Thermatel®
Model TD1/TD2
Installation and Operating Manual
Thermal Dispersion
Flow/Level/Interface
Switch
Model TD2
with spherical probe
Model TD1
with twin-tip probe
Model TD2
with low flow body
Model TD2
with hygienic stainless
steel enclosure
& spherical tip probe
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
Installation Category II, Pollution Degree 2. 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.
Electrical components are sensitive to electrostatic discharge. To prevent equipment damage, observe safety
procedures when working with electrostatic sensitive
components.
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 Installation Category II. If equipment is used
in a manner not specified by the manufacturer, protection
provided by equipment may be impaired.
Notice of Copyright and Limitations
Magnetrol® & Magnetrol® logotype, and Thermatel® are
registered trademarks of Magnetrol® International,
Incorporated.
Copyright © 2012 Magnetrol® International, Incorporated.
All rights reserved.
Performance specifications are effective with date of issue
and are subject to change without notice. MAGNETROL
reserves the right to make changes to the product
described in this manual at any time without notice.
MAGNETROL makes no warranty with respect to the
accuracy of the information in this manual.
Warranty
All MAGNETROL 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 will repair or replace the control at no
cost to the purchaser (or owner) other than transportation.
MAGNETROL 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
products.
Quality Assurance
The quality assurance system in place at MAGNETROL
guarantees the highest level of quality throughout the
company. MAGNETROL is committed to providing
full customer satisfaction both in quality products and
quality service.
The MAGNETROL 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.
54-610 Thermatel® Model TD1/TD2 Flow Level Switch
Thermatel® Model TD1/TD2
Thermal Dispersion Flow/Level Switch
Table of Contents
1.0 Quick Start
2.0 Installation
2.1 Unpacking ................................................................4
2.2 Electrostatic Discharge (ESD) Handling Procedure...4
2.3 Mounting..................................................................5
2.4 Wiring ......................................................................6
2.4.1 Relay Connections .........................................7
2.4.2 Remote Electronics Wiring (TD2 only) .........8
2.4.3 mA Output Wiring (TD2 only).....................8
2.5 Setup.........................................................................9
2.5.1 Switch Settings ...............................................9
2.5.2 LED Operation ............................................10
2.5.3 LED Initialization ........................................10
2.5.4 Time Delay (TD2 only) ...............................10
2.6 Calibration..............................................................11
2.6.1 Adjustment Procedure for
LEVEL Applications.....................................11
2.6.1.1 Unable to Change Level ........................13
2.6.2 Adjustment Procedure
LOW FLOW/NO FLOW............................13
2.6.3 Adjustment Procedure for
HIGH FLOW Detection .............................14
2.6.3.1 Unable to Change Flow Rate ................14
2.6.4 Advanced Calibration Procedure (TD2).......15
3.0 Reference Information
3.1 Description .............................................................16
3.2 Theory of Operation...............................................16
3.3 Fault Detection .......................................................17
3.4 Resistance Values.....................................................17
3.5 Troubleshooting ......................................................18
3.6 Maintenance ...........................................................19
3.6.1 Cleaning.......................................................19
3.6.2 Probe Replacement.......................................19
3.6.2.1 Integral Electronics................................19
3.6.2.2 Remote Electronics (TD2) ....................20
54-610 Thermatel® Model TD1/TD2 Flow Level Switch
3.7 Agency Approvals....................................................21
3.8 Replacement Parts...................................................22
3.8.1 Model TD1 ..................................................22
3.8.2 Model TD2 ..................................................23
3.9 Specifications ..........................................................24
3.9.1 Performance .................................................24
3.9.2 Probe............................................................25
3.9.3 Physical ........................................................26
3.10Model Numbers......................................................27
3.10.1 Model TD1 .................................................27
3.10.2 Model TD2 .................................................27
3.10.3 Standard Probe ............................................28
3.10.4 High Temperature Probe .............................29
3.10.5 Low Flow Body ...........................................30
3.10.6 Mini Sensor.................................................30
3.10.7 Connecting Cable........................................31
1.0
Quick Start
Unless ordered with factory calibration, the set point of
the unit must be adjusted for your application.
To calibrate, adjust the alarm set point potentiometer.
Turn the potentiometer clockwise to go out of alarm. Turn
potentiometer counterclockwise to cause the switch to go
into alarm (red LED on). Refer to the Calibration section
on page 11 for detailed procedure.
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.
Serial Number
2.2
Electrostatic Discharge (ESD)
Handling Procedure
1.
2.
3.
4.
4
Magnetrol® 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:
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.
Use a grounding wrist strap when installing and removing
circuit boards. A grounded workstation is also recommended.
Handle printed circuit boards only by the edges. Do not
touch components or connector pins.
Ensure that all electrical connections are completely made
and none are partial or floating. Ground all equipment to
a good, earth ground.
54-610 Thermatel® Model TD1/TD2 Flow Level Switch
2.3
Mounting
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.
THERMATEL Flow/Level Switches should be located to
allow easy access for service. During operation the electronics
should not be exposed to ambient temperature above
+158° F (+70° C) or below -40° F (-40° C). Special precaution should be taken to prevent exposure to corrosive
atmosphere, excessive vibration, shock or physical damage.
The switch can be exposed to storage temperature of
-58° F (-50° C).
NOTE: All wiring, conduit and electrical fittings must conform to local
electrical codes for the location selected.
Figure 1
Mounting
The THERMATEL Flow/Level Switch has a standard
3
⁄4" NPT mount designed for easy installation through a
threaded connection. Optional threaded and flanged connections are also available.
1. Apply thread sealant to the sensor and insert the sensor
into the threaded connection.
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.
Figure 2
Mounting
2. Make sure the sensor is properly oriented to the flow (refer
to Figures 3 and 4) or level (refer to Figure 5).
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.
Direction of
Level Movement
Direction
of Flow
Direction
of Flow
Figure 3
Figure 4
Figure 5
Tee Connection
Low Flow Body
Level
54-610 Thermatel® Model TD1/TD2 Flow Level Switch
5
2.4
Wiring
The wiring connections for the power and relay are
suitable for 12–24 AWG wire.
Caution: OBSERVE ALL APPLICABLE ELECTRICAL CODES
AND PROPER WIRING PROCEDURES.
NC
C
NO
NC
C
NO
POWER
HEATER
TEMP COMP
MEDIA
RANGE
FAILSAFE
FAULT
O G
F A
F S E
O
H F
L F
ALARM
O L S
N I
Q
L O
L N
MODEL TD1
Figure 6
TD1 Wiring
Relay
Power
mA
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. Refer to Figure 6
for TD1 or Figure 7 for TD2 electronics. Note that the
TD1 is only available with 24 VDC input power. The
TD2 is available for AC power (100 to 260 VAC) or as a
DC power (19.2 to 28.8 VDC).
a. AC power – Connect “hot” wire to terminal marked L1
and the “neutral” wire to the terminal marked L2/N (TD2
Only). The green screw should be used for grounding.
b. DC Power – Connect wires to terminals (+) and (-) on the
terminal block. Unshielded cable can be utilized.
5. Perform Relay Connections (refer to Figure 6 for TD1 or
Figure 7 for TD2 electronics).
