type 4X and IP 65 TXX-XXX0-Y00 PROBE MODEL ➁ Explosion Proof XTX-XXXX-XXX Class I, Div 1; Groups B, C, D XT9-XXXX-X00 Class II & III, Div 1; Groups E, F, G ➁ NEMA Type 4X and IP 65 17 Thermatel Model TDF/TDL and TSF/TSL Thermal Dispersion Flow/Level Switch, 54-601 4.3 Agency Approvals 4.3.2 CSA (Canadian Standards Association) ➀ AGENCY MODEL APPROVED TXX-XXX0-E00 APPROVAL CATEGORY Explosion Proof APPROVAL CLASSES Class I, Div 1; Groups C, D Class II & III, Div 1; Groups E, F, G T4A TXX-XXX0-Y00 Type 4X TXX-XX00-J00 Explosion Proof Class I, Div 1; Groups B, C, D ➂ Class II & III, Div 1; Groups E, F, G T4A TXX-XX00-R00 Type 4X TXX-XXX0-E00 Suitable for Class I, Div 2; Groups A, B, C, D TXX-XXX0-R00 Class II & III, Div 2; Groups E, F, G T4A TXX-XXX0-J00 Type 4X TXX-XXX0-Y00 PROBE MODEL ➁ Explosion Proof Class I, Div 1; Groups B, C, D ➁ XTX-XXXX-XXX Class II & III, Div 1; Groups E, F, G XT9-XXXX-X00 Type 4X 4.3.3 CENELEC (Comité Européen de Normalisation Electotechnique) ➃ AGENCY MODEL APPROVED TXX-XXX0-U00 APPROVAL CATEGORY Explosion Proof TXX-XXX0-V00 APPROVAL CLASSES EEx d II C T5 (-20 C° to +90° C) T4 (-40 C° to +55° C) TXX-XXX0-W00 4.3.4 SAA MODEL APPROVED TDF-1100-E00 APPROVAL CATEGORY Explosion Proof APPROVAL CLASSES Ex d IIC (Hydrogen Only) T6 IP65 TDF-1120-E00 ➀ FM/CSA approved based on a maximum temperature rise of sensor of 180° F (100° C) above the process temperature. These units have been tested to EN 50081-2 and EN 50082-2 and are in compliance with the EMC Directive 89/336/EEC. ➁ Probe type XT1-XXX0-XXX limited to Class I Locations only. Class II, Groups E, F & G approval only with spherical tip (XT2-XXX0-XXX) ➂ CSA approval for Group B with integral electronics only. ➃ Other CENELEC approved model available. Thermatel Model TDF/TDL and TSF/TSL Thermal Dispersion Flow/Level Switch, 54-601 18 4.3.5 Explosion Proof 4.4 Parts 8 2 10 4 9 11 5 7 3 1 6 12 13 14 Front view 19 Side view Thermatel Model TDF/TDL and TSF/TSL Thermal Dispersion Flow/Level Switch, 54-601 4.4.2 Replacement Parts Item Description 1 Base NEMA 4X/7/9 2 Cover, NEMA 4X/7/9 3 O-Ring, NEMA 4X/7/9 4 Main PC Board Integral Sensor 120 VAC 240 VAC 24 VDC Main PC Board Remote Electronics 120 VAC 240 VAC 24 VDC Main PC Board, Integral Electronics 120 VAC 240 VAC 24 VDC Main PC Board, Remote Electronics 120 VAC 240 VAC 24 VDC Bracket Kit Remote Mounting Bracket 1 ⁄2" NPT Conduit Connection 3 ⁄4" NPT Conduit Connection Remote Sensor Housing Base Remote Sensor Housing Cover Remote Sensor Housing O-Ring Remote Sensor PC Board Remote Sensor Bracket Kit Standard Probe 316L Stainless Steel Hastelloy C Monel High Temperature Probe 316L Stainless Steel Hastelloy C Low Flow Body 5 6 7 8 9 10 11 12* 13* 14 Part Number 004-9182-003 002-6204-600 012-2101-345 TDF/TDL with 10 amp SPDT relay Z30-3536-002 Z30-3536-004 Z30-3536-006 TSF/TSL with 10 amp DPDT relay Z30-3572-001 Z30-3572-003 Z30-3572-005 Z30-3536-003 Z30-3536-005 Z30-3536-007 Z30-3572-002 Z30-3572-004 Z30-3572-006 TSF/TSL with 5 amp Hermetic Sealed relay Z30-3571-001 Z30-3571-003 Z30-3571-005 Z30-3571-002 Z30-3571-004 Z30-3571-006 089-5212-001 036-3805-001 036-3805-003 004-9104-001 004-9105-001 012-2101-345 Z30-3540-001 089-5212-002 XTX-X220-XXX XTX-XHC0-XXX XTX-XMM0-XXX XTH-XXS0-XXX XTH-XXH0-XXX XT9-X22X-XXX *XXX = Insertion length in inches or centimeters Example: 4T1-1220-012 has a 12 inch insertion length; 6T1-1220-012 has a 12 cm insertion length Thermatel Model TDF/TDL and TSF/TSL Thermal Dispersion Flow/Level Switch, 54-601 20 4.5 Model Numbers 4.5.1 Electronics Models BASIC MODEL NUMBER D Standard (TD) SPDT Relay S On-demand electronic self-test (TS) DPDT relay APPLICATION F Flow L Level OUTPUT 1 10 Amp SPDT relay w/gold flashed contacts (Model TD) 2 10 Amp DPDT relay w/gold flashed contacts (Model TS) 4 5 Amp hermetically sealed DPDT relay w/gold flashed contacts (Model TS) INPUT VOLTAGE 0 120 VAC 1 240 VAC 2 24 VDC MOUNTING 0 Integral 2 Remote (includes electronics housing bracket and remote sensor housing) HOUSING