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Sierra Innova-Switch 615-FS4200 Instruction Manual

615 series mass flow/level switch
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Innova-Switch™ Series
615 Series Mass Flow/Level Switch

Instruction Manual

Part Number: IM-615, Rev. E 5/17

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Summary of Contents for Sierra Innova-Switch 615-FS4200

  • Page 1: Instruction Manual

    Innova-Switch™ Series 615 Series Mass Flow/Level Switch Instruction Manual Part Number: IM-615, Rev. E 5/17...

  • Page 2: Before Starting

    Innova-Switch™ Instruction Manual 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.
  • Page 3 Sierra Instruments Innova-Switch™ Instruction Manual 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 OF 30 SECONDS SHOULD BE OBSERVED TO ALLOW FOR STABILIZATION OF TEMPERATURE.
  • Page 4 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.

  • Page 5: Table Of Contents

    Sierra Instruments Innova-Switch™ Instruction Manual TABLE OF CONTENTS INTRODUCTION DESCRIPTION 2.1 LEVEL SWITCHING FLOW SWITCHING INSTALLATION MECHANICAL INSTALLATION 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) OPERATION AND CALIBRATION OF THE INNOVA-SWITCH™...
  • Page 6 Sierra Instruments Innova-Switch™ Instruction Manual APPENDIX VOLUME FLOW CONVERSION CHART FLOW CONVERSION CHART FLOW OF WATER THROUGH SCHEDULE 40 STEEL PIPE (AVAILABLE IN PRINTED MANUAL ONLY) OPTIONS 10.1 LIVETAP (LT) 10.2 VARIABLE INSERTION (VI) 10.3 SANITARY (3A1) 10.4 INNOVASWITCH SINGLE CHANNEL MASS FLOW OR POINT LEVEL SWITCH...

  • Page 7: Introduction

    Sierra Instruments Innova-Switch™ Instruction Manual 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.
  • Page 8 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)
  • Page 9 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)
  • Page 10 Sierra Instruments Innova-Switch™ Instruction Manual 5.1 (129.54) REF. 6.0 (152.4) REF. 5.20 (132) REF. .8 (20.32) REF. 2.00 (50.8) REF. 5.04 (128) REF. 3.88 (98.6) REF. SEE FIGURE 5 DIMENSIONS IN INCHES (MILLIMETERS) DRAWING FILE: CIXI.DWG FIGURE 1C INNOVA-SWITCH 615 SERIES OUTLINE DIAGRAM STANDARD 2.0 INCH...

  • Page 11: Level Switching

    Sierra Instruments Innova-Switch™ Instruction Manual 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.

  • Page 12: Flow Switching

    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.
  • Page 13 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.
  • Page 14 Sierra Instruments Innova-Switch™ Instruction Manual FIGURE 2B INNOVA-SWITCH MODEL 615 FLOW RESPONSE FOR THREE MEDIA...
  • Page 15 Sierra Instruments Innova-Switch™ Instruction Manual Figure 3.A shows a block diagram of the Innova-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.
  • Page 16 Sierra Instruments Innova-Switch™ Instruction Manual 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...
  • Page 17 Sierra Instruments Innova-Switch™ Instruction Manual The instrument enclosure at the top of unit contains the Innova-Switch™ electronics board which is removable to access the terminal block and facilitate field wiring (see Figure 4.0). For applications where the electronics must be located away from the sensors due to elevated process temperature, accessibility, etc., another instrument head containing the electronics is remotely located (See option...
  • Page 18 Sierra Instruments Innova-Switch™ Instruction Manual This page left blank intentionally.

