Proteus 500 Series Manuel du produit

Proteus Industries Inc.

500

SERIES

METERING

FLOW

SWITCHES

TECHNICAL REFERENCE MANUAL

Proteus 5-Year Warranty

A full statement of our warranty is available on our website at www.proteusind.com/warranty/.

500TRM-002 Page 1 of 22 March 2007

500TRM-002 Page 2 of 22 March 2007

Table of Contents

Page

1. Introduction 3

2. Features and functions 3

3. How the flow sensor works 6

4. Specifications and performance 7

5. Product certifications 8

6. Installation 8

7. Selecting Trip Points 12

8. Measuring Flow Rate 16

9. Digital Displays 17

10. Cleaning and Maintenance 18

11. Calibration & Recalibration 21

12. Replacement Parts 22

Section 1 Introduction

500 Series Metering Flow Switches have been created to provide a more effective monitoring and control

capability for applications in which liquid flow rates up to 4.5 GPM (17 LPM) must be monitored and

controlled over extended temperature and pressure ranges.

Capabilities required for extreme operating conditions have been incorporated in the basic product,

allowing the size-reduced metering flow switch to be used in situations in which specialized products were

previously required.

The 500 Series Metering Flow Switches have been developed from Proteus’ experience in satisfying the

needs of thousands of demanding users in widely diverse applications since 1978.

Section 2 Features and Functions

•Flow ranges from 0.15 to 4.5 GPM, 0.6 to 17 LPM.

Two flow ranges are provided in the 500 Series. Refer to Specifications on page 7.

Proteus 800 Series Metering Flow Switches formed in brass, polypropylene or stainless steel provide

similar measurement and control capabilities for higher flow ranges than the 500 Series.

•Calibrated 0-5VDC output

The 500 Series’ is calibrated to provide a 5 VDC output for 2.0 or 4.5 GPM (7.5 or 17 LPM). Actual

flow rate can be determined by attaching a voltmeter. An optional scaleable digital voltmeter can be

calibrated to provide a direct local display of flow rate.

•Compact design

2.5” center to cente

500TRM-002 Page 3 of 22 March 2007

Figure 1: Dimensions of 500 Series Flow Sensor

•Compact design is easily retrofittable

Mechanical and electrical interfaces are identical to those of hundreds of thousands of Proteus

24VDC flow switches and flow meters already in use.

The 500 Series is completely retrofittable in place of an existing Proteus flow switch with ¼”NPT

or 9/16” SAE connections.

The distance between the 500 Series pipe or fitting connections is identical to those of previous

Proteus flow sensors.

Weighing only 16.8 oz (470 g), the metering flow switch can be mounted directly to your pipe or

tubing.

Mounting lugs are located at the place of previously used panel mounting screws. The 500

Series metering flow switch can be panel mounted with two screws and appropriate standoffs.

•Stainless Steel faceplate extends operating range

The rugged stainless steel faceplate permits operation from –40 to 140ºC and 250 psi(1720 kPa).

A Viton® O-ring provides the liquid seal. Other materials are optionally available for enhanced

chemical compatibility with specialized coolants.

•Space requirements reduced by more than 50%

•Trip point is user selectable.

500TRM-002 Page 4 of 22 March 2007

Trip points are selected by adjusting a 16-

position switch as shown in Table 1.

This feature provides the ability to change trip

point settings predictably, accurately and

precisely without the use of complex

instrumentation.

Tri-color LED

See Section 7 for instructions on selecting trip

points.

•Optional potentiometer provides fine tuning capability

If your trip point must be set with finer control than is provided by the 16-position switch a

potentiometer provides the adjustment you need. This potentiometer can be adjusted from 7.00

o’clock to 5.00 o’clock positions. Refer to Section 7 for instructions on selecting trip points.

Switch Position

Model

Number 0 1 2 3 4 5 6 7 8 9 A B C D E F

0504SA2

0504SN2

0.12

0.24

0.35

0.47

0.59

0.71

0.82

0.94

1.06

1.18

1.29

1.41

1.53

1.65

1.76

1.88

0504SA4

0504SN4

0.26

0.53

0.79

1.06

1.32

1.59

1.85

2.12

2.38

2.65

2.91

3.18

3.44

3.71

3.97

4.24

Table 1: Flow Rate in GPM at selected Switch Positions with straight connection to inlet

port and fine adjustment potentiometer in the 12 o’clock position.

Note

Elbows and other devices installed that induce swirling motion in the flowing liquid that are

installed within 4 inches (16 cm) of the inlet port reduce the linear velocity of liquid through the

flow sensor.

When such devices are present the actual flow rate through the flow sensor may be HIGHER

than is suggested in Table 1.

