Fluid Components International FLT User Manual
INSTALLATION, OPERATION AND
MAINTENANCE MANUAL
FLT
ÔÔ
Ô
ÔÔ
Series FlexSwitch
ÔÔ
Ô
ÔÔ
Flow, Level, Temperature
Switch/Monitor
Doc. No. 06EN003246 Rev. B
Notice of Proprietary Rights
This document contains confidential technical data, including trade
secrets and proprietary information which are the property of Fluid
Components Intl (FCI).
Disclosure of this data to you is expressly conditioned upon your assent
that its use is limited to use within your company only (and does not
include manufacture or processing uses). Any other use is strictly
prohibited without the prior written consent of FCI.
FLTÔ uses FCI's Proprietary FLEXSWITCHÔ Technology.
Patent 4,967,593
© Copyright 1996 Fluid Components Intl
a limited liability company
All Rights Reserved
9/29/94
CUSTOMER COMMITMENT PLEDGE
We will work closely with our customers to provide the best products and service
• at a competitive value
• on time
• with unquestioned support
in full compliance with our COMPLETE CUSTOMER COMMITMENT.
COMMITMENT TO QUALITY
In keeping with the overall commitment of management and employees of Fluid Components Intl to Total Quality
Management, the publications department expresses its pledge and mission to you, our customer:
“To support the creation and publication of world-class technical material which is technically accurate and
practical, concise and user-friendly, attractive and professional in appearance, and consistent in form, format,
content, and style.”
QUALITY IMPROVEMENT
FLUID COMPONENTS INTL
We appreciate your comments and suggestions which support our effort to constantly improve our product and
services. Please address comments and suggestions to your nearest field representative or in-house technical
support representative. Thank you.
FCI Technical Publications Department
Doc. No. 06EN003246 Rev. B iii FLTÔ Series FlexSwitchÔ
FLUID COMPONENTS INTL
CUSTOMER SERVICE/TECHNICAL SUPPORT
FCI provides full in-house technical support for our products 7 a.m. to 5 p.m. PST, Monday through Friday
(excepting holidays and an annual plant closure between Christmas and New Year's day). Also, additional
technical representation is provided by FCI field representatives. Before contacting one of our field or in-house
representatives, please ensure that you have performed the troubleshooting techniques outlined in this document.
By Mail
Fluid Components Intl
1755 La Costa Meadows Dr.
San Marcos, CA 92069
Attn: Customer Service Department
By Phone
Contact the FCI regional representative in your area. If your are unable to contact the field representative
or are unable to satisfactorily resolve the situation, contact the FCI Customer Service Department at
1 (800) 854-1993, toll free.
By Fax
To describe your problems in a more graphic or pictorial manner, send your fax including your phone or
fax number to your regional representative. Again FCI is available through facsimile if you have
exhausted your possibilities with the authorized factory representative. Our fax number is
(760) 736-6250; it is available 7 days a week, 24 hours a day.
International Support
For product information or product support outside the contiguous United States, Alaska, or Hawaii,
contact your country’s FCI International Representative or the one nearest to you. See the list on
following pages.
Appendix C contains a detailed explanation of the FCI customer service policy on returns, adjustments, in-field or
factory repair, in- or out-of-warranty.
FLTÔ Series FlexSwitchÔ
iv Doc. No. 06EN003246 Rev. B
FLUID COMPONENTS INTL
REVISIONS
REV. DESCRIPTION DATE AUTHOR
A
Added Revision Page. Revised Table of Contents.
Chapter 1 Theory of Operation: Changed wording; signal conditioner to control
circuit.
Chapter 1 Specifications: Revised Specification information .
Chapter 3 Page 3-1, Heater Cut-Off: Revised description.
Chapter 3 Table 3-1: Corrected typographical error. Deleted an incorrect statement.
Chapter 3 Figure 3-1: Added potentiometer call out R5 to the figure.
Chapter 3 Table 3-3A: Changed asterisk information.
Chapter 3 Tables 3-3A, 3-3B: Changed wattage values.
Appendix A Figure A-1, A-7 and A-8: Updated drawings.
Appendix A Figures A-1, A-4, A-5, A-7 and A-9: Changed the figure captions to
correctly identify the figures.
Appendix A Added Figures A-13, A-14 and A-15.
Appendix C Pages C-1, C-3, C-4 and C-5: Changed wording; Attachment to
Document. Added paragraph to clarify that documents are indeed added
to the appendix.
1/24/95
R. Sanders
Appendix D Page D-2, Step 5. Corrected jumper number and added a reference to
Figure 3-1.
Appendix D Table D-1: Changed wattage and a voltage values.
B Added Appendix E CE Mark information. Added information on FLT93-C 2-25-96 R. Sanders
and FLT93-L. Added remote relay wiring information. Change bars have also
been added to draw attention to new information.
