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
Flowline on the Navigation Bar along the side of the home page.
If for some reason your product must be returned for factory service, go to
the Flowline website listed above. Online Factory Service can be found
under Contact Flowline on the Navigation Bar along the side of the home
page. Click on Return Authorization to begin the registration process.
You will need the following information at the time of registration:
1. Part Number and full Serial Number from product
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 5.1A
© 2007 FLOWLINE Inc.
All rights reserved.
Manual # MNC 40100 09/07
Remote Relay Controller
LC40, LC41 and LC42 Series
Owner’s Manual
Step One
SPECIFICATIONS
Supply voltage: 120 VAC (240 VAC), 50 - 60 Hz.
Consumption: 5 Watts max.
Sensor inputs: LC42: 1-3 sensors
LC41: 1-2 sensors
LC40: 1 sensor
Sensor supply: 13.5 VDC @ 27 mA
Relay type: LC42: (1) SPDT, (1) Latched SPDT
LC41: (1) Latched SPDT
LC40: (1) SPDT
Relay rating: 250 VAC, 10A, 1/4 hp.
Relay mode: Selectable, NO or NC
Relay latch: ON or OFF
Time delay: 0 to 60 seconds
LED indication: Sensor, relay & power status
Fail safety: Power fail-safe
Temperature range: F: -40° to 158°
C: -40° to 70°
Enclosure rating: 35 mm DIN (EN 50 022)
Enclosure material: Polypropylene (U.L. 94 VO)
Certificate number: LR 79326-3
CE compliance: EN 61326 EMC
EN 61010-1 safety
3.1" (79mm)
35mm
DIN Rail
3.6" (92mm)
3.9" (98mm)
1.8"
(44mm)
2.7"
(68mm)
STANDARD
CONTROLLER
RELAY 1 RELAY 2
POWER
INPUT 1 INPUT 2A INPUT 2B
-
+
-
+
INVERT
DELAY
INVERT
DELAY
LATCH
ON OFF
LC4 _ - 1 0 0 1
Configuration
0 - 1 Input, 1 Relay
1 - 2 Inputs, 1 Relay
2 - 3 Inputs, 2 Relays
Remote Relay Controller
STANDARD
CONTROLLER
RELAY 1 RELAY 2
POWER
INPUT 1 INPUT 2A INPUT 2B
-
+
-
+
INVERT
DELAY
INVERT
DELAY
LATCH
ON OFF
STANDARD
CONTROLLER
RELAY 1
POWER
INPUT 1A INPUT 1B
-
+
INVERT
DELAY
LATCH
ON OFF
STANDARD
CONTROLLER
RELAY 1
POWER
INPUT 1
-
+
INVERT
DELAY
L1
L2
GND
(+) (-)
NC
C
NO
(+)
(-)
(+) (-)
NC
C
NO
Latch/Invert Logic
Time Delay
Latch/Invert Logic
Time Delay
Sensor
Input
1A
Power
Supply
Sensor
Input
A*
Sensor
Input
A*
Relay
("Relay 1"
in LC42)
Relay
("Relay 2" in LC42)
Dimensions
Internal Controller Logic
LC42-1001 Faceplate
LC41-1001 Faceplate
LC40-1001 Faceplate
Step Two Step Three
SAFETY PRECAUTIONS INTRODUCTION
About This Manual:
PLEASE READ THE ENTIRE MANUAL PRIOR TO
INSTALLING OR USING THIS PRODUCT. This manual
includes information on three different models of Remote Relay
Controllers from FLOWLINE: LC40-1001, LC41-1001 and LC42-
1001. Many aspects of installation and use are similar between the
three models. Where they differ, the manual will note it. Please
refer to the part number on the controller you have purchased as
you read.
User’s Responsibility for Safety:
FLOWLINE manufactures several models of controller, with different mounting and switching configurations. It is the user’s
responsibility to select a controller model that is appropriate for the
application, install it properly, perform tests of the installed system,
and maintain all components.
Electrical Shock Hazard:
It is possible to contact components on the controller that carry
high voltage, causing serious injury or death. All power to the controller and the relay circuit(s) it controls should be turned OFF prior
to working on the controller. If it is necessary to make adjustments
during powered operation, use extreme caution and use only insulated tools. Making adjustments to powered controllers is not recommended. Wiring should be preformed by qualified personnel in
accordance with all applicable national, state and local electrical
codes.
Flammable or Explosive Applications:
LC40 series remote mount controllers should not be used with
explosive or flammable liquids, which require an intrinsically
safe rating such as the FLOWLINE LC90 series. If you are
unsure of the suitability of a controller for your installation, consult your FLOWLINE representative for further information.