16-position

switch

Fine adjust

otentiomete

500TRM-002 Page 5 of 22 March 2007

•LED provides instant status information.

Like a traffic signal, the green, amber and red lights indicate flow status so that problems are easily

detected. Green, amber and red lights provide instant inidication of the status the flow switch and the

flow rate. An additional LED monitor can be remotely mounted at your control panel.

If the three-color LED is ON you know that 24VDC power is being delivered to the flow

switch and the flow switch is functional.

The color of the LED changes depending on the ratio of the actual flow rate to the Trip Point

Relay State

LED

Color

Flow Rate Status Example Trip Point

1.0 GPM NO contact NC contact

Green Greater than 1.15 x flow

rate at selected trip point Actual Flow > 1.15 GPM

Closed

Open

Amber Between 1x and 1.15 x flow

rate at selected trip point 1.0 < Actual Flow < 1.15

GPM

Closed

Open

Red Less than flow rate at

selected trip point Actual Flow < 1.0 GPM

Open

Closed

•Multiple outputs provide control flexibility

The 8-pin connector provides a range of control options and delivers 24VDC power to the metering

flow switch. See Section 6, Installation for connection details.

Position Function Notes

1 Power input 24 VDC ± 10%

2 Ground connection for power & output

signals Should be connected to a valid system ground

3 Output Voltage Calibrated to provide 5VDC for 2.0 or 4.5 GPM.

Custom calibrations are available.

4 Normally Closed relay contact Connects to NC contact of relay.

5 Common relay contact Connects to Common contact of relay

6 Normally Open relay contact Connects to NO contact of relay

7 Red LED anode

8 Green LED anode

Connections for a remote tri-color LED indicator.

Common cathode of tri-color LED should be connected

to ground

Hall-effect senso

Section 3 How the flow sensor works

500TRM-002 Page 6 of 22 March 2007

The rotor spins when liquid flows through the

meter.

Magnets in the rotor switch a Hall-effect sensor

mounted in the meter body.

The resulting pulse train is converted by the

electronics to a voltage that is proportional

to the linear velocity at which the liquid flows

through the meter.

Switching

The measured output voltage is continuously compared to a user-selected trip point voltage. When the

measured voltage is above the trip point, the built-in relay remains in its active state. If the measured

voltage falls below the trip point due to reduced or stopped flow, the relay contacts open, signaling an

alarm condition to your control system.

Metering

Accuracy of calibration to ± 2% of range is established against a flow standard with a certified accuracy of

± 0.5%. Calibration is traceable to a NIST reference. Linearity is better than ± 0.5%.

nets

Roto

500TRM-002 Page 7 of 22 March 2007

Section 4 Specifications and performance

The most current information on the performance capability of these sensors is accessible on the Proteus

website at www.proteusind.com.

Flow Range

GPM 0.15 - 2.0 0.3 – 4.5

LPM 0.6 – 7.5 1.2 – 17.0

Connections Part Number

9/16 -18 SAE 0504SA2 0504SA4

¼” FNPT 0504SN2 0504SN4

Liquid operating Limits

Temperature -40 to 140oC -40 to 284oF

Electronics must be thermally isolated from flow sensor at temperatures

above 85°C and below dew point.

Pressure 1720 kPa 250 psi

Kinematic Viscosity To 120 centistokes

Wetted Materials

Flow Sensor Body 304 Stainless Steel

Faceplate 316 Stainless Steel

Sealing O-ring Viton ® . Other materials are available.

Rotor Carbon fiber-filled Nylon. Other materials are available.

Rotor Shaft 316 Stainless Steel. Other materials are available.

Meter Performance

Voltage Output 0 - 5 VDC for the 2.0 GPM or 4.5 GPM.

Accuracy ± 2 % of range.

Improved accuracy and linearity performance over smaller flow ranges can

be achieved by specialized NIST-traceable calibration procedures.

Linearity Better than ± 1% from 10 to 100% of nominal flow range

Repeatability Better than ± 0.5% above 10% of nominal flow range

Switch Performance

Trip Point Selection 16 position changes trip points in steps of 6% of nominal flow range with fine

adjustment between steps.

Hysteresis / Dead Band < 5% of actual flow rate

Switch type Relay Closure

Relay rating SPDT 48 VDC, 1.0 A

Electrical

Power Requirements 24 VDC, 40 mA

Electrical Connection Plug type EDZ1550/8 with screw fastening of 8 conductors up to #16 gauge.

Remote Electronics Optional mounting locates electronics up to 30 ft from flow sensor. Required

for operation above 85°C.

Flow Certification Standard products are provided with certificates of compliance. Specialized

calibration certificates are optionally available.

Digital Display Optional panel mounted displays flow rate GPM or LPM on 3½ digits.

