FCI FLT93B, FLT93C, FLT93F, FLT93S, FLT93L Installation, Operation & Maintenance Manual

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Installation, Operation & Maintenance Manual

Installation, Betrieb und Wartungshandbuch Manual de Instalación, Operación y Mantenimiento

安装、操作和维护手册

FLT®93 Series FlexSwitch

Flow, Level, Temperature Switch / Monitor

Models: FLT93B, FLT93C, FLT93F, FLT93L, FLT93S

™

FLT® Series FlexSwitch

This document contains conﬁdential technical data, including trade secrets and proprietary information which is the property of Fluid Components International LLC (FCI). Disclosure of this data to you is expressly conditioned upon your assent that its use is limited to use within your company only (and does not include manufacture or processing uses). Any other use is strictly prohibited without the prior written consent of FCI.

Manufactured in accordance with one or more of the following patents: 5,600,528; 6,340,243. FCI is a registered trademark of Fluid Components International LLC. Information subject to change without notice.

Fluid Components International LLC

Notice of Proprietary Rights

FLT® Series FlexSwitchTM 06EN003401 Rev. C

Table of Contents

1 GENERAL.....................................................................................................................................................................................................1

Description........................................................................................................................................................................................................................1

Theory of Operation ..........................................................................................................................................................................................................1

Sensing Element ...............................................................................................................................................................................................................1

Control Circuit ...................................................................................................................................................................................................................1

Technical Speciﬁcations ...................................................................................................................................................................................................2

2 INSTALLATION ...........................................................................................................................................................................................5

Receiving/Inspection ........................................................................................................................................................................................................5

Packing/Shipping/Returns ................................................................................................................................................................................................5

Factory Calibration Note...................................................................................................................................................................................................5

Pre-Installation Procedure ................................................................................................................................................................................................5

Use Standard ESD Precautions .....................................................................................................................................................................................5

Prepare or Verify Sensing Element Location .................................................................................................................................................................5

Verify Dimensions .........................................................................................................................................................................................................5

Verify Sensing Element Flow Direction and Placement Orientation (Flow Application) ..............................................................................................5

Verify Sensing Element Flow Direction and Placement Orientation (Level Application) .............................................................................................5

Install the Sensing Element..............................................................................................................................................................................................6

Male NPT Mounting ......................................................................................................................................................................................................6

Flange Mounting ...........................................................................................................................................................................................................6

Packing Gland Assembly ...............................................................................................................................................................................................7

In-line NPT Assembly (FLT93L) ......................................................................................................................................................................................7

Sanitary Assembly (FLT93C) ..........................................................................................................................................................................................8

Install and Wire the Enclosure(s) .....................................................................................................................................................................................8

Disconnect Device .........................................................................................................................................................................................................8

Minimum Wire Size.......................................................................................................................................................................................................8

Enclosures Covers .........................................................................................................................................................................................................8

Cable and Conduit Entry Devices ..................................................................................................................................................................................9

Enclosure Grounding .....................................................................................................................................................................................................9

Wiring the Local Enclosure Conﬁguration ..................................................................................................................................................................11

Wiring The Remote Enclosure Conﬁguration ..............................................................................................................................................................12

Locate the Remote Hardware Location.......................................................................................................................................................................12

Wiring Output Signal Terminals .....................................................................................................................................................................................13

Wiring Input Power.........................................................................................................................................................................................................13

3 OPERATION ..............................................................................................................................................................................................17

Factory Default Jumper Conﬁguration ...........................................................................................................................................................................17

Conﬁguration Jumpers ...................................................................................................................................................................................................17

Heater Cut-Off ................................................................................................................................................................................................................17

Alarm Setpoint Adjustments ..........................................................................................................................................................................................18

Numerical Adjustment Versus Adjustment by Observation .......................................................................................................................................18

Numerical Alarm Setpoint Adjustment ..........................................................................................................................................................................19

Air/Gas Flow Applications ..........................................................................................................................................................................................19

Wet/Dry Liquid Level Applications .............................................................................................................................................................................22

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06EN003401 Rev. C FLT® Series FlexSwitch

Liquid Flow Applications .............................................................................................................................................................................................23

Adjustment by Observation ............................................................................................................................................................................................25

Flow Applications ........................................................................................................................................................................................................25

Level Applications .......................................................................................................................................................................................................26

Temperature Applications ..............................................................................................................................................................................................26

Converting Temp Out Voltage to Temp in Degrees F or Degrees C ............................................................................................................................28

Fail-Safe Alarm Setting .................................................................................................................................................................................................34

Low Flow Alarm Settings ............................................................................................................................................................................................34

High Flow Alarm Settings ...........................................................................................................................................................................................34

Low Level Alarm Settings (Sensing Element Normally Wet) ....................................................................................................................................35

High Level Alarm Settings (Sensing Element Normally Dry) .....................................................................................................................................35

4 MAINTENANCE .......................................................................................................................................................................................37

Maintenance ...................................................................................................................................................................................................................37

Calibration ...................................................................................................................................................................................................................37

Cleaning .......................................................................................................................................................................................................................37

Electrical Connections .................................................................................................................................................................................................37

Remote Enclosure ........................................................................................................................................................................................................37

Electrical Wiring ..........................................................................................................................................................................................................37

Sensing Element Connections.....................................................................................................................................................................................37

Sensing Element Assembly .........................................................................................................................................................................................37

5 TROUBLESHOOTING ...............................................................................................................................................................................39

Tools Needed ...............................................................................................................................................................................................................39

Quick Check .................................................................................................................................................................................................................39

Non-maintenance Observations..................................................................................................................................................................................39

Check Serial Numbers .................................................................................................................................................................................................39

Check Input Power .......................................................................................................................................................................................................39

Check the Instrument Installation ...............................................................................................................................................................................39

Check for Moisture ......................................................................................................................................................................................................39

Check Application Design Requirements ....................................................................................................................................................................39

Troubleshooting the Flow Element .................................................................................................................................................................................40

Troubleshooting the Control Circuit ................................................................................................................................................................................42

Enclosures ...................................................................................................................................................................................................................43

Spares ..........................................................................................................................................................................................................................43

Defective Parts ............................................................................................................................................................................................................43

Customer Service ........................................................................................................................................................................................................43

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FLT® Series FlexSwitchTM 06EN003401 Rev. C

APPENDIX A DRAWINGS .........................................................................................................................................................................45

APPENDIX B GLOSSARY ...........................................................................................................................................................................75

APPENDIX C APPROVAL INFORMATION ...............................................................................................................................................77

EC Information .............................................................................................................................................................................................................77

Safety Instructions for the Use of the FLT93 Flowswitch in Hazardous Areas ...........................................................................................................79

Annex 1 ........................................................................................................................................................................................................................83

SIL Information ............................................................................................................................................................................................................89

APPENDIX D TEMPERATURE COMPENSATION ...................................................................................................................................91

Introduction .....................................................................................................................................................................................................................91

Factory Temperature Compensation Settings ................................................................................................................................................................91

Balance Procedure ..........................................................................................................................................................................................................92

Field Temp Comp Calibration ..........................................................................................................................................................................................92

APPENDIX E CUSTOMER SERVICE .........................................................................................................................................................95

Customer Service/Technical Support ..........................................................................................................................................................................95

Warranty Repairs or Returns .......................................................................................................................................................................................95

Non-Warranty Repairs or Returns ...............................................................................................................................................................................96

Extended Warranty ......................................................................................................................................................................................................96

Return to Stock Equipment..........................................................................................................................................................................................96

Field Service Procedures .............................................................................................................................................................................................96

Field Service Rates ......................................................................................................................................................................................................96

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FLT® Series FlexSwitchTM GENERAL

1 GENERAL

Description

The FLT Series models are multipurpose measurement instruments. The models included in this manual are FLT93B (Basic), FLT93C (Sanitary), FLT93F (Fast Response), FLT93L (In-Line) and FLT93S (Heavy Duty). Each model is a single instrument that is capable of detecting ﬂuid ﬂow and temperature. It is also able to detect liquid level or ﬂuid media interfaces. The instrument has two ﬁeld adjustable alarm setpoints, two buffered voltage outputs, as well as a built-in calibration circuit. The output of the alarm setpoints are relay contacts that can be used to control customer process applications. One buffered voltage output is available for ﬂow or level monitoring and the second buffered voltage output is available for temperature monitoring.

Theory of Operation

The ﬂow switch is a ﬁxed position, single-point ﬂow, level, interface and temperature switch. The operation of the sensing element is based upon the thermal dispersion principle: A low-powered heater is used to produce a temperature differential between two Resistance Temperature Detectors (RTDs). The RTD temperature differential varies as a function of forced convection for ﬂow measurement and as a function of ﬂuid thermal conductivity for level and interface measurement. The measurement of the ﬂuid’s temperature is obtained from the non-heated RTD.

Sensing Element

The sensing element consists of two thermowells (hollow tubes) that when inserted into the ﬂow process allows an unimpeded ﬂow inside the process line. The top thermowell has a heated RTD inserted into it. The bottom thermowell has a reference RTD inserted into it. In order to correctly orient the sensing element a ﬂow arrow has been etched onto the threaded portion of the sensing element. See Figure 1-1 for a view of the sensing element.

Control Circuit

The control circuit converts the sensing element’s RTD temperature differential into an analog DC voltage signal. Dual comparators monitor the sensing element signal and activates the relay alarm circuits if the signal exceeds an adjustable setpoint.

The control circuit contains ﬁeld selectable jumpers that are used to conﬁgure the instrument for the application.

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Figure 1-1 View of the Sensing Element

GENERAL FLT® Series FlexSwitch

Technical Specications

Application

Flow rate and/or level/interface and temperature sensing in liquid, gas and slurry applications.

Sensing Element

 Process Connection

Model B

Standard: 3/4” male NPT.

Models S and F

Standard: 3/4” male NPT. Optional: 1” BSP, 1” or 1 1/4” male NPT; ﬂanges, spool pieces, sanitary ﬁttings or retractable sensing element.

Model L

Standard: 1” male NPT or 3/4” female NPT. Optional: Flange and low-ﬂow oriﬁce.

Model C

Standard: Sanitary ﬂange

 Insertion Length

Model B

Standard: 1.2” [30 mm], 2” [51 mm], 4” [102 mm].

Models S and F

Standard: 1.2” [30 mm], 2” [51 mm], 4” [102 mm], 6” [152 mm], 9” [229 mm], 12” [305 mm],18” [457 mm]. Optional: Custom-speciﬁed lengths.

Model L

Threaded connections: 3.375” [86 mm] in-line body length. Flanged connections: 12” [305 mm] in-line body length.

Model C

See chart on outline dimensional, Appendix A.

 Sensor Wetted Materials

Model B

Standard: 316L stainless steel with all-welded construction.

Models S and F

Standard: 316L stainless steel with all-welded construction. Optional: Hastelloy C, Monel 400, electro-polished stainless steel and titanium (FLT93S only). Other spray coatings are available on special request (i.e., tantalum, chromium carbide, Kynar).

Model L

Standard: 316L stainless steel with all-welded construction. Optional: Hastelloy C, Monel 400 and titanium.

Model C

Standard: 316L stainless steel with all-welded construction electro-polished to 20 Ra.

 Operating Temperature

All Models

Standard temperature conﬁguration:

-40 °F to +350 °F [-40 °C to +177 °C] Medium temperature conﬁguration:

-100 °F to +500 °F [-73 °C to +260 °C]

Model S Only

High temperature conﬁguration:

-100 °F to +850 °F [-73 °C to +454 °C]

 Operating Pressure (w/NPT Process Connection)

Models S, B, F and L

2350 psig [162 bar(g)] -100 °F to 500 °F [-73 °C to 260 °C]

Models S, B

1450 psig [100 bar(g)] 501 °F to 850 °F [261 °C to 454 °C]

Model C

1500 psig [103 bar(g)] -100 °F to 500 °F [-73 °C to 260 °C]

Higher ratings available with special construction and test certiﬁcation.

Environmental Conditioning

Indoor or outdoor use. Maximum Relative Humidity: 100% Maximum Altitude: 12,000 ft.

Control Circuit (5208)

 Conﬁguration

Standard: Plug-in, socket mounted with dual alarm/trip epoxy sealed relays. Optional: Rack-mount conﬁguration (card cage or enclosure not included).

 Output Signals

Standard: Analog DC voltage related to ﬂow or level/interface signal and analog DC voltage proportional to temperature.

 Input Power

Standard: Field selectable for 120 VAC (108-132 VAC), 13 W 100 mA maximum; 230 VAC (207-253 VAC), 14 W 50 mA maximum; 24 VDC (21-30 VDC), 7 W, 230 mA maximum or 24 VAC (18-28 VAC), 7 W, 230 mA maximum. Optional: Low supply voltage operation for applications with line voltage supplies lower than 108 VAC. Field selectable for 100 VAC (90-110 VAC), 13 W, 100 mA maximum; 200 VAC (180-220 VAC) 14 W, 50 mA maximum. All AC power rated at 50-60 Hz. Power “ON” amber LED provided.

 Serviceable Fuse Rating

For the 120/230 VAC input power conﬁguration, there are two serviceable fuses located on the top side of the control circuit. These are labeled F1 and F2.

Fuse Speciﬁcations

Power: 1.6 amps, 250 VAC, Slo-Blo® (time delay) Package size: TRS (8.5 x 8 mm) radial lead plug-in type FCI part number: 019933-01 Tyco part number: 37411600410

For the 24 VDC/VAC input power conﬁguration, there is a fuse located on the bottom side of the control circuit. The replacement of this fuse requires a qualiﬁed technician knowledgeable in SMD, and RoHS soldering practices.

Fuse Speciﬁcations

Power: 1.5 amps, 125 VDC, SLO-BLO® (time delay) Package size: 6.1 x 2.69 mm SMD FCI part number: 020399-02 Littelfuse part number: 045201.5

 Heater Power

Field or factory selected to optimize switching performance and rangeability and selectable for speciﬁc ﬂuid service requirements.

Typical Service Sensing Element Power (W) Gas or Air S/B-Style 0.75 F-Style 0.25 Liquids S/B-Style 3.0

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FLT® Series FlexSwitchTM GENERAL

The above typical service power selections are for reference only. Depending on application requirements, surface temperature rating requirements, and rangeability expectations, alternate power selections may be recommended. Other intermediate power selections can be made.

 Relay Rating

Standard: Dual alarm, SPDT or single alarm DPDT ﬁeld conﬁgurable, 6 amps resistive load at 240 VAC, 120 VAC, 24 VDC. Optional: Dual alarm SPDT or single alarm DPDT ﬁeld conﬁgurable hermetically sealed relay, 0.5 amps at 115 VAC/2 amps at 28 VDC.

 Electrical Enclosure

Aluminum (epoxy coated) or optional stainless steel. Enclosures are rated for hazardous location use (Class I and II, Division 1 and 2, Group B, C, D, E, F and G; and EEx d IIC) and weather and corrosion resistant (NEMA and CSA Type 4X and equivalent to IP66).

 Operating Temperature

Ambient -40 °F to +140 °F [-40 °C to + 60 °C]

For Flow Service

 Setpoint Range

Models S, B

Water-based Liquids:

0.01 FPS to 0.5 FPS [0.003 MPS to 1.52 MPS] with 0.75 watt heater;

0.01 FPS to 3.0 FPS [0.003 MPS to 0.9 MPS] with 3.0 watt heater.

Hydrocarbon-based Liquids:

0.01 FPS to 1.0 FPS [0.003 MPS to 0.3 MPS] with 0.75 watt heater;

0.01 FPS to 5.0 FPS with [0.003 MPS to 1.5 MPS] with 3.0 watt heater.

Air/Gas:

0.25 SFPS to 120 SFPS [0.08 NMPS to 37 NMPS] with 0.75 watt heater at standard conditions; 70 °F [21.1 °C], 14.7 psia [1.013 bar(g)].

Other Fluids: Contact the factory for approximate rangeability.

Model F

Air/Gas:

0.25 SFPS to 120 SFPS [0.08 NMPS to 37 NMPS] 0.25 watt heater at standard conditions; 70 °F [21.1 °C], 14.7 psig [1.013 bar(g)].

Model L

Water-based Liquids: 0.015 cc/sec to 50 cc/sec

Hydrocarbon-based Liquids: 0.033 cc/sec to 110 cc/sec

Air/Gas: 0.6 cc/sec to 20,000 cc/sec

Model C

Water-based Liquids: 0.01 FPS to 3.0 FPS [0.003 MPS to 0.9 MPS]

Syrup: to 5.0 FPS [0.0003 MPS to 1.5 MPS]

Air/Gas: 0.25 SFPS to 120 SFPS [0.08 NMPS to 36.6 NMPS]

 Factory Calibrated Switch Point Accuracy

Any ﬂow rate within the instrument ﬂow range may be selected as a setpoint alarm. A factory-calibrated setpoint adjustment may be optimally preset with accuracy of ±2% of setpoint velocity over an operating temperature range of ±50 °F [±28 °C].

 Monitoring Accuracy

Based on the non-linear output voltage (P1, pins 1 & 2) over the entire ﬂow range, a 100 °F (56 °C) max. temperature span, and a max. operating pressure range of ±100 psig [±7 bar(g)]:

Liquids: ±5% reading or ±0.04 SFPS [±0.012 NMPS], whichever is larger. Gases: ±5% reading or ±2 SFPS [±0.61 NMPS], whichever is larger.

 Repeatability

±0.5% reading

For Level/Interface Service

 Accuracy

Models S, B

±0.25” [±6.4 mm]

Model F

±0.1” [±2.5 mm]

 Repeatability

Models S, B

±0.125” [±3.2 mm]

Model F

±0.05” [±1.3 mm]

For Temperature Service

 Accuracy

±2.0 °F [±1 °C] with ﬁeld setpoint adjustment. Monitoring accuracy ±3.5 °F [±2 °C] with standard curve ﬁt output voltage operation across the selected instrument temperature range. Higher accuracy available with factory calibrations.

 Repeatability

±1.0 °F [±0.6 °C]

The above accuracy is based on liquid or slurry service and in gas service with a minimum 1 SFPS [0.3 NMPS] velocity past the sensing element or with the heater deactivated for temperature sensing service only.

 SIL: SIL-2 compliant, safe failure fraction (SFF) 82% to 84%

Factory Application-Specic Setup and Setpoint Calibration

Standard instrument factory default settings (unless otherwise selected at order entry):

• 120 VAC input power for all domestic units.

• 230 VAC for all other agency approval units. Field selectable.

