Dwyer | Series TDS | Instruction manual | Dwyer Series TDS Instruction Manual

Dwyer Series TDS Instruction Manual
Series TDS
T
Flow
w Switch
Owne
er’s Man
nual
Dwyer In
nstruments,, Inc.
102 Ind
diana Hwy. 212
2
(P.O
O. Box 373)
Michigan City, IN 46360 (4
46361) USA
www.D
Dwyer‐Inst.co
om
MN8
890640A
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2
INTRODUCTION / TABLE OF CONTENTS
Step One
Offered in liquid and gas sensor types, the general purpose flow switch provides reliable low or no‐flow
detection of relatively clean, non‐coating media with one 1A relay output. Liquid examples in clued water and
acetic acid. Available in Polypropylene‐Ryton® or PVDF, the short flow sensor is used in pipe or ducting from
½” to 1‐1/2”, and the long flow sensor is used in 2” and up. The flow switch set point may be adjusted from
0.04 to 3 fps in liquids or 1 to 90 fps in gases as a low‐flow alarm. The flow sensor is best applied in
applications with relatively constant temperatures.
New Features
 Rugged Polypropylene‐Ryton® or PVDF sensor for corrosive liquids and gasses.
 Adjustable set point with LED for flow or no‐flow status indication.
 60VA relay selectable NO or NC via power supply wiring polarity
 Solid State sensor is not damaged by over‐ranging flow velocities.
Make a Fail‐Safe System: Design a fail‐safe system that accommodates the possibility of switch and/or
power failure. Dwyer Instruments recommends the use of redundant backup systems and alarms in
addition to the primary system. Adding a redundant alarm switch to the system is a cost effective means
to prevent costly run‐dry issues.
Table of Contents
Specifications: ......................................................................................................................................................... 3
Dimensions:................................................................................................................................................. 3
Safety Precautions: ................................................................................................................................................ 4
Introductions:.......................................................................................................................................................... 5
Configurations:............................................................................................................................................ 5
Technology: ................................................................................................................................................. 5
Installation: ............................................................................................................................................................. 6
Wiring: ..................................................................................................................................................................... 7
Wiring to a Dwyer Instruments: ................................................................................................................. 7
Wiring the Relay output:............................................................................................................................. 8
Wiring as a P‐Channel or N‐Channel Output: ............................................................................................. 9
Calibration: ............................................................................................................................................................ 10
Set Point: ................................................................................................................................................... 10
Maintenance: ....................................................................................................................................................... 11
Cleaning Procedure: .................................................................................................................................. 11
Testing the Sensor (TDS Series Only): ....................................................................................................... 11
Warranty: .............................................................................................................................................................. 12
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MN890640A
SPECIFICATIONS / DIMENSIONS
Set point range:
Factory set point:
Repeatability:
Response time:
Set point adjust.:
LED indication:
Viscosity range:
Supply Voltage:
Consumption:
Contact type:
Contact rating:
Contact output:
Process temp.:
Electronics temp.
Pressure:
Sensor rating:
Sensor Material:
Cable jacket mat.:
Cable type:
Cable length:
Process mount:
Classification:
CE compliance:
Step One
.04 to 3 fps / (.012 to .91 mps)
.2 fps (.06 mps)
±.5% of set point @ fixed temp.
1‐10 seconds
Potentiometer
Flow Status
1‐200 centipoise
14‐36 VDC
70 mA maximum
(1) SPST relay
60 VA, 1A max
Selectable NO/NC
F: 32° to 140° / C: 0° to 60°
F: ‐40° to 140° / C: ‐40° to 60°
150 psi (10 bar) @ 25°C., derated @ 1.667
psi (.113 bar) per °C. Above 25° C.
NEMA 4X (IP65)
TDS1_2: PP‐Ryton®
TDS2_2:PVDF
TDS1_2: PP
TDS2_2: FEP
4‐conductor, #22 AWG (shielded)
Standard: 10’ (3m)
3/4" NPT
General purpose
EN 61326 EMC / EN 61010‐1 safety
Long Sensor
Short Sensor
MN890640A
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SAFETY PRECAUTIONS
Step Two
About This Manual: PLEASE READ THE ENTIRE MANUAL PRIOR TO INSTALLING OR USING THIS PRODUCT.