Section 5 Product certifications

500 Series Metering Flow Switches are CE marked for compliance with the EU Directive 89/336/EEC for

Electromagnetic Compatibility.

500 Series Metering Flow Switches have been Safety Certified by RWTUV as a low voltage, Class III

devices.

Section 6 Installation

CAUTION!

It is generally undesirable to mount any plumbing connections directly over

electronic controls or instruments.

WARNING!

If the 500 Series flow sensor is mounted in a vertical pipeline, any leakage from the topmost

connection could enter the unit and cause permanent damage to the electronics.

Pipe or tubing mounting

If rigid piping or tubing is used, the 500 Series metering flow switch may be supported by direct

connection to the pipe or tubing.

Panel mounting

Locate holes for 8-32 screws in the panel with 2.5” between centers. Spacing sleeves placed over the

shaft of the securing screws are recommended to prevent the faceplate or rear cover of the sensor from

making contact with the panel. Refer to Figure 1 for dimensions.

Figure 1: Dimensions of 500 Series Metering Flow Switch.

Contact [email protected] should you require DWG files for integration with your drawings.

500TRM-002 Page 8 of 22 March 2007

500TRM-002 Page 9 of 22 March 2007

Plumbing Connections

Note

Before connecting a sensor into your fluid line, verify that the normal flow rates expected in that line

are within the operating range of the sensor.

Extended use above the rated maximum flow rate of the sensor will reduce its useable life.

Note

It is recommended that connections to the stainless steel flow sensor be made with stainless steel or

materials of similarly chemical inertness to minimize potential corrosion damage.

Note

The flow response of the sensor, and thus its calibration may be dependent on the internal diameter

(ID) of an incoming pipe, or the ID of a tube connection.

If the ID of your pipe or tube fitting where it connects to the inlet port is LESS than the value shown in

Table 2, calibration values may be invalid.

Appropriate calibration procedures can be applied to allow the 500 Series flow sensor to be used with

pipes and connections with ID’s smaller than those shown in Table 2. Contact Proteus for assistance.

Flow Range Orifice ID

Model # GPM LPM inches mm

0504SA2 0.1 – 2.0 0.6 – 7.5 0.187 4.76

0504SN2 0.1 – 2.0 0.6 – 7.5 0.187 4.76

0504SA4 0.3 – 4.5 1.2 – 17.0 0.270 6.86

0504SN4 0.3 – 4.5 1.2 – 17.0 0.270 6.86

Table 2: Minimum ID of pipe or connection for calibrations to be valid.

Note

The flow response of 500 Series sensors and thus their calibration may be dependent on the form of the

device attached to the inlet connection and other closely located up-stream devices.

Elbows, T-pieces, valves and filters located immediately up-stream from the flow sensor can introduce

swirling motion to the liquid flow. The swirling motion reduces the linear velocity of the flow stream.

We recommend that a straight run of pipe of more than 10 x pipe ID (~4 inches or 10 cm) be used

between the flow sensor and any up-stream devices to minimize these effects.

Appropriate calibration procedures must be used to provide an accurate flow measurement with elbows

or T-pieces that must be attached directly to the inlet connection.

The 500 Series sensor is typically unaffected by the form or proximity of devices on its downstream side.

Sensor Orientation

For the best results, 500 Series sensors should be mounted with the faceplate in the vertical plane.

Mounting the device with the flow connections uppermost can help eliminate entrained air from your

system.

Flow Direction

The 500 Series Metering Flow Switch is not sensitive to flow direction. Flow can be introduced to the

sensor from either side.

NPT pipe thread connections

Pipe threads seal by making metal-to-metal contact between male and female components.

Consequently they are particularly prone to the damaging effects of galling, which occurs when two

surfaces move against each other under pressure. When installing pipe threads it is essential to use a

high quality lubricating and sealing material.

•Use Teflon tape or a PTFE-based liquid sealant to provide lubrication for the junction and a leak-tight

connection at both input and output connections. Real-Tuff and Hercules are two of many suitable

brands of PTFE-based sealants.

•Do not over-tighten the connection. Refer to instructions for installation of the mating fittings for

information on torque requirements.

•Leak testing of all connections in your flow circuit is recommended. Pressurizing the system with air

and external testing with a dilute soap solution can help identify leaking connections.

SAE straight thread connections

With these connectors, an O-ring makes the seal while the threads hold the connecting assembly in

place. Straight thread connections should receive a small amount of high-pressure lubricant before

installation to prevent galling.

Non-adjustable fittings

1. Bring the non-adjustable fitting into firm

contact with the face of the port, using a

wrench.

2. Check to be certain that the O-ring fits

easily into the non-threaded receiving

area of the port, and is not pinched.

500TRM-002 Page 10 of 22 March 2007

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