operation and maintenance manualsoutheastern-automation.com/pdf/deltam/manuals/fs... · switch is...

PROPRIETARY INFORMATION

THIS DOCUMENT IS THE PROPERTY OF DELTA M CORPORATION AND MAYCONTAIN INFORMATION COVERED BY PATENTS AND/OR CONSIDEREDCONFIDENTIAL. UNLESS RIGHTS ARE EXPRESSLY GRANTED BY WRITTENPERMISSION OF DELTA M CORPORATION THIS INFORMATION IN WHOLE ORIN PART MAY NOT BE DISCLOSED OR USED IN THE DESIGN, SALE,MANUFACTURE, TEST, OR SUPPLY OF THE SAME OR SIMILAR PRODUCTS.

OPERATION AND MAINTENANCE MANUAL

microtuf®

MODEL FS4200 SERIES – MASS FLOW SWITCH

MODEL LS3200 SERIES – POINT LEVEL SWITCH

DOCUMENT 3242-OM-03

REVISION 3

FEBRUARY 2001

DELTA M CORPORATION1003 LARSEN DRIVE

OAK RIDGE, TENNESSEE 37830PH 865-483-1569FAX 865-483-1142

TOLL FREE 800-922-0083www.deltamcorp.com

email: [email protected]

MODEL NO. SERIAL NO.

DATE OF SHIPMENT INSTALLATION DATE

CUSTOMER TAG NO. PO NO.

OPTIONS

SPECIAL NOTES

http://www.deltamcorp.com/

DELTA M Corporation 3242-OM-03 2/12/01

ii

BEFORE STARTING

DELTA M appreciates your choosing our product for your liquid level or liquid/gas flow switchingapplication. We are committed to providing reliable, quality instrumentation to our customers.

To ensure the maximum and intended benefit of this instrument, we encourage you to read this briefoperation and maintenance manual in its entirety prior to unpacking and installing the unit.

The following precautions should be noted immediately:

USE A 1 1/8 INCH (28.575mm) OPEN-END WRENCH TO TIGHTEN AT THE HEX FLATS OFTHE MNPT OF A STANDARD SWITCH. (IF YOU HAVE A NON-STANDARD SWITCH ANALTERNATE SIZE WRENCH MAY BE REQUIRED). DO NOT USE THE INSTRUMENT HEADTO TIGHTEN THE SWITCH TO THE MOUNTING PORT. ROTATION OF THE INSTRUMENTHEAD WITH RESPECT TO THE SENSOR BODY CAN CAUSE INTERNAL WIRING DAMAGE(SEE FIGURES 1).

THE SWITCH BODY MUST BE ORIENTED TO HAVE THE TWIN SENSORS PARALLEL TOTHE LEVEL BEING DETECTED WHEN BEING INSTALLED HORIZONTALLY FOR POINTLEVEL APPLICATIONS. LIKEWISE, FOR FLOW APPLICATIONS, THE SWITCH BODYMUST BE ORIENTED TO HAVE THE TWIN SENSORS PERPENDICULAR TO THE FLOWBEING DETECTED. DUE TO THE PIPE THREAD MOUNTING, IT MAY BE NECESSARY TOMAKE A TRIAL FIT, ADD OR REMOVE TEFLON TAPE OR OTHER PIPE THREADSEALANT, AND REINSTALL TO ACHIEVE A SATISFACTORY SEAL WITH THE SENSORSPROPERLY ORIENTED. FOR VERTICAL INSTALLATIONS FOR POINT LEVELDETECTION THE ORIENTATION MAKES NO DIFFERENCE. PROPER ORIENTATION ISMARKED ON THE SWITCH BODY FOR REFERENCE (SEE FIGURE 5).

A GROUND WIRE MUST BE ATTACHED TO THE GROUND SCREW LOCATED INSIDE THEINSTRUMENT ENCLOSURE FOR PROPER OPERATION. FOR CENELEC/CE OPTION THEGROUND SCREW IS LOCATED OUTSIDE THE BODY OF THE INSTRUMENT ENCLOSURE(SEE FIGURE 6).

BE SURE TO APPLY THE PROPER VOLTAGE AS CONFIGURED AT THE FACTORY. DONOT APPLY 115 VAC TO 24 VDC VERSIONS OR 24 VDC TO 115 VAC VERSIONS.(LIKEWISE 230 VAC).

FOR OPTIMUM OPERATION, CALIBRATION MUST BE ACCOMPLISHED AT ACTUALPROCESS TEMPERATURE AND PRESSURE CONDITIONS IN GASES AND AT ACTUALPROCESS TEMPERATURE CONDITIONS IN LIQUIDS.

DO NOT SANDBLAST OR ABRASIVE CLEAN THE SENSING PROBES. THE SENSINGPROBES COULD BE DAMAGED BY ABRASIVES.

ALL DIMENSIONS GIVEN IN THIS MANUAL ARE IN INCHES (AND MILLIMETERS).

If you have any questions prior to or during installation and calibration, please do not hesitate to call thefactory for assistance. We want to ensure the very best possible installation and operational results foryour benefit.


iii

The electronic assemblies contained in the microtuf® models are configured for specific voltages and have specificmodifications to accommodate the various agency approvals. When ordering spare electronics, replacements, orexchanges in the field please ensure you identify the specific configuration you have by noting the boxes marked onthe transformer configuration tag.