Doc. No. 06EN003246 Rev. B vii FLTÔ Series FlexSwitchÔ
FLUID COMPONENTS INTL
Contents
1. General Information
2. Installation
Description ........................................................................................................................... 1 - 1
Theory of Operation ............................................................................................................. 1 - 1
Sensing Element .................................................................................................................. 1 - 1
Control Circuit ..................................................................................................................... 1 - 1
Technical Specifications ...................................................................................................... 1 - 2
Receiving/Inspection ............................................................................................................ 2 - 1
Packing/Shipping/Returns ................................................................................................... 2 - 1
Factory Calibration Note ...................................................................................................... 2 - 1
Pre-Installation Procedure ................................................................................................... 2 - 1
Use Standard ESD Precautions .................................................................................... 2 - 1
Prepare or Verify Sensing Element Location ............................................................... 2 - 2
Verify Dimensions ........................................................................................................ 2 - 2
Verify Sensing Element Flow Direction and Placement Orientation (Flow) ............. 2 - 2
Verify Sensing Element Flow Direction and Placement Orientation (Level) ............ 2 - 2
Install the Sensing Element ................................................................................................. 2 - 2
Male NPT Mounting ..................................................................................................... 2 - 2
Flange Mounting ........................................................................................................... 2 - 3
Packing Gland Assembly .............................................................................................. 2 - 3
In-Line NPT Assembly ................................................................................................. 2 - 3
Sanitary Assembly ........................................................................................................ 2 - 4
Install and Wire the Enclosure ............................................................................................ 2 - 4
Minimum Wire Size ..................................................................................................... 2 - 4
Wiring the Local Enclosure .......................................................................................... 2 - 5
Wiring at the Remote Enclosure .................................................................................. 2 - 6
Locate the Remote Hardware Location ........................................................................ 2 - 6
Wiring Remote Enclosure with Auxiliary Relay.......................................................... 2 - 7
Wiring a Remote Control Circuit To A Auxiliary Relay Board .................................. 2 - 8
Wiring Output Signal Terminals ......................................................................................... 2 - 8
3. Operation
Factory Default Jumper Configuration ................................................................................ 3 - 1
Configuration Jumpers ......................................................................................................... 3 - 1
Heater Cut-Off ...................................................................................................................... 3 - 1
Alarm Set Point Adjustment ................................................................................................ 3 - 2
Numerical Adjustment Versus Adjustment by Observation ........................................ 3 - 2
Numerical Set Point Adjustment ......................................................................................... 3 - 3
Air/Gas Flow Applications ........................................................................................... 3 - 4
Wet/Dry Liquid Level Applications ............................................................................. 3 - 7
Temperature Applications ............................................................................................ 3 - 8
Liquid Flow Applications ............................................................................................. 3 - 10
Adjustment by Observation .................................................................................................. 3 - 12
Flow Applications ......................................................................................................... 3 - 12
Level Applications ........................................................................................................ 3 - 12
Temperature Applications ............................................................................................ 3 - 13
Converting Temp Out Voltage to Temp in Degrees F ................................................. 3 - 19
Fail Safe Alarm Setting ....................................................................................................... 3 - 20
Low Flow Alarm Setting .............................................................................................. 3 - 20
High Flow Alarm Setting ............................................................................................. 2 - 20
Low Level Alarm Setting ............................................................................................. 3 - 20
High Level Alarm Setting............................................................................................. 2 - 20
4. Maintenance
Maintenance ......................................................................................................................... 4 - 1
Calibration .................................................................................................................... 4 - 1
Electrical Connections .................................................................................................. 4 - 1
FLTÔ Series FlexSwitchÔ
viii Doc. No. 06EN003246 Rev. B
Remote Enclosure ......................................................................................................... 4 - 1
Electrical Wiring .......................................................................................................... 4 - 1
Sensing Element Connections ...................................................................................... 4 - 1
Sensing Element Assembly .......................................................................................... 4 - 1
5. Troubleshooting
Tools Needed ........................................................................................................................ 5 - 1
Quick Check ......................................................................................................................... 5 - 1
Non-maintenance Observations ........................................................................................... 5 - 1
Check Serial Numbers .................................................................................................. 5 - 1
Check Input Power ........................................................................................................ 5 - 1
Check the Instrument Installation ................................................................................ 5 - 1
Check for Moisture ....................................................................................................... 5 - 1
Check Application Design Requirements .................................................................... 5 - 2
Troubleshooting the Flow Element ..................................................................................... 5 - 2
Troubleshooting the Flow Transmitter ................................................................................ 5 - 2
Spares ................................................................................................................................... 5 - 4