• Dual SPDT alarms set for: Alarm No. 1: Preset for ﬂow or level and to de-energize with decreasing conditions. Alarm No. 2: Preset to de-energize for increasing temperature at 10 °F [5 °C] below the maximum instrument process temperature.

• Heater power at 0.25 watt on Model F or 0.75 watt on Model S/B.

• Mode switch set to “operate”.

Factory calibration including set up for speciﬁc service, process ﬂuid and alarm conditions optionally available. Contact factory for ﬂuid handling capabilities.

Agency Approvals

FM, FMc XP, Class I, Division 1, Groups B, C, D DIP, Class II/III, Division 1, Groups E, F, G T4, Ta = 60 °C; T3A, Ta = 60 °C

ATEX II 2 G Ex d IIC T6...T2 -40 °C to 60 °C Gb IECEx Ex d IIC T6 or T5

Tamb (Housing) = -40 °C to 40 °C, T6 Tamb (Housing) = -40 °C to 60 °C, T5 Tp (Sensing Element) = -40 °C to 77 °C, T4 Tp (Sensing Element) = -40 °C to 177 °C, T2

Other Certiﬁcations: SIL-2 rated, CRN, probe complies with Canadian Electrical Code requirements of ANSI/ISA 12.27.01-2011 as a single seal device, CE marking, RoHS2 compliant

Shipping Weight (approximate)

Integral: 8 lb [3.6 kg] Remote: 13 lb [5.9 kg]

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GENERAL FLT® Series FlexSwitch

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FLT® Series FlexSwitchTM INSTALLATION

2 INSTALLATION

Receiving/Inspection

• Unpack carefully.

• Verify that all items in the packing list are received and are correct.

• Inspect all instruments for damage or contaminants prior to installation.

If the above three items are satisfactory, proceed with the installation. If not, then stop and contact a customer service representative.

Packing/Shipping/Returns

These issues are addressed in Appendix E - Customer Service.

Factory Calibration Note

The instrument is factory calibrated to the applications as speciﬁed at the time of order. There is no need to perform any veriﬁcation or calibration steps prior to installing and placing the instrument in service unless the application has changed.

Pre-Installation Procedure

Warning:

Caution:

The instrument is not designed for weld-in-place applications. Never weld to a process connection or a structural support.

Damage resulting from moisture penetration of the control circuit or ﬂow element enclosure is not covered by product warranty.

Use Standard ESD Precautions

Use standard ESD precautions when opening an instrument enclosure or handling the control circuit. FCI recommends the use of the following precautions: Use a wrist band or heel strap with a 1 megohm resistor connected to ground. If the instrument is in a shop setting use workstations with static conductive mats on the work table and ﬂoor with a 1 megohm resistor connected to ground. Connect the instrument to ground. Apply antistatic agents to hand tools to be used on the instrument. Keep high static producing items away from the instrument such as non-ESD approved plastic, tape and packing foam.

For sensors and ﬂanges containing titanium, ignition hazards due to impact or friction must be avoided according to EN/IEC 60079-0, clause 8.3.

The above precautions are minimum requirements to be used. The complete use of ESD precautions can be found in the U.S. Department Of Defense Handbook 263.

Prepare or Verify Sensing Element Location

Prepare the process pipe for installation, or inspect the already prepared location to ensure that the instrument will ﬁt into the system.

Review the requirement for the supply power and alarm circuit connections.

Verify Dimensions

Verify the instrument’s dimensions versus the process location to be sure of a correct ﬁt. Also see Appendix A for dimensions.

Verify Sensing Element Flow Direction and Placement Orientation (Flow Application)

For ﬂow detection, the sensing element surface marked with direction arrows should be oriented parallel to the process ﬂow. The ﬂow can be from either direction.

Mount the sensing element at least 20 diameters downstream and 10 diameters upstream from any bends or interference in the process pipe or duct to achieve the greatest accuracy.

For liquid ﬂow service, locate the sensing element in the process pipe so that the thermowells are always completely wet.

When mounted in a tee or section of pipe larger than the normal process pipe, position in a vertical run of pipe with ﬂow upward. This will prevent air or gas bubbles from becoming trapped at the sensor assembly.

Vertical positioning with ﬂow downward is only recommended for higher ﬂow rate applications (consult FCI).

Verify Sensing Element Flow Direction and Placement Orientation (Level Application)

If the sensing element is side-mounted on the process vessel, then the surface marked with direction arrows should be vertically oriented.

If the sensing element is top- or bottom-mounted on the process vessel, the orientation of the surface marked with direction arrows does not matter.

This instrument must be installed by qualiﬁed personnel only. Install and follow safety procedures in accordance with local

and national electrical codes and regulations. Ensure that power is OFF during installation. Any instances where power is applied to the instrument will be noted in this manual. Where the instructions call for the use of electrical current, the operator assumes all responsibility for conformance to safety standards and practices.

The instrument contains electrostatic discharge (ESD) sensitive devices. Use standard ESD precautions when handling the

control circuit. See below, for ESD details.

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INSTALLATION FLT® Series FlexSwitch

Install the Sensing Element

Male NPT Mounting

When mounting the sensing element to the process pipe, it is important that a lubricant/sealant be applied to the male threads of all connections. Be sure to use a lubricant/sealant compatible with the process environment. All connections should be tightened ﬁrmly. To avoid leaks, do not overtighten or cross-thread connections. See Figure 2-1 and the appropriate drawings in Appendix A for proper mounting.

Figure 2-1 NPT Pipe Thread Mount

Flange Mounting

For ﬂange mounted sensing elements, attach the process mating ﬂange with care. The correct orientation of the sensing element must be maintained to ensure optimum performance or calibration. See Figure 2-2 and the appropriate drawings in Appendix A.

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Figure 2-2 Flange Mount

FLT® Series FlexSwitchTM INSTALLATION

Packing Gland Assembly

For applications involving the use of a packing gland (low or medium pressure) refer to the drawings in Appendix A for additional detail.

1. Threaded or ﬂanged packing gland mounts are available. The valve assembly with appropriate connections are customer supplied. Follow the male NPT mounting procedure above to attach the pipe thread portion or ﬂange mounting portion as applicable.

2. Tighten the packing nut until the internal packing is tight enough so that the friction ﬁt on the shaft is adequate to prevent leakage but not prevent the shaft from sliding. Position the etched ﬂow arrow parallel with the ﬂow (±1° of level) and position the ﬂow arrow so it is pointing in the direction of the ﬂow.

3. Proceed to insert the probe into the process media line.

4. For medium pressure packing gland only (PGM): Use the adjusting nuts on the all-thread to pull the sensing element into proper predetermined depth position.

5. For medium pressure packing gland only (PGM): Tighten the opposing lock nuts on the all-threads.

6. Tighten the packing nut another half to full turn until tight (approximately 65 to 85 ft-lbs [88 to 115 N-m] torque).

7. Rotate the split ring locking collar to line up with the connecting strap welded to the packing nut. Tighten the two 1/4-28 hex socket cap screws on the split ring locking collar.

Reverse these steps for removal.

In-line NPT Assembly (FLT93L)

Check the body length of the in-line assembly to make sure the assembly will ﬁt into the process line. See the appropriate drawing in Appendix A to determine the assembly length. The direction of ﬂow is important for proper operation. There is a ﬂow direction arrow on the in-line pipe that is to point in the direction of ﬂow. See Figure 2-3 for the correct orientation.

If the instrument is a butt weld assembly, be sure to do the following: Remove the circuit board, properly ground the ﬂow element before welding.

Figure 2-3 FLT93L In-Line Flow Element (Shown with 1-Inch MNPT Ports)

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INSTALLATION FLT® Series FlexSwitch

Sanitary Assembly (FLT93C)

The instrument is inserted into the process connection with removable clamp ﬁttings. The Removable Clamp (RC) sanitary assembly contains a removable clamp connection to the ﬂow element. The Clean-In-Place (CIP) sanitary assembly has the ﬂow element directly welded into the process stand pipe. Otherwise these instruments function exactly the same as an FLT93F or FLT93S. See Appendix A for outline dimensions of the instruments. Figure 2-4 also shows the sanitary assemblies.

Figure 2-4 FLT93C Sanitary Flow Elements (RC and CIP)

Install and Wire the Enclosure(s)

Warning:

Install an input power disconnect switch and fuse near the instrument to interrupt power during installation and

Caution:

Mount and wire the control circuit either locally or remotely (option) by following the local or remote enclosure procedure below.

Disconnect Device

IEC 61010-1 requires the installation of an external switch or circuit breaker on the 120/220 VAC power source. It is recommended that the switch or the circuit breaker be in close proximity to the ﬂow switch and within easy reach of the operator. The recommended breaker trip value for 120/220 VAC is 3 amps. If 24 VDC/VAC input power is being used a disconnect switch or breaker is also recommended. Recommended breaker value is 3 amps. All disconnect devices shall be clearly marked for the ﬂow switch.

Minimum Wire Size

Table 2-1 shows the smallest (maximum AWG number) copper wire that is used in the electrical cables. Use a lower gauge of wire for less of a voltage drop. Contact FCI concerning greater distances than those listed in the table. The sensing element cable must be shielded. If the cable is spliced the shield wire must be continued through the splice. If a terminal block is used, the shield must have its own terminal.

Enclosures Covers

All enclosure covers must be in place and securely closed to achieve environmental and safety classiﬁcations.

Tighten all circular thread-on covers about 1 full turn past hand tight.

Cover locks must be in place and secure if required by a particular approval.

In applications where the sensing element is located in an explosive environment, isolate the conduit before it leaves the

environment. A silicone encapsulant/potting compound can be used to provide the isolation.

maintenance.

Always disconnect/shut-off power before wiring

Pulling wires can cause damage to the control circuit. Therefore, remove the control circuit from the enclosure and use

extreme care when pulling wires into the enclosure.

Note:

Nitrile (buna-N) O-rings are standard on the circular thread covers. These O-rings have a 250 °F (121 °C) maximum usage

temperature.

A Viton O-ring [400 °F (204 °C) max. temp.] is available for the thread-on covers.

To receive a Viton O-ring, provide FCI with the following information:

• Shipping address

• Quantity required

• Desired P/N: Use P/N 000391-01 for the single conduit port enclosure (Local) Use P/N 000391-07 for the dual conduit port enclosure (Remote)

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FLT® Series FlexSwitchTM INSTALLATION

Maximum Distance for AWG

Connection

10 ft.

(3m)

50 ft

(15m)

100 ft.

(31m)

250 ft.

(76m)

500 ft.

(152m)

1000 ft.

(305m)

AC/DC Power 22 22 22 20 18 16

Relay (6A) 28 22 20 16 12 10

Flow Element Wires* 22 20 20 18 18 18

* Requires a shielded cable with the shield wire connected to the terminal board only.

Table 2-1 Maximum AWG Number

Cable and Conduit Entry Devices

The cable and conduit entry devices and blanking elements shall be of a certiﬁed ﬂameproof type Ex db and Ex tb suitable for T ratings up to 106 °C, suitable for the conditions of use and correctly installed. With the use of conduit entries a sealing device shall be provided immediately on the entrance of the device.

All cable glands and conduit ﬁttings, including conduit plugs, must meet or exceed the area approval where the unit is being installed.

Enclosure Grounding

To ensure an Ex-compliant installation, follow the below steps to ground the enclosure.

Warning:

Ensure that all power is OFF before wiring any circuit.

Tools required:

• Wire Stripper for 10-12 AWG (3.3-5.3 mm2)

• Crimping Tool for 10-12 AWG (3.3-5.3 mm2), TE Connectivity CERTI-CRIMP Direct Action Hand Tool 49935 (or equivalent)

• M4 hex key/Allen wrench

1. Strip .250”-.281” [6.35-7.14 mm] insulation from ground wire, stranded or solid (12-10 AWG).

Note: Avoid nicking or cutting wire strands when stripping the wire insulation.

2. Remove M4 socket cap screw, M4 split washer and ring lug from enclosure using M4 hex key (Allen wrench). The enclosure’s ground wire hardware is installed at the factory. See Figure 2-5 below.

ENCLOSURE

M4 HEX KEY

RING LUG, 10-12 AWG

M4 SOCKET

CAP SCREW

Figure 2-5 Removing Ground Wire Securing Hardware from Enclosure

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M4 SPLIT LOCK WASHER

C01332-1-1

INSTALLATION FLT® Series FlexSwitch

3. Place center of ring lug barrel in appropriate crimping tool chamber. Squeeze tool handles together with just enough force to hold barrel in place (do not deform barrel).

4. Insert stripped end of ground wire into barrel. Place the wire such that the insulation does not enter barrel and that the stripped wire end does not extend beyond barrel.

5. While holding the wire in place, squeeze the tool handles together until the ratchet releases, then allow the tool handle to open fully. See Figure 2-6.

Caution:

The crimping jaws bottom before ratchet releases. This feature ensures maximum electrical tensile performance of the crimp.

Do NOT re-adjust the ratchet.

CRIMPING TOOL

RING LUG WITH

RING LUG

CRIMPED GROUND WIRE

C01333-1-1

Figure 2-6 Crimping Ground Wire Ring Lug

6. Install ground wire ring lug with end of lug barrel touching the side of the enclosure’s mounting boss as shown in Figure 2-7. Place the ring lug on either side of the mounting boss as needed for the installation. Install with the hardware in this order: socket cap screw, split lock washer, ring lug. Torque cap screw to 23 in-lb (2.6 N-m).

ENCLOSURE GROUND SCREW MOUNTING BOSS

M4 SOCKET CAP SCREW

M4 HEX KEY

RING LUG

TERMINATED

GROUND WIRE

(a) Enclosure Top View (b) Detail View

SPLIT LOCK WASHER

Position ring lug barrel

on either side of

enclosure’s

mounting boss.

C01334-1-1

Figure 2-7 Installing Ring Lug Terminated Ground Wire

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FLT® Series FlexSwitchTM INSTALLATION

Wiring the Local Enclosure Conﬁguration

Warning:

Ensure that all power is OFF before wiring any circuit.

This procedure is for instruments with the control circuit located in the sensing element enclosure.

1. Remove the control circuit from the terminal board socket by loosening the two thumbscrews on top of the transformer bracket. Note: the screws are captive. Note the orientation of the control circuit. Grab hold of the transformer bracket where the screws are and unplug the control circuit from the terminal board by pulling on the transformer bracket.

2. Install conduit between the local enclosure, disconnect device and the power source and monitoring circuit. Provide watertight hardware and apply thread sealant to all connections to prevent water damage.

3. Refer to the Wiring Input Power section at the end of this section for the available input power conﬁgurations. Input power wiring conﬁgurations are the same for local and remote enclosure options and also any output relay conﬁguration. Wire in accordance with the system requirements.

4. When connecting the relay wiring, do so with complete understanding of what the process requires of the instrument. The instrument has dual SPDT or single DPDT relay output contacts dependent on the jumper conﬁguration for each alarm switch point. For the relay terminals and logic, refer to Figure 2-8. Also refer to Table 3-5 and Table 3-6 in Section 3 - Operation. Relay contacts are shown with the relays de-energized.

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Figure 2-8 Local Wiring Diagram

INSTALLATION FLT® Series FlexSwitch

Wiring The Remote Enclosure Conﬁguration

This procedure is for instruments with the control circuit located remotely (remote housing) from the sensing element (local enclosure).

Locate the Remote Hardware Location

Warning:

Ensure that all power is off before wiring any circuit.

Drawings in Appendix A show the remote enclosure along with the physical dimensions to properly mount it. Select a location for the remote enclosure within 1000 feet (305 m) of the sensing element NOTE: Maximum cable length is 1000 ft. Pigtail sensing elements cannot be located more than 10 feet (3 m) from the enclosure unless the pigtail is extended with the proper size cable listed in Table 2-1. If the cable is extended the cable connections should be located in a junction box with a 6-position terminal block. All 5 conductors and the shield must have their own termination. The remote enclosure should be easily accessible with enough room to open the enclosure cover at any time. Secure the remote enclosure solidly to a vertical surface capable of providing support. Use appropriate hardware to secure the enclosure.

1. Remove the control circuit from the terminal board socket by loosening the two thumbscrews on top of the transformer bracket. Note: The screws are captive. Note the orientation of the control circuit. Grab hold of the transformer bracket where the screws are and unplug the control circuit from the terminal board by pulling on the transformer bracket.

2. Install conduit between the remote (electronics) enclosure, disconnect device and the power source\monitoring circuit. Install conduit from the remote electronics enclosure to the local (sensing element) enclosure. Provide watertight hardware and apply thread sealant to all connection to prevent water damage.

3. Refer to the Wiring Input Power discussion at the end of this section for the available input power conﬁgurations. Input power wiring conﬁgurations are the same for local and remote enclosure options and also any output relay conﬁguration.

4. Run a ﬁve-conductor, shielded cable from the local enclosure to the remote enclosure. Use Table 2-1 to determine which wire gauge to use (wire between the local and remote enclosures according to Figure 2-6). It is recommended to include a 14 AWG wire between the two enclosures connected to the grounding lugs and then to earth ground close to the control circuit housing, with the connection not to exceed 1 ohm.

5. When connecting the relay wiring, do so with complete understanding of what the process requires of the instrument. The instrument has dual SPDT or single DPDT relay output contacts dependent on the jumper conﬁguration for each alarm switch point. For the relay terminals and logic, refer to Figure 2-9. Also refer to Table 3-5 and Table 3-6 in Section 3 - Operation. Relay contacts are shown with the relays de-energized. Wire in accordance with the system requirements.

12 Fluid Components International LLC

Figure 2-9 Remote Wiring Diagram

FLT® Series FlexSwitchTM INSTALLATION

Wiring Output Signal Terminals

The primary outputs on the FLT are the relays. Voltage ouputs relative to ﬂow/level and temperature are provided on the terminal board at TB3. The signal voltage at positions 1 and 2 represents the process change (non-linear to ﬂow). The signal voltage at positions 3 and 4 is proportional to the temperature at the sensing element. See Figures 2-8 and 2-9. See also Section 3 for the physical layout of the control circuit.

Caution:

These voltages can be used by other peripherals with a minimum load of 100K ohms. The terminal block can be wired with between gauge 24 and 20 wire. The maximum recommended length of wire is 100 feet. Shielding is required on any length of cable. Terminate the shield to earth ground.

To easily monitor output voltages locally while the instrument is powered, the control circuit has test points available at P1. These test points can be probed with pointed test leads or hooked on to with test clips (Pomona Mini Grabbers or Easy Hooks). See Figure 3-2 (Operation).