NOTICE

This manual covers the following model numbers:

microtuf® Series Models FS4200 LS3200

Agency Approvals Explosion-Proof rating Mass Flow Switch Point Level Switch

CENELEC EEx d IIC T4 FS42CN LS32CN European

CSA Class I, Group B,C,D FS42CS LS32CS Canadian Standards Class II, Group E,F,G

Non-Approved Non-Explosion Proof FS42NX LS32NX

Switch Kits Not Rated FS42SK LS32SK (No Enclosures)

CE EMC Directive: 89/336/EEC Option – CE Option -CE

SPECIAL NOTICE


iv

TABLE OF CONTENTS

1.0 INTRODUCTION

2.0 DESCRIPTION

2.1 LEVEL SWITCHING

2.2 FLOW SWITCHING

3.0 INSTALLATION

3.1 MECHANICAL INSTALLATION

3.2 ELECTRICAL INSTALLATION

3.2.1 LOCAL ELECTRONICS (LE OPTION/STANDARD)

3.2.2 REMOTE ELECTRONICS (RE) OPTION

4.0 OPERATION AND CALIBRATION OF THE microtuf® SWITCH FOR FLOW APPLICATIONS

4.1 PRE-OPERATIONAL CHECKS

4.2 L.E.D. AND RELAY STATUS LOGIC (FAIL-SAFE)

4.3 CALIBRATION – FLOW

5.0 OPERATION AND CALIBRATION OF THE microtuf® SWITCH FOR POINT LEVEL

APPLICATIONS

5.1 PRE-OPERATIONAL CHECKS

5.2 L.E.D. AND RELAY STATUS LOGIC (FAIL-SAFE)

5.3 CALIBRATION – LEVEL

6.0 MAINTENANCE AND TROUBLE SHOOTING

6.1 CLEANING

6.2 TROUBLE SHOOTING

6.2.1 POWER AND CONTINUITY VERIFICATION

6.2.2 SENSOR/ELECTRONICS FUNCTIONALITY VERIFICATION

7.0 SPECIFICATIONS

8.0 WARRANTY AND SERVICE

8.1 WARRANTY

8.2 SERVICE

9.0 APPENDIX

9.1 VOLUME FLOW CONVERSION CHART

9.2 FLOW CONVERSION CHART

9.3 FLOW OF WATER THROUGH SCHEDULE 40 STEEL PIPE (AVAILABLE IN PRINTEDMANUAL ONLY)

9.4 MODEL NUMBER DESIGNATION AND AVAILABLE OPTIONS


1

1.0 INTRODUCTION

The DELTA M microtuf® Switch is the state-of-the-art in gaseous and liquid flow

switching or liquid level control. Flow or level detection is accomplished by using ahigh resolution thermal differential technique. The sensor wetted parts are ofdurable 316 series stainless steel, all welded construction with no moving parts. Theswitch is easy to install and adjust, giving reliable, low maintenance performance inthe most demanding applications.

2.0 DESCRIPTION

The microtuf® Switch uses a thermal differential technique to sense changes in the

heat transfer characteristics of a media. Figures 1A and 1B show the outline of themicrotuf

® Switch. The sensor consists of a pair of matched, Resistance

Temperature Detectors (RTD's) encased in twin 316 series stainless steel tubes.One RTD is self-heated using a constant DC current. The other RTD is unheated toprovide an accurate process temperature reference. The thermal differentialcreated between the heated and reference RTD pair is a function of the densityand/or velocity of the media with which the sensor is in contact. Other physicalproperties may have a secondary effect as well. The differential is greatest at a noflow (or dry) condition and decreases as the rate of flow increases (or as a liquidquenches the sensor/wet condition).

The DELTA M Corporation sensor excitation method relies on constant current to theheated and reference sensors. Thus power to the heated sensor is not constant butchanges linearly with temperature as the sensor resistance changes. Temperaturecompensation is accomplished by using the amplified reference sensor voltagewhich also changes linearly with temperature, as a dynamic reference. Duringcalibration dry/no flow and wet/full flow conditions are impressed across the trip pointpotentiometer. Since this reference is not fixed but is set with respect to thereference sensor voltage, as temperature changes the trip point potentiometervoltage changes with temperature exactly the same as that of the heated sensorvoltage with which it is being compared. Thus full temperature compensation isachieved with non constant power.


2

4.75 (120.65)

(2 PLACES)

(2 PLACES)

5.50 (139.7)

.25 (6.35) DIA. MOUNTING HOLES

MOUNTING

.75 (19.05)MNPT

2.42 (61.47)

2.0 (50.8)

LENGTH

.8 (20.32) REF.

6.1 (154.94) REF.

STD. INSERTION

3.875 (98.42)

STANDARD FITTING

SEE FIGURE 5

.75 (19.05) FNPT FIELDWIRING CONNECTION

DRAWING FILE: MTF1A00.DWG/.FCW

DIMENSIONS IN INCHES (MILLIMETERS)

CO

RP

OR

ATIO

N

FIGURE 1A CSA APPROVED SWITCH OUTLINE DIAGRAM (MTF1A00.DWG/.FCW)


3

FIGURE 1B CENELEC APPROVED SWITCH OUTLINE DIAGRAM MTF1B00.DWG/.FCW)

G

4.50 (114.3) REF.

.10 (2.54) REF.

4.88 (123.95) REF.

2.00 (50.8) REF. .8 (20.32) REF.

6.0 (152.4) REF.

5.20 (132.08) REF.

6.31 (160.27) REF.

