FlowLine Thermo-Flo LC30 Series User manual

RevBMN3015151of14
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Thermo‐Flo™
CompactFlowController
LC30SeriesManual
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FlowlineInc.
10500HumboltStreet
LosAlamitos,CA90720
Tel:(562)598‐3015
Fax:(562)431‐8507
www.flowline.com
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2of14MN301515RevB
INTRODUCTION/TABLEOFCONTENTSStepOne
TheLC30SeriesControllersaregeneral‐purposeflowcontrollerthatacceptsoneflowsensorinputand
providesone16Arelayforlow‐flowpumporprocessprotection.Thispackagehasanoptionalflashingalarm
andisidealforalarmindication.Packagethisflowcontrollerwithourliquidorgasflowswitchsensors.
Features
Fail‐Saferelaycontrolofpumps,valvesoralarmswitha0to60seconddelay
Optionalflashingalarmbringsimmediateattentiontolevelalarmconditions.
PolypropyleneenclosureratedNEMA4Xwithswivelbaseforconduitalignment.
EasysetupwithLEDindicatorsforsensor(s),powerandrelaystatus.
InvertswitchchangesrelaystatefromNOtoNCwithoutrewiring.
ACpowered
TableofContents
Specifications:.........................................................................................................................................................3
Dimensions:.............................................................................................................................................................3
SafetyPrecautions:.................................................................................................................................................4
MakeaFail‐SafeSystem:............................................................................................................................5
Components:...............................................................................................................................................5
GettingStarted:.......................................................................................................................................................6
GuidetoControls:.......................................................................................................................................6
Electrical..................................................................................................................................................................7
ConnectingSwitchestoInputTerminals:...................................................................................................7
VACPowerInputWiring:............................................................................................................................7
RelayInputWiring:.....................................................................................................................................7
StrobeAlertOutput:...................................................................................................................................8
Changingfrom120to240VAC...................................................................................................................8
Installation..............................................................................................................................................................9
MountingonaSensor:................................................................................................................................9
ApplicationExamples............................................................................................................................................11
LowFlowAlarm:........................................................................................................................................11
LEDIndication:..........................................................................................................................................11
FlowSwitchCalibration:.......................................................................................................................................12
SetPoints:.................................................................................................................................................12
AccessingtheAdjustmentPotentiometer:...............................................................................................12
