FlowLine Thermo-Flo LC80 Series User manual

RevBMN3015301of14


Thermo‐Flo™
RemoteFlowController
LC80&LC82SeriesManual











FlowlineInc.
10500HumboltStreet
LosAlamitos,CA90720
Tel:(562)598‐3015
Fax:(562)431‐8507
www.flowline.com


2of14MN301530RevB
INTRODUCTION/TABLEOFCONTENTSStepOne
Thegeneral‐purposeflowcontrollerisofferedintwoconfigurationsforlow‐flowpumpandprocess
protection.TheLC80Seriesacceptsoneflowsensorinputandprovidesone10Arelayforlowflowcontrol.
TheLC82Seriesacceptstwoflowsensorinputsandprovidestwo10Arelaysforduallowflowcontrol.Package
thisflowcontrollerwithourliquidorgasflowswitchsensors.Forfieldmountinstallation,addasingleordual
controllerNEMAbox.
Features
Fail‐Saferelaycontrolofpumps,valvesoralarmswitha0to60seconddelay.
EasysetupwithLEDindicatorsforsensor(s),powerandrelaystatus.
35mmDINrailmountpolypropyleneenclosurewithremovableterminalstrips.
InvertswitchchangesrelaystatefromNOtoNCwithoutrewiring.
ACpowered
TableofContents
Specifications:.........................................................................................................................................................3
Dimensions:.............................................................................................................................................................3
SafetyPrecautions:.................................................................................................................................................4
Components:...............................................................................................................................................4
MakeaFail‐SafeSystem:............................................................................................................................5
ControllerLogic:..........................................................................................................................................5
GettingStarted:.......................................................................................................................................................6
GuidetoControls:.......................................................................................................................................6
Electrical..................................................................................................................................................................7
VACPowerInputWiring:............................................................................................................................7
RelayInputWiring:.....................................................................................................................................8
Changingfrom120to240VAC...................................................................................................................9
Wiring:.....................................................................................................................................................................8
ConnectingSwitchestoInputTerminals:...................................................................................................8
Installation..............................................................................................................................................................8
ApplicationExamples..............................................................................................................................................9
LEDIndication:............................................................................................................................................9
LowFlowAlarm:........................................................................................................................................10
DualFlowAlarms:.....................................................................................................................................10
FlowSwitchCalibration:.......................................................................................................................................11
SetPoints:.................................................................................................................................................11
Appendix...............................................................................................................................................................12
ControllerLogic.........................................................................................................................................12
Troubleshooting........................................................................................................................................12
RelayLatchLogic(LC82Seriesonly).........................................................................................................13
Warranty...............................................................................................................................................................14


RevBMN3015303of14
SPECIFICATIONS/DIMENSIONSStepTwo
Supplyvoltage:120/240VAC,50‐60Hz.
Consumption:5Wattsmax.
Sensorinputs:LC80:(1)flowswitch
LC82:(2)flowswitches
Sensorsupply:24VDC@100mA
LEDindication:Sensor,power&relaystatus
Contacttype:LC80:(1)SPDTRelay
LC82:(2)SPDTRelays
Contactrating:250VAC@10A
Contactoutput:SelectableNOorNC
Contactdelay:0to60seconds
Electronicstemp.:F:‐40°to158°
C:‐40°to70°
Enclosurerating:35mmDIN(EN50022)
Enclosurematerial:PP(U.L.94VO)
Failsafety:Powerfail‐safe
Classification:Generalpurpose
Approvals:CSA,LR79326‐3
LC80seriesfaceplate:1sensorinput,1relayoutput.

LC82seriesfaceplate:2sensorinput,2relayoutputs.One
relayforeachsensorinput.

TheLC82Seriescanalsobeusedasalevelcontrollerwith3
sensorinputsand2relayoutputs.Onerelayislatchingand
theotherisasingleinputrelay.
TopView


SideView

InternalControllerLogic





4of14MN301530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threedifferentmodelsofRemoteRelayFlowControllersfrom
FLOWLINE:LC80andLC82series.Manyaspectsofinstallationandusearesimilarbetweenthethree
models.Wheretheydiffer,themanualwillnoteit.Pleaserefertothepartnumberonthecontrolleryou
havepurchasedasyouread.
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:TheentireLC80seriesremotemountcontrollersshouldnotbeused
withexplosiveorflammableliquids,whichrequireanintrinsicallysafeorexplosionproof.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controllerhousingisnotdesignedtobeimmersed.Wheninstalledproperly,
itshouldbemountedinsuchawaythatitdoesnotnormallycomeintocontactwithliquid.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10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10ampratingdoesnotprovideanamplemarginforsuchinrushcurrents.
Components:
PartNumberVACConfigurationCSAApprovalInputsOutput
LC80‐1001120
Yes
SingleSingleRelay
LC80‐1001‐E240
LC82‐1001120
DualDualRelay
LC82‐1001‐E240
Owner’sManual