Defective Parts ..................................................................................................................... 5 - 4
Customer Service ................................................................................................................. 5 - 4
Appendix A. Drawings
Outline Drawings ................................................................................................................. A - 1
Appendix B. Glossary
Abbreviations and Explanation of Terms ............................................................................ B - 1
FLUID COMPONENTS INTL
Figures
Appendix C. Customer Service
Policy and Procedures .......................................................................................................... C - 1
Appendix D. Temperature Compensation
Temperature Compensation Procedure................................................................................ D - 1
Appendix E. CE Conformance
CE Conformance Information ............................................................................................. E - 1
Figure 1-1. View of the Sensing Element ............................................................................................. 1 - 1
Figure 2-1. NPT Pipe Thread Mount .................................................................................................... 2 - 2
Figure 2-2. Flange Mount ......................................................................................................................2 - 3
Figure 2-3. FLT93-L In-line Flow Element ..........................................................................................2 - 4
Figure 2-4. FLT93-C Sanitary Flow Elements ......................................................................................2 - 4
Figure 2-5. Local Wiring Diagram ........................................................................................................ 2 - 5
Figure 2-6. Remote Wiring Diagram ....................................................................................................2 - 6
Figure 2-7. Auxiliary Relay Board Wiring Diagram ............................................................................2 - 7
Figure 3-1. 5294 Control Circuit Jumper Locations .............................................................................3 - 2
Figure 3-2. 5294 Control Circuit Component Locations ......................................................................3 - 4
Figure 3-3. Flow Application Signal Output ......................................................................................... 3 - 5
Figure 3-4. Level Application Signal Output ........................................................................................3 - 7
Figure 3-5. Low Flow Fail Safe Alarm.................................................................................................. 3 - 20
Figure 3-6. High Flow Fail Safe Alarm ................................................................................................. 3 - 20
Figure 3-7. Low Level Fail Safe Alarm ................................................................................................. 3 - 21
Figure 3-8. High Level Fail Safe Alarm ................................................................................................3 - 21
Figure 5-1. Troubleshooting Chart ........................................................................................................5 - 3
Figure A-1. Local Enclosure, NEMA Type 4X and Hazardous Location ............................................A - 1
Doc. No. 06EN003246 Rev. B ix FLTÔ Series FlexSwitchÔ
FLUID COMPONENTS INTL
Figure A-2. Local Enclosure NEMA Type 4X ...................................................................................... A - 1
Figure A-3. Remote Enclosure NEMA Type 4X .................................................................................. A - 1
Figure A-4. Remote Enclosure NEMA Type 4 and Hazardous Location ............................................. A - 2
Figure A-5. Remote Enclosure, Killark, NEMA Type 4 and Hazardous Location ..............................A - 2
Figure A-6. 1/4, 3/4 or 1 Inch NPT Process Connection ......................................................................A - 2
Figure A-7. Flanged Process Connection ..............................................................................................A - 3
Figure A-8. Low Pressure Packing Gland .............................................................................................A - 3
Figure A-9. Flanged Low Pressure Packing Gland Process Connection ...............................................A - 3
Figure A-10. 1-1/4 Inch Medium Pressure Packing Gland Connection ................................................ A - 4
Figure A-11. Flanged Medium Pressure Packing Gland Process Connection ...................................... A - 4
Figure A-12. 1/4 Inch Process Connection ............................................................................................A - 4
Figure A-13. Wire Pigtail Process Connection ...................................................................................... A - 5
Figure A-14. Injection Tube with Tee Fitting ....................................................................................... A - 5
Figure A-15. 3/4 Inch Female NPT FLT93-L With U-Bolt Bracket Kit ..............................................A - 5
Figure A-16. 1 Inch NPT FLT93-L .......................................................................................................A - 6
Figure A-17. 1 Inch RF Flanged FLT93-L............................................................................................ A - 6
Figure A-18. FLT93-C Sanitary Removable Clamp Instrument .......................................................... A - 6
Figure A-19. FLT93-C Sanitary Clean-In-Place Instrument ................................................................A - 7
Figure A-20. FLT93 Auxiliary Relay ....................................................................................................A - 7
Figure A-21. FLT93 PWB Module ........................................................................................................ A - 8
Figure D-1. Sensing Element Calibration Connections ........................................................................ D - 3
Tables
Table 2-1. Maximum AWG Number ....................................................................................................2 - 5
Table 3-1. Standard Jumper Default Configuration .............................................................................. 3 - 1
Table 3-2. Input Power .......................................................................................................................... 3 - 3
Table 3-3A. Selectable Heater Wattage Control ....................................................................................3 - 3
Table 3-3B. Fixed Heater Wattage Control ............................................................................................3 - 3
Table 3-4. Application ...........................................................................................................................3 - 3
Table 3-5. Relay Energization ...............................................................................................................3 - 3
Table 3-6. Relay Contact Configuration ................................................................................................ 3 - 3
Table 3-7. Temperature Versus Voltage Output .................................................................................... 3 - 14
Table 5-1. Resistance at Control Circuit Terminal Block Socket ......................................................... 5 - 2
Table 5-2. Resistance at Flow Element Enclosure Terminal Block ..................................................... 5 - 2
Table D-1. Heater Voltage Settings .......................................................................................................D - 3
Table D-2. Temp Comp Factor Table .................................................................................................... D - 5
FLTÔ Series FlexSwitchÔ
x Doc. No. 06EN003246 Rev. B
Symbols
The following symbols are used throughout the manual to draw attention to items or procedures that require
special notice or care.
FLUID COMPONENTS INTL
Warning:
Caution:
Note:
Warns of possible personal danger to those handling the equipment.