Do not ground terminal 2 of TB3. (Terminal 2 is the negative lead of the process signal.) This terminal is 9 volts above the

control circuit ground. The peripheral using this signal must have a differential input.

Wiring Input Power

The “Normal AC Line Input Voltages” and the “24 VDC/VAC” are the standard conﬁgurations provided and are selectable in the ﬁeld. Refer to Table 2-2. An option for “Low AC Line Input Voltages” is available.

120 or 230 VAC Input: When wiring the terminal board for 120 or 230 VAC, refer to Table 2-2, Figure 2-10, 2-11 and Figure 2-12. Note the required power jumper and the position of the power input wires. The wire gauge range for TB1 is 24 to 12 AWG. Make sure all wires going into one position are properly attached by tugging on each wire individually. Once the terminal board is wired, the control circuit can be connected to the terminal board and secured with the thumbscrews. The control circuit does not need to be conﬁgured for power input.

24 VDC/VAC: When wiring the terminal board for 24 VDC/VAC refer to Table 2-2 and Figure 2-13. TB4 is a compression screw terminal block that has a wire range of 30 to 12 AWG. Make sure that all wires going into one position are properly attached by tugging each wire individually. When using 24 VDC the polarity does not need to be considered. DC can be connected in either polarity.

5208 – A X X

STANDARD AC LINE

INPUT VOLTAGES

5208 – (A or B) X X

24 VDC/VAC

5208 – B X X

LOW AC LINE

INPUT VOLTAGES

Power Jumper RED BLUE NA RED BLUE

Main Feed 108 - 132 VAC 207 - 253 VAC 21 - 30 VDC

18 - 28 VAC

LINE 1 TB1C-1 TB1C - 1 NA TB1C-1 TB1C - 1

NEUT / LINE 2 TB1C-2 TB1C-2 TB1C-2 TB1C-2

- 24 VDC/VAC NA NA TB4- 24 DC/AC NA NA

+ 24 VDC/VAC NA NA TB4+ 24 DC/AC NA NA

Table 2-2 Input Power Wiring Conﬁgurations

90 - 110 VAC 180 - 220 VAC

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INSTALLATION FLT® Series FlexSwitch

14 Fluid Components International LLC

Figure 2-7 Power Jumper Diagram

FLT® Series FlexSwitchTM INSTALLATION

Figure 2-8 120 VAC Input Power Wiring Diagram

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Figure 2-9 230 VAC Input Power Wiring Diagram

INSTALLATION FLT® Series FlexSwitch

Figure 2-13 24 VAC/VDC Input Power Wiring Diagram

Figures 2-11, 2-12 and 2-13 can be cross referenced in Appendix A with FCI drawings 022580 [Wiring Diagram FLT93/5208 Integral Control Circuit] and 022581 [Wiring Diagram FLT93/5208 Remote Control Circuit].

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FLT® Series FlexSwitchTM OPERATION

3 OPERATION

Caution:

The control circuit contains electrostatic discharge (ESD) sensitive devices. Use standard ESD precautions when handling the

control circuit. See Section 2, Operation, for ESD details.

Factory Default Jumper Conguration

Unless a custom factory setup or calibration is speciﬁed, the instrument is delivered in a standard factory conﬁguration. The standard default jumper conﬁguration is shown in Table 3-1.

Heater Power

Number of Alarms Two (J23). Each alarm has one set of SPDT contacts

Alarm No. 1 Red LED

Setpoint Pot, R26

Alarm No. 2 Green LED

Setpoint Pot, R25

If the order includes custom factory setup and calibration, leave all settings alone. The instrument is ready for service without changes.

If custom factory setup or calibration was not ordered, conﬁgure the control circuit using the jumper tables (Tables 3-2 to 3-6) and then follow the setpoint adjustment section that is appropriate for the application.

FLT93S/FLT93B 0.75 watts for air or liquid level applications. (J13)

FLT93F 0.25 watts for air or liquid level applications. (J14)

Set to monitor ﬂow or level signals (J20). Relay energized at ﬂow or wet (J27)

Set to monitor temperature signals (J19). Relay energized below temperature (J25). Setpoint at approximately: 350 °F (121 °C) for standard temperature, 500 °F (260 °C) for medium temperature, 850 °F (454 °C) for high temperature (FLT93S Only)

Table 3-1 Standard Jumper Default Conﬁguration

Conguration Jumpers

If the order did not specify for the control circuit to be factory conﬁgured, the standard conﬁguration can be changed using Figure 3-1 and Table 3-1 through Table 3-6. The factory default conﬁguration is shown underlined.

Heater Cut-Off

The 5208 control circuit has a heater cutoff switch that limits the skin temperature of the sensing element to a temperature differential of approximately 150 °F (66 °C) above the process temperature. In the case where the instrument is used as a gas ﬂow switch, and the heater wattage is set too high, the temperature differential between the RTDs may exceed the usable input range of the control circuit. The usable input range can also be exceeded in the case where the instrument is used in liquid ﬂow applications where the heater wattage is set at the highest value, and the sensing elements go dry. When the temperature differential is less than 150 °F (66 °C) the heater automatically turns back on. The yellow power indicator LED (DS3) turns on and off with the heater for a visual indication of the heater state. The LED will alternate between on and off (i.e., ﬂashing) until the condition is corrected.

The reason for operating in the above extreme conditions is to insure that the input signal range is at the widest point making the alarm setpoint adjustment easier to perform. If the heater does cycle the operator may need to use the next lower wattage setting.

In some applications it is desirable to set the heater wattage high, even though the sensing element goes into the heater cutoff mode. An example is when the instrument is used to detect the interface of two liquids. These liquids may have viscosities that will have signals very close to each other. In order to have the maximum signal difference between the signals the heater wattage is set to its maximum. If the sensing element detects a dry condition the control circuit will indicate a heater cutoff condition. The sensing element will not be damaged if it is left dry with the maximum heater wattage. The alarms can be set so one alarm will switch at the interface and one alarm can detect when the element goes dry.

Fluid Components International LLC 17

OPERATION FLT® Series FlexSwitch

Alarm Setpoint Adjustments

Numerical Adjustment Versus Adjustment by Observation

An alarm setpoint is established using either numerical adjustment or adjustment by observation. The adjustment by observation requires the customer to establish normal process operation and adjust the alarm setpoint relative to this condition. The numerical approach requires measuring normal and alarm process conditions with a voltmeter and setting up the instrument in the calibrate mode based on these values. The adjustment by observation requires less time to establish the alarm setpoint. The numerical adjustment requires control of the process as well as additional time to establish the alarm setpoint. Use the adjustment procedure that is the most appropriate for the application requirement.

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Figure 3-1 5208 Control Circuit Jumper Locations

FLT® Series FlexSwitchTM OPERATION

Jumper

FLT93S/FLT93B Element Wattage

(110-ohm Heater)

FLT93F Element Wattage

(560-ohm Heater)

*J13 is standard for FLT93S/FLT93B and J14 is standard for FLT93F

Table 3-2 Selectable Heater Wattage Control

Jumper

FLT93F Element Wattage

(560-ohm Heater)

FLT93S/FLT93B Element Wattage

(110-ohm Heater)

Table 3-3 Fixed Heater Wattage Control (T4 Settings)

Jumper Alarm No. 1

J27 Relay De-Energized With Low Flow, Low Level (Dry)

Or High Temperature

J26 Relay De-Energized With High Flow, High Level (Wet)

Or Low Temperature

Jumper Alarm No. 2

J13 J14 J33

N.A. 0.25 watts OFF

0.75 watts N.A. OFF

J32 J12 J13 J14 J33

3 watts 1.75 watts 0.75 watts* 0.21 watts OFF

0.57 watts 0.52 watts 0.49 watts 0.25 watts* OFF

Flow/Level Temperature

Alarm No. 1

Alarm No. 2

Table 3-4 Alarm Duty/Application

J23 Dual SPDT (One Relay Per Alarm)

J22 Single DPDT (Disables Alarm No. 2)

Table 3-6 Alarm Qty./Relay Contact Conﬁguration

J20 J21

J18

J19

J25 Relay De-Energized With Low Flow, Low Level (Dry)

Or High Temperature

J24 Relay De-Energized With High Flow, High Level (Wet)

Or Low Temperature

Table 3-5 Relay Energization

Numerical Alarm Setpoint Adjustment

The control circuit has two mutually exclusive alarms identiﬁed as Alarm No. 1 and Alarm No. 2. Each has an alarm setpoint adjustment potentiometer and LED indicator. Both alarms can be set up for one of three applications; ﬂow, level/interface, or temperature. The following application speciﬁc adjustment procedures are generic and can be used for setting either or both alarms. Use Figure 3-2 to help locate the important setup components (potentiometers, LEDs, etc.)

Air/Gas Flow Applications

1. Remove the instrument’s enclosure cover.

2. Ensure the conﬁguration jumpers on the control circuit are correct for this application. See Tables 3-2 through 3-6.

3. Make sure the input power is wired correctly (see Section 2).

4. Apply power to the instrument. Verify the yellow LED is on. Allow ﬁfteen minutes for the instrument to warm-up.

5. Verify the Mode switch is in the RUN position.

6. Attach a DC voltmeter to the P1 test points with the positive (+) lead to position one (red) and the negative (-) lead to position two (blue).

7. Establish the normal process ﬂow condition and allow the signal to stabilize.

Note:

The output signal at the P1 test points will vary inversely with changes in the process ﬂow rate. The output signal level is

relative to the type of process media being measured and the heater wattage setting. See Figures 3-2 and 3-3.

8. Record the normal ﬂow signal value.

Normal Flow Signal = ________ volts DC

Fluid Components International LLC 19

OPERATION FLT® Series FlexSwitch

Figure 3-2 5208 Control Circuit Component Locations

9. Follow either the Detecting Decreasing Flow or the Detecting Increasing Flow procedure for each ﬂow application alarm.

Detecting Decreasing Flow (Low Flow Alarm)

1. Stop the process ﬂow and allow the signal to stabilize.

2. Record the no-ﬂow signal. Observe that the no-ﬂow signal is greater than the normal ﬂow signal.

No-Flow Signal = ________ volts DC

3. Determine the setpoint by calculating the average of the normal (step 8) and no-ﬂow output signals; e.g., if the normal signal is 2.000 volts and the no-ﬂow signal is 5.000 volts, then the calculated setpoint would be 3.500 volts.

4. Record this value.

Calculated Setpoint = ________ volts DC

Note:

The calculated setpoint must be at least 0.050 volts greater than the normal signal to ensure that the alarm will reset.

5. Move the Mode switch to the CAL position.

6. Adjust the calibration potentiometer (R24) until the voltmeter equals the calculated setpoint.

7. For the appropriate alarm, determine whether the status LED is on or off (red for Alarm No. 1 or green for Alarm No. 2). If the LED is off, turn the setpoint adjustment potentiometer (R26 for Alarm No. 1 or R25 for Alarm No. 2) slowly clockwise just until the LED turns on.

If the LED is on, turn the setpoint adjustment potentiometer (R26 for Alarm No. 1 or R25 for Alarm No. 2) counterclockwise until the LED turns off and then turn pot slowly clockwise just until the LED turns on.

8. If this is the only ﬂow application alarm to be set up, then skip to the Continue With The Air/Gas Flow Applications Procedure.

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FLT® Series FlexSwitchTM OPERATION

AIR OR GAS

OIL

WATER

OUTPUT VOLTAGE

Potentiometer

FLOW

FIELD ADJUSTABLE

SET POINT

(POT)

R25 AND R26

LED ON

ABOVE SETPOINT

LED OFF

BELOW SETPOINT

Adjust

Clockwise,

Turns

LED ON

SET POINT

Adjust

Counter-

clockwise,

Turns

LED OFF

C00204-1-2

Figure 3-3 Flow Application Signal Output

Detecting Increasing Flow (High Flow Alarm)

1. Establish the excessive process ﬂow condition and allow the signal to stabilize.

2. Record the high ﬂow signal. Observe that the high ﬂow signal is less than the normal ﬂow signal.

High Flow Signal = ________ volts DC

3. Determine the setpoint by calculating the average of the normal (step 8, page 17 - Air/Gas Flow Applications) and high ﬂow output signals; e.g., if the normal signal is 2.000 volts and the high ﬂow signal is 1.000 volts, then the calculated setpoint would be 1.500 volts. Record this value.

Calculated Setpoint = ________ volts DC

Note:

The calculated setpoint must be at least 0.50 volts less than the normal signal to ensure that the alarm will reset.

4. Move the Mode switch to the CAL position.

5. Adjust the calibration potentiometer (R24) until the voltmeter equals the calculated setpoint.

6. For the appropriate alarm, determine whether the status LED is on or off (red for Alarm No. 1 or green for Alarm No. 2). If the LED is on, turn the setpoint adjustment potentiometer (R26 for Alarm No. 1 or R25 for Alarm No. 2) slowly counterclockwise just until the LED turns off.

If the LED is off, turn the setpoint adjustment potentiometer (R26 for Alarm No. 1 or R25 for Alarm No. 2) clockwise until the LED turns on and then turn pot slowly counterclockwise just until the LED turns off.

Continue With The Air/Gas Flow Applications Procedure

1. Move the Mode switch to the RUN position.

2. Establish the normal process ﬂow condition. For low-ﬂow alarm setups, verify that the status LED is off. For high ﬂow alarm setups, verify that the status LED is on.

3. Establish the process alarm condition and monitor the voltmeter display.

4. When the output signal passes through the calculated setpoint value, verify that the status LED turns on for low-ﬂow alarms, or turns off for high ﬂow alarms, and that the relay contacts change state.

5. Reestablish the normal process ﬂow condition. Verify that the LED and the relay contacts reset.

Fluid Components International LLC 21

OPERATION FLT® Series FlexSwitch

SET POINT

TIME

OUTPUT VOLTAGE

AIR OR GAS

OIL

WATER

LED ON

ABOVE SETPOINT

LED OFF

BELOW SETPOINT

R25 AND R26

Adjust

Clockwise,

Turns

LED ON

Adjust

Counter-

clockwise,

Turns

LED OFF

FIELD ADJUSTABLE

SET POINT

Potentiometer

(POT)

DIESEL

C00070-1-2

6. Disconnect the voltmeter from P1.

7. Replace the enclosure cover.

Note:

The alarm can be set for a speciﬁc ﬂow rate. Follow the Air/Gas Flow Applications procedure up to step 7 except establish

ing Increasing Flow, respectively. Enter the speciﬁc ﬂow rate value as the setpoint. Then follow the Continue With the Air/ Gas Flow Procedure steps.

The default relay logic conﬁguration is for the relay coil to be de-energized when the ﬂow signal voltage is greater than the

setpoint value; i.e., in a normal process ﬂow condition the relay coil is energized if the alarm has been set for low-ﬂow detection and de-energized if the alarm has been set for high ﬂow detection. It is recommended to have the relay coils energized when the process condition is normal. This lets the relay go into a fail-safe alarm state in case of a power failure.

Wet/Dry Liquid Level Applications

1. Remove the instrument’s enclosure cover.

2. Ensure the conﬁguration jumpers on the control circuit are correct for this application. See Tables 3-2 through 3-6.

3. Make sure the input power is wired correctly (see Section 2).

4. Apply power to the instrument. Verify the yellow LED is on. Allow ﬁfteen minutes for the instrument to warm-up.

5. Verify the Mode switch is in the RUN position.

6. Attach a DC voltmeter to P1 with the positive (+) lead to position one (red) and the negative (-) lead to position two (blue).

7. Raise the process ﬂuid level so the sensing element is wet.

8. Allow the output signal to stabilize and record the wet condition value.

Wet Condition Signal = ________ volts DC

Note:

The output signal at P1 is relative to the type of process media detected. See Figure 3-4.

9. Lower the process ﬂuid level so the sensing element is dry.

10. Allow the output signal to stabilize and record the dry condition value. Observe that the dry signal is greater than the wet signal.

Dry Condition Signal = ________ volts DC

Figure 3-4. Level Application Signal Output

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FLT® Series FlexSwitchTM OPERATION

11. Determine the setpoint by calculating the average of the wet and dry output signals; e.g., if the wet signal is 0.200 volts and the dry signal is 4.000 volts, then the calculated setpoint would be 2.100 volts.

12. Record this value.

Calculated Setpoint = ________ volts DC

Note:

The calculated setpoint must be at least 0.030 volts greater than the wet signal and 0.040 volts less than the dry signal to

ensure that the alarm will reset.

13. Move the Mode switch to the CAL position.

14. Adjust the calibration potentiometer (R24) until the voltmeter equals the calculated setpoint.

15. For the appropriate alarm, determine whether the status LED is on or off (red for Alarm No. 1 or green for Alarm No. 2).

16. Follow either the Detecting Dry Condition or the Detecting Wet Condition for each level application alarm.

Detecting Dry Condition (Low Level Alarm)

If the status LED is off, turn the setpoint adjustment potentiometer (R26 for Alarm No. 1 or R25 for Alarm No. 2) slowly clockwise just until the LED turns on.

If the status LED is on, turn the setpoint adjustment potentiometer (R26 for Alarm No. 1 or R25 for Alarm No. 2) counterclockwise until the LED turns off and then turn pot slowly clockwise just until the LED turns on.

Detecting Wet Condition (High Level Alarm)

If the status LED is on, turn the setpoint adjustment potentiometer (R26 for Alarm No. 1 or R25 for Alarm No. 2) slowly counterclockwise just until the LED turns off.

If the status LED is off, turn the setpoint adjustment potentiometer (R26 for Alarm No. 1 or R25 for Alarm No. 2) clockwise until the LED turns on and then turn pot slowly counterclockwise just until the LED turns off.

17. Move the Mode switch to the RUN position. Observe that the status LED is on if the sensing element is dry or off if the sensing element is wet.

18. Monitor the voltmeter display while raising or lowering the process ﬂuid level. When the output signal passes through the setpoint, observe that the status LED and relay contacts change state.

19. Reestablish the normal level condition. Verify that the LED and relay contacts reset.

20. Disconnect the voltmeter from P1.

21. Replace the enclosure cover.

Note:

The default relay logic conﬁguration is for the relay coil to be de-energized when the level signal is greater than the setpoint

value; i.e., the relay coil will be de-energized when the sensing element is dry. It is recommended to have the relay coils energized when the process condition is normal. This lets the relay go into a fail-safe alarm state in case of a power failure.

