Warranty, Service & Repair

To register your product with the manufacturer, go to the Flowline website for on-line registration. The website address is as follows:

Non-Intrusive RF Capacitance Level Switch LP50 Series Owners Manual

www.flowline.com.
On-line Warranty Registration can be found under Contact Us in the Navigation Bar along the side of the home page. If for some reason your product must be returned for factory ser vice, contact Flowline Inc. at (562)598-3015 to receive a Material Return Authorization number (MRA), providing the following information: 1. Part Number, Serial Number 2. Name and telephone number of someone who can answer technical questions related to the product and its application. 3. Return Shipping Address 4. Brief Description of the Symptom 5. Brief Description of the Application Once you have received a Material Return Authorization number, ship the product prepaid in its original packing to: Flowline Factory Service
MRA _____
10500 Humbolt Street
Los Alamitos, CA 90720
To avoid delays in processing your repair, write the MRA on the shipping label. Please include the information about the malfunc tion with your product. This information enables our service tech nicians to process your repair order as quickly as possible.

Version 6.0A
2002 FLOWLINE Inc.
All rights reserved.
Manual # LP900002 - LP50-0510-M6_0A

WARRANTY

Flowline warrants to the original purchaser of its products that such products will be free from defects in material and workmanship under normal use and service for a period which is equal to the shorter of one year from the date of purchase of such products or two years from the date of manufacture of such products. This warranty covers only those components of the products which are non-moving and not subject to normal wear. Moreover, products which are modified or altered, and electrical cables which are cut to length during installation are not covered by this warranty. FLOWLINE's obligation under this warranty is solely and exclusively limited to the repair or replacement, at FLOWLINE's option, of the prod ucts (or components thereof) which FLOWLINE's examination proves to its satisfaction to be defective. FLOWLINE SHALL HAVE NO OBLIGATION FOR CONSEQUENTIAL DAMAGES TO PERSONAL OR REAL PROPERTY, OR FOR INJURY TO ANY PERSON. This warranty does not apply to products which have been subject to electrical or chemical damage due to improper use, accident, negligence, abuse or misuse. Abuse shall be assumed when indicated by electrical damage to relays, reed switches or other components. The warranty does not apply to products which are damaged during ship ment back to FLOWLINE's factory or designated service center or are returned without the original casing on the products. Moreover, this warranty becomes immediately null and void if anyone other than ser vice personnel authorized by Flowline attempts to repair the defective products. Products which are thought to be defective must be shipped prepaid
and insured to FLOWLINE's factory or a designated service center
(the identity and address of which will be provided upon request)
within 30 days of the discovery of the defect. Such defective products
must be accompanied by proof of the date of purchase.
Flowline further reserves the right to unilaterally wave this warranty
and to dispose of any product returned to Flowline where:
a. There is evidence of a potentially hazardous material present
with product.
b. The product has remained unclaimed at Flowline for longer than 30 days after dutifully requesting disposition of the product. THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE OF THIS WARRANTY. This warranty and the obligations and liabilities of Flowline under it are exclusive and instead of, and the original purchaser hereby waives, all other remedies, warranties, guarantees or liabilities, express or implied. EXCLUDED FROM THIS WARRANTY IS THE IMPLIED WARRANTY OF FITNESS OF THE PRODUCTS FOR A PARTIC ULAR PURPOSE OR USE AND THE IMPLIED WARRANTY OF MERCHANT ABILITY OF THE PRODUCTS. This warranty may not be extended, altered or varied except by a written instrument signed by a duly-authorized officer of Flowline, Inc.