Appendix...............................................................................................................................................................13
ControllerLogic.........................................................................................................................................13
Troubleshooting........................................................................................................................................13
Warranty...............................................................................................................................................................14
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RevBMN3015153of14
SPECIFICATIONS/DIMENSIONSStepTwo
Controller
Supplyvoltage:120/240VAC,50‐60Hz.
Consumption:5Wattsmax.
Sensorinputs:(1)flowswitch
Sensorsupply:24VDC@50mA
LEDindication:Sensor,relay&powerstatus
Contacttype:(1)SPDTRelay
Contactrating:250VAC,16A
Contactoutput:SelectableNOorNC
Contactdelay:0to60seconds
Electronicstemp.:F:‐40°to158°
C:‐40°to70°
Enclosurerating:NEMA4X(IP65)
Enclosurematerial:PP(U.L.94VO)
Enclosuremount.:3/4”NPT(Rc)
Enclosurerotation:300°swivelbase
Conduitentrance:Single,1/2"NPT
Classification:Generalpurpose
Certificatenumber:LR79326‐3
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StrobeAlert
Flashtype:Xenontube
Flashfrequency:1persecond
Strobelife:10Mcycles
Supplyvoltage:120VAC,50‐60Hz.
Consumption:3Wattsmax.
Material:Polycarbonate
Enclosurerating:NEMA4X(IP65)
Color:Amber
TerminalLabels:
(S)terminal:Provides14VDCtotheswitchinput
(‐)terminal: Ground
(+)terminal:Provides24VDCpowertotheswitch
SideView
(LC30‐1001&LC30‐1051)
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SideViewwithStrobeAlert
(LC30‐1002&LC30‐1052)
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LC30SeriesFunctionalDiagram
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4of14MN301515RevB
SAFETYPRECAUTIONSStepThree
AboutThisManual:PLEASEREADTHEENTIREMANUALPRIORTOINSTALLINGORUSINGTHISPRODUCT.
ThismanualincludesinformationontwodifferentmodelsofCompactRelayFlowControllersfrom
Flowline:LC30‐10_1andLC30‐10_2.TheLC30‐10_1isasingle‐inputflowcontrollerandtheLC30‐10_2isa
single‐inputcontrollerwithaStrobeAlert™flashalarm.Manyaspectsofinstallationandusearesimilar
betweenthetwomodels.
User’sResponsibilityforSafety:FLOWLINEmanufacturesseveralmodelsofcontroller,withdifferent
mountingandswitchingconfigurations.Itistheuser’sresponsibilitytoselectacontrollermodelthatis
appropriatefortheapplication,installitproperly,performtestsoftheinstalledsystem,andmaintainall
components.
ElectricalShockHazard:Itispossibletocontactcomponentsonthecontrollerthatcarryhighvoltage,
causingseriousinjuryordeath.Allpowertothecontrollerandtherelaycircuit(s)itcontrolsshouldbe
turnedOFFpriortoworkingonthecontroller.Ifitisnecessarytomakeadjustmentsduringpowered
operation,useextremecautionanduseonlyinsulatedtools.Makingadjustmentstopoweredcontrollers
isnotrecommended.Wiringshouldbeperformedbyqualifiedpersonnelinaccordancewithallapplicable
national,stateandlocalelectricalcodes.
FlammableorExplosiveApplications:Sensormountcontrollersshouldnotbeusedwithexplosiveor
flammableliquids,whichrequireanintrinsicallysafeorexplosionproofrating.Ifyouareunsureofthe
suitabilityofacontrollerforyourinstallation,consultyourFlowlinerepresentativeforfurtherinformation.
InstallInaDryLocation:TheLC30Seriescontrollerhousingisliquid‐resistantandmadeofPolypropylene
(PP).Wheninstalledproperly,thecontrollerisnotdesignedtobeimmersed.Itshouldbemountedin
suchawaythatitdoesnotnormallycomeintocontactwithfluid.Refertoanindustryreferencetoensure
thatcompoundsthatmaysplashontothecontrollerhousingwillnotdamageit.Suchdamageisnot
coveredbythewarranty.
RelayContactRating:Therelayisratedfora16ampresistiveload.Manyloads(suchasamotorduring
start‐uporincandescentlights)arereactiveandmayhaveaninrushcurrentcharacteristicthatmaybe10
to20timestheirsteady‐stateloadrating.Theuseofacontactprotectioncircuitmaybenecessaryfor
yourinstallationifthe16ampratingdoesnotprovideanamplemarginforsuchinrushcurrents.
SafetyCover:Baseduponthepartnumberselected,asafetycoverhasbeenplacedwithintheenclosure.
Alwaysreplacethesafetycoverafteranyservice.
StandardVersion
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RevBMN3015155of14
SAFETYPRECAUTIONS(cont.)StepThree
MakeaFail‐SafeSystem:Designafail‐safesystemthataccommodatesthepossibilityofrelayorpower