6. Prevent moisture seepage into housing by installing an
approved seal drain fitting in the conduit run leading to
the unit.
7. Installation is complete. Replace housing cover.
Caution: In hazardous areas, do not power the unit until the
conduit is sealed and enclosure cover is screwed
down securely.
L1
L2
NC
C
NO
NC
C
NO
TP2
TP1
TIME
DELAY
ALARM
MODEL TD2
Figure 7
TD2 Wiring
6
NOTE: For supply connections use wire with a minimum rating of
+75° C, as required by process conditions. Use a minimum of
12–16 AWG wire for power and ground field wires.
NOTE: An approved disconnect device and current limiting device or
circuit breaker, maximum 15A shall be installed in close proximity to equipment and within easy reach of operator.
It shall be marked as the disconnecting device for the equipment.
NOTE: Housing must be grounded via protective ground screw in the
base of the housing.
54-610 Thermatel® Model TD1/TD2 Flow Level Switch
2.4.1 Relay Connections
TD1/TD2:
DPDT
8 amp at 120–250 VAC
8 amp at 30 VDC, 0.5 amp at 125 VDC resistive
TD2 with Hermetically sealed relay:
DPDT 1 amp at 28 VDC, 0.5 amp at 125 VDC resistive
The switch may be configured so that the relay either
energizes or de-energizes when the set point is reached.
Locating the fail-safe switch in the LL position places the
switch in a low level fail-safe (LLFS) position. This causes
the relay to energize when the flow rate is higher than the
set point or when the sensor is immersed. Locating the
fail-safe switch in the HL position places the switch in a
high level fail-safe (HLFS) position. This causes the relay to
energize when the flow rate is less than the set point or
when the sensor is dry. Refer to the following chart.
Power
On
On
Fail
Fail
Flow Level
Fail-Safe Position
High
Low
High
Low
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
Chart Notes and Definitions
1. Equipment controlled by the THERMATEL relay is assumed to be powered from
one source, while the THERMATEL unit itself is assumed to be powered from a
different source.
2. “Fail” means a loss of power to the THERMATEL unit.
3. HL means a flow rate or level which is above the adjusted set point.
4. LL means a flow rate or level which is less than the adjusted set point.
5. 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).
6. 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.
54-610 Thermatel® Model TD1/TD2 Flow Level Switch
7
2.4.2 Remote Electronics Wiring (TD2 only)
When using remote electronics, the sensor and electronic circuit board are contained in separate enclosures. A
six conductor shielded cable is required for connection
between the enclosures.
TD2 Electronics
6
1
TB4
1 - white
2 - black
3 - red
4 - green
5 - orange
6 - blue
The cable is routed to the electronic circuit board and
connected to the green, 6-position terminal block (TB4).
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 sensor housing. If the cable is
supplied by MAGNETROL, then this connection is
pre-wired at the circuit board. The user only needs to
connect the wiring at the terminal connection on the
sensor enclosure.
If cable is supplied by user, remove bezel by placing
screwdriver blade in slot in center of bezel and gently
pull the handle away from the terminal strips. Then
remove screws and lift out the electronic module. Attach
the cable wiring as shown in Figure 8.
The sensor enclosure includes a 6-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 enclosure. The cable shield is
connected to the green ground screw. Refer to Figure 8
for the pin numbers.
NOTE: The six conductors must be wired so that each terminal on
the sensor terminal block TB4 (see Figure 8) is connected
to its corresponding terminal on the electronic circuit board.
Failure to do so will cause improper switch operation.
2.4.3 mA Output Wiring (TD2 only)
Shield
1 2 3 4 5 6
The TD2 will output a mA signal which can be used for
diagnostics or to provide trend indication from the
switch. This mA output represents the sensor signal.
The signal cannot be scaled by the user. The output is
proportional to the flow rate. The range of outputs will
vary for each unit due to differences in probes. The
range of the mA output is also dependent upon the
switch setting (section 2.5).
The mA output can also be used for fault detection. In
the event of a fault, the mA output will be greater than
22 mA if HLFS is selected or less than 3.6 mA if LLFS
is selected.
Sensor Enclosure
Figure 8
The mA output is isolated from the input power.
Wiring of the mA output is shown in Figure 7 on page 6.
Wiring should be 16 to 26 AWG.
NOTE: Due to ATEX requirements, the mA output is not
provided on the TD2-XD0X-XCX.
8
54-610 Thermatel® Model TD1/TD2 Flow Level Switch
2.5
NC
C
NO
NC
C
Setup
2.5.1 Switch Settings
NO
POWER
The TD1 and TD2 have a series of switches which may
require field adjustment depending upon the application.
Switch position for the TD1 is shown in Figure 9 and
switch position of the TD2 is shown in Figure 10.
HEATER
TEMP COMP
MEDIA
RANGE
FAILSAFE
FAULT
O G
F A
F S E
O
H F
L F
ALARM
O L S
N I
Q
There are two sets of switches on the TD1/TD2. One set
has 4 switches, the second set has two switches.
L O
L N
MODEL TD1
The switch settings are set at MAGNETROL during
setup. Changes in the positions may be required in the
field depending upon the application. There is a tag wired
onto the switch which indicates the default settings. See
Figure 11. Use the following table for recommended
switch settings.
Figure 9
TD1
L1
L2
NC
C
NO
NC
C
NO
TP2
TP1
TIME
DELAY
ALARM
MODEL TD2
Four-position Switch
Figure 10
Switch
TD2
Heater
Purpose
Options
Control heat to sensor See sensor table below
Default is “+”
Temperature
Compensation
ON/OFF
See sensor table below
Default is “on”
Media
Gas/liquid
Select
Default is liquid “L”
Use gas “G” position
only for gas flow
applications
Range
Expand sensitivity for
water flow applications
Switch to “E” position
for water flow
applications to
improve sensitivity
Default is “S”
Two-position Switch
Fail-safe
HL = High Level Fail-safe
LL = Low Level Fail-safe
Fault detection
Should be on (some applications may require
that this be turned off, see Section 3.5).
Sensor
Sensor
Spherical Tip
(TXA, TXB)
Application
Heater
TempComp
Media
Liquid Flow
+
+*
+
+*
+
+
+
+
on
L
on
G
on
L
Gas Flow
Level
Liquid Flow
Twin Tip
(TXC, TXD)
Gas Flow
Level
Liquid Flow
HTHP
(TXH)
Figure 11
Gas Flow
Level
TD1/TD2 Setup Tag
Flow Body
(TXL)
Liquid Flow
Gas Flow
on
L
on
G
on
L
on
L
on
L**
on
L
on
L
on
L*
* Applications at no flow or low flow should be set with heater to “-”.
** For best results use “L” setting for HTHP probe and low flow body.
54-610 Thermatel® Model TD1/TD2 Flow Level Switch
9
2.5.2 LED Operation
TD1 – Two LEDs (Green & Red)
• Green LED glows when power is on.
• Red LED, glows when an alarm condition exists. The
LED operation is independent of relay operation.
• The red LED will blink rapidly if the switch detects a fault.
It will blink slowly during initial power-on.
TD2 – Four LEDs (Red, Yellow, & 2 Green)
LEDs indicate alarm status and fault indication. The LED
operation is independent of relay operation.
• Red LED glows when an alarm condition exists. It will
blink if the switch detects a fault.
