ACS Thermocont TS4L User manual

07.17
Technical manual
Applications
Hygienic and aseptic applications in
• Food and beverage industry
• Pharmaceutical industry
• Biotechnology
• Sterile process engineering
Thermocont TS4L
Temperature switch for hygienic applications
Monitoring of temperatures
in gases, vapors, liquids and dust
Main features
Wide range of applications
• Wide process temperature range –99,9°C to +500°C
• High process pressure tightness up to 50 bar
• Wide variety of hygienic and aseptic process connections
• High protection class IP65 / IP67
• Wide environmental temperature range –40°C to +85°C
Long term stable temperature sensor platinum Pt100 class A – DIN EN
60751
Increased process safety and cost saving by self-supervising
measuring system for drift monitoring and redundancy function
High accuracy – characteristic deviation ≤ 0,5% of measuring range
Short response time
Integrated evaluation electronic
• Digital display, function LED’s, keyboard
• 2x PNP switch output
• 1x current output 4…20mA
• Connector plug M12
High operating comfort
• Enclosure and display rotatable for optimal operability in each
installation position
• Robust high brightness LED display for best readability
• 3-key operation without additional assistance with tactile feedback

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You have purchased a high-grade and modern measuring device of ACS-CONTROL-SYSTEM GmbH.
We want to give thanks for your purchase and for your condence to us.
The actual technical manual includes instructions for installation, electrical connection and inauguration,
as well as the technical data of the device.
Modications, that answer the purpose of the technical progress, are reserved by
ACS-CONTROL-SYSTEM GmbH without prior notice.
If a question occurs, that can‘t be answered by the listed informations, please call on our technicians
team in Eggenfelden Tel: [phone] or [email protected]
All rights reserved

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Index
1 Systemdescription................................................4
1.1 Intended use................................................... 4
1.2 Field of application........................................... 4
1.3 System components......................................... 5
1.4 Function ......................................................... 5
2 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.1 Operational safety............................................ 6
2.2 Installation, connection, commissioning, operation6
3 Installation......................................................7
3.1 Installation place ............................................. 7
3.2 Process and environmental temperature ............. 8
3.3 Installation notes............................................. 8
4 Electricalconnection ..............................................9
4.1 Potential equalization – earthing ........................ 9
4.2 Connection cable ............................................. 9
4.3 Supply voltage ................................................ 9
4.4 Load resistor .................................................. 9
4.5 Switch output.................................................. 9
4.6 Connection scheme.......................................... 10
5 Operation......................................................11
5.1 Operation and display parts............................... 11
5.2 Function modes ............................................... 11
5.3 Switch output S1 / S2 ...................................... 12
5.4 Current output ................................................ 13
5.5 Self-supervising function................................... 14
5.6 Menu structure................................................ 15
5.7 Parameter overview ......................................... 18
5.8 Error indication at operation.............................. 21
5.9 Software history .............................................. 21
6 Service........................................................22
6.1 Maintenance.................................................... 22
6.2 Dismounting.................................................... 22
6.3 Repair ............................................................ 22
6.4 Return............................................................ 22
6.5 Disposal ......................................................... 22
7 TechnicalData..................................................23
7.1 Auxiliary power supply...................................... 23
7.2 Output Switch output ....................................... 23
7.3 Output current 4…20mA ................................... 23
7.4 Measuring accuracy.......................................... 23
7.5 Process conditions............................................ 24
7.6 Environmental conditions.................................. 25
7.7 Materials - process wetted ................................ 25
7.8 Materials - not process wetted........................... 25
8 Dimensiondrawings..............................................26
8.1 Terminal enclosure........................................... 26
8.2 Process connection........................................... 26
8.3 Sensor tube .................................................... 28
9 Orderinginformation.............................................29
9.1 Order code...................................................... 29
9.2 Additional options ............................................ 30
9.3 Accessories..................................................... 30

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1 System description
1.1 Intended use
The device is an electronic temperature switch for monitoring, control as well as continuous
measurement of temperatures in gases, vapors, liquids and dusts.
The operational reliability of the device is ensured only at the intended use.
1.2 Field of application
Due to the device construction with
• Process temperature from up to –99,9°C to +500°C
• Process pressures up to 50 bar
• Process contacting material stainless steel V4A
as well as the availability of a variety of process connections like
• Elastomer-free and free of dead space metallic sealing connection, EHEDG-/3A-/FDA-
conformal
• Varivent®
• Dairy coupling DIN 11851
• Clamp ISO 2852 / BS 4825 / DIN 32676
• Aseptic tube coupling DIN 11864-1-A
the device is especially suitable for the use for
• food and beverage industry
• pharmaceutical industry
• biotechnology
• sterile process engineering
The temperature switch is suitable for demanding measuring requirements.
Due to its high accuracy and the high exibility of conguration, the device can be suited a wide
variety of applications.
Compared with temperature sensors, which are calibrated cyclic, the process safety increases when
using the temperature switch with self-supervision. At cyclic calibration an occurring drift will be
also detected, but an undened time it has been produced with a drift aected sensor. Because the
device generates a signal immediately at exceedance of the set drift limit, it must not be waited until
to the end of the calibration interval. Thus the process safety and with this the product quality will be
improved signicantly.
Besides the increased process safety, the use of the temperature switch with self-supervision
allows substantial cost savings. Due to the use of two redundantly working sensors, which are
mutually monitored, the calibration intervals can be increased und thus calibrations can be saved.
Although the device is a little bit more expensive at the acquisition costs than a standard temperature
sensor, when saving only one calibration the acquisition price will pay o shortly.
The process connection with metallic sealing has been specically designed for the hygienic, dead-
space and elastomer-free process adaption.
The robust design and the high-quality workmanship turns the device into a very high quality
product, which even the most adverse environmental conditions cannot aect, whether the lowest
temperatures when used outdoors, extreme shock and vibration or aggressive media.
A captive laser marking of the type label ensures the identiability throughout the entire lifetime of
the device.
Obviously is the optional marking of a measurement point designation resp. TAG, a customer label or
of a neutral type label, of course also per laser marking.
A LABS-free resp. silicone-free version, a factory calibration with calibration certicate and a customer
specic conguration resp. preset is also optionally available like a material test certicate EN10204
3.1 or factory certications for drink water resp. food suitability.