Cautions against possible equipment damage.
Contains important information.
Doc. No. 06EN003246 Rev. B xi FLTÔ Series FlexSwitchÔ
CHAPTER 1 - GENERAL INFORMATION FLUID COMPONENTS, INTL
1. General Information
Description
The FLT Series models are multipurpose measurement instruments. The FLT Series models that are included in
this manual are FLT93-C, FLT93-F, FLT93-L and FLT93-S. Each model is a single instrument that is capable of
detecting air flow, fluid flow and temperature. It is also able to detect liquid level or fluid media interfaces. The
instrument has two field adjustable alarm set points, two buffered voltage outputs, as well as a built-in calibration
circuit. The output of the alarm set points are 6 amp relay contacts that can be used to control customer process
applications. One buffered voltage output is available for flow or level monitoring and the second buffered voltage
output is available for temperature monitoring.
Theory of Operation
The flow switch is a fixed position, single-point flow, level, interface and temperature switch. The operation of the
sensing element is based upon the thermal dispersion principle: A low-powered heater is used to produce a
temperature differential between two Resistance Temperature Detectors (RTDs). The RTD temperature differential
varies as a function of forced convection for flow measurement and as a function of fluid thermal conductivity for
level and interface measurement. The measurement of the fluid's temperature is obtained from the non-heated
RTD.
Sensing Element
The sensing element consists of two thermowells (hollow tubes) that when inserted into the flow process allows an
unimpeded flow inside the process line. The top thermowell has a self-heated RTD inserted into it. The bottom
thermowell has a reference RTD inserted into it. In order to correctly orient the sensing element a flow arrow has
been etched onto the threaded portion of the sensing element. See Figure 1-1 for a view of the sensing element.
Control Circuit
The control circuit converts the sensing element's RTD temperature differential into an analog DC voltage signal.
Dual comparators monitor the sensing element signal and activates the relay alarm circuits if the signal exceeds an
adjustable set point.
The control circuit contains all the removable jumpers that configure the instrument to perform as needed by the
customer.
Doc. No. 06EN003246 Rev. B
Figure 1-1 View of the Sensing Element
1 - 1
FLTÔ Series FlexSwitchÔ
FLUID COMPONENTS, INTL CHAPTER 1 - GENERAL INFORMATION
Technical Specifications
• Process Connection
3/4 inch male NPT standard. 1 inch BSP, 1 inch
male NPT, 1/4 inch male NPT (FLT93-F only),
flanged mounting, spool piece with 3/4 inch NPT tee
or retractable sensing element available.
• Insertion Length
Beginning as low as 0.9 inches (23 mm). Standard as
well as custom lengths are available.
• Sensing Element Material
All wetted surfaces are 316 Stainless steel, with allwelded construction. Hastelloy C-276, Monel 400
and electro-polished stainless steel surface preparation
optionally available. Titanium is optionally available
on the FLT93-S configuration only.
• Operating Temperature
Control circuit:
Ambient: -40 to 140°F (-40 to 60°C).
Sensing element:
Standard temperature configuration:
-40 to 350°F (-40 to 177°C).
Medium temperature configuration:
-100 to 500°F (-73 to 260°C).
High temperature configuration:
-100 to 850°F (-73 to 454°C).
• Operating Pressure
Hydrostatically proof pressure tested to 3500 psi
(241.3 bar) at 70°F (21.1°C). De-rated with
temperature, the maximum recommended operation
service is 2350 psi (162 bar) at 500°F (260°C).
Higher ratings available with special construction and
test certification.
• Flow Range
From 0.01 to 5 fps (0.006 to 0.15mps) with fluid or
0.25 to 120 fps (0.076 to 38.1 mps) with gas,
depending upon model.
• Signal Output
Buffered voltage output available as a standard for
temperature and either flow or level/interface. The
minimum load impedance is 100 K ohms.
• Accuracy
Switch point accuracy:
Up to ± 2% of the switch point
velocity.
Monitoring accuracy:
±5 % reading (or ±0.04 fps, 0.012 mps,
which ever is larger for liquid applications
and ±2 fps, 0.061 mps, which ever is larger
for gas applications).
Level accuracy:
Down to ±0.1 inch (±0.25 cm)
Temperature accuracy:
Up to ±2 °F, (±1.1°C) depending upon
application. Higher accuracy is available
with factory calibration.
• Repeatability
±0.5% of monitor reading.
Up to ±0.05 inch (±0.13 cm) of level depending on
model.
±1.0°F, (±0.56°C) of temperature.
• Response Time
Alarm set point may be set as low as 0.5 seconds.
Alarm reset may be as low as 2.5 seconds.
• Input Power
Field or factory selectable for 115 Vac ±15V, 13VA
100 mA maximum; 230 Vac ±30V 14 VA 50mA
maximum; 24 Vac +2 to -6V 12.5 VA 485 mA
maximum; or 24 Vdc +6, to -3V, 7 watts, 230 mA
maximum. 100 Vac ±10 V is optionally available.
All AC Power is 50 to 60 Hz. Power applied is
indicated by an LED.