  • Page 19: Installation

    (25.4mm) MNPT and flange mounts. Conduit is recommended for all wiring to the switch. *IMPORTANT* WHEN INSTALLING YOUR SIERRA INNOVA-SWITCHINTO 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.
  • Page 20 Sierra Instruments Innova-Switch™ Instruction Manual FIGURE 5: PROPER ORIENTATION OF THE SENSOR PROBE FOR LEVEL AND FLOW APPLICATION IS INDICATED BY THE ARROW ON THE FLAT OF THE MOUNTING FITTING. (MTF500.DWG/.FCW)

  • Page 21: Electrical Installation

    Sierra Instruments Innova-Switch™ Instruction Manual ELECTRICAL INSTALLATION 3.2.1 LOCAL ELECTRONICS (LE OPTION/STANDARD) Remove the instrument enclosure lid by unscrewing in a counter clockwise direction. Unscrew (CCW) the printed circuit board captive screws (See Figure 4.0 for locations). Remove the PC board by grasping the transformer and pulling it straight out. Connect power and alarm relay wiring to Terminal Block (TBB) as shown in Figure 6.0.
  • Page 22 Sierra Instruments Innova-Switch™ Instruction Manual 3.2.2 REMOTE ELECTRONICS (RE OPTION) For the remote electronics option, mount the remote instrument head using two mounting wings or bracket provided. Connect the switch wiring between the Innova-Switch™ remote electronics as shown in Figure 7.0. Connect power wiring and alarm relay wiring to the remote enclosure as shown in Figure 7.0.
  • Page 23 Sierra Instruments Innova-Switch™ Instruction Manual...
  • Page 24 Sierra Instruments Innova-Switch™ Instruction Manual...

  • Page 25: Ce Option Filter Board Connector Plate Wiring (Ce Option)

    Sierra Instruments Innova-Switch™ Instruction Manual 3.2.3 CE OPTION FILTER BOARD CONNECTOR PLATE WIRING (CE OPTION) Remove the instrument enclosure lid by unscrewing in a counter clockwise direction. Unscrew (CCW) the printed circuit board captive screws (See Figure 4.0 for locations).
  • Page 26 Sierra Instruments Innova-Switch™ Instruction Manual This page left blank intentionally.

  • Page 27: And Relay Status Logic (Fail-Safe)

    Sierra Instruments Innova-Switch™ Instruction Manual OPERATION AND CALIBRATION OF THE INNOVA- SWITCH™ MODEL 615 FOR FLOW APPLICATIONS Pre-Operational Check With the switch installed and process conditions at no-flow, the following procedure can be used to verify preliminary operation. 4.1.1 Remove the instrument enclosure cover by turning counter clockwise (ccw) to expose the Innova-Switch™...
  • Page 28 Sierra Instruments Innova-Switch™ Instruction Manual FIGURE 8.0 INNOVA-SWITCH™ ELECTRONICS (MTF800.FCW/.DWG) 4.2.3 Alternate Operation (Field Selectable) The relay logic may be reversed by moving the J-2 jumper to position A(1-2). (Refer to Figure 8.0.) RELAY GREEN RELAY CONTACT SENSOR STATUS COIL STATUS...
  • Page 29 Sierra Instruments Innova-Switch™ Instruction Manual FIGURE 9.0 INNOVA-SWITCH MODEL 615 FLOW SWITCH CALIBRATION REFERENCE DRAWING (MTF900.DWG.FCW)

  • Page 30: Calibration - Flow

    Sierra Instruments Innova-Switch™ Instruction Manual CALIBRATION – FLOW **IMPORTANT** FOR OPTIMUM OPERATION, CALIBRATION MUST BE ACCOMPLISHED AT ACTUAL PROCESS TEMPERATURE AND PRESSURE CONDITIONS IN GASES AND AT ACTUAL PROCESS TEMPERATURE CONDITIONS IN LIQUIDS. See Figures 8.0 and 9.0 for location of potentiometers and LEDS on electronics PCB.

  • Page 31: And Relay Status Logic (Fail-Safe)

    Sierra Instruments Innova-Switch™ Instruction Manual 13. Adjust the trip adjust pot to obtain a trip as exhibited by an LED illumination. If a trip on decreasing flow is desired set for Red LED illumination. If a trip on increasing flow is desired set for Green LED illumination.
  • Page 32 Sierra Instruments Innova-Switch™ Instruction Manual 5.2.3 ALTERNATE OPERATION (FIELD SELECTABLE) The relay logic may be reversed by moving the J-2 jumper to position A(1-2). (Refer to Figure 8.0.) RELAY GREEN RELAY CONTACT SENSOR STATUS COIL STATUS STATUS o NC Dry, or Lower Thermal...