This manual includes information on all models of the Dwyer Instruments Thermal Dispersion Flow Switch:
TDS Series. Please refer to the part number located on the switch label to verify the exact model which
you have purchased.
User’s Responsibility for safety: Dwyer Instruments manufactures a wide range of flow switches and
technologies, while each of these sensors is designed to operate in a wide variety of applications; it is the
user’s responsibility to select a sensor model that is appropriate for the application, install it properly,
perform 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 eclectically operated device, only properly trained
staff should install and/or repair this product. Use a proper sealant with all installations. Never over
tighten the sensor within the fitting, beyond a maximum of 80 inch‐pounds torque. Always check for leaks
prior to system start‐up.
Material Compatibility: The TDS series sensors are available in two different wetted materials. Models
TDS1_2 are made of Polypropylene (PP) with Ryton® tips. Models TDS 2_2 are made of Polyvinylidene
Fluoride (PVDF). Make sure that the model you have selected is compatible with the application liquid. To
determine the chemical compatibility between the sensor and its application liquids, refer to an industry
reference such as the Compass Corrosion Guide (available from Compass Publications).
Wiring and Electrical: The supply voltage used to power the 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: DO NOT USE THE TDS SERIES GENERAL PURPOSE
FLOW SWITCHES IN HAZAROUS LOCATIONS.
Warning
The rating for the relay is 120 VAC / 60 VDC @ 1A. For CE rated applications, the relay rating is 60
VAC / 60 VDC @ 1Amp.
Dwyer Instrument’s Thermal Dispersion flow switches are not recommendable for use with
electrically charged application liquids. For most reliable operation, the liquid being measured may
need to be electrically grounded.
The sensing tip of the sensor must always be submersed in the liquid and never exposed to air.
The liquid temperature must remain constant and not change throughout the process.
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MN890640A
INTRODUCTION
Step Three
Configurations:
Part
Number
TDS112
TDS122
TDS212
TDS222
Length
Short (3”)
Long (4.5”)
Short (3”)
Long (4.5”)
Material
(body)
PP‐Ryton®
PP‐Ryton®
PVDF
PVDF
Material
(cable)
Polypropylene
Polypropylene
FEP
FEP
Technology: The thermal dispersion flow switches measure liquid temperature to determine changes in flow
velocity. As fluid flows across the sensing tips, the temperature is reduced proportionately as a function of the
flow rate. When a temperature or velocity shift reaches the user defined set point, the switch changes state
indicating the appropriate flow condition (flow of no‐flow).
Dwyer Instrument’s sophisticated electronics convert the temperature shift into a signal which indicates
whether a flow or no‐flow condition occurs. Depending on how the sensor is wired, this signal may be wired
for normally open or normally closed circuits.
Dwyer Instrument’s Thermal Dispersion flow switches have no moving parts to clog or foul, making them
suitable for a verity of applications, including non‐coating and non‐scaling liquids. The TDS series directly
measure mass flow and can operate over board range of liquids from 0.4 to 1.2 specific gravity and 1 to 200
cp.
Initializing Sequence for TDS series: Powering up the TDS series is different in liquid and air. When the flow
switch is powered up while submersed, the TDS series will immediately indicate flow before switching to its
correct state. When the flow switch is powered up in air, the TDS series will immediately indicate no‐flow
before indicating its correct state. A time delay may be used to eliminate the initialization sequence. Dwyer
Instrument’s thermal dispersion relay controllers feature a 0 to 60 second time delay for your convenience.
Set Points: The TDS series flow switch set point is factory calibrated to 0.2 fps. To convert feet/sec to GPM,
please refer to the chart below.
Flow Rate vs. Velocity
(gpm vs. fps)
MN890640A
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Installation
Step Four
The TDS series flow switch must always be in contact with the
liquid being measured. The flow switches feature a 3/4” NPT
threads which will allow it to be used with various types of
fittings. Be sure to check the insertion depth of the flow
switch in the fitting after it is installed. See the diagram to the
right for the recommended insertion depth.

The two tip of the sensor are to be perpendicular to
the flow (as seen to the right). Never mount the tips
with one in from t of the other.
When using any type of fitting, the orientation as well as the
insertion depth of the flow switch in the pipe is critical. See
the diagram to the right for the recommended orientation.
