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 (562)598-3015 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 # LM900005 04/05
Smart Trak™
w/ Compact
Junction Box
A _ _ _ Series
Owner’s Manual
Step One
SPECIFICATIONS
4.2"(106mm)
5.7"(145mm)
2.8"
(71mm)
E (Specify)
B (Specify)
D (Specify)
C (Specify)
A (Specify)
2" NPT (2" G)
1" Square
(25.4 mm)
Specifications:
Length: 8" to 10' (20 cm to 3m)
Switch points: 1 to 4 (field adjustable)
Orientation: ± 30˚ vertical
Process temp.: F: -40˚ to 194˚
C: -40˚ to 90˚
Pressure: Atmospheric
Wetted 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
Supply voltage: 12-36 VDC
Consumption: 25 mA maximum
Contact type: (1) SPST relay
Contact rating: 120 VAC/VDC @ 60 VA
Cable type: 4-conductor / sensor, #22 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: EN 50082-2 immunity
EN 55011 emission
EN 61010-1 safety
Step Two
COMPONENTS
Ultrasonic
AU35-4343
3 x LU10-1305
1 x LM10-1_01
3 x LM30-1001
1 x LC05-1001
AU35-4347
3 x LU10-1325
1 x LM10-1_61
3 x LM30-1051
1 x LC05-1051
Buoyancy
AV36-4343
3 x LV10-1301
1 x LM10-1_01
3 x LM30-1001
1 x LC05-1001
A
V36-4347
3 x LV10-1351
1 x LM10-1_61
3 x LM30-1051
1 x LC05-1051
Vibration
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
Component List:
B (Specify)
A (Specify)
Smart Trak Fitting
P/N: LM10-1_01 or LM10-1_61
Compact Junction Box
P/N: LC05-1001 or LC05-1051
Switch Car Kit
P/N: LM30-1001 or LM30-1051
Switch-Tek Level Switch
P/N: LU10-1305. LU10-1325,
LV10-1301, LV10-1351
or LZ12-1405
Ultrasonic
AU15-4343
1 x LU10-1305
1 x LM10-1_01
1 x LM30-1001
1 x LC05-1001
AU15-4347
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
Vibration
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
Ultrasonic
AU25-4343
2 x LU10-1305
1 x LM10-1_01
2 x LM30-1001
1 x LC05-1001
AU25-4347
2 x LU10-1325
1 x LM10-1_61
2 x LM30-1051
1 x LC05-1051
Buoyancy
AV26-4343
2 x LV10-1301
1 x LM10-1_01
2 x LM30-1001
1 x LC05-1001
AV26-4347
2 x LV10-1351
1 x LM10-1_61
2 x LM30-1051
1 x LC05-1051
Vibration
AZ28-4343
2 x LZ12-1405
1 x LM10-1_01
2 x LM30-1001
1 x LC05-1001
AZ28-4347
2 x LZ12-1405
1 x LM10-1_61
2 x LM30-1001
1 x LC05-1051
Ultrasonic
AU45-4343
4 x LU10-1305
1 x LM10-1_01
4 x LM30-1001
1 x LC05-1001
AU45-4347
4 x LU10-1325
1 x LM10-1_61
4 x LM30-1051
1 x LC05-1051
Buoyancy
AV46-4343
4 x LV10-1301
1 x LM10-1_01
4 x LM30-1001
1 x LC05-1001
AV46-4347
4 x LV10-1351
1 x LM10-1_61
4 x LM30-1051
1 x LC05-1051
Vibration
AV48-4343
4 x LZ12-1405
1 x LM10-1_01
4 x LM30-1001
1 x LC05-1001
AZ48-4347
4 x LZ12-1405
1 x LM10-1_61
4 x LM30-1001
1 x LC05-1051
Two Sensors Configuration:
(AU25-434_, A V26-434_ or AZ28-434_)
Three Sensors Configuration:
(AU35-434_, A V36-434_ or AZ38-434_)
Four Sensors Configuration:
(AU45-434_, A V46-434_ or AZ48-434_)
One Sensor Configuration:
(AU15-434_, A V16-434_ or AZ18-434_)
C (Specify)
B (Specify)
A (Specify)
D (Specify)
C (Specify)
B (Specify)
A (Specify)
E (Specify)
D (Specify)
C (Specify)
B (Specify)
A (Specify)
Step Four
ASSEMBLY OF SMART TRAK™
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 Smart Trak™ with Compact
Junction Box: AU_5-434_, 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 overtighten the components. Always
check for leaks prior to system start-up.
Material Compatibility:
Glass filled Polypropylene (PP, a polyolefin): Track, end cap, wire
retainer clips, bayonet adapter, level switch and sensor car for all
Smart Trak Assemblies.
Polychlorotrifluoroethylene (PCTFE, a fluoroplastic): Sensor car
locking bolt and screw.
Polypropylene (PP, a polyolefin): Sensor, top compression fitting,
thrust plate, locking pin and 2" NPT fitting.
Viton (a fluorocarbon): O-ring.
Neoprene (w/silicon gel for lubrication): Wire gasket.