• Heater Power
Field or factory selectable for specific fluid service
requirements.
• Relay Rating
Dual alarm SPDT or single alarm DPDT field
configurable 6 amp resistive at 240 Vac, 115 Vac or
24 Vdc. Options available on auxiliary relay board
are 2 amp or 10 amp DPDT, plastic sealed, 0.5 amp
DPDT hermetically sealed.
• Enclosure
FLTÔ Series FlexSwitchÔ
Hazardous Location Class I, II, Div. 1, 2 Groups B, C,
D, E, F, and G. NEMA type 4X optionally available.
• Electronics
Part Number: 5294- _ _ _ FlexSwitch™
• Agency Approvals
Factory Mutual and CSA system approved.
CENELEC (hazardous location only) system
approved. Approved CE marking.
1 - 2
Doc. No. 06EN003246 Rev. B
CHAPTER 2 - INSTALLATION FLUID COMPONENTS, INTL
2. Installation
Receiving/Inspection
• Unpack carefully.
• Verify that all items in the packing list are received and are correct.
• Inspect all instruments for damage or contaminants prior to installation.
If the above three items are satisfactory, proceed with the installation. If not, then stop and contact a customer
service representative.
Packing/Shipping/Returns
These issues are addressed in Appendix C - Customer Service.
Factory Calibration Note
The instrument is factory calibrated to the applications as specified at the time of order. There is no need to perform
any verification or calibration steps prior to installing and placing the instrument in service unless the application has
been varied.
Pre-Installation Procedure
Warning: Only qualified personnel should install this instrument. Install and follow safety procedures in
accordance with the current National Electrical Code. Ensure that power is off during installation.
Any instances where power is applied to the instrument will be noted in this manual. Where the
instructions call for the use of electrical current, the operator assumes all responsibility for
conformance to safety standards and practices.
Caution:
Use Standard ESD Precautions
Use standard ESD precautions when opening an instrument enclosure or handling the control circuit. FCI
recommends the use of the following precautions: Use a wrist band or heel strap with a 1 megohm resistor connected
to ground. If the instrument is in a shop setting there should be static conductive mats on the work table and floor
with a 1 megohm resistor connected to ground. Connect the instrument to ground. Apply antistatic agents to hand
tools to be used on the instrument. Keep high static producing items away from the instrument such as non-ESD
approved plastic, tape and packing foam.
The instrument contains electrostatic discharge (ESD) sensitive devices. Use standard ESD precautions
when handling the control circuit. See below, for ESD details.
The instrument is not designed for weld-in-place applications. Never weld to a process connection or a
structural support.
Damage resulting from moisture penetration of the control circuit or flow element enclosure is not
covered by product warranty.
The above precautions are minimum requirements to be used. The complete use of ESD precautions can be found in
the U.S. Department Of Defense Handbook 263.
Doc. No. 06EN003246 Rev. B 2 - 1 FLTÔ Series FlexSwitchÔ
FLUID COMPONENTS, INTL CHAPTER 2 - INSTALLATION
Prepare or Verify Sensing Element Location
Prepare the process pipe for installation, or inspect the already prepared location to ensure that the instrument will fit
into the system.
Review the requirement for the supply power and alarm circuit connections.
Verify Dimensions
Verify the instrument's dimensions versus the process location to be sure of a correct fit. Also see Appendix A for
dimensions.
Verify Sensing Element Flow Direction and Placement Orientation (Flow Application)
For flow detection, the sensing element surface marked with direction arrows should be oriented parallel to the
process flow. The flow can be from either direction. See the appropriate figure in Appendix A for the flow arrow
marking.
Mount the sensing element at least 20 diameters downstream and 10 diameters upstream from any bends or
interference in the process pipe or duct to achieve the greatest accuracy.
For liquid flow service, the sensing element should be located in the process pipe so that the thermowells are always
completely wet.
When mounted in a tee or section of pipe larger than the normal process pipe, position in a vertical run of pipe with
flow upward. This will prevent air or gas bubbles from becoming trapped at the sensor assembly.
Vertical positioning with flow downward is only recommended for higher flow rate applications (consult FCI).
Verify Sensing Element Flow Direction and Placement Orientation (Level Application)
If the sensing element is side-mounted on the process vessel, then the surface marked with direction arrows should be
vertically oriented.
If the sensing element is top- or bottom-mounted on the process vessel, the orientation of the surface marked with
direction arrows does not matter.
Install the Sensing Element
Male NPT Mounting
When mounting the sensing element to the process pipe, it is important that a lubricant/sealant be applied to the male
threads of all connections. Be sure to use a lubricant/sealant compatible with the process environment. All
connections should be tightened firmly. To avoid leaks, do not overtighten or cross-thread connections. See
Figure 2-1 and the appropriate figure in Appendix A for proper mounting.
