Sierra 615-FS4200 User Manual

Innova-Switch™ Series

615 Series Mass Flow/ Level Switch

Instruction Manual

Part Number: Im-615, Rev. B, July 2010

CCOORRPPOORRAATTEE HHEEAADDQQUUAARRTTEERRSS

5 Harris Court, Building L, Monterey, C A 93 940 U.S.A.

Phone [phone] Toll Free [phone] Fax [phone]

www.sierrainstruments.com

EEUURROOPPEEAANN HHEEAADDQQUUAARRTTEERRSS

Bijlmansweid 2, 1934RE Egmond aan den Hoef

The Netherlands

Phone [phone] Fax [phone]

AASSIIAA--PPAACCIIFFIICC HHEEAADDQQUUAARRTTEERRSS

RM. 618, Tomson Centre, Bldg. A, 188 Zhang Yang Road

Pu Dong New District, Shanghai, P. R. China

Phone [phone] Fax [phone]

Sierra Instruments Innova-Switch™ Instruction Manual

© COPYRIGHT SIERRA INSTRUMENTS 2010

No part of this publication may be copied or distributed, transmitted, transcribed, stored in a retrieval system, or
translated into any human or computer language, in any form or by any means, electronic, mechanical, manual, or
otherwise, or disclosed to third parties without the express written permission of Sierra Instruments. The information
contained in this manual is subject to change without notice.

TRADEMARKS

Innova-Swtich™ is a registered trademark of Sierra Instruments, Inc. Other product and company names listed in
this manual are trademarks or trade names of their respective manufacturers.

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Sierra Instruments Innova-Switch™ Instruction Manual

IMPORTANT CUSTOMER NOTICE

Before installing and operating the flow meter, please read this manual carefully and follow its instructions.
¾ Sierra has verified the conformity between the contents in this manual and the hardware and software

described. However, errors may still exist. We regularly review the materials covered in this manual and
correct errors with revisions. Any suggestions for improvement will be appreciated.

¾ Go to www.sierrainstruments.com/products/downloads.html for a most current electronic version of this

manual.

¾ We reserve the right to change the content of this manual without prior notification.
¾ If you have any questions or problems regarding this manual, please contact Sierra’s Customer Service

Department:
Toll Free: 800-866-0200 Phone: [phone] Fax: [phone]

Email: [e-mail]

WARNINGS IN THIS MANUAL

Caution and warning statements are used throughout this book to draw your attention to important information.

WARNINGS

“Warning” indicates that ignoring the relevant
requirements or precautions may result in
personal injury or flow meter damage.

NOTES

“Note” indicates that ignoring the relevant
requirements or precautions may result in flow
meter damage or malfunction.

BEFORE STARTING

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Sierra Instruments Innova-Switch™ Instruction Manual

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:

φ WHEN INSTALLING YOUR SIERRA INNOVA-SWITCH™ INTO A PIPE OR VESSEL USE A 1

1/8 INCH (28.575mm) OPEN-END OR ADJUSTABLE 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).

φ 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).

φ 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).

φ 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).

φ FOR OPTIMUM OPERATION, CALIBRATION MUST BE ACCOMPLISHED AT ACTUAL

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

φ TO ENSURE ACCURATE CALIBRATION AND AVOID SET POINT DRIFT, IT IS IMPERATIVE

THAT A MINIMUM OF 10 MINUTE WAIT BE OBSERVED AFTER POWER IS APPLIED TO
ALLOW THE SENSOR TO WARM-UP TO THE AMBIENT FLUID TEMPERATURE.

LIKEWISE, WHEN ADJUSTING THE ZERO, SPAN, AND SET POINTS POTS, A MINIMUM

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Sierra Instruments Innova-Switch™ Instruction Manual

OF 30 SECONDS SHOULD BE OBSERVED TO ALLOW FOR STABILIZATION OF
TEMPERATURE.

φ 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.

NOTICE

This manual covers the following model numbers:

Innova-Switch™ Series Models 615- FS4200 615-LS3200

Agency Approvals Explosion-Proof rating Mass Flow Switch Point Level Switch

CENELEC EEx d IIB T4 (Killark Enclosure)
European EEx d IIC T4 (Akron Electric Enclosure) FS42CN LS32CN
See Figure 1A and 1B

CSA T4A
Canadian Standards Class I, Group B,C,D FS42CS LS32CS
Class II, Group E,F,G
(Both Akron Electric and Killark)

Non-Approved Non-Explosion Proof FS42NX LS32NX
Switch Kits

(No Enclosures) Not Rated FS42SK LS32SK

(Ref. Section
CE 3.2.3 wiring) EMC Directive: 89/336/EEC Option – CE Option -CE

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Sierra Instruments Innova-Switch™ Instruction Manual

SPECIAL NOTICE

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.