• Yellow LED glows when approaching an alarm condition
• Green LEDs glow as the actual condition is further away
from the alarm set point. This represents a safe mode.
2.5.3 LED Initialization
The TD1/TD2 has an initializing period to allow the
sensor to heat up.
TD1 – The red LED will blink slowly during the initialization period.
TD2 – All LEDs will turn on then individually turn off.
When complete the TD2 will resume normal operation.
2.5.4 Time delay (TD2 only)
Turning the time delay potentiometer clockwise increases
response time. This adjustment adds time delay in addition to the sensor response time. Generally this is set to
full counterclockwise position unless additional time delay
is required due to pulsating flow, turbulence, or splashing.
If time delay is used, the red alarm LED will first illuminate when an alarm condition occurs, the relay activation
will occur after the appropriate time delay. Time delay
occurs while going into alarm. There is no time delay
(other than sensor response time) coming out of alarm.
10
54-610 Thermatel® Model TD1/TD2 Flow Level Switch
2.6 Calibration
Calibration must be performed using the actual fluid.
The switch detects the cooling capabilities of the media.
Calibrating the switch in a different media may change
the set point.
NOTE: Set the switches (Section 2.5.1) to the desired position before
performing the calibration. Changing the Heater, Range,
Fail-safe, or Temperature Compensation settings will affect
the set point.
Alarm
Select the fail-safe mode (HL or LL) before performing the
calibration. The fail-safe selection does affect the calibration set point.
Turn
to go into alarm
Turn
to come out of alarm
Turning the alarm potentiometer clockwise to go from an
alarm condition to the normal (safe) condition. Turn the
alarm potentiometer counterclockwise to go into alarm.
NOTE: The LED operation changes with the fail-safe mode selection.
The red LED is illuminated when an alarm condition exists.
Switch Position
HLFS
LLFS
High Level Fail-safe
HLFS – The switch goes into alarm under a wet (high
level) condition or if the flow rate has increased above the
set point. On the TD2, the green and yellow LEDs will be
on at low flows or low level indicating a normal condition.
The number of green LEDs illuminated will decrease as
the flow rate increases.
Low Level Fail-safe
LLFS – The switch goes into alarm under a dry (low level)
condition or if the flow rate has dropped below the set
point. On the TD2, the green and yellow LEDs will be on
at high flow rates or high level indicating a normal condition. The number of green LEDs illuminated will decrease
as the flow rate decreases.
2.6.1 Adjustment Procedure for LEVEL Applications
1. Place HTR Switch in "-" position ( ).
2. Set desired fail-safe condition.
3. Ensure time delay potentiometer (TD2 only) is fully counterclockwise (rotate 30 turns or until clicks are heard).
4. Immerse in still liquid. Wait a minimum of 3 minutes for
the sensor to stabilize. (On the TD2, the mA output can
be monitored to determine when stable).
Follow procedure below for either High Level, Low Level,
or interface applications.
54-610 Thermatel® Model TD1/TD2 Flow Level Switch
11
High Level Adjustment
(High Level Fail-safe)
Turn
for faster response to detect
a high level (wet) condition
5a. High Level Applications
a. Set fail-safe switch to the “HL” position (switch up ).
b. Turn alarm potentiometer counterclockwise until red
LED turns on.
c. Turn alarm potentiometer clockwise until red LED
turns off.
d. Repeat steps b and c several times leaving the red
LED on.
e. Turn alarm potentiometer counterclockwise one
additional turn.
f. Remove from the liquid. The switch will reset.
g. Put back in liquid. If response time to detect level is too
long then turn one half turn counterclockwise and retest.
Turn alarm potentiometer counterclockwise for the switch to
respond quicker to detect level. Turn alarm potentiometer
clockwise to decrease time to detect dry condition.
Low Level Adjustment
(Low Level Fail-safe)
Turn
for faster response to detect
a low level (dry) condition
5b.Low Level applications
a. Set fail-safe switch to the “LL” position (switch
down ).
b. Turn alarm potentiometer counterclockwise until red
LED turns on.
c. Turn alarm potentiometer clockwise until red LED
turns off.
d. Repeat steps b and c several times leaving the red
LED off.
e. Turn alarm potentiometer clockwise 1⁄2 additional turn.
f. Remove from the liquid. If the response time to detect a
dry condition is too long, turn the alarm potentiometer
counterclockwise and retest.
5c. Interface applications
Follow either of the procedures above substituting the
oil (or low thermal conductive fluid) for the dry condition and water (or high thermal conductivity fluid) for
the wet condition.
6. The switch will typically detect level within 3 to 5 seconds
and detect a dry condition within 5 to 10 seconds. This
depends upon set point adjustment and type of sensor.
12
54-610 Thermatel® Model TD1/TD2 Flow Level Switch
2.6.1.1 Unable to Change Level
Typical Switch Settings:
(See page 9 for detail settings)
NC
C
NO
NC
C
NO
POWER
HEATER
TEMP COMP
MEDIA
RANGE
FAILSAFE
FAULT
O G
F A
F S E
O
H F
L F
ALARM
O L S
N I
Q
L O
L N
MODEL TD1
Figure 9
TD1
L1
L2
NC
C
NO
NC
C
NO
TP2
TP1
TIME
DELAY
ALARM
• Low Level: Follow the procedures in Step 5b, steps a–e on
page 12. Any change in media will cause a low level alarm
indication.
• High Level:
1. Ensure that the sensor is located above the level of the
fluid.
2. Set Fail-safe to the “HL” position ( ).
3. Turn alarm potentiometer counterclockwise until the red
LED goes on.
4. Turn alarm potentiometer clockwise until red LED goes
off. If unable to get the red LED to turn off, change the
HTR position to “–”.
5. Repeat steps 3 and 4 several times leaving the red LED off.
Turn potentiometer 1⁄2 additional turn clockwise.
6. Any change in media will cause the switch to go into alarm.
MODEL TD2
NOTE: The time to reset may be lengthy. This time can be decreased
by turning the potentiometer clockwise.
Figure 10
TD2
2.6.2 Adjustment Procedure LOW FLOW/NO FLOW
TD1
TD2
Heater
HTR
+ Flow Applications
- Level Applications
Temp Comp TC
Media
Media
ON
G Gas
Liquid Flow
and Level
L
HTHP and
low flow body
Range
Range
S Standard (default)
E Expanded
Fail Safe
FS
HL High Level
LL Low Level
Fault
FLT
OFF
ON Default
Low Flow Adjustment
(Low Level Fail-safe)
Turn
Faster response to
low flow or decrease
alarm point
1. Put HTR Switch in the "+" position ( ).
2. Place Fail-safe in the “LL” position ( ).
3. Reduce the flow rate to the desired alarm point. Allow 3
minutes for the sensor to stabilize.
4. Rotate alarm potentiometer clockwise until the red LED
turns off.
5. Rotate alarm potentiometer counterclockwise until the red
LED turns on.
6. Repeat steps 4 and 5 several times leaving the red LED in
the "on" position.
7. Resume full flow. The alarm should reset.
8. Reduce flow to no flow or the desired alarm point. If the
response time required to alarm is too long, rotate alarm
potentiometer counterclockwise 1⁄2 turn and test again.