Figure 2-1. NPT Pipe Thread Mount
FLTÔ Series FlexSwitchÔ 2 - 2 Doc. No. 06EN003246 Rev. B
CHAPTER 2 - INSTALLATION FLUID COMPONENTS, INTL
Flange Mounting
For flange mounted sensing elements, attach the process mating flange with care. The correct orientation of the
sensing element must be maintained to ensure optimum performance or calibration. See Figure 2-2 and the
appropriate drawings in Appendix A.
Figure 2-2. Flange Mount
Packing Gland Assembly
Applications involving the use of a packing gland (low or medium pressure) should refer to the drawings in
Appendix A for additional detail.
1. Threaded or flanged packing gland mounts are available. The valve assembly with appropriate connections are
customer supplied. Follow the male NPT mounting procedure above to attach the pipe thread portion or flange
mounting portion as applicable.
2. Tighten the packing nut until the internal packing is tight enough so that the friction fit on the shaft is adequate
to prevent leakage but not prevent the shaft from sliding. Position the etched flow arrow parallel with the flow
(±1° of level) and position the flow arrow so it is pointing in the direction of the flow.
3. Proceed to insert the probe into the process media line. Use the adjusting nuts on the all-thread to pull the
sensing element into proper predetermined depth position.
4. Tighten the opposing lock nuts on the all-threads. Tighten the packing nut another half to full turn until tight
(approximately 65 to 85 ft-lbs [88 to 115 N-m] torque).
5. Rotate the split ring locking collar to line up with the connecting strap welded to the packing nut. Tighten the
two 1/4-28 hex socket cap screws on the split ring locking collar.
Reverse these steps for removal.
In-line NPT Assembly (FLT93-L)
The body length of the in-line assembly should be verified to be sure the assembly will fit into the process line. See
the appropriate figure in Appendix A to determine the assemblies length. The direction of flow is important for
proper operation. There is a flow direction arrow on the in-line pipe that is to point in the direction of flow. See
Figure 2-3 for the correct orientation.
Doc. No. 06EN003246 Rev. B 2 - 3 FLTÔ Series FlexSwitchÔ
FLUID COMPONENTS, INTL CHAPTER 2 - INSTALLATION
Figure 2-3. FLT93-L In-line Flow Element
Sanitary Assembly (FLT93-C)
The instrument is inserted into the process connection with a removable clamp fittings. The Removable Clamp (RC)
sanitary assembly contains a removable clamp connection to the flow element. The Clean-In-Place (CIP) sanitary
assembly has the flow element directly welded into the process stand pipe. Otherwise these instruments function
exactly the same as an FLT93-F or FLT93-S. See Appendix A for an outline dimensions of the instruments.
Figure 2-4 also shows the sanitary assemblies.
Figure 2-4. FLT93-C Sanitary Flow Elements (RC and CIP Respectively)
Install and Wire the Enclosure(s)
Caution:
In applications where the sensing element is located in an explosive environment, isolate the conduit
before it leaves the environment. A potting Y may be used to provide the isolation.
Pulling wires can cause damage to the control circuit. Therefore, remove the control circuit from the
enclosure and use extreme care when pulling wires into the enclosure.
Mount and wire the control circuit either locally or remotely (option) by following the local or remote enclosure
procedure below.
Minimum Wire Size
Table 2-1 shows the smallest (maximum AWG number) copper wire that is used in the electrical cables. Use a lower
gauge of wire for less of a voltage drop. Contact FCI concerning greater distances than those listed in the table. The
sensing element cable must be shielded. If the cable is spliced the shield wire must be continued through the splice.
If a terminal block is used, the shield must have its own terminal.
FLTÔ Series FlexSwitchÔ 2 - 4 Doc. No. 06EN003246 Rev. B
CHAPTER 2 - INSTALLATION FLUID COMPONENTS, INTL
Table 2-1. Maximum AWG Number
GWArofecnatsiDmumixaM
noitcennoC
.tf01
)m3(
.tf05
)m51(
.tf001
)m13(
.tf052
)m67(
.tf005
)m251
.tf0001
)m503(
rewoPCA222222028161
)A2(yaleR822202612101
*seriWtnemelEwolF220202818181
.ylnotekcoslortnocehtotdetcennoceriwdleihsehthtiwelbacdedleihsaseriuqeR*
Wiring the Local Enclosure
This procedure is for instruments with the control circuit located in the sensing element enclosure.
1. Remove the control circuit from its socket. Do not remove the control circuit socket. Removal of the control
circuit socket may cause damage to the instrument.
2. Install conduit between the local enclosure and the power source and monitoring circuit. Provide watertight
hardware and apply thread sealant to all connections to prevent water damage.
Warning:
3. When connecting the relay wiring, do so with complete understanding of what the process requires of the
instrument. The instrument has dual SPDT or single DPDT relay output contacts dependent on the jumper
configuration for each alarm switch point. For the relay logic, refer to Figure 2-5. Also refer to Table 3-5 and
Table 3-6 in Chapter 3 - Operation. Relay contacts are shown with the relays de-energized. Wire in accordance
with the system requirements.
Ensure that all power is off before wiring any circuit.