SPECIFICATIONS

Step One
Non-intrusive Non-metallic < 1" (25 mm) 1 mm in water 0.5 mm in water > 10 constants > 100 micromhos 12-36 VDC 25 mA maximum (1) SPST relay 120 VAC/VDC @ 1A (CE: 60 VAC/VDC @ 1A) Contact output: Selectable NO/NC Process temp.: F: -40 to 176 C: -40 to 80 Enclosure rating: NEMA 4X (IP65) Enclosure mat.: PSO Conduit entrance: Single, 1/2" NPT Bracket material: 1 0 0 5 : P P 5005: PVDF 6005: PE Bracket mounting: 3M adhesive / plastic thermal weld Cable jacket mat.: PP Cable type: 4-conductor, #22 AWG (shielded) Cable length: Standard: 10' (3m) Special order: 25' (7.6m) or 50' (15.2m) Classification: General purpose CE compliance: EN 61326 EMC EN 61010-1 safety Tank mounting: Tank mat. comp.: Tank wall thick.: Accuracy: Repeatability: Dielectric range: Conductive range: Supply voltage: Consumption: Contact type: Contact rating:
Ambient Sensor Temperature (C) 4-20 mA Sensor Electrical Loading Limits 1,600 1,400 1,200 1,000 800 600 400 200 0 12 Acceptable Range 18 24 30 Supply Voltage (VDC) 36 Unacceptable Range Maximum Tem. / Voltage Derating Continuous 20 mA Sinking Curve 100 80 60 40 20 00 -20 12 16 20 24 28 32 Operating Voltage (VDC) 36 Acceptable Range Unacceptable Range

Technology:
The non-intrusive RF capacitance switch detects the pres ence of liquid or air by measuring the conductive or dielec tric values which are present in all materials. An electrical capacitor is formed between the level switch and the outer tank wall. As liquid rises and falls against the inner wall, the capacitance effect is greatly increased and the 1A SPST relay changes state.

Max. Series Resistance (Ohms)

2.2"(56mm) 1.0"
(25mm)

1.6"(41mm)

RELAY
Red (+)
Black (-)
White NO/NC Green COM Shld

8 Cable (2.5m)

1.7" (44mm) 2.8" (71mm)

Table of Common Dielectric Constants:

NOTE: Liquids with a conductivity value > 100 U are fine if coating is not an issue. Liquids with a dielectric constant less than 20 may not be reli ably detected by an LP50 series level switch, depending on conditions.
Acetone 21 Acetoaldehyde 22.2 Acetyl methyl hexyl ketone 28 Alcohol 16 to 31 Ammonia 15 to 25 Acetic acid 4.1 to 6.2 Butyl chloride 9.6 Barium chloride 9 to 11 Benzene 2.3 Benzine 2.3 Barium nitrate 5.6 Bromine 3.1 Chlorobenzene 4.7 to 6 Chlorotoluene 4.7 Chloroform 4.5 to 5.0 Chlorine, liquid 2.0 Carbon tetrachloride 2.2 Cyan 2.6 Cyclohexanemethanol 3.7 D.I. Water 20 Ethyl toluene 2.2 Ethyl alcohol 23 Ethylene glycol 37 Ethylene oxide 14 Ethylene dichloride 11 to 17 Ethylene chloride 10.5 Ethyl acetate 6.4 Ethyl salicylate 8.6 Ethyl stearate 2.9 Ethyl silicote 4.1 Formic acid 59 Ferric oleate 2.6 Freon 2.2 Glycerine 47 Glycol 30 Glycol nitrite 27 Gasoline 2 to 2.2 Hydrochloric acid 4.6 Isobutyric acid 2.7 Isobutyl methyl ketone 13 Jet fuel 1.7 Lead carbonate 18 Lead nitrate 38 Methyl salicylate 9.0 Methanol 33 Methyl alcohol 33 to 38
Margarine,liquid 2.8 to 3.2
Methyl acetate 7.3
N-butyl formate 2.4
Nitrobenzene 26 to 35 Nitrotoluene 25 Naphthalene 2.3 to 2.5 Oils, vegetable 2.5 to 3.5 Oils, mineral 2.3 to 2.4 Oils, petroleum 1.8 to 2.2 Oleic acid 2.5 Propane, liquid 1.8 to 1.9 Potassium nitrate 5.0 to 5.9 Potassium chloride 5.0 Stearic acid 2.3 Toluene 2.4 Trichloroethylene 3.4 Trichloroacetic acid 4.5 Terephthalic acid 1.5 to 1.7 Thinner 3.7 Urea 3.5 Vinyl chloride 2.8 to 6 Vinyl alcohol 1.8 to 2.0 Water, 20C 80 Water, 100C 48