Liquid Flow Applications

1. Remove the instrument’s enclosure cover.

2. Make sure the input power is wired correctly (see Section 2).

3. As necessary, set the following control circuit conﬁguration jumpers. See Tables 3-2 through 3-6. Application: J20 or J18 (Flow/Level) for alarm No. 1 or No. 2, respectively. Heater Power: J32 (3 watts for FLT93S/FLT93B or 0.57 watts for FLT93F).

4. Apply power to the instrument. Verify the yellow LED is on. Allow ﬁfteen minutes for the instrument to warm-up.

5. Verify the Mode switch is in the RUN position.

6. Attach a DC voltmeter to P1 connector with the positive (+) lead to position one (red) and the negative (-) lead to position two (blue).

Fluid Components International LLC 23

OPERATION FLT® Series FlexSwitch

Note:

The output signal at connector P1 varies inversely with changes in the process ﬂow rate. The output signal level is also rela-

tive to the type of process media being measured. See Figure 3-3.

7. Establish the normal process ﬂow condition and allow the signal to stabilize.

8. Record the normal ﬂow signal value.

Normal Flow Signal = ________ volts DC

9. Follow either the Detecting Decreasing Flow or Detecting Increasing Flow procedure for each Liquid ﬂow application alarm.

Detecting Decreasing Flow (Low Flow Alarm)

1. Stop the process ﬂow and allow the signal to stabilize.

2. Record the no-ﬂow signal. Observe that the no-ﬂow signal is greater than the normal ﬂow signal.

No-Flow Signal = ________ volts DC

3. Determine the setpoint by calculating the average of the normal and no-ﬂow output signals; e.g., if the normal signal is 0.080 volts and the no-ﬂow signal is 0.300 volts, then the calculated setpoint would be 0.190 volts.

4. Record this value.

Calculated Setpoint = ________ volts DC

Note:

The calculated setpoint must be at least 0.050 volts greater than the normal signal to ensure that the alarm will reset.

5. Move the Mode switch to the CAL position.

6. Adjust the calibration potentiometer (R24) until the voltmeter equals the calculated setpoint.

For the appropriate alarm, determine whether the status LED is on or off (red for No. 1 or green for No. 2).

If the LED is off, turn the setpoint adjustment potentiometer (R26 for Alarm No. 1 or R25 for Alarm No. 2) slowly clockwise just until the LED turns on.

7. If this is the only ﬂow application alarm to be set up, then skip to Continue With The Liquid Flow Applications Procedure.

Detecting Increasing Flow Rate (High Flow Alarm)

1. Establish the excessive ﬂow condition and allow the signal to stabilize.

2. Record the high ﬂow signal. Observe that the high ﬂow signal is less than the normal ﬂow signal.

High Flow Signal = ________ volts DC

3. Determine the setpoint by calculating the average of the normal (step 8 - Liquid Flow Applications) and high ﬂow output signals; i.e., if the normal signal is 0.38 volts and the high ﬂow signal is 0.13 volts, then the calculated setpoint would be 0.255 volts.

4. Record this value.

Calculated Setpoint = ________ volts DC

Note:

The calculated setpoint must be at least 0.050 volts less than the normal signal to ensure that the alarm will reset.

5. Move the Mode switch to the CAL position.

6. Adjust the calibration potentiometer (R24) until the voltmeter equals the calculated setpoint.

24 Fluid Components International LLC

FLT® Series FlexSwitchTM OPERATION

For the appropriate alarm, determine whether the status LED is on or off (red for No. 1 or green for No. 2).

If the LED is on, turn the setpoint adjustment potentiometer (R26 for Alarm No. 1 or R25 for Alarm No. 2) slowly counterclockwise just until the LED turns off.

If the LED is off, turn the setpoint adjustment potentiometer (R26 for Alarm No. 1 or R25 for Alarm No. 2) clockwise until the LED turns on and then slowly turn pot counterclockwise just until the LED turns off.

Continue With The Liquid Flow Applications Procedure

1. Move the Mode switch to the RUN position.

2. Establish the normal process ﬂow condition. For low-ﬂow alarm setups, observe that the status LED is off. For high ﬂow alarm setups observe that the status LED is on.

3. Establish the process alarm condition and monitor the voltmeter display.

4. When the output signal passes through the calculated setpoint value observe that the status LED should turns on for low-ﬂow alarms or off for high ﬂow alarms, and that the relay contacts change state.

5. Reestablish the normal process ﬂow condition. Observe that the LED and the relay contacts reset.

6. Disconnect the voltmeter from P1.

7. Replace the enclosure cover.

Note:

The alarm can be set for a speciﬁc ﬂow rate. Follow the Liquid Flow Applications procedure up to step 7 except establish

the speciﬁc ﬂow rate rather than the normal ﬂow. The output signal will be the setpoint value. Determine whether the alarm should actuate with decreasing or increasing ﬂow and skip to the appropriate step 4 in Detecting Decreasing Flow or Detecting Increasing Flow respectively. Enter the speciﬁc ﬂow rate value as the setpoint. Then continue with the rest of the procedure.

The default relay logic conﬁguration is for the relay coil to be de-energized when the ﬂow signal voltage is greater than the

Adjustment by Observation

Note:

The control circuit has two mutually exclusive alarms identiﬁed as Alarm No. 1 and Alarm No. 2. Each alarm has its own set-

point adjustment potentiometer and LED indicator. Each alarm can be set up for one of three applications: ﬂow, level/interface, or temperature. The following application speciﬁc adjustment procedures are generic and can be used for setting either or both alarms. The mode switch must be in the RUN position. Use Figure 3-2 to help locate the adjustment potentiometers and LEDs.

Flow Applications

1. Ensure that the instrument has been properly installed in the pipeline. Fill the pipeline so the sensing element is surrounded by the process medium.

2. Apply power to the instrument. Allow ﬁfteen minutes for the sensing element to stabilize.

3. Flow the pipeline at the normal or expected rate. Remove the enclosure cover to access the control circuit for adjustments.

Detecting Decreasing Flow (Low Flow Alarm)

If the status LED is off, turn the setpoint adjustment potentiometer clockwise until the LED turns on. With the LED on, slowly turn the potentiometer counterclockwise one turn past the point at which the LED just turns off. The potentiometer may have up to one-quarter turn of hysteresis; therefore, if the mark is overshot, repeat the procedure.

Detecting Increasing Flow (High Flow Alarm)

If the status LED is on, turn the setpoint adjustment potentiometer counterclockwise until the LED turns off. With the LED off, slowly turn the potentiometer clockwise one-half turn past the point at which the LED just turns on. The potentiometer may have up to one-quarter turn of hysteresis; therefore, if the mark is overshot, repeat the procedure.

Fluid Components International LLC 25

OPERATION FLT® Series FlexSwitch

Level Applications

1. Ensure that the instrument has been properly installed in the vessel.

2. Apply power to the instrument. Allow ﬁfteen minutes for the sensing element to stabilize.

3. Remove the enclosure cover to access the control circuit for adjustments.

Detecting Dry Condition (Adjustment With Sensing Element Wet)

Verify that the sensing element is wet. If the status LED is off, turn the setpoint adjustment potentiometer clockwise until the LED turns on. With the LED on, slowly turn the potentiometer counterclockwise one turn past the point at which the LED just turns off. The potentiometer may have up to one-quarter turn of hysteresis; therefore, if the mark is overshot, repeat the procedure.

Detecting Wet Condition (Adjustment With Sensing Element Dry)

Caution:

Give consideration to the fact that air or gas ﬂowing over the sensing element may decrease the output signal resulting in

a false alarm. If the sensing element is exposed to air or gas ﬂow in the dry condition, or where the process media is highly viscous, make setpoint adjustments in the wet condition only.

Field adjustments made in the dry condition should be performed in the actual service environment or within a condition that approximates that environment. Provision should be made for the worst case condition of air or gas ﬂow on the sensing element. If the status LED is on, turn the setpoint adjustment potentiometer counterclockwise until the LED turns off. (If the LED cannot be turned off, the instrument must be set in the wet condition.)

With the LED off, slowly turn the potentiometer clockwise 1 turn past the point at which the LED just goes on. The potentiometer may have up to one-quarter turn of hysteresis; therefore, if the mark is overshot, repeat the procedure.

Signal Output for Level Applications

The output signal at P1 is lowest in water and highest in air. See Figure 3-4.

Temperature Applications

For temperature versus voltage values, see Table 3-7 located at the rear of this section. These values have an accuracy of ±5 °F (±2.78 °C). There is also a conversion formula later in this section to convert the temperature output voltage to degrees Fahrenheit. If a factory calibration chart was ordered look at the back of this manual. Make sure the serial number of the chart matches the instrument to be adjusted.Remove the instrument’s enclosure cover.

1. Remove the instrument’s enclosure cover.

Caution:

2. Apply power to the instrument. Verify the yellow LED is on. Allow ﬁfteen minutes for the instrument to warm-up.

3. Verify the Mode switch is in the RUN position.

4. Attach a DC voltmeter to P1 with the positive (+) lead to position 3 (yellow) and the negative (-) lead to position 4 (black).

5. Establish the normal process temperature condition and allow the signal to stabilize.

6. Record the normal temperature signal value.

If both alarms are to be used for temperature, then remove the heater control jumper from the heater, control header. The

jumper may be stored on the control circuit by plugging it on position J33. Placing the jumper here will not turn on the heater. If one alarm is for temperature and the other is for ﬂow or level, then set the heater power according to the application. Use alarm No. 2 for the temperature alarm. See Table 3-2 or 3-3.

Normal Temperature Signal = ________ volts DC

Note:

The output signal at connector P1 varies in proportion to the process temperature.

7. Follow either the Detecting Increasing Temperature or the Detecting Decreasing Temperature procedure for each temperature application alarm.

26 Fluid Components International LLC

FLT® Series FlexSwitchTM OPERATION

Detecting Increasing Temperature (High Temperature Alarm)

1. Move the Mode switch to the CAL position.

2. Adjust the calibrate potentiometer (R24) until the voltmeter equals the desired temperature signal as indicated in Table 3-7.

For the appropriate alarm, determine whether the status LED is on or off (red for Alarm No. 1 or green for Alarm No. 2).

If the LED is off, turn the setpoint adjustment potentiometer (R26 for Alarm No. 1 or R25 for Alarm No. 2) slowly clockwise just until the LED turns on.

If the LED is on, turn the setpoint adjustment potentiometer (R26 for Alarm No. 1 or R25 for Alarm No. 2) counterclockwise until the LED turns off and then slowly turn pot clockwise just until the LED turns on.

If this is the only temperature application alarm to be set up, then skip to the Continue With The Temperature Applications Procedure.

Detecting Decreasing Temperature (Low Temperature Alarm)

1. Move the Mode switch to the CAL position.

2. Adjust the calibration potentiometer (R24) until the voltmeter equals the normal temperature signal.

3. For the appropriate alarm, determine whether the status LED is on or off (red for Alarm No. 1 or green for Alarm No. 2).

If the LED is on, turn the setpoint adjustment potentiometer (R26 for Alarm No. 1 or R25 for Alarm No. 2) slowly counterclockwise just until the LED turns off.

Continue With The Temperature Applications Procedure

1. Move the Mode switch to the RUN position.

2. Establish the normal process temperature condition. For the high temperature alarm setups, observe that the status LED is off at normal temperatures. For the low temperature alarm setups, observe that the status LED is on at normal temperatures.

3. Establish the process alarm condition and monitor the voltmeter display.

4. When the output signal passes through the setpoint value, observe that the status LED turns on for high temperature alarms or off for low temperature alarms, and that the relay contacts change state.

5. Reestablish the normal process temperature condition. Observe that the LED and relay contacts reset.

6. Disconnect the voltmeter from P1.

7. Replace the enclosure cover.

Note:

The default relay logic conﬁguration is for the relay coil to be de-energized when the temperature signal voltage is greater

than the setpoint value; i.e., in a normal process temperature condition the relay coil is energized. It is recommended to have the relay coils energized when the process temperature is normal. This lets the relay go into a fail-safe alarm state in case of a power failure.

Fluid Components International LLC 27

OPERATION FLT® Series FlexSwitch

Converting Temp Out Voltage to Temp in Degrees F or Degrees C

This formula is useful when monitoring the temperature output voltage with a data acquisition system where the formula can be used in the program.

Use the following formula to determine what the temperature is in degrees Fahrenheit, if the FLT temperature output voltage is known.

y = a + b(x/0.002) + c(x/0.002)

Where: y = Temperature in Degrees F

x = FLT Temperature Output Voltage

a = -409.3253

b = 0.42224

c = .00001904

Use the following equation to convert the temperature from degrees Fahrenheit to Celsius:

