Switch-Pak™
w/ Compact Junction Box
AU18, AV16 & AZ18 Series
Owner’s Manual
Flowline, Inc. |. 10500 Humbolt Street, Los Alamitos, CA 90720. p 562.598.3015. f 562.431.8507. w flowline.com MN301440 Rev A
Specifications
Step One
Length: 6" to 10' (15 cm to 3m)
Switch point: 1 (set by factory)
Orientation: ± 20˚ vertical
Process temp.: F: -40˚ to 176˚
C: -40˚ to 80˚
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 (LZ12 series)
Typically applied in wastewater media with light coating and/or
foaming characteristics
Supply voltage: 12-30 VDC
Consumption: 25 mA maximum
Contact type: (1) SPST relay
Contact rating: 120 VAC/VDC @ 1A
Contact output: Selectable NO/NC
Classification: General purpose
| 2
MN301440 Rev A
Components
V
A
Step Two
ONE SENSOR CONFIGURATION:
(AU18-_24_, AV16-_24_ or AZ18-_24_)
Ultrasonic
AU18-4243
1 x LU10-1305
1 x LM45-1001
1 x LC06-1001
AU18-4247
1 x LU10-1325
1 x LM45-1061
1 x LC06-1051
AU18-5243
1 x LU10-2305
1 x LM45-5001
1 x LC06-1001
AU18-5247
1 x LU10-2325
1 x LM45-5061
1 x LC06-1051
Buoyancy
AV16-4243
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
COMPONENT LIST:
ibration
AZ18-4243
1 x LZ12-1405
1 x LM45-1001
1 x LC06-1001
Z18-4247
1 x LZ12-1425
1 x LM45-1061
1 x LC06-1051
Compact Relay Controller
P/N: LC06-1001 or LC06-1051
Switch-Tek Level Switch
Switch-Pak™ Fitting
P/N: LM45-1001, LM45-1061,
LM45-5001 or LM45-5061
MN301440 Rev A 3 |
P/N: LU10-1305. LU10-1325,
LU10-2305, LU10-2325
LV10-1301, LV10-1351,
LV10-5301, LV10-5351,
LZ12-1405 or LZ12-1425
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 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.
Temperature and Pressure: Switch-Pak™ is designed for use in application temperatures up to 80° C
(176° F). The Vibration 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.
| 4 MN301440 Rev A
Assembly of Switch-Pak™ Step Four
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 Vibration. Each technology features a unique wiring/power
configuration (Ultrasonic requires 12-36 VDC power for operation and Vibration
require 12 to 30 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:
Compact
Junction Box
(inside shown)
Compact
Junction Box
(inside shown)
ULTRASONIC (LU10-_305 OR LU10-_325) WIRE CONFIGURATION:
BUOYANCY (LV10-_301 OR LV10-_351) WIRE CONFIGURATION
MN301440 Rev A 5 |
Installation
SWITCH-PAK™, IN-TANK INSTALLATION:
Step Five
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, LM501001, enables Switch-Pak™ to be installed directly to the side wall or lip of the tank.
TANK ADAPTER:
FLANGE MOUNTING:
SIDE MOUNT BRACKET:
LIP OF TANK SIDE-WALL
| 6
MN301440 Rev A
Wiring
ULTRASONIC AND VIBRATION SWITCHES
Step Six
(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 ultrasonic switch requires 12 - 36 VDC power while each vibration switch requires 12-30
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 Yellow 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 Yellow wire to identify when the Vibration switch requires cleaning (see the LZ12 manual for wiring
information).
MN301440 Rev A 7 |
Wiring
BUOYANCY LEVEL SWITCH (LV10-1301 & LV10-1351):
Step Seven
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.
| 8
MN301440 Rev A
Maintenance
Step Eight
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 detergent, 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 installation 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.
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.
MN301440 Rev A 9 |
Warranty, Returns and Limitations Step Nine
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 in accordance with instructions furnished by Flowline
for a period of two years from the date of manufacture of such products. 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, which Flowline's examination determines to its satisfaction to be defective in material or
workmanship within the warranty period. Flowline must be notified pursuant to the instructions below of any
claim under this warranty within thirty (30) days of any claimed lack of conformity of the product. Any product
repaired under this warranty will be warranted only for the remainder of the original warranty period. Any
product provided as a replacement under this warranty will be warranted for the full two years from the date of
manufacture.
RETURNS
Products cannot be returned to Flowline without Flowline's prior authorization. To return a product that is
thought to be defective, go to www.flowline.com, and submit a customer return (MRA) request form and follow
the instructions therein. All warranty and non-warranty product returns to Flowline must be shipped prepaid
and insured. Flowline will not be responsible for any products lost or damaged in shipment.
LIMITATIONS
This warranty does not apply to products which: 1) are beyond the warranty period or are products for which
the original purchaser does not follow the warranty procedures outlined above; 2) have been subjected to
electrical, mechanical or chemical damage due to improper, accidental or negligent use; 3) have been modified
or altered; 4) anyone other than service personnel authorized by Flowline have attempted to repair; 5) have
been involved in accidents or natural disasters; or 6) are damaged during return shipment to Flowline. Flowline
reserves the right to unilaterally waive this warranty and dispose of any product returned to Flowline where: 1)
there is evidence of a potentially hazardous material present with the product; or 2) the product has remained
unclaimed at Flowline for more than 30 days after Flowline has dutifully requested disposition. This warranty
contains the sole express warranty made by Flowline in connection with its products. ALL IMPLIED
WARRANTIES, INCLUDING WITHOUT LIMITATION, THE WARRANTIES OF MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE, ARE EXPRESSLY DISCLAIMED. The remedies of repair or
replacement as stated above are the exclusive remedies for the breach of this warranty. IN NO EVENT SHALL
FLOWLINE BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND
INCLUDING PERSONAL OR REAL PROPERTY OR FOR INJURY TO ANY PERSON. THIS WARRANTY
CONSTITUTES THE FINAL, COMPLETE AND EXCLUSIVE STATEMENT OF WARRANTY TERMS AND NO
PERSON IS AUTHORIZED TO MAKE ANY OTHER WARRANTIES OR REPRESENTATIONS ON BEHALF
OF FLOWLINE. This warranty will be interpreted pursuant to the laws of the State of California. If any portion
of this warranty is held to be invalid or unenforceable for any reason, such finding will not invalidate any other
provision of this warranty.
For complete product documentation, video training, and technical support, go to www.flowline.com.
For phone support, call 562-598-3015 from 8am to 5pm PST, Mon - Fri.
(Please make sure you have the Part and Serial number available.)
| 10 MN301440 Rev A
Loading...