3.2"(81mm)

SAFETY PRECAUTIONS
Step Two

INTRODUCTION
Step Three

About this Manual:

PLEASE READ THE ENTIRE MANUAL PRIOR TO INSTALLING OR USING THIS PRODUCT. This manual includes information on all models of the Switch-Tek NonIntrusive RF Capacitance level switch from Flowline, LP50-_005. Please refer to the part number located on the switch label to veri fy the exact model which you have purchased.

About Non-Intrusive RF Capacitance Technology:

FLOWLINE's LP50 series level switch generates a high radio fre quency signal from the capacitance electrode on the tank side of each sensor. Depending on the thickness of the tank wall and the material of which it is made, there is a particular minimum dielectric value the electrode measures when there is no liquid on the other side of the tank wall from the sensor. When liquid is on the other side of the wall, the dielectric value rises. As part of installation, a two-step calibration procedure ensures that the threshold between wet and dry is set at the ideal point for your particular tank and application fluid, without the use of any external test equipment. The sensors operation and point of actuation may vary based on the dielectric properties of various application liquids, tank materials and thicknesses. The LP50 series sensor is intended to be used with liquids with a dielectric value between 20 and 80. Due to its user calibration capability it may be able to detect liquids below a dielectric constant of 20 under certain conditions, but this must be verified by experimentation.

Users Responsibility for Safety:

Flowline manufactures a wide range of liquid level sensors and tech nologies. While each of these sensors is designed to operate in a wide variety of applications, it is the users responsibility to select a sensor model that is appropriate for the application, install it properly, per form tests of the installed system, and maintain all components. The failure to do so could result in property damage or serious injury.

Proper Installation and Handling:

Because this is an electrically operated device, only properlytrained staff should install and/or repair this product. The adhesive on the fitting is for temporary installation only. For permanent installation, the fitting for the sensor should be welded, glassed or strapped to the tank itself using approved plastic welding tech niques. Do not install the LP50 series sensor on a metal tank, or within 6" of any metal pipe or fitting.

Mounting Bracket:
The LP50 series sensor may be mounted in four different fittings. A PE bracket (polyethylene, colored white), model LP95-6001. Other brackets available are LP95-1001 (PP, polypropylene) or LP95-5001 (PVDF, polyvinylidene fluoride). Make sure that the fitting which you have selected is compatible with the tank it will be applied to.

Material Compatibility:
The sensor itself is not designed to be immersed. It should be mounted in such a way that it does not normally come into contact with fluid. Its case is made out of Polysulfone (PSO). Refer to an industry reference such as the Compass Corrosion Guide (available from Compass Publications, phone 858-589-9636) to ensure that compounds that may splash onto the controller housing will not damage it. Such damage is not covered by the warranty.

Wiring and Electrical:

The supply voltage used to power the LP50 series sensor should never exceed a maximum of 36 volts DC. Electrical wiring of the sensor should be performed in accordance with all applicable national, state, and local codes.

Flammable, Explosive and Hazardous Applications:

The LP50-_005 series switch is not rated for use in hazardous loca tions. Refer to the National Electric Code (NEC) for all applicable installation requirements in hazardous locations. DO NOT USE THE LP50-_005 GENERAL PURPOSE SWITCH IN HAZ ARDOUS LOCATIONS. WARNING Do not install the LP50 level switch on a metallic tank, or with in 6" of any metallic object. Metal will adversely affect the dielectric sensitivity of the sensor. FLOWLINE's LP50 series sensors are not recommended for use with electrically charged application liquids. For most reliable operation, the liquid being measured may need to be electrically grounded.

INSTALLATION
Step Four FLOWLINE's LP50 series level switch may be installed anywhere on a tank wall using the supplied PE, PP, or PVDF fitting that the switch slides into. The fitting comes with adhesive on the tank side that is sufficient to hold the sensor in position temporarily while the instal lation is tested, but for permanent installation the fitting must be welded, glassed or strapped to the tank. Extra fittings are available from Flowline, so that the level switch may be moved to different locations on the tank by sliding it into other fittings.