9. If the response time required to sense flow is too long,
rotate the alarm potentiometer clockwise 1⁄2 turn and
test again.
10. Repeat steps 8 and 9 until desired response times for flow
and no flow are attained. Normal delays range from two
seconds to over fifteen seconds, depending on the fluid
and the flow rate.
Turn
Faster response to
reset or increase
alarm point
54-610 Thermatel® Model TD1/TD2 Flow Level Switch
13
2.6.3 Adjustment Procedure – HIGH FLOW Detection
1. Place Fail-safe in the “HL” position ( ).
2. Increase the flow rate to desired alarm point. Allow 3
minutes for the sensor to stabilize.
3. Rotate alarm potentiometer counterclockwise until the red
LED turns on.
4. Rotate alarm potentiometer clockwise until the red LED
goes out.
5. Repeat steps 4 and 5 several times leaving the red LED in
the “on” position.
6. Reduce flow to normal condition, the alarm should reset.
7. Increase flow to the desired alarm point. If the response
time required to detect high flow is too long, rotate alarm
potentiometer counterclockwise 1⁄2 turn and test again.
2.6.3.1 Unable to Change Flow Rate
1. Maintain flow rate at normal operating conditions. Allow
3 minutes for the sensor to stabilize.
2. Follow the procedures below for Low Flow Alarm or High
Flow Alarm.
Low Flow Alarm
a. Set fail-safe to “LL” position ( ).
b. Rotate alarm potentiometer counterclockwise until the red
LED turns on.
c. Rotate alarm potentiometer clockwise until the red LED
goes out.
d. Repeat steps b and c several times leaving the LED in the
off position. Continue to rotate the potentiometer 1⁄2 turn
clockwise. The set point is now just below the present flow
rate. When the flow rate drops below the present flow rate
the red LED will turn on and the relay will de-energize.
High Flow Adjustment
(High Level Fail-safe)
Turn
Faster alarm or
decrease alarm point
14
Turn
Faster reset or
increase alarm point
High Flow Alarm
a. Set fail-safe to “HL” position ( ).
b. Rotate alarm potentiometer counterclockwise until the red
LED turns on.
c. Rotate alarm potentiometer clockwise until the red LED
goes out.
d. Repeat steps b and c several times leaving the LED in the
"off" position. Continue to rotate the potentiometer 1⁄2
turn clockwise. The set point is now just higher than the
present flow rate. When the flow rate increases above the
present flow rate the red LED will turn on and the relay
will de-energize.
54-610 Thermatel® Model TD1/TD2 Flow Level Switch
2.6.4 Advanced Calibration Procedure (TD2 only)
Measure and record the voltage between TP1 and TP2.
This voltage will change as the set point potentiometer is
adjusted. Voltage readings will be between 0 and 5 VDC.
This value may be used for future reference or adjustment
of set point. This value can be recorded and checked in the
future to ensure that the set point has not changed since
last calibration.
NOTE: Due to ATEX requirements, these test points (TP1 and TP2)
are not provided on the TD2-XD0X-XCX.
54-610 Thermatel® Model TD1/TD2 Flow Level Switch
15
3.0 Reference Information
3.1
Description
THERMATEL TD1/TD2 switches are used for flow, level,
and interface detection and control. Level detection is
accomplished by sensing changes in the heat transfer characteristics of the media. Flow detection is accomplished by
sensing changes in heat transfer caused by the flowing media.
The TD1 is the basic version while the TD2 offers
advanced options including LED indication of flow/level,
optional remote electronics, mA output representing the
sensor signal, time delay, and a voltage signal representing
the set point of the unit.
Sensors are available in 316/316L stainless steel, Hastelloy C,
or Monel® welded construction. The easy to install and
adjust units provide reliable, low maintenance performance
in the most demanding applications.
®
Both switches have continuous diagnostics to detect a
failure of the sensor. This is accomplished by continuously
monitoring the signal from the sensor which must remain
within set levels. In the event the switch detects a fault,
the relay will de-energize and the red LED will blink.
3.2
Theory 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 (TD2 only).
Each element of the sensor is a miniature RTD (Resistance
Temperature Detector). One element measures the temperature of the process, 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. When the temperature difference reaches the
set point, the relay will change state. Sensor designs are
suitable for operation in temperatures of -100° to +850° F
(-73° to +454° C).
16
54-610 Thermatel® Model TD1/TD2 Flow Level Switch
3.3
4
Fault Detection
The TD1 and TD2 have continuous self diagnostics to
ensure the signal from the sensor is within a select range. If
the electronics detect an out of range signal, the switch will
go into fault mode.
1
In the event of a fault, the red LED will blink and the
relay will de-energize. In the TD2, the mA output will go
to less than 3.6 mA if low level fail-safe is selected or
greater than 22 mA if high level fail-safe is detected.
Unmarked Wires
Marked Wires
4
If a fault is detected, refer to 3.5 Troubleshooting.
1
3.4
Figure 12
TD1 Probe Connections
Resistance Values
The following tables provide the expected resistance values
for the sensor. Refer to the indicated figures for pin locations.
Refer to 3.6.2 Probe Replacement for removing bezel and
circuit boards.
TD1 (see Figure 12)
6
1
Pin
Expected Resistance
1 to 3
90 to 180 ohms
(275 ohms with high temperature probe)
2 to 4
90 to 180 ohms
(275 ohms with high temperature probe)
Unmarked Wires
Marked Wires
6
1
TD2 – Integral Electronics (see Figure 13)
TD2 – Remote Electronic Enclosure (see Figure 14)
Pin
Expected Resistance
1 to 3 or 4
90 to 180 ohms
(90 to 275 ohms with high temperature probe)
2 to 5 or 6
90 to 180 ohms
(90 to 275 ohms with high temperature probe)
Figure 13
TD2 Probe Connections
1 to 2, 3 to 4,
0 to 12 ohms
5 to 6
Shield
1 2 3 4 5 6
Figure 14
TD2 Remote Probe Connections
54-610 Thermatel® Model TD1/TD2 Flow Level Switch
17
3.5
Troubleshooting
The TD1/TD2 switches have various settings to handle a wide variety of flow and level applications.
If the switch is not performing properly, check the switch settings on page 9 or the following:
Symptom
Unable to adjust set point
to obtain alarm
Application
Air Flow Detection
Action*
Ensure that the probe is extended into the flow
Change HEATER (Model TD1) / HTR (Model TD2) to “–”
Fault LED blinks
Switch indicates a fault (red Liquid Level – Sensor Wet
LED will blink)
Verify HEATER (TD1) / HTR (TD2) is set to “–”
Liquid Level – Sensor Dry
Verify HEATER (TD1) / HTR (TD2) is set to “–”
Change HEATER/HTR to “+”
Light goes off—operate in this mode
Light stays on—check resistance to determine if a problem exists
with the probe or electronics. Refer to Section
3.4, Resistance Values on page 17. Probe
and/or electronics may need to be replaced.
Turn off FAULT (TD1) / FLT (TD2)
Light goes off—operate in this mode
Light stays on—check resistance to determine if a problem exists
with the probe or electronics. Refer to Section
3.4, Resistance Values on page 17. Probe
and/or electronics may need to be replaced.