CL

MOUNT STRAP (OPTIONAL)

DRAWING FILE: MTF1B00.DWG /.FCW

DIMENSIONS IN INCHES (MILLIMETERS)


4

SIGNAL

VACUUM

AIR

HYDROCARBON LIQUIDS

WATERLIQUID METALS

MEDIA

DECR

EASI

NG T

HERM

AL D

ISPE

RSIO

N O

R HE

AT T

RANS

FER

0

DRAWING FILE: MTF2A0.DWG

2.1 Level Switching

The thermal differential created between the heated and reference unheated RTD pair is afunction of the liquid or gas medium with which the sensor is in contact.

The point level measurement application uses the heat transfer differences between two mediato detect liquid level. For example, air has a relatively poor heat transfer characteristic so theheated sensor will become relatively hot. If the sensor is then immersed in water, the relativelyhigh heat transfer characteristics of water will cool the heated RTD surface causing a decreasein the signal output.

This same rational applies for any two media in contact with the sensor. Each medium willhave its own characteristic heat transfer properties. As long as there is a reasonabledifference in the heat transfer properties between the two media, the microtuf® can discriminatebetween them. Figure 2A shows the relative signal output of the microtuf® sensor to a range ofdifferent media. The maximum difference in output occurs between vacuum and liquid metal.However, a significant difference occurs between water and hydrocarbon liquids so themicrotuf ® can be used to detect a water/hydrocarbon liquid-liquid interface. In general, theinterface between any two media with differing heat transfer properties can be detected.

FIGURE 2A: RELATIVE CHANGE IN RESPONSE OF A HEATED RTD IMMERSED IN VARIOUS MEDIA


5

2.2 Flow Switching

Most mass flow monitoring techniques calculate mass indirectly by measuring volumetric flowsuch as gallons per minute or cubic cm per second, then either measure density separately orcalculate it from temperature measurements of the fluid and, finally, combine density andvolumetric flow to obtain mass flow. The DELTA M thermal-differential technique is one of twomethods that directly measure the mass flow. For ease of comparison most flow applicationsare presented in terms of velocity which is independent of the flow cross sectional area (i.e.feet per second (FPS)). The true mass flow equivalent would be FPS multiplied by density butfor simplicity FPS is used and density effects are ignored. This is normally not critical for flowswitching applications.

When the sensor is inserted into a liquid or gas the heated RTD is strongly affected by thevelocity of the medium. Flow past the heated RTD changes the heat transferred from thesurface of the sensor. This cooling effect reduces the temperature of the sensor. Themicrotuf® compares this change to a preset flow trip point to switch the output. Figure 2Bshows the model FS4200 signal change vs flow rate for air, light hydrocarbon liquids, andwater. The signal change vs velocity has the same general shape for all three media but thechange is larger for air and the sensitive range is different for each. For air and mostgaseous media the range is 0.1 to 500 feet per second (FPS). For most liquid media therange is 0.01 to 5 FPS. Appendices in section 9.0 contain flow conversion information tofacilitate conversion from various units and pipe dimensions into flow velocity in feet persecond.

FIGURE 2B microtuf® MODEL FS4200 FLOW RESPONSE FOR THREE MEDIA ANDCALIBRATION SETTINGS FOR EACH

0

HYDROCARBONS

WATER

0.01 0.1 1.0 10.0

1.0 10.0 100.0 1000.0

VELOCITY (FT./SEC.)DRAWING FILE: MTF2B0.DWG

SIG

NA

L (m

V)

SENSOR SIGNAL

AIR

LIQUID (F/S)(MM/S)

GAS (F/S)(MM/S)

0.001

0.305

0.103.05

3.05

30.5

30.5

304.8

304.8

3048

3048

30480


6

1000

%

TRIP POINT

CALIBRATION

SIGNAL PROCESSING ELECTRONICS

0 FLOW / DRY CAL. MAX.FLOW / WET CAL.

VCC

1NC

NO2

3C

CONTACT 2

4NC

NO5

6C

CONTACT # 1

H7

8N

POWER IN

RELAY

LED LIGHTS

RED

GREEN

A B

FAILSAFE LOGIC

RELAY DRIVER

VCC

VCC1

RTNS

RTN

2

3

CS4

C

HS

5

H

VCC

COMPARATOR

CURRENT SOURCES

SENSORS EXCIT. CURRENTS RETURN

9

10

PROBE

ENCLOSURE

POWER SUPPLY

VCC

SAFETY GROUND

TEST POINTS

6

TBA

DRAWING FILE: MTF3A00.DWG/.FC

Figure 3.A shows a block diagram of the microtuf® switch.

Once the switch is set to respond to the minimum and maximum flow rates (or wet vs. dryconditions), the trip point is set by adjusting the Trip Adjust Potentiometer. Solid stateelectronics transform the flow (or wetting) induced temperature differential into a voltage thatis compared to a control voltage. Matching voltages cause actuation of a relay to indicate achange in state (flow vs. no-flow or dry vs. wet).

FIGURE 3A: MICROTUF SERIES SWITCH BLOCK DIAGRAMMODELS LS32CS/FS42CS, LS32CN/FS42CN, LS32NX/FS42NX,AND LS32SK/FS42SK(MTF3A00.DWG/.FCW)


7

1000%

TRIP POINT

CALIBRATION

SIGNAL PROCESSING ELECTRONICS

0 FLOW / DRY CAL. MAX.FLOW / WET CAL.

R10 R13

VCC

1NC

NO2

3C

CONTACT 2

4NC

NO5

6C

CONTACT # 1

H7

8N

POWER IN

RELAY

LED LIGHTS

RED

GREEN

A B

FAILSAFE LOGIC

RELAY DRIVER

VCC

VCC1

RTNS

RTN

2

3

CS4

C

HS

5

H

VCC

COMPARATOR

CURRENT SOURCES

SENSORS EXCIT. CURRENTS RETURN

9

10

PROBE ENCLOSURE

POWER SUPPLY

VCC

SAFETY GROUND

H

NFILTERED POWER

TEST POINTS

TBA

TBB

6

DRAWING FILE: MTF3B00.DWG

EMC FILTER

CEAPPROVEDSWITCHES

Figure 3B shows a block diagram of the microtuf® switch with the addition of an EMC filterrequired for the CE options (see section 7.0).