ELECTRICAL
Step Five

Supply Voltage:
The supply voltage to the Switch-Tek level switch should never exceed a maximum of 36 VDC. Flowline controllers have a built-in 13.5 VDC power supply which provides power to all of FLOWLINE's electrical ly powered sensors. Alternative controllers and power supplies, with a minimum output of 12 VDC up to a maximum output of 36 VDC, may also be used with the Switch-Tek level switch.

Attach the fitting to the tank:

1. Determine whether the tank is PP, PE or PVDF. The slide-in fit ting shipped with the sensor is determined by the part number. If necessary, obtain an additional fit ting.
Switch Part No. LP50-1005 LP50-5005 LP50-6005 Bracket Material PP PVDF PE Bracket Part No. LP95-1001 LP95-5001 LP95-6001
Sensor Screw 1/2" NPT 2. Determine the mounting location Connector for the level switch. The point of actuation (where the sensor will send a wet signal) is most often at the center of the sensor; however the actual Point of Actuation (POA) may differ depending on the application liquid and tank wall characteristics. After positioning the fitting to check clear ances, etc., remove the paper protective strips from the adhesive of the fitting. Weld Fitting

Required Cable Length:

Determine the length of cable required between the Switch-Tek level switch and its point of termination. Allow enough slack to ensure the easy installation, removal and/or maintenance of the sensor. The cable length may be extended up to a maximum of 1000 feet, using a well-insulated, 14 to 20 gauge shielded four conductor cable.

Wire Stripping:
Using a 10 gauge wire stripper, carefully remove the outer layer of insulation from the last 1-1/4" of the sensor's cable. Unwrap and dis card the exposed foil shield from around the signal wires, leaving the drain wire attached if desired. With a 20 gauge wire stripper, remove the last 1/4" of the colored insulation from the signal wires.

Signal Outputs (Current sensing):

The standard method used by Flowline controllers; this technology uses only two wires (Red and Black). The sensor draws 5 mA when it is dry, and 19 mA when wet. NC/NO status must be set by the controller. The Green and White wires are not used.
Red + Shield Ground Black + 24 VDC Power Supply Multimeter (mA)

3. Press the fitting into place. The adhesive provides a seal between the sensor and the tank wall, and will hold it in place during test ing and installation. If desired, the sensor may be installed temporarily without weld ing the fitting to the wall. If several different locations must be tried before permanent installation, use double-sided foam stick tape designed for PP, PE or PVDF, for example Arclad type PE 6024, CO#7331 (from Adhesive Research Inc., Glen Rock PA 17327) or equivalent. 4. After the sensor has been tested to verify the POA, weld, glass or strap the fitting to the tank using standard industrial plastic tech niques.

Signal Outputs (Relay switching):

Allows the sensor to switch a small load on or off directly, using an internal 1 A relay (60 VAC/60 VDC). All models, LP50-_005, use the relay and features 4 wires (red, black, white and green) and a shield wire. The NO/NC status is set by the polarity of the voltage feeding the Red and Black wires. The Green wire is the common for the relay and the White is the NO or NC, depending on the polarity of Red and Black.

Normally Open Wiring:

Red Black Shield Ground White Green + + 24 VDC Power Supply Multimeter (Continuity)

Special note for small round tanks:

The fitting may be attached to small, round tanks, as long as the majority of the fitting is firmly attached to the wall. However, extreme installations may effect the switches performance.

Mount the sensor in the fitting:

1. Slide the sensor into the fitting. 2. After trimming the sensor wire to length if needed by the installa tion, thread the sensor wire into a plastic flexible conduit with a 1/2" male fitting. Screw the conduit into the sensor, being careful not to cross the threads. Do not over tighten the conduit in the sensor as this may break the fitting. Such damage is not covered by the warranty. Take care while pulling the wire through conduit that no excessive tension is placed on the sensor end of the wire, so that the wire is not broken from the sensor housing. 3. Connect the sensor wire to the controller following the instruc tions in its manual. See the following Wiring Section for detailed wiring instructions.