Install In a Dry Location:
The controller housing is not designed to be immersed. It should
me mounted in such a way that it does not come into contact with
liquid. Its case is made out of PP (polypropylene). Refer to an
industry reference to ensure that compounds that may splash onto
the controller housing will not damage it. Such damage is not covered by the warranty.
Relay Contact Rating:
The relay is rated for a 10 amp resistive load. Many loads (such as
a motor during start-up or incandescent lights) are reactive and may
have an inrush current characteristic that may be 10 to 20 times
their steady-state load rating. The use of a contact protection circuit
may be necessary for your installation if the 10 amp rating does not
provide an ample margin for such inrush currents.
Make a Fail-Safe System:
Design a fail-safe system that accommodates the possibility of relay
or power failure. If power is cut off to the controller, it will de-energize the relay. Make sure that the de-ener gized state of the relay is the
safe state in your process. For example, if controller power is lost, a
pump filling a tank will turn off if it is connected to the Normally
Open side of the relay.
While the internal relay is reliable, over the course of time relay failure is possible in two modes: under a heavy load the contacts may be
“welded” or stuck into the energized position, or corrosion may build
up on a contact so that it will not complete the circuit when it should.
In critical applications, redundant backup systems and alarms must be
used in addition to the primary system. Such backup systems should
use different sensor technologies where possible.
While this manual offers some examples and suggestions to help
explain the operation of FLOWLINE products, such examples are for
information only and are not intended as a complete guide to
installing any specific system.
Step Four Step Five
GUIDE TO CONTROLS INSTALLATION
1. Power indicator: This green LED lights when AC power is ON.
2. Relay indicator: This red LED will light whenever the con-
troller energizes the relay, in response to the proper condition at
the sensor input(s) and after the time delay.
3. AC Power terminals: Connection of 120 VAC power to the
controller. The setting may be changed to 240 VAC if desired.
This requires changing internal jumpers; this is covered in the
Installation section of the manual. Polarity (neutral and hot) does
not matter.
4. Relay terminals (NC, C, NO): Connect the device you wish to
control (pump, alarm etc.) to these terminals: supply to the COM
terminal, and the device to the NO or NC terminal as required.
The switched device should be a noninductive load of not more
than 10 amps; for reactive loads the current must be derated or
protection circuits used. When the red LED is ON and the relay is
in the energized state, the NO terminal will be closed and the NC
terminal will be open.
5. Time delay: Use potentiometer to set delay from 0.15 to 60 sec-
onds. Delay occurs during switch make and switch break .
6. Input indicators: Use these LEDs for indicating Wet or Dry sta-
tus of switch. When switch is Wet, LED will be Amber. When
switch is dry, LED will either be Green for powered switches or
Off for reed switches. Note: Powered switches may be reversed
for Wet/Off, Dry/Amber indication.
7. Invert switch: This switch reverses the logic of the relay control
in response to the switch(es): conditions that used to energize the
relay will now de-energize the relay and vice versa.
8. Latch switch (LC41 and LC42): This switch determines how
the relay will be energized in response to the two sensor inputs.
When LATCH is OFF, the relay responds to sensor Input Aonly;
when LATCH is ON, the relay will energize or de-energize only
when both switches (Aand B) are in the same condition (both wet
or both dry). The relay will remain latched until both switches
change conditions.
9. Input terminals: Connect the switch wires to these terminals:
Note the polarity: (+) is a 13.5 VDC, 27 mA power supply (connected to the red wire of a FLOWLINE level switch), and (-) is
the return path from the sensor (connected to the black wire of a
FLOWLINE level switch). If polarity is reversed, the sensors will
not work.
Panel DIN Rail Mounting
The controller may be mounted by either a back panel using two
screws through mounting holes located at the corners of the controller
or by snapping the controller on 35 mm DIN Rail.
Note: Always install the controller in a location where it does not
come into contact with liquid.
Connecting switches to input terminals:
Please note a difference between FLOWLINE powered level switches
and reed switches. All powered level switches (models LO10, LP10,
LP15, LP50, LU10, LZ12) will be wired with the Red wire to the (+)
terminal and the Black wire to the (-) terminal. FLOWLINE reed
switches (models L V10, LV20, LV30, LH20 and LH30) will have a particular wiring based upon part number. See the illustration below to
indicate wiring for your switch. Note: the Shield wire will be used only
for long cable runs or where excessive electrical noise is present.
