Flowline AX1X User Manual

Warranty, Service & Repair

WARRANTY

Flowline warrants to the original purchaser of its products that such
products will be free from defects in material and workmanship under
normal use and service for a period which is equal to the shorter of
one year from the date of purchase of such products or two years from
the date of manufacture of such products.

This warranty covers only those components of the products which
are non-moving and not subject to normal wear. Moreover, products
which are modified or altered, and electrical cables which are cut to
length during installation are not covered by this warranty.

Flowline’s obligation under this warranty is solely and exclusively
limited to the repair or replacement, at Flowline’s option, of the prod­ucts (or components thereof) which Flowline’s examination proves to
its satisfaction to be defective. FLOWLINE SHALL HAVE NO
OBLIGATION FOR CONSEQUENTIAL DAMAGES TO PERSON­AL OR REAL PROPERTY, OR FOR INJURY TO ANYPERSON.

This warranty does not apply to products which have been subject to
electrical or chemical damage due to improper use, accident, negli­gence, abuse or misuse. Abuse shall be assumed when indicated by
electrical damage to relays, reed switches or other components. The
warranty does not apply to products which are damaged during ship­ment back to Flowline’s factory or designated service center or are
returned without the original casing on the products. Moreover, this
warranty becomes immediately null and void if anyone other than ser­vice personnel authorized by Flowline attempts to repair the defective
products.

Products which are thought to be defective must be shipped prepaid
and insured to Flowline’s factory or a designated service center (the
identity and address of which will be provided upon request) within
30 days of the discovery of the defect. Such defective products must
be accompanied by proof of the date of purchase.

Flowline further reserves the right to unilaterally wave this warranty
and to dispose of any product returned to Flowline where:

a. There is evidence of a potentially hazardous material present

with product.

b. The product has remained unclaimed at Flowline for longer than

30 days after dutifully requesting disposition of the product.

THERE ARE NO WARRANTIES WHICH EXTEND BEYOND
THE DESCRIPTION ON THE FACE OF THIS WARRANTY. This
warranty and the obligations and liabilities of Flowline under it are
exclusive and instead of, and the original purchaser hereby waives, all
other remedies, warranties, guarantees or liabilities, express or
implied. EXCLUDED FROM THIS WARRANTY IS THE IMPLIED
WARRANTY OF FITNESS OF THE PRODUCTS FOR A PARTIC­ULAR PURPOSE OR USE AND THE IMPLIED WARRANTY OF
MERCHANT ABILITY OF THE PRODUCTS.

This warranty may not be extended, altered or varied except by a writ­ten instrument signed by a duly-authorized officer of Flowline, Inc.

To register your product with the manufacturer, go to the Flowline
website for on-line registration. The website address is as follows:

www.flowline.com

On-line Warranty Registration can be found under Contact Us in
the Navigation Bar along the side of the home page.

If for some reason your product must be returned for factory ser­vice, contact Flowline Inc. at [phone] to receive a Material
Return Authorization number (MRA), providing the following
information:

1. Part Number, Serial Number

2. Name and telephone number of someone who can answer
technical questions related to the product and its application.

3. Return Shipping Address

4. Brief Description of the Symptom

5. Brief Description of the Application

Once you have received a Material Return Authorization number,
ship the product prepaid in its original packing to:

Flowline Factory Service
MRA _____
10500 Humbolt Street
Los Alamitos, CA 90720

To avoid delays in processing your repair, write the MRA on the
shipping label. Please include the information about the malfunc­tion with your product. This information enables our service tech­nicians to process your repair order as quickly as possible.