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Customer specic special versions can be realized short-term on request, e.g.
• software adaption (menu navigation, special functions, etc.),
• changed terminal assignment resp. connector orientation,
• design adaption of the user surface,
• special designs for the process connection
 ange acc. to EN 1092-1/DIN 2527, ASME or JIS
 hygienic and aseptic connections, e.g. DIN 11853, DRD, SMS, APV-Inline, BioControl®,
Aseptoex, etc.
• other process materials, e.g. Hastelloy, Titan, etc.
• surface coating, e.g. PTFE
• special adjustment
1.3 System components
The device consists on the components:
• Sensor tube, as junction point in direct contact with the applied medium.
• Process connection, for installation into the wall of the container or of the pipeline.
• Neck tube, for decoupling of the terminal enclosure from high process temperatures.
• Terminal enclosure, rotatable by 300°, for protection of the integrated signal processing
electronic and for the electrical connection.
The components cannot be separated by the user.
1.4 Function
1.4.1Measuring principle
The detection of the process temperature is made by the measurement of the temperature dependent
change of resistance of a precise and long term stable resistive temperature sensor Pt100 class A,
which is installed in the sensor tube.
1.4.2Self-supervision function
At the self-supervising measuring system with drift monitoring and redundancy function the recording
of the Temperature is made additionally by a semiconductor temperature sensor.
Because of the parallel measurement with two physically dierent thermal coupled sensor elements,
the device detects impermissible drifts of a sensor and errors at the temperature measurement
automatically.
At the failure of one of the two sensor elements the temperature measurement can be also continued
with the second element, what realizes a redundancy function.
1.4.3Signal processing
The temperature signal is converted by the temperature sensor into an electrical signal and processed
by the integrated evaluation electronic according to the respective preferences:
• The measuring value is monitored by two PNP switch outputs for exceedance of limit values.
• The measuring value is converted into a continuous current signal 4...20mA.
• The measuring value is displayed at the robust high brightness LED display.
• Several function LED’s signal the device state.
• All settings can be changed comfortable and easy by a 3-key operation without additional
assistance with tactile feedback.
The device includes numerous functions to the adaption to nearly each measuring task:
• Adjustable measuring range down to 25% of nominal measuring span
• Integrated unit conversion °C – °K – °F
• Peak value memory minimum – maximum
• Error memory for fast failure analysis
• Hysteresis or window function, time delay and working principle of the switch outputs
• Error indication function to switch output, current output and display
• Simulation of the switch outputs and the current output

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2 Safety notes
2.1 Operational safety
The device is safely built and tested according to state-of-the-art technology and has left the factory in
perfect condition as regards technical safety.
The device meets the legal requirements of all relevant EU directives. This is conrmed by attaching
the CE mark.
This measuring device meets article 4 (3) of the EU directive 2014/68/EU (pressure equipment device
directive) and is designed and produced in good engineer practice.
2.2 Installation, connection, commissioning, operation
Installation, electrical connection, commissioning and operation of the device must be made by a
qualied and authorized expert according to the information’s in this technical manual and the relevant
standards and rules. This expert must have read and understood this technical manual and especially
the safety notes.
The device may only be used within the permitted operation limits that are listed in this technical
manual. Every use besides these limits as agreed can lead to serious dangers.
The materials of the device must be checked for compatibility with the respective application
requirements (contacting materials, process temperature) before use. An unsuitable material can lead
to damage, abnormal behavior or destruction of the device and to the resulting dangers.
The sensors may not be used as sole device for prevention of dangerous conditions in machines and
plants.
Using the device in a manner that does not fall within the scope of its intended use, disregarding
this instruction, using under-qualied personnel, or making unauthorized alterations releases the
manufacturer from liability for any resulting damage. This renders the manufacturer‘s warranty null
and void.