LED Indication:
Use LED's located above the input terminals to indicate whether the
switch is in a wet or dry state. With powered switches, Green indicates dry and Amber indicates wet. With reed switches, Amber indicates wet and no LED indicates dry. Note: reed switches may be
wired in reverse so that wet indicates dry and Amber indicates dry.
Green Amber Off Amber
Powered Switches Reed Switches
STANDARD
CONTROLLER
RELAY 1 RELAY 2
POWER
INPUT 1 INPUT 2A INPUT 2B
-
+
-
+
INVERT
DELAY
INVERT
DELAY
LATCH
ON OFF
1
3
7
2
5
4 4
7
2
5
6
8
66
9
9 9
3.475"
2.2"
.275"
.225"
35mm
INPUT
13.5 VDC
30 mA MAX
(-) (+)
INPUT 1
INPUT 1
INPUT 1
INPUT 1
INPUT 1 INPUT 2A INPUT 2B
LATCH
ON OFF
Black
Red
Black
Red
Black
White
LZ10
LP50
LP10
LV10-12_1
LU10
LP15
LO10
LV10-52_1
LV10-13_1
LV10-53_1
LH10-13_1
(Use Red &
Black for NC)
VAC Power Input Wiring:
Observe the POWER SUPPLY label on the LC40
series. The label identifies the power requirement
(120 or 240 VAC) and the terminal wiring. Note:
Polarity does not matter with the AC input terminal.
Step Six Step Seven
INSTALLATION APPLICATION EXAMPLES
Relay Input Wiring
The relay is a single pole, double throw type rated
at 250 Volts AC, 10 Amps, 1/4 Hp. The two terminal NO and NC (normally open and normally
closed) will be used in different applications.
Remember that the "normal" state is when the
relay coil is de-energized and the Red relay LED
is Off / de-energized.
Changing from 120 to 240 VAC
1. Remove the back panel of the controller and gently slide the printed
circuit board from the housing. Use caution when removing the PCB.
2. Located jumpers JW1, JW2 and JW3 on the PCB.
3. To change to 240 VAC, remove jumpers from JW1 and JW2 and
place a single jumper across JW3. T o change to 120 VAC, remove
jumper JW3 and place jumpers across JW1 and JW2.
4. Gently return PCB into housing and replace back panel.
Low Level Alarm
The goal is to make sure that the liquid level does not fall below a certain point. If it does, an alarm is supposed to sound, alerting the operator of a low level condition.
If power is accidentally cut to the controller, the sensor's ability to
notify the operator of a low level condition could be lost. The system
must alert the operator not only to low liquid level, but to controller
power loss.
To do this, connect the hot lead of
the alarm to the NC side of the
relay terminal of the controller. If
power is lost, the relay will be deenergized, and the alarm will
sound (if there is still power to the
alarm circuit itself). The alarm circuit should have a non-interruptible power supply or some other
indicator or backup alarm to warn
of a power failure in the alarm circuit.
In this application, the normal status if the sensor at the bottom if the
tank will be wet, and the relay will be energized holding the alarm circuit open. Both the relay LED and the Input LED will be on simultaneously, so for this application, Invert should be set to the Of f position.
High Level Alarm
In the same manor, this system can be used to sound an alarm when
fluid reaches a high level, with just a change in the location of the sensor and the setting of the Invert switch.
The alarm is still connected to the
NC side of the relay to allow for a
power failure alarm.
The sensor is normally dry. In this
condition, we want the relay to be
energized so the alarm does not
sound: i.e., the Red relay LED
should be on whenever the Input
LED is Amber. So we turn Invert
On. If the fluid level rises to the
high sensor point, the sensor goes on, the relay de-energizes, and the
alarm sounds.
INPUT
120 VAC, 50 - 60 Hz
240 VAC. 50 - 60 Hz
L1 L2 ( )
RELAY OUTPUT
250 VAC, 10A, 1/4 Hp
NO NC
C
120 VAC
JWB
JWA
JWC
240 VAC
JWB
JWA
JWC
POWER
Ground
Neutral
Hot
INVERT
-
DELAY
+
RELAY 1
POWER
Ground
Neutral
Hot
INVERT
-
DELAY
+
RELAY 1
POWER
INVERT
-
+
INVERT
DELAY
RELAY 1 RELAY 2
-
+
DELAY
POWER
INVERT
-
+
INVERT
DELAY
-
+
RELAY 1 RELAY 2
DELAY
Step Eight Step Nine
APPLICATION EXAMPLES TROUBLESHOOTING
Automatic Fill:
This system consists of a tank with a high level sensor, a low level
sensor, and a pump that is controlled by the controller. Part of a proper fail-safe design for this particular system is that if power is lost to
the controller for any reason, the
pump filling the tank must be
turned off. Therefore, we connect
the pump to the NO side of the
relay. When the relay is energized,
the pump will turn on and fill the
tank. The relay indicator will correspond directly to the On/Off status of the pump.