C = (F - 32) x 5/9

28 Fluid Components International LLC

FLT® Series FlexSwitchTM OPERATION

0.00385 OHMS/OHMS/ºC 1000 OHM PLATINUM SENSORS

TEMPERATURE VERSUS VOLTAGE OUTPUT, FLT93

Temp Output

Voltage

°F °C Temp Output

Voltage

°F °C Temp Output

Voltage

°F °C Temp Output

Voltage

°F °C

1.400 -104 -76 1.600 -59 -51 1.800 -14 -25 2.000 32 0

1.405 -103 -75 1.605 -58 -50 1.805 -13 -25 2.005 33 1

1.410 -102 -75 1.610 -57 -49 1.810 -12 -24 2.010 34 1

1.415 -101 -74 1.615 -56 -49 1.815 -10 -24 2.015 35 2

1.420 -100 -73 1.620 -55 -48 1.820 -9 -23 2.020 37 3

1.425 -99 -73 1.625 -54 -48 1.825 -8 -22 2.025 38 3

1.430 -98 -72 1.630 -53 -47 1.830 -7 -22 2.030 39 4

1.435 -97 -71 1.635 -51 -46 1.835 -6 -21 2.035 40 4

1.440 -95 -71 1.640 -50 -46 1.840 -5 -20 2.040 41 5

1.445 -94 -70 1.645 -49 -45 1.845 -4 -20 2.045 42 6

1.450 -93 -70 1.650 -48 -44 1.850 -2 -19 2.050 43 6

1.455 -92 -69 1.655 -47 -44 1.855 -1 -19 2.055 45 7

1.460 -91 -68 1.660 -46 -43 1.860 0 -18 2.060 46 8

1.465 -90 -68 1.665 -45 -43 1.865 1 -17 2.065 47 8

1.470 -89 -67 1.670 -43 -42 1.870 2 -17 2.070 48 9

1.475 -88 -66 1.675 -42 -41 1.875 3 -16 2.075 49 10

1.480 -86 -66 1.680 -41 -41 1.880 4 -15 2.080 50 10

1.485 -85 -65 1.685 -40 -40 1.885 6 -15 2.085 52 11

1.490 -84 -65 1.690 -39 -39 1.890 7 -14 2.090 53 12

1.495 -83 -64 1.695 -38 -39 1.895 8 -13 2.095 54 12

1.500 -82 -63 1.700 -37 -38 1.900 9 -13 2.100 55 13

1.505 -81 -63 1.705 -36 -38 1.905 10 -12 2.105 56 13

1.510 -80 -62 1.710 -34 -37 1.910 11 -12 2.110 57 14

1.515 -79 -61 1.715 -33 -36 1.915 12 -11 2.115 58 15

1.520 -77 -61 1.720 -32 -36 1.920 14 -10 2.120 60 15

1.525 -76 -60 1.725 -31 -35 1.925 15 -10 2.125 61 16

1.530 -75 -60 1.730 -30 -34 1.930 16 -9 2.130 62 17

1.535 -74 -59 1.735 -29 -34 1.935 17 -8 2.135 63 17

1.540 -73 -58 1.740 -28 -33 1.940 18 -8 2.140 64 18

1.545 -72 -58 1.745 -26 -32 1.945 19 -7 2.145 65 19

1.550 -71 -57 1.750 -25 -32 1.950 20 -6 2.150 67 19

1.555 -70 -56 1.755 -24 -31

1.955 22 -6 2.155 68 20

1.560 -68 -56 1.760 -23 -31 1.960 23 -5 2.160 69 20

1.565 -67 -55 1.765 -22 -30 1.965 24 -5 2.165 70 21

1.570 -66 -55 1.770 -21 -29 1.970 25 -4 2.170 71 22

1.575 -65 -54 1.775 -20 -29 1.975 26 -3 2.175 72 22

1.580 -64 -53 1.780 -18 -28 1.980 27 -3 2.180 74 23

1.585 -63 -53 1.785 -17 -27 1.985 28 -2 2.185 75 24

1.590 -62 -52 1.790 -16 -27 1.990 30 -1 2.190 76 24

1.595 -60 -51 1.795 -15 -26 1.995 31 -1 2.195 77 25

Table 3-7. Temperature versus Voltage Output - Page 1

Fluid Components International LLC 29

OPERATION FLT® Series FlexSwitch

0.00385 OHMS/OHMS/ºC 1000 OHM PLATINUM SENSORS

TEMPERATURE VERSUS VOLTAGE OUTPUT, FLT93

Temp Output

Voltage

°F °C Temp Output

Voltage

°F °C Temp Output

Voltage

°F °C Temp Output

Voltage

°F °C

2.200 78 26 2.400 125 52 2.600 172 78 2.800 219 104

2.205 79 26 2.405 126 52 2.605 173 78 2.805 220 105

2.210 80 27 2.410 127 53 2.610 174 79 2.810 221 105

2.215 82 28 2.415 128 53 2.615 175 80 2.815 223 106

2.220 83 28 2.420 129 54 2.620 176 80 2.820 224 107

2.225 84 29 2.425 131 55 2.625 178 81 2.825 225 107

2.230 85 30 2.430 132 55 2.630 179 82 2.830 226 108

2.235 86 30 2.435 133 56 2.635 180 82 2.835 227 109

2.240 87 31 2.440 134 57 2.640 181 83 2.840 229 109

2.245 89 31 2.445 135 57 2.645 182 84 2.845 230 110

2.250 90 32 2.450 136 58 2.650 184 84 2.850 231 111

2.255 91 33 2.455 138 59 2.655 185 85 2.855 232 111

2.260 92 33 2.460 139 59 2.660 186 86 2.860 233 112

2.265 93 34 2.465 140 60 2.665 187 86 2.865 235 113

2.270 94 35 2.470 141 61 2.670 188 87 2.870 236 113

2.275 96 35 2.475 142 61 2.675 189 87 2.875 237 114

2.280 97 36 2.480 144 62 2.680 191 88 2.880 238 115

2.285 98 37 2.485 145 63 2.685 192 89 2.885 239 115

2.290 99 37 2.490 146 63 2.690 193 89 2.890 241 116

2.295 100 38 2.495 147 64 2.695 194 90 2.895 242 117

2.300 101 39 2.500 148 65 2.700 195 91 2.900 243 117

2.305 103 39 2.505 149 65 2.705 197 91 2.905 244 118

2.310 104 40 2.510 151 66 2.710 198 92 2.910 245 119

2.315 105 41 2.515 152 67 2.715 199 93 2.915 247 119

2.320 106 41 2.520 153 67 2.720 200 93 2.920 248 120

2.325 107 42 2.525 154 68 2.725 201 94 2.925 249 121

2.330 108 42 2.530 155 68 2.730 202 95 2.930 250 121

2.335 110 43 2.535 156 69 2.735 204 95 2.935 251 122

2.340 111 44 2.540 158 70 2.740 205 96 2.940 253 123

2.345 112 44 2.545 159 70 2.745 206 97 2.945 254 123

2.350 113 45 2.550 160 71 2.750 207 97 2.950 255 124

2.355 114 46 2.555 161 72

2.755 208 98 2.955 256 124

2.360 115 46 2.560 162 72 2.760 210 99 2.960 257 125

2.365 117 47 2.565 164 73 2.765 211 99 2.965 258 126

2.370 118 48 2.570 165 74 2.770 212 100 2.970 260 126

2.375 119 48 2.575 166 74 2.775 213 101 2.975 261 127

2.380 120 49 2.580 167 75 2.780 214 101 2.980 262 128

2.385 121 50 2.585 168 76 2.785 216 102 2.985 263 128

2.390 122 50 2.590 169 76 2.790 217 103 2.990 264 129

2.395 124 51 2.595 171 77 2.795 218 103 2.995 266 130

Table 3-7. Temperature versus Voltage Output - Page 2

30 Fluid Components International LLC

FLT® Series FlexSwitchTM OPERATION

0.00385 OHMS/OHMS/ºC 1000 OHM PLATINUM SENSORS

TEMPERATURE VERSUS VOLTAGE OUTPUT, FLT93

Temp Output

Voltage

°F °C Temp Output

Voltage

°F °C Temp Output

Voltage

°F °C Temp Output

Voltage

°F °C

3.000 267 130 3.200 315 157 3.400 363 184 3.600 412 211

3.005 268 131 3.205 316 158 3.405 365 185 3.605 414 212

3.010 269 132 3.210 317 159 3.410 366 186 3.610 415 213

3.015 270 132 3.215 319 159 3.415 367 186 3.615 416 213

3.020 272 133 3.220 320 160 3.420 368 187 3.620 417 214

3.025 273 134 3.225 321 161 3.425 370 188 3.625 419 215

3.030 274 134 3.230 322 161 3.430 371 188 3.630 420 215

3.035 275 135 3.235 323 162 3.435 372 189 3.635 421 216

3.040 276 136 3.240 325 163 3.440 373 190 3.640 422 217

3.045 278 136 3.245 326 163 3.445 374 190 3.645 423 217

3.050 279 137 3.250 327 164 3.450 376 191 3.650 425 218

3.055 280 138 3.255 328 165 3.455 377 192 3.655 426 219

3.060 281 138 3.260 330 165 3.460 378 192 3.660 427 220

3.065 282 139 3.265 331 166 3.465 379 193 3.665 428 220

3.070 284 140 3.270 332 167 3.470 381 194 3.670 430 221

3.075 285 140 3.275 333 167 3.475 382 194 3.675 431 222

3.080 286 141 3.280 334 168 3.480 383 195 3.680 432 222

3.085 287 142 3.285 336 169 3.485 384 196 3.685 433 223

3.090 288 142 3.290 337 169 3.490 385 196 3.690 435 224

3.095 290 143 3.295 338 170 3.495 387 197 3.695 436 224

3.100 291 144 3.300 339 171 3.500 388 198 3.700 437 225

3.105 292 144 3.305 340 171 3.505 389 198 3.705 438 226

3.110 293 145 3.310 342 172 3.510 390 199 3.710 439 226

3.115 294 146 3.315 343 173 3.515 392 200 3.715 441 227

3.120 296 146 3.320 344 173 3.520 393 200 3.720 442 228

3.125 297 147 3.325 345 174 3.525 394 201 3.725 443 228

3.130 298 148 3.330 346 175 3.530 395 202 3.730 444 229

3.135 299 149 3.335 348 175 3.535 396 202 3.735 446 230

3.140 301 149 3.340 349 176 3.540 398 203 3.740 447 230

3.145 302 150 3.345 350 177 3.545 399 204 3.745 448 231

3.150 303 151 3.350 351 177 3.550 400 205 3.750 449 232

3.155 304 151 3.355 353 178

3.555 401 205 3.755 451 233

3.160 305 152 3.360 354 179 3.560 403 206 3.760 452 233

3.165 307 153 3.365 355 179 3.565 404 207 3.765 453 234

3.170 308 153 3.370 356 180 3.570 405 207 3.770 454 235

3.175 309 154 3.375 357 181 3.575 406 208 3.775 455 235

3.180 310 155 3.380 359 181 3.580 407 209 3.780 457 236

3.185 311 155 3.385 360 182 3.585 409 209 3.785 458 237

3.190 313 156 3.390 361 183 3.590 410 210 3.790 459 237

3.195 314 157 3.395 362 183 3.595 411 211 3.795 460 238

Table 3-7. Temperature versus Voltage Output - Page 3

Fluid Components International LLC 31

OPERATION FLT® Series FlexSwitch

0.00385 OHMS/OHMS/ºC 1000 OHM PLATINUM SENSORS

TEMPERATURE VERSUS VOLTAGE OUTPUT, FLT93

Temp Output

Voltage

°F °C Temp Output

Voltage

°F °C Temp Output

Voltage

°F °C Temp Output

Voltage

°F °C

3.800 462 239 4.000 511 266 4.200 561 294 4.400 612 322

3.805 463 239 4.005 513 267 4.205 563 295 4.405 613 323

3.810 464 240 4.010 514 268 4.210 564 295 4.410 614 323

3.815 465 241 4.015 515 268 4.215 565 296 4.415 616 324

3.820 467 241 4.020 516 269 4.220 566 297 4.420 617 325

3.825 468 242 4.025 518 270 4.225 568 298 4.425 618 326

3.830 469 243 4.030 519 270 4.230 569 298 4.430 619 326

3.835 470 244 4.035 520 271 4.235 570 299 4.435 621 327

3.840 472 244 4.040 521 272 4.240 571 300 4.440 622 328

3.845 473 245 4.045 523 273 4.245 573 300 4.445 623 328

3.850 474 246 4.050 524 273 4.250 574 301 4.450 624 329

3.855 475 246 4.055 525 274 4.255 575 302 4.455 626 330

3.860 477 247 4.060 526 275 4.260 576 302 4.460 627 331

3.865 478 248 4.065 528 275 4.265 578 303 4.465 628 331

3.870 479 248 4.070 529 276 4.270 579 304 4.470 629 332

3.875 480 249 4.075 530 277 4.275 580 305 4.475 631 333

3.880 481 250 4.080 531 277 4.280 581 305 4.480 632 333

3.885 483 250 4.085 533 278 4.285 583 306 4.485 633 334

3.890 484 251 4.090 534 279 4.290 584 307 4.490 635 335

3.895 485 252 4.095 535 279 4.295 585 307 4.495 636 335

3.900 486 252 4.100 536 280 4.300 586 308 4.500 637 336

3.905 488 253 4.105 538 281 4.305 588 309 4.505 638 337

3.910 489 254 4.110 539 282 4.310 589 309 4.510 640 338

3.915 490 255 4.115 540 282 4.315 590 310 4.515 641 338

3.920 491 255 4.120 541 283 4.320 592 311 4.520 642 339

3.925 493 256 4.125 543 284 4.325 593 312 4.525 643 340

3.930 494 257 4.130 544 284 4.330 594 312 4.530 645 340

3.935 495 257 4.135 545 285 4.335 595 313 4.535 646 341

3.940 496 258 4.140 546 286 4.340 597 314 4.540 647 342

3.945 498 259 4.145 548 286 4.345 598 314 4.545 649 343

3.950 499 259 4.150 549 287 4.350 599 315 4.550 650 343

3.955 500 260 4.155 550 288

4.355 600 316 4.555 651 344

3.960 501 261 4.160 551 288 4.360 602 316 4.560 652 345

3.965 503 261 4.165 553 289 4.365 603 317 4.565 654 345

3.970 504 262 4.170 554 290 4.370 604 318 4.570 655 346

3.975 505 263 4.175 555 291 4.375 605 319 4.575 656 347

3.980 506 264 4.180 556 291 4.380 607 319 4.580 657 347

3.985 508 264 4.185 558 292 4.385 608 320 4.585 659 348

3.990 509 265 4.190 559 293 4.390 609 321 4.590 660 349

3.995 510 266 4.195 560 293 4.395 610 321 4.595 661 350

Table 3-7. Temperature versus Voltage Output - Page 4

32 Fluid Components International LLC

FLT® Series FlexSwitchTM OPERATION

0.00385 OHMS/OHMS/ºC 1000 OHM PLATINUM SENSORS

TEMPERATURE VERSUS VOLTAGE OUTPUT, FLT93

Temp Output

Voltage

4.600 663 350 4.800 714 379 5.000 765 407 5.200 817 436

4.605 664 351 4.805 715 379 5.005 767 408 5.205 818 437

4.610 665 352 4.810 716 380 5.010 768 409 5.210 820 438

4.615 666 352 4.815 718 381 5.015 769 410 5.215 821 438

4.620 668 353 4.820 719 382 5.020 770 410 5.220 822 439

4.625 669 354 4.825 720 382 5.025 772 411 5.225 824 440

4.630 670 355 4.830 721 383 5.030 773 412 5.230 825 441

4.635 671 355 4.835 723 384 5.035 774 412 5.235 826 441

4.640 673 356 4.840 724 384 5.040 776 413 5.240 828 442

4.645 674 357 4.845 725 385 5.045 777 414 5.245 829 443

4.650 675 357 4.850 727 386 5.050 778 415 5.250 830 443

4.655 677 358 4.855 728 387 5.055 779 415 5.255 832 444

4.660 678 359 4.860 729 387 5.060 781 416 5.260 833 445

4.665 679 360 4.865 730 388 5.065 782 417 5.265 834 446

4.670 680 360 4.870 732 389 5.070 783 417 5.270 835 446

4.675 682 361 4.875 733 389 5.075 785 418 5.275 837 447

4.680 683 362 4.880 734 390 5.080 786 419 5.280 838 448

4.685 684 362 4.885 736 391 5.085 787 420 5.285 839 449

4.690 686 363 4.890 737 392 5.090 789 420 5.290 841 449

4.695 687 364 4.895 738 392 5.095 790 421 5.295 842 450

4.700 688 364 4.900 739 393 5.100 791 422 5.300 843 451

4.705 689 365 4.905 741 394 5.105 792 422 5.305 845 451

4.710 691 366 4.910 742 394 5.110 794 423 5.310 846 452

4.715 692 367 4.915 743 395 5.115 795 424 5.315 847 453

4.720 693 367 4.920 745 396 5.120 796 425 5.320 849 454

4.725 694 368 4.925 746 397 5.125 798 425 5.325 850 454

4.730 696 369 4.930 747 397 5.130 799 426 5.330 851 455

4.735 697 369 4.935 748 398 5.135 800 427 5.335 852 456

4.740 698 370 4.940 750 399 5.140 802 428 5.340 854 457

4.745 700 371 4.945 751 399 5.145 803 428 5.345 855 457

4.750 701 372 4.950 752 400 5.150 804 429 5.350 856 458

4.755 702 372 4.955 754 401

4.760 703 373 4.960 755 402 5.160 807 430 5.360 859 459

4.765 705 374 4.965 756 402 5.165 808 431 5.365 860 460

4.770 706 374 4.970 757 403 5.170 809 432 5.370 862 461

4.775 707 375 4.975 759 404 5.175 811 433 5.375 863 462

4.780 709 376 4.980 760 404 5.180 812 433 5.380 864 462

4.785 710 377 4.985 761 405 5.185 813 434 5.385 866 463

4.790 711 377 4.990 763 406 5.190 815 435 5.390 867 464

4.795 712 378 4.995 764 407 5.195 816 435 5.395 868 465

°F °C Temp Output

Voltage

°F °C Temp Output

Voltage

5.155 805 430 5.355 858 459

°F °C Temp Output

Voltage

°F °C

Table 3-7. Temperature versus Voltage Output - Page 5

Fluid Components International LLC 33

OPERATION FLT® Series FlexSwitch

Fail-Safe Alarm Setting

These procedures set the second relay to detect component failure (fail-safe).

Low Flow Alarm Settings

Install the following jumpers for the low ﬂow fail-safe setup: J18, J20, J23, J24, J27.

Figure 3-5. Low Flow Fail-Safe Alarm

The following information is assumed:

Relay is de-energized in the ALARM condition.

Alarm 1 setpoint is adjusted for desired low ﬂow alarm velocity or signal.

Alarm 2 setpoint is adjusted slightly below minimum signal output (over range ﬂow).

High Flow Alarm Settings

Install the following jumpers for the high ﬂow fail-safe setup: J18, J20, J23, J25, J26.

The following information is assumed:

Relay is de-energized in the ALARM condition.

Alarm 1 setpoint is adjusted for desired high ﬂow alarm velocity or signal.

Alarm 2 setpoint is adjusted above maximum signal output (under range ﬂow not to exceed 7.0 volts).

34 Fluid Components International LLC

Figure 3-6. High Flow Fail-Safe Alarm

FLT® Series FlexSwitchTM OPERATION

Low Level Alarm Settings (Sensing Element Normally Wet)

Install the following jumpers for the low level fail-safe setup: J18, J20, J23, J24, J27.

Figure 3-7. Low Level Fail-Safe Alarm

The following information is assumed:

Relay is de-energized in the ALARM condition.

Alarm 1 setpoint is adjusted for the mean value between the air and liquid signals.

Alarm 2 setpoint is adjusted to approximately half of the liquid signal. (A lower setting might be needed if the liquid is moving.)

High Level Alarm Settings (Sensing Element Normally Dry)

Install the following jumpers for the high level fail-safe setup: J18, J20, J23, J25, J26.

Figure 3-8. High Level Fail-Safe Alarm

The following information is assumed:

Relay is de-energized in the ALARM condition.

Alarm 1 setpoint is adjusted for the mean value between the air and liquid signals.

Alarm 2 setpoint is adjusted above maximum signal output for air (not to exceed 7.0 volts).

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OPERATION FLT® Series FlexSwitch

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36 Fluid Components International LLC

FLT® Series FlexSwitchTM MAINTENANCE

4 MAINTENANCE

Warning:

Caution:

The FCI instrument requires very little maintenance. There are no moving parts or mechanical parts subject to wear in the instrument. The sensor assembly which is exposed to the process media is all stainless steel construction and is only susceptible to chemical attack based on the corrosion relationship of the RTD thermowell material with the process media.

To avoid hazards to personnel, ensure that all environmental isolation seals are properly maintained.

The insturment contains electrostatic discharge (ESD) sensitive devices. Use standard ESD precautions when handling the

control circuit. See Section 2, Operation, for ESD details.

Maintenance

Without detailed knowledge of the environmental parameters of the application surroundings and process media, FCI cannot make speciﬁc recommendations for periodic inspection, cleaning, or testing procedures. However, some suggested general guidelines for maintenance steps are offered below. Use operating experience to establish the frequency of each type of maintenance.

Calibration

Periodically verify the calibration of the output and re-calibrate if necessary. See Section 3 for instructions.

Cleaning

If cleaning is necessary, use a cloth dampened with plain water to avoid danger of ignition due to electrostatic charges on painted enclosure according to EN/IEC 60079-0 clause 7.4.2 and 7.4.3.

Electrical Connections

Periodically inspect cable connections on terminal strips and terminal blocks. Verify that terminal connections are tight and in good condition with no sign of corrosion.

Remote Enclosure

Verify that the moisture barriers and seals protecting the electronics in the local and remote enclosures are adequate and that no moisture is entering those enclosures.

Electrical Wiring

FCI recommends occasional inspection of the system’s interconnecting cable, power wiring and sensing element wiring on a common sense basis related to the application environment. Periodically inspect conductors for corrosion as well as the cable insulation for signs of deterioration.

Sensing Element Connections

Verify that all seals are performing properly and that there is no leakage of the process media. Check for deterioration of the gaskets and environmental seals used.

Sensing Element Assembly

Periodically remove the sensing element for inspection based on historical evidence of debris, foreign matter, or scale buildup during appropriate plant shutdown schedules and procedures. Check for corrosion, stress cracking, and/or buildup of oxides, salts, or other substances. The thermowells must be free of excessive contaminants and be physically intact. Any debris or residue buildup could cause inaccurate switching. Clean the sensing element with a soft brush and available solvents that are compatible with the instruments wetted metal.

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MAINTENANCE FLT® Series FlexSwitch

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FLT® Series FlexSwitchTM TROUBLESHOOTING

5 TROUBLESHOOTING

Warning:

Caution:

Tools Needed

Digital Multimeter (DMM) 3 Slotted Screwdrivers - 3/32” (2 mm); 1/8” (3 mm); 1/4” (6 mm) Small Phillips head screwdriver

Quick Check

• Verify that the control circuit is seated ﬁrmly in the terminal board socket.

• Verify that LED DS3 (yellow LED) is on when power is applied.

• If LED DS3 ﬂashes the heater power is set too high for most applications.

• Ensure that the jumpers are in the correct position. See Section 3 for the correct positions. Check input power.

• Ensure that the Mode switch is in the RUN position (switch S1 positioned toward the heat sink).

• Check any customer supplied fuses or disconnects.

• See the troubleshooting chart in Figure 5-1 at the end of this section.

Non-maintenance Observations

At this point, observe the system setup to verify operation. No disassembly or testing is required at this time.

Only qualiﬁed personnel should attempt to test this instrument. The operator assumes all responsibilities for safe practices

while troubleshooting.

The control circuit contains electrostatic discharge (ESD) sensitive devices. Use standard ESD precautions when handling the

control circuit. See Section 2, Operation, for ESD details.

Check Serial Numbers

Verify that the serial number of the sensing element and the control circuit are the same number. The sensing element and the control circuit are a matched set and cannot be operated independently of each other. The exception to this is if a removal and replacement have been done for repair purposes. All calibrations and jumpers must have been done and set.