RevBMN301530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.
ControllerLogic:
LC80Series:TheLC80seriesfeaturesasinglesensor
inputandasinglerelayoutput.Connecttheswitch
inputtoInput1terminal.Wirethedeviceyouwant
tocontroltoRelay1terminal.
LC82Series:TheLC82seriesfeaturesathree(3)
sensorinputsandatwo(2)relayoutput.Ina
majorityofapplications,theLC82serieswillbeused
asa2input/2relayoutputcontroller.Inthiscase,
SensorInput1directlycontrolsRelay1andSensor
Input2AdirectlycontrolsRelay2.

Note:IfthelatchswitchisturnedON,thenRelay2requiresbothInputs2A&2Btobeinthesamestatebeforeit
willswitch.Thisrelaylogicisidealforautomaticfillingoremptyingoftanksandisnotusedforflow/no‐flow
applications.IfusingtheLC82seriesasaflow/no‐flowcontroller,makesuretheLatchswitchisturnedOFF.

6of14MN301530RevB
GETTINGSTARTED(continued)StepFour
TheLC80SeriesmaybeusedwithalmostanyFlowlineflow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LC80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:
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(s)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10
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. Timedelay:Usepotentiometertosetdelayfrom0.15to60seconds.Delayoccursduringswitchmake
andswitchbreak.
6. Inputindicators:UsetheseLEDsforindicatingFloworNo‐Flowstatusofswitch.WhenswitchisClosed,
LEDwillbeAmber.WhenswitchisOpen,LEDwilleitherbeOFF.Note:Consultthemanualfortheflow
switchtodetermineexactwiringaswellasswitchpolarity(OpenorClosedduringFlow).
7. Invertswitch:Thisswitchreversesthelogicoftherelaycontrolinresponsetotheswitch:conditionsthat
usedtoenergizetherelaywillnowde‐energizetherelayandviceversa.
8. Latchswitch(LC82seriesonly):Thisswitchdetermineshowtherelaywillbeenergizedinresponseto
eitheroneinput(Input2A)ortwoinputs(Inputs2Aand2B).WhenLATCHisOFF,therelayrespondsto
sensorInput2Aonly;whenLATCHisON,therelaywillenergizeorde‐energizeonlywhenbothswitches
(2Aand2B)areinthesamestate(bothopenorbothclosed).Note:Inamajorityofflow/no‐flow
applications,thelatchwillbeturnedOFF.
9. Inputterminals:Connecttheswitchwirestotheseterminals:(+)isa24VDC,100mApowersupply,(‐)is
thereturnpathfromthesensorand(S)isapoweredswitchinput(14VDC,25mA).Consulttheflowswitch
manualforswitchpolarity(Ex:OpenorClosedforFlow)aswellaswiringinformation.

RevBMN3015307of14
ELECTRICALStepFive
VACPowerInputWiring:ObservethePOWERSUPPLYlabelontheLC80series.Thelabelidentifiesthepower
requirement(120or240VAC)andtheterminalwiring.Note:PolaritydoesnotmatterwiththeACinput
terminal.



RelayInputWiring:Therelayisadry‐contactsinglepole,doublethrow(SPDT)typeratedat250VAC,10Amps.
Therelayisdesignedtoswitchpoweronandofftoadevice.Thereisnoactivepowerwithintherelaycontacts
alone.Powermustbeintroducedfromsecondarysourceorfromthepowerbeingusedbythecontroller.
Powerfromasecondarysource

Powerfromthesamesourceasthecontroller

ThetwoterminalNormallyOpen(NO)andNormallyClosed(NC)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.Bothterminalssharethe
Common(C)terminal.Whenrelayisde‐energized,CtoNOwillbeopenandCtoNC
willbeclosed.Whenrelayisenergized,CtoNOwillbeclosedandCtoNCwillbe
open.Ifpowerisremovedtothecontroller,therelaywillreturntoade‐energized
state.

Changingfrom120to240VAC:
1. Removethebackpanelofthecontrollerand
gentlyslidetheprintedcircuitboardfromthe
housing.UsecautionwhenremovingthePCB.
2. LocatedjumpersJW1,JW2andJW3onthePCB.
3. Tochangeto240VAC,removejumpersfromJW1
andJW2andplaceasinglejumperacrossJW3.To
changeto120VAC,removejumperJW3andplace
jumpersacrossJW1andJW2.
4. GentlyreturnPCBintohousingandreplaceback
panel.

