Sierra 215 User Manual

INNOVA-SWITCH™ SERIES

INSTRUCTION MANUAL

Model 215 Mass Flow/Level Switch

( Model FS4200 Series – Mass Flow Switch / Model LS3200 Series – Point Level Switch )

Document IM 215

Rev-A.1

February 2006

Sierra Instruments, Inc., Headquarters

5 Harris Court, Building L

Monterey, California, USA 93940

Toll Free: 800-866-0200 (USA only)

Phone: [phone] ; Fax: [phone]

Website: www.sierrainstruments.com

Sierra Europe, European Headquarters

Bijlmansweid 2

1934RE Egmond a/d Hoef

The Netherlands

Phone: [phone] ; Fax: [phone]

Sierra Asia, Asia-Pacific Headquarters

100 Jaingnan Daidao Suite 2303

Guangzhou, China

Phone: [phone], Fax: [phone]

IM-215 Rev-A.1 Series Innova-Switch™ Page 2 of 42

BEFORE STARTING

SIERRA INSTRUMENTS appreciates your choosing our product for your liquid level or liquid/gas flow
switching application. We are committed to providing reliable, quality instrumentation to our customers.

To ensure the maximum and intended benefit of this instrument, we encourage you to read this brief
operation and maintenance manual in its entirety prior to unpacking and installing the unit.

The following precautions should be noted immediately:

• WHEN INSTALLING YOUR INNOVA-SWITCH™ INTO A PIPE OR VESSEL USE A 1 1/8 INCH

(28.575mm) OPEN-END WRENCH TO TIGHTEN AT THE HEX FLATS OF THE MNPT OF A
STANDARD SWITCH. (IF YOU HAVE A NON-STANDARD SWITCH AN ALTERNATE SIZE
WRENCH MAY BE REQUIRED). DO NOT USE THE INSTRUMENT HEAD TO TIGHTEN THE
SWITCH TO THE MOUNTING PORT. ROTATION OF THE INSTRUMENT HEAD WITH
RESPECT TO THE SENSOR BODY CAN CAUSE INTERNAL WIRING DAMAGE (SEE
FIGURES 1).

• THE SWITCH BODY MUST BE ORIENTED TO HAVE THE TWIN SENSORS PARALLEL TO

THE LEVEL BEING DETECTED WHEN THE SENSOR IS INSTALLED HORIZONTALLY FOR
POINT LEVEL APPLICATIONS. LIKEWISE, FOR FLOW APPLICATIONS, THE SWITCH
BODY MUST BE ORIENTED TO HAVE THE TWIN SENSORS PERPENDICULAR TO THE
FLOW BEING DETECTED. DUE TO THE PIPE THREAD MOUNTING, IT MAY BE
NECESSARY TO MAKE A TRIAL FIT, ADD OR REMOVE TEFLON TAPE OR OTHER PIPE
THREAD SEALANT, AND REINSTALL TO ACHIEVE A SATISFACTORY SEAL WITH THE
SENSORS PROPERLY ORIENTED. FOR VERTICAL INSTALLATION OF SENSORS FOR
POINT LEVEL DETECTION THE ORIENTATION MAKES NO DIFFERENCE. PROPER
ORIENTATION IS MARKED ON THE SWITCH BODY FOR REFERENCE (SEE FIGURE 5).

• A GROUND WIRE MUST BE ATTACHED TO THE GROUND SCREW LOCATED INSIDE THE

INSTRUMENT ENCLOSURE FOR PROPER OPERATION. FOR CENELEC/CE OPTION THE
GROUND SCREW IS LOCATED OUTSIDE THE BODY OF THE INSTRUMENT ENCLOSURE
(SEE FIGURE 6).

• BE SURE TO APPLY THE PROPER VOLTAGE AS CONFIGURED AT THE FACTORY. DO

NOT APPLY 115 VAC TO 24 VDC VERSIONS OR 24 VDC TO 115 VAC VERSIONS.
(LIKEWISE 230 VAC).

• FOR OPTIMUM OPERATION, CALIBRATION MUST BE ACCOMPLISHED AT ACTUAL

PROCESS TEMPERATURE AND PRESSURE CONDITIONS IN GASES AND AT ACTUAL
PROCESS TEMPERATURE CONDITIONS IN LIQUIDS.

• DO NOT SANDBLAST OR ABRASIVE CLEAN THE SENSING PROBES. THE SENSING

PROBES COULD BE DAMAGED BY ABRASIVES.

• ALL DIMENSIONS GIVEN IN THIS MANUAL ARE IN INCHES (AND MILLIMETERS).

If you have any questions prior to or during installation and calibration, please do not hesitate to call the
factory for assistance. We want to ensure the very best possible installation and operational results for
your benefit.

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The electronic assemblies contained in the Innova-Switch™ models are configured for specific
voltages and have specific modifications to accommodate the various agency approvals. When
ordering spare electronics, replacements, or exchanges in the field please ensure you identify the
specific configuration you have by noting the boxes marked on the transformer configuration tag.