failure.Ifpoweriscutofftothecontroller,itwillde‐energizetherelay.Makesurethatthede‐energized
stateoftherelayisthesafestateinyourprocess.Forexample,ifcontrollerpowerislost,apumpfillingatank
willturnoffifitisconnectedtotheNormallyOpensideoftherelay.
Whiletheinternalrelayisreliable,overthecourseoftimerelayfailureispossibleintwomodes:undera
heavyloadthecontactsmaybe“welded”orstuckintotheenergizedposition,orcorrosionmaybuildupona
contactsothatitwillnotcompletethecircuitwhenitshould.Incriticalapplications,redundantbackup
systemsandalarmsmustbeusedinadditiontotheprimarysystem.Suchbackupsystemsshoulduse
differentsensortechnologieswherepossible.
WhilethismanualofferssomeexamplesandsuggestionstohelpexplaintheoperationofFLOWLINEproducts,
suchexamplesareforinformationonlyandarenotintendedasacompleteguidetoinstallinganyspecific
system.
Sensor‐mountcontrollers:TheLC30Seriesisacost‐effective,modularflowcontroller,whosebody
incorporatesafemale3/4"NPT(3/4"R)fitting,allowingittobemounteddirectlyontoanyFlowlinesensoror
any3/4"connection.SimplyprovideitsrequiredACpowerandacontrolleddevicesuchasavalve,pump,or
alarmthatcanbeswitchedbythecontroller’srelayinresponsetothesensorinput.
FeaturesoftheLC30SingleInputController:TheLC30Controllerisdesignedtoreceiveasignalfromasingle
flowswitch.ItturnsitsinternalrelayOnorOff(assetbytheinvertswitch)inresponsetothepresenceofflow
orno‐flow,andchangestherelaystatusbackagainwhenthesensorreverses.TheLC30maybeusedwithany
FLOWLINEN‐channelorrelayflowswitch.Therelayisasinglepole,doublethrowtype;thecontrolleddevice
canbeconnectedtoeitherthenormallyopenornormallyclosedsideoftherelay.Atimedelayfrom0to60
secondscanbesetbeforetherelayrespondstothesensorinput.
TypicalapplicationsfortheLC30arefloworno‐flowswitch/alarmoperations(activatinganalarmatno‐flow).
Components:
PartNumberThreadPowerCSAStrobeAlert™
LC30‐1001
¾”NPT
120
YesNo
LC30‐1001‐E240
LC30‐1051
¾”Rc
120
LC30‐1051‐E240
LC30‐1002
¾”NPT
120
NoYes
LC30‐1002‐E240
LC30‐1052
¾”Rc
120
LC30‐1052‐E240
Owner’sManual
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6of14MN301515RevB
GETTINGSTARTEDStepFour
TheLC30SeriesmaybeusedwithanyFlowlineflowswitchwithanN‐channel(endsin“‐___2”)orrelay
(endsin“‐___5”)output.Therelayisasinglepole,doublethrowtype;thecontrolleddevicecanbe
connectedtoeitherthenormallyopenornormallyclosedsideoftherelay.Atimedelayfrom0to60seconds
canbesetbeforetherelayrespondstothesensorinput.TypicalapplicationsfortheLC30Seriesarepump
protection,no‐flowindicationorchemicalinjection.
GuidetoControls:Belowisalistingandthelocationofthedifferentcomponentsforthecontroller:
StandardVersion
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1. Powerindicator:ThisgreenLEDlightswhenACpowerisON.
2. Relayindicator:ThisredLEDwilllightwheneverthecontrollerenergizestherelay,inresponsetothe
properconditionatthesensorinputandafterthetimedelay.
3. ACPowerterminals:Connectionof120VACpowertothecontroller.Thesettingmaybechangedto240
VACifdesired.Thisrequireschanginginternaljumpers;thisiscoveredintheInstallationsectionofthe
manual.Polarity(neutralandhot)doesnotmatter.
4. Relayterminals(NC,C,NO):Connectthedeviceyouwishtocontrol(pump,alarmetc.)tothese
terminals:supplytotheCOMterminal,andthedevicetotheNOorNCterminalasrequired.Theswitched
deviceshouldbeanoninductiveloadofnotmorethan16amps;forreactiveloadsthecurrentmustbe
deratedorprotectioncircuitsused.WhentheredLEDisONandtherelayisintheenergizedstate,theNO
terminalwillbeclosedandtheNCterminalwillbeopen.
5. Invertswitch:ThisDIPswitchreversesthelogicoftherelaycontrolinresponsetothesensor(s):
conditionsthatusedtoenergizetherelaywillmakeitturnoffandviceversa.
6. TimeDelay:Aftertheinput(s)change(s)state,thiscontrolsetsadelayfrom0.15to60secondsbeforethe
relaywillrespond.
7. Input1Aindicator:TheseamberLEDwilllightimmediatelywhenevertheappropriatesensorattachedto
theterminalsdetectsno‐flow,andwillturnoffwhenitdetectsflow.Thispolaritycanbereversedby
changeoftheswitchespolarity.
8. Inputterminals:Connectthewiringfromthesensorstotheseterminals:Notethepolarity:(+)isa24
VDC,100mApowersupply(tobeconnectedtotheredwireofaFlowlinesensor),and(‐)isthereturn
pathfromthesensor(tobeconnectedtotheblackwireofaFlowlinesensor).(S)istherelaysignalinput
tobeconnectedtothewhitewire.Theremaininggreenwirewillreturntothe(‐)terminal.Ifpolarityis
reversed,thesensorswillnotwork.

