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INNOVA-SWITCH™ SERIES
INSTRUCTION MANUAL
Model 215 Mass Flow/Level Switch
( Model FS4200 Series – Mass Flow Switch / Model LS3200 Series – Point Level Switch )
Document IM 215
Rev-A.1
February 2006
Sierra Instruments, Inc., Headquarters
5 Harris Court, Building L
Monterey, California, USA 93940
Toll Free: 800-866-0200 (USA only)
Phone: 831-373-0200 ; Fax: 831-373-4402
Website: www.sierrainstruments.com
Sierra Europe, European Headqu
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BEFORE STARTING SIERRA INSTRUMENTS appreciates your choosing our product for your liquid level or liquid/gas flow switching application. 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 brief operation and maintenance manual in its entirety prior to unpacking and installing the unit. The following precautions should be noted immediately: • WHEN INSTALLI
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NOTICE This manual covers the following model numbers: Innova-Switch™ Series Models 215 - FS4200 215 - LS3200 Agency Approvals Explosion-Proof rating Mass Flow Switch Point Level Switch FS42CN LS32CN CENELEC EEX d IIB T4 (Killark Enclosure) European EEx d IIC T4 (Akron Electric Enclosure) See Figure 1A and 1B CSA T4A FS42CS LS32CS Canadian Standards Class I, Group B,C,D Class II, Group E, F, G (Both Akron Electric and Killark) Non-Ap
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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 3.2.3 CE OPTION FILTER BOARD CONNECTOR PLATE WIRING (CE OPTION) ™ 4.0 OPERATION AND CALIBRATION OF THE Innova-Switch SWITCH FOR FLOW APPLICATIONS 4.1 PRE-OPERATIONAL CHECKS 4.2 L.E.D. AND RELA
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1.0 INTRODUCTION ™ The SIERRA INSTRUMENTS Innova-Switch 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 a high resolution thermal differential technique. The sensor wetted parts are of durable 316L series stainless steel, all welded construction with no moving parts. The switch is easy to install and adjust, giving reliable, low maintenance performance in the most demanding applications.
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FIGURE 1A LS3200/FS4200 Innova-Switch™ OUTLINE DIAGRAM STANDARD 2.0 INCH INSERTION (KILLARK ENCLOSURE – NEMA 4-EExd 11B, T4) IM-215 Rev-A.1 Series Innova-Switch™ Page 6 of 42
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FIGURE 1B LS3200/FS4200 Innova-Switch™ OUTLINE DIAGRAM STANDARD 2.0 INCH INSERTION (AKRON ELECTRIC ENCLOSURE – NEMA 4X – EexdIIC, T4) IM-215 Rev-A.1 Series Innova-Switch™ Page 7 of 42
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2.1 LEVEL SWITCHING The thermal differential created between the heated and reference unheated RTD pair is a function 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 media to detect liquid level. For example, air has a relatively poor heat transfer characteristic so the heated sensor will become relatively hot. If the sensor is then immersed in water, the relatively high heat tr
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FIGURE 2A: RELATIVE CHANGE IN RESPONSE OF A HEATED RTD IMMERSED IN VARIOUS MEDIA 2.2 Flow Switching Most mass flow monitoring techniques calculate mass indirectly by measuring volumetric flow such as gallons per minute or cubic cm per second, then either measure density separately or calculate it from temperature measurements of the fluid and, finally, combine density and volumetric flow to obtain mass flow. Th
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When the sensor is inserted into a liquid or gas the heated RTD is strongly affected by the velocity of the medium. Flow past the heated RTD changes the heat transferred from the surface of the sensor. This cooling effect reduces the ™ temperature of the sensor. The Innova-Switch compares this change to a preset flow trip point to switch the output. Figure 2B shows the model FS4200 signal change vs. flow rate for air, light hydrocarbon liquids, and water. The signal change vs velo
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FIGURE 2B Innova-Switch™ MODEL FS4200 FLOW RESPONSE FOR THREE MEDIA IM-215 Rev-A.1 Series Innova-Switch™ Page 11 of 42
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Figure 3.A shows a block diagram of the Innova-Switch™ switch. Once the switch is set to respond to the minimum and maximum flow rates (or wet vs. dry conditions), the trip point is set by adjusting the Trip Adjust Potentiometer. Solid state electronics transform the flow (or wetting) induced temperature differential into a voltage that is compared to a control voltage. Matching voltages cause actuation of a relay to indicate a change in state (flow vs. no-flow or dry vs. wet).
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Figure 3B shows a block diagram of the Innova-Switch™ with the addition of an EMC filter required for the CE options (see section 7.0). FIGURE 3B: Innova-Switch™ MODELS WITH THE CE OPTION SWITCH BLOCK DIAGRAM IM-215 Rev-A.1 Series Innova-Switch™ Page 13 of 42
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The instrument enclosure at the top of unit contains the Innova-Switch™ electronics board which 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 to elevated process temperature, accessibility, etc., another instrument head containing the electronics is remotely located (See option RE-Remote Electronics section 3.2.2).
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3.0 Installation 3.1 Mechanical Installation ™ The standard Innova-Switch has a .75 inch (19.05mm) MNPT mount designed for easy installation 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* WHEN INSTALLING YOUR SIERRA INSTRUMENTS SWITCH INTO A PIPE OR VESSEL USE A 1 1/8 INCH (28.575mm) OPEN-END WRENCH TO TIGHTEN AT THE HEX FLATS OF THE MNPT OF
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FIGURE 5: PROPER ORIENTATION OF THE SENSOR PROBE FOR LEVEL AND FLOW APPLICATION IS INDICATED BY THE ARROW ON THE FLAT OF THE MOUNTING FITTING. IM-215 Rev-A.1 Series Innova-Switch™ Page 16 of 42
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3.2 Electrical Installation 3.2.1 CE Option Filter Board Connector Plate Wiring (CE Option) 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. Connect power and alarm relay wiring to Terminal Block (TBB) as shown in ™ Figures 6.0 and 6.0A. Reinstall the Innova-Switch Switch electronics
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mounting wings or bracket provided. Connect the switch wiring between the Innova- ™ Switch Switch remote electronics as shown in Figure 7.0. Connect power wiring and alarm relay wiring to the remote enclosure as shown in Figure 7.0. Upon completion of wiring reinstall the Innova-Switch™ electronics and secure with the captive screws. *IMPORTANT* BE SURE TO APPLY THE PROPER VOLTAGE AS CONFIGURED AT THE FACTORY. DO NOT APPLY 115 VAC TO 24 VDC VERSIONS OR 24 VDC TO 115 VAC VERSIONS
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IM-215 Rev-A.1 Series Innova-Switch™ Page 19 of 42 FIGURE 7A Innova Switch FLOW SWITCH REMOTE ELECTRONICS OPTION FIELD WIRING
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IM-215 Rev-A.1 Series Innova-Switch™ Page 20 of 42 FIGURE 7B REMOTE ELECTRONICS CABLE TERMINATION AND CONNECTIONS