NOTICE

This manual covers the following model numbers:

Innova-Switch™ Series Models

215 - FS4200

215 - LS3200

Agency Approvals

Explosion-Proof rating

Mass Flow Switch

Point Level Switch

CENELEC
European

EEX d IIB T4 (Killark Enclosure)
EEx d IIC T4 (Akron Electric
Enclosure)
See Figure 1A and 1B

FS42CN

LS32CN

CSA
Canadian Standards

T4A
Class I, Group B,C,D
Class II, Group E, F, G
(Both Akron Electric and Killark)

FS42CS

LS32CS

Non-Approved

Non-Explosion Proof

FS42NX

LS32NX

(Ref. Section CE 3.2.3
wiring)

EMC Directive: 89/336/EEC

Option-CE

Option-CE

SPECIAL NOTICE

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TABLE OF CONTENTS

1.0 INTRODUCTION

2.0 DESCRIPTION

2.1 LEVEL SWITCHING

2.2 FLOW SWITCHING

3.0 INSTALLATION

3.1 MECHANICAL INSTALLATION

3.2 ELECTRICAL INSTALLATION

3.2.1 LOCAL ELECTRONICS (LE OPTION/STANDARD)

3.2.2 REMOTE ELECTRONICS (RE) OPTION

3.2.3 CE OPTION FILTER BOARD CONNECTOR PLATE WIRING (CE OPTION)

4.0 OPERATION AND CALIBRATION OF THE Innova-Switch™ SWITCH FOR FLOW APPLICATIONS

4.1 PRE-OPERATIONAL CHECKS

4.2 L.E.D. AND RELAY STATUS LOGIC (FAIL-SAFE)

4.3 CALIBRATION – FLOW

5.0 OPERATION AND CALIBRATION OF THE Innova-Switch™ SWITCH FOR POINT LEVEL

APPLICATIONS

5.1 PRE-OPERATIONAL CHECKS

5.2 L.E.D. AND RELAY STATUS LOGIC (FAIL-SAFE)

5.3 CALIBRATION – LEVEL

6.0 MAINTENANCE AND TROUBLE SHOOTING

6.1 CLEANING

6.2 TROUBLE SHOOTING

6.2.1 POWER AND CONTINUITY VERIFICATION

6.2.2 SENSOR/ELECTRONICS FUNCTIONALITY VERIFICATION

7.0 SPECIFICATIONS

8.0 WARRANTY AND SERVICE

8.1 WARRANTY

8.2 SERVICE

8.3 SPARE PARTS LIST

9.0 APPENDIX

9.1 VOLUME FLOW CONVERSION CHART

9.2 FLOW CONVERSION CHART

9.3 FLOW OF WATER THROUGH SCHEDULE 40 STEEL PIPE (AVAILABLE IN PRINTED
MANUAL ONLY)

10 OPTIONS

10.1 LIVETAP (LT)

10.2 VARIABLE INSERTION (VI)

10.3 THERMOCOUPLE OUTPUT (TO)

10.4 RTD OUTPUT(RT)

10.5 SANITARY (3A1)

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1.0 INTRODUCTION

The SIERRA INSTRUMENTS Innova-Switch™ Switch is the state-of-the-art in

gaseous and liquid flow switching or liquid level control. Flow or level detection is
accomplished by using a high resolution thermal differential technique. The sensor
wetted parts are of durable 316L series stainless steel, all welded construction with
no moving parts. The switch is easy to install and adjust, giving reliable, low
maintenance performance in the most demanding applications.

2.0 DESCRIPTION

The Innova-Switch™ uses a thermal differential technique to sense changes in the

heat transfer characteristics of a media. Figures 1A and 1B show the outline of the
Innova-Switch™. The sensor consists of a pair of matched Resistance Temperature

Detectors (RTD's) encased in twin 316L series stainless steel tubes. One RTD is
self-heated using a constant DC current. The other RTD is unheated to provide an
accurate process temperature reference. The thermal differential created between
the heated and reference RTD pair is a function of the density and/or velocity of the
media with which the sensor is in contact. Other physical properties may have a
secondary effect as well. The differential is greatest at a no flow (or dry) condition
and decreases as the rate of flow increases (or as a liquid quenches the sensor/wet
condition).

The SIERRA INSTRUMENTS sensor excitation method relies on constant current to

the heated and reference sensors. Thus power to the heated sensor is not constant
but changes linearly with temperature as the sensor resistance changes.
Temperature compensation is accomplished by using the amplified reference sensor
voltage that also changes linearly with temperature, as a dynamic reference. During
calibration dry/no flow and wet/full flow conditions are impressed across the trip point
potentiometer. Since this reference is not fixed but is set with respect to the
reference sensor voltage, as temperature changes the trip point potentiometer
voltage changes with temperature exactly the same as that of the heated sensor
voltage with which it is being compared. Thus full temperature compensation is
achieved with non-constant power.

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FIGURE 1A LS3200/FS4200 Innova-Switch™ OUTLINE DIAGRAM STANDARD 2.0

INCH INSERTION (KILLARK ENCLOSURE – NEMA 4-EExd 11B, T4)

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FIGURE 1B LS3200/FS4200 Innova-Switch™ OUTLINE DIAGRAM STANDARD 2.0

INCH INSERTION (AKRON ELECTRIC ENCLOSURE – NEMA 4X –
EexdIIC, T4)

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2.1 LEVEL SWITCHING

The thermal differential created between the heated and reference unheated RTD pair is

a function of the liquid or gas medium with which the sensor is in contact.