Best location for installation will be along the top of the pipe.
Warning
The flow switch tips have a thin plastic wall which may be damaged if dropped or installed improperly.
The TDS series flow switch is designed for use in liquid. For best results, avoid installing the TDS series
where bubbles are present or where the tips of the switch may be out of the liquid.
The two temperature probes (tips) must always be perpendicular to the flow (see the flow at the same
time).
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MN890640A
WIRING
Step Five
Supply Voltage: The supply voltage to the TDS series flow switch should never exceed a maximum output of
36 VDC. Use controllers or power supplied, with a minimum output of 14 VDC or maximum output of 36 VDC.
Required Cable Length: Determine the length of the cable required between the TDS series flow 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 ft, using a well‐insulated, 14 to 20
gauge shield 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 discard 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 Output (Relay Switching):
Allows the sensor to switch a small load on or off
directly, using an internal 1A relay [120 VDC/VDC or
(CE: 60 VDC/VDC)]. 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 wire is the NO or NC, depending on the
polarity of red and black.
Wiring to a Dwyer Instruments Controller:
TDC Series Controller
MN890640A
Normally Open Wiring:
TSP Series Controller
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WIRING
Step Six
Wiring the Relay Output: The TDS series relay output can be wired as a dry contact to a VDC or VAC power
source. The TDS series does require 14‐36 VDC power to operate the sensor and switch the relay. All
installations below identify a dry switch state as the normal position of the relay.
Switching a Normally Open DC Load (Open during Flow, Closed during No‐Flow):
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 connecting the Green to
(+) VDC power or White to (‐) VDC power (see
illustration to the right).
Switching a Normally Closed DC Load (Closed during Flow, Open during No‐Flow):
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 connecting the Green
to (+) VDC power or White to (‐) VDC power (see
illustration to the right).
Switching a Normally Open AC Load (Open during Flow, Closed during No‐Flow):
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 to the right). Low
voltage VAC is less than 36 VAC.
Switching a Normally Closed AC Load (Closed during Flow, Open during No‐Flow):
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 to the
right). Low voltage VAC is less than 36 VAC.
For all Sensor Wiring diagrams above:
Sensor Power: Red and Black Wires (36 VDC Max.)
Relay Rating: Green and White Wires (60VA, 1A Max.)
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MN890640A
WIRING
Step Seven
Wiring as a P‐Channel or N‐Channel output: The TDS series can be substituted for either a P‐Channel (PNP,
Sourcing) output or N‐Channel (NPN, sinking) output.
Normally Open DC Load as a P‐Channel Output (Open during Flow, Closed during No‐Flow):
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 jumping to the Red
wire while the White wire is connected to the LOAD.
Jumper the LOAD back to the Negative (‐) to complete
the circuit.
Normally Closed DC Load as a P‐Channel Output (Closed during Flow, Open during No‐Flow):
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 jumping 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 (Open during Flow, Closed during No‐Flow):
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 jumping to the Black
wire while the Green wire is connected to the LOAD.
Jumper the LOAD back to the Positive (+) to complete
the circuit.
Normally Closed DC Load as a N‐Channel Output (Closed during Flow, Open during No‐Flow):
To wire as a NC N‐Channel output, follow the
directions below. The Black wire connects to Positive
(+) of the directions below. The Black Wire connects
to Negative (‐). The white wire is jumping to the Red
wire while the White wire is connected to the LOAD.
Jumper the LOAD back to Positive (+) to complete the
circuit.
For all Sensor Wiring diagrams above:
Sensor Power: Red and Black Wires (36 VDC Max.)
Relay Rating: Green and White Wires (60VA, 1A Max.)
MN890640A
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CALIBRATION
Step Eight
Set Point: If the preset factory calibration is not adequate for your application, follow the calibration steps
listed below.
Note: The switch’s internal LED will be on when the switch detects no‐flow and will off when the switch
detects flow, regardless of the polarity of the Red and Black wires. Reversing the Red and Black wires will
reverse the polarity of the relay switch, but not the internal LED.
1. Install the fitting and flow switch as described in the Installation section of this manual. Turn the flow
switch and controller power on and adjust the flow rate to the application setting. If the medium to be
sensed is likely to be subject to any temperature variation, the flow switch should be set as the highest
normal temperature likely to be encountered.