Figure 2-5. Local Wiring Diagram
Doc. No. 06EN003246 Rev. B 2 - 5 FLTÔ Series FlexSwitchÔ
FLUID COMPONENTS, INTL CHAPTER 2 - INSTALLATION
Wiring The Remote Enclosure
This procedure is for instruments with the control circuit located remotely from the sensing element.
Locate the Remote Hardware Location
Appendix A shows the remote enclosure along with the physical dimensions to properly mount it. Select a location
for the remote enclosure within a 1000 feet (305 m) of the sensing element. Pigtail sensing elements can not be
located more than 10 feet (3 m) from the enclosure unless the pigtail is extended with the proper size cable listed in
Table 2-1. If the cable is extended the cable connections should be located in a junction box with a 6 position
terminal block. All 5 conductors and the shield must have its own termination. The remote enclosure should be
easily accessible with enough room to open the enclosure cabinet cover at any time. Secure the remote enclosure
solidly to a vertical surface capable of providing support. Use appropriate hardware to secure the enclosure.
1. Remove the control circuit from the remote enclosure.
2. Run a five-conductor, shielded cable from the local enclosure to the remote enclosure. Use Table 2-1 to
determine which wire gauge to use.
3. Wire between the local and remote enclosures according to Figure 2-6.
Warning:
Ensure that all power is off before wiring any circuit.
4. When connecting the relay wiring, do so with complete understanding of what the process requires of the
instrument. The instrument has dual SPDT or single DPDT relay output contacts dependent on the jumper
configuration for each alarm switch point. For the relay logic, refer to Figure 2-6. Also refer to Table 3-5 and
Table 3-6 in Chapter 3 - Operation. Relay contacts are shown with the relays de-energized. Wire in accordance
with the system requirements.
Figure 2-6. Remote Wiring Diagram
FLTÔ Series FlexSwitchÔ 2 - 6 Doc. No. 06EN003246 Rev. B
CHAPTER 2 - INSTALLATION FLUID COMPONENTS, INTL
Figure 2-7. Auxiliary Relay Board Wiring Diagram
Wiring Remote Enclosure with Auxiliary Relay
Refer to the "Wiring the Remote Enclosure" section to run the cable between the local and remote enclosures. In
most cases the auxiliary relay board is in the same enclosure as the control circuit. Both boards are mounted on the
same panel and have been wired together at the factory. This configuration can be ordered without an enclosure
which can be supplied by the customer.
The alarm connections are made at the auxiliary relay board where each alarm is driving a DPDT relay.
Caution:
This configuration uses a control circuit that provides a switching voltage signal instead of relay contacts. The
switch voltage is wired from the control circuit socket to the auxiliary relay board actuating the relays.
The auxiliary relay board has several relay options that can be ordered. The options are as follows:
Do not connect any loads to the control circuit socket. Damage will occur to the control circuit if the
alarm circuit is energized.
Be sure the correct relay board has been ordered for the correct output. See the following paragraph.
• Dry to 2 amps at 115 Vac or 28Vdc, Dry to 1 amp at 230 Vac (relay is enclosed in a plastic sealed cover).
• 100mA to 10mA at 115 Vac or 28Vdc, 50mA to 3 amps at 230 Vac (relay is enclosed in a plastic sealed cover).
• Dry to 0.5 amps at 115 Vac, hermetically sealed relay.
Doc. No. 06EN003246 Rev. B 2 - 7 FLTÔ Series FlexSwitchÔ
FLUID COMPONENTS, INTL CHAPTER 2 - INSTALLATION
Make sure that the proper relays have been selected for the intended load. See Appendix A for the auxiliary relay
board configuration drawing.
When connecting the relay wiring, do so with complete understanding of what the process requires of the instrument.
The instrument has dual DPDT or single 4PDT relay output contacts dependent on the jumper configuration for each
alarm switch point. For the relay logic, refer to Figure 2-5. Also refer to Table 3-5 and Table 3-6 in
Chapter 3 - Operation. Relay contacts are shown with the relays de-energized. Wire in accordance with the system
requirements.
The control circuit can be ordered with switching voltage outputs without ordering a relay board. This can be used
with customer supplied relays or any other device that has a differential input. The output voltage is 17 Vdc and will
drive a load as low as 1500 ohms. Refer to Figure 2-7 for the output terminals.
Wiring A Remote Control Circuit To An Auxiliary Relay Board
1. Run a four-conductor cable from the control circuit to the auxiliary relay board if the board was not factory
installed. Use the wiring diagram in Figure 2-7 to wire the boards together.
2. Attach the customer wiring as desired using Figure 2-7 as a wiring guide.
Wiring for this configuration is the same as the sensing element wiring to the control circuit on a remote instrument.
Wiring Output Signal Terminals
Two output signals are provided on the control circuit at P1. The signal voltage at positions 1 and 2 represents the
process change. The signal voltage at positions 3 and 4 is proportional to the temperature at the sensing element.
See Figures 2-5 through 2-7. See also Chapter 3 for the physical layout of the control circuit.