  • Page 33: Calibration - Level

    Sierra Instruments Innova-Switch™ Instruction Manual CALIBRATION – LEVEL **IMPORTANT** FOR OPTIMUM OPERATION CALIBRATION MUST BE ACCOMPLISHED AT ACTUAL PROCESS TEMPERATURE CONDITIONS. FIGURE 10.0 INNOVA-SWITCH MODEL 615 POINT LEVEL SWITCH CALIBRATION REFERENCE DRAWING (MTF1000.DWG/.FCW)
  • Page 34 Sierra Instruments Innova-Switch™ Instruction Manual CALIBRATION - LEVEL Using Figure 10.0 as a location guide adjust the system as follows: Remove the instrument enclosure lid by turning ccw. Apply power to the unit. Allow 10 minute warm-up. For optimum calibration results, wet sensor and drain but do not dry.

  • Page 35: Maintenance And Trouble Shooting

    150°F is permissible to speed this process. The acid must be thoroughly rinsed off once cleaned. For unusual cleaning problems, call Sierra and determine the exact materials of construction and chemical compatibility before using strong acids or unusual cleansers. **IMPORTANT** DO NOT SANDBLAST OR ABRASIVE CLEAN THE SENSING PROBES.

  • Page 36: Sensor/Electronics Functionality Verification

    Sierra Instruments Innova-Switch™ Instruction Manual 6.2.2 SENSOR/ELECTRONICS FUNCTIONALITY VERIFICATION Turn power off to Innova-Switch™. Allow a 5 minute cool down. Measure the resistance of each RTD at pins 1 and 6 of TBA (see Figure 6.0 or 7.0) for the hot RTD and pins 3 and 5 of TBA for the cold RTD. These resistances should be 110 ±...

  • Page 37: Specifications

    0.5 to 10 seconds no-flow (dry) to flow (wet) and 2 to 60 seconds flow (wet) to no-flow (dry) (application dependent) INPUT POWER: 110 Vac, 50/60HZ standard. (220 Vac, 50/60HZ, 24 Vdc, or 24 Vac optional); 3.1w. maximum. SIERRA PART NO. FUSE REQUIREMENTS (F1): CSA/FM CENELEC 110 Vac: 1/4 amp...

  • Page 38: Appendix

    Sierra Instruments Innova-Switch™ Instruction Manual APPENDIX VOLUME FLOW CONVERSION CHART Convert known units to cubic feet per second (CFPS) or gallons per minute (GPM) for use with Chart A.2 TO CONVERT FROM MULTIPLY BY Gallons Per Minute (GPM) Cubic Feet Per 2.228 E-03...

  • Page 39: Flow Conversion Chart

    Sierra Instruments Innova-Switch™ Instruction Manual FLOW CONVERSION CHART...

  • Page 40: 9.3 Flow Of Water Through Schedule 40 Steel Pipe

    Sierra Instruments Innova-Switch™ Instruction Manual 9.3 FLOW OF WATER THROUGH SCHEDULE 40 STEEL PIPE...

  • Page 41: Options

    Sierra Instruments Innova-Switch™ Instruction Manual 10.0 OPTIONS 10.1 LIVETAP (LT)

  • Page 42: Variable Insertion (Vi)

    Sierra Instruments Innova-Switch™ Instruction Manual 10.2 VARIABLE INSERTION (VI)

  • Page 43: Sanitary (3A1)

    SANITARY (3A1) Sanitary Switch Operating Instructions Innova-Switch™ Sanitary Installation Sierra’s Sanitary Switch Option is to be installed using industry standard piping practices. Make sure that you have selected the proper gasket and clamp designed for your pressure, temperature and process fluid.

  • Page 44: Innovaswitch Single Channel Mass Flow Or Point Level Switch Product Specifications)

    Sierra Instruments Innova-Switch™ Instruction Manual 10.4 InnovaSwitch Single Channel Mass Flow Or Point level Switch Product Specifications)
  • Page 45 Sierra Instruments Innova-Switch™ Instruction Manual...

This manual is also suitable for:

Innova-switch 615-ls3200

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