Normally Open Wiring:

Black Red Shield Ground White Green + + 24 VDC Power Supply Multimeter (Continuity)

WIRING
Step Six

WIRING
Step Seven

Wiring to a Flowline Controller

LC40 Series Controller:

Wiring the Relay Output:

The Switch-Tek relay output can be wired as a dry contact to a VDC or VAC power source. LP50 Series requires 12 - 36 VDC power to operate the sensor and switch the relay. All illustrations below iden tify a Dry switch state as the normal position of the relay. Switching a Normally Open DC Load: The Red wire connects to Positive (+) of the power supply and the Black wire connects to Negative (-). The LOAD can be attached to either the Green or White wires. Complete the circuit by either con necting the Green to (+) VDC power or White to (-) VDC power (see illustration below).
[Dry Condition] RED GRN SHLD WHT BLK [+] LOAD OR LOAD [-]

POWER

INVERT

DELAY

INVERT

DELAY

-+
STANDARD CONTROLLER
RELAY 1

-+
RELAY 2

LATCH

INPUT 1

INPUT 2A

ON OFF

INPUT 2B

Red Black Shield White and Green - Not Used

Wiring as a P-Channel or N-Channel output:

The LP50 Series can be substituted for either a P-Channel (PNP, sourcing) output or a N-Channel (NPN, sinking) output. Normally Open DC Load as a P-Channel Output: To wire as a NO P-Channel output, follow the directions below. The Red wire connects to Positive (+) of the power supply and the Black wire connects to Negative (-). The Green wire is jumpered to the Red wire while the White wire is connected to the LOAD. Jumper the LOAD back to the Negative (-) to complete the circuit.
[Dry Condition] RED GRN SHLD WHT BLK [+]

Sensor (NO)

Switching a Normally Closed DC Load: The Black wire connects to Positive (+) of the power supply and the Red wire connects to Negative (-). The LOAD can be attached to either the Green or White wires. Complete the circuit by either con necting the Green to (+) VDC power or White to (-) VDC power (see illustration below).
[Dry Condition] BLK GRN SHLD WHT RED [+] LOAD OR LOAD [-]

Sensor (NO)

Sensor (NC) LOAD [-]

Normally Closed DC Load as a P-Channel Output: To wire as a NC P-Channel output, follow the directions below. The Black wire connects to Positive (+) of the power supply and the Red wire connects to Negative (-). The Green wire is jumpered to the Black wire while the White wire is connected to the LOAD. Jumper the LOAD back to the Negative (-) to complete the circuit. Normally Open DC Load as a N-Channel Output: To wire as a NO N-Channel output, follow the directions below. The Red wire connects to Positive (+) of the power supply and the Black wire connects to Negative (-). The White wire is jumpered to the Black wire while the Green wire is connected to the LOAD. Jumper the LOAD back to the Positive (+) to complete the circuit.
[Dry Condition] RED GRN SHLD WHT BLK [+] LOAD

Switching a Normally Open AC Load: The Red wire connects to Positive (+) of the DC power supply and the Black wire connects to Negative (-). The LOAD can be attached to the Green wire and the Hot of the VAC power. Connect the White to the Neutral of the VAC power (see illustration below).
[Dry Condition] RED GRN SHLD WHT BLK [+] LOAD [AC Power] [-]

Sensor (NO)

Sensor (NO)

Switching a Normally Closed AC Load: The Black wire connects to Positive (+) of the DC power supply and the Red wire connects to Negative (-). The LOAD can be attached to the Green wire and the Hot of the VAC power. Connect the White to the Neutral of the VAC power (see illustration below).
[Dry Condition] BLK GRN SHLD WHT RED [+] LOAD [AC Power] [-]

[-]

Normally Closed DC Load as a N-Channel Output: To wire as a NC N-Channel output, follow the directions below. The Black wire connects to Positive (+) of the power supply and the Red wire connects to Negative (-). The White wire is jumpered to the Red wire while the White wire is connected to the LOAD. Jumper the LOAD back to the Positive (+) to complete the circuit.