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3 Installation
The correct function of the device within the specic technical data can only be guaranteed, if
the permitted process and environmental temperatures (see chapter „Technical data“) will not be
exceeded.
3.1 Installation place
The choice of the place of installation of the sensor and the length of the sensor tube are of
considerable importance for the quality and the reliability of the measuring results.
If the sensor isn’t installed deeply enough, an error in the measured temperature can occur because of
the dierent process ow temperature at the pipeline wall and the heat transfer along the sensor tube.
The appearance of the error should not be ignored if a considerable dierence between process
temperature and environmental temperature exists.
Thus it is suggested to use an installation length of at least 80...100 mm.
The shorter the installation length, the greater is the deviation against the real medium temperature
caused by the heat transfer.
The following general recommendations can be applied as approximately guideline:
• In liquids, the sensor tube length should be 5...6 times greater than the diameter of the
sensor tube plus the sensitive length of 50 mm.
• In steam, air and gases, the sensor tube length should be 10...15 times greater than the
diameter of the sensor tube plus the sensitive length of 50 mm.
In pipelines with small diameter the tip of the sensor tube should reach the axis line, that means the
middle of the pipeline, and if possible additionally a little more.
By isolating the external parts of the sensor, the eect caused by too low installation depth, can be
reduced.
An additional solution for optimizing the measurement quality of small formatted pipelines could be
the installation of the sensor tube diagonal to the pipeline longitudinal axis or the installation of the
sensor tube in the pipeline arc.
A) In the pipe arc against the ow direction
B) In small pipes diagonal against the ow direction
C) Vertical to the ow direction
At a horizontal installation, especially in hygienic applications, the probe should be installed with a
decline against the horizontal of minimum 3°, to ensure a self-emptying.

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3.2 Process and environmental temperature
At high process temperatures a heat transfer to the terminal enclosure can be reduced by isolation of
the medium carrying part of the plant or by the use of a neck tube.
3.2.1Neck tube
The neck tube is used to decouple the temperatures between medium and the terminal enclosure in
order to reduce the temperature at the terminal enclosure.
By using a neck tube at extreme process temperatures it can be achieved, that the permitted
environmental temperature range in the area of the terminal enclosure will not be exceeded.
The length of the needed neck tube depends on the height of the process temperature and the
respective installation situation.
Like shown in the graphic, the length of the neck tube can considerably inuence the temperature at
the terminal enclosure.
The graphic is only an approximately guide, because the real heating of the terminal enclosure can be
inuenced by additional factors, e.g. a system isolation or also the position of the terminal enclosure.
3.3 Installation notes
Drive the system pressure free prior installation resp. deinstallation of the sensor.
Be sure that no medium is owing in the system. At extreme system or medium temperatures there
could exist serious dangers.
The screw-in of the thread process connection by using the terminal enclosure, the connection plug
resp. the connection cable is not permitted.
The tightening of the thread process connection may only be done at the hexagon by a suitable
spanner and with the maximum permitted torque strength (see chapter „Technical data“).

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4 Electrical connection
The electrical connection of the device must be carried out according to the respective country specic
standards.
Incorrect installation or adjustment could cause applicationally conditioned risks.
Warning!
The instrument may only be installed if the supply voltage is switched o.
4.1 Potential equalization - earthing
The device must be grounded.
The earthing can be carried out by the metallic process connection.
The metallic parts of the device are electrically connected with the socket of the plug M12.
4.2 Connection cable
Use only shielded signal and measurement wires and install these wires separated from power leading
wires.
Connect the cable shield of a connected cable only at one side to earth, ideally at the installation place
of the device.
4.3 Supply voltage
The voltage applied to the terminal contacts may not exceed the maximum permitted supply voltage
to avoid damage of the electronic.
The maximum permitted supply voltage range is:
All versions 10,5…35VDC
All connections are reverse polarity protected.
4.4 Switch output
Warning!
Inductive loads at the PNP switch outputs, e.g. relays, contactors or magnetic vents may only be used
with a free-wheeling diode or a RC protection circuit to avoid high voltage peaks.
Note!
For inauguration it is suggested, to deactivate all connected control devices, to avoid unwanted control
reactions.
The load at the PNP switch output will be connected to the terminal +L of the supply voltage by a
semiconductor switch contactless and by this bounce-free.
At an activated switch state a positive signal near supply voltage is feed to the output.
At deactivated switch state and at failure of supply voltage the semiconductor switch is shut o.
The PNP switch output is current limited, overload and short circuit protected.
4.5 Analogue output
4.5.1 Current output – Load resistor
A load resistor, e.g. the measuring shunt of an evaluation device, requires a minimum supply voltage.
Dependent on the connected supply voltage and the maximum output current, it results in a maximum
value for this resistor, where a correct function is still possible.

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4.6 Connection scheme
Conductor color standard connection cable M12 – A-coded:
• BN = brown
• WH = white
• BU = blue
• BK = black
• GY = grey
1.1.1Electronic output type A
2x switch PNP, supply 24VDC
1.1.2Electronic output type B
1x signal 4…20mA, 1x switch PNP, supply 24VDC
1.1.3Electronic output type C
1x signal 4…20mA, 2x switch PNP, supply 24VDC
1.1.4Electronic output type D
1x signal 4…20mA, 1x switch PNP, supply 24VDC / Desina conformal