RevBMN3015157of14
ELECTRICALStepFive
Connectingswitchestoinputterminals:PleasenoteadifferencebetweenFLOWLINEflowswitches.Allflow
switcheswillbewiredwiththeWhitewiretothe(S)terminal.ModelsFT10‐___5andGT10‐___5willbe
wiredwiththeGreenwiretothe(‐)terminal).TheRedandBlackwirescanbewiredtoeitherthe(+)terminal
or(‐)terminalbaseduponswitchpolarity.Seetheillustrationbelowtoindicatewiringforyourswitch.Note:
theShieldwirewillbeusedonlyforlongcablerunsorwhereexcessiveelectricalnoiseispresent.
NormallyClosedNormallyOpen

SwitchCable:WheninstallingaFlowlineflowswitch,
adjustthecableawayfromtheprintedcircuitboards
inthecontrollerbody.Avoidbreakingtheseal
betweenthetopofthelevelswitchandtheplastic
coatedcable.

VACPowerInputWiring:Observethelabelingon
theLC30Series.Note:Polaritydoesnotmatterwith
theACinputterminal.
 
RelayInputWiring:Therelayisasinglepole,double
throwtyperatedat250VoltsAC,16Amps.Thetwo
terminalNOandNC(normallyopenandnormally
closed)willbeusedindifferentapplications.
Rememberthatthe"normal"stateiswhentherelay
coilisde‐energizedandtheRedrelayLEDisOff/de‐
energized.



8of14MN301515RevB
ELECTRICALStepFive
StrobeAlertOutput(LC30‐___2Series):Withthe
StrobeAlertwiredNC;itcanbeusedasahighorlow
levelalarm,dependingonthesettingfortheinvert
switch.TheStrobeAlertcanalsobewiredNO.

Changingfrom120to240VAC:
1. Removethetwoscrewsfromthetopofthe
printedcircuitboard(PCB)andgentlyslidethe
PCBfromthehousing.Usecautionwhen
removingthePCB.
2. LocatedjumpersJWA,JWBandJWConthePCB.
3. Tochangeto240VAC,removejumpersfromJWB
andJWCandplaceasinglejumperacrossJWA.
Tochangeto120VAC,removejumperJWAand
placejumpersacrossJWBandJWC.
4. GentlyreturnPCBintohousingandreplacethe
twoscrews.
StandardVersion

120VAC240VAC
ConfigurationConfiguration







RevBMN3015159of14
INSTALLATIONStepSix
MountingonaSensor:Thefollowingprocedureshouldbeusedwhenmountingthecontrollerdirectlyona
flowsensor.Allpowertothesystemmustbeoffbeforeinstallingthejunctionbox.
1. Preparethesensor:Thefollowinginstructionsassumethesensorisalreadymountedinapositionon
itsfitting(asdescribedinthesensormanual).Notethatbecausetheinsulationjacketofthesensoris
lessflexiblethanmost(toensurechemicalcompatibility),itisimportantthatyoufollowthe
instructionsexactly.
a. Cutthewire4‐1/4”fromthetopofthesensor.
b. Usinga10gaugewirestripper,stripthewhiteouterlayerofinsulationfromthelast1‐1/4”of
thesensorwire.Trimoffanddiscardtheexposedfoilshieldflushwiththeinsulationjacket.In
longcableruns,donotcutoffthedrainwire.
c. Usinga20gaugewirestripper,stripthelast¼”ofinsulationfromthesignalwires.