Check Input Power

Verify that the correct power source is turned on and connected. Verify that the correct power jumper is installed and the power wiring is correct for the application. See Section 3 for the correct positions.

Check the Instrument Installation

Review the information on instrument installation in Section 2 to verify correct mechanical and electrical installation.

Check for Moisture

Check for moisture on the control circuit, whether in the local sensor enclosure (integral) or remote control circuit enclosure (remote). Moisture on the control circuit may cause intermittent operation.

Check Application Design Requirements

Application design problems may occur with ﬁrst time application instruments, although the design should also be checked on instruments that have been in operation for some time. If the application design does not match ﬁeld conditions, errors occur.

1. Review the application design with plant operation personnel and plant engineers.

2. Ensure that plant equipment such as pressure and temperature instruments conform to the actual conditions.

3. Verify operating temperature, operating pressure, line size, and process medium.

If conditions and speciﬁcations are satisfactory, then refer to the troubleshooting chart in the back of this section for troubleshooting suggestions.

Fluid Components International LLC 39

TROUBLESHOOTING FLT® Series FlexSwitch

Troubleshooting the Flow Element

Use Tables 5-1 and 5-2 to determine if the ﬂow element is wired correctly or has failed. Turn off the input power to the instrument. Unplug the control circuit from its socket and measure the resistances below from the terminal board.

If the instrument is set up in remote conﬁguration (ﬂow element enclosure separate from the control circuit enclosure), and the ohm readings are incorrect, disconnect the ﬂow element cable at the local (ﬂow element) enclosure. Measure the resistance as shown in Table 5-2. If the resistances are correct then the cable between the enclosures is probably bad or not connected properly (loose, corroded, or connected to the wrong terminals).

For normally dry conditions check for moisture on the sensing element. If a component of the process media is near its saturation temperature it may condense on the sensing element. Place the sensing element where the process media is well above the saturation temperature of any of the process gases.

NOMINAL RESISTANCE READINGS AT THE TERMINAL BOARD

@ 78 °F PROCESS TEMPERATURE

TERMINAL NUMBER RESISTANCE

ACT TO COM 1.1 K OHMS*

ACT TO REF 2.2 K OHMS*

COM TO REF 1.1 K OHMS*

HTR+ TO HTR-

110-120 OHMS FOR FLT93S 548-620 OHMS FOR FLT93F

Table 5-1. Resistance at Control Circuit Terminal Board

(See Fig. 5-1 for test points)

NOMINAL RESISTANCE AT LOCAL ENCLOSURE TERMINAL BLOCK

TERMINAL NO. RESISTANCE

1 TO 2

110 OHMS FOR FLT93S

548-620 OHMS FOR FLT93F

3 TO 4 1.1 K OHMS*

3 TO 5 2.2 K OHMS*

4 TO 5 1.1 K OHMS*

SHIELD CONNECTED TO CONTROL CIRCUIT SOCKET ONLY. NO

CONNECTION TO LOCAL ENCLOSURE OR ITS TERMINAL BLOCK **

Table 5-2. Resistance at Flow Element enclosure Terminal Block (Remote Applications Only)

* Approximate at 78 °F (26 °C) process temperature.

** Reference wiring diagrams in the Installation section of the manual.

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FLT® Series FlexSwitchTM TROUBLESHOOTING

Figure 5-1 Terminal Board, Test Points

Fluid Components International LLC 41

TROUBLESHOOTING FLT® Series FlexSwitch

Troubleshooting the Control Circuit

1 Is the Yellow Power indicator LED:

Dim, Off or Blinking

Yellow LED dim or off

With the power applied, measure the 9-volt reference voltage at P1, pins 2 (blue) to 4 (black). See Figure 3-2 for the location of P1. Verify a voltage of 9 volts DC ±2% (8.82-9.18 V). Not OK: Low Reading: A low reading may indicate incorrect power is being applied. Turn off the power and remove the control circuit. Caution: While the power is on, use extreme care when measuring the input voltage. Check the input power wiring on the terminal board and make corrections if necessary. Before reinstalling the control circuit, apply the input voltage to verify or correct. Check disconnects. Turn off the power and reinstall the control circuit. Apply power and re-check the 9-volt reference.

Not OK: No Reading: Go to step 2 and check the fuses.

OK: If the 9-volt reference measures correctly and the yellow LED is off, refer to

the Troubleshooting the Flow Element discussion in this section. On remote installa- tions, the interconnect cable may be miswired or a wire may be disconnected. If the ﬂow element resistances are not correct contact the factory. If the sensor is OK then proceed to step 4.

Yellow LED Blinking: For Liquid Flow Applications: Line is Dry. Make sure that the line is packed. For Gas Flow Applications: Heater power set too high. Set to a lower value. For Liquid Level Applications: Heater power set too high. Set to lower value. For Liquid Interface Application: In some cases it is necessary to set the heater power to the maximum value to achieve the maximum signal difference between the two liquids. Blinking is okay.

2 Fuse Check Turn off the power and remove the control circuit. For installations using 120/230

VAC, remove F1 and F2. With an ohmmeter, measure the continuity of the fuses. If one or both of the fuses are open, replace and recheck if the control circuit functions properly. If the one or both fuses open again, contact the factory. If the fuses are OK but the control circuit does not power up contact the factory.

For installations using 24 VAC/VDC, remove the bottom insulator and locate F3. With an ohmmeter, measure the continuity across the fuses. If the fuse is open, replace and recheck if the control circuit functions properly. If fuse opens again, contact the factory. If the fuse is OK but the control circuit does not power up contact the factory.

3 Flow switch not responding Is the Mode switch in the “RUN” position?

Is the signal voltage reacting to ﬂow or liquid level movement and is the signal within the usable range of 0-7.0 volts at P1 pin 1 (red) and 2 (blue)?

Not OK: Go to step 4.

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FLT® Series FlexSwitchTM TROUBLESHOOTING

4 Signal Voltage Observation With the power applied, note the position of the heater wattage control jumper

plug and remove it. Place the jumper plug temporally on position J33. With a voltmeter measure the voltage at P1 pins 1 (red) and 2 (blue).

a) The voltage is 0 volts ±25 mV: OK

Reinstall the jumper plug and wait 5 minutes. Go to c) or d) whichever is applicable.

b) The voltage is out of tolerance: NOT OK. Make sure the serial numbers from the sensor element and the control circuit match. If the serial numbers match then go the Restoring the Temp Comp Adjustments procedure in appendix D then go to c) or d) whichever is applicable.

c) The voltage is between 0 and 7 volts and changes with ﬂow or level changes: OK.

See Step 5 switch point

d) The voltage is still about 0 volts: or the voltage is stuck over ±7 volts: or the voltage is negative between 0 and –7 volts and changes with ﬂow or level changes: Not OK. The sensing element may be miswired or defective.

Miswiring is more common on remote installations at the initial installation. Refer to the Troubleshooting the Flow Element discussion in this section. On remote installations, the interconnect cable may be miswired or a wire may be disconnected. If the ﬂow element resistances are not correct contact the factory.

5 Alarm Switch Make sure that the jumpers are set correctly. The related settings are the “Alarm

Duty”, “Alarm Quantity”, and the “Energization”. Refer to the charts in Section 3 or the label on the bottom side of the control circuit.

Using the Mode Switch set to CAL, check and record the alarm settings. Compare these settings to the signals generated by the process and make adjustment if necessary. Refer to the Operation section for guidelines on setting a switch point in your particular application.

Table 5-3. Troubleshooting Chart

Enclosures

To maintain Hazardous Locations Approvals, no repairs are allowed for defective or damaged enclosures. These enclosures shall be replaced by FCI to ensure the ﬂameproof threaded joints continue to comply in accordance to the certiﬁcations.

Spares

FCI recommends an extra control circuit to be kept as a spare. The control circuit part number is 5208-XXX. The dash number can be found on the control circuit, the enclosure and on the order documents. Also recommended is an extra terminal board as a spare, part number 020786-01.

Defective Parts

Before returning any equipment to FCI, please obtain an RA number for authorization, tracking, and repair/replacement instructions. If a return is required, remove defective instrument, replace with spare, calibrate, then return defective instrument to FCI freight prepaid for disposition.

Customer Service

1. In the event of problems or inquiries regarding the instrument, please contact an authorized FCI ﬁeld agent for the region or country.

Refer to the FCI website: http://www.ﬂuidcomponents.com/ for a list of ﬁeld service representatives (which includes phone and email contact information) and a list of service centers around the world.

2. Before contacting the FCI representative, please be sure that all the applicable information is near so that a more effective, efﬁcient and

timely response may be provided.

3. Refer to Appendix E for speciﬁc Customer Service policy provisions.

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TROUBLESHOOTING FLT® Series FlexSwitch

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FLT® Series FlexSwitchTM APPENDIX A - DRAWINGS

APPENDIX A DRAWINGS

3/4” NPT with Local Hazardous Location Type 4X Enclosure

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APPENDIX A - DRAWINGS FLT® Series FlexSwitch

3/4” NPT with Local Hazardous Location Type 4X Enclosure: 3-Port Remote Type 4X

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FLT® Series FlexSwitchTM APPENDIX A - DRAWINGS

1” NPT with Local Hazardous Location Type 4X Enclosure

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APPENDIX A - DRAWINGS FLT® Series FlexSwitch

1” NPT with Local Hazardous Location Type 4X Enclosure: 3-Port Remote Type 4X

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FLT® Series FlexSwitchTM APPENDIX A - DRAWINGS

Flanged with Local Hazardous Location Type 4X Enclosure

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APPENDIX A - DRAWINGS FLT® Series FlexSwitch

Flanged with Local Hazardous Location Type 4X Enclosure: 3-Port Remote Type 4X

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FLT® Series FlexSwitchTM APPENDIX A - DRAWINGS

1-1/4” NPT Low Pressure Packing Gland with Local Hazardous Location Type 4X Enclosure

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APPENDIX A - DRAWINGS FLT® Series FlexSwitch

1-1/4” NPT Low Pressure Packing Gland with Local Hazardous Location Type 4X Enclosure: 3-Port Remote Type 4X

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FLT® Series FlexSwitchTM APPENDIX A - DRAWINGS

Flanged Low Pressure Packing Gland with Local Hazardous Location Type 4X Enclosure

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APPENDIX A - DRAWINGS FLT® Series FlexSwitch

Flanged Low Pressure Packing Gland with Local Hazardous Location Type 4X Enclosure: 3-Port Remote Type 4X

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FLT® Series FlexSwitchTM APPENDIX A - DRAWINGS

1-1/4” NPT, Medium Pressure Packing Gland with Local Hazardous Location Type 4X Enclosure

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APPENDIX A - DRAWINGS FLT® Series FlexSwitch

1-1/4” NPT, Medium Pressure Packing Gland with Local Hazardous Location Type 4X Enclosure: 3-Port Remote Type 4X

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FLT® Series FlexSwitchTM APPENDIX A - DRAWINGS

Flanged, Medium Pressure Packing Gland with Local Hazardous Location Type 4X Enclosure

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APPENDIX A - DRAWINGS FLT® Series FlexSwitch

Flanged, Medium Pressure Packing Gland with Local Hazardous Location Type 4X Enclosure: 3-Port Remote Type 4X

58 Fluid Components International LLC

FLT® Series FlexSwitchTM APPENDIX A - DRAWINGS

3/4” MNPT Compression Fitting with Local Hazardous Location Type 4X Enclosure

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APPENDIX A - DRAWINGS FLT® Series FlexSwitch

3/4” MNPT Compression Fitting with Local Hazardous Location Type 4X Enclosure: 3-Port Remote Type 4X

60 Fluid Components International LLC

FLT® Series FlexSwitchTM APPENDIX A - DRAWINGS

Flanged Compression Fitting with Local Hazardous Location Type 4X Enclosure

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APPENDIX A - DRAWINGS FLT® Series FlexSwitch

Flanged Compression Fitting with Local Hazardous Location Type 4X Enclosure: 3-Port Remote Type 4X

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FLT® Series FlexSwitchTM APPENDIX A - DRAWINGS

FLT93F Style Head : 1/4” NPT with Local Hazardous Location Type 4X Enclosure

Fluid Components International LLC 63

APPENDIX A - DRAWINGS FLT® Series FlexSwitch

FLT93F Style Head: 1/4” NPT with Local Hazardous Location Type 4X Enclosure: 3-Port Remote Type 4X

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FLT® Series FlexSwitchTM APPENDIX A - DRAWINGS

FLT93L: 3/4” NPT with Local Hazardous Location Type 4X Enclosure

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APPENDIX A - DRAWINGS FLT® Series FlexSwitch

FLT93L: 3/4” NPT with Local Hazardous Location Type 4X Enclosure: 3-Port Remote Type 4X

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FLT® Series FlexSwitchTM APPENDIX A - DRAWINGS

FLT93L: 1” NPT with Local Hazardous Location Type 4X Enclosure

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APPENDIX A - DRAWINGS FLT® Series FlexSwitch

FLT93L: 1” NPT with Local Hazardous Location Type 4X Enclosure: 3-Port Remote Type 4X

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FLT® Series FlexSwitchTM APPENDIX A - DRAWINGS

FLT93L: Flanged with Local Hazardous Location Type 4X Enclosure

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APPENDIX A - DRAWINGS FLT® Series FlexSwitch

FLT93L: Flanged with Local Hazardous Location Type 4X Enclosure: 3-Port Remote Type 4X

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FLT® Series FlexSwitchTM APPENDIX A - DRAWINGS

FLT93C : Sanitary Flange with Local Hazardous Location Type 4X Enclosure

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APPENDIX A - DRAWINGS FLT® Series FlexSwitch

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FLT93 Surface Mount: Local Wiring Diagram

FLT® Series FlexSwitchTM APPENDIX A - DRAWINGS

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FLT93 Surface Mount : Remote Wiring Diagram

APPENDIX A - DRAWINGS FLT® Series FlexSwitch

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FLT93 PWB Module: 5208

FLT® Series FlexSwitchTM APPENDIX B - GLOSSARY

APPENDIX B GLOSSARY

Abbreviations

Delta-R (DR) Differential Resistance

Delta-T (DT) Differential Temperature

DMM Digital Multimeter

DPDT Double Pole Double Throw

FCI Fluid Components Intl

HTR Heater

LED Light Emitting Diode

POT Potentiometer

RA Return Authorization

RTD Resistance Temperature Detector

SFPS Standard Feet Per Second

SPDT Single Pole Double Throw

Deﬁnitions

Active RTD The sensing element that is heated by the heater. The active RTD is cooled due to increases in the

process ﬂuid ﬂow rate or density (level sensing).

Differential resistance Delta-R (DR) The difference in resistance between the active and reference RTDs.

Differential temperature Delta-T (DT) The difference in temperature between the active and reference RTDs.

Heater (HTR) The part of the sensing element that heats the active RTD.

Local enclosure The enclosure attached to the sensing element. (Usually contains the control circuit and mounting socket.)

Reference RTD The part of the sensing element that senses the process media temperature.

Remote enclosure An optional protective enclosure for the control circuit. Used when the control circuit must be located away

from the sensing element.

Resistance Temperature Detector (RTD) A sensor whose resistance changes proportionally to temperature changes.

Sensing element The transducer portion of the instrument. The sensing element produces an electrical signal that is related to

the ﬂow rate, density (level sensing), and temperature of the process media.

Thermowell The part of the sensing element that protects the heater and RTDs from the process ﬂuid.

Turndown The ratio of minimum ﬂow rate to maximum ﬂow rate.

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APPENDIX B - GLOSSARY FLT® Series FlexSwitch

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FLT® Series FlexSwitchTM APPENDIX C - APPROVAL INFORMATION

APPENDIX C APPROVAL INFORMATION

EC Information

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APPENDIX C - APPROVAL INFORMATION FLT® Series FlexSwitch

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FLT® Series FlexSwitchTM APPENDIX C - APPROVAL INFORMATION

Safety Instructions for the Use of the FLT93 Flowswitch in Hazardous Areas

Approval KEMA 02ATEX2166 X and Approval IEC certiﬁcate IECEx DEK14.0080X for:

Integral Version:

II 2 G Ex db IIC T4…T2 Gb II 2 D Ex tb IIIC T135 °C…T300 °C Db

Remote Enclosure + Electronics:

II 2 G Ex db IIC T6 Gb II 2 D Ex tb IIIC T85 °C Db

Local Enclosure + Sensor:

II 2 G Ex db IIC T4…T1 Gb II 2 D Ex tb IIIC T135 °C…T345 °C Db

Pigtail Variant:

II 2 G Ex db IIC T4…T3 Gb II 2 D Ex tb IIIC T135 °C…T200 °C Db

Compliance with Essential Health and Safety Requirements:

EN 60079-0 : 2012+A11 EN 60079-1 : 2014 EN 60079-31 : 2014 IEC 60079-0 : 2011 IEC 60079-1 : 2014 IEC 60079-31 : 2013

Special condition for safe use: Contact manufacturer for information with regard to ﬂame-proof joints.

Dansk Sikkerhedsforskrier Italiano Normative di sicurezza Deutsch Sicherheitshinweise Nederlands Veiligheidsinstructies English Safety instructions Português Normas de segurança Υπ Υπ_δεί_εις ασφαλείας Español Instrucciones de seguridad Suomi Turvallisuusohjeet Svenska Säkerhetsanvisningar Français Consignes de sécurité

DK Dansk- Sikkerhedsforskrifter

Disse sikkerhedsforskrier gælder for Fluid Components, FLT93 Flowswitch EF-typeafprøvningsattest-nr. KEMA 02 ATEX 2166 (attestens nummer på typeskiltet) er egnet til at blive benyttet i eksplosiv atmosfære kategori II 2 G.

1) Ex-anlæg skal principielt opstilles af specialiseret personale.

2) FLT93 Flowswitch skal jordforbindes.

3) Klemmerne og elektronikken er monteret i et hus, som er beskyttet af en eksplosionssikker kapsling med følgende noter:

• Gevindspalten mellem huset og låget er på en sådan måde, at ild ikke kan brede sig inden i det.

• Ex-„d“ tilslutningshuset er forsynet med et 1" NPT og/eller 3/4" NPT gevind for montering af en Ex-„d“ kabelindføring, der er attesteret iht. EN/IEC 60079-1

• Det er vigtigt at sørge for, at forsyningsledningen er uden spænding eller eksplosiv atmosfære ikke er til stede, før låget åbnes og når låget er åbent på „d” huset (f.eks. ved tilslutning eller servicearbejde).