FIGURE 3B: MICROTUF MODELS WITH THE CE OPTION SWITCH BLOCK DIAGRAM(MTF3B00.DWG)


8

ELECTRONIC ASSY. CONNECTOR PLATE

ENCLOSURE ASSEMBLY

BLANK COVER

(STANDARD)

PROBE ASSEMBLY

DRAWING FILE: MTF400.DWG /.FCW

N H C NO

NC

NC

C NO

POWER REL1-1 REL1-2

- +

USE MIN. 75 DEG. C RATED

FIELD CONDUCTORS

1

1

A B

GREEN

RED

FUSE

RELAY

R13

H2

H1

N2

N1

R10

0

50

100

Q1

U1

U3

L1

R15

GND

J1

TP3

TP2

U2

TP1

TP4

Q6

J2

T1

U4

CAPTIVE SCREWS(2 PLACES)

TRANSFORMER

FIELD WIRING (TBB)

SENSORS WIRING (TBA)

The instrument enclosure at the top of unit contains the microtuf® Switch electronics boardwhich is removable to access the terminal block and facilitate field wiring (see Figure 4.0).For applications where the electronics must be located away from the sensors due toelevated process temperature, accessibility, etc., another instrument head containing theelectronics is remotely located (See option RE-Remote Electronics section 3.2.2).

FIGURE 4 microtuf® SWITCH ASSEMBLY(MTF400.DWG/.FCW)


9

3.0 INSTALLATION

3.1 Mechanical Installation

The standard microtuf® Switch has a .75 inch (19.05mm) MNPT mount designed for easyinstallation through a threaded port. Optional configurations include .5” (12.7mm) or 1.0”(25.4mm) MNPT and flange mounts. Conduit is recommended for all wiring to the switch.

*IMPORTANT*

USE A 1 1/8 INCH (28.575mm) OPEN-END WRENCH TO TIGHTEN AT THEHEX FLATS OF THE MNPT OF A STANDARD SWITCH. (IF YOU HAVE ANON-STANDARD SWITCH AN ALTERNATE SIZE WRENCH MAY BEREQUIRED). DO NOT USE THE INSTRUMENT HEAD TO TIGHTEN THESWITCH TO THE MOUNTING PORT. ROTATION OF THE INSTRUMENTHEAD WITH RESPECT TO THE SENSOR BODY CAN CAUSE INTERNALWIRING DAMAGE.

*IMPORTANT*

THE SWITCH BODY MUST BE ORIENTED TO HAVE THE TWIN SENSORSPROPERLY ORIENTED. DUE TO THE PIPE THREAD MOUNTING, IT MAYBE NECESSARY TO MAKE A TRIAL FIT, ADD OR REMOVE TEFLONTAPE OR OTHER PIPE THREAD SEALANT, AND REINSTALL TOACHIEVE A SATISFACTORY SEAL WITH THE SENSORS PROPERLYORIENTED. PROPER ORIENTATION IS MARKED ON THE SWITCH BODYFOR REFERENCE. SEE FIGURE 5.0 FOR DETAILS.


10

This page left blank intentionally.


11

FIGURE 5: PROPER ORIENTATION OF THE SENSOR PROBE FOR LEVEL ANDFLOW APPLICATION IS INDICATED BY THE ARROW ON THE FLAT OFTHE MOUNTING FITTING. (MTF500.DWG/.FCW)

A A

B

B

LEVEL APPLICATIONFOR VERTICAL MOUNTING

FOR HORIZONTAL MOUNTING

LEVEL APPLICATION

VIEW B-B

VIEW A-A

FLOW APPLICATION VIEW C-C

C

C

FLOW

NOTES:

THE ARROWS ON THE FLATS OF THE MOUNTING FITTING INDICATES:

1. FOR FLOW APPLICATION-THE DIRECTION OF FLOW.

2. FOR LEVEL APPLICATION WITH HORIZONTAL MOUNTING-THE DIRECTI

OF VERTICAL TO THE LEVEL SURFACE.

3. FOR LEVEL APPLICATION WITH VERTICAL MOUNTING-THE DIRECTION

OF THE ARROW HAS NO SIGNIFICANCE.

DRAWING FILE: MTF500.DWG/.F

CO

RP

OR

ATIO

N

CORPORATION

CORPORATION


12

3.2 Electrical Installation

3.2.1 microtuf® Local Electronics (LE Option/Standard)

Remove the instrument enclosure lid by unscrewing in a counter clockwise direction.Unscrew (CCW) the printed circuit board captive screws (See Figure 4.0 for locations).Remove the PC board by grasping the transformer and pulling it straight out. Connectpower and alarm relay wiring to Terminal Block (TBB) as shown in Figure 6.0. Reinstall themicrotuf® Switch electronics and tighten the captive screws.

FIGURE 6.0 microtuf® SWITCH LOCAL ELECTRONICS FIELD WIRING DIAGRAM(MTF600FCW/.DWG)

NOTES:1. Connections to sensors terminal block A (TBA) are factory installed and should

not be disconnected in the field. Note Jumpers 1-2, 3-4, and 5-6 must be in placeon TBA for proper operation of local electronics.