Sensor (NC)

CALIBRATION
Step Eight After it is installed in place, the Switch-Tek must be calibrated by the user before operation. Everything needed for the procedure is self-con tained within the electronics of the LP50 series level switch. Two dielectric statesfull condition and empty conditionare measured by the Switch-Tek, and then averaged to set the threshold between wet and dry at the sensor. The empty state must be at least 6" below the bottom of the sensor for calibration. The full state must be to the top of the sensor (not just to the point of actuation) for calibration. The actu al application fluid at its intended operating temperature must be used during calibration. Use the following procedure assumes that the sen sor has already been wired to a power supply. 1. Remove the cap from the sensor body by loosening the two screws located below the sensor. Do not remove the screws from the sensor. Insert a small screwdriver into the small slot at the edge of the cap and gently pry upwards. 2. Looking down you will see a small three-position switch and two trimpots marked Full and Empty. You may start with whatever state the tank is in. 3. Full state: With EMPTY OPERATE FULL the tank filled to CAL CAL the top of the sen Switch sor, set the switch to the Full posi FULL Screw Housings EMPTY tion (right). Make sure your hands or Empty Pot Full Pot any other objects LED are not touching the sensor while calibrating because this will cause a false read ing. Using a small nonmetallic screwdriver or alignment tool, turn trimpot Full until the LED just lights, and no farther. Note the position. Now turn the trimpot back until the LED turns off. The ideal setting for the trimpot is midway between these on and off points. 4. Empty state: With the tank drained to a point no closer than 6 inches below the bottom of the sensor, set the switch to the Empty position (left). Set the Empty trimpot as in Step 3. 5. After completing calibration, make sure to return the switch to the center position. Snap the cap back on by pressing down, and tight en the two screws.
Operate Empty Full Cal Cal Switch

CALIBRATION
Step Nine

Checking the Point of Actuation:

Raise the fluid level to the point 1" where the sensor sends a wet max. signal (Input LED will turn Full Amber on Flowline con- Calibration Point trollers). The dry signal should be sent when the fluid Point of level is lowered (Input LED Actuation (POA) will turn Green on Flowline controllers). The actual Point of Actuation (POA) depends on many vari ables, including the thickness of the wall 6" and the dielectric value of the liquid. min. For example, thicker tank walls can raise the POA while thin- Empty ner walls could lower the POA. Calibration If the POA needs to be changed, measure the distance and remount the sensor in a new location.
Point Non-conductive plastic tank wall

Do not attempt to change the Point of Actuation by intentional miscalibration. If the sensor does not signal wet and dry reliably, it may be that: the dielectric constant of the application fluid is too low the tank wall is too thick for the application fluid there are static or other electrical charges in the fluid metal objects are within 6" of the sensor calibration was performed incorrectly Try the calibration procedure again, after making corrections if possi ble. If the full and empty states are too similar dielectrically, it may not be possible to use a capacitance sensor.

Testing the Sensor:

1. Power: Apply power to sensor, by connecting power to the con troller and/or power supply. 2. Full condition: Fill the tank with the application liquid, by filling the tank up to the sensors point of actuation. 3. Test: With the sensor being fluctuated between wet and dry states, use a multimeter to ensure that the correct signals are being pro duced by the Switch-Tek level switch, or observe the sensor indi cator light in the controller. 4. Point of Actuation: Observe the point at which the rising or falling fluid level causes the sensor to change state, and move the installation of the sensor if necessary.

Empty Pot

LED

Full Pot

Maintenance:
The LP50 series level switch itself requires no periodic maintenance except cleaning as required. However, periodically clean any coating or scaling on the tank wall the sensor is attached to and check the cal ibration. It is the responsibility of the user to determine the appropri ate maintenance schedule, based on the specific characteristics of the application liquids. In addition, any dripping or condensation between the sensor and the tank wall fitting may need to be periodi cally cleaned to maintain accuracy.

Screws