Liquid Flow – Sensor Dry
or
No Air Flow
Turn off FAULT (TD1) / FLT (TD2)
Light goes off—run HEATER/HTR at “+” and FAULT/FLT “off”
or run HEATER/HTR at “-”
Light stays on—check resistance to determine if a problem exists
Fault indication goes away with
with the probe or electronics. Refer to Section
presence of liquid or increase
3.4, Resistance Values on page 17. Probe
in air flow.
and/or electronics may need to be replaced.
Liquid Flow – Sensor Wet No
Flow
Switch HEATER/HTR to “-”
Light goes off—run HEATER/HTR at “+” and FAULT/FLT “off”
or run HEATER/HTR at “-”
Light stays on—check resistance to determine if a problem exists
with the probe or electronics. Refer to Section
3.4, Resistance Values on page 17. Probe
and/or electronics may need to be replaced.
Liquid Flow – Flow Present
Turn off TEMP COMP (TD1) / TC (TD2)
Light goes off—operate in this mode
Light stays on—check resistance to determine if a problem exists
with the probe or electronics. Refer to Section
3.4, Resistance Values on page 17. Probe
and/or electronics may need to be replaced.
Air Flow – Flow Present
Switch HEATER/HTR to “-”
Light goes off—Operate at lower heater power (with less
sensitivity). Turn TEMP COMP/TC off if problem
continues (requires re-calibration) or operate at
HEATER/HTR “+” and make sure FAULT/FLT
switch is “off”
Light stays on—Return HEATER/HTR switch to “+” and turn
TEMP COMP/TC “off”. If light goes off then
recalibrate and operate in this mode. If light stays
on check resistance to determine if a problem
exists with the probe or electronics. Refer to
Section 3.4, Resistance Values on page 17. Probe
and/or electronics may need to be replaced.
* Changing HEATER/HTR, TEMP COMP/TC or media switch position will require recalibration.
18
54-610 Thermatel® Model TD1/TD2 Flow Level Switch
3.6
Maintenance
3.6.1 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 (+66° C)
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.
3.6.2 Probe Replacement
NOTE: The switch will require recalibration (section 2.6) following
probe replacement.
3.6.2.1 Integral Electronics
1.
2.
3.
a.
b.
4.
5.
6.
54-610 Thermatel® Model TD1/TD2 Flow Level Switch
Removal of probe
Make sure the power source is turned off.
Unscrew and remove housing cover.
Remove the bezel by:
TD1 – removing the fastening screws.
TD2 – put a screwdriver blade through hole in center and
gently pull the handle away from the terminal strips.
Remove the fastening screws for the bracket. Remove
bracket and attached circuit boards.
Loosen the screws on the terminal block to remove the
four leads from the probe. Note that the TD1 uses a four
position terminal block and the TD2 uses a six position
terminal block.
Unscrew probe from enclosure.
19
4
Installation of replacement probe
(Refer to Figures 15 & 16).
1. The probe’s leads have been separated at the factory.
One set of leads is marked with a “1,” the second set is
unmarked. Connect leads from RTD #1:
TD1 – Connect between terminals 1 and 3.
TD2 – Connect between terminals 2 and 5.
2. Connect the second set of leads:
TD1 – Connect between terminals 2 and 4.
TD2 – Connect between terminals 1 and 4.
3. Replace bezel and housing cover.
TD1 – Replace bezel and refasten screws.
TD2 – Reinstall bracket assembly. Ensure that the tab at
the bottom of the bracket engages in the hole in the bottom
of housing. Reinstall bracket mounting screws. Replace
bezel by gently pressing down on the center of the bezel.
Ensure that the outer edge of bezel is evenly seated in
the housing.
4. Replace housing cover.
5. Apply power.
6. Recalibrate as described in Section 2.6.
1
Unmarked Wires
Marked Wires
4
1
Figure 15
TD1 Probe Connections
6
1
Unmarked Wires
3.6.2.2 Remote Electronics (TD2 only)
Marked Wires
6
1
Figure 16
TD2 Probe Connections
TB1
1
4
1. Make sure the power source is turned off.
2. Remove the cover from the sensor enclosure.
3. Loosen the screws on the four position terminal block
(TB1) to remove the leads from the probe.
4. Unscrew probe from enclosure.
a. The probe’s leads have been separated at the factory.
Connect leads from RTD #1, which are grouped and
marked, to pins 3 & 4 (the two terminals on TB1 closest to
the sensor label) refer to Figure 17.
b. Connect the other pair of leads, which are not marked, to
pins 1 & 2 (the remaining two positions on TB1).
5. Replace housing cover.
6. Apply power.
7. Recalibrate as described in Section 2.6.
Unmarked Wires
Marked Wires
Figure 17
TD2 Remote Probe Connections
20
54-610 Thermatel® Model TD1/TD2 Flow Level Switch
3.7
Agency Approvals
AGENCY
MODEL APPROVED
APPROVAL CATEGORY
APPROVAL CLASSES
FM
TD1-2D00-0XX
TD2-XX0X-Xab
a = 3, C, G
b = 0, 1, 2, 3
Explosion Proof
Class I, Div 1; Groups B, C, D TD1=T6 TD2=T5
TD1-2D00-0XX
TD2-XX0X-XXX
Non-Incendive
Class II & III, Div 1; Groups E, F, G
Type 4X and IP67
Class I, Div 2; Groups A, B, C, D
Class II & III, Div 2; Groups E, F, G T4
Type 4X and IP67
PROBE MODEL
TXX-XXXX-XXX
Explosion Proof
Class I, Div 1; Groups B, C, D T4
Class II & III, Div 1; Groups E, F, G
Type 4X and IP 67
CSA
These probes comply
with Canadian Electrical
code requirements of
ANSI/ISA 12.27.01-2003
as a single seal device
TD1-2D00-0XX
TD2-XX0X-Xab
a = 3, C, G
b = 0, 1, 2, 3
Explosion Proof
TD1-2D00-0XX
TD2-XX0X-XXX
Suitable for
Class I, Div 1; Groups B, C, D T6
Class II & III, Div 1; Groups E, F, G
Type 4X and IP67
Class I, Div 2; Groups A, B, C, D
Class II & III, Div 2; Groups E, F, G T4
Type 4X and IP67
TD1-2D00-0X0
TD2-XX0X-Xab
a = 3, C, G
b = 0, 1, 2, 3
Explosion Proof
Class I, Zone 1, Ex d IIC T6
PROBE MODEL
TXX-XXX0-XXX
Explosion Proof
Class I, Div 1; Groups B, C, D T4
Class II & III, Div 1; Groups E, F, G
Type 4X and IP67
ATEX/IEC
Zone 0 Service
TXX-XDXX-XCX
EEx d Explosion Proof
w/IS probe
II 1/2G EEx d+ib d{ib} IIC T5/T4 IP66
Ex d [ib] / d + ib IIC T5/T4 Gb/Ga
TXX-XHXX-XCX
EEx d Explosion Proof
II 1/2G EEx d IIC T5/T4 IP66
Ex d IIC T5/T4 Gb/Ga
(requires 1 mm probe provided when fourth digit of probe model number is B, C, or D)
Zone 1 Service
INMETRO
TXX-XXXX-XGX
EEx d Explosion Proof
II 2G EEx d IIC T5/T4 IP66
Ex d IIC T5/T4 Gb
TD1-2D00-0XX
Ex d Explosion Proof
BR-Ex d[ib] IIC T5/T4 IP66 - Electronics
TD2-XD0X-XCX
w/IS probe circuit
BR-Ex d+ib IIC T5/T4 IP66 - Probe
EEx d Explosion Proof
BR-Ex d IIC T5/T4 IP66
TXX-XHXX-XCX
(requires 1 mm probe provided when fourth digit of probe model number is B, C, or D)
Zone 1 Service
ROSTECH/FSTS
CCOE
TXX-XXXX-XGX
EEx d Explosion Proof
BR-Ex d IIC T5/T4 IP66
TDX-XXXX-XCX
Russian Authorisation Standards
TDX-XXXX-XGX
Consult MAGNETROL for details.