Important:Donotstripmorethan0.2”(5mm)ofinsulationfromanywirethatwillbeconnectedtothe
terminalstrip.Longerinsulatedwiremaycontacttheterminalstrippanel,causingashortcircuit
leadingtoasystemfailure.
2. Positionthecontrolleronthesensor:Tomakethemountingandwiringeasier,
youmustfirstremovetheprintercircuitboard(PCB)fromthecontroller.
a. Unscrewthelidofthecontroller.
b. RemovethetwoscrewsholdingthePCBtothecontroller.
c. GentlytipthecontrollertoslideoutthePCBandplaceitaside.
d. Threadthepre‐trimmedsensorwiresthroughthe¾”NPTentrancetothe
junctionbox,andplacethecontrollerinpositionoverthesensor.
e. Beingcarefulnottocrossthethreads,screwthecontrolleronthesensor.
Stopwhenthecapofthesensorbecomesflushwiththebottomwallofthe
controller,orwhenthe½”powerconduitentranceisinthedesired
location.
3. Connectthesensorinputwires:
a. Routethesensor‐wiresoitstaysasclosetothehousingaspossible,butdo
notbendthewiresharplyatthecapofthesensor.(iftheinstallation
allows,youmayrotatethecontrollerand/orthesensoruntilthewire
outletofthesensorisinthebestposition.)
b. PositionthePCBinthehousingalignedwiththetwochannelsdesignedto
holdit.Donotinsertthepanelallthewayintothehousing,butletitrest
onthetopofthehousingtofacilitatethewiring.
c. Usingasmallscrewdriver,loosentheterminalscrews.Insertthesensor
wiresintotheholeonthesensorinputterminal,andtightentheterminal
screws.
d. OncecompletedseatthePCBbackintothechannelsandrestoreonlyone
screwtoholdthePCBinplace.


10of14MN301515RevB
INSTALLATION(continued)StepSix
4. Mechanicalconnectiontoconduit:Allwiringbetweenacontrollerandsensorsshouldbeinconduit.
Thepowerentranceofthecontrollerisastandard½”NPTfemalefittingthatwillattachtostandard
electricalconduit,eitherplasticormetal,asspecifiedbylocalcodes.Keepinmindthatthehousing
mayhavetobeunscrewedfromthesensorforperiodiccleaningofthesensor.Forthisreasontheuse
offlexibleconduit,providingenoughslackforeasyaccessisrecommended.
5. Connecttheextensionwiring:
Beforemakingconnections,makesureallpowertothesystem(controller,motor,valve,alarm,etc.)
isOFFwithasafetylockoutonthecircuitbreaker.
a. Theextensionwiringtocontrollershouldtakeintoaccountlongcableruns.Iftherunislong,it
mayneedtobeaslightlythickergaugesotheseriesresistanceiskelpwithinallowablelimits.
b. Threadtheextensionwiringthroughthepowerconduitentranceofthehousing.
c. Strip¼”oftheinsulationfromtheendsofthewires.
d. Loosentheappropriateterminalscrews.Inserttheextensionwiresintothecorresponding
terminals,matchingthesensorwires.
e. Tightentheterminalscrews.
f. Returnthewireprotectortoitslocationandrestorethefinalscrewwhichholdsthewire
protectedandPCBinitsplace.
g. Replacethecap.
Note:Insomecases,additionaluser‐providedcomponentsmayneedtobeattachedtotheterminals.If
so,makesurethatbothwiresand/orcomponentsenteringtheterminalaresecureafterthescrewsare
tightened.
Note:Alwaystightenthecontrollerfromthewrenchflatlocatedonthe
swivelbase.Nevertightenfromthebodyofthecontroller.

