Thermatel TDF-TSF Instruction Manual BE54-601

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]