E NEMA 4X/7/9 Polymer coated aluminum dual conduit connection, 3⁄4" NPT J R NEMA 4X/7/9 Polymer coated cast iron (integral only) Group B Single conduit connection, 1" NPT NEMA 4X/7/9 Polymer coated die-cast aluminum Group B U CENELEC * V CENELEC * Y NEMA 4X/7/9 W CENELEC * dual conduit connection, 1" NPT Polymer coated aluminum dual cable entry, PG 13.5 Polymer coated aluminum dual cable entry, 3⁄4" NPT 316 stainless steel, single conduit connection, 3⁄4" NPT Polymer coated aluminum, dual cable entry, M 20 X 1.5 *additional CENELEC approved housings available; consult factory. T 21 0 0 0 complete order code for Thermatel Electronics Thermatel Model TDF/TDL and TSF/TSL Thermal Dispersion Flow/Level Switch, 54-601 4.5 Model Numbers 4.5.2 Probe Models PROBE DESIGN 4 Probe length in inches 6 Probe length in centimeters TIP STYLE 1 Twin tip 2 Spherical tip – available in 316L stainless steel only (code 22) PROCESS CONNECTION* 1 3 ⁄4" NPT 2 1" NPT 3 11⁄2" sanitary flange 4 2" sanitary flange A 1 B 1" 150# C 11⁄2" 150# D 2" 150# E 1" 300# Raised faced flange F 1 ⁄2" 300# socket welded to probe G 2" 300# ⁄2" NPT – Twin tip, stainless steel only 1 H 1" 600# J 11⁄2" 600# K 2" 600# * DIN flange process connections available – consult factory MATERIAL 22 316L stainless steel HC Hastelloy C-276 MM Monel Construction to meet NACE Std. MR0175 is also available; consult factory. INSERTION LENGTH with PROBE DESIGN code 4 001 1" min. (1⁄2" NPT connection only) 002 2" min. (ESP with 3⁄4" NPT connection only) * 3" to 130" max. in 1" increments * Example: 4 inches = Code 004. For lengths over 130 inches, consult factory. INSERTION LENGTH with PROBE DESIGN code 6 003 2.5 cm min. (1⁄2" NPT connection only) 005 5 cm min. (ESP with 3⁄4" NPT connection only) * 6 to 330 cm max., 1 cm increments * Example: 25 cm = Code 025. For lengths over 330 cm, consult factory. T 0 Thermatel Model TDF/TDL and TSF/TSL Thermal Dispersion Flow/Level Switch, 54-601 complete order code for Thermatel Probe 22 4.5 Model Numbers 4.5.3 High Temperature Probe* Models High temperature probe includes 8" (20 cm) heat extension PROBE DESIGN 4 Probe length in inches 6 Probe length in centimeters PROCESS CONNECTION* 11 3 ⁄4" NPT 21 1" NPT 23 1" 150# 24 1" 300# 25 1" 600# 26 1" 1500# 33 11⁄2" 150# 34 11⁄2" 300# Raised faced flange 35 11⁄2" 600# socket welded to probe 36 11⁄2" 1500# 37 11⁄2" 2500# 43 2" 150# 44 2" 300# 45 2" 600# 46 2" 1500# 47 2" 2500# * DIN flange process connections available – consult factory MATERIAL S 316L stainless steel H Hastelloy C-276 INSERTION LENGTH with PROBE DESIGN code 4 or 5 002 to 036 2" to 36" max. in 1" increments Example: 4 inches = Code 004 INSERTION LENGTH with PROBE DESIGN code 6 or 7 T 23 H 0 005 5 cm minimum 007 to 091 7 cm to 91 cm max. in 1 cm increments Example: 8 cm = Code 008 complete order code for Thermatel High temperature probe Thermatel Model TDF/TDL and TSF/TSL Thermal Dispersion Flow/Level Switch, 54-601 4.5 Model Numbers 4.5.4 Low Flow Body Models LOW FLOW DESIGN 4 Standard FLOW BODY CODE C 1 D 1 ⁄4" ⁄2" PROCESS CONNECTION 1 NPT 2 BSP MOUNTING BRACELET T 9 2 2 0 None 1 Provided 0 0 complete order code for Thermatel Low flow body 4.5.5 Connecting Cable Models CONNECTING CABLE IN FEET Cable length in feet; 10 feet minimum, 500 feet maximum length Example: 12 feet = Code 012 0 3 7 3 1 8 6 complete order code for Thermatel Connecting cable CONNECTING CABLE IN METERS 3 meters minimum, 152 meters maximum length Example: 3 meters = Code 003 0 3 7 3 1 9 8 Thermatel Model TDF/TDL and TSF/TSL Thermal Dispersion Flow/Level Switch, 54-601 complete order code for Thermatel Connecting cable 24 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 3. 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 © 2003 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. The brand and product names contained within this document are trademarks or registered trademarks of their respective holders. BULLETIN: 54-601.14 EFFECTIVE: February 2003 SUPERSEDES: May 2002