2. For 24 VDC operation (factory prepared), connect +positive to TBB7 and –negativereturn to TBB8. For 115 VAC or 230 VAC connect hot to TBB7 and neutral toTBB8.

3. Connect ground wire to ground screw located in or on the instrument enclosure.4. Use supply wires suitable for 10 Degree C above ambient.

*IMPORTANT*

A GROUND WIRE MUST BE ATTACHED TO THE GROUND SCREWLOCATED INSIDE OR OUTSIDE OF THE INSTRUMENT ENCLOSURE FORPROPER OPERATION.

10 9 8 7 6 5 4 3 2 1

NO C

ON

NO C

ON

- + C NO NC

SAFETY GND

POWER

WIRING CONNECTIONS (NOTE

TBB

654321

HOT

SENSOR

TBA

SAFETY GROUND

TERMINAL BLOCK

LOCATIONS

TBB

TBA

INSTRUMENT HEADWITH COVER

REMOVED

TO SENSORS DRAWING FILE: MTF600.DWG/.FCW

COLD

SENSOR

C NO NC

RELAYN H C N

ONC

NC

C NO

P OWE R REL1-1 REL1-2

- +

1

1

(NOTE 3)

(NOTE 2)

(NOTE 1)

(DPDT)N H

CAUTION

USE SUPPLY WIRES SUITABLEFOR 10 DEG. C ABOVE AMBIENT


13


3.2.2 Remote Electronics (RE Option)

For the remote electronics option, mount the remote instrument head using two mountingwings or bracket provided. Connect the switch wiring between the microtuf® Switch remoteelectronics as shown in Figure 7.0. Connect power wiring and alarm relay wiring to theremote enclosure as shown in Figure 7.0. Upon completion of wiring reinstall the microtuf®

Switch electronics and secure with the captive screws.

*IMPORTANT*BE SURE TO APPLY THE PROPER VOLTAGE AS CONFIGURED AT THEFACTORY. DO NOT APPLY 115 VAC TO 24 VDC VERSIONS OR 24 VDCTO 115 VAC VERSIONS (LIKEWISE 230 VAC).

SPECIAL NOTICE


14

FIG

UR

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A

m

icro

tuf®

FL

OW

SW

ITC

H R

EM

OT

E E

LE

CT

RO

NIC

S O

PT

ION

FIE

LD

WIR

ING

D

IAG

RA

M

(M

TF

70

1.D

WG

/.F

CW

)

109

87

65

43

21

NO CON

NO CON

-

+

C

NO

NC

PO

WE

R

TB

B

65

43

21

HO

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SE

NS

OR

TB

C

TB

B

TB

A

TO

SE

NS

OR

S

SA

FE

TY G

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RE

MO

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5M

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FO

R R

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ICS

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15

FIG

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mic

rotu

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16

NOTES:1. Connections to sensors terminal block A (TBA) are factory installed and should

not be disconnected in the field. Note Jumpers 1-2, 3-4, and 5-6 must be in placeon TBA for proper operation of local electronics.

2. For 24 VDC operation (factory prepared), connect +positive to TBB7 and –negativereturn to TBB8. For 115 VAC or 230 VAC connect hot to TBB7 and neutral toTBB8.

3. Connect ground wire to ground screw located in or on the instrument enclosure.

4.0 OPERATION AND CALIBRATION OF THE microtuf® FS4200 SWITCH FORFLOW APPLICATIONS

4.1 Pre-Operational Check

With the switch installed and process conditions at no-flow, the following procedure can beused to verify preliminary operation.

4.1.1 Remove the instrument enclosure cover by turning counter clockwise (ccw) to expose themicrotuf® Switch electronics.

4.1.2 Turn on power at its source.

4.1.3 Observe that either the red or green LED comes on.

4.1.4 If neither lamp illuminates refer to the trouble shooting Section, 6.2.

4.2 L.E.D. and Relay Status Logic (Fail-safe)

4.2.1 The L.E.D.s (Red; Green) are an indication of the sensors status (ie. flow below the setpointor flow above the set point) and are not affected by the position of the failsafe jumper J-2.The failsafe jumper J-2 changes the relay activation status allowing the user to select thefailsafe power off condition most appropriate to the application. Refer to the tables belowthat show the logic conditions between the sensors, L.E.D. lights, relay coil and contacts foreach position of the failsafe jumper J-2.

4.2.2 Normal Operation (as set at factory)

The switch comes configured from the factory with the following operation with the J-2jumper in the B(2-3) position. (Refer to Figure 8.0.)

RELAYRED GREEN RELAY CONTACT

SENSOR STATUS LED LED COIL STATUS STATUS

o NCNo Flow or Flow Below Set Point ON OFF Activated

o NO

o NCFlow or Flow Above Set Point OFF ON Deactivated

o NO


17

A

A B

B

GREEN

RED

FUSE

RELAY

R13

H2

H1

N2

N1

R10

0

50

100

Q1

U1

U3

L1

R15

GND

J1

TP3

TP2

U2

TP1

TP4

Q6

J2

J2

U4

LED LIGHTS

FAILSAFE JUMPER

CAPTIVE SCREWS (2 PLS.)

ZERO ADJ.

SPAN ADJ.

TRIP POINT ADJ.