®

Version 0.1A
© 2005 FLOWLINE Inc.
All rights reserved.
Manual # LM900006 05/05

Switch Pak™
w/ Compact
Junction Box
A _ 1 _ Series
Owner’s Manual

Step One

SPECIFICATIONS

2.5"(64mm)

3.6"(92mm)

2.8"

(71mm)

2" NPT (1-1/2" G)

A (Specify)

Specifications:

Length: 6" to 10' (15 cm to 3m)
Switch point: 1 (set by factory)
Orientation: ± 30˚ vertical
Process temp.: F: -40˚ to 194˚

C: -40˚ to 90˚

Pressure: AU1_: 150 psi (10 bar)

AZ1_: 150 psi (10 bar)
AV1_: 25 psi (1.7 bar)

Wetted material: 424_: PP

524_: PVDF Kynar®

Process mount: _243: 2" NPT

_247: 1 1/2" G
Enclosure rating: NEMA 4X (IP65)
Installed height: 3.6" (9.1 cm) above tank process mount
Encl. material: PP, UL94VO
Conduit entrance: Single, 1/2" NPT
Termination: 2-4 poles
CE compliance: EN 50082-2 immunity

EN 55011 emission

EN 61010-1 safety

Sensor Technologies:

Ultrasonic (LU10 series)

Broadly applied in chemical, solvent, hydrocarbon and
light weight oil media
Supply voltage: 12-36 VDC
Consumption: 25 mA maximum
Contact type: (1) SPST relay
Contact rating: GP: 120 VAC/VDC @ 1A

IS: 32 VDC @ 0.5A
Contact output: Selectable NO/NC
Classification: Intrinsically safe

Buoyancy (LV10 series)

Best applied in clean water or water-like chemical
media that is non-coating or scaling
Contact type: (1) SPDT reed
Contact rating: 120 VAC/VDC @ 15 VA
Contact output: Selectable NO/NC
Classification: General purpose

Vibration (LZ10 series)

Typically applied in wastewater media with light coat­ing and/or foaming characteristics
Supply voltage: 12-36 VDC
Consumption: 25 mA maximum
Contact type: (1) SPST relay
Contact rating: 120 VAC/VDC @ 1A
Contact output: Selectable NO/NC
Classification: General purpose

Step Two

COMPONENTS

Ultrasonic

AU15-4243

1 x LU10-1305
1 x LM45-1001
1 x LC06-1001

AU15-4247

1 x LU10-1325
1 x LM45-1061
1 x LC06-1051

AU15-5243

1 x LU10-2305
1 x LM45-5001
1 x LC06-1001

AU15-5247

1 x LU10-2325
1 x LM45-5061
1 x LC06-1051

Buoyancy

A

V16-4243

1 x LV10-1301
1 x LM45-1001
1 x LC06-1001

AV16-4247

1 x LV10-1351
1 x LM45-1061
1 x LC06-1051

AV16-5243

1 x LV10-5301
1 x LM45-5001
1 x LC06-1001

AV16-5247

1 x LV10-5351
1 x LM45-5061
1 x LC06-1051

Vibration

AZ18-4243

1 x LZ12-1405
1 x LM45-1001
1 x LC06-1001

AZ18-4247

1 x LZ12-1425
1 x LM45-1061
1 x LC06-1051

Component List:

A (Specify)

Switch Pak Fitting

P/N: LM45-1001, LM45-1061,

LM45-5001 or LM45-5061

Compact Relay Controller

P/N: LC06-1001 or LC06-1051

Switch-Tek Level Switch

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

LU10-2305, LU10-2325
LV10-1301, LV10-1351,
LV10-5301, LV10-5351,

LZ12-1405 or LZ10-1425

Standard Configuration:

(AU15-_24_, A V16-_24_ or AZ18-_24_)

3/4" NPT

(3/4" G)

2" NPT

(1-1/2" G)

Pipe

Socket

Pipe

Coupling

w/ 3/4"
Thread

Switch Pak Fitting includes
the following parts:

1 Fitting
1 Coupling
1 Customer specified pipe

Step Four

ASSEMBLY OF SWITCH PAK™

Step Three

SAFETY PRECAUTIONS

About this Manual: PLEASE READ THE ENTIRE MANU-

AL PRIOR TO INSTALLING OR USING THIS PRODUCT. This
manual includes information on the Switch Pak™ with Compact
Relay Controller: AU15-_24_, AZ18-_24_ and AV16-_24_. The
units are identical except for the material of construction 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 overtighten the components. Always
check for leaks prior to system start-up.