*WARNING*

THE WETTED SENSOR OF THE SWITCH IS OF AN ALL WELDED CONSTRUCTION

CREATING A PRESSURE BOUNDARY FROM THE PROCESS FLUID (LIQUID OR

GAS). ANY BREACH OF THIS BOUNDARY THROUGH CORROSION,

MISTREATMENT, OR MISAPPLICATION COULD ALLOW THE PROCESS FLUID TO

ENTER THE ENCLOSURE OF THE UNIT.

PROCEED WITH CAUTION WHEN OPENING THE ENCLOSURE AFTER A BREACH OF

THE PRESSURE BOUNDARY TO AVOID CONTACT WITH ANY PROCESS FLUIDS THAT

MAYBE CONTAINED WITHIN THE ENCLOSURE.

*CAUTION*

IF THE FLUID PROCESS TEMPERATURE EXCEEDS 40 DEG C, THIS INSTRUMENT

CANNOT BE USED IN AN EXPLOSION PROOF APPLICATION UNLESS THE IGNITION

TEMPERATURE OF THE FLUID ATMOSPHERE IS A MINIMUM OF 80 DEG C HIGHER

THAN THE PROCESS TEMPERATURE.

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Sierra Instruments Innova-Switch™ Instruction Manual

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™ 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™ 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

6.2.3 SET POINT DRIFT

7.0 SPECIFICATIONS

8.0 WARRANTY AND SERVICE

8.1 WARRANTY

8.2 SERVICE

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Sierra Instruments Innova-Switch™ Instruction Manual

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 SANITARY (3A1)

10.4 LOW FLOW SENSOR (LFS)

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Sierra Instruments Innova-Switch™ Instruction Manual

1.0 INTRODUCTION

The Sierra Innova-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

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

The Sierra Instruments’ sensor excitation method relies on constant current to the heated

DESCRIPTION

transfer characteristics of a media. Figures 1A and 1B show the outline of the Innova­Switch™. 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).

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 which 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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Sierra Instruments Innova-Switch™ Instruction Manual

DIMENSIONS IN INCHES (MILLIMETERS)
FIGURE 1A INNOVA-SWITCH OUTLINE DIAGRAM STANDARD 2.0 INCH INSERTION

(KILLARK ENCLOSURE – NEMA 4-EExd 11B, T4) (MTF1A00.DWG/.FCW)

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Sierra Instruments Innova-Switch™ Instruction Manual

FIGURE 1B INNOVA-SWITCH 615 SERIES OUTLINE DIAGRAM STANDARD 2.0 INCH

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

(MTF1B00.DWG/.FCW)

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Sierra Instruments Innova-Switch™ Instruction Manual

5.1 (129.54) REF.

6.0 (152.4) REF.

2.00 (50.8) REF.

DRAWING FILE: CIXI.DWG

5.20 (132) REF.

.8 (20.32) REF.

5.04 (128) REF.

3.88 (98.6) REF.

SEE FIGURE 5

DIMENSIONS IN INCHES (MILLIMETERS)

FIGURE 1C INNOVA-SWITCH 615 SERIES OUTLINE DIAGRAM STANDARD 2.0 INCH

INSERTION (CIXI ENCLOSURE – NEMA 4X)(CIXI.DWG)

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Sierra Instruments Innova-Switch™ Instruction Manual

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 Innova­Switch™ 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.

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Sierra Instruments Innova-Switch™ Instruction Manual

SIGNAL

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

IN VARIOUS MEDIA

VACUUM

DECREASING THERMAL DISPERSION OR HEAT TRANSFER

0

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 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.

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™ compa re s th is c hange to a preset flow trip point to switch the output. Figure
2B shows the model 615 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

AIR

HYDROCARBON LIQUIDS

WATER

LIQUID METALS

MEDIA

DRAWING FILE: MTF2A0.DWG

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Sierra Instruments Innova-Switch™ Instruction Manual

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 (Hydrocarbons) and 0.01 to 2.5 FPS (water). 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

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

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

combination
determines the
measurable
velocity. In water
velocities from 0.01
to 2.5 FPS are
measurable. In
Hydrocarbons
velocities from 0.01
to 5 FPS are
measurable,
whereas in air
velocities of 0.1 to
500 FPS can be
measured.

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 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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