NOTE: If the pump motor load exceeds the rating of the controller’s
relay, a stepper relay of higher capacity must be used as part of the
system design.
Determining the settings of LATCH and INVERT
This is the way the system must operate:
• When both the high and low sensors are dry, the pump should turn
on, starting to fill the tank.
• When the low sensor gets wet, the pump should stay on.
• When the high sensor gets wet, the pump should turn off.
Latch: In any two-sensor control system, LATCH must be ON.
Invert: Referring to the logic chart in Step Nine, we look for the set-
ting that will de-energize the relay (start the pump) when both inputs
are wet (Amber LEDs). In this system, Invert should be ON.
Determining A or B input connections: When LATCH is ON,
there is no effective difference between Input Aand B, since both sensors must have the same signal in order for status to change. When
wiring any two-input relay section, the only consideration for hooking a particular sensor to Aor B is if LATCH will be OFF.
Automatic Empty:
Note that a similar system logic can be used for an automatic empty
operation simply by controlling a pump that pumps fluid out of the
tank instead of into it. However, note the importance of fail-safe
design. If the tank is being passively filled, and a pump must be used
to actively empty it, a power failure to either the controller or the
pump circuits will cause overflow.
Alternatively, an electrically-controlled drain valve could be used. In
this case, the valve should be a type that will automatically open if
power is lost; in other words, power must be used to hold it closed.
The valve would be connected to the NO side of the relay—if power
is lost to the controller, the relay de-energizes, the valve loses the
power that was holding it shut, and fluid will drain from the tank into
some other safe containment until
power is restored. In this system,
whenever the red relay LED of the
controller is ON, the drain is
closed, allowing fluid to rise.
In this case, Invert should be On:
when both sensors are wet, the
relay de-energizes, the switch to
the valve opens, and the tank will
drain.
Controller Logic
For all controllers, please use the following guide to understand the
operation of the FLOWLINE LC40/LC41/LC42 controllers.
1. Make sure the Green power LED is On when power is supplied to
the controller.
2. The input LED's on the controllers will be Amber when the switch
is wet and Green when the switch is dry. Note: see Step 4 regard-
ing reed switches. If the LED's are not switching the input LED,
test the level switch.
3. When the input LED's turn Off and On, the relay LED will also
switch. With invert Off, the relay LED will be On when the input
LED is On and Off when the input LED is Off. With invert On,
the relay LED will be Off when the input LED is On and On when
the input LED is Off.
4. LC41 and LC42 model only: When both inputs are wet (Amber
LED's On), the relay will be energized (Red LED On). After that,
if one switch becomes dry, the relay will remain energized. Only
when both switches are dry (both amber LED's Off) will the controller de-energize the relay. The relay will not energize again
until both switches are wet. See the Relay Latch Logic Chart
below for further explanation.
Relay Latch Logic Table:
Relay 2 can either be a independent relay similar to relay 1 or can be
a latching relay with latch ON. With Latch Off, relay 2 will only
respond to the INPUT 2A setting. INPUT 2B will be ignored.
With Latch ON, relay 2 will actuate when INPUT2Aand INPUT 2B are
in the same condition. The relay will not change its condition until both
inputs reverse their state.
Caution: Some sensors (particularly buoyancy sensors) may have
their own inverting capability (wired NO or NC). This will change the
logic of the invert switch. Check your system design.
POWER
INVERT
-
+
INVERT
DELAY
RELAY 1 RELAY 2
DELAY
-
+
POWER
INVERT
-
+
RELAY 1 RELAY 2
DELAY
INVERT
DELAY
-
+
Invert OFF Latch OFF
INPUT 2A*
ON
OFF
INPUT 2B*
No Effect
No Effect
Relay
ON
OFF
Invert OFF Latch ON
INPUT 2A*
ON
OFF
ON
OFF
INPUT 2B*
ON
ON
OFF
OFF
Relay
ON
No Change
No Change
OFF
Invert ON Latch Off
INPUT 2A*
INPUT 2A*
INPUT 2B*
No Effect
ON
OFF
OFF
OFF
No Effect
Invert ON Latch ON
INPUT 2B*
ON
ON
ON
ON
OFF
OFF
Relay
OFF
ON
Relay
OFF
No Change
No Change
ON
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