TDX-XXXX-XCX
Hazardous Approvals - India
TDX-XXXX-XGX
Consult MAGNETROL for details.
These units have been tested to
EN 61326 and are in compliance
with the EMC Directive 89/336/EEC.
54-610 Thermatel® Model TD1/TD2 Flow Level Switch
21
3.8
Replacement Parts
3.8.1 Model TD1
1
2
3
4
Model TD1
Item
22
Description
Part Number
1
Aluminum Cover
2
O-ring
089-6607-XXX
Consult Factory
012-2201-237
3
Electronic module with bracket
089-7250-001
4
Probe
See Probe Model Number
54-610 Thermatel® Model TD1/TD2 Flow Level Switch
3.8.2 Model TD2
Model TD2
Item
1
Description
Part Number
Aluminum Cover (without window)
089-6607-XXX
Consult Factory
Aluminum Cover (with window)
2
O-Ring
3
Remote Housing Cover
4
Bezel
012-2201-237
089-6607-XXX
Consult Factory
003-1230-004
5
Electronic Module
see table below
6
Probe
See Probe Model Number
7
Remote Circuit Board
030-3586-001
Electronic Module – 8 amp DPDT relay
(use with TD2-XX0X-X3X and TD2-XX0X-XGX)
Integral (8th digit = 0)
Remote (8th digit = 1)
AC (4th digit = 7)
089-7250-002
089-7250-004
DC (4th digit = 8)
089-7250-003
089-7250-005
1
2
4
Electronic Module – 1 amp Hermetically Sealed Relay
(use with TD2-XH0X-XXX)
Integral (8th digit = 0)
Remote (8th digit = 1)
AC (4th digit = 7)
089-7250-006
089-7250-008
DC (4th digit = 8)
089-7250-007
089-7250-009
5
Electronic Module – 8 amp DPDT Zone 0 Service
(use with TD2-XX0X-XCX)
Integral (8th digit = 0)
Remote (8th digit = 1)
AC (4th digit = 7)
089-7250-010
089-7250-012
DC (4th digit = 8)
089-7250-011
089-7250-013
NOTE: Contact MAGNETROL for Modules for Hygienic Enclosure (digit 10 = 4 or 5).
3
6
54-610 Thermatel® Model TD1/TD2 Flow Level Switch
23
3.9 Specifications
3.9.1 Performance
Supply Voltage
TD1 19.2 to 28.8 VDC
TD2 19.2 to 28.8 VDC or 100 to 264 VAC
Power Consumption
TD1:
3.5 Watts at 24 VDC, 4.5 Watts at 30 VDC
TD2:
4 Watts at 24 VDC, 4.5 Watts at 30 VDC,
, 50–60 Hz
5 Watts at 100 to 264 VAC
Power to Probe
Output Relay
Less than 1 Watt
TD1 Electronics:
(gold flashed)
DPDT, 8 Amp, 120 VAC, 250 VAC
8 Amp at 30 VDC, 0.5 Amp at 125 VDC
TD2 Electronics:
DPDT, 8 Amp at 120 VAC, 250 VAC
8 Amp at 30 VDC, 0.5 Amp at 125 VDC or
Hermetically Sealed DPDT 1 Amp at 28 VDC, 0.5 Amp at 125 VDC
Ambient Temperature
Electronics:
-40° to +158° F (-40° to +70° C)
Storage Temperature
Electronics:
-58° to +170° F (-50° to +76° C)
Operating Temperature
Sensor:
-100° to +400° F (-73° to +200° C) High Temperature Sensor
-100° to +850° F (-73° to +454° C)
Response Time
1–10 seconds (typical – dependent upon sensor type, application,
and set point adjustment)
Set Point Range
Water:
0.01 to 5.0 fps (0.003 to 1.5 m/s) (spherical tip and twin tip sensors)
0.01 to 1.0 fps (0.003 to 0.3 m/s) (HTHP, Hastelloy®, Monel sensors)
Air:
0.1 to 500 fps (0.3 to 150 m/s)
Time Delay (TD2 only)
0–100 seconds adjustable (time delay in addition to sensor response)
Repeatability
<1% at constant temperature
Enclosure Material
Cast aluminum A356 containing less than 0.2% copper,
24
316 stainless steel or 304 stainless steel
Use a probe with heat extension or remote electronics for process temperatures greater than +250° F (+120° C)
54-610 Thermatel® Model TD1/TD2 Flow Level Switch
3.9.2 Probe
Probe Materials of Construction
Twin Tip
All wetted parts of 316/316L stainless steel, Hastelloy C, or Monel
Mini Sensor
316/316L stainless steel
Spherical Tip
316/316L stainless steel
Low Flow Body
316/316L stainless steel
Process Connection
Refer to part number construction
TXA, TXB, TXC, TXD Probe Insertion Length
2" (5 cm) minimum.
Available in lengths from 2 to 130" in 1" increments (5 to 330 cm in 1 cm increments)
TEM, TMM sensor
1" (2.5 cm) minimum.
Available insertion lengths 1" to 60" (5 to 152 cm)
TEH, TMH Sensor
2" (5 cm) minimum
Available in lengths from 2 to 36" in 1" increments (5 to 91 cm in 1 cm increments)
TEL,TML, Low Flow Body
1
Cable Length
500 feet (150 meters) maximum
Shipping Weight
4.6 lbs. (with 2" probe)
⁄4" and 1⁄2" NPT and G (BSP) threads.
Longer lengths available. Consult factory.