DRAWING FILE: MTF800.DWG/.FCW

220 VAC 110 VAC

24 VDC

24 VAC

SN

PN 200203

TRANSFORMER

CORPORATION

2

2

3

3

1

1

FIGURE 8.0 microtuf® SWITCH ELECTRONICS(MTF800.FCW/.DWG)

4.2.3 Alternate Operation (Field Selectable)

The relay logic may be reversed by moving the J-2 jumper to position A(1-2). (Refer toFigure 8.0.)



o NCNo Flow or Flow Below Set Point ON OFF Deactivated

o NO

o NCFlow or Flow Above Set Point OFF ON Activated

o NO


18

FIGURE 9.0 microtuf® FS4200 FLOW SWITCHCALIBRATION REFERENCE DRAWING(MTF900.DWG.FCW)

<----->

SIGNAL (mV)

AIR

HYDROCARBONS

WATER

0.0010.10

0.011.0

0.1010.0

1.0100.0

101000

0

CALIBRATION SETTINGS FOR EACH

VELOCITY (FPS)

GASES

R10

R13

PROBE FLOW RESPONSE FOR THREE MEDIA AND


A B

GREEN

RED

FUSE

RELAY

R13

H2

H1

N2

N1

R10

0

50

100

Q1

U1

U3

L1

R15

GND

J1

TP3

TP2

U2

TP1

TP4

Q6

J2

T1

U4

LIQUIDS 0.0010.10

0.011.0

0.1010.0

1.0100.0

1010

VELOCITY (FPS)

GASES

NORMALIZED RESPONSE AFTER CALIBRATION

LIQUIDS

0

100

50

SPAN

TRIP POINT

100

50

0

% SPAN

% SPAN

0

(ZERO ADJ.)

(SPAN ADJ.)

TRIP POINT POT. (R15) SCALE

FS42CS

FS42CE

FS42NX

FS42SK

R15(TRIP POINT ADJ.)

FAILSAFE JUMPER (J2)

LED LIGHTSGREEN

RED


19

4.3 Calibration – Flow

**IMPORTANT**FOR OPTIMUM OPERATION, CALIBRATION MUST BE ACCOMPLISHEDAT ACTUAL PROCESS TEMPERATURE AND PRESSURE CONDITIONS INGASES AND AT ACTUAL PROCESS TEMPERATURE CONDITIONS INLIQUIDS.

See Figures 8.0 and 9.0 for location of potentiometers and LEDS on electronics PCB.

4.3.1 Calibration Procedure for Flow Switches

1. Remove the instrument enclosure lid by turning ccw.

2. Apply power to FS4200. Allow 5 minute warm-up.

3. Ensure that the pipeline is filled with fluid and at no or minimum flow.

4. Set the trip adjust pot to zero fully counterclockwise (fully ccw).

5. Adjust the zero adjust pot so that the Red LED just does illuminate. This is a 25 turn pot. If theGreen LED is on, turn the pot ccw. If the Red LED is on, turn the pot clockwise (cw).

6. Toggle the zero adjust pot back and forth until the switching point is well defined. Leave the RedLED illuminated.

7. Adjust the liquid or gas flow to maximum velocity. Insure that the flow is homogenous, constantand free of bubbles if a liquid.

**NOTE**The flow rate (maximum) should be at least 5 fps (liquid) or 500 fps (gas) if possible for bestcalibration.

8. Set the trip adjust pot to 100 (fully cw).

9. Adjust the span adjust pot so that the Green LED just does illuminate. This is a 25 turn pot.If the Green LED is on, turn the pot cw. If the Red LED is on, turn the pot ccw.

10. Toggle the span adjust pot back and forth until the switching point is well defined. Leave theGreen LED illuminated.

11. If the switch is to be used for flow - no flow, set the trip adjust pot to 50 and go to step 14. (Note:This adjustment can be set for tripping points between 10% and 90% of the span from no flow tomax flow).

12. A more exact flow rate setting may be made by establishing the flow at the desired rate with aseparate flow meter and proceeding to step 13, to establish the trip point.

13. Adjust the trip adjust pot to obtain a trip as exhibited by an LED illumination. If a trip ondecreasing flow is desired set for Red LED illumination. If a trip on increasing flow is desired setfor Green LED illumination.

14. Verify that the switch will reset by returning the actual product flow to the maximum or minimumflow rates.


20

5.0 OPERATION AND CALIBRATION OF THE microtuf® LS3200 SERIES SWITCH FORPOINT LEVEL APPLICATIONS

5.1 Pre-Operational Check

The switch is installed and the product level is below sensor level (dry), the followingprocedure can be used to verify preliminary operation.

1. Remove the instrument enclosure cover by turning counter clockwise to expose theLS3200 Switch electronics.

2. Turn on power at its source.3. Observe that either the red or green LED comes on.4. If neither lamp illuminates refer to the trouble shooting Section, 6.2.

5.2 L.E.D. and Relay Status Logic (Fail-Safe)

5.2.1 The L.E.D.s (Red and Green) are an indication of the sensors status (ie. dry or wet) and arenot affected by the position of the fail-safe jumper J-2. The fail-safe jumper J-2 changes therelay activation status allowing the user to select the fail-safe power off condition mostappropriate to the application. Refer to the tables below that show the logic conditionsbetween the sensors, L.E.D. lights, relay coil and contacts for each position of the fail-safejumper J-2.

5.2.2 Normal Operation (as set at factory)

The switch comes configured from the factory with the following operation with the J-2jumper in the B (2-3) position. (Refer to Figure 8.0.)