• Låget på „d” huset skal være skruet helt ind, når apparatet er i brug. Det skal sikres ved at dreje en af låseskruerne på låget ud.

D A Deutsch-Sicherheitshinweise

Diese Sicherheitshinweise gelten für die Fluid Components, FLT93 Flowswitch gemäß der EG-Baumusterprüescheinigung Nr. KEMA 02 ATEX 2166 (Bescheinigungsnummer auf dem Typschild) der Kategorie II 2 G.

1) Die Errichtung von Ex-Anlagen muss grundsätzlich durch Fachpersonal vorgenommen werden.

2) Der FLT93 Flowswitch muß geerdet werden.

3) Die Klemmen und Elektroniken sind in einem Gehäuse in der Zündschutzart druckfeste Kapselung („d“ ) eingebaut.

• Der Gewindespalt zwischen dem Gehäuse und dem Deckel ist ein zünddurchschlagsicherer Spalt.

• Das Ex-“d“ Anschlussgehäuse besitzt ein 3/4“ und/oder 1” NPT Gewinde für den Einbau einer nach EN/IEC 60079-1 bescheinigten Ex-“d“ Kabeleinführung.

• Es ist sicherzustellen, dass vor dem Önen und bei geönetem Deckel des „d“ Gehäuses (z.B. bei Anschluss oder Service- Arbeiten) entweder die Versorgungsleitung spannungsfrei oder keine explosionsfähige Atmosphäre vorhanden ist.

• Der Deckel des „d“ Gehäuses muss im Betrieb bis zum Anschlag hineingedreht sein. Er ist durch eine der Deckelarretierungsschrauben zu sichern.

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APPENDIX C - APPROVAL INFORMATION FLT® Series FlexSwitch

GB IRL English- Safety instructions

ese safety instructions are valid for the Fluid Components, FLT93 Flowswitch to the EC type approval certicate no. KEMA 02 ATEX 2166 (certicate number on the type label) for use in potentially explosive atmospheres in Category II 2 G.

1) e installation of Ex-instruments must be made by trained personnel.

2) e FLT93 Flowswitch must be grounded.

3) e terminals and electronics are installed in a ame proof and pressure-tight housing with following notes:

• e gap between the housing and cover is an ignition-proof gap.

• e Ex-“d“ housing connection has a 1” and/or 3/4 “ NPT cable entry for mounting an Ex-d cable entry certied acc. to EN/IEC 60079-1.

• Make sure that before opening the cover of the Ex”d“ housing, the power supply is disconnected or there is no explosive atmosphere present (e.g. during connection or service work).

• During normal operation: e cover of the “d“ housing must be screwed in completely and locked by tightening one of the cover locking screws.

GR Υπ_δεί_εις ασφαλείας

Αυτές οι οδηγίες ασφαλείας ισχύουν για τα Ροόμετρα της Fluid Components τύπου FLT93 Flowswitch που φέρουν Πιστοποιητικό Εγκρίσεως Ευρωπαϊκής Ένωσης, με αριθμό πιστοποίησης KEMA 02 ATEX 2166 (ο αριθμός πιστοποίησης βρίσκεται πάνω στην ετικέτα τύπου του οργάνου) για χρήση σε εκρηκτικές ατμόσφαιρες της κατηγορίας II 2 G.

1) Η εγκατάσταση των οργάνων με αντιεκρηκτική προστασία πρέπει να γίνει από εξειδικευμένο προσωπικό.

2) Το όργανο τύπου FLT93 Flowswitch πρέπει να είναι γειωμένο.

3) Τα τερματικά ηλεκτρικών συνδέσεων (κλέμες) και τα ηλεκτρονικά κυκλώματα είναι εγκατεστημένα σε περίβλημα αντιεκρηκτικό και αεροστεγές σύμφωνα με τις ακόλουθες παρατηρήσεις:

• Το κενό ανάμεσα στο περίβλημα και στο κάλυμμα είναι τέτοιο που αποτρέπει την διάδοση σπινθήρα.

• Το “Ex-d” αντιεκρηκτικό περίβλημα, έχει ανοίγματα εισόδου καλωδίου με διάμετρο ¾ ή/και 1 ίντσα NPT, κατάλληλα για τοποθέτηση υποδοχής αντιεκρηκτικού καλωδίου πιστοποιημένης κατά EN/IEC 60079-1

• Βεβαιωθείτε ότι πριν το άνοιγμα καλύμματος του του “Ex-d” αντιεκρηκτικού περιβλήματος, η τάση τροφοδοσίας είναι αποσυνδεδεμένη ή ότι δεν υφίσταται στη περιοχή εκρηκτική ατμόσφαιρα (π.χ. κατά τη διάρκεια της σύνδεσης ή εργασιών συντήρησης)

• Κατά τη διάρκεια ομαλής λειτουργίας: Το κάλυμα του “d” καλύμματος αντιεκρηκτικού περιβλήματος πρέπει να είναι εντελώς βιδωμένο και ασφαλισμένο, σφίγγοντας μία από τις βίδες ασφαλείας του περιβλήματος.

FIN Suomi - Turvallisuusohjeet

Nämä turvallisuusohjeet koskevat Flud Components, FLT93 Flowswitch EY-tyyppitarkastustodistuksen nro. KEMA 02 ATEX 2166 mukaisesti (todistuksen numero näkyy tyyppikilvestä) käytettäessä räjähdysvaarallisissa tiloissa luokassa II 2G.

1) Ex-laitteet on aina asennettava ammattihenkilökunnan toimesta.

2) FLT93 Flowswitch on maadoitettava.

3) Syöttöjännitteen kytkemisessä tarvittavat liittimet ja elektroniikka on asennettu koteloon jonka rakenne kestää räjähdyspaineen seuraavin lisäyksin:

• Kotelon ja kannen välissä on räjähdyksen purkausväli.

• Ex-d liitäntäkotelossa on 3/4“ NPT ja/tai 1“ NPT kierre EN/IEC 60079-1 mukaisen Ex-d kaapeliläpiviennin asennusta varten

• Kun “d“-kotelon kansi avataan (esim. liitännän tai huollon yhteydessä), on varmistettava, että joko syöttöjohto on jännitteetön tai ympäristössä ei ole räjähtäviä aineita.

• “d“ -kotelon kansi on kierrettävä aivan kiinni käytön yhteydessä ja on varmistettava kiertämällä yksi kannen lukitusruuveista kiinni.

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FLT® Series FlexSwitchTM APPENDIX C - APPROVAL INFORMATION

F B L Consignes de sécurité

Ces consignes de sécurité sont valables pour le modèle FLT93 Flowswitch de la société Fluid Components (FCI) conforme au certicat d’épreuves de type KEMA 02 ATEX 2166 (numéro du certicat sur l’étiquette signalétique) conçu pour les applications dans lesquelles un matériel de la catégorie II2G est nécessaire.

1) Seul un personnel spécialisé et qualié est autorisé à installer le matériel Ex.

2) Les FLT93 Flowswitch doivent être reliés à la terre.

3) Les bornes pour le branchement de la tension d’alimentation et l’électronique sont logées dans un boîtier à enveloppe antidéagrante avec les notes suivantes:

• Le volume entre le boîtier et le couvercle est protégé en cas d’amorçage.

• Le boîtier de raccordement Ex-d dispose d’un letage ¾’’ NPT et/ou 1’’ NPT pour le montage d’un presse-étoupe Ex-d certié selon la EN/IEC 60079-1.

• Avant d’ouvrir le couvercle du boîtier « d » et pendant toute la durée où il le restera (pour des travaux de raccordement, d’entretien ou de dépannage par exemple), il faut veiller à ce que la ligne d’alimentation soit hors tension ou à ce qu’il n’y ait pas d’atmosphère explosive.

• Pendant le fonctionnement de l’appareil, le couvercle du boîtier « d » doit être vissé et serré jusqu’en butée. La bonne xation du couvercle doit être assurée en serrant une des vis d’arrêt du couvercle.

I Italiano - Normative di sicurezza

Queste normative di sicurezza si riferiscono ai Fluid Components, FLT93 Flowswitch secondo il certicato CE di prova di omologazione n° KEMA 02 ATEX 2166 (numero del certicato sulla targhetta d’identicazione) sono idonei all’impiego in atmosfere esplosive applicazioni che richiedono apparecchiature elettriche della Categoria II 2 G.

1) L’installazione di sistemi Ex deve essere eseguita esclusivamente da personale specializzato.

2) I FLT93 Flowswitch devono essere collegati a terra.

3) I morsetti per il collegamento e l’elettronica sono incorporati in una custodia a prova di esplosione („d“) con le seguenti note:

• La sicurezza si ottiene grazie ai cosidetti „interstizi sperimentali massimi“, attraverso i quali una eventuale accensione all’interno della custodia non può propagarsi all’esterno o raggiungere altre parti dell’impianto.

• La scatola di collegamento Ex-d ha una lettatura 3/4“ e/o 1“ NPT per il montaggio di un passacavo omologato Ex-d secondo EN/IEC 60079-1.

• Prima di aprire il coperchio della custodia „d“ (per es. durante operazioni di collegamento o di manutenzione) accertarsi che l’apparecchio sia disinserito o che non si trovi in presenza di atmosfere esplosive.

• Avvitare il coperchio della custodia „d“ no all’arresto. Per impedire lo svitamento del coperchio é possibile allentare una delle 2 viti esagonali poste sul corpo della custodia, incastrandola nella sagoma del coperchio.

NL B Nederlands - Veiligheidsinstructies

Deze veiligheidsinstructies gelden voor de Fluid Components, FLT93 Flowswitch overeenkomstig de EG-typeverklaring nr. KEMA 02 ATEX 2166 (nummer van de verklaring op het typeplaatje) voor gebruik in een explosieve atmosfeer volgens Categorie II 2G.

1) Installatie van Ex-instrumenten dient altijd te geschieden door geschoold personeel.

2) De FLT93 moet geaard worden.

3) De aansluitklemmen en de electronika zijn ingebouwd in een drukvaste behuizing met de volgende opmerkingen:

• De schroefdraadspleet tussen de behuizing en de deksel is een ontstekingsdoorslagveilige spleet.

• De Ex-d aansluitbehuizing hee een ¾” of een 1” NPT schroefdraad voor aansluiting van een volgens EN/IEC 60079-1 goedgekeurde Ex- ‘d’ kabelinvoer.

• Er moet worden veilig gesteld dat vóór het openen bij een geopende deksel van de ‘d’ behuizing (bijv. bij aansluit- of servicewerkzaamheden) hetzij de voedingsleiding spanningsvrij is, hetzij geen explosieve atmosfeer aanwezig is.

• De deksel van de ‘d’ behuizing moet tijdens bedrijf tot aan de aanslag erin geschroefd zijn. Hij moet door het eruit draaien van een van de dekselborgschroeven worden geborgd.

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APPENDIX C - APPROVAL INFORMATION FLT® Series FlexSwitch

P Português - Normas de segurança

Estas normas de segurança são válidas para os Fluid Components, FLT93 Flowswitch conforme o certicado de teste de modelo N.º KEMA 02 ATEX 2166 (número do certicado na plaqueta com os dados do equipamento) são apropriados para utilização em atmosferas explosivas categoria II 2 G.

1) A instalação de equipamentos em zonas sujeitas a explosão deve, por princípio, ser executada por técnicos qualicados.

2) Os FLT93 Flowswitch precisam ser ligados à terra.

3) Os terminais e a electrónica para a conexão da tensão de alimentação estão instalados num envólucro com protecção contra ignição á prova de sobrepressão com as seguintes notas:

• A fenda entre o envólucro e a tampa deve ser á prova de passagem de centelha.

• O envólucro de conexão Ex-“d“ possui uma rosca 1“ NPT e/ou 3/4“ NPT para a entrada de cabos Ex-“d“ certicado conforme a

norma EN/IEC 60079-1.

• Deve-se assegurar que, antes de abrir a tampa do armário „d“ ( por exemplo, ao efectuar a conexão ou durante trabalhos de

manutenção), o cabo de alimentação esteja sem tensão ou que a atmosfera não seja explosíva.

• Durante a operação, a tampa do envólucro „d“ deve estar aparafusada até o encosto. A tampa deve ser bloqueada, por um dos

parafusos de xação.

E Español - Instrucciones de seguridad

Estas indicaciones de seguridad son de aplicación para el modelo FLT93 Flowswitch de Fluid Components, según la certicación CE de modelo Nº KEMA 02 ATEX 2166 para aplicaciones en atmósferas potencialmente explosivas según la categoría II 2 G (el número de certicación se indica sobre la placa informativa del equipo).

1) La instalación de equipos Ex tiene que ser realizada por personal especializado.

2) Los FLT93 Flowswitch tienen que ser conectados a tierra.

3) Los bornes de conexión y la unidad electrónica están montados dentro de una caja con protección antideagrante y resistente a presión, considerándose los siguientes puntos:

• La holgura entre la rosca de la tapa y la propia de la caja está diseñada a prueba contra ignición.

• La caja tiene conexiones eléctricas para entrada de cables con rosca 3/4" y/o 1" NPT, donde deberán conectarse prensaestopas

certicados Exd según EN/IEC 60079-1.

• Antes de la apertura de la tapa de la caja “Exd” (p. ej. durante los trabajos de conexionado o de puesta en marcha) hay que asegu-

rar que el equipo se halle sin tensión o que no exista presencia de atmósfera explosiva.

• Durante el funcionamiento normal: la tapa de la caja antideagrante tiene que estar cerrada, roscada hasta el tope, debiendose

asegurar apretando los tornillos de bloqueo.

S Svenska - Säkerhetsanvisningar

Säkerhetsanvisningarna gäller för Fluid Components, Flödesmätare typ FLT93 Flowswitch enligt EG-typkontrollintyg nr KEMA 02 ATEX 2166 (intygsnumret åternns på typskylten) är lämpad för användning i explosiv gasblandning i kategori II 2 G.

1) Installation av Ex- klassade instrument måste alltid utföras av fackpersonal.

2) FLT93 Flowswitch måste jordas.

3) Anslutningsklämmorna och elektroniken är inbyggda i en explosions och trycktät kapsling med följande kommentar:

• Spalten mellan kapslingen och lockets gänga är amsäker.

• Ex-d kapslingen har en 3/4" och / eller 1" NPT gänga för montering av en EN/IEC 60079-1 typkontrollerad Ex- „d” kabel försk-

ruvning

• När Ex- „d”-kapslingens lock är öppet (t.ex. vid inkoppling - eller servicearbeten) ska man se till att enheten är spänningslös

eller att ingen explosiv gasblandning förekommer. Under dri måste Ex - d”-kapslingens lock vara iskruvad till anslaget. För att säkra locket skruvarman i en av lockets insex låsskruvar.

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FLT® Series FlexSwitchTM APPENDIX C - APPROVAL INFORMATION

FLT93

S3B1A

custom

B4custom

custom

IIIIII

V till VII

VIII

X till XII

XIII

XIV till XV

Pos.

Explanation

Value

Explanation

FLT93S

FLT93C

Insertion style with larger OD thermowells (S=Std response time)

Insertion style with larger OD thermowells Sanitary version

Agency Approval 36

ATEX approved IECEx approved

Customer tagplate

12-40 °C to + 177 °C

(Refer to thermal data in this Annex.)

316 (L) stainless steel (only for S and F type of sensor)

Titanium grade 2 (only for S type of sensor)

Process

insertion length

Pigtail version; sensor with cable pigtail

Stainless steel Ex d enclosure with single cable entry

Configuration

electronics)

Application

calibrations

None (the electronics is mounted inside local enclosure of pos. VIII.)

Stainless steel Ex d enclosure with single cable entry

Annex 1

Annex 1 to Certificate of Conformity IECEx DEK 14.0080X, issue 0 Annex 1 to IECEx TR NL/DEK/ExTR14.0088/00 Annex 1 to EU Type Examination Certificate KEMA 02ATEX2166 X, issue 4

Note 1: in this document [.] is used as decimal separator.

Type designation Flow, Level or Temperature FlexSwitch Series FLT93

The Flow, Level or Temperature FlexSwitch Series FLT93 are divided into three styles: Insertion style: FLT93S, FLT93F and FLT93C Basic insertion style: FLT93B In-line style: FLT93L

Model decoding FLT93S, FLT93F and FLT93C series Insertion style

II.

III.

IV.

V till VII

VIII.

IX.

X till XII

Type of sensor

Process temperature

Material of sensor

connections, size of process connection and

Local enclosure (local = at sensor)

(type of

alarm point 1, 2,

FTL93F

custom

custom Not relevant for Ex type of protection

Insertion style with small OD thermowells (F=Fast response time)

B 316L stainless steel

-40 °C to + 260 °C (only with remote enclosure, pos. XIII ≠ 0)

316 (L) stainless steel electro polished

Hastelloy C276 (only for S and F type of sensor)

Monel 400 (only for S and F type of sensor)

Process connection & size not relevant for Ex type of protection Insertion length till 3 050 mm. Material of flange stainless steel, carbon steel or same as sensor.

(only when I=3 and XIII = B, G or C)

Aluminium Ex d enclosure with single cable entry

Aluminium Ex d enclosure with dual cable entry

Standard version of electronics

Electronic with hermitically sealed relays contacts

Remote

XIII.

enclosure

DEKRA Certification B.V. Meander 1051, 6825 MJ Arnhem P.O. Box 5185, 6802 ED Arnhem The Netherlands T +31 88 9683000 F +31 88 9683100 www.dekra-certification.com Registered Arnhem 09085396

Fluid Components International LLC 83

B G

Aluminum Ex d enclosure with single cable entries Aluminum Ex d enclosure with dual cable entries

Page 1 of 5

Form 124

Version 2 (2013-07)

APPENDIX C - APPROVAL INFORMATION FLT® Series FlexSwitch

Pos.

Explanation

Value

Explanation

FLT93

BBcustom

II till V

Pos.

Explanation

Value

Explanation

Model FLT93B is a preconfigured version of FCI's model FLT93S in

with single cable entry

Agency Approval

ATEX approved IECEx approved

II.

Identification Tag

IV.