Material Compatibility:

Polypropylene (PP, a polyolefin): Sensor, Switch Pak™ fitting,
Controller Housing.

Polyvinylidene Fluoride (PVDF): Sensor and SWitch Pak™ fitting.
Viton (a fluorocarbon): O-ring.

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 (phone [phone]).

Temperature and Pressure: Switch Pak™ is designed for

use in application temperatures up to 90° C (194° F). The V ibration
and Ultrasonic packages are designed for pressurized applications
up to 150 psi (10 bar) and the Buoyancy package is designed for
use up to 25 psi (1.7 bar).

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 Switch Pak™ system. Such breaks of the liq­uid seal of the sensor system may lead to component failure.

Flammable, Explosive and Hazardous Applications:

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

About Switch Pak™: Flowline’s Switch Pak™ with Compact

Junction Box Assembly is an single-point mounting system for
installing one level sensor vertically within a tank. The compact junc­tion box features termination for the various wires from each level
switch as well as a 1/2” conduit connection. Switch Pak™ mounts
vertically through a standard 2" NPT tank adapter, or on a side mount
bracket (such as the LM50-1001).

Level Switches: Switch Pak™ includes

a single level switch used to identify it’s own
unique wet / dry condition. The technologies
used to indicate level are either Ultrasonic,
Buoyancy or V ibration. Each technology fea­tures a unique wiring/power configuration
(Ultrasonic and Vibration technologies
require 12 to 36 VDC power for operation,
see below). The switch is terminated in the
Compact Junction Box. The Compact
Junction Box provides a 1/2” Conduit con­nection and 6 poles for wire termination.

Vibration (LZ12-1405)
Wire Configuration:

RELAY

Red

Black

White

Green

Orange

(+)
(-)
N/A
N/A
N/A
Shld

RELAY

(+)
(-)
N/A
N/A
Shld

Red

Black

White

Green

REED

N/A
(-)
(+)
Shld

Red
Black
White

Ultrasonic (LU10-_305 or LU10-_325) Wire
Configuration:

Buoyancy (LV10-_301 or LV10-_351) Wire
Configuration:

Compact

Junction Box

(inside shown)

Step Five

INSTALLATION

Switch Pak™, In-Tank Installation:

Flowline's Switch Pak™ mounting system is an in-tank fitting, which
enables users to install any technology, along the entire length of
track. Switch Pak™ may be installed thru the top wall of any tank or
flange, using a standard 2" NPT tank adapter or blind flange. If tank
top is not available, Flowline's side mount bracket, LM50-1001,
enables Switch Pak™ to be installed directly to the side wall or lip of
the tank.

T ank Adapter:

Flange Mounting:

Side Mount Bracket:

Lip of Tank Side-Wall

Step Six

WIRING

[Dry Condition]

Sensor

(NO)

RED
GRN
SHLD
WHT
BLK

LOAD

LOAD

OR

[+]

[-]

[Dry Condition]

Sensor

(NC)

BLK
GRN
SHLD
WHT
RED

LOAD

LOAD

OR

[+]

[-]

Ultrasonic and Vibration Switches

(LU10-1305, LU10-1325, LZ12-1405, LZ12-1425):

The LU10-13_5 and LZ12-14_5 switch can be wired normally open
or normally closed for your application requirement. Each switch
requires 12 - 36 VDC power to operate the sensor and switch the
relay. The relay output can be wired as a dry contact. All illustrations
below identify a Dry switch state as the normal position of the relay.