Dry, or Lower Thermal o NC Dispersion Fluid ON OFF Activated(ie. hydrocarbons) o NO

Wet, or Higher Thermal o NC Dispersion Fluid OFF ON Deactivated(ie. water) o NO


21

5.2.3 Alternate Operation (Field Selectable)

The relay logic may be reversed by moving the J-2 jumper to position A(1-2). (Refer toFigure 8.0.)



o NCDry, or Lower Thermal ON OFF Deactivated Dispersion Fluid o NO (ie. hydrocarbons)

o NCWet, or Higher Thermal OFF ON Activated Dispersion Fluid o NO (ie. water)

FIGURE 8.0 microtuf® SWITCH ELECTRONICS(MTF800.FCW/.DWG)

A

A B

B

GREEN

RED

FUSE

RELAY

R13

H2

H1

N2

N1

R10

0

50

100

Q1

U1

U3

L1

R15

GND

J1

TP3

TP2

U2

TP1

TP4

Q6

J2

J2

U4

LED LIGHTS

FAILSAFE JUMPER

CAPTIVE SCREWS (2 PLS.)

ZERO ADJ.

SPAN ADJ.

TRIP POINT ADJ.


220 VAC 110 VAC

24 VDC

24 VAC

SN

PN 200203

TRANSFORMER

CORPORATION

2

2

3

3

1

1


22

5.3 Calibration – Level

**IMPORTANT**

FOR OPTIMUM OPERATION CALIBRATION MUST BE ACCOMPLISHED ATACTUAL PROCESS TEMPERATURE CONDITIONS.

FIGURE 10.0 microtuf® LS3200 POINT LEVEL SWITCH CALIBRATION REFERENCE DRAWING

(MTF1000.DWG/.FCW)

<----->

0 10050

SPAN ADJUSTMENTZERO ADJUSTMENT

VACUUM

HYDROCARBON LIQUIDS

WATER

LIQUID METALS

FLUIDS

0.0

SENSORSIGNAL (mV)

DECREASING THERMAL DISPERSION

TRIP POINT POT SCALE

TRIP POINT

COVER GAS

(R10) (R13)

OR AIR

DRAWING FILE: MTF1000.DWG/.fcw

A B

GREEN

RED

FUSE

RELAY

R13

H2

H1

N2

N1

R10

0

50

100

Q1

U1

U3

L1

R15

GND

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TP4

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T1

U4

LS32CSLS32CNLS32NXLS32SK

FAILSAFE JUMPER (J2)

LED LIGHTS GREEN

RED


23

5.3 Calibration - Level

Using Figure 10.0 as a location guide adjust the system as follows:

1. Remove the instrument enclosure lid by turning ccw.

2. Apply power to the unit. Allow 5 minute warm-up.

3. For optimum calibration results, wet sensor and drain but do not dry.

4. Ensure that the tank liquid level is below the probe sensor tips.

5. Set the trip adjust pot to zero, fully counterclockwise (fully ccw).

6. Adjust the zero adjust pot so that the Red LED just does illuminate. This is a 25 turnpot. If the green LED is on, turn the pot counterclockwise (ccw). If red LED is on, turnthe pot clockwise (cw).

7. Toggle the zero adjust pot back and forth until the switching point is well defined. Leavethe Red LED illuminated.

8. Raise the level of the liquid to be detected until the probe/sensor tips are submergedand wet (covered).

9. Set the trip adjust pot to 100 (fully cw).

10. Adjust the span adjust pot so that the Green LED just does illuminate. This is a 25 turnpot. If the Green LED is on, turn the pot cw. If the Red LED is on, turn the pot ccw.

11. Toggle the span adjust pot back and forth until the switching point is well defined.Leave the green LED illuminated.

12. Adjust the trip adjust pot to 80 and the calibration is complete. Setting this pot to 80gives an approximate equal trip time from wet to dry and from dry to wet. Setting thispot closer to zero will speed up dry to wet trip time and slow down wet to dry trip time.Setting this pot closer to 100 will slow down the dry to wet trip time and speed up wet todry trip time.


24

6.0 MAINTENANCE AND TROUBLE SHOOTING

6.1 Cleaning

The switch can be cleaned by soaking, spraying solvents or detergent-and-water onto thesensor tubes, or by ultrasonic cleaning.

Lime deposits can be safely removed by soaking in 20% hydrochloric acid. Warming to150°F is permissible to speed this process.

For unusual cleaning problems, call DELTA M and determine the exact materials ofconstruction and chemical compatibility before using strong acids or unusual cleansers.

**IMPORTANT**

DO NOT SANDBLAST OR ABRASIVE CLEAN THE SENSING PROBES.THE SENSING PROBES COULD BE DAMAGED BY ABRASIVES.

6.2 Troubleshooting

6.2.1 Power and Continuity Verification

1. Turn power off to the microtuf® Switch.

2. Remove the instrument enclosure cover (ccw).

3. Loosen the two PC captive screws (see Figure 4.0 for location).

4. Unplug the PC board from the instrument enclosure by pulling straight out on thetransformer.

5. Reapply power and verify correct voltage at pins 7 (positive for DC) and 8 (negative forDC) of TBB (see Figures 6.0 or 7.0).

6. If voltage is correct, verify the fuse (F1) on the PC board is not blown (See Figure 8.0). Iffuse is not blown proceed to 6.2.2.

7. If fuse is blown replace with appropriate value (See 7.0 Specification).


25


6.2.2 Sensor/Electronics Functionality Verification

1. Turn power off to microtuf® Switch.

2. Allow a 5 minute cool down.

3. Measure the resistance of each RTD at pins 1 and 6 of TBA (see Figure 6.0 or 7.0) forthe hot RTD and pins 3 and 5 of TBA for the cold RTD. These resistances should be110 ± 10 ohms (with sensors at approximately 70°F) and within 5% of each other invalue.

