Flowline AU18, AU28, AU38, AU48, AV16 Operating Manual

Smart Trak

w/ Compact Junction Box

™



AU18, AU28, AU38, AU48, AV16, AV26, AV36, AV46,
AZ18, AZ28, AZ38 & AZ48 Series
Owner’s Manual

Flowline, Inc. |. 10500 Humbolt Street, Los Alamitos, CA 90720. p 562.598.3015. f 562.431.8507. w flowline.com

MN301420 Rev A

Specifications

Length: 8" to 10' (20 cm to 3m)
Switch points: 1 t 4 (field adjustable)
Orientation: ± 20˚ vertical
Process temp.: F: -40˚ to 1 7 6 ˚
C: -40˚ to 80˚
Pressure: Atmospheric
Wette d material: PP (20% glass fill)
Process mount: 2" NPT (2" G)
Enclosure rating: NEMA 4X (IP65)
Installed height: 5.7" (14.4 cm) above tank process mount
Encl. material: PP , UL94VO
Conduit entrance: Single, 1/2" NPT
Termination: 12 poles

ULTRASONIC SENSOR

Supply voltage: 12-36 VDC
Consumption: 25 mA maximum
Contact type: (1) SPST relay
Contact rating: GP: 120 VAC/VDC @ 60 VA
IS: 32 VDC @ 0.5A
Cable type: 4-conductor / sensor, #22 AWG (shielded)
Contact output: Selectable NO/NC
Classification: Intrinsically safe
CE compliance: EN 50082-2 immunity
EN 55011 emission
EN 61010-1 safety

VIBRATION SENSOR

Step One

Supply voltage: 12-30 VDC
Consumption: 25 mA maximum
Contact type: (1) SPST relay
Contact rating: 120 VAC/VDC @ 60 VA
Cable type: 5-conductor / sensor, #24 AWG (shielded)
Contact output: Selectable NO/NC
Classification: General purpose
CE compliance: EN 50082-2 immunity
EN 55011 emission
EN 61010-1 safety

BUOYANCY SENSOR

Contact type: (1) SPDT reed
Contact rating: 120 VAC/VDC @ 15 VA
Cable type: 3-conductor / sensor, #22 AWG (shielded)
Contact output: Selectable NO/NC
Classification: General purpose
CE compliance: EN50082-2 immunity
EN 55011 emission
EN61010-1 safety

| 2

MN301420 rev A

Components

V

V

A

A

A

V

V

A

A

A

Step Two

ONE SENSOR CONFIGURATION:

(AU18-434_, AV16-434_ or AZ18-434_)

Ultrasonic
AU18-4343

1 x LU10-1305
1 x LM10-1_01
1 x LM30-1001
1 x LC05-1001

AU18-4347

1 x LU10-1325
1 x LM10-1_61
1 x LM30-1051
1 x LC05-1051

Buoyancy
AV16-4343

1 x LV10-1301
1 x LM10-1_01
1 x LM30-1001
1 x LC05-1001

AV16-4347

1 x LV10-1351
1 x LM10-1_61
1 x LM30-1051
1 x LC05-1051

ibration

AZ18-4343

1 x LZ12-1405
1 x LM10-1_01
1 x LM30-1001
1 x LC05-1001

AZ18-4347

1 x LZ12-1405
1 x LM10-1_61
1 x LM30-1001
1 x LC05-1051

THREE SENSORS CONFIGURATION:

(AU18-434_, AV16-434_ or AZ18-434_)

TWO SENSORS CONFIGURATION:

(AU28-434_, AV26-434_ or AZ28-434_)

Ultrasonic
AU28-4343

2 x LU10-1305
1 x LM10-1_01
2 x LM30-1001
1 x LC05-1001

U28-4347

2 x LU10-1325
1 x LM10-1_61
2 x LM30-1051
1 x LC05-1051

FOUR SENSORS CONFIGURATION:

(AU28-434_, AV26-434_ or AZ28-434_)

Buoyancy
AV26-4343

2 x LV10-1301
1 x LM10-1_01
2 x LM30-1001
1 x LC05-1001

V26-4347

2 x LV10-1351
1 x LM10-1_61
2 x LM30-1051
1 x LC05-1051

ibration

AZ28-4343

2 x LZ12-1405
1 x LM10-1_01
2 x LM30-1001
1 x LC05-1001

Z28-4347

2 x LZ12-1405
1 x LM10-1_61
2 x LM30-1001
1 x LC05-1051

Ultrasonic
AU38-4343

3 x LU10-1305
1 x LM10-1_01
3 x LM30-1001
1 x LC05-1001

AU38-4347

3 x LU10-1325
1 x LM10-1_61
3 x LM30-1051
1 x LC05-1051

COMPONENT LIST:

Buoyancy
AV36-4343

3 x LV10-1301
1 x LM10-1_01
3 x LM30-1001
1 x LC05-1001

AV36-4347

3 x LV10-1351
1 x LM10-1_61
3 x LM30-1051
1 x LC05-1051

Smart Trak Fitting

P/N: LM10-1_01 or LM10-1_61

ibration

AZ38-4343

3 x LZ12-1405
1 x LM10-1_01
3 x LM30-1001
1 x LC05-1001

AZ38-4347

3 x LZ12-1405
1 x LM10-1_61
3 x LM30-1001
1 x LC05-1051

Compact Junction Box

P/N: LC05-1001 or LC05-1051

Ultrasonic
AU48-4343

4 x LU10-1305
1 x LM10-1_01
4 x LM30-1001
1 x LC05-1001

U48-4347

4 x LU10-1325
1 x LM10-1_61
4 x LM30-1051
1 x LC05-1051

Switch Car Kit

P/N: LM30-1001 or LM30-1051

Buoyancy
AV46-4343

4 x LV10-1301
1 x LM10-1_01
4 x LM30-1001
1 x LC05-1001

V46-4347

4 x LV10-1351
1 x LM10-1_61
4 x LM30-1051
1 x LC05-1051

ibration

AV48-4343

4 x LZ12-1405
1 x LM10-1_01
4 x LM30-1001
1 x LC05-1001

Z48-4347

4 x LZ12-1405
1 x LM10-1_61
4 x LM30-1001
1 x LC05-1051

Switch-Tek Level Switch

P/N: LU10-1305. LU10-1325,

LV10-1301, LV10-1351

or LZ12-1405

MN301420 rev A 3 |

Safety Precautions Step Three

About this Manual: PLEASE READ THE ENTIRE MANUAL PRIOR TO INSTALLING OR USING THIS

PRODUCT. This manual includes information on the Smart Trak™ with Compact Junction Box: AU_5­434_, AZ_8-434_ and AV_6-343_. The units are identical except for the number of switch points and the
sensors technology.

User's Responsibility for Safety: Flowline manufactures a wide range of liquid level sensors, controllers,

and mounting systems. It is the user's responsibility to select components that are appropriate for the
application, install them properly, perform tests of the installed system, and maintain all components. The
failure to do so could result in property damage or serious injury.

Proper Installation and Handling: Use a proper sealant with all installations. Never over tighten the

components. Always check for leaks prior to system start-up.

Material Compatibility:

o Glass filled Polypropylene (PP, a polyolefin): Track, end cap, wire retainer clips, bayonet

adapter, level switch and sensor car for all Smart Trak Assemblies.

o Polychlorotrifluoroethylene (PCTFE, a fluoroplastic): Sensor car locking bolt and screw.
o Polypropylene (PP, a polyolefin): Sensor, top compression fitting, thrust plate, locking pin and 2"

NPT fitting.

o Viton (a fluorocarbon): O-ring.
o Neoprene (w/silicon gel for lubrication): Wire gasket.
o Santoprene (w/silicon gel for lubrication): Seal plug.

Make sure that the application liquids are compatible with the materials that will be wetted. To determine
the chemical compatibility between the components and its application liquids, refer to the Compass
Corrosion Guide, available from Compass Publications.

Temperature and Pressure: Smart Trak™ is designed for use in application temperatures up to 80° C

(176° F). It is not designed for pressurized applications due to the wiring that must travel through a gasket
at the head.

Wiring and Electrical: Electrical wiring of any liquid level control system should be performed in

accordance with all applicable national, state, and local codes. Take care not to cut or break the outer
insulation jacket of wiring that may be immersed while routing cables in the Smart Trak™ system. Such
breaks of the liquid seal of the sensor system may lead to component failure.

Flammable, Explosive and Hazardous Applications: Smart Trak™ may be used within flammable or

explosive applications only if the associated components are rated intrinsically safe for such use. In
hazardous applications, use redundant measurement and control points, each having a different sensing
technology.

Make a Fail-Safe System: Design a fail-safe system that accommodates the possibility of transmitter or

power failure. In critical applications, Flowline recommends the use of redundant backup systems and
alarms in addition to the primary system.

| 4 MN301420 rev A

Assembly of Smart Trak™

Step Four

About Smart Trak™: Flowline’s Smart Trak™ with Compact Junction Box Assembly is an adjustable

mounting system for installing multiple level sensors vertically within a tank. Mounted through a single point at
the top of the tank, up to 4 different sensors can be located at any depth on Smart Trak™. The compact
junction box features termination for the various wires from each level switch as well as a 1/2” conduit
connection. Smart Trak™ mounts vertically through a standard 2" NPT tank adapter, or on a side mount
bracket (such as the LM50-1001). Unlike prefabricated “trees” or pipes, Smart Trak™ allows you to experiment
with sensor position to account for variations in the point of actuation of each sensor during process testing.

Track: The track itself is approximately 1" square, and is from 8” to 10' long depending on the A-Dimension.
The track may be cut to length if desired. Four separate grooves run the length of the track, one on each side
of the square. These grooves hold the sensor cars that attach to Flowline sensors, and also serve to contain
the switch cable. The bottom of the track is capped with an end cap.

Level Switches: Smart Trak™ will include from 1 to 4 level switches used to identify
it’s own unique wet / dry

condition. The technologies used to indicate level are either
Ultrasonic, Buoyancy or Vibration. Each technology features a unique wiring/power
configuration (Ultrasonic and Vibration technologies require 12 to 36 VDC power for
operation, see below). All of the switches are terminated in the Compact Junction Box.
The Compact Junction Box provides a 1/2” Conduit connection and 12 poles for wire
termination (for models AU45-434_ and AZ48-434_, common terminals such as
Positive (+) and Negative (-) power must be shared).

Compact Junction Box

(inside shown)

Vibration (LZ12-1405)
Wire Configuration

Ultrasonic (LU10-1305 or LU10-1325) Wire
Configuration

Buoyancy (LV10-1301 or LV10-1351)
Wire Configuration

MN301420 rev A 5 |