Switching a Normally Open DC Load:

The Red wire connects to Positive (+) of the power supply and the
Black wire connects to Negative (-). The LOAD can be attached to
either the Green or White wires. Complete the circuit by either con­necting the Green to (+) VDC power or White to (-) VDC power (see
illustration below).

Switching a Normally Closed DC Load:

The Black wire connects to Positive (+) of the power supply and the
Red wire connects to Negative (-). The LOAD can be attached to
either the Green or White wires. Complete the circuit by either con­necting the Green to (+) VDC power or White to (-) VDC power (see
illustration below).

Maintenance Alarm (LZ12 Vibration only):

For optimum performance and proactive maintenance, the sensor
automatically adjusts for coating, and if necessary, outputs a preven­tative maintenance alarm. The Orange wire is a NPN transistor
designed to switch when a build-up of material prevents the vibration
switch from operating at its operational frequency. Use the Orange
wire to identify when the Vibration switch requires cleaning (see the
LZ12 manual for wiring information).

Step Seven

WIRING

Step Eight

MAINTENANCE

General: The Switch Pak™ with Compact Junction Box requires

no periodic maintenance except cleaning as required. It is the respon­sibility of the user to determine the appropriate maintenance schedule,
based on the specific characteristics of the application liquids.

Cleaning Procedure:

1. Power: Make Sure that all power to the sensor, controller and/or

power supply is completely disconnected.

2. Sensor Removal: Make sure that the tank is in a state where it

is safe to remove the sensors. Carefully, remove the Switch Pak™
from the installation.

3. Cleaning the Sensor: Use a soft bristle brush and mild deter-

gent, carefully wash the Switch Pak™. Do not use harsh abra­sives such as steel wool or sandpaper, which might damage the
surface sensor. Do not use incompatible solvents which may
damage the sensor's PP or Ryton plastic body.

4. Sensor Installation: Follow the appropriate steps of installa-

tion as outlined in the installation section of this manual.

Testing the installation:

1. Power: Turn on power to the switches and/or power supply.

2. Immersing the switch: Immerse the sensing tip of each switch

in its application liquid, by filling the tank up to the switches point
of actuation. An alternate method of immersing the switch during
preliminary testing is to hold a cup filled with application liquid
up to the switch's tip.

3. Test: With the switch being fluctuated between wet and dry

states, the switch will open or close depending on wiring status.
If the system doesn't have an input indicator, use a multimeter to
ensure that the switch produces the correct signal.

Current Test (Ultrasonic and Vibration only):

Used to verify if the sensor is indicating a wet or dry condition. This
test uses only two wires (Red and Black). The sensor draws 5 mA
(ultrasonic) or 8 mA (vibration) when it is dry, and 19 mA when wet.
The White and Green wires are not used.

Contact Test (Buoyancy only):

Used to verify if the reed switch is switching between dry (open) and
wet (closed). Check for continuity across Black and White (open for
dry and closed for wet). Checking across Black and Red will result
in a closed when dry and open when wet condition.

Red

24 VDC

Power Supply

+

-

Multimeter

(mA)

-

+

Black

White
Black

Multimeter

(Continuity)

-

+

Normally Open

(Dry)

Buoyancy Level Switch (LV10-1301 & LV10-1351):

The LV10-13_1 switch can be wired normally open or normally
closed for your application requirement.

Normally Open:

Use the Black and White wires for operating the LV10-_3_1 in a nor­mally open state. Normally open is defined as the switch being open
when the float is dry and closed when the float becomes submersed.
This operation is typical for indicating a high level.

Normally Closed:

Use the Black and Red wires for operating the LV10-_3_1 in a nor­mally closed state. Normally closed is defined as the switch being
closed when the float is dry and open when the float becomes sub­mersed. This operation is typical for indicating a low level.

White

Power

Supply

Black
White

Power

Supply

Black

Red

Power

Supply

Black
Red

Power

Supply

Black