Input Power

custom

Field selectable, see electrical data

Annex 1 to Certificate of Conformity IECEx DEK 14.0080X, issue 0 Annex 1 to IECEx TR NL/DEK/ExTR14.0088/00 Annex 1 to EU Type Examination Certificate KEMA 02ATEX2166 X, issue 4

XIV

Cable material

till XV

& length

Model decoding FLT93B series Basic Insertion style

Type of sensor FLT93B

custom PVC or Teflon cable, length not relevant of Ex type of protection

the following configuration: FLT series Basic x Type of sensor: S style (insertion style with larger OD

thermowells)

x Process temperature: -40 °C to + 177 °C x Material of sensor: 316L stainless steel x Process connection: 3/4 “ NPT Male x Local enclosure: electronics integral in aluminum Ex d enclosure

Insertion length custom Insertion length till 102 mm.

III.

custom Not relevant for Ex type of protection

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FLT® Series FlexSwitchTM APPENDIX C - APPROVAL INFORMATION

FLT93L

3B1

custom

B4custom

custom

IIIIII

IV VVI

VII

VIII

IX till XI

XII

XIII till XIV

Pos.

Explanation

Value

Explanation

Type of sensor

FLT93L

In-line version (thermowells placed inside pipe spoolpiece)

Agency Approval

36ATEX approved

IECEx approved

II.

Customer tagplate

12-40 °C to + 177 °C

(Refer to thermal data in this Annex.)

Sensor configuration

316 (L) stainless steel

Titanium grade 2

Process connections

Process connection not relevant for Ex type of protection. Material of flange stainless steel, carbon steel or same as sensor.

Sensor with cable pigtail: requires Ex d adapter and cable gland (only

Stainless steel Ex d enclosure with single cable entry

Configuration

electronics)

Application

calibrations

None (the electronics is mounted inside local enclosure of pos. VII.)

Stainless steel Ex d enclosure with single cable entry

XIII

XIV

Annex 1 to Certificate of Conformity IECEx DEK 14.0080X, issue 0 Annex 1 to IECEx TR NL/DEK/ExTR14.0088/00 Annex 1 to EU Type Examination Certificate KEMA 02ATEX2166 X, issue 4

Model decoding FLT93L series In-line style

B 316L stainless steel

Process

III.

temperature

IV.

Material of

sensor

VI.

Local enclosure

VII.

(local = at sensor)

VIII.

(type of

IX till

alarm point 1, 2,

Remote

XII.

enclosure

Cable material

till

& length

-40 °C to + 260 °C (only with remote enclosure, pos. XII ≠ 0)

custom Not relevant for Ex type of protection

Hastelloy C276

Monel 400

custom

when I = 3 and XII = B, G, C)

Aluminium Ex d enclosure with single cable entry Aluminium Ex d enclosure with dual cable entry

Standard version of electronics

Electronic with hermitically sealed relays contacts

custom Not relevant for Ex type of protection

Aluminum Ex d enclosure with single cable entries

Aluminum Ex d enclosure with dual cable entries

custom PVC or Teflon cable, length not relevant of Ex type of protection

Electrical data:

Power supply : 115 Vac (± 15) 50/60 Hz; 13 watts, 100 mA max. : 230 Vac (± 10) 50/60 Hz; 14 watts, 50 mA max. : 24 Vac (18 V to 26 Vac) 50/60 Hz; 7 watts, 230 mA max. : 24 Vdc (21 V to 30 Vdc); 7 watts, 230 mA max. Relay Rating : 115 Vac / 240 Vac or 24 Vdc, 6A Sensing Element Heater Power : 3.0 W max.

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APPENDIX C - APPROVAL INFORMATION FLT® Series FlexSwitch

Temperature class

Maximum surface temperature

Ambient temperature

T85 °C

-40 °C to +60 °C

Temperature class

Maximum surface temperature

Ambient temperature

T85 °C

-34 °C to +60 °C

Temperature class

Maximum surface temperature

Ambient temperature

Process temperature

T135 ºC

-40 °C to +45 °C

T200 ºC

-40 °C to +65 °C

-40 °C to +110 °C

T300 ºC

-40 °C to +65 °C

-40 °C to +177 °C

Temperature class

Maximum surface temperature

Ambient temperature

Process temperature

T135 ºC

-34 °C to +45 °C

T200 ºC

-34 °C to +50 °C

-34 °C to +110 °C

T300 ºC

-34 °C to +50 °C

-34 °C to +177 °C

Temperature class

Maximum surface temperature

Ambient temperature

Process temperature

T135 ºC

-40 °C to +45 °C

T200 ºC

-40 °C to +65 °C

-40 °C to +110 °C

T300 ºC

-40 °C to +65 °C

-40 °C to +177 °C

T345 ºC

-40 °C to +65 °C

-40 °C to +260 °C

Temperature class

Maximum surface temperature

Ambient temperature

Process temperature

T135 ºC

-34 °C to +45 °C

T200 ºC

-34 °C to +50 °C

-34 °C to +110 °C

T300 ºC

-34 °C to +50 °C

-34 °C to +177 °C

T345 ºC

-34 °C to +50 °C

-34 °C to +260 °C

Annex 1 to Certificate of Conformity IECEx DEK 14.0080X, issue 0 Annex 1 to IECEx TR NL/DEK/ExTR14.0088/00 Annex 1 to EU Type Examination Certificate KEMA 02ATEX2166 X, issue 4

Thermal data

The relation between temperature class, maximum surface temperature, ambient temperature and process temperature of the different configurations are indicated below.

Integral version

Integral enclosure in single cable entry variant:

Integral enclosure in dual cable entry variant:

Remote enclosure + electronics

Remote enclosure in single cable entry variant:

Remote enclosure in dual cable entry variant:

Local enclosure + sensor

Local enclosure in single cable entry variant:

Local enclosure in dual cable entry variant:

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FLT® Series FlexSwitchTM APPENDIX C - APPROVAL INFORMATION

Temperature class

Maximum surface temperature

Ambient temperature

Process temperature

T135 ºC

-20 °C to +45 °C

T200 ºC

-20 °C to +55 °C

Annex 1 to Certificate of Conformity IECEx DEK 14.0080X, issue 0 Annex 1 to IECEx TR NL/DEK/ExTR14.0088/00 Annex 1 to EU Type Examination Certificate KEMA 02ATEX2166 X, issue 4

Pigtail version (only for ATEX)

Local enclosure in pigtail variant:

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FLT® Series FlexSwitchTM APPENDIX C - APPROVAL INFORMATION

SIL Information

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INTENTIONALLY LEFT BLANK

90 Fluid Components International LLC

FLT® Series FlexSwitchTM APPENDIX D - TEMP COMP

APPENDIX D TEMPERATURE COMPENSATION

Introduction

Temperature compensation (Temp Comp) is an essential part of the FLT FlexSwitch circuitry. When the Temp Comp is set correctly, the instrument stays accurate over a process temperature range of 100 °F. The instrument is a thermal dispersion device. It relies on the temperature differential between the reference RTD, which is at the process media temperature, and the active RTD, which is heated to produce a temperature differential (TD). For example; with constant temperature, ﬂow rate, process media and heater power, the TD is reduced and reaches a stable value. If the process media temperature goes up and all other conditions stay the same, the TD is reduced. Without Temp Comp the circuitry would process the signal as an increased ﬂow rate.

To understand Temp Comp the output signal needs to be understood ﬁrst. This temperature output signal is the absolute voltage drop across the reference RTD, and proportional to temperature. The instrument uses this voltage for two purposes. The voltage drop across the reference RTD is subtracted from the voltage drop across the Active RTD to produce a voltage differential. The voltage differential is used to set ﬂow or liquid level alarms. Also, the voltage drop across the reference RTD adds to, or subtracts from, the output signal as a function of TD.

Note:

To adjust the Temp Comp correctly certain parameters must be measured and calculated. Convert all temperature measure-

ments to degrees Fahrenheit before a temperature differential is found. These parameters and measurements are discussed later in this appendix.

Factory Temperature Compensation Settings

A Temp Comp adjustment procedure is performed on the instrument before it is shipped. Under normal conditions this setting will not have to be done by the customer. However, if there have been changes in environment since the instrument was ordered then the following instructions may need to be done by the customer.

Restoring Temp Comp Adjustments

When the control circuit is replaced or if the Temp Comp potentiometers are accidently moved the adjustments must be restored. There are three adjustments that need to be made on the control circuit in order to set the Temp Comp. Two of the adjustments are done with no power applied to the instrument and a third adjustment is done with power applied. Calibration values for each instrument are on the Temp Comp calibration sheet that is found in the plastic page protector at the back of this manual. The calibration values are listed by the serial number of the instrument.

Equipment Required

• 5-1/2 digit digital multimeter (DMM). (Small clip leads are desirable.)

• Flat screw driver, capable of adjusting control circuit potentiometers.

• Temp Comp calibration values from the page protector in the back of this manual.

• Insulating varnish or equivalent to reseal the potentiometers.

Caution:

Procedure

1. Turn off the instrument power. Remove the control circuit from the terminal board.

2. Write down where the heater wattage control jumper is located in the area of the upper left hand side of the control circuit (11 o’clock, P1 at top). Remove the heater wattage control jumper and place it on position J33. Refer to Figure 3-1 for the jumper location.

3. Remove jumpers J10 and J11 at the right side of the control circuit (2 o’clock) and set them aside.

4. Connect the DMM from TP1 (by J10), to the right jumper post of J10. Set the DMM to ohms. See Figure 3-2 for component placement.

5. Adjust potentiometer R5 (3 o’clock, next to the right thumbscrew) until the DMM reads the ohm value for R5 as shown on the Temp Comp calibration sheet that is in the plastic page protector in the back of this manual.

6. Remove the DMM, and reconnect it between TP2 (by J11), and the right jumper post of J11. Figure 3-1 shows jumper post location.

7. Adjust pot R8 (next to J10) until the ohm value for R8 is as shown on the Temp Comp Cal sheet.

8. Remove the DMM and reinstall jumpers J10 and J11. Continue.

The instrument contains electrostatic discharge (ESD) sensitive devices. Use standard ESD precautions when handling the

control circuit. See Section 2, Installation, for ESD details.

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APPENDIX D - TEMP COMP FLT® Series FlexSwitch

Balance Procedure

The following steps are the ﬂow element balance procedure required to complete the Temp Comp restoration and must be used when installing remote units with more than 10 feet of cable.

1. Connect the DMM to P1 with the positive lead connected to position 1 (Red) and the negative lead connected to position 2 (Blue). Reinstall the control circuit on the terminal board. Set the DMM to volts DC. Place the heater jumper on J33.

2. Turn on the instrument power and wait ﬁfteen minutes for the instrument to stabilize. During this time make sure that the process media is ﬂowing or the sensing elements are submerged. Do not make the following adjustment in still gas.

3. Adjust potentiometer R13 (to the right of S1) until the DMM reads 0 volts ±5 mV.

4. Turn off the instrument power and remove the DMM. Re-install the heater jumper in its original position.

The Temp Comp adjustments are now restored. Turn on the power and make sure the instrument is functioning properly. Make adjustments to the alarm setpoints if needed.

Field Temp Comp Calibration

If the application of the instrument changes the Temp Comp may need to be re-calibrated. An example of when the Temp Comp needs to be re-calibrated is as follows: The process media is gas, the factory set Temp Comp is 40 to 140 °F. The instrument is then placed in an application that varies in temperature from 300 to 400 °F. In this case the instrument’s accuracy would be greater with a new Temp Comp calibration performed.

Another example of where the accuracy will be affected and a Temp Comp calibration would need to be done is when the process media is changed, i.e. from water to heavy oil.

Temp Comp calibration is possible to do in the ﬁeld if the test conditions are met and the data is measured correctly. However, in many applications it is difﬁcult to achieve these parameters and it is easier to have the switch factory calibrated. To do the procedure the following parameters are required:

• The maximum temperature change does not exceed 100 °F.

• The maximum temperature does not exceed the instruments rated maximum temperature.

• The velocity at which the switch will alarm needs to be known, and the same at both test temperatures.

Equipment Required

1 each DC Power Supply, 0 to 20 Vdc minimum, at 0.5 Amps.

2 each 5-1/2 Digit DMM with 4 wire clip leads.

1 each #1 ﬂat blade screw driver.

1 each Flat screw driver, capable of adjusting control circuit potentiometers.

As req. Insulating varnish or equivalent to reseal the potentiometers.

Procedure

1. Turn off the instrument power.

2. Install the instrument into the pipe or a test stand where it can be calibrated. Start the process media ﬂowing at a normal rate. Cool the process media to the lowest temperature in the expected operating range.

3. Remove the control circuit. Disconnect the element wires on terminal board, TB2A AND TB2B. Note: These are spring terminals.

4. Connect the DMMs and the power supply to the sensing element as shown in Figure D-1.

5. Set the power supply voltage to the proper voltage as shown in Table D-1. Turn on the power supply and check the voltage setting.

6. Stop the process media ﬂow and make sure that the media is at no ﬂow and then let the instrument stabilize for ﬁfteen minutes.

7. Record the resistance values of the sensing elements and calculate the resistance differential (DR). If DR does not exceed the maximum DR of 280 ohms then proceed with the calibration. If the DR is above 280 ohms use the next lower heater wattage setting and let the instrument stabilize. Recheck the DR.

8. Start the process media ﬂowing at the desired switch point velocity and at the low temperature, let the instrument stabilize for ﬁfteen minutes.

9. Record the resistance values of the active and reference RTDs at the low temperature.

92 Fluid Components International LLC

FLT® Series FlexSwitchTM APPENDIX D - TEMP COMP

10. Raise the temperature of the process media to the maximum expected temperature. The difference between the low and the high temperature is not to exceed 100 °F.

11. Set the ﬂow rate to the same value used for the low temperature.

Note:

The ﬂow rate must be the same at both the low and high temperature. For gases, the ﬂow rate must be held constant in

terms of volumetric ﬂow rate (SCFM, NCMH, etc.).

12. With the instrument power on, let the instrument stabilize for ﬁfteen minutes.

13. Record the resistance values of the active and reference RTDs for the high temperature.

14. Calculate the Temp Comp factor with the formula shown below.

TEMP COMP

FACTOR

(R Reference High Temperature) - (R Reference Low Temperature)

R Low Temperature - R High Temperature

The Temp Comp factor is not to exceed ±0.041.

15. If the Temp Comp factor is within tolerance, turn off the power to the instrument and stop the process media if needed. Disconnect the DMM’s and the power supply from the instrument. Reconnect the sensing element wires to the control circuit socket and reinstall the socket in the enclosure if it was previously removed. Do not pinch the wires between the socket and the enclosure.

16. Look up the resistance values to adjust potentiometers R5 and R8 in the Temp Comp Factor table (Table D-2). Follow the procedure in the Restoring Temp Comp adjustment section using the values found in the table below.

17. If the calculated Temp Comp factor exceeds the allowable tolerance by a small amount (±0.01), using the maximum Temp Comp factor may make the instrument perform satisfactorily. However, if the factor is out of tolerance by more than ±0.01 then it will be necessary to repeat the calibration to verify the result. Continue with the adjustment procedure if the second result is within tolerance.

Figure D-1. Sensing Element Calibration Connections

FLT93S

3 Watts 1.75 Watts 0.75 Watts 0.21 Watts

Set For 18.0 Vdc Set For 13.8 Vdc Set For 9.0 Vdc Set For 4.9 Vdc

0.57 Watts 0.52 Watts 0.49 Watts 0.25 Watts

FLT93F

Set For 18.0 Vdc Set For 17.0 Vdc Set For 15.0 Vdc Set For 11.8 Vdc

Fluid Components International LLC 93

POWER SUPPLY SETTINGS

Table D-1. Heater Voltage Settings

APPENDIX D - TEMP COMP FLT® Series FlexSwitch

TEMP COMP R5 R8

FACTOR K OHMS K OHMS

0.042 119.75 263.16

0.041 119.88 256.41

0.04 120.00 250.00

0.039 120.13 243.9

0.038 120.25 238.10

0.037 120.38 232.56

0.036 120.5 227.27

0.035 120.63 222.22

0.034 120.75 217.39

0.033 120.88 212.77

0.032 121.00 208.33

0.031 121.13 204.08

0.030 121.25 200.00

0.029 121.38 196.08

0.028 121.5 192.31

0.027 121.63 188.68

0.026 121.75 185.19

0.025 121.88 181.82

0.024 122.00 178.57

0.023 122.13 175.44

0.022 122.25 172.41

0.021 122.38 169.49

0.020 122.5 166.67

0.019 122.63 163.93

0.018 122.75 161.29

0.017 122.88 158.73

0.016 123.00 156.25

0.015 123.13 153.85

0.014 123.25 151.52

TEMP COMP R5 R8

FACTOR K OHMS K OHMS

0.013 123.38 149.25

0.012 123.50 147.06

0.011 123.63 144.93

0.010 123.75 142.86

0.009 123.88 140.85

0.008 124.00 138.89

0.007 124.13 136.99

0.006 124.25 135.14

0.005 124.38 133.33

0.004 124.50 131.58

0.003 124.63 129.87

0.002 124.75 128.21

0.001 124.88 126.58

0.000 125.00 125.00

-0.001 125.13 123.46

-0.002 125.25 121.95

-0.003 125.38 120.48

-0.004 125.50 119.05

-0.005 125.63 117.65

-0.006 125.75 116.28

-0.007 125.88 114.94

-0.008 126.00 113.64

-0.009 126.13 112.36

-0.010 126.25 111.11

-0.011 126.38 109.89

-0.012 126.50 108.70

-0.013 126.63 107.53

-0.014 126.75 106.38

-0.015 126.88 105.26

TEMP COMP R5 R8

FACTOR K OHMS K OHMS

-0.016 127.00 104.17

-0.017 127.13 103.09

-0.018 127.25 102.04

-0.019 127.38 101.01

-0.020 127.50 100.00

-0.021 127.63 99.01

-0.022 127.75 98.04

-0.023 127.88 97.09

-0.024 128.00 96.15

-0.025 128.13 95.24

-0.026 128.25 94.34

-0.027 128.38 93.46

-0.028 128.50 92.59

-0.029 128.63 91.74

-0.030 128.75 90.91

-0.031 128.88 90.09

-0.032 129.00 89.29

-0.033 129.13 88.50

-0.034 129.25 87.72

-0.035 129.38 86.96

-0.036 129.50 86.21

-0.037 129.63 85.47

-0.038 129.75 84.75

-0.039 129.88 84.03

-0.040 130.00 83.33

-0.041 130.13 82.64

-0.042 130.25 81.97

94 Fluid Components International LLC

Table D-2. Temp Comp Factor Table

FCI FLT93B, FLT93C, FLT93F, FLT93S, FLT93L Installation, Operation & Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

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