Pressure/Temperature Rating
(DEPENDENT ON PROCESS CONNECTION)
Probe Style
Insertion Length
Process / Temperature Rating
+100° F (+38° C)
+250° F (+121° C)
+400° F (+204° C)
+850° F (+454° C)
2" (5 cm)
3000 psig
(206 bar)
2460 psig
(169 bar)
2140 psig
(147 bar)
—
3 –130" (7– 330 cm)
1850 psig
(127 bar)
1517 psig
(104 bar)
1320 psig
(91 bar)
—
2" (5 cm)
3000 psig
(206 bar)
2627 psig
(181 bar)
2340 psig
(161 bar)
—
3 –130" (7– 330 cm)
1500 psig
(103 bar)
1313 psig
(90 bar)
1170 psig
(80 bar)
—
2" (5 cm)
2500 psig
(172 bar)
2125 psig
(146 bar)
1980 psig
(136 bar)
—
3 –130" (7– 330 cm)
1200 psig
(82 bar)
1020 psig
(70 bar)
950 psig
(65 bar)
—
2 –130" (5 – 330 cm)
600 psig
(41 bar)
490 psig
(34 bar)
415 psig
(28 bar)
—
1" (2.5 cm)
3000 psig
(206 bar)
2460 psig
(169 bar)
2140 psig
(147 bar)
—
2 –130" (5 – 330 cm)
1850 psig
(127 bar)
1517 psig
(104 bar)
1320 psig
(91 bar)
—
—
5800 psig
(400 bar)
4760 psig
(328 bar)
4100 psig
(282 bar)
—
2 – 36" (5 – 90 cm)
6000 psig
(413 bar)
4920 psig
(339 bar)
4280 psig
(295 bar)
3380 psig
(233 bar)
Twin Tip (TXC, TXD)
(stainless steel)
Twin Tip (TXC, TXD)
(Hastelloy C)
Twin Tip (TXC, TXD)
(Monel)
Spherical Tip
(TXA, TXB)
Mini Sensor
(TXM)
Low Flow Body
(TEL)
High Temperature/
High Pressure (TXH)
54-610 Thermatel® Model TD1/TD2 Flow Level Switch
25
3.9.3 Physical – inches (mm)
5.24
(133)
4.00
(102)
4.00
(102)
Without Window
4.43 (113)
4.13
(105)
5.75
(146)
With Window
4.85 (123)
1.8 (46) Typical
1.05 (26)
Typical
1.8 (46) Typical
Insertion
length Insertion
length
BSP(G)
NPT
Threads
Threads
Insertion
length
Insertion
length
.875
(22) Dia.
0.875 (22) Dia.
.875
(22) Dia.
Model TD1
with Twin Tip Probe
Model TD2
with Hygienic Housing
16-Amp Fitting
Model TD2 Integral Electronics
with Spherical Tip Probe
1/2", 3/4",
8.00
(203)
1” NPT
Process
connection
10.75
(273)
1/4" or 1/2"
NPT or BSP
Insertion
length
Insertion
length
BSP(G)
connection
Insertion
length
NPT
connection
Insertion
length
flanged
connection
2.00 (51)
Low Flow Body Sensors
(TXL)
.625
(16) Dia.
Mini Sensor
(TXM)
.84
(21) Dia.
High Temp/Pressure Sensor
(TXH)
4.00
(102)
4.13
(105)
Without Window
4.43 (113)
With Window
4.85 (123)
2 Holes
.38 (10) dia.
2.75
(70)
3.00
(76)
2.00
(51)
3.50
(89)
Model TD2
with Remote Electronics
26
2.35 (60) Typical
Insertion
length
0.875 (22) Dia.
Remote Spherical Tip Probe
with Flange Connection
54-610 Thermatel® Model TD1/TD2 Flow Level Switch
3.10 Model Numbers
3.10.1 Model TD1
AGENCY APPROVAL
3
C
General Purpose, FM/CSA Explosion Proof
ATEX/IECEx Ex d + ib, Zone 0 – Flameproof
ENCLOSURE TYPE
0
1
T
D
1
2
D
0
0
Aluminum A356 – 3⁄4" NPT
Aluminum A356 – M20
0
3.10.2 Model TD2
POWER
7
8
AC Power
DC Power
RELAY OUTPUT
D
H
DPDT Relay
DPDT Hermetically Sealed Relay
GLASS WINDOW IN ENCLOSURE
0
1
None
Window provided (not available on enclosure codes 2 & 3)
LOCATION
0
1
Integral
Remote (not available on enclosure codes 4 & 5)
AGENCY
3
7
C
G
General Purpose FM/CSA Class I, Division 1 & 2
General Purpose FM/CSA Class I, Division 2 ATEX/IECEx Ex d + ib - Zone 0
FM/CSA Class I, Div. 1 & 2
ATEX/IECEx Ex d – Zone 1
FM/CSA Class I, Div. 1 & 2
Use with enclosure codes 4 & 5
ENCLOSURE TYPE/ CONDUIT CONNECTION
0
1
2
3
4
5
T
D
2
Aluminum A356 – 3⁄4" NPT (dual entry)
Aluminum A356 – M20 (dual entry)
Cast 316 stainless steel – 3⁄4" NPT (dual entry)
Cast 316 stainless steel – M20 (dual entry)
304 stainless steel – 1⁄2" NPT (single entry)
304 stainless steel – M20* (dual entry)
Only available with Agency code 7
0
54-610 Thermatel® Model TD1/TD2 Flow Level Switch
27
3.10.3 Standard Probe
MODEL
TE
TM
Probe length in inches
Probe length in centimeters
TIP STYLE
A
B
C
D
Spherical tip Spherical tip – with 6" (15 cm) heat extension Twin tip
Twin tip – with 6" (15 cm) heat extension
max.
max.
max.
max.
+250°
+400°
+250°
+400°
F
F
F
F
(+121°
(+204°
(+121°
(+204°
Available only with stainless steel construction
Consult pressure/temperature chart on page 25 for pressure rating on extended length probe.
C)/max.
C)/max.
C)/max.
C)/max.
600 psi (41 bar)
600 psi (41 bar)
3000 psi (207 bar) 3000 psi (207 bar) MATERIAL OF CONSTRUCTION
A
B
C
D
316/316L stainless steel
Hastelloy® C Monel® 316/316L stainless steel with 1 mm probe thickness Available only with TMX probes
PROCESS CONNECTION SIZE/TYPE
11
21
22
⁄4" NPT Thread
1" NPT Thread
G1 (1" BSP) Thread
3
ANSI RAISED FACE FLANGE CONNECTIONS
23
24
25
33
34
1"
1"
1"
11⁄2"
11⁄2"
150#
300#
600#
150#
300#
ANSI
ANSI
ANSI
ANSI
ANSI
RF
RF
RF
RF
RF
Flange
Flange
Flange
Flange
Flange
35
43
44
45
11⁄2"
2"
2"
2"
600#
150#
300#
600#
CC
DA
DB
DD
DE
DN 40
DN 50
DN 50
DN 50
DN 50
ANSI RF Flange
ANSI RF Flange
ANSI RF Flange
ANSI RF Flange
EN/DIN FLANGED CONNECTIONS BA
BB
BC
CA
CB
DN 25
DN 25
DN 25
DN 40
DN 40
PN 16
PN 25/40
PN 64/100
PN 16
PN 25/40
EN 1092-1 Type A
EN 1092-1 Type A
EN 1092-1 Type B2
EN 1092-1 Type A
EN 1092-1 Type A
HYGIENIC FLANGE CONNECTIONS
3T
4T
VV
11⁄2"
2"
DN65
3A compatible
3A compatible
Varivent® PN 64/100
PN 16
PN 25/40
PN 64
PN 100
EN 1092-1 Type B2
EN 1092-1 Type A
EN 1092-1 Type A
EN 1092-1 Type B2
EN 1092-1 Type B2
DIN flanges only available in metric length
(TMX) probes.
Tri-Clamp® Tri-Clamp® Only available for Spherical Sensor (TMA/TMB)
Contact MAGNETROL for other hygienic fittings
including Neumo, G1A, and DIN 11.851.
Only available for TXA TipStyle.