2. Locate the potentiometer knob at the top of the flow switch. The red LED is visible through the
potentiometer. The adjustment is a single turn 270° potentiometer. The initial response time of the flow
switch after adjustment is 1 to 10 seconds. Adjust the potentiometer in slow increments and wait for the
response.
a. LED is ON ‐ If the LED is on, slowly adjust the potentiometer counter‐clockwise, with a small flat head
screwdriver until the LED turn off.
b. LED is OFF ‐ If the LED is off, slowly adjust the potentiometer clockwise. with a small flat head
screwdriver until the light turns on.
3. Adjust the potentiometer back and forth where the LED is switching, eventually settling for where the LED
is OFF (this is the low flow state for the switch).
a. If the flow is increased, the LED will remain OFF indicating a flow condition
b. If the flow is decrease, the LED will turn ON indicating a no‐flow condition.
4. Verify that the new calibration is correct by lowering the system flow rate below the set point and check to
see that the red LED turns on. Then increase the flow rate above the set point and verify that the red LED
turns off accordingly.
TDS SERIES Flow Switch
(Liquid Only)
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Potentiometer
Location
MN890640A
MAINTENANCE
Step Nine
MAINTENANCE/REPAIR: The TDS Series is not field serviceable and should be returned if repair is needed (field repair
should not be attempted and may void warranty).
General: The TDS series flow switch requires no periodic maintenance except to clean off any deposits or
scaling from the sensor tip as necessary. It is the responsibility of the user to determine the appropriate
maintenance schedule, based on the specific characteristics of the application liquids.
Cleaning Procedure:
1. Power: Make sure that all power to the sensor, controller and/or power supply is completely
disconnected.
2. Sensor Removal: Make sure that the flow is off and the pressure is down prior to removing the TDS series
flows switch. Carefully, remove the sensor from the installation. Replace the sensor with a 3/4” NPT plug
to insure that the liquid does not leak out during this procedure. Do not re‐install the TDS series if the
threads are damaged.
3. Cleaning the sensor: Use a soft bristle brush and mild detergent, carefully wash the TDS series flow switch.
Do not use harsh abrasives such as steel wool or sandpaper, which might damage the surface sensor. Do
not use incompatible solvents which may damage the surface sensor. Do not use incompatible solvents
which may damage the sensor’s PP/Ryton or PVDF plastic body.
4. Sensor Installation: Follow the appropriate steps of installation as outlined in the installation section of
this manual.
Testing the Sensor:
1. Immersing the switch: Place the switch in a cup of water. Make sure the tips are submersed in the water.
2. Power: Turn on power to the switch with Red to (+) and Black to (‐). You can reverse the polarity if
desired.
3. No‐Flow/Flow Test: With the switch setting still in the cup, wait until the Red LED turns ON (no‐flow
condition).
a. Swirl the switch in the cup and wait until the Red LED turn OFF (flow condition).
b. Stop swirling the sensor and let it rest in the cup waiting for the Red LED to turn ON again (no‐flow
condition).
c. Repeat the above two steps.
4. Relay Test: Connect a multimeter (set to read Ohms) to the White and Green Wires. Perform the above
No‐Flow/Flow test with the multimeter connect to observe the actuation of the relay.
a. With Red to (+) and Black to (‐), the multimeter will read a small resistance during no‐flow (closed
relay) and OL during a flow condition (open relay).
b. Reverse Polarity [Red to (‐) and Black to (+)] to see the multimeter read OL during a no‐flow state
(open relay) and a small resistance during a flow condition (closed relay).
The No‐Flow/Flow test determines if the switch is capable of sensing the changes between no‐flow and flow.
The Relay test determines the ability of the relay to switch between a no‐flow and flow condition. This is the
basic test to determine functionality of the sensor.
MN890640A
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WARRANTY
Step Eleven
WARRANTY/RETURN
Refer to “Terms and Conditions of Sale” in our catalog or on our website. Contact customer service to receive a Return
Goods Authorization number before shipping your product back for repair. Be sure to include a brief description of the
problem plus any relevant application notes.
Dwyer Instruments, Inc.
Attn: Repair Department
102 Highway 212
Michigan City, IN 46360
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MN890640A
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