Caution:
Do not ground terminal 2 of P1. (Terminal 2 is the negative lead of the process signal.) This terminal
is 9 volts above the control circuit ground. The peripheral using this signal must have a differential
input.
These voltages can be used by other peripherals with a minimum load of 100K ohms. The terminal block can be
wired with between gauge 26 and 18 wire (22 gauge wire is normally used). The maximum recommended length of
wire is 1000 feet. Shielding is required on any length of cable. The shield must be terminated at position 4 on P1.
Early versions of the FLT93 require a connecting harness that was supplied with each instrument. The harness can
be ordered if it is missing. The FCI part number is 015664-01. Newer versions of the FLT93 require a supplied
terminal plug.
FLTÔ Series FlexSwitchÔ 2 - 8 Doc. No. 06EN003246 Rev. B
CHAPTER 3 - OPERATION FLUID COMPONENTS INTL
3. Operation
Caution: The control circuit contains electrostatic discharge (ESD) sensitive devices. Use standard ESD precautions
when handling the control circuit. See Chapter 2, Operation, for ESD details.
Factory Default Jumper Configuration
Unless a custom factory setup or calibration is specified, the instrument is delivered in a standard factory
configuration. The standard default jumper configuration is shown in Table 3-1.
Table 3-1. Standard Jumper Default Configuration
rewoPtupnI.)6Jdna5J,2J(caV032
S-39TLF
rewoPretaeH
F-39TLF
smralAforebmuN.stcatnocTDPSfotesenosahmralahcaE.)32J(owT
DELdeR1.oNmralA
62R.toPtnioPteS
neerG2.oNmralA
.toPtnioPteSDEL
52R
)31J(
)41J(
.)72J(tewrowolf
.)52J(erutarepmetwoleb
:yletamixorppatatniopteS
,erutarepmetdradnatsrof)C121(F052
,erutarepmetmuidemrof)C062(F005
.snoitacilppaleveldiuqilroriarofsttaw57.0
.snoitacilppaleveldiuqilroriarofsttaw52.0
tadezigreneyaleR.)02J(slangislevelrowolfrotinomotteS
dezigreneyaleR.)91J(slangiserutarepmetrotinomotteS
.)ylnOS-39TLF(erutarepmethgihrof)C454(F058
If the order included custom factory setup and calibration, leave all settings alone. The instrument is ready for
service without changes.
If custom factory setup or calibration was not ordered, configure the control circuit using the jumper tables
(Tables 3-2 to 3-6) and then follow the set point adjustment section that is appropriate for the application.
Configuration Jumpers
If the order did not specify for the control circuit to be factory configured, the standard configuration can be changed
using Figure 3-1 and Table 3-2 though Table 3-6. The factory default configuration is shown as being underlined.
Heater Cut-Off
The 5294 control circuit has a heater cutoff switch that limits the skin temperature of the sensing element to a
temperature differential of approximately 150°F (66°C) above the process temperature. In the case where the
instrument is used as a gas flow switch, and the heater wattage is set too high, the temperature differential (DT)
between the RTDs may exceed the usable input range of the control circuit. The usable input range can also be
exceeded in the case where the instrument is used in liquid flow applications where the heater wattage is set at the
highest value, and when the sensing elements go dry. When the temperature differential is less than 150°F (66°C)
the heater automatically turns back on. The yellow power indicator LED (DS3) turns on and off with the heater for a
visual indication of the heater state. The LED will alternate between on and off until the condition iss corrected.
Doc. No. 06EN003246 Rev. B 3 - 1 FLTÔ Series FlexSwitchÔ
FLUID COMPONENTS INTL CHAPTER 3 - OPERATION
Figure 3-1. 5294 Control Circuit Jumper Locations
The reason for operation in the above extreme conditions is that the input signal range is at the widest point making
the alarm set point adjustment easier to perform. If the heater does cycle the operator may need to use the next lower
wattage setting.
In some applications it is desirable to set the heater wattage high, even though the sensing element goes into the
heater cutoff mode. An example is when the instrument is used to detect the interface of two liquids. These liquids
may have viscosities that will have signals very close to each other. In order to have the maximum signal difference
between the signals the heater wattage is set to its maximum. If the sensing element detects a dry condition the
control circuit will indicate a heater cutoff condition. The sensing element will not be dammaged if it is left dry with
the maximum heater wattage. The alarms can be set so one alarm will switch at the interface and one alarm can
detect when the element goes dry.
Alarm Set Point Adjustments
Numerical Adjustment Versus Adjustment by Observation
An alarm set point is established using either numerical adjustment or adjustment by observation. The adjustment by
observation requires the customer to establish normal process operation and adjust the alarm set point relative to this
condition. The numerical approach requires measuring normal and alarm process conditions with a voltmeter and
setting up the instrument in the calibrate mode based on these values. The adjustment by observation requires less
time to establish the alarm set point. The numerical adjustment requires control of the process as well as additional
time to establish the alarm set point. Use the adjustment procedure that is the most appropriate for the application
requirement.
FLTÔ Series FlexSwitchÔ 3 - 2 Doc. No. 06EN003246 Rev. B
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