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 (phone 858-589-9636).
Temperature and Pressure: Smart Trak™ is designed for
use in application temperatures up to 90° C (194° 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.
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 AU45434_ and AZ48-434_, common terminals such as Positive (+) and
Negative (-) power must be shared).
Vibration (LZ12-1405) Wire Configuration:
RELAY
Red
Black
White
Green
Orange
(+)
(-)
NC/NO
COM
Maint.
Shld
RELAY
(+)
(-)
NO/NC
COM
Shld
Red
Black
White
Green
REED
NC
COM
NO
Shld
Red
Black
White
Ultrasonic (LU10-1305 or LU10-1325) Wire
Configuration:
Buoyancy (LV10-1301 or LV10-1351) Wire
Configuration:
Compact
Junction Box
(inside shown)
Step Five
INSTALLATION
Smart Trak™, In-Tank Installation:
Flowline's Smart Trak™ mounting system is an in-tank fitting, which
enables users to install any technology, along the entire length of
track. Smart Trak™ 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 Smart Trak™ 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
INSTALLATION
2.1"
Smart Trak™, Installation:
The Smart Trak™ with Compact Junction Box assembly is designed
to be installed through a 2” NPT (2” G) thread. The level switches
will be staggered through the fitting for installation.
A key feature of Smart Trak™ is the adjustability of the level switches. When two level switches are placed close together, one of the
switches will need to be moved to allow for the switches to be staggered into the installation fitting. Once installed, the level switch can
be returned to its required position.
Step Seven
WIRING
Step Eight
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):
The LU10-13_5 and LZ12-1405 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).
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
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 Nine
ASSEMBLY OF SMART TRAK™
Smart Trak™ Assembly Drawing (Side View)
Inventory:
One Smart Trak™ kit (LM10-1__1) includes the following parts:
1 Seal Plug 1 Top compression fitting
1 Wire gasket 1 Thrust Plate
1 Locking pin 1 2" NPT fitting
1 Track 1 End cap
2 Wire retainer clips (not shown)
Smart Trak™ Assembly Drawing (Top View):
Seal Plug Assembly Drawing (Side View)
Seal Plug
Seal Plug
Sensor Wire
Wire Gasket
Thrust Plate
Locking Pin
2” NPT
Fitting
2” NPT
Fitting
Cable
Cable
must fit
into side of
track next
to locking pin
Track
End cap
Wires
Top Compression
Fitting
Top Compression
Fitting
Step Ten
ASSEMBLY OF SWITCH CAR
Sensor car and bayonet adapter:
The sensor car assembly is the heart of the Smart Trak™ system. It
slides in the grooves of the track, and is locked into position by a plastic bolt and screw. The bayonet to 3/4" NPTadapter has a female 3/4"
NPT fitting on one end where the sensor (not included) will screw in,
and a bayonet fitting on the other end that attaches it onto the sensor
car with a slight turn, with an O-ring in-between to provide tension
for the push-and-turn connection.
Switch Car Kit Assembly Drawing (Side View)
Inventory:
One switch car kit (LM30-10_1) consists of the following parts:
1 Locking bolt 1 Locking Nut
1 Sensor car 1 O-ring
1 Bayonet to 3/4” NPT adapter
Switch Car Kit to Smart Trak™
(Top View) (Side View)
Determine the Proper Wire Length:
Don’t make the mistake of trimming the sensor wires too short before
the process is tested. If the sensors might need to be lowered in the
future, leave sufficient slack in the wires to allow for future adjustment. This extra wire may be stored in the bottom of the terminal strip
housing, or elsewhere above the compression fitting.
Sensor
Wire
Shoe
Sensor Lock
Bolt & Nut
Sensor
Car
O-ring
Flowline
Sensor
Bayonet to
3/4” NPT
Adapter
Step Eleven
MAINTENANCE
Step Twelve
MAINTENANCE
General:
The Smart Trak™ 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 Smart T rak™
from the installation.
3. Cleaning the Sensor: Use a soft bristle brush and mild deter-
gent, carefully wash the Smart Trak™. 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 voltmeter or
ammeter to ensure that the switch produces the correct signal.
4. Point of actuation: Observe the point at which the rising or
falling fluid level causes the switch to change state, and adjust the
installation of the switch if necessary.
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.
Red
Black
24 VDC
Power Supply
+
-
Multimeter
(Continuity)
-
+
White
Green
Red
24 VDC
Power Supply
+
-
Multimeter
(mA)
-
+
Black
Normally Open Wiring:
Relay Contact Test (Ultrasonic and Vibration only):
Used to verify if the relay contact is switching between dry (open) and
wet (closed). Test requires Red wired to Positive (+) and Black wired
to Negative (-) on a 12 to 36 VDC power supply. Check for continuity across Green and White (open for dry and closed for wet).
Reversing Red and Black wires will result in a closed when dry and
open when wet condition.
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.
White
Black
Multimeter
(Continuity)
-
+
Normally Open
(Dry)
Red
Black
Multimeter
(Continuity)
-
+
Normally Closed
(Dry)
Loading...