INSERTION LENGTH
2" to 130" in 1" increments Example: 4 inches = code 004
Note: minimum 3" with flanges and G1 (BSP) threads
005
008
Minimum length 50 mm with NPT threads
Minimum length 80 mm with G1 (BSP) and flange connections
Extended lengths in 10 mm increments to length 3300 mm Examples: 50 mm = code 005, 3300 mm = code 330
Longer lengths available — consult factory
T
28
0
54-610 Thermatel® Model TD1/TD2 Flow Level Switch
3.10.4 High Temperature Probe
MODEL
TE
TM
Probe length in inches
Probe length in centimeters
TIP STYLE
H
High temperature/high pressure twin tip
max. +850° F (+450° C)/max. 6000 psi (413 bar)
MATERIAL OF CONSTRUCTION
A
B
D
316/316L stainless steel
Hastelloy® C
316/316L stainless steel with 1 mm probe thickness Available only with TMX probes
PROCESS CONNECTION SIZE/TYPE
11
21
22
⁄4" NPT Thread
1" NPT Thread
G1 (1" BSP) Thread
3
ANSI RAISED FACE FLANGE CONNECTIONS
23
24
25
27
33
34
35
1"
1"
1"
1"
11⁄2"
11⁄2"
11⁄2"
150#
300#
600#
900/1500#
150#
300#
600#
ANSI
ANSI
ANSI
ANSI
ANSI
ANSI
ANSI
RF
RF
RF
RF
RF
RF
RF
Flange
Flange
Flange
Flange
Flange
Flange
Flange
EN/DIN FLANGED CONNECTIONS
BA
BB
BC
BG
CA
CB
CC
CG
CJ
DN 25
DN 25
DN 25
DN 25
DN 40
DN 40
DN 40
DN 40
DN 40
PN 16
PN 25/40
PN 64/100
PN 250
PN 16
PN 25/40
PN 64/100
PN 250
PN 400
37
38
43
44
45
47
48
11⁄2"
11⁄2"
2"
2"
2"
2"
2"
900/1500#
2500#
150#
300#
600#
900/1500#
2500#
ANSI RF Flange
ANSI RF Flange
ANSI RF Flange
ANSI RF Flange
ANSI RF Flange
ANSI RF Flange
ANSI RF Flange
DA
DB
DD
DE
DG
DJ
DN 50
DN 50
DN 50
DN 50
DN 50
DN 50
PN 16
PN 25/40
PN 64
PN 100
PN 250
PN 400
EN 1092-1 Type A
EN 1092-1 Type A
EN 1092-1 Type B2
EN 1092-1 Type B2
DIN 2527, Form E
DIN 2527, Form E
EN 1092-1 Type A
EN 1092-1 Type A
EN 1092-1 Type B2
DIN 2527, Form E
EN 1092-1 Type A
EN 1092-1 Type A
EN 1092-1 Type B2
DIN 2527, Form E
DIN 2527, Form E
DIN flanges only available on metric
length (TMH) probes.
INSERTION LENGTH
2" to 36" in 1" increments Example: 6 inch probe = 006
Note: minimum 3" with Flanges and G1 (BSP) threads
005
007
Minimum length 50 mm with NPT Threads
Minimum length 70 mm with G1 (BSP) or flange connections
Extended lengths in 10 mm increments to 910 mm Examples: 50 mm = code 005, 910 mm = code 091
T
H
Longer lengths available — consult factory
0
54-610 Thermatel® Model TD1/TD2 Flow Level Switch
29
3.10.5 Low Flow Body
MODEL
TEL
Low Flow Body
MATERIAL OF CONSTRUCTION
A
316/316L stainless steel
PROCESS CONNECTION SIZE/TYPE
T1
V1
T0
V0
⁄4" NPT Thread
⁄2" NPT Thread
G 1⁄4 (1⁄4" BSP) Thread
G 1⁄2 (1⁄2" BSP) Thread
1
1
MOUNTING BRACKET
000
100
T
E
L
A
None
With mounting bracket
0
3.10.6 Mini Sensor
MODEL
TE
TM
Probe length in inches
Probe length in centimeters
BODY STYLE
M
max. +400° F (+204° C)/max. 3000 psi (207 bar) for standard sensor length
max. +400° F (+204° C)/max. 1850 psi (127 bar) for sensors ≥ 2" (50 mm)
Mini twin tip
MATERIAL OF CONSTRUCTION
A
316/316L stainless steel
PROCESS CONNECTION SIZE/TYPE
01
11
21
⁄2" NPT Thread
⁄4" NPT Thread
1" NPT Thread
1
3
INSERTION LENGTH
1" to 130" in 1" increments
Example: 6 inch probe = code 006
50 mm to 3300 mm in 10 mm increments
Examples: 50 mm = code 005, 3300 mm = code 330
Note: Use code 003 for minimum length of 25 mm
M
30
A
0
54-610 Thermatel® Model TD1/TD2 Flow Level Switch
3.10.7 Connecting Cable (General Purpose, FM/CSA)
CONNECTING CABLE IN FEET
Cable length in feet; 10 feet minimum to 500 feet maximum length
Example: 12 feet = code 012
0
3
7
3
1
8
6
CONNECTING CABLE IN METERS
3 meters minimum to 152 meters maximum length
Example: 3 meters = code 003
0
3
7
3
1
9
8
54-610 Thermatel® Model TD1/TD2 Flow Level Switch
31
ASSURED QUALITY & SERVICE COST LESS
Service Policy
Return Material Procedure
Owners of MAGNETROL 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 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 your MAGNETROL local representative or by
contacting the factory. Please supply the following
information:
1. Returned within the warranty period; and
2. The factory inspection finds the cause of the claim to
be covered under the warranty.
If the trouble is the result of conditions beyond our
control; or, is NOT covered by the warranty, there will be
charges for labor and the parts required to rebuild or
replace the equipment.
In some cases it may be expedient to ship replacement
parts; or, in extreme cases a complete new control, to
replace the original equipment before it is returned. If this
is desired, notify the factory of both the model and serial
numbers of the control to be replaced. In such cases, credit
for the materials returned will be determined on the basis
of the applicability of our warranty.
No claims for misapplication, labor, direct or consequential damage will be allowed.
1.
2.
3.
4.
5.
Company Name
Description of Material
Serial Number
Reason for Return
Application
Any unit that was used in a process must be properly
cleaned in accordance with OSHA standards, before it is
returned to the factory.
A Material Safety Data Sheet (MSDS) must accompany
material that was used in any media.
All shipments returned to the factory must be by prepaid
transportation.
All replacements will be shipped F.O.B. factory.
NOTE: See Electrostatic Discharge Handling
Procedure on page 4.
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
Copyright © 2012 Magnetrol International, Incorporated. All rights reserved. Printed in the USA.
Magnetrol, Magnetrol logotype and Thermatel are registered trademarks of Magnetrol International, Incorporated.
CSA logotype is a registered trademark of Canadian Standards Association.
Hastelloy® and C22® are registered trademarks of Haynes International, Inc.
Monel® is a registered trademark of Special Metals Corporation (Formerly Inco Alloys International).
Varivent® is a registered trademark of Tuchenhagen GmbH LTD.
BULLETIN: 54-610.8
EFFECTIVE: April 2012
SUPERSEDES: November 2010