4. Measure the insulation resistance between pin 1 of TBA and the case of the microtuf®

Switch. It should be greater than 20 megohms.

5. If the microtuf® Switch sensor assembly resistances are not as specified above, theswitch sensor assembly must be replaced.

6. If the microtuf® Switch sensor assembly resistances are as specified, the microtuf®

Switch PC electronic board must be replaced.

SPECIAL NOTICE


26

7.0 SPECIFICATIONS

TYPE: Thermal Differential-Dual RTD Sensors

PROCESS CONNECTIONS: 0.75” (19.05mm) MNPT Standard, 0.5"(12.7mm), 1" (25.4mm)MNPT, and various flanges optional.

INSERTION LENGTH: Two inch (50.8mm) Standard, (shorter 0.5 inch (12.7mm) andlonger to 120 inch (3048mm) optional).

CONSTRUCTION MATERIALS: Wetted parts are 316L SS welded construction (alternatematerials for corrosive environments available as options.Consult factory.)

AGENCY INSTRUMENT RATINGS: CSA Explosion Proof: (CS series)CENELEC/Explosion Proof (CN Series): EEx d IIC T4CE: EMC Directive: 89/336/EEC (CE Option)

OPERATING TEMPERATURE: Process: -70°C to + 200°C (-100°F to +390°F) standard (to + 600°C (+1000°F) optional

Electronics: -40°C to +60°C (-40°F to +140°F)

PRESSURE RATED: To 3000 psig (20.4 MPa)

RANGE Gaseous Mass Flow: 0.1 to 500 fpsLiquid Mass Flow: 0.01 to 5 fps

REPEATABILITY: ± 1% of Set Point or ± 1/32 inch (±.8mm)

TIME RESPONSE: 0.5 to 10 seconds no-flow (dry) to flow (wet) and 2 to 60seconds flow (wet) to no-flow (dry) (application dependent)

INPUT POWER: 115 Vac, 50/60HZ standard. (230 Vac, 50/60HZ, 24 Vdc, or 24Vac optional); 3.1w. maximum.

DELTA M PART NO.FUSE REQUIREMENTS (F1): CSA/FM CENELEC

115 Vac: 1/4 amp 101603 101605

230 Vac: 1/4 amp 101603 101605

24 Vdc: 1/4 amp 101603 101605

OUTPUT: 5A, 250 VAC, DPDT Standard (Optional 10A, 250 Vac SPDT)5A 30 VDC

STABILITY: Temperature compensated over entire range.


27

8.0 WARRANTY AND SERVICE

8.1 Warranty

DELTA M Corporation warranties microtuf® switches for a period of one year from the dateof shipment and will repair or replace this product in the event of a defect in materials orworkmanship. To have a product repaired, it should be returned at customer's expense,after obtaining return authorization as described in Section 7.2, to a repair facility designatedby DELTA M and, after repair, DELTA M will prepay transportation to return the product tothe customer. This limited warranty only covers failures due to defects in materials orworkmanship which occur during normal use.

LIMITS AND EXCLUSIONS

DELTA M CORPORATION SHALL NOT BE LIABLE FOR INCIDENTAL ORCONSEQUENTIAL DAMAGES (INCLUDING, BUT NOT LIMITED TO,LOSS OF USE, LOSS OF SALES, OR INCONVENIENCE) RESULTINGFROM THE USE OF THESE PRODUCTS, OR ARISING OUT OF ANYBREACH OF THIS WARRANTY. EXCEPT AS SET FORTH ABOVE, THEREARE NO EXPRESS OR IMPLIED WARRANTIES OR WARRANTIES OFMERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

8.2 Service

To receive prompt service call DELTA M's Customer Service Dept. (865) 483-1569 or tollfree 1-800-922-0083. A representative will assist you in determining if the unit must bereturned to the factory. A Return Authorization Number (RAN) will be given and shouldclearly mark the outside of the returning package. Prior to calling, be sure to have themodel number and serial number information for quick identification and serviceresponse.


28

9.1 VOLUME FLOW CONVERSION CHART

Convert known units to cubic feet per second (CFPS) or gallons per minute (GPM)for use with Chart A.2

TO CONVERT FROM TO MULTIPLY BY

Gallons Per Minute (GPM) Cubic Feet Per 2.228 E-03Per Second (CFPS)

Gallons Per Day (GPD) CFPS 1.547 E-06

Barrels Per Day (BPD) CFPS 6.531 E-5

Cubic Ft. Per Minute (CFPM) CFPS 1.667 E-02

Cubic In. Per Minute (CIPM) CFPS 9.645 E-06

Milliliters Per Minute (MLPM) CFPS 5.886 E-07

Milliliters Per Second (MLPS) CFPS 3.531 E-05

Milliliters Per Hour (MLPH) CPFS 9.810 E-09

Liters Per Day (LPD) CPFS 4.087 E-07

Gallons Per Day (GPD) GPM 6.944 E-04

Barrels Per Day (BPD) GPM 2.931 E-02

Cubic Ft. Per Second (CFPS) GPM 4.488 E+02

Cubic Ft. Per Minute (CFPM) GPM 7.481

Cubic In. Per Minute (CIPM) GPM 4.329 E-03

Milliliters Per Minute (MLPM) GPM 2.642 E-04

Milliliters Per Second (MLPS) GPM 4.403 E-06

Milliliters Per Hour (MLPH) GPM 1.585 E-02

Liters Per Day (LPD) GPM 1.835 E-04


29

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30

This page left blank intentionally.


31

9.3 FLOW OF WATER THROUGH SCHEDULE 40 STEEL PIPE


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