120VAC240VAC
ConfigurationConfiguration


8of14MN301530RevB
WIRING/INSTALLATIONStepSix
Connectingflowswitchestoinputterminals:TherearetwotypesofflowswitchoutputsfromFlowlinethat
arecompatiblewiththeLC80seriesofcontroller.Thetypical/mostcommonflowswitcheshavearelay
output(modelsFT10‐___5andGT10‐___5)with4wiresastheoutput(Red,Black,GreenandWhite).
Notascommon,FlowSwitcheswithFEToutputs(N‐Channelonly,modelsFT10‐___2andGT10‐___2)
withthreewires(Red,BlackandWhite)canalsobewiredtotheflowcontroller.Seetheillustrationbelowto
indicatewiringforyourswitchandthepolarityoftheswitchoutput.Note:theShieldwirewillbeusedonlyfor
longcablerunsorwhereexcessiveelectricalnoiseispresent.
StandardRelayOutputFlowSwitchesFETSwitch(N‐Channel*)FlowSwitches
*P‐ChannelFETswitchescannotbeusedwithFlow
Controller
PanelDINRailMounting:Thecontrollermaybemountedbyeitherabackpanelusingtwoscrewsthrough
mountingholeslocatedatthecornersofthecontrollerorbysnappingthecontrolleron35mmDINRail.
 
Note:Alwaysinstallthecontrollerinalocationwhereitdoesnotcomeintocontactwithliquid.


RevBMN3015309of14
APPLICATIONEXAMPLESStepSeven
LEDIndication:UseLED'slocatedabovetheinputterminalstoindicatewhethertheswitchisinaFloworNo‐
Flowstate.WiththeflowswitchwiredNC,theAmberLEDindicatesNo‐FlowandnoLEDindicatesflow.
WiringtheswitchNO(reversingtheRedandBlackwires),theAmberLEDindicatesFlowandnoLEDindicates
No‐Flow.
NCWiring
AmberLED
NCWiring
LEDOFF
NOWiring
AmberLED
NOWiring
LEDOFF





10of14MN301530RevB
APPLICATIONEXAMPLESStepSeven
LowFlowAlarm:Thegoalistoindicatewhentheflowratefallsbelowacertainpoint.Ifitdoes,analarmis
supposedtosound,alertingtheoperatorofalowflowcondition.TheflowswitchiswiredtoInput1andthe
alarmiswiredthroughRelay1.
Ifpowerisaccidentallycuttothecontroller,thesensor'sabilitytonotify
theoperatorofalowflowconditioncouldbelost.Thesystemmust
alerttheoperatornotonlytolowflow,buttocontrollerpowerloss.To
dothis,connectthehotleadofthealarmtotheNCsideoftherelay
terminalofthecontroller.Ifpowerislost,therelaywillbede‐
energized,andthealarmwillsound(ifthereisstillpowertothealarm
circuititself).Thealarmcircuitshouldhaveanon‐interruptiblepower
supplyorsomeotherindicatororbackupalarmtowarnofapower
failureinthealarmcircuit.
Inthisapplication,thenormalstatusiswhenthesensorisintheflow
condition,andtherelaywillbeenergizedholdingthealarmcircuit
Open.
IftheswitchiswiredNC,theinputLEDwillbeOFFandtherelay
LEDwillbeON.Soforthiswiringconfiguration,Invertshouldbe
settotheONposition.
IftheswitchiswiredNO,theinputLEDandtherelayLEDwillbe
ONsimultaneously.Soforthiswiringconfiguration,Invert
shouldbesettotheOFF(‐)position.

DualFlowAlarm:Thegoalistoindicatewhentheflowratefallsbelow
acertainpointontwodifferentlines.Ifitdoes,analarmissupposedto
sound,alertingtheoperatorofalowflowconditionforthespecificline.
ForLine#1,theflowswitchiswiredtoInput1andthealarmiswired
throughRelay1.ForLine#2,theflowswitchiswiredtoInput2Aand
thealarmiswiredthroughRelay2.
Accidentalpowercuttothecontrollermustbetakenintoaccountasin
theLowFlowAlarmexampleseenabove.FollowthesamelogicforLow
FlowAlarmaswithDualFlowAlarm.
Inthisapplication,thenormalstatusiswhenthesensorisintheflow
condition,andtherelaywillbeenergizedholdingthealarmcircuit
Open.
IftheswitchesarewiredNC,theinputLEDwillbeOFFandthe
relayLEDwillbeON.Soforthiswiringconfiguration,Invert
shouldbesettotheONposition.
IftheswitchesarewiredNO,theinputLEDandtherelayLEDwill
beONsimultaneously.Soforthiswiringconfiguration,Invert
shouldbesettotheOFF(‐)position.