The point level measurement application uses the heat transfer differences between two

media to detect liquid level. For example, air has a relatively poor heat transfer
characteristic so the heated sensor will become relatively hot. If the sensor is then
immersed in water, the relatively high heat transfer characteristics of water will cool the
heated RTD surface causing a decrease in the signal output.

This same rational applies for any two media in contact with the sensor. Each medium

will have its own characteristic heat transfer properties. As long as there is a reasonable
difference in the heat transfer properties between the two media, the Innova-Switch™
can discriminate between them. Figure 2A shows the relative signal output of the
Innova-Switch™sensor to a range of different media. The maximum difference in output
occurs between vacuum and liquid metal. However, a significant difference occurs
between water and hydrocarbon liquids so the Innova-Switch ™ can be used to detect a
water/hydrocarbon liquid-liquid interface. In general, the interface between any two
media with differing heat transfer properties can be detected.

Thermal Differential Theory of Operation

Note: Probe tips contain

matched RTD’s one of
which is self-heated with
about 400mw of power.
The other provides
temperature
compensation.

The heated RTD
responds to the heat
transfer coefficient of the
media with which it is in
contact. Gases with low
heat transfer result in a
high differential
temperature between the
heated and reference tips.

When the heated tip
makes contact with a
liquid with higher heat
transfer the differential
temperature drops and
the lower differential
results in a switch trip to
indicate liquid.

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FIGURE 2A: RELATIVE CHANGE IN RESPONSE OF A HEATED RTD IMMERSED

IN VARIOUS MEDIA

2.2 Flow Switching

Most mass flow monitoring techniques calculate mass indirectly by measuring

volumetric flow such as gallons per minute or cubic cm per second, then either measure
density separately or calculate it from temperature measurements of the fluid and,
finally, combine density and volumetric flow to obtain mass flow. The SIERRA
INSTRUMENTS thermal-differential technique is one of two methods that directly
measure the mass flow. For ease of comparison most flow applications are presented
in terms of velocity which is independent of the flow cross sectional area (i.e. feet per
second (FPS)). The true mass flow equivalent would be FPS multiplied by density but
for simplicity FPS is used and density effects are ignored. This is normally not critical for
flow switching applications.

IM-215 Rev-A.1 Series Innova-Switch™ Page 10 of 42

When the sensor is inserted into a liquid or gas the heated RTD is strongly affected

by the velocity of the medium. Flow past the heated RTD changes the heat
transferred from the surface of the sensor. This cooling effect reduces the
temperature of the sensor. The Innova-Switch™ compares this change to a preset
flow trip point to switch the output. Figure 2B shows the model FS4200 signal
change vs. flow rate for air, light hydrocarbon liquids, and water.
The signal change vs velocity has the same general shape for all three media but the
change is larger for air and the sensitive range is different for each. For air and most
gaseous media the range is 0.1 to 500 feet per second (FPS). For most liquid media
the range is 0.01 to 5 FPS. Appendices in section 9.0 contain flow conversion
information to facilitate conversion from various units and pipe dimensions into flow
velocity in feet per second.

Gas Or Liquid Flow

Note: The fluid velocity and

heat absorption ability
determine the differential
between the tips. Their
combination determines the
measurable velocity. In
water velocities from 0.01 to
5 FPS are measurable,
whereas in air velocities of

0.1 to 500 FPS can be
measured.

For a no flow condition the
thermal differential between
the two tips is high because of
relatively low heat transfer.

Flow across the tips decreases
the thermal differential
because of the higher heat
transfer of flowing fluids. This
differential is compared with
the trip point.

When the lower differential
matches the customer select
flow velocity trip point (set
point) the switch relay and
red LED are tripped.

When flow is above the trip
point the differential is smaller
than at the set point and the

relay and Led remain tripped.

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FIGURE 2B Innova-Switch™ MODEL FS4200 FLOW RESPONSE FOR THREE MEDIA

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Figure 3.A shows a block diagram of the Innova-Switch™ switch.

Once the switch is set to respond to the minimum and maximum flow rates (or wet vs.

dry conditions), the trip point is set by adjusting the Trip Adjust Potentiometer. Solid
state electronics transform the flow (or wetting) induced temperature differential into a
voltage that is compared to a control voltage. Matching voltages cause actuation of a
relay to indicate a change in state (flow vs. no-flow or dry vs. wet).

FIGURE 3A: Innova-Switch™ SERIES S BLOCK DIAGRAM MODELS
LS32CS/FS42CS, LS32CN/FS42CN, LS32NX/FS42NX

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Figure 3B shows a block diagram of the Innova-Switch™ with the addition of an EMC filter
required for the CE options (see section 7.0).

FIGURE 3B: Innova-Switch™ MODELS WITH THE CE OPTION SWITCH BLOCK DIAGRAM